Research On Lost Foam Casting Of Steel Anode Used In Electrolytic Aluminum

XXX steel foundry mainly produces steel anode used in electrolytic aluminum, there are many quality problems need to be improved in the production process. The hole type defects has been the main defect of the steel anode, seriously affect the use of performance and appearance quality, lead to high rejection rate and low economic benefits. Combined with the production practice, this paper analyzed hole type defects produced in different parts, studied the mechanism of defects, and improved the production process, ultimately reduced or eliminated the hole type defects.Using DOE experimental design method, the charge composition was optimized, experimental results showed that the lower quality burden ratio can reduce the gas defects; the outlet temperature was optimized, the experimental results showed that the outlet temperature should be controlled at 1550-1600 ℃in summer, and the outlet temperature should be controlled at 1600-1650℃ in winter, which can reduce the generation of shrinkage defects.Using InteCAST CAE based on the numerical simulation of steel anode, research results showed that the down casting model consisting of risers, vents, and runners improved as the up casting model consisting of riser-vents, can avoid the shrinkage defects, and has higher production efficiency and more economic benefits.Through the theoretical analysis of shoulder slag defects of improvement scheme, the inclined shoulder steel anode was designed, the original using size of steel anode was maintained, the height of the welding surface of anode rod and anode steel was increased, the corrosion resistance of the weld block was enhanced, and the rate of finished products and production efficiency was improved.Through above researches, hole type defects of anode steel was improved obviously, the rejection rate was reduced, production efficiency and economic benefit was improved significantly.