SBIR Phase II: On-Line Optoelectronic Sensing of Molten Metal Chemistry

该小型企业创新研究（SBIR）第二阶段项目将开发一种高度创新的高速光电传感器系统，能够在铸造和熔化操作期间连续监测熔融金属合金成分。我们的目标是设计和构建一个商业上可行的传感器系统，能够执行高精度的定量测量熔融铝合金成分在一个积极的工业环境。该传感器的开发是金属铸造行业和铝行业在其未来行业路线图中确定的最高优先级技术需求之一。为了有效竞争，美国金属行业必须增加低成本废料的使用，还必须找到提高生产效率的方法。所提出的传感器将比目前的商业方法快数千倍地获得关键成分数据，并且将在实时基础上操作，而不需要将传感器与熔融金属接触。在这样的速度下，熔炼车间每天可以多生产一批金属（“热”），从而使生产率提高15%。采用这种创新的光电传感器系统将大大提高生产效率，使生产率提高15%。因此，300亿美元的铝冶炼工业可以实现45亿美元的产量增加，除了传感器系统的成本之外，几乎没有额外的资本投资。事实上，由于生产率的提高，拟议活动最直接的更广泛影响将是提高美国铝铸造厂和冶炼厂的竞争力。此外，拟议的技术将对过程控制和质量保证产生重大的积极影响，从而提供进一步的竞争优势。通过缩短熔化周期减少排放和节约能源，也将对我们的社会产生更广泛的影响。类似的改进对于锌、铜、黄铜、青铜、铁、陶瓷和玻璃工业也是可能的，这些工业也需要类似的连续传感器系统来实时监测和控制成分和质量。

This Small Business Innovation Research (SBIR) Phase II project will develop a highly innovative, high-speed optoelectronic sensor system capable of continuously monitoring molten metal alloy compositions during casting and melting operations. The goal is to design and construct a commercially-viable sensor system capable of performing highly-accurate quantitative measurement of molten aluminum alloy compositions in an aggressive industrial setting. Development of this sensor is among the highest priority technology needs identified by both the metal casting industry and the aluminum industry in their industry roadmaps of the future. In order to effectively compete, U.S. metal industries must increase their use of low cost scrap and must also find ways to increase production efficiency. The proposed sensor will acquire critical compositional data thousands of times faster than current commercial methods and will operate on a real-time basis without the need to place the sensor in contact with the molten metal. At these speeds, a melt shop could produce one extra metal production batch ('heat') per day, resulting in a 15% increase in productivity.The incorporation of this innovative optoelectronic sensor system will result in a tremendous increase in production efficiency, providing for a 15% gain in productivity. Thus, the $30 billion aluminum smelting industry could realize a $4.5 billion increase in production output with little or no additional capital investment other than the cost of the sensor system. In fact, the most immediate broader impact of the proposed activity will be to enhance U.S. competitiveness of aluminum casters and smelters because of this productivity improvement. In addition, the proposed technology will have a significant positive effect on process control and quality assurance, thereby providing further competitive advantages. Broader impact to our society will also be brought about through reduced emissions and energy savings resulting from shorter melting cycles. Similar improvements would be possible for zinc, copper, brass, bronze, iron, ceramic and glass industries that also have need for a similar continuous sensor system to monitor and control composition and quality on a real-time basis.