{"id":4432,"date":"2019-03-21T02:38:42","date_gmt":"2019-03-21T02:38:42","guid":{"rendered":"http:\/\/www.adtechamm.com\/?p=4432"},"modified":"2026-08-24T06:31:31","modified_gmt":"2026-08-24T06:31:31","slug":"aluminium-degassing","status":"publish","type":"post","link":"https:\/\/www.adtechamm.com\/ar\/aluminium-degassing\/","title":{"rendered":"\u0625\u0632\u0627\u0644\u0629 \u0627\u0644\u063a\u0627\u0632\u0627\u062a \u0645\u0646 \u0627\u0644\u0623\u0644\u0648\u0645\u0646\u064a\u0648\u0645"},"content":{"rendered":"

Aluminium Degassing<\/p>\n

AdTech Online Aluminium Degassing Machine is installed between the furnace and the casting machine to remove hydrogen and other residues from the molten Aluminium Degassing and its alloys that affect its quality and mechanical properties.<\/p>\n

In Aluminium Degassing control, metal casting must complete two things
\n1. Prevent and minimize the introduction of hydrogen in the melt.
\n2. Pre-casting hydrogen. The Aluminium Degassing will focus on measurement and removal, usually introduced into the melt by a rotary degasser.
\nWhen the purge gas bubbles are introduced into the melt, they collect hydrogen as they float on the surface.
\nThe best case is that these hydrogen-saturated bubbles leave the melt and reduce the hydrogen content.
\nIn this case, from a thermodynamic point of view, the process efficiency is 100%, but as the gas content in the melt decreases, the equilibrium pressure of hydrogen in the bubble also decreases, so the purge gas required to remove residual hydrogen The amount must increase.<\/p>\n

Aluminium Degassing Performance:
\n1. The aluminum water online degasser mainly processes the molten aluminum liquid containing a certain amount of hydrogen and other residues (alkali metal, slag inclusion), and is removed after being treated by the degassing equipment.
\n2. The principle of treatment is gas flotation.<\/p>\n

The aluminum degassing machine<\/a> has the characteristics of saving energy and lowering the ambient temperature, heating and rapid temperature control in real time, long service life, simple maintenance, large adjustable power range, practical and reliable.
\nThe aluminum alloy flawless holding furnace is designed in the form of flawless structure. The molten pool is made of imported high-quality pouring and grouting. It is non-stick aluminum and does not hang slag. It is directly heated by electric energy, clean and environmentally friendly. It is faster than indirect transmission heating and saves electricity. The heating furnace cover is pneumatically opened and closed.
\nClean slag maintenance, temperature control, temperature accuracy, aluminum liquid thermocouple protection using silicon nitride material, no iron, long life, safe and reliable, with overheat protection, overload protection and over-temperature protection, fully protect equipment and operation Safety.<\/p>\n

\"Aluminium<\/p>\n

The principle of the device is that the rotor rotating in the work breaks the inert gas (argon or nitrogen) blown into the aluminum water into a large amount of dispersed bubbles and disperses it in the aluminum liquid; the bubble is in the melt by the gas partial pressure difference And surface adsorption
\nThe principle is to absorb the hydrogen in the melt, adsorb the oxidized slag, and take it out of the surface of the melt as the bubble rises, so that the melt can be purified; because the bubbles are finely dispersed, uniformly mix with the rotating melt, and then rotate with a spiral Slow shape
\nWhen it comes up, it does not form a continuous airflow when it comes into contact with the melt, which significantly improves the purification effect. Both argon and nitrogen can be used as a degassing solution for aluminum. The purity of the inert gas must be above 99.95%.<\/p>\n

What Happens Inside Molten Aluminium Before Degassing?<\/h2>\n

Aluminium in liquid form behaves like a sponge for hydrogen. At 660\u00b0C, molten aluminium can hold roughly 0.69 ml of hydrogen per 100 grams of metal, but solid aluminium at room temperature holds only about 0.03 to 0.05 ml\/100g. That massive solubility drop, close to a 20-fold difference, means any hydrogen dissolved during melting has almost nowhere to go except out through the surface, or trapped inside the casting as bubbles.<\/p>\n

