CN113305282B - Foamed aluminum production process based on electrified production equipment - Google Patents
Foamed aluminum production process based on electrified production equipment Download PDFInfo
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- CN113305282B CN113305282B CN202110460188.8A CN202110460188A CN113305282B CN 113305282 B CN113305282 B CN 113305282B CN 202110460188 A CN202110460188 A CN 202110460188A CN 113305282 B CN113305282 B CN 113305282B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/005—Casting metal foams
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention relates to the technical field of foamed aluminum production, in particular to a foamed aluminum production process based on electrified production equipment, which comprises the steps of putting an aluminum ingot into a melting furnace to be melted to obtain aluminum liquid, then adding a tackifier into the melting furnace, stirring and tackifying; pouring the tackified aluminum liquid into a mold, adding a foaming agent while stirring, uniformly dispersing the foaming agent by stirring after adding, and carrying out heat preservation foaming in the mold; moving out the heating module at the bottom of the die, moving the heating module into the cooling module, cooling the foamed aluminum blank in the die, moving the cooling module away after cooling is completed, and jacking the foamed aluminum blank in the die through a hydraulic push rod arranged right below the die; compared with the traditional process, the production process provided by the invention has the advantages of less processes, simple process, high production efficiency, good product consistency and high quality.
Description
Technical Field
The invention relates to the technical field of foamed aluminum production, in particular to a foamed aluminum production process based on electrified production equipment.
Background
The foamed aluminum is prepared by adding an additive into pure aluminum or aluminum alloy and then performing a foaming process, and has both metal and bubble characteristics. The high-density fireproof composite material has the characteristics of small density, high impact absorption capacity, high temperature resistance, high fireproof performance, corrosion resistance, sound insulation, noise reduction, low heat conductivity, high electromagnetic shielding performance, high weather resistance and the like, and is applied to the fields of collision prevention of aerospace ships and ships, automobile collision prevention, road sound insulation, building fire prevention and the like.
In the existing production process of foamed aluminum, an aluminum ingot needs to be transferred to the next station for tackifying after being smelted, so that heat loss is inevitably caused in the transfer process, energy waste is caused, and the production efficiency is low; in addition, in the prior art, three working procedures of foaming, cooling and demoulding of aluminum liquid are developed at different stations, and the problems of energy waste and low production efficiency are caused due to the existence of two transferring processes.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, provides a foamed aluminum production process based on electrified production equipment,
in order to achieve the purpose, the invention adopts the following technical scheme:
a foamed aluminum production process based on electrified production equipment comprises the steps of putting an aluminum ingot into a melting furnace to be melted to obtain aluminum liquid, then adding a tackifier into the melting furnace, and stirring and tackifying;
pouring the tackified aluminum liquid into a mold, adding a foaming agent while stirring, uniformly dispersing the foaming agent by stirring after adding, and carrying out heat preservation foaming in the mold;
and moving out the heating module at the bottom of the die, moving the heating module into the cooling module, cooling the foamed aluminum blank in the die, removing the cooling module after cooling is completed, and jacking the foamed aluminum blank in the die through a hydraulic push rod arranged right below the die.
In a further technical scheme, the conditions for smelting the aluminum ingot by the melting furnace comprise: the temperature is 700-800 ℃ in the inert gas atmosphere.
In a further technical scheme, the tackifier adopts calcium particles, the addition amount of the calcium particles is 1-2% of the weight of the aluminum liquid in the melting furnace, and the addition condition is to control the temperature of the aluminum liquid in the melting furnace to be 600-700 ℃.
In a further technical scheme, the foaming agent is titanium hydride with the granularity of 74 mu m, and the addition amount of the titanium hydride is 1.2-2.6% of the weight of the melt in the die.
In a further technical scheme, the conditions of the heat preservation foaming comprise that the foaming temperature is 620-630 ℃.
