Wu Yunfei, Yan Hao, Wang Jiahao, Na Xianzhao, Wang Xiaodong, Zheng Jincan
State Key Laboratory of Advanced Steel Processes and Products, Central Iron and Steel Research Institute, Beijing 100081, China.
College of Materials Science and Opto-Electronic Technology, University of Chinese Academy of Sciences, Beijing 100049, China.
Sensors (Basel). 2024 Apr 26;24(9):2767. doi: 10.3390/s24092767.
Traditional methods for assessing the cleanliness of liquid metal are characterized by prolonged detection times, delays, and susceptibility to variations in sampling conditions. To address these limitations, an online cleanliness-analyzing system grounded in the method of the electrical sensing zone has been developed. This system facilitates real-time, in situ, and quantitative analysis of inclusion size and amount in liquid metal. Comprising pneumatic, embedded, and host computer modules, the system supports the continuous, online evaluation of metal cleanliness across various metallurgical processes in high-temperature environments. Tests conducted with gallium liquid at 90 °C and aluminum melt at 800 °C have validated the system's ability to precisely and quantitatively detect inclusions in molten metal in real time. The detection procedure is stable and reliable, offering immediate data feedback that effectively captures fluctuations in inclusion amount, thereby meeting the metallurgical industry's demand for real-time analyzing and control of inclusion cleanliness in liquid metal. Additionally, the system was used to analyze inclusion size distribution during the hot-dip galvanizing process. At a zinc melt temperature of 500 °C, it achieved a detection limit of 21 μm, simultaneously providing real-time data on the size and amount distribution of inclusions. This represents a novel strategy for the online monitoring and quality control of zinc slag throughout the hot-dip galvanizing process.
传统的评估液态金属清洁度的方法具有检测时间长、存在延迟以及易受采样条件变化影响的特点。为了解决这些局限性，已经开发了一种基于电传感区方法的在线清洁度分析系统。该系统有助于对液态金属中的夹杂物尺寸和数量进行实时、原位和定量分析。该系统由气动模块、嵌入式模块和主机模块组成，支持在高温环境下对各种冶金过程中的金属清洁度进行连续在线评估。在90°C的镓液和800°C的铝熔体上进行的测试验证了该系统实时精确且定量检测熔融金属中夹杂物的能力。检测过程稳定可靠，可提供即时数据反馈，有效捕捉夹杂物数量的波动，从而满足冶金行业对液态金属夹杂物清洁度进行实时分析和控制的需求。此外，该系统还用于分析热镀锌过程中的夹杂物尺寸分布。在500°C的锌熔体温度下，其检测限达到21μm，同时提供夹杂物尺寸和数量分布的实时数据。这代表了一种在整个热镀锌过程中对锌渣进行在线监测和质量控制的新策略。
