Pretreatment of aluminum scrap is an essential step in the recycling process to ensure the production of high-quality recycled aluminum. The Scrap Pretreatment process helps remove impurities, contaminants, and coatings from the scrap material, allowing for better recovery of pure aluminum. Some common steps involved in the pretreatment of aluminum scrap: Collection and Sorting, Cleaning, Size Reduction, Magnetic Separation, Eddy Current Separation, X-ray Separation.

By implementing these Scrap Pretreatment steps, the recycled aluminum can be of higher quality, while minimizing the environmental impact of the recycling process.

Next step for the clean and shredded scrap is the decoating process by Thermal Pyrolysis, involving the decomposition of organic materials at elevated temperatures in the absence of oxygen, separating organic coatings or substances from the aluminum through high-temperature treatment.

Insertec´s IDEX® decoating technology ensures the highest metal efficiency when melting the scrap in the Aluswirler® vortex system.

The aluminum melting process at a die cast foundry is a crucial step in the production of aluminum products. The foundry is a facility where aluminum is melted and cast into various shapes and forms, such as engine blocks, pistons, etc, which are then used for further processing in industries like automotive & aerospace.

The prepared primary aluminum or scrap is charged into a melting furnace. There are different types of furnaces used in the foundry:

Melting towers, used in general for primary and process scrap aluminum melting, holding, and alloying.

Side Well furnaces, used in general for chips scrap re-melting, equipped with ALUSWIRLER® vortex system.

The heat can be generated through combustion (natural gas….), electricity, or a combination of both, depending on the type of furnace and other considerations.

The polluted air containing fumes and particulate matter is drawn into a Baghouse system. The fabric filter bags act as a barrier, allowing air to pass through while trapping the particulates on the surface of the bags. Cleaned air is then released back into the environment.

Aluminio casthouse es una instalación donde el aluminio se procesa y se funde en diversas formas. Aluminio casthouse ,consiste en transformar el aluminio fundido en productos sólidos. Antes de la colada, el aluminio fundido pasa por diferentes etapas:

El refinado consiste en eliminar las impurezas del aluminio fundido para obtener un producto final de alta calidad.

La desgasificación es un proceso para eliminar los gases disueltos, como el hidrógeno y el nitrógeno, del aluminio fundido. Un contenido excesivo de gas en el aluminio puede provocar defectos en el producto final.

El filtrado se emplea para eliminar las impurezas sólidas del aluminio fundido. Esto ayuda a producir un metal más limpio y de mayor calidad.

Para la fundición de tochos y desbastes, se utiliza una máquina de fundición vertical, que vierte el aluminio fundido en moldes específicos, equipados con un sistema de refrigeración eficaz para controlar el proceso de solidificación del aluminio y garantizar las propiedades metalúrgicas deseadas. El diseño del molde es crucial para conseguir la forma y las dimensiones deseadas del tocho o planchón.

Handling, finishing and packaging of aluminum semi-finished products involves several important steps to ensure material quality and safety between the different stages of aluminum production. The Insertec team always suggests the most appropriate solution based on the different inputs (product dimensions, alloy, etc.

Pretreatment of aluminum scrap is an essential step in the recycling process to ensure the production of high-quality recycled aluminum. The Scrap Pretreatment process helps remove impurities, contaminants, and coatings from the scrap material, allowing for better recovery of pure aluminum. Some common steps involved in the pretreatment of aluminum scrap: Collection and Sorting, Cleaning, Size Reduction, Magnetic Separation, Eddy Current Separation, X-ray Separation.

By implementing these Scrap Pretreatment steps, the recycled aluminum can be of higher quality, while minimizing the environmental impact of the recycling process.

Next step for the clean and shredded scrap is the decoating process by Thermal Pyrolysis, involving the decomposition of organic materials at elevated temperatures in the absence of oxygen, separating organic coatings or substances from the aluminum through high-temperature treatment.

Insertec´s IDEX® decoating technology ensures the highest metal efficiency when melting the scrap in the Aluswirler® vortex system.

The aluminum melting process at a die cast foundry is a crucial step in the production of aluminum products. The foundry is a facility where aluminum is melted and cast into various shapes and forms, such as engine blocks, pistons, etc, which are then used for further processing in industries like automotive & aerospace.

The prepared primary aluminum or scrap is charged into a melting furnace. There are different types of furnaces used in the foundry:

Melting towers, used in general for primary and process scrap aluminum melting, holding, and alloying.

Side Well furnaces, used in general for chips scrap re-melting, equipped with ALUSWIRLER® vortex system.

The heat can be generated through combustion (natural gas….), electricity, or a combination of both, depending on the type of furnace and other considerations.

