I. Application

The presence of hydrogen gas, the only gas that exists in large quantities in molten aluminum, and various inclusions, makes aluminum castings highly prone to defects such as pinholes and micro-porosity, significantly reducing the mechanical properties and internal quality of the castings.

·Hydrogen tester is an indicator that comprehensively reflects the purity of metal, and further detects the cleanliness of aluminum liquid (including gas content and slag content).

·The Aluminum Alloy Hydrometer is used to test the density equivalent value of aluminum alloy samples, detecting the actual purity (density) of aluminum alloy samples, thereby accurately and quantitatively reflecting the impact of hydrogen and various inclusions in the aluminum melt on aluminum alloy castings.

·The hydrogen tester for molten aluminum is an ideal practical means for quality control in the production of aluminum alloy casting, assessing degassing, refining effects, the quality of molten aluminum, and the smelting process.

Easy to operate, suitable for on-site melting process testing, especially for foundry or aluminum processing sites with multiple holding furnaces, such as aluminum casting and aluminum profile processing.

II. Terms of Use

The Aluminum Alloy Hydrometer is suitable for the following working environments:

1. Not exceeding 1500 meters in altitude.

2. The environmental temperature is within the range of 0~90℃.

3. There is no conductive dust, explosive gases, or corrosive gases that can severely damage metals and insulation. All electrical equipment should not be damaged by physical and chemical operations (such as environmental thermal effects, humidity, etc.) during normal operation.

4. Indoor Use

Section 3: Instrument Features

Absolute Pressure Value Display:

Absolute value pressure display; this equipment utilizes a Japanese-imported digital pressure gauge and is equipped with a precision U.S.-manufactured absolute pressure sensor for signal collection. Traditional pointer-style pressure gauges are affected by pressure variations due to altitude differences between regions; the pressure reading varies with altitude changes. However, with our absolute pressure sensor, the equipment accurately displays the true pressure value regardless of its location.

Digital Pressure Gauge

2. Durable and sturdy vacuum cover:

The vacuum chamber does not use a fully glass bell jar, eliminating concerns of damage to the bell jar. The chamber is machined from aluminum alloy material, assembled with a 10mm thick high-temperature glass and a high-temperature sealing gasket, offering advantages such as shock resistance, rapid heat dissipation, and high-temperature resistance up to 100℃. Additionally, due to the high-temperature transparent glass used at the top of the vacuum cover, the process of sample preparation can be easily observed within the vacuum chamber, just as conveniently as through a glass bell jar.

Vacuum Cover

Vacuum Chamber Base

3. Easy-to-move casters

Convenient portable structure for detecting gas content in aluminum liquid at various fixed positions; versatile in use. Equipped with four polyurethane casters for minimal vibration during movement; the front wheel also features a braking function, allowing easy immobilization at the work position, ensuring it stays put during operation.

Mobile casters

4. Sample Cooling System:

Due to the high temperature of the sample immediately after extraction, natural cooling is too slow. Water cooling at the casting site is also too dangerous; therefore, the CQY-1000 hydrogen tester is equipped with an air cooling system, specifically designed for rapid cooling of the sample. This not only shortens the cooling time and improves efficiency but also ensures safety at the casting site.

5. High-temperature-resistant 304 stainless steel countertop

Hydrogen testers, working on foundry sites, are at risk of being damaged by accidentally spilled aluminum liquid or other corrosive substances, leading to surface deformation, discoloration, and making the equipment appear dirty and worn, which affects the company's image. In contrast, our CQY-1000 hydrogen tester features a stainless steel brushed surface, which is resistant to minor spills of aluminum liquid, doesn't deform or discolor, has excellent corrosion resistance, and is easy to clean, ensuring the equipment stays fresh and new.

6. Excellent Output:

Equipped with a 7-inch computer monitor, it clearly displays all test results; also includes a printer, allowing users to choose whether to print the test results. The system is equipped with a USB output interface, enabling the export of historical data at any time for analysis in other systems.

7-inch computer monitor

Printer

7. Testable for reducing density and preparing reducing pressure samples; versatile machine for multiple uses.

8. Fast analysis speed. Under on-site conditions, quality analysis of aluminum liquid can be completed within 5 minutes.

9. Test results are authentic and reliable with good reproducibility. By integrating various analytical methods, an accurate assessment of the aluminum liquid quality can be made, providing a solid and dependable guide for production.

10. The aluminum alloy density tester uses a method to amplify defects in aluminum liquid for quality assessment. Thus, this instrument enables a finer and more accurate detection of aluminum liquid quality.

11. Quantitative testing. Eliminate ambiguity and uncertainty in conventional methods such as solidification state of routine samples and observation of sample cross-sectional states.

12. Easy to operate, safe to use. No extensive experience required for the operator; with minimal training, proper usage is ensured.

