CN102978488B - 用于汽车保险杠的铝合金型材生产工艺 - Google Patents
用于汽车保险杠的铝合金型材生产工艺 Download PDFInfo
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- CN102978488B CN102978488B CN201210532733.0A CN201210532733A CN102978488B CN 102978488 B CN102978488 B CN 102978488B CN 201210532733 A CN201210532733 A CN 201210532733A CN 102978488 B CN102978488 B CN 102978488B
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- 229910000838 Al alloys Inorganic materials 0.000 title claims abstract description 18
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 238000005516 engineering processes Methods 0.000 title claims abstract description 15
- 238000005266 casting Methods 0.000 claims abstract description 44
- 230000000171 quenching Effects 0.000 claims abstract description 15
- 238000001125 extrusion Methods 0.000 claims abstract description 14
- 238000010791 quenching Methods 0.000 claims abstract description 14
- 238000007670 refining Methods 0.000 claims abstract description 14
- 238000001914 filtration Methods 0.000 claims abstract description 9
- 239000007789 gases Substances 0.000 claims abstract description 7
- 238000007792 addition Methods 0.000 claims abstract description 5
- 238000010438 heat treatment Methods 0.000 claims abstract description 5
- 238000002844 melting Methods 0.000 claims abstract description 5
- 229910052751 metals Inorganic materials 0.000 claims abstract description 5
- 239000002184 metals Substances 0.000 claims abstract description 5
- 238000005070 sampling Methods 0.000 claims abstract description 4
- 241001081830 Degeneriaceae Species 0.000 claims description 44
- 239000000155 melts Substances 0.000 claims description 30
- REDXJYDRNCIFBQ-UHFFFAOYSA-N aluminium(3+) Chemical class data:image/svg+xml;base64,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 data:image/svg+xml;base64,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 [Al+3] REDXJYDRNCIFBQ-UHFFFAOYSA-N 0.000 claims description 28
- 229910045601 alloys Inorganic materials 0.000 claims description 27
