CN111128445B - Aluminum-manganese alloy steel-clad reinforced overhead conductor and preparation process thereof - Google Patents
Aluminum-manganese alloy steel-clad reinforced overhead conductor and preparation process thereof Download PDFInfo
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- H01B9/00—Power cables
- H01B9/008—Power cables for overhead application
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
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- H01B7/00—Insulated conductors or cables characterised by their form
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- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/22—Metal wires or tapes, e.g. made of steel
- H01B7/221—Longitudinally placed metal wires or tapes
- H01B7/223—Longitudinally placed metal wires or tapes forming part of a high tensile strength core
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- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
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Abstract
The invention discloses an aluminum-manganese alloy steel-clad reinforced overhead conductor and a preparation process thereof. The reinforced overhead conductor comprises a reinforced core and a conductor; the reinforced core is formed by stranding a plurality of aluminum-manganese alloy steel-clad single wires; the conductor is stranded on the outer layer of the reinforced core; the tensile strength of the aluminum-manganese alloy steel-clad single wire is more than or equal to 1400 MPa. The preparation process comprises the steps of preparing an aluminum-manganese alloy melt, degassing, casting and rolling an aluminum-manganese alloy ingot blank to obtain an aluminum-manganese alloy rod, continuously coating the alloy rod on the surface of a lead-quenched steel wire, drawing and twisting to obtain a reinforced core, and twisting the reinforced core and a conductor to obtain different types of overhead conductors. Because the aluminum-manganese alloy has higher strength and more excellent corrosion resistance than common aluminum, the aluminum-manganese alloy is coated on the overhead conductor prepared by taking the surface of the patented steel wire as the reinforcing core, the tension is large, the corrosion resistance is good, and the safety and the service life in a corrosive environment are greatly improved.
Description
Technical Field
The invention belongs to the technical field of wire manufacturing, and particularly relates to an aluminum-manganese alloy steel-clad reinforced overhead wire and a preparation process thereof.
Background
With the rapid development of the world's economy, power supply is a key factor ensuring its keeping up with the development of the times in almost all countries and regions. Since the invention of the end of the 19 th century, overhead conductors have made an important contribution to the advancement of society. However, with the continuous expansion of the application range and the complexity and changeability of the world environment, the service environment of the overhead conductor is continuously changed and deteriorated, and a plurality of factors cause the service life of the overhead conductor to be greatly shortened and safety accidents in the use process to occur. In terms of the failure mode of the lead, corrosion breakage is the most important reason for the failure of the overhead lead and accounts for about one fourth of the accident of the whole overhead line.
Generally, the design life of an overhead conductor is 30 to 50 years, and with the development of times and the technological progress, people have improved expected life, in coastal areas and industrial areas, the corrosion environment is complex and various, the conductor is chemically corroded and electrochemically corroded due to moisture, acid, industrial pollutants and the like, the tension of the corroded conductor is sharply reduced, so that the use value of the conductor is completely lost, the service life of the overhead conductor in the areas is only 15 years or even lower, and how to reduce the corrosion and disconnection of the overhead conductor becomes a difficult problem for restricting the use of the overhead line.
The research on improving the corrosion resistance of the overhead conductor is not interrupted, for example, measures such as a galvanized steel core, a zinc-aluminum alloy coating steel core, an aluminum-clad steel core, coating of anticorrosive oil and the like are adopted, so that the corrosion resistance of the conductor can be enhanced to a certain extent, and the service life of the conductor can be prolonged. And science and technology is developing, more needs further to improve overhead line corrosion resistance, guarantees can not appear because of corroding the broken string in the design life-span, improves the circuit design life-span even, improves the tensile strength of wire simultaneously.
Disclosure of Invention
The invention aims to provide an aluminum-manganese alloy steel-clad reinforced overhead conductor and a preparation process thereof, which can improve the corrosion resistance of an overhead line, ensure that the line is not broken due to corrosion within the design life and improve the tensile strength of the conductor.