The polluted air containing fumes and particulate matter is drawn into a Baghouse system. The fabric filter bags act as a barrier, allowing air to pass through while trapping the particulates on the surface of the bags. Cleaned air is then released back into the environment.

Aluminio casthouse es una instalación donde el aluminio se procesa y se funde en diversas formas. El proceso de casthouse consiste en transformar el aluminio fundido en productos sólidos. Antes de la colada, el aluminio fundido pasa por diferentes etapas:

El refinado consiste en eliminar las impurezas del aluminio fundido para obtener un producto final de alta calidad.

La desgasificación es un proceso para eliminar los gases disueltos, como el hidrógeno y el nitrógeno, del aluminio fundido. Un contenido excesivo de gas en el aluminio puede provocar defectos en el producto final.

El filtrado se emplea para eliminar las impurezas sólidas del aluminio fundido. Esto ayuda a producir un metal más limpio y de mayor calidad.

Para la fundición de lingotes, se diseña una máquina de fundición específicamente para la fundición de lingotes de aluminio. El proceso de fundición de lingotes implica verter aluminio fundido en moldes para solidificar y formar lingotes o cerdas. Para la producción de lingotes, la máquina de colada puede constar de una rueda de colada, un sistema de refrigeración, un transportador de moldes y otros componentes.

La manipulación, el acabado y el embalaje de productos semiacabados de aluminio implican varios pasos importantes para garantizar la calidad y la seguridad del material entre las distintas fases de producción del aluminio. El equipo de Insertec sugiere siempre la solución más adecuada en función de las diferentes entradas (dimensiones del producto, aleación, etc.

Pretreatment of aluminum scrap is an essential step in the recycling process to ensure the production of high-quality recycled aluminum. The Scrap Pretreatment process helps remove impurities, contaminants, and coatings from the scrap material, allowing for better recovery of pure aluminum. Some common steps involved in the pretreatment of aluminum scrap: Collection and Sorting, Cleaning, Size Reduction, Magnetic Separation, Eddy Current Separation, X-ray Separation.

By implementing these Scrap Pretreatment steps, the recycled aluminum can be of higher quality, while minimizing the environmental impact of the recycling process.

Next step for the clean and shredded scrap is the decoating process by Thermal Pyrolysis, involving the decomposition of organic materials at elevated temperatures in the absence of oxygen, separating organic coatings or substances from the aluminum through high-temperature treatment.

Insertec´s IDEX® decoating technology ensures the highest metal efficiency when melting the scrap in the Aluswirler® vortex system.

The aluminum melting process at a die cast foundry is a crucial step in the production of aluminum products. The foundry is a facility where aluminum is melted and cast into various shapes and forms, such as engine blocks, pistons, etc, which are then used for further processing in industries like automotive & aerospace.

The prepared primary aluminum or scrap is charged into a melting furnace. There are different types of furnaces used in the foundry:

Melting towers, used in general for primary and process scrap aluminum melting, holding, and alloying.

Side Well furnaces, used in general for chips scrap re-melting, equipped with ALUSWIRLER® vortex system.

The heat can be generated through combustion (natural gas….), electricity, or a combination of both, depending on the type of furnace and other considerations.

The polluted air containing fumes and particulate matter is drawn into a Baghouse system. The fabric filter bags act as a barrier, allowing air to pass through while trapping the particulates on the surface of the bags. Cleaned air is then released back into the environment.

Aluminum Die casting is a widely used manufacturing process that involves the production of intricate and complex metal parts by pouring molten aluminum into a mold. There are several casting techniques for aluminum, each with its own advantages and applications. Insertec´s metallurgical experts will study the complete process, suggesting the most suitable casting technique. Before casting, the molten aluminium passes through different steps:

Refining involves the removal of impurities from the molten aluminum to achieve a high-quality final product.

Degassing is a process to remove dissolved gases, such as hydrogen and nitrogen, from the molten aluminum. Excessive gas content in aluminum can lead to defects in the final product.

Filtering is employed to remove solid impurities from the molten aluminum. This helps in producing a cleaner and higher-quality metal.

There are several die casting techniques for aluminum, each with its own advantages and applications as Sand Casting, Low-Pressure Casting, High-Pressure Casting, etc.

Selecting the appropriate Die casting technique depends on factors such as the desired part geometry, production volume, cost considerations, and required material properties. Each technique has its own set of advantages and limitations.

Handling, finishing and packaging of aluminum semi-finished products involves several important steps to ensure material quality and safety between the different stages of aluminum production. The Insertec team always suggests the most appropriate solution based on the different inputs (product dimensions, alloy, etc.