CN117467870A - 一种铝合金、铝合金单丝及其制备方法、钢芯铝绞线 - Google Patents
一种铝合金、铝合金单丝及其制备方法、钢芯铝绞线 Download PDFInfo
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- B21B1/16—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling wire rods, bars, merchant bars, rounds wire or material of like small cross-section
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- B21B1/46—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling metal immediately subsequent to continuous casting
- B21B1/463—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling metal immediately subsequent to continuous casting in a continuous process, i.e. the cast not being cut before rolling
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- B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
- B21C1/02—Drawing metal wire or like flexible metallic material by drawing machines or apparatus in which the drawing action is effected by drums
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- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
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Abstract
一种铝合金、铝合金单丝及其制备方法、钢芯铝绞线,属于电工导体材料技术领域,克服现有技术中铝合金导电材料难以兼顾电学性能和力学性能的缺陷。本发明铝合金以质量百分比计,成分为B:0.05~0.1%,Fe≤0.3%,Sc:0.05~0.1%,Zr:0.06~0.1%,Zn:0.05~0.1%,Si≤0.1%,(Ti+V+Cr+Mn)≤0.01%,余量为铝和不可避免杂质。本发明通过低合金化设计的方式获得了兼顾力学和电学性能的铝合金单丝,综合性能优良,可在较高温度下长期服役。
Description
技术领域
本发明属于电工导体材料技术领域,具体涉及一种铝合金、铝合金单丝及其制备方法、钢芯铝绞线。
背景技术
大规模输电工程对高效率低成本输电提出了越来越高的要求,高导耐热导线的应用可以在线路中减少不必要的损耗,节省能源,减少碳排放,有助于资源节约型和环境友好型社会的建设。
架空输电导线采用的钢芯铝绞线由芯部钢芯和外部铝合金导电材料组成。现役的普通钢芯铝绞线和钢芯高导硬铝导线的铝合金导线抗拉强度在160~200MPa范围内,但普通钢芯铝绞线中铝合金的导电率仅为61%IACS,输电线损高,不符合节能环保要求;高导硬铝导线的导电率为61.5%~62.5%IACS,但其制造成本高出普通铝合金导线15%以上,限制了其大规模推广。钢芯软铝绞线是一种高导电率的特种导线,外层软铝线的导电率≥63%IACS,但由于其抗拉仅强度为60~95MPa,钢芯软铝绞线在施工过程中导线表面容易损伤,造成安全隐患。
发明内容
因此,本发明要解决的技术问题在于克服现有技术中铝合金导电材料难以兼顾电学性能和力学性能的缺陷,从而提供一种铝合金、铝合金单丝及其制备方法、钢芯铝绞线。
为此,本发明提供了以下技术方案。
第一方面,本发明提供了一种铝合金,以质量百分比计,成分为B:0.05~0.1%,Fe≤0.3%,Sc:0.05~0.1%,Zr:0.06~0.1%,Zn:0.05~0.1%,Si≤0.1%,(Ti+V+Cr+Mn)≤0.01%,余量为铝和不可避免杂质。
