CN111618401A - Welding process of aluminum alloy air cylinder - Google Patents
Welding process of aluminum alloy air cylinder Download PDFInfo
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- CN111618401A CN111618401A CN202010383341.7A CN202010383341A CN111618401A CN 111618401 A CN111618401 A CN 111618401A CN 202010383341 A CN202010383341 A CN 202010383341A CN 111618401 A CN111618401 A CN 111618401A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/02—Seam welding; Backing means; Inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/12—Vessels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/10—Aluminium or alloys thereof
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- Engineering & Computer Science (AREA)
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- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Arc Welding In General (AREA)
Abstract
The invention relates to a welding process of an aluminum alloy air cylinder, which belongs to the technical field of welding and comprises the following steps: positioning and rotationally fixing the end cover and the end cover nut, and automatically welding the end cover and the end cover nut through a TIG (tungsten inert gas) welding machine and an automatic wire feeding controller under protective gas; positioning and fixing the cylinder body, and automatically welding the longitudinal joint of the cylinder body through an FSW welding machine; the cylinder and the cylinder nut are positioned, rotated and fixed, and are automatically welded through a TIG welding machine and an automatic wire feeding controller under the protection gas; and positioning and rotationally fixing the cylinder body and the end covers at the two ends of the cylinder body, and automatically welding the cylinder body and the end covers through an MIG welding machine under protective gas. The technology adopts FSW welding to replace traditional MIG welding or TIG welding to the longitudinal seam of the cylinder, improves the quality of the welding seam, reduces the repair rate of products, ensures that the product size reaches the standard, and simultaneously improves the production efficiency.
Description
Technical Field
The invention belongs to the technical field of welding, and relates to a welding process of an aluminum alloy air cylinder.
Background
Traditionally, the cylinder body of the aluminum alloy air cylinder for the automobile is a longitudinal seam of the cylinder body welded in a mode of MIG welding or TIG welding after a plate is rolled. The welding method has high requirement on environment, welding defects such as welding through, air holes, cracks, incomplete penetration, incomplete fusion and the like are easy to occur after welding, so that the welding line quality is poor, the repair rate is high, and the product size deformation is difficult to reach the standard. In addition, an aluminum alloy oxide film needs to be cleaned before welding, and impurities such as black ash and splashing need to be cleaned after welding, so that the production efficiency is influenced. Therefore, it is necessary to search for a new process for welding the gas cylinder.
Disclosure of Invention
In view of the above, the present invention provides a welding process for an aluminum alloy gas cylinder, which adopts FSW welding (friction stir welding) to replace conventional MIG welding and TIG welding for welding a longitudinal seam of a cylinder body of the gas cylinder, so as to improve the quality of the welding seam, reduce the repair rate of the product, ensure the product size to reach the standard, and improve the production efficiency.
In order to achieve the purpose, the invention provides the following technical scheme:
the utility model provides a welding process of aluminum alloy gas receiver, the gas receiver includes the barrel, welds barrel nut on the barrel outer peripheral face, welds the end cover at barrel both ends to and the end cover nut of welding on the end cover, welding process includes following step:
the end cover and the end cover nut are automatically welded by TIG welding: positioning and rotationally fixing the end cover and the end cover nut, controlling a welding gun of a TIG welding machine and a wire feeding nozzle of an automatic wire feeding controller to align to the welding position between the end cover and the end cover nut, and automatically welding the end cover and the end cover nut under the protection of protective gas;
longitudinal seams of the cylinder are automatically welded by FSW welding: positioning and fixing the cylinder, and controlling the rotating edge of the stirring head of the FSW welding machine to automatically weld along the longitudinal seam of the cylinder;
the cylinder and the cylinder nut are automatically welded by TIG welding: the cylinder and the cylinder nut are positioned, rotated and fixed, a welding gun of a TIG welding machine and a wire feeding nozzle of an automatic wire feeding controller are controlled to be aligned to the welding position between the cylinder and the cylinder nut, and the cylinder nut are automatically welded under the protection of protective gas;
the circumferential weld of the cylinder body and the end cover adopts MIG welding automatic welding: and positioning and rotationally fixing the cylinder body and the end covers at the two ends of the cylinder body, controlling a welding gun of the MIG welding machine to respectively align at the circular seams between the cylinder body and the end covers at the two ends of the cylinder body, and automatically welding the cylinder body and the end covers at the two ends of the cylinder body under the protection action of protective gas.