Where does the hydrogen come from in the first place? Moisture is the primary culprit. Humid shop air reacts with the aluminium surface, water vapor breaks down into hydrogen and oxygen, and the hydrogen dissolves straight into the melt. Wet or oily scrap, damp refractory linings on furnaces and ladles, and even condensation on charging tools all contribute. We’ve seen foundries in coastal, humid regions struggle with hydrogen pickup that never shows up in drier inland plants running identical alloys, which tells you how much ambient moisture matters.<\/p>\n

Oxide films complicate things further. Aluminium forms a thin oxide skin almost instantly on contact with air, and that skin can fold into the melt during pouring or stirring, creating pockets where hydrogen collects. This is why degassing and inclusion removal are often treated together rather than as separate operations.<\/p>\n

Why Does Hydrogen Cause So Much Trouble in Aluminium Castings?<\/h2>\n

When molten aluminium cools and solidifies, dissolved hydrogen has nowhere to sit. It comes out of solution and forms tiny gas pockets, which we call microporosity, or larger voids in severe cases. These defects weaken the casting from the inside.<\/p>\n

\n\n\n\n\n\n\n\n\n\n
Defect Type<\/th>\nRoot Cause<\/th>\nTypical Impact<\/th>\n<\/tr>\n<\/thead>\n
Microporosity<\/td>\nHydrogen rejected during solidification<\/td>\nReduced fatigue life, lower elongation<\/td>\n<\/tr>\n
Macroporosity<\/td>\nCombined shrinkage and gas porosity<\/td>\nLeak paths in pressure-tight parts<\/td>\n<\/tr>\n
Surface pinholes<\/td>\nTrapped hydrogen near mold wall<\/td>\nCosmetic rejection, machining exposes voids<\/td>\n<\/tr>\n
Reduced tensile strength<\/td>\nVoid concentration in load-bearing sections<\/td>\nFailure below rated stress in service<\/td>\n<\/tr>\n
Machining scrap<\/td>\nSubsurface porosity revealed after cutting<\/td>\nWasted machining time, batch rejection<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

A part that looks perfect coming out of the mold can fail an X-ray inspection or a pressure test hours later once porosity is revealed. In our experience supporting die casting and gravity casting operations, hydrogen-related rejects are one of the most expensive quality problems because the defect is invisible until later in the process, sometimes after machining costs have already been added.<\/p>\n

\"AdTech

AdTech Inline degassing aluminum machine<\/p><\/div>\n

What Are the Proven Methods for Removing Hydrogen from Molten Aluminium?<\/h2>\n

There isn’t a single correct way to degas aluminium. The right method depends on batch size, alloy type, budget, and how tight your porosity tolerance needs to be.<\/p>\n

\n\n\n\n\n\n\n\n\n
Method<\/th>\nHow It Works<\/th>\nTypical Hydrogen Removal<\/th>\nBest Suited For<\/th>\n<\/tr>\n<\/thead>\n
Rotary degassing<\/td>\nRotating graphite rotor disperses fine inert gas bubbles through the melt<\/td>\n60-80% reduction, reaches <0.15 ml\/100g<\/td>\nMedium to large foundries, continuous production<\/td>\n<\/tr>\n
Lance\/porous plug<\/td>\nGas injected through a stationary tube or diffuser stone<\/td>\n30-50% reduction, less efficient bubble distribution<\/td>\nSmall shops, low-volume operations<\/td>\n<\/tr>\n
Tablet\/flux degassing<\/td>\nSolid tablets release gas (often hexachloroethane) when submerged<\/td>\nModerate, but produces toxic fumes<\/td>\nLegacy operations, being phased out<\/td>\n<\/tr>\n
Vacuum degassing<\/td>\nMelt exposed to reduced pressure, pulling dissolved gas out<\/td>\nHigh, but slow and equipment-intensive<\/td>\nSpecialty alloys, aerospace-grade requirements<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Rotary degassing has become the industry default for good reason. The spinning rotor breaks incoming gas into thousands of small bubbles rather than a handful of large ones, and smaller bubbles mean more surface area for hydrogen to diffuse into as it rises through the melt. Lance degassing, by contrast, produces bigger bubbles that rise quickly and don’t give hydrogen enough contact time to transfer out efficiently.<\/p>\n

Rotary Degassing Systems: How Do They Actually Work?<\/h2>\n

A rotary degassing unit has three main working parts: a motor, a rotating shaft, and a graphite or CFC (carbon fiber composite) rotor head submerged in the melt. Inert gas flows down the hollow shaft and exits through small ports in the rotor. As the rotor spins, it shears the gas into a fine cloud of bubbles that disperses across the crucible or furnace bath.<\/p>\n

