Image Analysis Procedures

The image analysis is performed through the following steps. To perform image analysis, you need IA500, cutter, resin embedding machine, polisher and MIRASYS.

(1) Filtration Test by IA500
First, molten aluminum is filtered through the filter in the IA500.
Impurities are deposited on the filter after filtration. The aluminum on the filter and the filter itself are taken out of the IA500 as a sample.

(2) Marilite Removal
Cut the Marilite part by contour machine, so that you can pick up the central part from marilite part. The central part is consists of the filter and aluminum.

(3) Cutting of the Central Part

Cut the central part with a cutter. Occasionally, the vibration of the cutter may cause the filter and aluminum parts to separate. Cut with as little vibration as possible to avoid separation.

(4) Covering by Resin
Cover the sample with resin and equipment.

(5) Polishing
Polish the cut surface which is cover by resin. General polishing methods are fine.

(6) Image Analysis by MIRASYS
Finally the cross section of the sample is analyzed by MIRASYS.

Image Analysis

Top and Bottom image
This is an images of top and bottom on the filter.
Inclusions and oxidation is shown on the blue line. Top is the dirty sample, and bottom is clean sample.

Middle image
This image was photographed in high magnification.
If you looks carefully, green part and blue part are existing.

New inspection method

(1)Customizing the inspection area
As left images, you can set the location to measure the sample by your selves. For example, it can be also measure floating oxidation which is not existing at the top of filter This gives us lots of flexibility.
(2)PSD of inclusions
It is possible to analyze the inclusion volume by PSD. So more detail analysis by PSD also possible.

Historical Data Record

Based upon out historical inspected data, now we can consulting the marketing information.

Elemental Analysis Services

Left: Results of elemental analysis by enlarging the area within the red frame in the above figure. The component name and percentage are displayed for each analyzed point.

By identifying the composition of foreign substances, it is possible to check whether there are causes of chipping defects such as oxide film and magnesium oxide.

Inspection Service

We do the inspection service for portrait analysis of inclusion / oxidation measurement by IA500. Feel free to contact us.
When requesting a filtration test, please have more than 3kg per sample. It is ideal if you can offer a 5kg sample.
Also, should you need to prepare a sample in the products, etc., make sure that there is no adhesion of foreign matter on the sample. Especially sand for casting or other metals except aluminum, will be impact in the analysis data.

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

Features

Vocalmass can measure the gas contaminated volume and those chemical composition from solid products.

Volcalmass can detect 10 chemical compositions; such as hydrogen, moisture, oxygen, hydrocarbon, etc.

Left graph shows contaminated gas comes out from the test sample during inspection time.

Data at the bottom is 10 chemical composition of inspected gas and calculated atomic mass numbers.

After the inspection, we will analyze the contaminated gas volume by sample as analysis report. See left graph example.

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

Ladle for Molten Aluminum (Large for Aluminum 200g / Small for Aluminum 50g)

Pechiney Type

Features

Brethmass is the very quick and accurate analysis equipment of exhalation components, and also the gas generated by any kinds of material.
It can be useful for variety of applications; such as sampling inspection and continuous online inspection, etc in the research laboratory or in the industrial factory.
Atm quantitative pulse introduction method makes Brethmass possible to measure the mass gas flow without contamination.
Repeat measurement can be done within a few minutes. Therefore, possible to measure the gas on site. For the “Inspection Service”, we will submit inspection data and gas contamination analysis report

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

Radiation measuring instrument for soil, water and food

PMT-2000 can measure the radiation in high speed, high precision, and onsite,  even if the area where radiation dose is very high.

Conventional high precision radiation measurement is required to send the sample to third party laboratoly and need to wait the result a few days or weeks. Therefore decontamination work, road construction, loading of seafood at the port were blocked their field operation.

PMT-2000 on Vehicle is reinstalled the radiation measurement instrument on the vehicle. So PMT-2000 makes field inspection available and remove the bottleneck of your field operation.

