Several methods using the concept of electromagnetic separation of nonmetallic inclusions from an aluminum melt were analytically studied and compared in this article. The migration rate of inclusion particles for each method by exerting different types of electromagnetic field, viz. DC electric field with steady magnetic field, AC magnetic field, and AC electric field, was calculated and compared with the gravity settling velocity. Effects of various operating parameters, such as the imposing time of electromagnetic field, the radius of circular pipe, and the magnitude of electromagnetic force, on inclusion removal efficiency were analyzed and illustrated for each case. It was found that the removal efficiency increases with the increase of imposing time and decreases dramatically with the increase of pipe radius, especially for the AC electric field method. As far as the removal of small inclusions is concerned, the AC magnetic field method is the most favorable one because it has the least dependence of removal efficiency upon the particle size. However, high frequency is needed in order to get the optimum results, and the best values of a/␦ are in the range of 2 to 3.
In this study, the separation of Fe-Al-Zn dross phase from hot dip galvanised zinc bath was conducted by using alternating magnetic field. The compositions of the zinc dross were detected by energy dispersive spectrum. The electrical conductivities were measured by physical properties measurement system. The separation efficiency of the zinc dross in different channels was examined by the quantitative metallographic method. Experimental results show that the zinc dross particles with diameter larger than 5 mm can be separated successfully when the processing parameters can selected appropriately.
Effect of boron on iron removal and the feasibility of formation of iron borides in Al melt were studied. The iron composition was not reduced by the addition of boron. Analysis using SEM/EDX and XRD indicated the formation of titanium and vanadium borides in the melt and no iron borides were detected. Thermodynamic calculations proved that iron cannot react with the added boron in the melt to form iron borides under the experimental conditions, and the lowest Fe concentration that can be purified by boron addition is ∼11·7 wt-%.
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