Rotor speed matters more than most operators realize. Run it too slow and bubble dispersion is poor, leaving dead zones where hydrogen barely moves. Run it too fast and you start pulling surface oxide down into the melt through vortex formation, which introduces new inclusion problems while you’re trying to solve a gas problem. We generally recommend starting around 400 rpm for smaller crucibles (under 500 kg) and adjusting upward toward 500-550 rpm for larger furnace volumes, then fine-tuning based on the vortex behavior you observe.<\/p>\n

Rotor lifespan is a real cost consideration. Graphite rotors are cheaper upfront but degrade faster in continuous-duty environments, often needing replacement every 4 to 8 weeks in high-throughput plants. CFC rotors cost more initially but can last three to five times longer, which usually makes them the better total-cost choice for foundries running multiple shifts.<\/p>\n

Typical Rotary Degassing Parameters<\/h3>\n
\n\n\n\n\n\n\n\n\n
Melt Volume<\/th>\nRotor Speed<\/th>\nTreatment Time<\/th>\nGas Flow Rate<\/th>\n<\/tr>\n<\/thead>\n
Under 300 kg<\/td>\n350-400 rpm<\/td>\n6-8 minutes<\/td>\n8-12 L\/min<\/td>\n<\/tr>\n
300-800 kg<\/td>\n400-450 rpm<\/td>\n8-12 minutes<\/td>\n12-20 L\/min<\/td>\n<\/tr>\n
800-2000 kg<\/td>\n450-500 rpm<\/td>\n12-18 minutes<\/td>\n20-35 L\/min<\/td>\n<\/tr>\n
Over 2000 kg<\/td>\n500-550 rpm<\/td>\n18-25 minutes<\/td>\n35-50 L\/min<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

These numbers shift depending on alloy family, initial hydrogen content, and furnace geometry, so treat them as starting points rather than fixed rules. We always tell customers to run a reduced pressure test before finalizing their cycle time rather than copying a number off a spec sheet.<\/p>\n

Which Gas Should You Use: Nitrogen, Argon, or a Chlorine Blend?<\/h2>\n

Gas choice affects both degassing performance and operating cost, and the differences are bigger than many buyers expect.<\/p>\n

\n\n\n\n\n\n\n\n\n
Gas<\/th>\nCost<\/th>\nEffectiveness<\/th>\nNotes<\/th>\n<\/tr>\n<\/thead>\n
Nitrogen<\/td>\nLow<\/td>\nGood for most wrought and casting alloys<\/td>\nCan react slightly with magnesium-heavy alloys at high temperature<\/td>\n<\/tr>\n
Argon<\/td>\nModerate to high<\/td>\nExcellent, fully inert<\/td>\nPreferred for high-magnesium alloys and critical applications<\/td>\n<\/tr>\n
Nitrogen\/chlorine blend (5-10% Cl2)<\/td>\nModerate<\/td>\nVery high, also removes some inclusions<\/td>\nFume extraction required, regulatory restrictions in many regions<\/td>\n<\/tr>\n
Pure chlorine<\/td>\nLow gas cost, high handling cost<\/td>\nVery effective but hazardous<\/td>\nLargely phased out due to safety and environmental rules<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Nitrogen is the workhorse for standard aluminium casting alloys because it’s inexpensive and does the job in most conditions. Argon becomes the better choice once magnesium content climbs above roughly 3-4%, since nitrogen can form magnesium nitride under certain conditions, creating a different kind of inclusion problem. Chlorine-bearing blends do improve degassing and inclusion removal simultaneously, but the fume handling requirements and worker safety concerns mean most modern facilities we work with have moved away from them entirely, or use them only in tightly controlled fume-hood setups.<\/p>\n

How Do You Test and Verify Degassing Results on the Shop Floor?<\/h2>\n

You cannot manage what you don’t measure, and hydrogen content is invisible to the naked eye. Two testing approaches dominate the industry.<\/p>\n

Reduced Pressure Test (RPT):<\/strong>\u00a0A small sample of molten metal solidifies inside a vacuum chamber at low pressure, typically around 80-100 millibar absolute. Because the pressure is reduced, dissolved hydrogen expands and forms visible porosity in the sample as it cools. Operators then compare the sample’s density against a fully dense reference, or visually grade the fracture surface against reference photographs. This test is cheap, fast (10-15 minutes including cooling), and doesn’t require expensive instrumentation, which is why it remains the most widely used method on production floors.<\/p>\n