各合金元素的作用及机理如下:
硼:铝合金基体内杂质元素的含量会显著影响材料的导电性能,目杂质元素即使含量极微,也会对电工铝合金的导电率带来很大负面影响。硼能与钛、钒、铬、锰等元素反应形成不溶解的硼化物或者复杂化合物,从而使原来固溶在铝中的杂质元素变成固体化合态,沉积于熔体底部,减少铝导体内部晶格的畸变,从而改善铝导体的导电性,达到提高导电率的目的。另外,硼在铝合金铸造过程起到细化剂的作用。元素硼质量分数超过0.1%时,导电率将出现明显降低。因此,本发明中硼元素质量分数为0.05~0.1%。
铁:铁与其他诸如硅、钒等元素相比,对导电率的影响相对较小,基体内含有适量的铁可以增大抗拉强度提高抗蠕变性和耐高温性能,特别是铁以尺寸细小的弥散相形式存在时会明显提升合金力学性能。因此铁元素可以适量留在电工铝基体中。为使铁元素以析出相形式在铝基体中,铁元素含量同样不宜过高,优选的,Fe质量含量为0.15~0.30wt.%。
优选的,铁与硅的质量分数比为3.0到3.8,可以降低其对导电率的不利影响。
钪:钪在铝合金中起到净化合金、改善铸锭组织以及抑制再结晶的作用,是铝合金中的弥散强化剂、强有力的晶粒细化剂、有效的再结晶抑制剂。钪的添加可提高铝合金的强度、塑性,并且具有优良的焊接性能、高温性能和抗蚀性能。在共晶转变温度下,钪在铝中的固溶度在660℃左右时达到最大,约为0.38wt.%。随着温度的降低,钪的固溶度急剧下降,能析出密度极高且与基体共格的Al3Sc,强化合金性能。综合钪元素在铝基体中固溶极限、钪成本较高、添加了合金化元素锆等因素,本发明钪元素质量分数在0.05~0.1%
锆:在铝中加入少量的锆形核时可成为异质形核核心,从而能够细化晶粒。此外,锆的加入能提高再结晶温度,改善韧性及应力腐蚀敏感性。采用钪和锆复合微合金化可显著提高合金的强度。锆的存在使Al3Sc生长过程中演变为Al3(Sc,Zr)复合结构粒子,形成特殊的核壳结构。凝固过程中成为异质形核核心,因此具有极强的晶粒细化作用。且锆相对于钪成本更加低廉,还能起到协同强化的作用。由于锆含量过高会明显降低材料导电率,因此本发明中锆元素质量分数范围在0.06~0.1%。
锌:锌在铝合金中有较大的溶解度,易溶于铝基体,通常情况是以固溶的形式存在于基体中,可起到固溶强化的作用。适量锌的加入可以促进强化相形核。而且锌会限制空位移动,强化相形核后不会快速长大,可以得到细小、均匀、弥散分布的强化相,从而提升力学、电学性能。为保证合金导电率,合金化元素整体含量不宜过高,本发明中锌元素质量分数范围为0.05~0.1%。
硅:硅是铝合金中最常见的元素,硅对于合金铸造性能和焊接流动性有很好的改善作用。而硅是一种常用的半导体材料,铝材的导电率会随着硅含量的升高而降低。室温下,硅在铝中的固溶度高达0.05%,属于固溶度较大的杂质,因此大量的硅会以固溶的形式存在于铝导体中难以除去。硅的存在会使合金塑韧性降低。因此,从导电率的角度考虑,合金中硅含量需要得到控制,本发明将硅的质量分数不超过0.1%。
钛、钒、铬、锰:铝合金导体中微量的钛、钒、铬、锰等过渡族元素对电阻率有很大影响,尤其是以固溶态形式存在时,由于吸收了导体内的自由电子填充自身不完整电子层,使得合金导电率下降。铝合金的电导率对这几种元素的敏感度远高于硅和铁,含有极为微量的此类元素,对电导率带来的影响是等量硅的五倍左右。因此,必须严格控制此类元素的含量,本发明严格控制除主要合金化元素外其他元素含量,使得(Ti+V+Cr+Mn)质量分数<0.01%。
第二方面,本发明提供了一种铝合金单丝,以质量百分比计,成分为B:0.05~0.1%,Fe≤0.3%,Sc:0.05~0.1%,Zr:0.06~0.1%,Zn:0.05~0.1%,Si≤0.1%,(Ti+V+Cr+Mn)≤0.01%,余量为铝和不可避免杂质。
进一步的,铝合金单丝的直径为3~4mm。
第三方面,本发明提供了一种铝合金单丝的制备方法,包括以下步骤:冶炼→精炼→铸锭→轧制→拉拔→时效。
进一步的,所述冶炼包括:将纯铝锭在730~750℃下完全熔化,然后加入Al-B中间合金,完全熔化后再加入Al-Sc、Al-Zr、Al-Fe中间合金和纯Zn锭,完全熔化后电磁搅拌15~20min,静置20~30min后得到铝合金液。
具体的,选取纯度≥99.85%的工业纯铝锭放入熔炼炉中,熔炼温度控制为730~750℃;待工业纯铝锭完全熔化后,加入Al-B中间合金进行硼化处理;Al-B中间合金熔化后加入Al-Sc、Al-Zr、Al-Fe中间合金和纯Zn锭,完全熔化后电磁搅拌15~20min,静置20~30min后得到铝合金液。
