CN117987694A - High-conductivity and high-corrosion-resistance aluminum monofilament and production process and application thereof - Google Patents
High-conductivity and high-corrosion-resistance aluminum monofilament and production process and application thereof Download PDFInfo
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 121
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 121
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 16
- 239000012535 impurity Substances 0.000 claims abstract description 46
- 238000007670 refining Methods 0.000 claims abstract description 38
- 238000005096 rolling process Methods 0.000 claims abstract description 31
- 230000007797 corrosion Effects 0.000 claims abstract description 29
- 238000005260 corrosion Methods 0.000 claims abstract description 29
- 238000007790 scraping Methods 0.000 claims abstract description 29
- 238000003723 Smelting Methods 0.000 claims abstract description 28
- 238000009749 continuous casting Methods 0.000 claims abstract description 14
- 239000000155 melt Substances 0.000 claims description 47
- 238000005266 casting Methods 0.000 claims description 41
- 238000007872 degassing Methods 0.000 claims description 36
- 229910045601 alloy Inorganic materials 0.000 claims description 34
- 239000000956 alloy Substances 0.000 claims description 34
- 229910000838 Al alloy Inorganic materials 0.000 claims description 29
- 150000003839 salts Chemical class 0.000 claims description 18
- 239000007921 spray Substances 0.000 claims description 18
- 239000007788 liquid Substances 0.000 claims description 15
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 12
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 12
- 239000000498 cooling water Substances 0.000 claims description 12
- 238000004321 preservation Methods 0.000 claims description 12
- 239000007924 injection Substances 0.000 claims description 11
- 238000002347 injection Methods 0.000 claims description 11
- 238000011068 loading method Methods 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 10
- HIPVTVNIGFETDW-UHFFFAOYSA-N aluminum cerium Chemical compound [Al].[Ce] HIPVTVNIGFETDW-UHFFFAOYSA-N 0.000 claims description 9
- 238000004458 analytical method Methods 0.000 claims description 9
- 230000007935 neutral effect Effects 0.000 claims description 9
- 238000000746 purification Methods 0.000 claims description 9
- 238000001914 filtration Methods 0.000 claims description 7
- 230000008569 process Effects 0.000 claims description 7
- 229910018084 Al-Fe Inorganic materials 0.000 claims description 6
- 229910018182 Al—Cu Inorganic materials 0.000 claims description 6
- 229910018192 Al—Fe Inorganic materials 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 6
- 229910052786 argon Inorganic materials 0.000 claims description 6
- 239000000919 ceramic Substances 0.000 claims description 6
- 239000003795 chemical substances by application Substances 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 6
- 229910002804 graphite Inorganic materials 0.000 claims description 6
- 239000010439 graphite Substances 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- VHHHONWQHHHLTI-UHFFFAOYSA-N hexachloroethane Chemical compound ClC(Cl)(Cl)C(Cl)(Cl)Cl VHHHONWQHHHLTI-UHFFFAOYSA-N 0.000 claims description 6
- 239000001257 hydrogen Substances 0.000 claims description 6
- 229910052739 hydrogen Inorganic materials 0.000 claims description 6
- 238000005121 nitriding Methods 0.000 claims description 6
- 229910052757 nitrogen Inorganic materials 0.000 claims description 6
- 238000004804 winding Methods 0.000 claims description 6
- 238000005491 wire drawing Methods 0.000 claims description 6
- 238000004381 surface treatment Methods 0.000 claims description 4
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 10
- 238000003756 stirring Methods 0.000 description 10
- 238000004364 calculation method Methods 0.000 description 8
- 239000007789 gas Substances 0.000 description 8
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- 230000000052 comparative effect Effects 0.000 description 7
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- 229910052761 rare earth metal Inorganic materials 0.000 description 7
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- 229910052684 Cerium Inorganic materials 0.000 description 2
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 229910052733 gallium Inorganic materials 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
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- 229910052742 iron Inorganic materials 0.000 description 1
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- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 150000002909 rare earth metal compounds Chemical class 0.000 description 1
- 238000012958 reprocessing Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
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- Manufacture And Refinement Of Metals (AREA)
Abstract
The invention provides a high-conductivity and high-corrosion-resistance aluminum monofilament and a production process and application thereof, wherein the aluminum monofilament comprises the following components in percentage by mass: 0.06-0.08% of Ce, 0.02-0.03% of Ga, 0.10-0.25% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, and the balance of Al and unavoidable impurities. The production process comprises the following steps: molten aluminum smelting, vacuum smelting, converter smelting, submerged-arc refining, continuous casting and rolling, drawing and scraping. The capacity-increasing lead produced by utilizing the aluminum monofilaments has the characteristics of low electric loss, high current carrying capacity, high conductivity and excellent corrosion resistance, effectively improves the transmission efficiency of a power transmission and transformation line, ensures the safe and reliable operation of a power grid, and has remarkable social and economic benefits. The production and preparation method of the material is simple and feasible, and has very wide production and application prospects.