- 239000000956 alloys Substances 0.000 claims description 27
- 239000000126 substances Substances 0.000 claims description 26
- 239000011701 zinc Substances 0.000 claims description 24
- 239000000203 mixtures Substances 0.000 claims description 21
- 238000001816 cooling Methods 0.000 claims description 15
- 239000003795 chemical substances by application Substances 0.000 claims description 11
- 239000011777 magnesium Substances 0.000 claims description 11
- 229910052725 zinc Inorganic materials 0.000 claims description 11
- 238000004166 bioassay Methods 0.000 claims description 10
- AHKZTVQIVOEVFO-UHFFFAOYSA-N oxide(2-) Chemical compound data:image/svg+xml;base64,PD94bWwgdmVyc2lvbj0nMS4wJyBlbmNvZGluZz0naXNvLTg4NTktMSc/Pgo8c3ZnIHZlcnNpb249JzEuMScgYmFzZVByb2ZpbGU9J2Z1bGwnCiAgICAgICAgICAgICAgeG1sbnM9J2h0dHA6Ly93d3cudzMub3JnLzIwMDAvc3ZnJwogICAgICAgICAgICAgICAgICAgICAgeG1sbnM6cmRraXQ9J2h0dHA6Ly93d3cucmRraXQub3JnL3htbCcKICAgICAgICAgICAgICAgICAgICAgIHhtbG5zOnhsaW5rPSdodHRwOi8vd3d3LnczLm9yZy8xOTk5L3hsaW5rJwogICAgICAgICAgICAgICAgICB4bWw6c3BhY2U9J3ByZXNlcnZlJwp3aWR0aD0nMzAwcHgnIGhlaWdodD0nMzAwcHgnIHZpZXdCb3g9JzAgMCAzMDAgMzAwJz4KPCEtLSBFTkQgT0YgSEVBREVSIC0tPgo8cmVjdCBzdHlsZT0nb3BhY2l0eToxLjA7ZmlsbDojRkZGRkZGO3N0cm9rZTpub25lJyB3aWR0aD0nMzAwJyBoZWlnaHQ9JzMwMCcgeD0nMCcgeT0nMCc+IDwvcmVjdD4KPHRleHQgZG9taW5hbnQtYmFzZWxpbmU9ImNlbnRyYWwiIHRleHQtYW5jaG9yPSJlbmQiIHg9JzE3NC45NTInIHk9JzE1Ni42JyBzdHlsZT0nZm9udC1zaXplOjQwcHg7Zm9udC1zdHlsZTpub3JtYWw7Zm9udC13ZWlnaHQ6bm9ybWFsO2ZpbGwtb3BhY2l0eToxO3N0cm9rZTpub25lO2ZvbnQtZmFtaWx5OnNhbnMtc2VyaWY7ZmlsbDojRTg0MjM1JyA+PHRzcGFuPk88L3RzcGFuPjx0c3BhbiBzdHlsZT0nYmFzZWxpbmUtc2hpZnQ6c3VwZXI7Zm9udC1zaXplOjMwcHg7Jz4tMjwvdHNwYW4+PHRzcGFuPjwvdHNwYW4+PC90ZXh0Pgo8L3N2Zz4K data:image/svg+xml;base64,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 [O-2] AHKZTVQIVOEVFO-UHFFFAOYSA-N 0.000 claims description 8
- KEAYESYHFKHZAL-UHFFFAOYSA-N sodium Chemical compound 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[Na] KEAYESYHFKHZAL-UHFFFAOYSA-N 0.000 claims description 8