Further, in the steps of performing TIG welding of the end cover and the end cover nut, performing FSW welding of the longitudinal seam of the cylinder, and performing TIG welding of the cylinder and the cylinder nut, the shielding gas is Ar gas with a purity of 99.99%.
Further, in the steps of performing TIG welding on the end cover and the end cover nut, performing FSW welding on the longitudinal seam of the cylinder, performing TIG welding on the cylinder and the cylinder nut, and performing MIG welding on the circumferential seam of the cylinder and the end cover, the positioning and the fixing are respectively performed through a special tool clamp.
Further, in the step of performing TIG welding on the end cover and the end cover nut and the step of performing TIG welding on the cylinder and the cylinder nut, the TIG welding machine is an AVP-360-OTC welding machine, and the automatic wire feeding controller is a KZ 3-FII type automatic wire feeding controller.
Further, in the step of performing FSW welding on the longitudinal seam of the cylinder, the FSW welding machine is an ESAB gantry type friction stir welding machine, and the diameter specification of the stirring head is 1.8 mm.
Further, in the step of carrying out MIG welding on the circumferential seam of the cylinder body and the end cover, the MIG welding machine is a DP-400(S-2) -OTC welding machine.
Further, in the step of performing TIG welding on the end cover and the end cover nut, the base current for performing TIG welding is 100A, the wire feed speed is 260cm/min, and the rotating speed of the end cover and the end cover nut is 2.2-2.3 rpm.
Further, in the step of FSW welding the longitudinal seam of the cylindrical body, the welding speed for FSW welding was 400mm/min, and the rotational speed of the stirring head was 1500 rpm.
Further, in the step of performing TIG welding on the cylinder and the cylinder nut, the base current for TIG welding is 110A, the wire feed speed is 261cm/min, and the rotation speed of the cylinder and the cylinder nut is 2.0-2.1 rpm.
Further, in the step of carrying out MIG welding on the circumferential seam of the cylinder and the end cover, the welding current of one end of the cylinder and the end cover is 134-140A, and the welding voltage is 21-22V; the welding current at the other end is 136-142A, and the welding voltage is 21.1-22.2V; the rotation speed of the cylinder and the end covers at the two ends of the cylinder is 0.5rpm, and the welding rotation is 368 degrees.
The invention has the beneficial effects that:
the welding process provided by the invention adopts different welding modes aiming at the welding seams at different positions on the air storage cylinder, and selects the optimal welding mode combination, thereby achieving the effects of quality and quantity conservation, and high speed and high efficiency of welding. The end cover and the end cover nut are subjected to TIG welding, because the end cover nut is arranged in the opening on the end cover in an inserting mode, the end cover is used as a bottom support in the welding process, and compared with MIG welding and FSW welding, the TIG welding has the advantage of better controlling heat input. The cylinder and the cylinder nut are also subjected to TIG welding, so that the cylinder can be well welded and formed, and the problem that the cylinder cannot bear corresponding pressure due to the defects of welding feathering and the like caused by MIG welding is avoided. The cylinder body is welded by FSW, under the specific process parameter setting of the invention, the compressive strength of the cylinder body reaches 6.0-6.6MPa, while the conventional TIG welding or MIG welding can only reach 5.0-5.6 MPa; moreover, the FSW welding process is stable, the quality of a welding seam is improved, the repair rate of a product is reduced, the size of the welded product is guaranteed to reach the standard, and the yield of the product is greatly improved; moreover, an oxide film does not need to be cleaned before welding, and sundries such as black ash and splashing do not need to be cleaned after welding, so that the production efficiency is improved. And the welding efficiency of the cylinder body and the end cover can be improved by 20% by adopting MIG welding.
Drawings
In order to make the objects, technical solutions and advantages of the present invention more clear, the present invention is illustrated by the following drawings:
FIG. 1 is a process flow diagram of a welding process of an aluminum alloy gas cylinder of the invention.