Density Index:<\/strong>\u00a0Calculated from the RPT sample using the formula:<\/p>\n

Density Index (%) = [(Density of solidified sample under normal pressure minus density under reduced pressure) divided by density under normal pressure] multiplied by 100<\/p>\n

A density index under 3% generally indicates good degassing, while anything above 5-7% signals a problem that needs immediate attention before pouring continues.<\/p>\n

Electronic hydrogen probes<\/strong>\u00a0(such as immersion sensors used in real-time monitoring systems) give a direct ml\/100g reading in under a minute and don’t require sample solidification. They cost significantly more than RPT equipment but pay off in high-volume operations where waiting 15 minutes between checks slows down production decisions. In our conversations with procurement teams, the probe method tends to win out once daily melt volume exceeds a few tonnes, simply because the labor savings and faster feedback loop offset the higher instrument cost within a year or two.<\/p>\n

What Should Buyers Look for When Sourcing Degassing Equipment?<\/h2>\n

This is where technical requirements meet budget reality, and it’s the section we get asked about most often by purchasing managers who aren’t necessarily metallurgists themselves.<\/p>\n

\n\n\n\n\n\n\n\n\n\n\n
Consideration<\/th>\nWhy It Matters<\/th>\nQuestions to Ask the Supplier<\/th>\n<\/tr>\n<\/thead>\n
Rotor material<\/td>\nAffects lifespan and replacement cost<\/td>\nGraphite or CFC? Expected service life in hours?<\/td>\n<\/tr>\n
Motor power and speed range<\/td>\nDetermines melt volume capacity<\/td>\nVariable speed drive included? What’s the rpm range?<\/td>\n<\/tr>\n
Gas control system<\/td>\nConsistency of flow affects degassing quality<\/td>\nDigital flow meter or manual valve? Calibration process?<\/td>\n<\/tr>\n
Shaft sealing<\/td>\nPrevents gas leaks and metal ingress<\/td>\nWhat sealing material, and how often does it need service?<\/td>\n<\/tr>\n
Automation level<\/td>\nLabor cost and repeatability<\/td>\nProgrammable cycle profiles? Data logging capability?<\/td>\n<\/tr>\n
Footprint and mounting<\/td>\nFit within existing furnace layout<\/td>\nFixed mount, portable cart, or overhead arm mounting?<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Equipment pricing varies widely depending on automation level and capacity. Entry-level manual rotary units for small foundries can run from a few thousand dollars, while fully automated, programmable systems with data logging for large-scale operations can reach well into five figures or higher once you add multiple treatment stations. We generally advise buyers to price out total cost of ownership, including rotor and shaft replacement over a two-year period, rather than comparing sticker prices alone, because a cheaper unit with fast-wearing components can end up costing more over time.<\/p>\n

Warranty terms and spare parts availability deserve equal attention. A degassing unit sitting idle for two weeks waiting on a replacement rotor shaft from overseas can cost a foundry far more in lost production than the machine’s original purchase price.<\/p>\n

Common Mistakes We See in Aluminium Degassing Operations<\/h2>\n

Having reviewed countless foundry setups over the years, certain mistakes come up again and again, regardless of company size or region.<\/p>\n

Treating a cold rotor.<\/strong>\u00a0Inserting a room-temperature rotor directly into molten metal causes thermal shock, which cracks graphite rotors prematurely and can also chill the melt locally, creating uneven treatment. Preheating the rotor before immersion solves this in most cases.<\/p>\n

Running the cycle too long or too fast in an attempt to “over-degas.”<\/strong>\u00a0Excessive rotor speed creates a vortex that pulls surface oxide into the bath, and excessive treatment time can actually reintroduce hydrogen if the shop atmosphere is humid and treatment runs longer than necessary. There’s a sweet spot, and it’s usually shorter than operators assume.<\/p>\n

Skipping the test step.<\/strong>\u00a0Some smaller operations degas on a fixed timer without ever running an RPT or hydrogen probe check, which means they have no actual evidence the process is working. We’ve walked into shops confident their degassing was fine, only to find density index readings above 8% once we actually tested.<\/p>\n

Using contaminated or wet gas lines.<\/strong>\u00a0A nitrogen or argon supply line with moisture contamination defeats the purpose of the entire process, since you’re injecting the very thing you’re trying to remove.<\/p>\n