- 229910052708 sodium Inorganic materials 0.000 claims description 8
- 239000011734 sodium Substances 0.000 claims description 8
- 239000010936 titanium Substances 0.000 claims description 8
- 229910052726 zirconium Inorganic materials 0.000 claims description 8
- 239000011651 chromium Substances 0.000 claims description 7
- 239000010949 copper Substances 0.000 claims description 7
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[Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 238000007872 degassing Methods 0.000 claims description 3
- 238000010304 firing Methods 0.000 claims description 3
- 238000007499 fusion processing Methods 0.000 claims description 3
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound 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Abstract
一种用于汽车保险杠的铝合金型材生产工艺，属于金属机械加工技术领域，通过配料→熔炼→永磁搅拌→测温→取样→调整成分及温度→倒炉→精炼(一次净化)→静置→在线加入Al-Ti-B丝→在线除气除渣(二次净化)→双级过滤→同水平热顶铸造→铸锭均匀化→铸锭的机械加工→铸锭检验→感应炉加热铸锭→挤压→精密在线淬火→拉伸校直→时效→型材的组织和性能检验→交货过程，完成汽车保险杠铝合金型材的加工。本发明加工出的铝合金型材具有良好的热变形性能，挤压时经在线淬火有较高的强度，制品的焊接性能，耐腐蚀性能良好，有一定的耐应力腐蚀性能，特别是具有较强的吸收冲击能力和抗击折叠的性能。
Description
技术领域
[0001] 本发明涉及一种金属机械加工，具体涉及一种用于汽车保险杠的铝合金型材生产 工艺。
背景技术
[0002] 目前，汽车行业快速发展，人们对汽车的性价比要求越来越高。汽车保险杠是一 种表面积大、形状复杂的薄臂结构部件，它要求具有优异的高、低温冲击韧性、刚性、耐老化 性、耐热性和耐寒性；而现有的汽车保险杠多采用聚氨酯弹性体和ABS等材料制备，这些材 料成型工艺复杂、价格昂贵，使得汽车成本增加，加大了购买者的负担；聚丙烯材料以其低 密度、易成型加工、可回收利用的优点，在汽车上的应用不断增大，但是聚丙烯材料韧性和 抗冲击强度低，增大了司机及乘客的风险，而且成品表面的光泽度和平滑度较差。
[0003] 7NB46属于Al-Zn-Mg系超硬铝合金，由于其具有良好的热变形性能，挤压时经在 线淬火有较高的强度，制品的焊接性能，耐腐蚀性能良好，有一定的耐应力腐蚀性能，特别 是具有较强的吸收冲击能力和抗击折叠的性能，因而特别适合挤压成空心型材制成汽车的 保险杠，如何用加工出类似性能或更优性能的铝合金型材是我们所要解决的问题，但是加 工此类型铝合金型材时，在生产过程中经常出现羽毛晶等缺陷。这些缺陷会在随后的生产 中"遗传"给挤压材，降低了制品的力学性能。羽毛晶具有粗大平直的晶轴，力学性能有很 强的各向导性，不仅破坏了工艺性能而且会大幅的降低力学性能。
发明内容
[0004] 本发明的目的是提供一种用于汽车保险杠的铝合金型材生产工艺，其加工出的铝 合金型材具有良好的热变形性能，挤压时经在线淬火有较高的强度，制品的焊接性能，耐腐 蚀性能良好，有一定的耐应力腐蚀性能，特别是具有较强的吸收冲击能力和抗击折叠的性 能。
[0005] 为了实现上述方案，本发明的技术解决方案为：一种用于汽车保险杠的铝合金型 材生产工艺，其包括以下步骤：
[0006] (1)先配料：合金的基体选用99. 85牌号的铝锭，Mg、Zn元素以纯金属的形式加入， 考虑Cu、Cr、Ti、Zr元素熔点较高，且在合金中含量较低，故以中间合金的形式加入；