Detailed Description
Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
As shown in fig. 1, the present embodiment provides a welding process for an aluminum alloy gas cylinder, where the gas cylinder includes a cylinder body, a cylinder nut welded on the outer peripheral surface of the cylinder body, end caps welded at two ends of the cylinder body, and end cap nuts welded on the end caps, and the welding process includes the following steps:
s1, automatically welding an end cover and an end cover nut by TIG welding: positioning and rotationally fixing the end cover and the end cover nut, controlling a welding gun of a TIG welding machine and a wire feeding nozzle of an automatic wire feeding controller to align to the welding position between the end cover and the end cover nut, and automatically welding the end cover and the end cover nut under the protection of protective gas;
s2, longitudinal joints of the cylinder are automatically welded by adopting FSW welding: positioning and fixing the cylinder, and controlling the rotating edge of the stirring head of the FSW welding machine to automatically weld along the longitudinal seam of the cylinder;
s3, automatically welding the cylinder and the cylinder nut by TIG welding: the cylinder and the cylinder nut are positioned, rotated and fixed, a welding gun of a TIG welding machine and a wire feeding nozzle of an automatic wire feeding controller are controlled to be aligned to the welding position between the cylinder and the cylinder nut, and the cylinder nut are automatically welded under the protection of protective gas;
s4, automatically welding the circumferential seams of the cylinder body and the end cover by MIG welding: and positioning and rotationally fixing the cylinder body and the end covers at the two ends of the cylinder body, controlling a welding gun of the MIG welding machine to respectively align at the circular seams between the cylinder body and the end covers at the two ends of the cylinder body, and automatically welding the cylinder body and the end covers at the two ends of the cylinder body under the protection action of protective gas.
And the steps S1-S4 are respectively positioned and fixed through a special tool clamp.
The symbols S1-S4 are only used for marking the corresponding steps and not for limiting the sequence of the steps, and the sequence of the steps S1-S4 can be arbitrarily combined and interchanged without departing from the protection scope of the present invention.
Specifically, the TIG welding machine in the step S1 is an AVP-360-OTC welding machine, the automatic wire feeding controller is a KZ 3-FII type automatic wire feeding controller, and the protective gas is Ar gas with the purity of 99.99%. Respectively placing the end cover and the end cover nut at corresponding positions of a special tool clamp for positioning and fixing, and rotating the end cover and the end cover nut together; pressing a 'start' button on a controller panel of the AVP-360-OTC welding machine, starting a KZ3-F II type automatic wire feeding controller to automatically feed welding wires, automatically descending a welding gun to a proper position, observing the relative positions of the welding gun and a wire feeding nozzle and a position to be welded, and adjusting if the relative positions are not aligned; closing the door and pressing the start button again, the welding machine starts automatic welding, and the welding gun automatically ascends after the welding is finished, so that the end cover nut is welded on the end cover. The specific process parameters for TIG welding in step S1 are as follows:
table 1:
as can be seen from Table 1, in the step S1, the base current for TIG welding is 100A, the wire feeding speed is 260cm/min, and the rotation speed of the end cap and the end cap nut is 2.2-2.3 rpm.
The FSW welding machine in the step S2 is an ESAB gantry type friction stir welding machine, and the diameter specification of the stirring head is 1.8 mm. Placing the barrel with the curled edges being pre-welded at a corresponding position of a special tool clamp for positioning and fixing, so that the barrel is transversely placed; operating an operating handle knob of the ESAB gantry type friction stir welding machine, automatically descending the welding gun to the proper position, observing the relative position of a longitudinal seam of the stirring head and the cylinder, and adjusting if the longitudinal seam is not aligned; and pressing a start button to start automatic welding by the welding machine, and automatically lifting the stirring head after the welding is finished so as to finish the welding of the longitudinal seam of the cylinder. The specific process parameters for FSW welding in step S2 are as follows:
table 2:
as can be seen from Table 2, in the step S2, the welding speed for FSW welding was 400mm/min, and the rotational speed of the stirring head was 1500 rpm.
In the step S3, the TIG welding machine is an AVP-360-OTC welding machine, the automatic wire feeding controller is a KZ 3-FII type automatic wire feeding controller, and the protective gas is Ar gas with the purity of 99.99 percent. Respectively placing the cylinder and the cylinder nut at corresponding positions of a special tool clamp for positioning and fixing, and rotating the cylinder and the cylinder nut together; pressing a 'start' button on a controller panel of the AVP-360-OTC welding machine, starting a KZ3-F II type automatic wire feeding controller to automatically feed welding wires, automatically descending a welding gun to a proper position, observing the relative positions of the welding gun and a wire feeding nozzle and a position to be welded, and adjusting if the relative positions are not aligned; and closing the door and pressing a start button again, starting automatic welding by the welding machine, and automatically lifting a welding gun after welding is finished so as to weld the barrel nut on the barrel. The specific process parameters for TIG welding in step S3 are as follows:
table 3:
as can be seen from Table 3, in the step S3, the base current for TIG welding was 110A, the wire feed rate was 261cm/min, and the rotational speed of the cylinder and the cylinder nut was 2.0 to 2.1 rpm.