The technical scheme for realizing the invention is as follows:
an aluminum-manganese alloy steel-clad reinforced overhead conductor comprises a reinforced core and a conductor; the reinforced core is formed by stranding a plurality of aluminum-manganese alloy steel-clad single wires; the conductor is stranded on the outer layer of the reinforced core; the tensile strength of the aluminum-manganese alloy steel-clad single wire is more than or equal to 1400 MPa;
further, the aluminum-manganese alloy steel-clad single wire comprises the following components in percentage by mass: mn: 0.5 to 1.2 percent; cu: 0.1 to 0.2 percent; si is less than or equal to 0.3 percent; fe: 0.4% -0.8%; zn is less than or equal to 0.2 percent; al is more than or equal to 97.90 percent.
Further, the conductor is aluminum or aluminum alloy, and the cross-sectional shape of the conductor is circular or irregular.
A preparation process of an aluminum-manganese alloy steel-clad reinforced overhead conductor comprises the following steps:
the method comprises the following steps: melting aluminum ingots into aluminum melt by using a melting furnace, allowing the melt to flow into a holding furnace, and sequentially adding various alloy ingots into the holding furnace for treatment to prepare an aluminum-manganese alloy melt;
step two: degassing and casting the aluminum-manganese alloy melt on line to obtain an aluminum-manganese alloy ingot blank with a compact structure and no surface cracks;
step three: heating the aluminum-manganese alloy ingot blank, and hot rolling to obtain an aluminum-manganese alloy rod, wherein the tensile strength of the alloy rod is 190-230 MPa, and the elongation is more than or equal to 6%;
step four: according to the performance requirement of the reinforcing core, selecting a patenting steel wire with a corresponding specification, and continuously and uniformly coating an aluminum-manganese alloy rod on the surface of the patenting steel wire to obtain a blank rod, wherein the tensile strength of the blank rod is 1200-1300 MPa, and the elongation is more than or equal to 7.5%;
step five: drawing the blank rod into aluminum-manganese alloy steel-clad single lines with various specifications, wherein the tensile strength of the aluminum-manganese alloy steel-clad single lines is more than or equal to 1400 MPa;
step six: and twisting a plurality of aluminum-manganese alloy steel-clad single wires to obtain the reinforced core, and twisting the reinforced core with the outer conductor according to actual requirements to obtain various aluminum-manganese alloy steel-clad reinforced overhead conductors.
Further, the method for preparing the aluminum-manganese alloy melt in the first step comprises the following steps: the purity of the aluminum ingot is 99.7%, the cost of the aluminum ingot is not increased, and the aluminum ingot is subjected to melt optimization and component proportion in a heat preservation furnace to prepare an aluminum alloy melt.
Further, the method for preparing the aluminum-manganese alloy melt in the first step comprises the following steps: controlling the temperature of the holding furnace at 720-740 ℃, adding an aluminum-boron alloy ingot into the aluminum alloy melt, adding an iron agent and an aluminum-copper alloy ingot, refining for 20-30 min, slagging off, and standing for 15-20 min; after stabilization, raising the temperature of the furnace to 760-770 ℃, adding an aluminum-manganese alloy ingot, smelting for 30-40 min, and standing for 30-35 min; and (4) analyzing the components by spectrum, and carrying out the next step if the components meet the requirements, and repeating the step if the components do not meet the requirements.
Further, in the second step, after the aluminum-manganese alloy melt is smelted, the aluminum-manganese alloy melt passes through an external degassing and filtering system in a launder, the hydrogen content is not higher than 0.15ml/100g, the casting temperature is 710-730 ℃, the surface of the prepared aluminum-manganese alloy ingot blank has no cracks, the cross section has no pores, and the aluminum-manganese alloy ingot blank is in isometric grain shape.
Further, in the third step, the aluminum manganese alloy ingot blank is subjected to online infrared induction heating before rolling, the rolling temperature is monitored in real time, the rolling temperature is controlled to be 500-520 ℃, the emulsion pressure of the rolling mill is adjusted, and the final rolling temperature is 230-250 ℃.