Compared with the prior art, the invention has the following technical effects:
according to the foamed aluminum production process provided by the invention, the tackifier is directly added into the melting furnace for stirring and tackifying, so that the transfer process that the aluminum liquid in the melting furnace is led out to another station for stirring and tackifying in the traditional process is avoided, the heat loss is avoided, and the production efficiency is improved;
according to the foamed aluminum production process, the aluminum liquid after stirring and tackifying is directly poured into the mold, then the foaming agent is added into the aluminum liquid in the mold, the aluminum liquid is uniformly mixed through stirring, then the foamed aluminum is directly subjected to heat preservation and foaming in the mold, and then the foamed aluminum blank is cooled and directly pushed out through the hydraulic push rod.
Compared with the traditional process, the production process provided by the invention has the advantages of less processes, simple process, high production efficiency, good product consistency and high quality.
Drawings
FIG. 1 is a flow diagram of an electrified production facility based aluminum foam production process provided in accordance with an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a melting furnace integrating melting, stirring and viscosity increasing provided by the invention;
FIG. 3 is an enlarged schematic view of position A of FIG. 2;
FIG. 4 is a schematic plan view of a melting furnace body according to the present invention;
FIG. 5 is a schematic structural view of a heating, cooling and demolding integrated mold in the present invention;
the reference numbers in the figures illustrate: 10-a melting furnace body, 11-a vertical guide rail, 12-a driving cylinder, 121-a telescopic shaft, 13-a groove, 14-a discharge pipe, 20-a mounting plate, 21-a servo motor, 211-a driving gear, 22-a first plate, 221-a connecting seat, 23-a second plate, 30-a supporting rod, 31-a driven gear, 32-a reinforcing rod, 40-a mounting rod, 41-a motor, 50-a stirring assembly, 51-a stirring shaft, 52-a stirring paddle and 53-a coupler; 100-a frame, 200-a mould body, 300-an electromagnetic induction heating module, 400-an electric heating module, 500-a cooling module, 510-a cooling pool, 520-a baffle, 600-a demoulding mechanism, 610-a push rod and 700-a screw rod.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further clarified by combining the specific drawings.
The inventor of the application finds in practice that after the traditional process is smelted, the aluminum liquid is transferred to the next station for tackifying, the heat loss exists in the transfer process, and the production efficiency is low. The three working procedures of foaming, cooling and demoulding in the traditional process are developed at different stations, and a twice transfer process exists. Compared with the traditional process, the invention has the advantages of less processes, simple process, high repeatability, high production efficiency, high product quality and good consistency.
Referring to fig. 1, the invention provides a foamed aluminum production process based on electrified production equipment, which specifically comprises the following steps:
s1: putting the aluminum ingot into a melting furnace to be melted to obtain aluminum liquid, then adding a tackifier into the melting furnace, and stirring and tackifying;
smelting an aluminum ingot by adopting a melting furnace, specifically putting the aluminum ingot into the melting furnace, and melting the aluminum ingot at the temperature of 700-; in the prior art, aluminum liquid obtained by smelting in a melting furnace is generally transferred to the next station for tackifying, but the transfer directly causes heat loss and has low production efficiency.
More specifically, in the invention, the tackifier adopts calcium particles, the addition amount of the calcium particles is 1-2% of the weight of the aluminum liquid in the melting furnace, and the addition condition is to control the temperature of the aluminum liquid in the melting furnace to be 600-700 ℃.
S2: pouring the tackified aluminum liquid into a mold, adding a foaming agent while stirring, uniformly dispersing the foaming agent by stirring after adding, moving a heating module into the bottom of the mold, heating the mold, and carrying out heat preservation foaming in the mold;
specifically, in the invention, the foaming agent is titanium hydride with the granularity of 74 mu m, and the addition amount of the foaming agent is 1.2-2.6% of the weight of the melt in the die; the temperature for heat preservation and foaming is 620-630 ℃.