The MIG welding machine in the step S4 is a DP-400(S-2) -OTC welding machine, and the protective gas is Ar gas with the purity of 99.99%. Respectively placing the cylinder body and the end covers at the two ends of the cylinder body at corresponding positions of a special tool clamp for positioning and fixing, so that the cylinder body is transversely placed, wherein the left end and the right end of the cylinder body are respectively provided with an end cover, and the cylinder body and the end covers at the left end and the right end of the cylinder body rotate together; pressing a 'start' button on an operation table of the DP-400(S-2) -OTC welding machine, enabling a machine head to advance in place, enabling a tailstock to advance in place, enabling a left-end welding gun and a right-end welding gun to descend in place, observing the relative positions of the left-end welding gun and the right-end welding gun and a to-be-welded circular seam respectively, and adjusting if the left-end welding gun and the right-end welding gun are not aligned; closing the door and pressing a start button again, starting automatic welding by the welding machine, automatically lifting and resetting a left end welding gun and a right end welding gun after welding is finished, resetting a machine head and a tail seat, and descending the bracket in place; and opening the door and taking out the welded air cylinder workpiece. The left-end specific process parameters and the right-end specific process parameters for MIG welding in step S4 are as follows in tables 4-1 and 4-2, respectively:
table 4-1:
tables 4-2:
as can be seen from tables 4-1 and 4-2, in the step S4, the welding current at the left end of MIG welding is 134-140A, and the welding voltage is 21-22V; the welding current at the right end is 136-142A, and the welding voltage is 21.1-22.2V; the rotation speed of the cylinder and the end covers at the two ends of the cylinder is 0.5rpm, and the welding rotation is 368 degrees.
The welding process of the aluminum alloy air cylinder provided by the embodiment adopts different welding modes aiming at the welding seams at different positions on the air cylinder, selects the best welding mode combination, and achieves the welding effect with quality and quantity guarantee and high efficiency. The welding effect of the welding process and other comparative welding processes is as follows 5:
table 5:
in the welding process, the end cover and the end cover nut are subjected to TIG welding because the end cover nut is arranged in the opening on the end cover in an inserting mode, the end cover is used as a bottom support in the welding process, and compared with MIG welding and FSW welding, the TIG welding has the advantage of better controlling heat input. The cylinder and the cylinder nut are also subjected to TIG welding, so that the cylinder can be well welded and formed, and the problem that the cylinder cannot bear corresponding pressure due to the defects of welding feathering and the like caused by MIG welding is avoided. The cylinder body is welded by FSW, under the specific process parameter setting provided by the embodiment, the compressive strength of the cylinder body reaches 6.0-6.6MPa, and the compressive strength of the cylinder body can only reach 5.0-5.6MPa by adopting conventional TIG welding or MIG welding; moreover, the FSW welding process is stable, the quality of a welding seam is improved, the repair rate of a product is reduced, the size of the welded product is guaranteed to reach the standard, and the yield of the product is greatly improved; moreover, an oxide film does not need to be cleaned before welding, and sundries such as black ash and splashing do not need to be cleaned after welding, so that the production efficiency is improved. And the welding efficiency of the cylinder body and the end cover can be improved by 20% by adopting MIG welding.
Finally, the above embodiments are only intended to illustrate the technical solutions of the present invention and not to limit the present invention, and although the present invention has been described in detail with reference to the preferred embodiments, it will be understood by those skilled in the art that modifications or equivalent substitutions may be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions, and all of them should be covered by the claims of the present invention.