Further, in the fourth step, according to the target performance of the aluminum-manganese-coated steel wire, a proper patenting steel wire is selected, two alloy rods with the diameter of 9.5mm are coated on the surface of the patenting steel wire through an extrusion wheel and a die by using an aluminum-coated steel continuous coating machine, the aluminum-manganese alloy section in the blank rod is controlled to account for 22% -25%, the temperature of a die cavity is controlled to be 440-460 ℃, and the rotating speed of the extrusion wheel is controlled to be 5-10 rmp/min.
Further, in the fifth step, the wire drawing method comprises the following steps: and drawing the blank rod into an aluminum-manganese alloy clad steel wire through bimetal drawing, wherein the reduction of area is 70-80%, and the pass reduction is 15-17%.
After the technical scheme is adopted, the invention has the following beneficial effects:
(1) the aluminum-manganese alloy reinforced core external stranded conductor structure greatly improves the corrosion resistance and tensile strength of the product, and further prolongs the service life of the lead.
(2) The conductor is made of aluminum or aluminum alloy, can be round or special, reduces the weight of the overhead conductor while ensuring the conductivity, does not need to increase the strength and the height of a tower, does not need to transform infrastructure, can reduce the transformation cost of a line, has various cross-section shapes, and meets different use requirements.
(3) The invention adopts degassing and slag-drawing treatment, can remove impurities in the alloy liquid, and avoids the defects of cracks, wrappings and the like in the casting process.
(4) The aluminum-manganese alloy ingot blank is subjected to online infrared induction heating before rolling, the rolling temperature is monitored in real time, and the stability of the process is ensured.
(5) The invention processes the aluminum manganese alloy ingot blank prepared according to a certain formula into an aluminum manganese alloy rod with high strength and strong corrosion resistance in a continuous casting and rolling way, and then coats the aluminum manganese alloy rod on the surface of the steel wire to form a coating layer, so that the prepared overhead conductor can avoid the electrochemical corrosion of a reinforced core and a conductor and the chemical and electrochemical corrosion of the coating layer, and the tension design allowance of the conductor is increased, thereby greatly improving the product performance and the service life, having practicability and foresight, and having higher use value and popularization and application prospect.
Detailed Description
(example 1)
Example 1 the aluminum-manganese alloy steel-clad single wire comprises the following components in percentage by mass: mn: 0.5 percent; si: 0.08 percent; fe: 0.6 percent; cu: 0.1 percent; zn:0.1 percent; al: 98.45 percent.
1. Heating the smelting furnace to 720 ℃, smelting an aluminum ingot with the purity of 99.7% into an aluminum melt, allowing the melt to flow into a holding furnace, adding 2.5kg of aluminum-boron alloy ingot, 55kg of iron agent and 15kg of aluminum-copper alloy ingot into each ton of aluminum alloy melt, refining for 20min, slagging off, and standing for 18min to remove impurities in the alloy liquid; heating the furnace to 765 ℃, adding 210kg of aluminum-manganese alloy ingot, smelting for 40min, and standing for 32 min; and (4) analyzing the components by spectrum, and carrying out the next step if the components meet the requirements, and repeating the step if the components do not meet the requirements.
2. And after the components meet the design requirements, the continuous casting and rolling are started. The melt was first passed through a long-term filtration system outside the furnace, and in order to further remove impurities from the alloy liquid, the hydrogen content was measured in a launder out of the system, and casting was carried out at a casting temperature of 725 ℃ when the hydrogen content was 0.15ml/100 g. And observing that the surface of the prepared aluminum-manganese alloy ingot blank has no cracks and the cross section has no air holes, and the ingot blank presents isometric crystal grains.