[0007] (2)之后采用25吨蓄热式燃气炉熔炼，熔炼温度不宜过高，为750±5°C ;
[0008] (3)在熔炼过程中，取样分析调整完化学成分和温度后即要抓紧倒炉，Si的质 量百分含量控制在〇. 10%，Fe的质量百分含量控制在0. 16% -0. 17%，Mg的质量百分含 量控制在1.20% -1.30%，Μη的质量百分含量控制在< 0.04%，Cu的质量百分含量控 制在0.20 % -0.22%，Cr的质量百分含量控制在< 0.04%，Zn的质量百分含量控制在 6. 50 % -6. 70 %，Zr的质量百分含量控制在0. 15 % -0. 16 %，非检测杂质单个质量百分含量 控制在0. 05%，总和控制在0. 10%，尽量缩短熔体在炉内停留的时间，倒入静置炉时对炉 内熔体边倒炉边用永磁搅拌器对炉内的熔体进行搅拌，倒炉时要保持熔体平稳流动，不得 有冲击翻滚现象；
[0009] (4)倒入静置炉后在750°C以上的条件下，用氩气喷吹无钠精炼剂进行精炼，精 炼剂用量1. 5kg/t，精炼时间为lOmin以上，扒净熔体表面的浮渣，向熔体表面均匀的撒上 l〇kg无钠覆盖剂；
[0010] (5)在线添加 Al-Ti-B丝，添加量为800mm/min，最终使合金达到Ti的质量百分含 量为 0· 03% -0· 04%
[0011] (6)为进一步提高熔体的纯洁度，用除气机进行第二次净化进一步除气除渣，除气 机转子转速控制在350r/min，氦气流量控制在2m 3/h，采用30ppi和50ppi的双级过滤滤除 熔体中的氧化夹杂物；
[0012] (7)待熔体撒上10kg无钠覆盖剂后20min内，使用Φ 304mm热顶同水平铸造；
[0013] (8)铸锭在250°C时装炉，先不点火升温，开风机运行lh后再点火升温，加热升温 速度90°C /h，均质温度485±5°C，保温8h，然后放入冷却炉冷却，冷却速度要> 100°C /h， 冷却到室温后出炉；
[0014] (9)之后，选用40MN挤压机挤压，铸锭加热温度500°C，挤压模具温度450°C，挤压 温度 480°C，挤压速度 3. 1-3. 2m/min ;
[0015] (10)之后对型材在线淬火，淬火温度为350°C _550°C，挤压型材的出模口温度不 得低于480°C，采用强风冷却；
[0016] (11)之后将型材用200T拉伸机拉直，变形量为1% -3%，校直后的型材经检验合 格后，按要求尺寸切成成品后，再进行双级时效即：100°C保温8h升温至145°C再保温llh。
[0017] 本发明用于汽车保险杠的铝合金型材生产工艺，其中所述步骤（2)中Zn锭分三批 用加料铲分数的加入炉内，加入一批待Zn熔化后，用永磁搅拌器搅拌lOmin，正反转各搅拌 5min，使炉内的化学成分和温度均匀。
[0018] 本发明用于汽车保险杠的铝合金型材生产工艺，其中所述步骤（4)从倒炉到铸 造，熔体在静置炉内停留时间不得超过lh。
[0019] 采用上述方案后，本发明用于汽车保险杠的铝合金型材生产工艺，通过控制合金 Zn的质量百分含量为6. 50% -6. 70 %，Mg为1. 20% -1. 30 %，在合金中，Zn、Mg共存时形成 了一系列的新相α相（Mg5A18)、η相（MgZn2)、T相（A12Mg3Zn)，其中η相和在A1中有较 高的溶解度和明显的温度关系，故该合金有强烈的时效硬化效应，通过控制Cu的质量百分 含量在0. 20% -0. 22%，提高合金的耐应力腐蚀、抗拉强度和塑性，通过控制Zr的质量百分 比为0. 15% -0. 16%，不仅能够显著地提高合金的焊接性能，还能急剧的提高合金的再结 晶终了温度和耐应力腐蚀性能，通过控制Mn的质量百分含量小于0. 04%，Cr小于0. 04%故 对合金的断裂性不会带来不良影响，将Fe的质量百分含量控制在0. 16% -0. 17%，其与合 金中的Si元素形成FeAlSi化合物，使Mg2Si脆性相在晶界和枝晶界呈不连续状态存在，从 而降低合金的热裂纹倾向，通过控制Si的质量百分含量在0. 10%，消除了合金中产生羽毛 晶的内在原因，控制熔炼温度不超过760°C，加强熔体的搅拌，控制熔体在炉内停留时间不 超过2h，增加 Al-Ti-B丝的添加量，将Ti成分控制在0. 03%-0. 04%，消除了羽毛晶产生的 外在条件；在熔炼过程中通过永磁搅拌器搅拌，倒炉时边搅拌边倒炉，在静置炉中，加强搅 拌缩短熔体在炉内停留的时间，有效防止Zn、Zr的比重偏析；熔体采取二次净化和双级过 滤工艺措施对保证铸淀的内部纯洁度，有效提1¾制品的性能；热顶铸造可以提1¾铸淀的内、 外部质量，为制品组织和性能的提高奠定了基础条件；在线淬火采用强风冷却，使冷却速度 达到200°C /min以上对提高制品的固溶程度，保证制品力学性能是至关重要的；根据制品 的使用特性要求，采用了双级时效是正确的，即保证了制品具有较高的强度，又保证了制品 有足够的塑性。
