How to enhance automotive aluminum casting applications with internal coatings?

[ALUMINIUM NETWORK] As aluminum has become the preferred material for automotive manufacturing, global leaders dedicated to the development and application of advanced materials are helping cast aluminum plants to increase production and reduce scrap rates by avoiding metal contamination from melting and heat preservation processes. .

Morgan Advanced Materials Corporation attaches great importance to the consequences of aluminum pollution, so the company continues to vigorously develop two specialized coatings for the diffusion barrier in the melting process. Although aluminum is often alloyed with other metals or elements to provide accurate mechanical and chemical properties for various applications, its chemical reaction with niobium creates pollution and impurities and affects the overall microstructure of the material after melting.

Mirco Pavoni, Global Technical Director of Molten Metal Systems for Advanced Materials at Morgan, explained: “The impurities and intermetallic compounds generated in the melting process of aluminum can reduce the overall ductility of aluminum materials and cause dislocations. The quality of castings is often significantly affected by metallic impurities. The impact has led to an increase in the scrap rate. As the auto industry has increased its use of aluminum and aims to reduce emissions by reducing weight, it is crucial to produce as pure materials as possible. The cost pressures are also increasing, which means that higher casting quality, lower scrap rate, and better crucible life time have a huge impact on costs.

To this end, Morgan developed PRO and STAR coatings that have been proven to be particularly effective in reducing aluminum alloy impurities, preventing material contamination, and slag in the crucible. These specialty formulas can be used on the inside surface of the crucible to prevent chemical reactions between the metal and the crucible and act as a barrier to reduce impurities. The application of the PRO coating is relatively simple and can be mixed with water and then applied by a trained hand worker to the crucible with a brush. It can also be used as a mortar to repair damaged or defective areas and extend the life of the crucible to a greater extent.

The STAR coating is more advanced and can provide better results for clay-bonded and carbon-bonded crucibles. It must be operated by a skilled supervisor, using a specific spray gun to form a nanoparticle layer within the crucible, and then sintering under specific conditions to ensure its firm bonding. This reduces the cleaning time while producing better metal purity than standard cesium.

Mirco also added: "PRO and STAR coatings are our expertise in materials science, applied engineering technology, and our long-term focus on end-user demand. Therefore, we can provide customers with better products. We also provide Internal R&D capabilities have been enhanced to serve the increasingly widespread mass market for aluminum applications such as automotive and aerospace industries.