3. And (3) carrying out online infrared induction heating before rolling, monitoring the temperature in real time to ensure the stability of the process, adjusting the emulsion pressure of a rolling mill to 190kpa when the rolling temperature reaches 500 ℃, and measuring the rolling temperature to 250 ℃. The tensile strength of the aluminum-manganese alloy rod manufactured by hot rolling is 195MPa, and the elongation is 6.8%.
4. Lead quenching steel wires with the diameter of 4.30mm are selected for coating, so that the prepared overhead conductor can avoid electrochemical corrosion of the reinforced core and the conductor and chemical and electrochemical corrosion of the coating layer. An aluminum-clad steel continuous cladding machine is used for cladding two alloy rods with the diameter of 9.5mm on the surface of the patented steel wire through an extrusion wheel and a die, the diameter of the cladding die is 4.90mm, the temperature of a die cavity is 460 ℃, the rotating speed of the extrusion wheel is 10rmp/min, the tensile strength of the clad aluminum-manganese alloy clad steel billet rod is 1276MPa, and the elongation is 7.8%.
5. The blank rod passes through 8 wire drawing dies to draw an aluminum-manganese alloy clad steel wire with the diameter of 2.27mm, the tensile strength of a single wire is 1470MPa, the aluminum-manganese alloy clad steel wire is rewound and twisted with 19 pieces by a JLK710/12+18+24 frame twisting machine to obtain a reinforced core, and the reinforced core and 45 trapezoidal aluminum conductors with the equivalent diameter of 4.61mm are twisted to obtain the overhead conductor, so that the corrosion resistance and the tensile strength of the product are greatly improved, and the service life of the conductor is further prolonged.
(example 2)
Example 2 the aluminum-manganese alloy steel-clad single wire comprises the following components in percentage by mass: mn: 0.8 percent; si: 0.1 percent; fe: 0.7 percent; cu: 0.15 percent; 0.1 percent of Zn; al: 98.03 percent.
1. Heating the smelting furnace to 730 ℃, smelting an aluminum ingot with the purity of 99.7 percent into an aluminum melt, allowing the melt to flow into a holding furnace, adding 2kg of aluminum-boron alloy ingot, 68kg of iron agent and 24kg of aluminum-copper alloy ingot into each ton of aluminum alloy melt, refining for 25min, slagging off, and standing for 15min to remove impurities in the alloy liquid; raising the temperature of the furnace to 760 ℃, adding 325kg of aluminum-manganese alloy ingot, smelting for 30min, and standing for 30 min; and (4) analyzing the components by spectrum, and carrying out the next step if the components meet the requirements, and repeating the step if the components do not meet the requirements.
2. And after the components meet the design requirements, the continuous casting and rolling are started. The melt was first passed through a long-term filtration system outside the furnace, and in order to further remove impurities from the alloy liquid, the hydrogen content was measured in a launder out of the system, and casting was carried out at a casting temperature of 715 ℃ when the hydrogen content was 0.13ml/100 g. And observing that the surface of the prepared aluminum-manganese alloy ingot blank has no cracks and the cross section has no air holes, and the ingot blank presents isometric crystal grains.
3. And (3) carrying out online infrared induction heating before rolling, monitoring the temperature in real time to ensure the stability of the process, adjusting the emulsion pressure of a rolling mill to 200kpa when the rolling temperature reaches 510 ℃, and measuring the rolling temperature to 230 ℃. The tensile strength of the aluminum-manganese alloy rod manufactured by hot rolling reaches 220MPaMPa, and the elongation reaches 6.5%.
4. Lead quenching steel wires with the diameter of 4.55mm are selected for coating, so that the prepared overhead conductor can avoid electrochemical corrosion of the reinforced core and the conductor and chemical and electrochemical corrosion of the coating layer. And (3) coating two alloy rods with the diameter of 9.5mm on the surface of the patented steel wire by using an aluminum-coated steel continuous coating machine through an extrusion wheel and a die, wherein the diameter of the coating die is 5.22mm, the temperature of a die cavity is 445 ℃, the rotating speed of the extrusion wheel is 7rmp/min, the tensile strength of the coated aluminum-manganese alloy coated steel rod reaches 1250MPa, and the elongation is 8.0%.