S3: moving out the heating module at the bottom of the mold, moving the heating module into the cooling module, cooling the foamed aluminum blank in the mold, and moving the cooling module away after cooling is completed;
s4: and jacking up the foamed aluminum blank in the die by a hydraulic push rod arranged right below the die.
Furthermore, in the invention, in order to match the use of the hydraulic push rod, the bottom of the die is provided with the push rod channel and the leakage-proof block matched with the push rod channel, when the die is normally used, the leakage-proof block blocks the push rod channel, and after aluminum liquid is poured in, the processes of heat preservation foaming and cooling are carried out, and when the die is demoulded, the leakage-proof block and the foamed aluminum blank are jacked up together by the hydraulic push rod through the push rod channel, so that the demoulding is finished.
Furthermore, according to the foamed aluminum production process provided by the invention, a mechanical clamp is arranged to take down the foamed aluminum blank jacked up by the hydraulic push rod and place the foamed aluminum blank in a required place;
in a specific embodiment, as shown in fig. 2 to 4, the invention provides a melting furnace integrating melting, stirring and viscosity increasing, which comprises a melting furnace body 10, a vertical guide rail 11, a mounting plate 20, a support rod 30 and a stirring assembly 50;
the melting furnace body 10 is provided with a containing space for containing an aluminum ingot to be melted; the melting furnace body 10 of the present invention is similar to the existing melting furnace, and also includes a heating element for providing heat to melt the aluminum ingot, and further includes components necessary for implementing melting, such as an electric automatic temperature control system, etc., which are not described herein again.
The vertical guide rail 11 extends vertically along the outer side wall of the melting furnace body 10;
the mounting plate 20 is movably arranged on the vertical guide rail 11, a driving cylinder 12 is arranged on the outer side wall of the melting furnace body 10, a telescopic shaft 121 of the driving cylinder 12 extends vertically, and the overhanging end part of the telescopic shaft is fixedly connected with the mounting plate 20; it should be noted that, in order to ensure the stability of the mounting plate 20 during the vertical movement, two vertical guide rails 11 are arranged in parallel and at intervals, and the mounting plate 20 is arranged on the vertical guide rails 11 through a sliding sleeve.
The supporting rod 30 is rotatably arranged on the mounting plate 20, a transversely arranged mounting rod 40 is arranged at the upper end of the supporting rod 30, and the suspension end of the mounting rod 40 extends towards the opening at the upper end of the melting furnace body 10;
the stirring assembly 50 is inserted into the accommodating space of the melting furnace body 10, and is driven by a motor 41 arranged on the mounting rod 40 to stir the melt in the melting furnace body 10.
When the integrated melting furnace is used specifically, firstly, an aluminum ingot is put into a melting furnace body 10 to be melted to obtain a melt, after the melt is completely melted, a tackifier is directly put into the melting furnace, a telescopic shaft 121 of a driving cylinder 12 drives a mounting plate 20 to move along a vertical guide rail 11, the bottommost part of a stirring assembly 50 crosses over the opening edge of the melting furnace body 10, then a supporting rod 30 rotates to enable the stirring assembly 50 to be placed right above the melting furnace body 10, the driving cylinder 12 drives the stirring assembly 50 to descend into an accommodating space of the melting furnace body 10, and a motor 41 is started to drive the stirring assembly 50 to stir and thicken the melt; after stirring and thickening are completed, the discharge pipe 14 with a valve on the side of the melting furnace body 10 is opened, so that the thickened aluminum liquid flows into the next working procedure, and then the operations of smelting, stirring and thickening of aluminum ingots are continued.
In the invention, the smelting of the aluminum ingot and the stirring and tackifying of the aluminum liquid are integrated in one melting furnace for operation, so that the operation of transferring the aluminum liquid in the prior art is avoided, the labor is saved, the efficiency is improved, and the problems of heat loss and influence on the product consistency during the transfer of the aluminum liquid are avoided.