13. Self-contained data calculation and storage.

14. Self-check function: If the operator places the samples in the wrong order, the system will automatically detect and prompt. If allowed by the user, the system can automatically swap the measured data.

IV. Calculation of Density Index

1. Density Equivalent (DI) Definition:

Two aluminum alloy samples were prepared: one was solidified under atmospheric pressure, and its density (pa) was measured; the other was solidified under reduced pressure conditions (a certain vacuum degree), and its density (pb) was measured. The density equivalent of the sample was calculated from these two densities.

Formula: Dl = (pa - pb) / pax100% = (1 - pb/pa) x 100%

During the process of obtaining specimens under a certain degree of vacuum, the aluminum liquid is expanded internally due to the balancing effect of internal and external pressures, causing pinholes and shrinkage cavities within the liquid to increase. Theoretically, for absolutely pure aluminum liquid, the values of the specimens prepared under normal pressure and reduced pressure are the same, i.e., pb = pa, Dl = 0; the purer the aluminum liquid, the closer pb is to pa, meaning the DI value is smaller. That is to say, the smaller the density equivalent DI value, the better the quality of the aluminum liquid. It can be known that the size of the DI value can accurately judge the overall quality of the aluminum liquid.

V. Instrument Composition

The RT-CQY-1000 hydrogen tester mainly consists of: the sample preparation system section and the data terminal.

5.1 Sample Preparation System: Part of the sample preparation is divided into two processes: normal pressure casting and vacuum degassing casting. Both processes scoop the same type of aluminum melt at the same moment.

5.1.1 Component Parts. The pressure-reducing test sample acquisition device consists of several parts, including the vacuum system, frame, and electrical control system.

A. Vacuum System. Includes: vacuum pumps, vacuum solenoid valves, vacuum chambers, pressure regulators, and vacuum pressure gauges. The vacuum chamber is positioned above the instrument, consisting of a vacuum hood and a lower sealed flat plate. The vacuum hood does not use a glass bell jar, eliminating concerns about damage.

B. The rack structure features a rigid skeleton for securing the vacuum system and other components. It is equipped with four load-bearing casters for easy mobility.

C. Electrical Control System. The vacuum pressure sensor transmits the pressure signal of the vacuum chamber to the pressure gauge, converting it into a digital signal for display; the control panel features two control buttons and a timer relay. By pressing the switch button, you can control the start/stop of the vacuum pump and the opening/closing of the solenoid valve, automatically completing operations such as evacuation.

5.1.2 Sample Preparation Process.

A. Vacuum Sample Preparation. A preheated crucible (coated with paint for nickel crucibles) is used to carefully extract a small amount of aluminum melt (approximately 100g) from the core of the aluminum melt to be tested. The crucible is immediately placed into the vacuum chamber (within less than 15 seconds). The vacuum chamber is rapidly evacuated to a certain vacuum level (typically 8kPa), and the aluminum melt in the crucible cools and solidifies, producing a vacuum sample.

B. Using a preheated crucible (Nickel crucible should be coated with paint), carefully remove a small amount of aluminum melt (about 100g) from the center of the aluminum melt to be tested. Place the crucible on a normal pressure test stand, cover it with a lid (to prevent external factors from affecting the cooling rate), and allow the aluminum melt in the crucible to cool and solidify naturally, thereby obtaining a normal pressure test sample.

5.2 Data Terminal

5.2.1 Components: Divided into data measurement section and data calculation, storage, and printing section.

A. The data measurement section consists of a precise electronic balance, sample holder, beaker, etc.

High-precision balance

B. Data Processing Section. Comprising of a display screen, printer, storage port, mouse, and other components.

Section 6: Technical Requirements

·Power Supply: 220V/50Hz

· Total Power of Instruments: <500W

· Ultimate vacuum degree: 3kPa (Absolute vacuum pressure is 30mba, relative to 1 atmosphere pressure is -0.097MPa)

· The vacuum level can be adjusted between 50-100 mba.

·Vacuum control accuracy: ±0.2 kPa.

· Sample Preparation Time: <5 mins

· Time to Ultimate Vacuum: ≤4S

· Maximum temperature in the vacuum chamber: 150℃

· Vacuum pressure gauge with digital display

· Vacuum time display: 3 minutes

· The vacuum chamber cover is equipped with high-strength heat-resistant glass

·Measurement accuracy of the actual density index value: <0.02

· Measured density index repeatability < 0.02 (Note: Equipment detection accuracy)

· Measurement range of the electronic balance: 500g

·Measurement results show accuracy: 0.01

·Measurement Repeatability: ±0.001g

· Measure response time: approximately 2S

· Automatically calculate density and quickly display the density value and density equivalent value

· Inside the electronic component box, there is a sealed dust-proof design