Revolutionary Solutions for Advanced Metal Production
Our Cutting-Edge HSMC Technology
Step into the future of metal production with Zyomax’s High-Shear Melt Conditioning (HSMC) technology. This groundbreaking innovation optimises metal microstructure at the molecular level, delivering unparalleled quality and sustainability in metal production.
How HSMC Works?
Our pioneering technology applies precisely controlled high-shear forces to molten metal, revolutionising the traditional casting process by:
- Breaking up particle clusters for uniform distribution.
- Enhancing nucleation to achieve superior structural integrity.
- Dramatically reducing defects in the final product.
- Enabling high-quality production using lower-grade scrap.
Our Cutting-Edge HSMC Technology
Step into the future of metal production with Zyomax’s High-Shear Melt Conditioning (HSMC) technology. This groundbreaking innovation optimises metal microstructure at the molecular level, delivering unparalleled quality and sustainability in metal production.
Advanced Metal Processing Solutions
Degassing of Aluminium Melts
Schematic comparing the conventional rotary degassing and the High Shear Melt Conditioning (HSMC) degassing process.
Rotary
HSMC
Experience superior degassing efficiency with our innovative HSMC system
Visualization and modelling of the HSMC degassing process in water with variation of inert gas flow rate and rotor speed.
Technical Excellence:
- Reduces hydrogen content to <0.1 ml/100g.
- Achieves up to 50% reduction in hydrogen levels compared to conventional methods.
- Cuts processing time through faster, more complete degassing.
- Reduces porosity by up to 40% in cast components.
Fractured surface of tensile bars cast after degassing with:
Tablet
Rotary
HSMC
Business Benefits:
- Minimises the need for repeated degassing cycles.
- Reduces alloy waste and processing costs.
- Delivers consistently higher quality outputs.
- Improves strength & elongation through refined microstructure.
De-Ironing of Aluminium Melts
Scheme of High Shear Melt Conditioning technology for continuous iron removal from aluminium alloy scrap melt.
Technical Advantages:
- Breaks down and disperses iron-rich intermetallic phases.
- Reduces harmful β-Al5FeSi phases by up to 30%.
- Achieves finer, more uniform microstructure.
- Increases tensile strength and elongation by up to 15%.
De-Ironing microstructure of ingots:
No HSMC
HSMC
Operational Benefits:
- Maintains higher alloy purity.
- Improves recycling potential.
- Reduces refining steps.
- Lowers production costs.
Melt Conditioned Direct Chill
(MC-DC)
Schematics of the solidification mechanisms causing the grain structural evolution during; DC-GR casting under natural convection, MC-DC casting at critical rotation speed under forced convection and, MC-DC casting at high rotation speed under forced convection.
Unique Advantages:
- Ensures uniform temperature and chemical composition.
- Eliminates the need for chemical grain refinement.
- Creates unique as-cast grain structure.
- Reducing processing energy and costs significantly.
Comparison of DC and MC-DC cast billet macrostructures without addition of Ti-B based grain refiner:
DC
MC-DC
Operational Benefits:
- Eliminates billet homogenisation requirements.
- Facilitates efficient alloy scrap recycling.
- Reduces energy consumption.
- Minimises environmental impact.
Case Studies: Innovation In Action
Case Studies:
Innovation In Action
Aerospace Excellence
Our AluZeroX-90 system revolutionised large-scale MC-DC casting of 7xxx series aluminium alloys:
- Successfully cast 24-inch thick, 66-inch wide, 100-inch long slabs.
- Significantly reduced chemical segregation.
- Minimised cracking issues in large-scale castings.
- Demonstrated industrial-scale capability and reliability.
Automotive Innovation
Implementation of MagnoZeroX-40 in 100kg Magnesium Alloy furnace delivered:
- Enhanced microstructure refinement.
- Reduced oxide film defects.
- Improved mechanical properties.
- Pioneered industrial-scale magnesium recycling.
Transform Your Metal Production Capabilities
Transform your metal production capabilities with Zyomax’s innovative solutions. Contact our team of experts today to discover how our HSMC technology can revolutionise your manufacturing processes while supporting your sustainability goals.
Zyomax’s Innovative Solutions
We are transforming metal manufacturing across industries, from electronics to renewables.
Reach Out to Us
Get in touch to discuss how we can optimise your metal operations and support your sustainability initiatives.