5. The blank rod is drawn into an aluminum-manganese alloy clad steel wire with the diameter of 2.50mm through 7 wire drawing dies, the tensile strength of a single wire is 1425MPa, the aluminum-manganese alloy clad steel wire is rewound and twisted with 7 wires through a JLK710/12+18+24 frame stranding machine to obtain a reinforced core, and then the reinforced core is twisted with 48 round aluminum conductors with the diameter of 3.22mm to obtain the overhead conductor, so that the corrosion resistance and the tensile strength of the product are greatly improved, and the service life of the conductor is further prolonged.
(example 3)
Example 3 the aluminum-manganese alloy steel-clad single wire comprises the following components in percentage by mass: mn: 1.1 percent; si: 0.07 percent; fe: 0.5 percent; cu: 0.15 percent; zn: 0.15 percent; al: 97.93 percent.
1. Heating the smelting furnace to 740 ℃, smelting an aluminum ingot with the purity of 99.7 percent into an aluminum melt, allowing the melt to flow into a holding furnace, adding 3kg of aluminum-boron alloy ingot, 46kg of iron agent and 23kg of aluminum-copper alloy ingot into each ton of aluminum alloy melt, refining for 30min, slagging off, and standing for 20min to remove impurities in the alloy liquid; raising the temperature of the furnace to 770 ℃, adding 445kg/t of aluminum-manganese alloy ingot, smelting for 35min, and standing for 35 min; and (4) analyzing the components by spectrum, and carrying out the next step if the components meet the requirements, and repeating the step if the components do not meet the requirements.
2. And after the components meet the design requirements, the continuous casting and rolling are started. The melt was first passed through a long-term filtration system outside the furnace, and in order to further remove impurities from the alloy liquid, the hydrogen content was measured in a launder out of the system, and casting was carried out at a casting temperature of 715 ℃ when the hydrogen content was 0.1ml/100 g. And observing that the surface of the prepared aluminum-manganese alloy ingot blank has no cracks and the cross section has no air holes, and the ingot blank presents isometric crystal grains.
3. And (3) carrying out online infrared induction heating before rolling, monitoring the temperature in real time to ensure the stability of the process, adjusting the emulsion pressure of a rolling mill to 225kpa when the rolling temperature reaches 520 ℃, and measuring the rolling temperature to 240 ℃. The tensile strength of the aluminum-manganese alloy rod manufactured by hot rolling reaches 210MPaMPa, and the elongation reaches 6.0%.
4. The lead quenching steel wire with the diameter of 5.1mm is selected for coating, so that the prepared overhead conductor can avoid electrochemical corrosion of the reinforced core and the conductor and chemical and electrochemical corrosion of the coating layer. An aluminum-clad steel continuous cladding machine is used for cladding two alloy rods with the diameter of 9.5mm on the surface of the patented steel wire through an extrusion wheel and a die, the diameter of the cladding die is 5.78mm, the temperature of a die cavity is 450 ℃, the rotating speed of the extrusion wheel is 5rmp/min, the tensile strength of the clad aluminum-manganese alloy clad steel billet rod reaches 1300MPa, and the elongation is 7.5%.
5. The blank rod is drawn into an aluminum-manganese alloy clad steel wire with the diameter of 2.80mm through 8 wire drawing dies, the tensile strength of a single wire is 1450MPa, the aluminum-manganese alloy clad steel wire is rewound and twisted with 7 wires through a JLK710/12+18+24 frame stranding machine to obtain a reinforced core, and the reinforced core is twisted with 45 round aluminum conductors with the diameter of 4.20mm to obtain the overhead conductor, so that the corrosion resistance and the tensile strength of the product are greatly improved, and the service life of the conductor is further prolonged.