Description
Technical Field
The invention belongs to the technical field of cable materials, and particularly relates to a high-conductivity and high-corrosion-resistance aluminum monofilament, and a production process and application thereof.
Background
The ultra-high voltage power transmission and transformation line has the characteristics of large capacity, long-distance power transmission, low loss and the like, and is closely concerned by national industrial policies and governments at all levels in recent years. The new energy supply and absorption system is to be built by increasing dynamics planning, and is based on a large-scale wind-light-electricity base, supported by clean, efficient, advanced and energy-saving coal electricity around the base and supported by a stable, safe and reliable extra-high voltage power transmission and transformation circuit.
The transmission cable of the extra-high voltage transmission and transformation line mainly adopts a steel-cored aluminum stranded wire, which is a cable formed by stranding aluminum wires and steel wires, wherein the steel core mainly plays a role in increasing strength, and the aluminum stranded wire mainly plays a role in transmitting electric energy. In order to reduce the electric energy loss of the transmission line as much as possible and maintain higher transmission efficiency, the aluminum stranded wire is mainly made of industrial pure aluminum. However, when the cable runs in a medium and strong corrosion atmospheric environment, the conductor material on the surface of the cable can be corroded rapidly and continuously, and the safe running of the power transmission and transformation circuit is affected.
In order to improve the conductivity of the active power transmission cable, enhance the corrosion resistance of the cable and prolong the service life of the cable product, a novel structure and function integrated lead material needs to be developed urgently, and has the characteristics of high conductivity and excellent corrosion resistance, so that the transmission efficiency of a power transmission and transformation circuit is improved, and the safe and reliable operation of a power grid is ensured. In view of this, the present invention has been made.
Disclosure of Invention
The invention aims to develop an aluminum and aluminum alloy conductor material which has good conductivity, good corrosion resistance, good strength and good plastic toughness and can be widely applied to the field of power industry. The invention also aims to provide the high-conductivity corrosion-resistant aluminum conductor which can be used as an aluminum stranded wire in the steel-cored aluminum stranded wire and can be applied to electric energy transmission under special working conditions such as heavy pollution, marine climate and the like.
The technical scheme of the invention is as follows:
A high-conductivity and high-corrosion-resistance aluminum monofilament comprises the following components in percentage by mass: 0.06-0.08% of Ce, 0.02-0.03% of Ga, 0.10-0.25% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurities is less than or equal to 0.005%, the total amount of the unavoidable impurities is less than or equal to 0.02%, and the mass ratio of Ga to Ce is 0.20-0.40.
The method for preparing the high-conductivity and high-corrosion-resistance aluminum monofilament comprises the following steps of:
(1) Smelting aluminum liquid: and (3) loading an aluminum ingot with the purity of more than 99.7% into a hearth of a smelting furnace, heating the furnace body to 760-800 ℃, adding a proper amount of Al-Fe intermediate alloy, al-Si intermediate alloy and Al-Cu intermediate alloy which are uniformly mixed according to the design requirement of material components after the aluminum ingot is melted, stirring and skimming after the aluminum ingot is fully melted, and then cooling the aluminum alloy melt to 740-760 ℃ to obtain the primary alloyed aluminum melt.