Ignoring furnace and ladle refractory moisture<\/strong>\u00a0after relining or repair. New refractory needs a proper bake-out schedule; skipping it introduces a fresh moisture source right at the point of melt contact.<\/p>\n

How Does Degassing Fit Into the Broader Melt Treatment Process?<\/h2>\n

Degassing rarely happens in isolation. A well-run melt treatment sequence generally follows this order: fluxing to remove non-metallic inclusions and clean the melt surface, degassing to strip dissolved hydrogen, grain refinement (often with titanium boron master alloys) to control solidification structure, and final filtration through ceramic foam filters just before pouring to catch any remaining oxide particles.<\/p>\n

Skipping steps or performing them out of sequence undermines the whole chain. Degassing before fluxing, for instance, means you’re stirring inclusions back into a melt you just tried to clean. We recommend treating this as a single integrated process with a documented sequence rather than a checklist where steps get skipped under time pressure.<\/p>\n

Frequently Asked Questions<\/h2>\n

1. How long does aluminium degassing actually take?<\/strong>
\nMost rotary degassing cycles run between 8 and 20 minutes depending on melt volume and starting hydrogen content. Smaller crucibles under 300 kg often finish in under 10 minutes, while large furnace volumes can require 20 minutes or more for thorough treatment.<\/p>\n

2. Can you over-degas aluminium?<\/strong>
\nYes. Running the rotor too fast or too long can pull oxide film into the melt through vortexing, and extended exposure to humid shop air during an overly long cycle can partially reintroduce hydrogen. There’s a practical limit past which additional time stops helping and starts hurting.<\/p>\n

3. What’s the acceptable hydrogen level for most aluminium castings?<\/strong>
\nGeneral industrial castings often target below 0.2 ml\/100g, while aerospace and high-integrity automotive components typically require below 0.1 to 0.15 ml\/100g. Specification requirements vary by alloy and application, so always check the governing standard for your specific part.<\/p>\n

4. Is nitrogen or argon better for degassing?<\/strong>
\nNitrogen works well for most standard casting alloys and costs less. Argon is preferred for alloys with higher magnesium content and for applications demanding the highest possible cleanliness, since it’s fully inert and won’t interact with reactive alloy elements.<\/p>\n

5. What’s the difference between rotary degassing and lance degassing?<\/strong>
\nRotary degassing uses a spinning rotor to create fine, well-distributed bubbles throughout the melt, achieving 60-80% hydrogen reduction. Lance degassing injects gas through a stationary tube, producing larger bubbles that rise faster and remove less hydrogen, typically 30-50%.<\/p>\n

6. How do I know if my aluminium melt needs degassing?<\/strong>
\nRun a reduced pressure test or use a hydrogen probe. If you’re seeing porosity in X-rays, leak failures on pressure-tested parts, or unexplained mechanical property drops, hydrogen content is one of the first things to check.<\/p>\n

7. Are degassing tablets (hexachloroethane) still used today?<\/strong>
\nSome smaller or older operations still use them, but many regions have restricted their use due to toxic fume generation. Rotary degassing with inert gas has largely replaced tablet fluxing in modern foundries.<\/p>\n

8. How often should the rotor be replaced?<\/strong>
\nGraphite rotors in continuous-duty operations typically last 4 to 8 weeks before wear affects bubble dispersion quality. CFC rotors can last three to five times longer, though the exact figure depends on melt temperature, alloy, and duty cycle.<\/p>\n

9. Does degassing remove inclusions as well as hydrogen?<\/strong>
\nRotary degassing removes some inclusions as bubbles rise and carry particles to the surface, but it’s not a substitute for proper fluxing and filtration. Treat degassing and inclusion removal as complementary steps, not interchangeable ones.<\/p>\n

10. What size degassing unit do I need for my furnace?<\/strong>
\nMatch rotor size, motor power, and gas flow rate to your typical melt volume. A unit sized for 500 kg batches will underperform on a 2-tonne furnace, and oversizing equipment for small batches wastes gas and increases oxide entrapment risk from excess turbulence. Supplier consultation based on your actual furnace dimensions gives more reliable sizing than generic charts.<\/p>\n","protected":false},"excerpt":{"rendered":"

Aluminium Degassing AdTech Online Aluminium Degassing Machine is installed between the furnace and the casting machine to remove hydrogen and other residues from the molten Aluminium Degassing and its alloys that affect its quality and mechanical properties. 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