Casting Machines for Aluminium ingots production with the innovative Wet & Dry Technology

The new Ingot Caster for Aluminum ingots production with the innovative Wet & Dry Technology (Patent Pending), has been conceived by GMS to provide ingot manufacturers with a simple, versatile, robust Machine, ideal for foundry operations in compliance with the concepts of Industry 4.0

During the first months of 2020, GMS launched on the market its continuous ingot casting line under the trade name of “WET & DRY” (Patent Pending).

The machine has been designed to produce both primary and secondary Aluminum ingots in continuous casting in two formats required by the market: the “Standard” one of 10 kg and the “Light” one of 8,5 kg.

The maximum production rate is 2.000 ingots / operating hour both in the “Standard” and in the “Light” formats.

The innovative technical Solutions have been conceived by our Engineers to ensure, over time, excellent hydraulic sealing between the Steel band and Copper molds and safe and reliable hydraulic sealing between adjacent molds even in the most critical operating conditions of the Machine. For these reasons, the entire Machine has been configurated to obtain the maximum elasticity of the continuous mold.

Among the most significant innovations, therefore, the self-closing system of the molds holder chain deserves a particular mention, which guarantees constant and perfect closure between adjacent molds and, above all, allows the chain to be dragged in traction, reducing the mechanical stress on the Steel band and obtaining constant and lasting mechanical stability of the system.

With reference to the figure:

(1) Pressing structure, with variable radius, for band Hi Force. It has been conceived to couple the blocks with the band with maximum effectiveness and minimum encumbrance at the start of the hypercritical zone (where the liquid metal enters the machine). At the same time, it drastically reduces the mechanical stress of the band when it changes the travelling direction.
(2) Structures pressing band Flexy Closing Arms. These mechanisms guarantee the maximum flexibility in the coupling among blocks and band even in the most critical operating conditions such as in presence of residual metallic or nonmetallic particles and/or wearing of moving parts.
(3) Large diameter band tensioning wheel. It allows to minimize the mechanical stress of the casting band when it changes the direction promising longer life for the band.
(4) Hi pressure blocks cleaning station “CIP” (Cleaning In Place). Any trace of dirty accumulated on the blocks in their active cycle is getting removed with high pressure water spray systems – not very much dissimilar to those used in car washing stations – in the non-active zone of the chain block.
(5) Blocks drying unit “Safe Dry”. After washing, drying is mandatory to comply with safety rules. The drying station performs blocks drying before they receive the liquid Aluminum.
(6) Dethatching fluid spraying system. The dethatching fluid is getting sprayed, in minimum quantity, in automatic and repeatable manner on blocks before receiving the molten metal as required by GMPs (Good Manufacturing Practices) applicable in Aluminum casting and molding.
(7) Cooling system Wet & Dry. The cooling system is designed to avoid even the minimum infiltration of water among blocks and band in the hypercritical zone of the Crystallizer.
(8) Rotary bar shear with independent drums. After observations and analysis, we came to the conclusion that different alloys have (or might have) different cutting aptitudes also in consideration of the momentum of inertia of the bar to be cut. For this reason, cutting operation can be optimized according to the type of Alloy processed thanks to the possibility of optimizing the action of the two blades during the cutting.

Each ingot is then marked with a bar code by means of a special ink jet and labelling station not shown in the figure.