PMT-2000 applied special radiation shielding application to avoid the impact of high radiation dose area. This special radiation shielding technologies was developed by Nikkin Flux with technical supervised by Japan Atomic

Energy Agency (JAEA). Based upon this technologies, PMT-2000 can measure the radiation quickly and accurately in the area where has high radiation dose. For example, measurement of radiation Cs volume in food takes about one (1) minutes, in case of 2L sample, area radiation dose: 2.5μSv/h and standard radiation: 100Bq/kg.

Measurement limits of different areal radiation dose.

Measurement limites means lowest detaction level of radiation
If radiation detection level is lower, then that equipment can be measure as much as possible.
*Measurement limit can be change depends of the field enviroment, test samples, and energy of inspection.

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

Compact size, Low cost and Custom Made

K40 sensors suitably measure relatively high-contaminated sludge or contaminated soilWe submitted joint patent of K40 with co-partner, JAEA.

We sell K40 Sensors, ando do inspection service. Pls feel free to contact us.

Size: OD40 x L 141mm

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

Filtration Test

The IA500 allows a simple monitoring of quality. By doing filtration tests, you can measure the aluminum transit time per unit of filtration weight. The shorter the filtration time, the higher the probability of good quality aluminum.

Before degassing, the total inclusions are 0.32 mm2/kg with a filtration time of 1 35 sec. After degassing, the total inclusions are 0.05 mm2/kg with a filtration time of 65 sec.
As you can see from the analysis image, the filtration time is shorter when there are fewer impurities on the filter.

Filtration Test Procedure

About 3 kg of molten aluminum is filtered through the filter in IA500.
In a typical filtration tester, molten aluminum is poured into the device. In that case, the results are affected by oxidation during the pouring in the device and by the impact of dropping in the device.
The IA500, on the other hand, does not have the risk of such effects, as the aluminum is fed into the apparatus in its pre-melted state and melted in the apparatus. After filtration, impurities are deposited on the filter.

Consumables List

Below is the consumables list for IA500.

NO.	Item Name and Replacement Timing	Picture	Size and Material
1	CERAMIC FILTER		ø120 x30t
	Each filtration test		Complex of Silicic-acid calcium & Ceramic SiC filter
2	GASKET SMALL		ø120-1xø90x1t
	Each filtration test		Carbon sheet processed goods
3	GASKET LARGE		ø190 x ø12O x 1t
	After 10 filtration tests		Carbon sheet processed goods
4	CUSHION PAPER		ø120 x ø65 X 3t
	After 3-5 filtration tests		Ceramic fiber paper processed goods which added and fabricated a little organic binders
5	CERAMICSHEATH (PROTECTION TUBE)		ø14 x 5OOL
	In case of breakage		Product slip cast article made from silicon nitride
6	ALUMINIUM REMOVER		ø26x600L
	Incase of breakage		Product slip cast article made from silicon nitride
7	KANTHALHEATER		ø350 x 250L (HAS2OO-25OG)
	In case of breakage		Ceramic fiber Kanthal resistance heating alloy
8	IA LADLE		ø60 x 600L
	In case of breakage		IRON or SUS
9	CERAMICCRUCIBLE		OD140-OD120x IDlOOx 300L
	In case of breakage		Silicon nitride

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

Quick Measurement, High Accuracy and Custom Made

The most crucial function of a radiation measuring instrument is the detection performance of the sensor, which aims to measure as much radiation as possible, thereby ensuring comprehensive and accurate readings.
High detection sensor makes measurement quickly and minimizing the operation time. This gives you an advantage of radiation exposure reduction.
Our PMT Sensors are adopted the photomultiplier tube technology that supported the receiving of Nobel Prize of Japan, and designed the instrument to get best performance of radiation detection.