(2) Vacuum smelting: and (3) loading the aluminum-cerium intermediate alloy and the Ga block into a vacuum smelting furnace, and carrying out vacuum refining purification at the temperature of 1300-1500 ℃ to remove impurities, oxides and other impurities in the alloy melt, thereby obtaining the secondary alloyed aluminum alloy melt. The melt has the characteristics of fine rare earth phase size, uniform distribution, small gas element content, more uniform components and the like.
(3) Refining in a converter: transferring the primary alloyed aluminum melt obtained in the step (1) to a heat preservation furnace, adopting a two-stage foamed ceramic filter plate (aperture 30/50 PPI) to carry out online filtration on the melt, then adding a massive hexachloroethane refining agent into the primary alloyed aluminum melt in the heat preservation furnace, degassing and deslagging the melt in the furnace, stirring, removing surface scum, and then controlling the temperature of the melt at 720-750 ℃, and standing for treatment.
(4) And (3) submerged injection refining: and (3) the secondary alloyed aluminum alloy melt obtained in the step (2) is submerged into the position below the liquid level of the primary alloyed aluminum alloy melt through a graphite pipe, so that the secondary alloyed aluminum alloy melt is prevented from being contacted with air, oxidation burning loss is reduced, and impurities such as oxide are introduced. And then carrying out online degassing on the mixed melt by adopting a rotary jetting degassing device, wherein high-purity argon or nitrogen is used as a degassing medium, the degassing time is 10min/200kgAl, and the hydrogen content in the melt after degassing is not more than 0.10ml/100gAl. Regulating the temperature of the melt to 710-730 ℃, and standing for 45min.
(5) Continuous casting and rolling: setting casting technological parameters of 710-730 ℃ of casting temperature, 10-14m/min of casting speed, 10-40 ℃ of cooling water temperature and 0.45-0.60MPa of cooling water pressure, and adjusting the casting blank rolling temperature to 500-520 ℃. Casting the melt subjected to online refining into a wheel type crystallizer for continuous casting to form a casting blank with the sectional area of 1800-2600mm, then continuously rolling the casting blank in a continuous rolling unit to obtain a round rod blank with the diameter of 9-12mm, and then rolling by adopting an automatic wire winding device to obtain the aluminum round rod blank.
(6) Drawing and scraping: and (3) selecting a hard nitriding surface treated alloy steel drawing die, and drawing the aluminum round rod blank obtained in the step (5) on a sliding wire drawing machine to obtain an aluminum monofilament with the diameter of 1.5-5.0mm, wherein the drawing speed is 6-8m/s, and the drawing dimensional accuracy of the final pass is required to be +/-0.02 mm. And (3) carrying out single-pass scraping on the aluminum monofilaments after drawing by adopting an alloy steel scraping die, wherein the scraping thickness is 0.02-0.05mm, the scraping speed is 8-10m/min, and the grease and fatigue layers on the surfaces of the wires are removed, so that a finished product with a smooth surface is obtained.
According to the analysis and comparison of the salt spray test (NSS-720 hours) of GB/T10125-2012, the white corrosion product is observed by naked eyes for the first time after the neutral salt spray test for 96 hours, and the corrosion rate is 1.11-1.16mg/dm < 3 > after 720 hours by weighing calculation. The conductivity of the finished aluminum monofilament is 36.77-37.00MS/m, the tensile strength Rm is 135-145MPa, and the elongation after break is 12.5-14.0%.
Advantageous technical effects
According to the high-conductivity and high-corrosion-resistance aluminum monofilament and the preparation method, the novel alloy formula is developed, and the composite process method of vacuum melting, purification and reprocessing and pressurized submerged gas injection refining is adopted, so that the conductivity and corrosion resistance of the aluminum monofilament are remarkably improved. Under the vacuum smelting purification effect, trace rare earth cerium and gallium obtain purification effect, and are easier to react with impurity elements iron and silicon, so that impurity phases are promoted to spheroidize, and adverse effects of the impurity elements are eliminated. Meanwhile, the defect of grain boundary is filled, a rare earth metal compound with a surface layer protection effect is generated, and the modification effect of rare earth cerium and gallium composite microalloying on an aluminum melt can be remarkably improved. Under the refining action of pressurized submerged gas injection, alloy elements can be rapidly and uniformly dispersed in the aluminum melt, so that the oxidation burning loss of trace elements is greatly reduced, the accurate control of the trace element content is realized, the content of gas elements in the aluminum melt is effectively reduced, and the components are more uniform. The aluminum monofilament produced by the invention has the characteristics of capacity-increasing effect, low electric loss, high current carrying capacity, high conductivity and excellent corrosion resistance. The power transmission and transformation circuit effectively improves the transmission efficiency of the power transmission and transformation circuit, ensures the safe and reliable operation of the power grid, and has remarkable social and economic benefits. The production and preparation method of the material is simple and feasible, and has very wide production and application prospects.