In the present invention, the support rod 30 is rotatably disposed on the mounting plate 20, and the stirring assembly 50 is inserted into the receiving space of the melting furnace body 10 or removed from the receiving space of the melting furnace body 10 in cooperation with the up-and-down movement of the mounting plate 20. As a specific embodiment of the rotatable arrangement of the support bar 30,
the bottom end of the support rod 30 is disposed on the mounting plate 20 via a bearing; the mounting plate 20 is provided with a servo motor 21, an output shaft of the servo motor 21 is provided with a driving gear 211 arranged coaxially, the supporting rod 30 is provided with a driven gear 31 arranged coaxially, and the driven gear 31 is meshed with the driving gear 211. The servo motor 21 drives the support rod 30 to rotate through the driving gear 211 and the driven gear 31 engaged with the driving gear.
Further, in the present invention, the mounting plate 20 includes a first plate 22 and a second plate 23 perpendicular to each other, the first plate 22 extends vertically, a plurality of connecting seats 221 are provided on a plate body of the first plate 22 at intervals along a height direction of the first plate, and the support rod 30 is inserted on the connecting seats 221 through a bearing. In this way, the stability of the support rod 30 during the rotation process is ensured, and preferably, two connection seats 221 are provided in the present invention.
In the present invention, in order to enhance the supporting strength of the supporting rod 30 to the mounting rod 40, an obliquely arranged reinforcing rod 32 is disposed between the mounting rod 40 and the supporting rod 30.
In the invention, the stirring component 50 is used for stirring the melt in the melting furnace body 10 to mix the melt with the tackifier, and the temperature of the melt in the melting furnace body 10 is uniform through stirring; as a specific embodiment of the stirring assembly 50, the stirring assembly 50 includes a stirring shaft 51 and a stirring paddle 52 disposed on the stirring shaft 51, and the stirring shaft 51 is fixed on the output shaft of the motor 41 via a coupling 53.
In the invention, a plurality of vertically extending grooves 13 are arranged on the inner side wall of the melting furnace body 10 for inserting baffles to divide the accommodating space into at least two areas, and the stirring assembly 50 is inserted into one area to stir the melt. In a specific using process, the melt in the melting furnace body 10 is divided into at least two parts by the baffle, the stirring assembly 50 is inserted into one part of the melt to stir and tackify, the volume is reduced, the effect of stirring and tackify the aluminum liquid is improved, after the tackified aluminum liquid flows into the next process through the discharge pipe 14, the baffle is removed, and the other part of the melted aluminum liquid is put in, so that the tackification process does not influence the melting of aluminum ingots, and the efficiency is further improved.
Referring to fig. 5, the present invention provides a heating, cooling and demolding integrated foaming mold, which includes a frame 100, a mold body 200, an electric heating module 400, a cooling module 500 and a demolding mechanism 600;
the frame 100 mainly serves to support and fix components such as the mold body 200, the electric heating module 400, the cooling module 500, and the demolding mechanism 600.
The die body 200 is used for forming a foamed aluminum product, is arranged on the frame 100, and is provided with an electromagnetic induction heating module 300 on the frame 100 beside the die body 200;
the electric heating module 400 is arranged on the frame 100 and located below the mold body 200, and the electric heating module 400 can be driven by a first driving mechanism to be right below the mold body 200 or to be in an avoiding position with the mold body 200 in the vertical direction;
the cooling module 500 is disposed on the rack 100 and located below the mold body 200, and the cooling module 500 may be driven by a second driving mechanism to a position directly below the mold body 200 or to a position which is vertically retracted from the mold body 200;
the demolding mechanism 600 is disposed on the frame 100 and located right below the mold body 200, and the demolding mechanism 600 includes a vertically arranged push rod 610 and a third driving mechanism for driving the push rod 610 to move in the vertical direction.