[0020] 本发明的进一步有益效果是：在步骤（2)中Zn锭分三批用加料铲分数的加入炉 内，加入一批待Zn熔化后，用永磁搅拌器搅拌lOmin，正反转各搅拌5min，使炉内的化学成 分和温度均匀，更为有效防止Zn、Zr的比重偏析。
[0021] 本发明的进一步有益效果是：步骤（4)从倒炉到铸造，熔体在静置炉内停留时间 不得超过lh，这样操作进一步消除了羽毛晶产生的外在条件。
[0022] 说明书附图
[0023] 图1为本发明的均火铸锭边部高倍组织X 200图；
[0024] 图2为本发明的均火铸锭半径1/2处高倍组织X 200图；
[0025] 图3为本发明的均火铸锭中心部位高倍组织X200图；
[0026] 图4为本发明的型材边部横向高倍组织X 200图；
[0027] 图5为本发明的型材边部纵向高倍组织X 200图；
[0028] 图6为本发明的型材中部横向高倍组织X200图；
[0029] 图7为本发明的型材中部纵向高倍组织X 200图。
具体实施方式
[0030] 本发明用于汽车保险杠的铝合金型材生产工艺，包括如下步骤；
[0031] (1)配料：合金的基体选用99. 85牌号的铝锭。Mg、Zn元素以纯金属的形式加入， 考虑Cu、Cr、Ti、Zr元素熔点较高，且在合金中含量较低，故以中间合金的形式加入。
[0032] (2)熔炼：采用25吨蓄热式燃气炉熔炼，考虑到该合金含Zn量较高，Zr的熔点较 高，易产生Zn、Zr的比重偏析和羽毛晶，因而采取以下措施：为防止产生羽毛晶，熔炼温度 不宜过高，为755°C ;
[0033] (3)为防止产生Zn、Zr比重偏析，将Zn锭分三批用加料铲分数的加入炉内，加入一 批待Zn熔化后，用永磁搅拌器搅拌lOmin，正反转各搅拌5min，使炉内的化学成分和温度均 匀，取样分析调整完化学成分和温度后即要抓紧倒炉，Si的质量百分含量控制在0. 10%， Fe的质量百分含量控制在0. 16% -0. 17%，Mg的质量百分含量控制在1. 20% -1. 30%，Μη 的质量百分含量控制在< 〇. 04%，Cu的质量百分含量控制在0. 20% -0. 22 %，Cr的质量百 分含量控制在< 〇. 04 %，Zn的质量百分含量控制在6. 50 % -6. 70 %，Zr的质量百分含量控 制在0. 15%-0. 16%，非检测杂质单个质量百分含量控制在0.05%，总和控制在0. 10%，尽 量缩短熔体在炉内停留的时间，倒炉时对炉内熔体边倒炉边用永磁搅拌器对炉内的熔体进 行搅拌；倒炉时要保持熔体平稳流动，不得有冲击翻滚现象；
[0034] (4)倒炉后在750°C以上的条件下，用氩气喷吹无钠精炼剂进行精炼，精炼剂用量 1. 5kg/t，精炼时间为lOmin以上；扒净熔体表面的浮渣，向熔体表面均匀的撒上10kg无钠 覆盖剂，静置20min后，即要抓紧铸造；从倒炉到铸造，熔体在静置炉内停留时间不得超过 lh，以免熔体中形成晶核的活化质点衰减，造成产生羽毛晶和Zn、Zr比重偏析的条件；
[0035] 由于该合金加入了 Zr，会对Al-Ti-B丝的细化效果造成不良影响。因为Zr会对 起细化作用的TiB2表面形成一层ZrB2或Zr的包复层，从而抑制了 TiB2细化晶粒的特性。 此外Zr还会置换TiA13中的一些Ti形成（Til-XZrx)A13类型的三元固溶体。改变了其晶 格常数和TiA13的形核特性，而且随着Zr含量的增加而使晶粒粗化，这是由于在形成的三 元相中Zr的摩尔份额增加，而降低了 TiA13的细化效果。综上所述Zr的加入会形成羽毛 晶的生成条件，为补偿因 Zr加入而引起的Al-Ti-B丝中的TiB2, TiA13粒子细化效果的降 低，采取了增加添加 Al-Ti-B丝量的办法，添加量为800mm/min最终使合金达到Ti的质量 百分含量为〇. 03% -0. 04% ;
[0036] (5)为进一步提高熔体的纯洁度，在铸造过程中在线用除气机进行第二次净化进 一步除气除渣，除气机转子转速350r/min氩气流量2m 3/h，合金中含有氧化物会破坏其基体 的连续性，进而影响合金的力学性能。为此在生产中要尽量降低熔体中的氧化夹杂物。一 是在工艺上采取措施尽量减少生产过程中氧化夹杂物的生成。二是把生成的氧化夹杂物采 取相应的工艺措施除去。在这里采用30ppi和50ppi的双级过滤就是为了滤除熔体中的氧 化夹杂物，一般可滤除10 μ以上的氧化夹杂物95%以上、5-10 μ的氧化夹杂物50%左右。