Detailed Description
In order to make the technical scheme and advantages of the present invention more clear, the technical scheme of the present invention will be clearly and completely described below by way of examples. The specific conditions are not noted in the examples and are carried out according to conventional conditions or conditions recommended by the manufacturer. The reagents or apparatus used were conventional products commercially available without the manufacturer's attention.
The invention provides a high-conductivity and high-corrosion-resistance aluminum monofilament and a preparation method thereof, and the invention is further described below with reference to examples.
A high-conductivity and high-corrosion-resistance aluminum monofilament comprises the following components in percentage by mass: 0.06-0.08% of Ce, 0.02-0.03% of Ga, 0.10-0.25% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurities is less than or equal to 0.005%, the total amount of the unavoidable impurities is less than or equal to 0.02%, and the mass ratio of Ga to Ce is 0.20-0.40.
The method for preparing the high-conductivity and high-corrosion-resistance aluminum monofilament comprises the following steps of:
(1) Smelting aluminum liquid: and (3) loading an aluminum ingot with the purity of more than 99.7% into a hearth of a smelting furnace, heating the furnace body to 760-800 ℃, adding a proper amount of Al-Fe intermediate alloy, al-Si intermediate alloy and Al-Cu intermediate alloy which are uniformly mixed according to the design requirement of material components after the aluminum ingot is melted, stirring and skimming after the aluminum ingot is fully melted, and then cooling the aluminum alloy melt to 740-760 ℃ to obtain the primary alloyed aluminum melt.
(2) Vacuum smelting: and (3) loading the aluminum-cerium intermediate alloy and the Ga block into a vacuum smelting furnace, and carrying out vacuum refining purification at the temperature of 1300-1500 ℃ to remove impurities, oxides and other impurities in the alloy melt, thereby obtaining the secondary alloyed aluminum alloy melt. The melt has the characteristics of fine rare earth metal phase size, uniform distribution, small gas element content, more uniform components and the like.
(3) Refining in a converter: transferring the primary alloyed aluminum melt obtained in the step (1) to a heat preservation furnace, adopting a two-stage foamed ceramic filter plate (aperture 30/50 PPI) to carry out online filtration on the melt, then adding a massive hexachloroethane refining agent into the primary alloyed aluminum melt in the heat preservation furnace, degassing and deslagging the melt in the furnace, stirring, removing surface scum, and then controlling the temperature of the melt at 720-750 ℃, and standing for treatment.
(4) And (3) submerged injection refining: and (3) the secondary alloyed aluminum alloy melt obtained in the step (2) is submerged into the position below the liquid level of the primary alloyed aluminum alloy melt through a graphite pipe, so that the secondary alloyed aluminum alloy melt is prevented from being contacted with air, oxidation burning loss is reduced, and impurities such as oxide are introduced. And then carrying out online degassing on the mixed melt by adopting a rotary jetting degassing device, wherein high-purity argon or nitrogen is used as a degassing medium, the degassing time is 10min/200kgAl, and the hydrogen content in the melt after degassing is not more than 0.10ml/100gAl. Regulating the temperature of the melt to 710-730 ℃, and standing for 45min.
(5) Continuous casting and rolling: setting casting technological parameters of 710-730 ℃ of casting temperature, 10-14m/min of casting speed, 10-40 ℃ of cooling water temperature and 0.45-0.60MPa of cooling water pressure, and adjusting the casting blank rolling temperature to 500-520 ℃. Casting the melt subjected to online refining into a wheel type crystallizer for continuous casting to form a casting blank with the sectional area of 1800-2600mm, then continuously rolling the casting blank in a continuous rolling unit to obtain a round rod blank with the diameter of 9-12mm, and then rolling by adopting an automatic wire winding device to obtain the aluminum round rod blank.