Size of Sensor

This is quick and high accuracy aluminum quality inspection equipment to check the gas volume and existence of inclusion in the molten aluminum. So performance of degassing treatment can be check before starting the casting.
Volcester STD: W800 x L550 x H1150(mm), 150kg

Consistent contents for BB Tester

Let the contaminated gas and inclusion / oxidation out from aluminum molten metal by vacuum exhaust process. Gas will be captured by inclusions and became bigger than others. Once the gas becomes bigger, it comes out from molten metal, and baster on the top surface. This equipment can be measure the busted pressure change by vacuum gauge.
Put the steel cup with 100 g of aluminum molten metal.

Metal sample and inspection screen samples

In case of lots of inclusions: Sample surface is busted and recognize lots of gas contamination.

In case of low inclusion: Sample Surface is flat and smooth, and no recognition of bubble.

Inspection

Bubble buster volume measured by BB Tester can be shown how many burst happen during inspection. This remaining bubble an be a cause of pinehole defect.
Bubble busted volume and density of solidification sample has strong correlation as attached left image.
Measurement Data:
Type of Molten Metal: ADC12
Inspection Temperature: about 620 degree C
Inspection periods: 180 sec.

Characteristic of Volcester

Total gas measurement system

Volcester can conduct a total gas measurement.
During inspection, it can be measure the total gas volume exhausted from sample.

Touch panel operation

   

Small Bubble Size

Compared with conventional mixer, the bubble size which comes from the mixer is much smaller. Bubble stay in molten longer and absorb impurities and float to the molten surface. After removing the impurities on the surface, molten get clean and it leads less defect.

Easily Installation In Small Space

Features

This device measures the gas content in aluminum molten metal by specific gravity, which indicates the metal’s grade. In high-quality aluminum casting, surface defects caused by residual gas holes, known as “pinholes,” represent a significant quality concern. Understanding the volume of gas contamination in the molten metal is crucial for planning the subsequent treatment, which is the degassing process.

・Able to predict the risk to get pinhole defect from Hydrogen gas.
・Measurement time is about 5 minutes.
・The exhaust flow volume and the time required to reach target pressure are adjustable.
・It is introduced at low cost.

Solidified sample by pinhole test NK1600.
The specific gravity differs depending on the exhaust flow gas volume.
By adjusting pressure reduction conditions, you can conduct solidification test under the high correlation with defect rate of your products.

Specifications

1 * Gauge unit shows the negative value in decompression side. International System of Units (SI) shows positive value ( basically in Pa) in decompression side. Mbar is used in Europe.

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

Features of Nikkin’s Degassing Mixer

High degassing effect

A wide variety of mixers are

Anti-oxidation treatment (impregnation treatment) on the surface of the mixer

Made of high quality domestic carbon

Carbon Mixer

MG90 (1kg Bar x 20pcs, 20kg/pack)

Ingot: 90% Magnesium and 10% Aluminum
This products allow you to melt magnesium into aluminum with good production rate, and minimizing the melting loss. Size is compact, so very easy to handling and also minimizing your storage space. From the view point of handling MG90 is much easier than pure Mg ingot.
Foe Example, added volume is 110g for the 100kg of molten metal in order to increase 0.1% of Mg ration in the molten metal.

SRM100 (100g Rod Type, 20kg/pack)

This is an mother ingots for the improvement treatment of hypo eutectic and eutectic alloy by strontium. It makes possible to maintain the effect of improvement of grain structure even hold the molten metal for a long time.
After the treatment of skimming and di-oxidation flux (#N100-N400), put SRM100W into the molten metal by phosphoric and mix well.
Once mixing is done well, do the degassing operation by dry Nitrogen or Argon gas. Pls double check the H2 contents before casting and then start casting. Do not use the chlorine based degassing which destroy the decrease of strontium from molten metal. The content of Sr is 10%. 100g/pcs.

TIBW500 (100g cut bar x 100pcs, 20kg/pack)

5% TI, 1% Boron wire for the hypoeutectic allo.y
Operation temperature: 680 ~800 degree C.
Volume: put 0.04~0.2wt% of molten metal (example 40g~200g for 100kg)
You can keep the micro grain structure for two hours after the melting.

