Aluminum Billet Melting and Casting Line
A Comprehensive Solution for High-Quality Aluminum Production
Aluminum Billet Casting Line – The Foundation of the Modern Aluminum Extrusion Industry
Aluminum billets are the essential feedstock that determines the quality of the entire extrusion process. To produce aluminum profiles with superior mechanical properties, excellent surface finish, and compliance with the stringent requirements of the construction, transportation, aerospace, and defense industries, billets must be manufactured on a modern production line with rigorous process control from melting and casting to heat treatment.
As a specialized supplier of equipment and technology transfer solutions for the aluminum industry, Ngo Hoang Co., Ltd. provides integrated aluminum billet melting and casting lines designed and manufactured in South Korea. These production lines are capable of producing high-quality aluminum alloys, including AA2024, AA6061, AA6063, AA6082, AA7075, and many other alloy grades.
Fully Integrated Production Process – From Melting to Finished Billets
The production line is designed as a fully integrated system covering every stage of billet production, including:
- Aluminum alloy melting
- Electromagnetic stirring for homogeneous metal composition
- Molten aluminum degassing and refining
- Metal filtration using Ceramic Foam Filters (CFF)
- Automatic Titanium wire and flux feeding
- Billet casting using Air-Slip technology
- Homogenization heat treatment
- Controlled cooling
- Billet butt-end trimming and length cutting
- Aluminum chip collection and recycling
- Billet packaging and transportation
By integrating all production stages into a single production line, metal loss is minimized, production efficiency is significantly improved, and consistent billet quality is maintained from batch to batch.
Advanced Melting Technology
At the heart of the production line is a tilting-type aluminum melting furnace equipped with regenerative burners, which recover waste heat from exhaust gases to preheat combustion air. This significantly reduces fuel consumption while improving thermal efficiency.
Key Specifications
- Melting Capacity: Customized according to production requirements (3–10 tons/hour)
- Holding Capacity: Customized according to customer requirements (10–50 tons)
- Fuel: Diesel
- Automatic furnace temperature control
The system is also equipped with an ABB electromagnetic stirring system (Sweden), which stirs the molten metal without direct contact, minimizing oxidation while ensuring uniform alloy composition and temperature distribution throughout the molten metal bath.
Molten Aluminum Refining – Quality Control from Within
Billet quality largely depends on the cleanliness of the molten aluminum before casting.
The production line incorporates a GBF degassing unit to:
- Remove dissolved hydrogen
- Reduce non-metallic inclusions
- Stabilize molten metal temperature
- Minimize gas porosity and internal billet defects
In addition, a Ceramic Foam Filter (CFF) equipped with 40 PPI filter media further removes residual oxides and inclusions, ensuring a high level of molten metal cleanliness prior to casting.
For alloy grades requiring fine grain structures, the production line also integrates:
Titanium wire feeding system (AlTiB)
Automatic flux injection system using Nitrogen (N₂)
These systems significantly improve the billet's grain structure, enhancing extrusion performance and finished product surface quality.
Air-Slip Casting Technology – Superior Billet Quality
The production line employs Air-Slip casting technology, one of the most advanced casting technologies widely adopted by modern billet manufacturing plants.
Production Capability
- 7-inch diameter billets
- 8-inch diameter billets
- Maximum billet length: up to 6,300 mm
- Casting capacity: over 10 tons per casting cycle
Advantages of Air-Slip Technology
- Smooth billet surface
- Reduced hot cracking
- Improved grain structure
- Reduced alloy segregation
- Higher extrusion yield
This technology is particularly suitable for producing high-strength aluminum alloys such as the 2xxx and 7xxx series.
Homogenization and Controlled Cooling
After casting, the billets are transferred to a Homogenizing Furnace with a capacity of 20–25 tons per batch.
The homogenization process, carried out at approximately 580 ± 5°C, provides the following benefits:
- Uniform chemical composition
- Dissolution of secondary phases
- Reduction of internal residual stress
- Improved extrudability
- Enhanced mechanical properties after subsequent heat treatment
Following homogenization, the billets are cooled in a Cooling Chamber, where the cooling rate is precisely controlled to stabilize the microstructure and ensure consistent billet quality.
Complete Auxiliary Equipment System
In addition to the main processing equipment, the production line incorporates a comprehensive range of auxiliary equipment to maximize production efficiency, including:
- Automatic billet cutting machine
- Aluminum chip extraction system
- Hydraulic chip briquetting machine
- 25-ton billet transfer vehicle
- Billet packaging equipment
- Billet loading and unloading equipment
- Roller conveyor system and billet storage tables
- Spare casting molds for 7-inch and 8-inch billets
These auxiliary systems enable continuous production, minimize downtime, and maximize operational efficiency.
Key Advantages of the Production Line
- Fully integrated system from melting to finished billets
- Advanced Korean technology
- ABB electromagnetic stirring system from Sweden
- Advanced Air-Slip casting technology
- Stable billet quality with minimal defects
- Reduced fuel and energy consumption
- High degree of automation
- Suitable for producing a wide range of aluminum alloy grades
- Meets the requirements of high-capacity aluminum extrusion plants
Comprehensive Solutions from Ngo Hoang Co., Ltd.
Beyond equipment supply, Ngo Hoang Co., Ltd. supports customers throughout the entire project lifecycle—from technology consulting, plant layout design, installation, commissioning, operator training, and technology transfer to comprehensive after-sales services.
Backed by an experienced engineering team and leading technology partners from South Korea, we are committed to delivering optimal solutions that help manufacturers improve productivity, maintain superior billet quality, and achieve sustainable growth in the aluminum industry.
Contact Ngo Hoang Co., Ltd. today to learn more about our aluminum billet melting and casting line solutions tailored to your production requirements.