The foregoing embodiments are provided to further explain the objects, technical solutions and advantages of the present invention in detail, and it should be understood that the above-mentioned reinforced al-mn alloy-clad overhead conductor and the preparation process are only representative of the embodiments of the present invention, and are not intended to limit the present invention, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (3)
1. A preparation process of an aluminum-manganese alloy steel-clad reinforced overhead conductor is characterized by comprising the following steps: the aluminum-manganese alloy steel-clad reinforced overhead conductor comprises a reinforced core and a conductor; the reinforced core is formed by stranding a plurality of aluminum-manganese alloy steel-clad single wires; the conductor is stranded on the outer layer of the reinforced core; the preparation process comprises the following steps:
the method comprises the following steps: melting an aluminum ingot into an aluminum melt by using a melting furnace, allowing the melt to flow into a holding furnace, controlling the temperature of the holding furnace at 720-740 ℃, adding an aluminum-boron alloy ingot, an iron agent and an aluminum-copper alloy ingot into the aluminum melt, refining for 20-30 min, slagging off, and standing for 15-20 min; after stabilization, raising the temperature of the furnace to 760-770 ℃, adding an aluminum-manganese alloy ingot, smelting for 30-40 min, and standing for 30-35 min; analyzing the components by spectrum, and performing the next step if the components meet the requirements, and repeating the step if the components do not meet the requirements;
step two: degassing and casting the aluminum-manganese alloy melt on line to obtain an aluminum-manganese alloy ingot blank with a compact structure and no surface cracks; after the aluminum-manganese alloy melt is smelted, the aluminum-manganese alloy melt passes through an external degassing and filtering system in a launder, the hydrogen content is not higher than 0.15ml/100g, the casting temperature is 710-730 ℃, and an aluminum-manganese alloy ingot blank with no surface cracks, no air holes in the cross section and isometric crystal grain shape is prepared;
step three: heating the aluminum-manganese alloy ingot blank, and hot rolling to prepare an aluminum-manganese alloy rod; before rolling, carrying out online infrared induction heating on an aluminum-manganese alloy ingot blank, controlling the rolling temperature to be 500-520 ℃, adjusting the emulsion pressure of a rolling mill, and controlling the final rolling temperature to be 230-250 ℃;
step four: selecting a lead quenching steel wire meeting the performance requirement of the reinforced core, and continuously and uniformly coating an aluminum-manganese alloy rod on the surface of the lead quenching steel wire to obtain a blank rod; coating two alloy rods with the diameter of 9.5mm on the surface of the patented steel wire by using an aluminum-clad steel continuous coating machine through an extrusion wheel and a die, controlling the aluminum-manganese alloy section proportion in the blank rod to be 22-25%, the die cavity temperature to be 440-460 ℃, and the rotation speed of the extrusion wheel to be 5-10 rmp/min;
step five: drawing the blank rod into aluminum-manganese alloy clad steel single wires with various specifications, drawing the blank rod into an aluminum-manganese alloy clad steel wire through bimetal drawing, wherein the reduction of area is 70-80%, the pass reduction is 15-17%, and the tensile strength of the aluminum-manganese alloy clad steel single wire is more than or equal to 1400 MPa;
step six: and stranding a plurality of aluminum-manganese alloy steel-clad single wires to obtain a reinforced core, and stranding the reinforced core and the outer conductor to obtain the aluminum-manganese alloy steel-clad reinforced overhead conductor.
2. The preparation process of the aluminum-manganese alloy steel-clad reinforced overhead conductor according to claim 1, characterized in that: the aluminum-manganese alloy steel-clad single wire comprises the following components in percentage by mass: mn: 0.5 to 1.2 percent; cu: 0.1 to 0.2 percent; si is less than or equal to 0.3 percent; fe: 0.4% -0.8%; zn is less than or equal to 0.2 percent; al is more than or equal to 97.9 percent.
3. The preparation process of the aluminum-manganese alloy steel-clad reinforced overhead conductor according to claim 2, characterized in that: the conductor is aluminum or aluminum alloy.
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