进一步的,所述精炼包括:温度控制在710~730℃之间,在铝合金液中吹入氮气10~15min,静置20~30min后扒渣;或
温度控制在710~730℃之间,加入铝合金液质量0.3%~0.5%的六氯乙烷,静置20~30min后扒渣。
精炼过程中吹入氮气或加入六氯乙烷的目的是除气精炼。
进一步的,所述铸锭包括:700~720℃将铝合金液浇入250~300℃预热的模具,浇铸成铝锭。
进一步的,铝锭横截面尺寸为18~22×18~22mm,例如20×20mm。
进一步的,浇注过程中铝合金液经过流槽时,采用泡沫陶瓷砖或玻璃丝网袋进行过滤。
进一步的,所述轧制包括:480~510℃保温6~8h,经过5~8道次轧制成φ9~11mm的铝合金圆杆,水冷。例如经过6道次轧制成φ9.5mm的铝合金圆杆。
进一步的,所述拉拔包括:将所述铝合金圆杆经过10~15道次拉拔,最终获得直径为3~4mm铝合金单丝。
进一步的,所述时效包括:在300~320℃下保温4~5h后室温冷却。时效过程中析出纳米级强化相,进一步提升铝合金单丝性能。
第四方面,本发明提供了一种钢芯铝绞线,包括上述铝合金单丝或根据上述方法制得的铝合金单丝。
本发明技术方案,具有如下优点:
1.本发明铝合金以质量百分比计,成分为B:0.05~0.1%,Fe≤0.3%,Sc:0.05~0.1%,Zr:0.06~0.1%,Zn:0.05~0.1%,Si≤0.1%,(Ti+V+Cr+Mn)≤0.01%,余量为铝和不可避免杂质。
本发明通过在铝合金中Sc元素和Zr元素的复合添加合金化设计,生成了Al3Sc和Al3Zr强化相,还可以形成具有核壳结构的Al3(Sc,Zr)强化相,且细小的Al3Sc和Al3Zr与Al基体之间为共格结构,具有较好的匹配性,降低晶格畸变,在保证强度和耐热性的基础之上提高了导电率。添加微量Zn元素,可加速强化相的析出,提高铝合金单丝的强度。在此合金成分配方基础之上,控制杂质元素的含量,得到的耐热铝合金单丝可以在保证力学性能和耐热性能的前提下显著提高导电率至62.5%IACS(20℃)。
本发明通过低合金化设计的方式获得了兼顾力学和电学性能的铝合金单丝,综合性能优良,可在较高温度下长期服役。
2.本发明铝合金单丝的制备方法包括以下步骤:冶炼→精炼→铸锭→轧制→拉拔→时效所述时效包括:在300~320℃下保温4~5h后室温冷却。在时效阶段可以析出弥散的Al3(Sc,Zr)强化相。Al3(Sc,Zr)热稳定性良好,可进一步提升合金力学性能、耐热稳定性,尤其是提升了合金高温抗蠕变性能。
3.本发明钢芯铝绞线包括本发明的铝合金单丝。可以同时满足输电性能服役条件和施工要求,实现节能降损、低成本输电。本发明高导电率、大容量、低成本的新型高导半硬铝导线在新能源送出线路、传统钢芯铝绞线的升级改造线路、常规负荷下的节能线路中具有广阔的应用前景,将有力支撑电网中新能源的大比例接入。
具体实施方式
提供下述实施例是为了更好地进一步理解本发明,并不局限于所述最佳实施方式,不对本发明的内容和保护范围构成限制,任何人在本发明的启示下或是将本发明与其他现有技术的特征进行组合而得出的任何与本发明相同或相近似的产品,均落在本发明的保护范围之内。
实施例中未注明具体实验步骤或条件者,按照本领域内的文献所描述的常规实验步骤的操作或条件即可进行。所用试剂或仪器未注明生产厂商者,均为可以通过市购获得的常规试剂产品。
本发明高导电率耐热铝合金单丝的制备方法是:
步骤1、熔炼:选取纯度≥99.85%的工业铝锭在730~750℃熔炼,待纯铝完全熔化后加入Al-B中间合金进行硼化处理;730~750℃加入Al-Fe、Al-Sc、Al-Zr中间合金和纯Zn锭,完全熔化后电磁搅拌15~20min,静置20~30min得到铝合金液。
步骤2、精炼:710~730℃吹入N2,吹气时间10~15min,或加入0.3%~0.5%的C2Cl6进行除气精炼,静置20~30min后扒渣。
步骤3、铸锭:700~720℃将铝合金液浇入250~300℃预热的金属型模具,浇铸成横截面为20×20mm的铝锭。浇注过程中铝液经过流槽时,采用泡沫陶瓷砖或玻璃丝网袋进行过滤。
步骤4、轧制:铝锭在马弗炉中480~510℃保温6~8h后经过6道次轧制或直接挤压,制成的铝合金圆杆,并喷水快速冷却。
步骤5、拉拔:铝合金圆杆经过10~15道次拉拔,获得铝合金单丝。
步骤6、时效:单丝在300~320℃下保温4~5h进行时效处理强化。
实施例1-实施例7的铝合金单丝成分见表1。
表1各实施例制备的高导半硬铝合金单丝成分表(wt.%)