[0037] (6)由于热顶同水平铸造结晶器短，铸造速度快，冷却强度大，故可以提高铸锭的 表面和内部质量及性能。因而本次试生产使用Φ304mm热顶同水平铸造。但在铸造时铸造 温度、铸造速度、冷却强度调配不当也会造成羽毛晶生成的条件。经认真分析研究，我们对 铸造参数，按表1数值控制：
[0038] 表 1
[0039]
[0040] (7)由于采用直接水冷热顶铸造冷却强度大，因而铸锭不可避免的会产生不平衡 结晶和内应力。为消除化学成分组织上的不均匀性和内应力，改善铸锭的加工性能，使最终 制品获得良好的力学性能，需对铸锭进行组织均匀化处理。均匀化制度如下：铸锭在250°C 时装炉，先不点火升温，开风机运行lh后再点火升温，加热升温速度90°C /h。均质温度 485±5°C，保温8h，然后放入冷却炉冷却，冷却速度要> 100°C /h，冷却到室温后出炉。
[0041] (8)由于该合金的变形抗力较大，根据所挤压型材断面尺寸，安排40MN挤压机挤 压。加工工艺如下：铸锭加热温度50(TC，挤压模具温度450°C，挤压温度480°C，挤压速度 3. 1-3. 2m/min〇
[0042] (9)型材在线精密淬火：淬火的目的是为了获得高浓度的过饱和固溶体，为随后 进行的时效创造条件。该合金的主要强化相为T相（Mg3Zn3A12)和η相（MgZn2)两个相 的强化效果相近，淬火的敏感性相对不太高，合金的淬火时加热温度很宽为350°C _550°C， 因此可以在线淬火。为保证淬火效果，对工艺参数必须严格控制。挤压型材的出模口温度 不得低于480°C，采用强风冷却。
[0043] (10)拉伸校直：型材的拉直在200T拉伸机上进行，变形量为1% -3%，校直后的 型材经检验合格后，按要求尺寸切成成品后，再进行双级时效，由于该型材要求有良好的综 合性能，因而时效时采用双级时效即：l〇〇°C保温8h升温至145°C再保温llh。这种时效可 以使合金具有良好的塑性及较高的抗拉强度。有利于提高制品的工作能力。经上述步骤加 工出的铸锭的表2检验结果：
[0044] 表2 质量分数％
[0045]
铸锭的化学成分均匀度见表3,在铸造过程中从铸造长度lm起每隔lm取一个化学成分试 样，分析化学成分
[0046] 表3 质量分数％
[0047]
[0048] 从表3可以看出铸锭纵向的化学成分相对时均匀的，其中以Zn、Mg的偏差最大分 别为0. 1 %和0. 08%，但整体化学成分在丛林成分内标的范围内。
[0049] 铸锭横向化学成分均匀度：在铸锭头部切取试片沿试片直径从边部起每隔38mm 打光谱分析铸锭化学成分（从左至右化学成分分析点的编号1-9依次排列）化学成分分析 结果见表4
[0050] 表4 质量分数％
[0051]
[0052] 从表4中可以看出沿铸锭横断面的化学成分也是相对均匀的，以Zn、Mg的偏差最 大也仅为〇. 09%和0. 07%，但也在丛林成分内标范围内。铸锭化学成分的相对均匀，使挤 压型材的化学成分均匀，进而为保证制品组织和性能的均匀奠定了基础条件。
[0053] 铸锭的低倍组织检验：在铸锭上切取低倍试片，做低倍组织检验。检验结果见表5
[0054] 表 5
[0055]
[0056] 铸锭均火后的高倍组织检验：在均火的铸锭上切取试片在试片的边部、1/2半径 处、中心部分别切取高倍试样进行检验。检验结果见图1、图2、图3和表6 :
[0057] 表 6
[0058]
[0059] 铸徒的力学性能检验：在铸徒的中部切取试片，按图4切取性能试样做机械性能 检验。检验结果见表7 ;
[0060] 表 7
[0061]
[0062] 型材的低倍组织检验：在型材上切取低倍试样，做低倍组织检验，检验结果见图5 和表8 :
[0063] 表 8
[0064]
[0065] 型材的高倍组织检验：在时效后的型材上沿纵向横向切取试片，分别切取高倍试 样做高倍组织检验。检验结果见图4、图5、图6、图7和表9 :
[0066] 表 9
[0067]
[0069] 型材的性能检验：在型材上切取纵向试样，然后在边部和中心部分别切取力学试 样，做力学性能检验。检验结果见表10
[0070] 表 10
[0071]
[0072] 以上所述实施例仅仅是对本发明的优选实施方式进行描述，并非对本发明的范围 进行限定，在不脱离本发明设计精神的前提下，本领域普通工程技术人员对本发明的技术 方案作出的各种变形和改进（包括类似材料焊接时，使用镍基合金作为过渡层），均应落入 本发明的权利要求书确定的保护范围内。
Claims (3)