(6) Drawing and scraping: and (3) selecting a hard nitriding surface treated alloy steel drawing die, and drawing the aluminum round rod blank into an aluminum monofilament with the diameter of 1.5-5.0mm on a sliding wire drawing machine, wherein the drawing speed is 6-8m/s, and the drawing dimensional accuracy requirement of the final pass is +/-0.02 mm. And (3) carrying out single-pass scraping on the aluminum monofilaments after drawing by adopting an alloy steel scraping die, wherein the scraping thickness is 0.02-0.05mm, the scraping speed is 8-10m/min, and the grease and fatigue layers on the surfaces of the wires are removed, so that a finished product with a smooth surface is obtained.
According to the analysis and comparison of the salt spray test (NSS-720 hours) of GB/T10125-2012, the white corrosion product is observed by naked eyes for the first time after the neutral salt spray test for 96 hours, and the corrosion rate is 1.11-1.16mg/dm < 3 > after 720 hours by weighing calculation. The conductivity of the finished aluminum monofilament is 36.77-37.00MS/m, the tensile strength Rm is 135-145MPa, and the elongation after break is 12.5-14.0%.
Examples
A production process of high-conductivity and high-corrosion-resistance aluminum monofilaments comprises the following steps:
(1) Smelting aluminum liquid: and (3) loading an aluminum ingot with the purity of more than 99.7% into a hearth of a smelting furnace, heating the furnace body to 760 ℃, adding a proper amount of Al-Fe intermediate alloy, al-Si intermediate alloy and Al-Cu intermediate alloy which are uniformly mixed according to the design requirement of material components after the aluminum ingot is melted, stirring and deslagging after the aluminum ingot is fully melted, and then cooling the aluminum alloy melt to 740 ℃ to obtain the primary alloyed aluminum melt.
(2) Vacuum smelting: and (3) loading the aluminum-cerium intermediate alloy and the Ga block into a vacuum smelting furnace, and carrying out vacuum refining purification at the temperature of 1300 ℃ to remove impurities, oxides and other impurity substances in the alloy melt, thereby obtaining the secondary alloyed aluminum alloy melt. The melt has the characteristics of fine rare earth phase size, uniform distribution, small gas element content, more uniform components and the like.
(3) Refining in a converter: transferring the primary alloyed aluminum melt obtained in the step (1) to a heat preservation furnace, adopting a two-stage foamed ceramic filter plate (aperture 30/50 PPI) to carry out online filtration on the melt, then adding a massive hexachloroethane refining agent into the primary alloyed aluminum melt in the heat preservation furnace, degassing and deslagging the melt in the furnace, stirring, removing surface scum, and then controlling the temperature of the melt at 720 ℃, and standing.
(4) And (3) submerged injection refining: and (3) the secondary alloyed aluminum alloy melt obtained in the step (2) is submerged into the position below the liquid level of the primary alloyed aluminum alloy melt through a graphite pipe, so that the secondary alloyed aluminum alloy melt is prevented from being contacted with air, oxidation burning loss is reduced, and impurities such as oxide are introduced. And then carrying out online degassing on the mixed melt by adopting a rotary jetting degassing device, wherein high-purity argon or nitrogen is used as a degassing medium, the degassing time is 10min/200kgAl, and the hydrogen content in the melt after degassing is not more than 0.10ml/100gAl. The temperature of the melt was adjusted to 710℃and allowed to stand for 45min.
(5) Continuous casting and rolling: the casting process parameters are set to be the casting temperature of 710 ℃, the casting speed of 10m/min, the cooling water temperature of 10 ℃, the cooling water pressure of 0.45MPa, and the casting blank rolling temperature of 500 ℃. Casting the melt subjected to online refining into a wheel type crystallizer for continuous casting to form a casting blank with the sectional area of 1800mm, then continuously rolling the casting blank in a continuous rolling unit to obtain a round rod blank with the diameter of 9mm, and then rolling by adopting an automatic wire winding device to obtain the aluminum round rod blank.