In the technical scheme provided by the invention, the electromagnetic induction heating module 300 is arranged beside the die body 200, the electric heating module 400 is arranged below the die body, and in the heat preservation foaming stage, the electromagnetic induction heating is mainly used, the electric heating is used as an auxiliary mode, so that the heat efficiency is higher, and the production efficiency is greatly improved;
in addition, compared with the traditional process equipment, in the technical scheme provided by the invention, the electric heating module 400 can be moved to a position which is in an avoidance state with the die body 200 in the vertical direction, so that the cooling module 500 can be moved to the position right below the die body 200, the cooling of the foamed aluminum blank in the die body 200 is realized, the transfer process is avoided, the production efficiency is higher, and the process is stable; in addition, in the technical scheme provided by the invention, the demoulding mechanism 600 is further arranged right below the die body 200, and after the heat-insulating foaming and cooling treatment is completed, the cooling module 500 can also move to a position which is in a avoiding state with the die body 200 in the vertical direction, so that the push rod 610 positioned right below the die body 200 can jack up the foamed aluminum blank in the die body 200 under the driving of the third driving mechanism, and demoulding is realized.
In general, the integrated foaming mold provided by the invention overcomes the problems of complexity and low efficiency of the traditional foamed aluminum production process, improves the production efficiency, and avoids the problem of overhigh energy consumption caused by multiple transfers.
Further, according to the present invention, a mold release opening is formed at the bottom of the mold body 200, and a leakage prevention block is disposed at the mold release opening to prevent the melt from leaking. In the demolding process, the push rod 610 can jack up the foamed aluminum blank together with the leakage-proof block, so that the integrated demolding is realized, the operation is convenient and fast, and the efficiency is high.
In the invention, the cooling module 500 comprises a cooling tank 510, a baffle 520 moving vertically is arranged on the periphery of the cooling tank 510, the baffle 520 can move up to abut against the bottom of the die body 200, and a cooling water pump is arranged in the cooling tank 510 and used for pumping cooling water to the die body 200 to cool the foamed aluminum blank. By the arrangement of the baffle 520, the problem of splashing of cooling water is avoided.
In the invention, the first driving mechanism and the second driving mechanism respectively drive the electric heating module 400 and the cooling module 500 to be positioned under the mold body 200 or move to a position which is in a way of avoiding the mold body 200 in the vertical direction, thereby realizing different process functions. As a specific embodiment of the first driving mechanism and the second driving mechanism, the first driving mechanism and the second driving mechanism each include a screw rod 700 and a servo motor for driving the screw rod 700 to rotate, the electric heating module 400 and the cooling module 500 are both sleeved on the screw rod 700 by threads, and a slide rail is provided on the rack 100 for the electric heating module 400 and the cooling module 500 to slide. In a specific working process, the servo motor drives the screw rod 700 to rotate forwards or backwards, so as to drive the electric heating module 400 and the cooling module 500 which are sleeved on the screw rod 700 in a threaded manner to move along a direction limited by the slide rail.
The foregoing shows and describes the general principles, essential features, and inventive features of this invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (5)
1. A foamed aluminum production process based on electrified production equipment is characterized by comprising the steps of putting an aluminum ingot into a melting furnace to be melted to obtain aluminum liquid, adding a tackifier into the melting furnace, stirring and tackifying;
pouring the tackified aluminum liquid into a mold, adding a foaming agent while stirring, uniformly dispersing the foaming agent by stirring after adding, and carrying out heat preservation foaming in the mold;
the mold comprises a frame, and a mold body, an electric heating module, a cooling module and a demolding mechanism which are arranged on the frame, wherein the electromagnetic induction heating module is arranged on the frame beside the mold body;
the electric heating module is arranged below the die body and is driven to be right below the die body by a first driving mechanism or to be in an avoiding position with the die body in the vertical direction; the cooling module is arranged below the die body and driven to be right below the die body by a second driving mechanism or driven to be in an avoidance position with the die body in the vertical direction; the demolding mechanism is arranged below the mold body and comprises push rods which are vertically arranged and a third driving mechanism which drives the push rods to move in the vertical direction;
when the mold is used for heat preservation and foaming, the electromagnetic induction heating module and the electric heating module are matched with each other to preserve heat of the mold body, after heat preservation and foaming are finished, the electric heating module is moved to be in an avoiding position in the vertical direction with the mold body, the cooling module is moved to be under the mold body to carry out cooling treatment on the mold body, then the cooling module is moved to be in an avoiding position in the vertical direction with the mold body, and a push rod under the mold body can jack up a foamed aluminum blank in the mold body under the driving of a third driving mechanism to realize demolding.