1. 一种用于汽车保险杠的铝合金型材生产工艺，其特征在于：包括以下步骤： ⑴先配料：合金的基体选用99. 85牌号的铝锭，Mg、Zn元素以纯金属的形式加入，考 虑Cu、Cr、Ti、Zr元素烙点较高，且在合金中含量较低,故以中间合金的形式加入； (2) 之后采用25吨蓄热式燃气炉熔炼，熔炼温度不宜过高，为750±5°C ; (3) 在熔炼过程中，取样分析调整完化学成分和温度后即要抓紧倒炉，Si的质量 百分含量控制在〇. 10%，Fe的质量百分含量控制在0. 16% -0. 17%，Mg的质量百分含 量控制在1.20% -1.30%，Μη的质量百分含量控制在< 0.04%，Cu的质量百分含量控 制在0.20 % -0.22%，Cr的质量百分含量控制在< 0.04%，Zn的质量百分含量控制在 6. 50 % -6. 70 %，Zr的质量百分含量控制在0. 15 % -0. 16 %，非检测杂质单个质量百分含量 控制在0. 05%，总和控制在0. 10%，尽量缩短熔体在炉内停留的时间，倒入静置炉时对炉 内熔体边倒炉边用永磁搅拌器对炉内的熔体进行搅拌，倒炉时要保持熔体平稳流动，不得 有冲击翻滚现象； (4) 倒入静置炉后在750°C以上的条件下，用氩气喷吹无钠精炼剂进行精炼，精炼剂用 量1. 5kg/t，精炼时间为lOmin以上，扒净熔体表面的浮渣，向熔体表面均匀的撒上10kg无 钠覆盖剂； (5) 在线添加 Al-Ti-B丝，添加量为800mm/min，最终使合金达到Ti的质量百分含量为 0. 03% -0. 04% (6) 为进一步提高熔体的纯洁度，用除气机进行第二次净化进一步除气除渣，除气机转 子转速控制在350r/min，氦气流量控制在2m 3/h，采用30ppi和50ppi的双级过滤滤除烙体 中的氧化夹杂物； (7) 待熔体撒上10kg无钠覆盖剂后20min内，使用Φ 304mm热顶同水平铸造； (8) 铸锭在250°C时装炉，先不点火升温，开风机运行lh后再点火升温，加热升温速度 90°C /h，均质温度485±5°C，保温8h，然后放入冷却炉冷却，冷却速度要> 100°C /h，冷却到 室温后出炉； (9) 之后，选用40MN挤压机挤压，铸锭加热温度500°C，挤压模具温度450°C，挤压温度 480°C，挤压速度 3. 1-3. 2m/min ; (10) 之后对型材在线淬火，淬火温度为350°C -550°C，挤压型材的出模口温度不得低 于480°C，采用强风冷却； (11) 之后将型材用200T拉伸机拉直，变形量为1 % -3 %，校直后的型材经检验合格后， 按要求尺寸切成成品后，再进行双级时效即：l〇〇°C保温8h升温至145°C再保温llh。
2. 如权利要求1所述的用于汽车保险杠的铝合金型材生产工艺，其特征在于：所述步 骤（2)中Zn锭分三批用加料铲分数的加入炉内，加入一批待Zn熔化后，用永磁搅拌器搅拌 lOmin,正反转各搅拌5min，使炉内的化学成分和温度均勻。
3. 如权利要求1所述的用于汽车保险杠的铝合金型材生产工艺，其特征在于：所述步 骤（4)从倒炉到铸造，熔体在静置炉内停留时间不得超过lh。
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| CN103643840B (zh) * | 2013-12-10 | 2016-06-01 | 南南铝业股份有限公司 | 铝合金拉手制作方法 |
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| CN104018038A (zh) * | 2014-05-20 | 2014-09-03 | 广东豪美铝业股份有限公司 | 一种汽车防撞梁用铝合金及其产品制造方法 |
| CN104073726B (zh) * | 2014-06-21 | 2016-07-06 | 辽宁工程技术大学 | 一种用于齿轮的合金材料的制备方法 |
| EP2993244B1 (en) * | 2014-09-05 | 2020-05-27 | Constellium Valais SA (AG, Ltd) | Method to produce high strength products extruded from 6xxx aluminium alloys having excellent crash performance |
| CN106086551B (zh) * | 2016-07-25 | 2018-09-25 | 慈溪市宜美佳铝业有限公司 | 一种保险杠用高强度高韧性铝合金型材及其制备方法 |
| CN106906393A (zh) * | 2017-04-05 | 2017-06-30 | 黄河科技学院 | 一种汽车车身用铝合金及其制备方法和应用 |
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