Inherit the ability of melting and casting and create a good result in the New year. In the first quarter, the comprehensive finished product rate of the melting and casting plant was 74.9%, an increase of 1.8% over the same period last year; the rate of finished products for flaw detection was 96.3%, an increase of 3% over the same period last year; and the rate of high-end alloy flaw detection was 98.56%, an increase of 1.4% over the same period last year. The delivery volume of completed ingots increased by 13.1% compared with the same period last year, achieving a good start to the first quarter.
Improving the quality of melt to boost the increment of high-end alloy
Keep an eye on management and strive for refinement. In order to improve the yield of flaw detection, on the basis of previous successful experience, the melting and casting plant has optimized and solidified a number of measures, starting from the details and in-depth analysis, so that the quality of the melt has been further improved.
The melting and casting plant focuses on monitoring the working status of the degassing equipment and the status of refractories, replacing the damaged degassing box lining, ensuring the degassing rate, reducing slagging in the box, improving melt purity, promoting standardized operation, making a liquid separation net frame with positioning, so as to facilitate the unified position of the liquid separation net between casting times. Popularize the new preheating method of shunt plate, improve the preheating uniformity, reduce the burning loss of refractories caused by open fire, promote the upgrading and transformation of refractories, reduce the difficulty of cleaning and improve the service life of refractories.
The waste oxide film is a difficult problem in the melting and casting plant, which is not only difficult to find and analyze the cause, but also can only be found in the finished product process, resulting in a large loss. In order to break through this key narrow mouth, the melting and casting factory jointly carried out technical research with the technology center and the manufacturing department, analyzing the mechanism of defects from the source, tracking the production process in detail, precise positioning and precise control, and effectively reducing the waste of oxide film. the company's high-end products delivered more than 1000 tons, a new high.
Continuous optimization of process to improve production efficiency
Keep an eye on the target. In the first quarter, the melting and casting plant focused on the use of purchased waste, continuously optimized the process, increased the input ratio of 5 series purchased waste from 20% to 30%, and increased the use of purchased waste by 96.6% compared with the same period last year.
The melting and casting plant dynamically adjusts the waste use structure and adopts the method of shutting down one furnace for every two furnaces used, so as to reduce the residence time of iron in the waste, and at the same time, increase the intensity of slag cleaning, so as to ensure that the element content is qualified. In addition, the melting and casting plant fully optimizes the furnace washing process and gradually replaces the original use of aluminum ingots to use waste to wash the furnace, and the cost reduction effect is obvious.
Through fine control of the use of purchased waste, strict re-inspection of furnace charge to prevent mixing, reduce analysis time, save energy, reduce production cost, reduce process time. In the first quarter, the qualified rate of one-time analysis in the melting and casting plant increased by 1.0% compared with the same period last year, which contributed to the successful completion of the output target in the first quarter.
Solve the bottleneck of increasing production by tackling key problems in key projects
Keep an eye on the problem for a breakthrough. The improvement of finished product rate is an effective means to increase output. Starting with reducing geometric waste, the melting and casting plant has carried out special projects such as sawing head and tail optimization, milling quantity optimization and so on, and the finished product rate has been significantly improved.
The high crack scrap rate is another difficulty restricting the increase of production. In order to reduce the crack scrap rate, the melting and casting plant has formulated a "special scheme for improving the finished product rate of round ingots" and formulated relevant measures and assessment schemes for round ingot crack waste products. After the implementation of this scheme, the standardized operation of the old round ingot is gradually realized, the crack waste caused by human operation difference is reduced, and the ingot delivery rate is improved.
High-end alloy homogenization has always been a narrow process in the melting and casting plant. Without equipment transformation, the melting and casting plant optimizes the square size of the soaking pad to make the north line No. 2 soaking furnace install one more layer of material and increase the charging capacity by 33.3%. The uniformity test is being carried out at present.
Innovative tooling design helps the company to increase production.
Keep an eye on tooling to promote promotion. In order to further improve the production efficiency and reduce the time of tool replacement, the melting and casting factory independently developed and designed a new type of mould, which is specially designed for soft alloys with various specifications. The use of a material with good lubrication performance on the crystal surface can not only improve the surface quality of the ingot and reduce the amount of lubricating oil, but also quickly change the specification and reduce the auxiliary time.
The maintenance quality of tooling is the key to control the quality of round ingots, and the auxiliary time is relatively long. in order to solve the contradiction that the maintenance time of tooling occupies the production time, the melting and casting plant designs the tipping maintenance platform independently and transfers the maintenance of round ingots to the offline line, which no longer occupies production time and effectively improves the production efficiency. The platform is under manufacture.
Since the beginning of the year, the melting and casting factory has persisted in not changing the direction and channels, thinking of ways and measures, and making every effort to promote the work of narrowing the mouth and increasing production. All the staff will take advantage of the opportunity of a good start in the first quarter to make unremitting efforts and work courageously to meet new challenges and continue to write new chapters.