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

NewALPUR brings you 4 advantages

1. Cost reduction of raw material
High degassing performance of NewALPUR can allow you to use low quality and cheap ingots.
You can recycle unknown scrap metal, cut chip, and dross.
2. Increasing the remelting performance
Reduce 80% of dross volume
3. Increasing your productivity
Treatment performance of NewALPUR can reduce contamination of inclusions and oxidation inside molten metal.
4. Reduction of consumption materials
Reduce 50% of innertgas (Ar, N2) consumption
Long life time of ceramic shaft are applied.

Performance of New ALPUR

This inspection data shows the difference before and after degassing by New ALPUR.

BBV and density of measurement sample has correlation. For the technical aspects of BBV

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

NC-8

Minimum lot 20 kg (5 kg/can x 4 cans)

NC-8 is developed as a coating agent for steel lance pipe of N2 blowing for the molten aluminum treatment.This coating agent exerts a strong corrosion resistance against all molten metal and prevent the erosion by aluminum with excellent in releasing property.

NC-10

Minimum lot 16 kg (4 kg/can x 4 cans)

NC-10 is used for aluminum die casting, which is a coating agent with an emphasis on reliability of the aluminum only.
Application target product:
(1) steel plate and, cast iron products (ladle, Stoke protective tube)
(2) fine ceramics products (ladle, Stoke protective tube)
(3) ceramic-fiber products (ladle, the molten metal distribution hot water products, etc.)

DNT64

Minimum lot 20 kg (5 kg/can x 4 cans)

A heat-resistant coating agent for aluminum alloy die casting, especially products with an emphasis on and finish of the casting surface of the casting, it demonstrates the effect on the product, which is required to size and accuracy.

Other items of Nikkin Flux
Request the quotation for Nikkin Flux

Features

Flux discharge amount is adjustable from 100g/min to 1kg/min

Accuracy of flux injection is within 5%

Adding operation is easy and not requiring specialized knowledge

Simple maintenance, hardly broken and incorruptible structure (SUS parts)

With it’s compact design and caster, Feeder can be easily and quickly installed

Specification

Cautions for use

Preheat gas- blowing pipe enough and remove foreign substance before use

Check that flux is dry and not solidified by moisture

Do not leave flux in tank. Remaining flux can cause failure.

We recommend to use our Inclusion Analysis Test (IA500) for checking the effect of flux treatment. For details, please feel free to contact us.

Other items of Nikkin Flux

Request the quotation for Nikkin Flux

Function of Flux

Aluminum has lots of advantages, such as light weight, corrosion resistance, good work-ability, recycling efficiency compare to any other metal. Therefore aluminum alloy are using for variety of applications in different market segment.
In aluminum casting, not only sophisticated cast design, but precise control of chemical composition is also required.

If molten metal quality is bad, application may have defect and we cannot use final product, even if you made perfect casting die design. Controlling molten metal is the key of the production.And the selection of good/suitable flux is necessary factor to control molten and produce your high-quality application.

Selection of Flux

We regard following points to be important for the selection of flux.
１）Purpose of use (e.g. skimming, Degassing, Improvement of metal quality, structure refinement, remove the contamination and inclusions,,, etc.)
２）Alloy type
３）Molten metal temperature
４）Environment-Conscious products, accepting criteria of smoke generation or generated gas

In order to using flux, please double check the temperature of molten metal and input volume of flux.

Distributing flux homogeneously and making contact molten metal as much surface of flux are the key to get efficient chemical reaction. So please make sure to rotate the molten metal after injecting the flux into molten metal.

Below points are also important for metal quality control.
１）Well select the required chemical composition for target alloy and make sure that unnecessary chemicals are not contained.
２）Remove the toxic gas (e.g. H2), inclusions, and oxidation contamination as much as possible.
３） Temperature control of molten metal and operation time control.
Once you clear all above factors and controlled the metal quality, let’s focusing also the commercial impact about consumption of Aluminum ingot and fuel additionally.

Other items of Nikkin Flux
Request the quotation for Nikkin Flux