(6) Drawing and scraping: and (3) selecting a drawing die of alloy steel with hard nitriding surface treatment, drawing an aluminum round rod blank on a sliding wire drawing machine to form an aluminum monofilament with the length of 1.5mm, wherein the drawing speed is 6m/s, and the drawing dimensional accuracy of the final pass is required to be +/-0.02 mm. And (3) carrying out single-pass scraping on the aluminum monofilament after drawing by adopting an alloy steel scraping die, wherein the scraping thickness is 0.02mm, the scraping speed is 8m/min, and the grease and fatigue layers on the surface of the wire are removed to obtain a finished product with a smooth surface.
The finished product comprises the following components in percentage by mass: 0.06% of Ce, 0.02% of Ga, 0.10% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, and the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurities is less than or equal to 0.005%, the total amount of the unavoidable impurities is less than or equal to 0.02%, and the mass ratio of Ga to Ce is 0.33.
According to the analysis and comparison of the salt spray test (NSS-720 hours) of GB/T10125-2012, the white corrosion product is observed by naked eyes for the first time after 96 hours of the neutral salt spray test, and the corrosion rate is 1.16mg/dm and d after 720 hours of weighing calculation. The conductivity of the finished aluminum monofilament is 36.77MS/m, the tensile strength Rm is 135MPa, and the elongation after breaking is 12.5%.
Examples
A production process of high-conductivity and high-corrosion-resistance aluminum monofilaments comprises the following steps:
(1) Smelting aluminum liquid: and (3) loading an aluminum ingot with the purity of more than 99.7% into a hearth of a smelting furnace, heating the furnace body to 780 ℃, adding a proper amount of Al-Fe intermediate alloy, al-Si intermediate alloy and Al-Cu intermediate alloy which are uniformly mixed according to the design requirement of material components after the aluminum ingot is melted, stirring and deslagging after the aluminum ingot is fully melted, and then cooling the aluminum alloy melt to 750 ℃ to obtain the primary alloyed aluminum melt.
(2) Vacuum smelting: and (3) loading the aluminum-cerium intermediate alloy and the Ga block into a vacuum smelting furnace, and carrying out vacuum refining purification at the temperature of 1400 ℃ to remove impurities, oxides and other impurity substances in the alloy melt, thereby obtaining the secondary alloyed aluminum alloy melt. The melt has the characteristics of fine rare earth phase size, uniform distribution, small gas element content, more uniform components and the like.
(3) Refining in a converter: transferring the primary alloyed aluminum melt obtained in the step (1) to a heat preservation furnace, adopting a two-stage foamed ceramic filter plate (aperture 30/50 PPI) to carry out online filtration on the melt, then adding a massive hexachloroethane refining agent into the primary alloyed aluminum melt in the heat preservation furnace, degassing and deslagging the melt in the furnace, stirring, removing surface scum, and then controlling the temperature of the melt to be 735 ℃, and standing.
(4) And (3) submerged injection refining: and (3) the secondary alloyed aluminum alloy melt obtained in the step (2) is submerged into the position below the liquid level of the primary alloyed aluminum alloy melt through a graphite pipe, so that the secondary alloyed aluminum alloy melt is prevented from being contacted with air, oxidation burning loss is reduced, and impurities such as oxide are introduced. And then carrying out online degassing on the mixed melt by adopting a rotary jetting degassing device, wherein high-purity argon or nitrogen is used as a degassing medium, the degassing time is 10min/200kgAl, and the hydrogen content in the melt after degassing is not more than 0.10ml/100gAl. The temperature of the melt is adjusted to 720 ℃, and the melt is kept stand for 45min.
(5) Continuous casting and rolling: the casting process parameters are set to be the casting temperature of 720 ℃, the casting speed of 12m/min, the cooling water temperature of 125 ℃, the cooling water pressure of 0.52MPa, and the casting blank rolling temperature of 515 ℃. Casting the melt subjected to online refining into a wheel type crystallizer for continuous casting to form a casting blank with the sectional area of 2200mm, then continuously rolling the casting blank in a continuous rolling unit to obtain a round rod blank with the diameter of 10mm, and then rolling by adopting an automatic wire winding device to obtain the aluminum round rod blank.