Claims (10)
1. The utility model provides a welding process of aluminum alloy gas receiver, the gas receiver includes the barrel, welds barrel nut, the end cover of welding at the barrel both ends on the barrel outer peripheral face to and the end cover nut of welding on the end cover, its characterized in that, welding process includes following step:
the end cover and the end cover nut are automatically welded by TIG welding: positioning and rotationally fixing the end cover and the end cover nut, controlling a welding gun of a TIG welding machine and a wire feeding nozzle of an automatic wire feeding controller to align to the welding position between the end cover and the end cover nut, and automatically welding the end cover and the end cover nut under the protection of protective gas;
longitudinal seams of the cylinder are automatically welded by FSW welding: positioning and fixing the cylinder, and controlling the rotating edge of the stirring head of the FSW welding machine to automatically weld along the longitudinal seam of the cylinder;
the cylinder and the cylinder nut are automatically welded by TIG welding: the cylinder and the cylinder nut are positioned, rotated and fixed, a welding gun of a TIG welding machine and a wire feeding nozzle of an automatic wire feeding controller are controlled to be aligned to the welding position between the cylinder and the cylinder nut, and the cylinder nut are automatically welded under the protection of protective gas;
the circumferential weld of the cylinder body and the end cover adopts MIG welding automatic welding: and positioning and rotationally fixing the cylinder body and the end covers at the two ends of the cylinder body, controlling a welding gun of the MIG welding machine to respectively align at the circular seams between the cylinder body and the end covers at the two ends of the cylinder body, and automatically welding the cylinder body and the end covers at the two ends of the cylinder body under the protection action of protective gas.
2. The welding process of the aluminum alloy gas cylinder according to claim 1, wherein in the step of performing TIG welding of the end cap and the end cap nut, performing FSW welding of the longitudinal seam of the cylinder body, and performing TIG welding of the cylinder body and the cylinder body nut, the shielding gas is Ar gas with a purity of 99.99%.
3. The welding process of the aluminum alloy gas cylinder as claimed in claim 1, wherein the positioning and fixing are respectively performed by a special tool fixture in the steps of TIG welding of the end cover and the end cover nut, FSW welding of the longitudinal seam of the cylinder body, TIG welding of the cylinder body and the cylinder body nut, and MIG welding of the circumferential seam of the cylinder body and the end cover.
4. The welding process of the aluminum alloy gas cylinder as set forth in claim 1, wherein in the step of performing TIG welding of the end cap and the end cap nut and TIG welding of the cylinder body and the cylinder body nut, the TIG welding machine is an AVP-360-OTC welding machine, and the automatic wire feed controller is a KZ 3-fii type automatic wire feed controller.
5. The welding process of the aluminum alloy gas cylinder as claimed in claim 1, wherein in the step of FSW welding the longitudinal seam of the cylinder body, the FSW welding machine is an ESAB gantry type friction stir welding machine, and the diameter specification of the stirring head is 1.8 mm.
6. The welding process of the aluminum alloy gas cylinder as set forth in claim 1, wherein the MIG welding machine is DP-400(S-2) -OTC welding machine in the MIG welding step of the circumferential seam of the cylinder body and the end cap.
7. The welding process of the aluminum alloy gas cylinder according to claim 1, wherein in the step of performing TIG welding of the end cap and the end cap nut, a base current of 100A is performed, a wire feed speed is 260cm/min, and a rotation speed of the end cap and the end cap nut is 2.2 to 2.3 rpm.
8. The process for welding an aluminum alloy gas cylinder as defined in claim 1, wherein in the step of FSW welding the longitudinal seam of the cylinder body, the FSW welding is performed at a welding speed of 400mm/min and the rotational speed of the stirring head is 1500 rpm.
9. The welding process of the aluminum alloy gas cylinder according to claim 1, wherein in the step of performing TIG welding on the cylinder and the cylinder nut, the base current for the TIG welding is 110A, the wire feed speed is 261cm/min, and the rotation speed of the cylinder and the cylinder nut is 2.0 to 2.1 rpm.
10. The welding process of the aluminum alloy gas cylinder as claimed in claim 1, wherein in the step of MIG welding the circumferential seam between the cylinder body and the end cover, the welding current at one end of the MIG welding is 134-140A, and the welding voltage is 21-22V; the welding current at the other end is 136-142A, and the welding voltage is 21.1-22.2V; the rotation speed of the cylinder and the end covers at the two ends of the cylinder is 0.5rpm, and the welding rotation is 368 degrees.
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CN104668306A (en) * | 2015-03-14 | 2015-06-03 | 郑英 | Production method of ultra-large-diameter thin-walled pressure-resistant aluminum alloy pipe |
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Application publication date: 20200904 |