实施例1-实施例7铝合金单丝的制备方法为:
步骤1、熔炼:选取纯度为99.85%的工业铝锭在750℃熔炼,待纯铝完全熔化后加入Al-B中间合金进行硼化处理;750℃加入Al-Fe、Al-Sc、Al-Zr中间合金和纯Zn锭使合金元素的最终含量如表1所示,完全熔化后电磁搅拌20min,静置30min得到铝合金液。
步骤2、精炼:在720℃加入铝合金液质量0.5%的C2Cl6进行除气精炼,静置30min后扒渣。
步骤3、铸锭:720℃将铝合金液浇入250℃预热的金属型模具,浇铸成横截面为20×20mm的铝锭。浇注过程中铝液经过流槽时,采用泡沫陶瓷砖进行过滤。
步骤4、轧制:铝锭在马弗炉中510℃保温6h后经过6道次轧制或直接挤压,制成的铝合金圆杆,并喷水快速冷却。
步骤5、拉拔:铝合金圆杆经过10道次拉拔,获得铝合金单丝。
步骤6、时效:单丝在300℃下保温5h进行时效处理强化。
试验例
对各实施例的力学、电学性能进行测试。导电率依据标准为GB/T3048.2,抗拉强度与延伸率依据标准为GB/T4909.3,耐热性依据标准为GB/T30551-2014。
测试结果见表2。
表2各实施例制备的高导半硬铝合金单丝性能测试结果
本发以纯度≥99.85%的铝锭为主要原材料,添加中间合金及纯金属锭进而改变成分,开发出一种Al-B-Fe-Sc-Zr-Zn体系高导电率、耐热性好的新型半硬铝合金导线,可兼顾硬铝和软铝导线的技术优势,既能提高施工效率与质量、保证导线的安全可靠性,又能实现节能降损、低成本生产的目标。本发明主要通过加入微量B、Fe、Sc、Zr、Zn合金化元素调控合金显微组织并提升力学、电学综合性能,开发出导电率不低于62.5%IACS(20℃)、抗拉强度为100~135MPa、延伸率不低于3.0%、230℃保温1h后的室温强度残存率≥90%、满足长期运行温度为150℃服役条件的高导电率半硬铝合金单丝。
显然,上述实施例仅仅是为清楚地说明所作的举例,而并非对实施方式的限定。对于所属领域的普通技术人员来说,在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引申出的显而易见的变化或变动仍处于本发明创造的保护范围之中。
Claims (10)
1.一种铝合金,其特征在于,以质量百分比计,成分为B:0.05~0.1%,Fe≤0.3%,Sc:0.05~0.1%,Zr:0.06~0.1%,Zn:0.05~0.1%,Si≤0.1%,(Ti+V+Cr+Mn)≤0.01%,余量为铝和不可避免杂质。
2.一种铝合金单丝,其特征在于,以质量百分比计,成分为B:0.05~0.1%,Fe≤0.3%,Sc:0.05~0.1%,Zr:0.06~0.1%,Zn:0.05~0.1%,Si≤0.1%,(Ti+V+Cr+Mn)≤0.01%,余量为铝和不可避免杂质。
3.一种权利要求2所述的铝合金单丝的制备方法,其特征在于,包括以下步骤:冶炼→精炼→铸锭→轧制→拉拔→时效。
4.根据权利要求3所述的铝合金单丝的制备方法,其特征在于,所述冶炼包括:将纯铝锭在730~750℃下完全熔化,然后加入Al-B中间合金,完全熔化后再加入Al-Sc、Al-Zr、Al-Fe中间合金和纯Zn锭,完全熔化后电磁搅拌15~20min,静置20~30min后得到铝合金液。
5.根据权利要求3所述的铝合金单丝的制备方法,其特征在于,所述精炼包括:温度控制在710~730℃之间,在铝合金液中吹入氮气10~15min,静置20~30min后扒渣;或
温度控制在710~730℃之间,加入铝合金液质量0.3%~0.5%的六氯乙烷,静置20~30min后扒渣。
6.根据权利要求3所述的铝合金的制备方法,其特征在于,所述铸锭包括:700~720℃将铝合金液浇入250~300℃预热的模具,浇铸成铝锭。
7.根据权利要求3所述的铝合金单丝的制备方法,其特征在于,所述轧制包括:480~510℃保温6~8h,经过5~8道次轧制成φ9~11mm的铝合金圆杆,水冷。
8.根据权利要求7所述的铝合金单丝的制备方法,其特征在于,所述拉拔包括:将所述铝合金圆杆经过10~15道次拉拔,获得直径φ为3~4mm的铝合金单丝。
9.根据权利要求3-8任一项所述的铝合金单丝的制备方法,其特征在于,所述时效包括:在300~320℃下保温4~5h后室温冷却。
10.一种钢芯铝绞线,其特征在于,包括权利要求2所述的铝合金单丝或根据权利要求3-9任一项所述方法制得的铝合金单丝。
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