(6) Drawing and scraping: and (3) selecting a drawing die of alloy steel with hard nitriding surface treatment, drawing an aluminum round rod blank on a sliding wire drawing machine to form an aluminum monofilament with the length of 3.5mm, wherein the drawing speed is 7m/s, and the drawing dimensional accuracy of the final pass is required to be +/-0.02 mm. And (3) carrying out single-pass scraping on the aluminum monofilament after drawing by adopting an alloy steel scraping die, wherein the scraping thickness is 0.03mm, the scraping speed is 9m/min, and the grease and fatigue layers on the surface of the wire are removed to obtain a finished product with a smooth surface.
The finished product comprises the following components in percentage by mass: 0.07% of Ce, 0.025% of Ga, 0.175% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, and the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurities is less than or equal to 0.005%, the total amount of the unavoidable impurities is less than or equal to 0.02%, and the mass ratio of Ga to Ce is 0.36.
According to the analysis and comparison of the salt spray test (NSS-720 hours) of GB/T10125-2012, the white corrosion product is observed by naked eyes for the first time after 96 hours of the neutral salt spray test, and the corrosion rate is 1.14mg/dm and d after 720 hours of weighing calculation. The conductivity of the finished aluminum monofilament is 36.89MS/m, the tensile strength Rm is 140MPa, and the elongation after breaking is 13.2%.
Examples
A production process of high-conductivity and high-corrosion-resistance aluminum monofilaments comprises the following steps:
(1) Smelting aluminum liquid: and (3) loading an aluminum ingot with the purity of more than 99.7% into a hearth of a smelting furnace, heating the furnace body to 800 ℃, adding a proper amount of Al-Fe intermediate alloy, al-Si intermediate alloy and Al-Cu intermediate alloy which are uniformly mixed according to the design requirement of material components after the aluminum ingot is melted, stirring and deslagging after the aluminum ingot is fully melted, and then cooling the aluminum alloy melt to 760 ℃ to obtain the primary alloyed aluminum melt.
(2) Vacuum smelting: and (3) loading the aluminum-cerium intermediate alloy and the Ga block into a vacuum smelting furnace, and carrying out vacuum refining purification at a temperature of between 1500 ℃ to remove impurities, oxides and other impurity substances in the alloy melt, thereby obtaining the secondary alloyed aluminum alloy melt. The melt has the characteristics of fine rare earth phase size, uniform distribution, small gas element content, more uniform components and the like.
(3) Refining in a converter: transferring the primary alloyed aluminum melt obtained in the step (1) to a heat preservation furnace, adopting a two-stage foamed ceramic filter plate (aperture 30/50 PPI) to carry out online filtration on the melt, then adding a massive hexachloroethane refining agent into the primary alloyed aluminum melt in the heat preservation furnace, degassing and deslagging the melt in the furnace, stirring, removing surface scum, and then controlling the temperature of the melt at 750 ℃, and standing.
(4) And (3) submerged injection refining: and (3) the secondary alloyed aluminum alloy melt obtained in the step (2) is submerged into the position below the liquid level of the primary alloyed aluminum alloy melt through a graphite pipe, so that the secondary alloyed aluminum alloy melt is prevented from being contacted with air, oxidation burning loss is reduced, and impurities such as oxide are introduced. And then carrying out online degassing on the mixed melt by adopting a rotary jetting degassing device, wherein high-purity argon or nitrogen is used as a degassing medium, the degassing time is 10min/200kgAl, and the hydrogen content in the melt after degassing is not more than 0.10ml/100gAl. The temperature of the melt is adjusted to 730 ℃ and the melt is kept stand for 45min.
(5) Continuous casting and rolling: the casting process parameters are set to be 730 ℃ of casting temperature, 14m/min of casting speed, 40 ℃ of cooling water temperature and 0.60MPa of cooling water pressure, and the casting blank rolling temperature is adjusted to be 520 ℃. Casting the melt subjected to online refining into a wheel type crystallizer for continuous casting to form a casting blank with the sectional area of 2600mm, then continuously rolling the casting blank in a continuous rolling unit to obtain a round rod blank with the diameter of 12mm, and then rolling by adopting an automatic wire winding device to obtain the aluminum round rod blank.