2. The foamed aluminum production process based on the electrified production equipment as claimed in claim 1, wherein the conditions for melting the aluminum ingot by the melting furnace comprise: the temperature is 700-800 ℃ in the inert gas atmosphere.
3. The foamed aluminum production process based on the electrified production equipment as claimed in claim 1, wherein the tackifier is calcium particles, the addition amount of the calcium particles is 1% -2% of the weight of the aluminum liquid in the melting furnace, and the addition condition is to control the temperature of the aluminum liquid in the melting furnace to be 600-700 ℃.
4. The electrified production facility-based foamed aluminum production process of claim 1, wherein the blowing agent is selected from titanium hydride with a particle size of 74 μm and is added in an amount of 1.2-2.6% by weight of the melt in the mold.
5. The foamed aluminum production process based on the electrified production equipment as claimed in claim 1, wherein the conditions for the thermal insulation foaming comprise a foaming temperature of 620 ℃ and 630 ℃.
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| CN202110460188.8A CN113305282B (en) | 2021-04-27 | 2021-04-27 | Foamed aluminum production process based on electrified production equipment |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109468482A (en) * | 2018-12-18 | 2019-03-15 | 辽宁融达新材料科技有限公司 | A kind of high intensity foam aluminium plate preparation method |
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| US4713277A (en) * | 1985-07-19 | 1987-12-15 | Agency Of Industrial Science And Technology | Foamed metal and method of producing same |
| CN1265004C (en) * | 2003-12-03 | 2006-07-19 | 东南大学 | Low porosity closed cell foam aluminum alloy and its preparation method |
| CN100482821C (en) * | 2007-07-13 | 2009-04-29 | 东南大学 | Method for preparing foam aluminum and alloy product with closed gradient pore structure |
| KR100874323B1 (en) * | 2008-06-30 | 2008-12-18 | 이동식 | Manufacturing method of bubble aluminum |
| DE102010024669B3 (en) * | 2010-06-18 | 2011-12-08 | Helmholtz-Zentrum Berlin Für Materialien Und Energie Gmbh | Producing metal foam with stabilizing particles in metal matrix, comprises producing foamable starting material, foaming the starting material, and generating stabilizing particles in in-situ reaction of reactive substance and molten metal |
| CN102002607B (en) * | 2010-12-14 | 2012-07-18 | 东莞理工学院 | Method for preparing foamed aluminum by foaming melt |
| CN104589567B (en) * | 2014-11-17 | 2017-02-22 | 界首市一鸣新材料科技有限公司 | Continuous foamed aluminum sheet material production line utilizing screw pushing and pressurization foaming |
| CN106086717B (en) * | 2016-07-03 | 2017-08-25 | 河北工业大学 | A kind of preparation method of foamed aluminium sound absorption acoustic dampening composite |
| CN106222470B (en) * | 2016-09-14 | 2018-07-31 | 郑州峰泰纳米材料有限公司 | A kind of preparation method of foam aluminium alloy |
| CN107988503A (en) * | 2017-11-16 | 2018-05-04 | 东北大学 | A kind of positive pressure foaming preparation method of aperture controllable foam aluminium |
| CN110042268B (en) * | 2019-05-23 | 2020-12-25 | 河北工业大学 | Mould and production equipment for preparing foam sandwich board |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109468482A (en) * | 2018-12-18 | 2019-03-15 | 辽宁融达新材料科技有限公司 | A kind of high intensity foam aluminium plate preparation method |
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