(6) Drawing and scraping: and (3) selecting a drawing die of alloy steel with hard nitriding surface treatment, drawing an aluminum round rod blank into an aluminum monofilament with the length of 5.0mm on a sliding wire drawing machine, wherein the drawing speed is 8m/s, and the drawing dimensional accuracy requirement of the final pass is +/-0.02 mm. And (3) carrying out single-pass scraping on the aluminum monofilament after drawing by adopting an alloy steel scraping die, wherein the scraping thickness is 0.05mm, the scraping speed is 10m/min, and the grease and fatigue layers on the surface of the wire are removed to obtain a finished product with a smooth surface.
The finished product comprises the following components in percentage by mass: 0.08% of Ce, 0.03% of Ga, 0.25% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, and the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurities is less than or equal to 0.005%, the total amount of the unavoidable impurities is less than or equal to 0.02%, and the mass ratio of Ga to Ce is 0.38.
According to the analysis and comparison of the salt spray test (NSS-720 hours) of GB/T10125-2012, the white corrosion product is observed by naked eyes for the first time after 96 hours of the neutral salt spray test, and the corrosion rate is 1.20mg/dm and d after 720 hours of weighing calculation. The conductivity of the finished aluminum monofilament is 37.00MS/m, the tensile strength Rm is 145MPa, and the elongation after breaking is 14.0%.
Comparative example 1
The present embodiment is substantially the same as the embodiment 1 in the production process of a high-conductivity and high-corrosion-resistance aluminum monofilament, except that: the aluminum-cerium intermediate alloy and the Ga block are not added, the vacuum refining treatment is not adopted, and the submerged injection refining mode below the liquid level of the melt is not adopted.
The finished product comprises the following components in percentage by mass: 0.10% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurities is less than or equal to 0.005%, and the total amount of the unavoidable impurities is less than or equal to 0.02%.
According to the test analysis of GB/T10125-2012 salt spray test (NSS-720 hours), white corrosion products are observed by naked eyes for the first time after 48 hours of a neutral salt spray test, and the corrosion rate is 2.16 mg/dm.d after 720 hours of weighing calculation. The conductivity of the finished aluminum monofilament prepared in the comparative example is 35.67MS/m, the tensile strength Rm is 114MPa, and the elongation after break is 11.2%.
Comparative example 2
The present example is substantially the same as example 2 in the production process of a high conductivity, high corrosion resistant aluminum monofilament, except that: the aluminum-cerium intermediate alloy and the Ga block are not added, the vacuum refining treatment is not adopted, and the submerged injection refining mode below the liquid level of the melt is not adopted.
The finished product comprises the following components in percentage by mass: 0.175% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurities is less than or equal to 0.005%, and the total amount of the unavoidable impurities is less than or equal to 0.02%.
According to the test analysis of GB/T10125-2012 salt spray test (NSS-720 hours), white corrosion products are observed by naked eyes for the first time after 48 hours of neutral salt spray test, and the corrosion rate is 2.34 mg/dm.d after 720 hours by weighing calculation. The conductivity of the finished aluminum monofilament prepared in the comparative example is 35.79MS/m, the tensile strength Rm is 116MPa, and the elongation after break is 11.4%.
Comparative example 3
The present embodiment is substantially the same as the embodiment 3 in the production process of a high-conductivity and high-corrosion-resistance aluminum monofilament, except that: the aluminum-cerium intermediate alloy and the Ga block are not added, the vacuum refining treatment is not adopted, and the submerged injection refining mode below the liquid level of the melt is not adopted.
The finished product comprises the following components in percentage by mass: 0.08% of Ce, 0.25% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, and the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurities is less than or equal to 0.005%, and the total amount of the unavoidable impurities is less than or equal to 0.02%.
According to the test analysis of GB/T10125-2012 salt spray test (NSS-720 hours), white corrosion products are observed by naked eyes for the first time after 48 hours of a neutral salt spray test, and the corrosion rate is 2.46 mg/dm.d after 720 hours of weighing calculation. The conductivity of the finished aluminum monofilament prepared in the comparative example is 35.96MS/m, the tensile strength Rm is 122MPa, and the elongation after breaking is 12%.
The aluminum monofilaments prepared in examples 1-3 and comparative examples 1-3 were produced by the process for producing high-conductivity and high-corrosion-resistance aluminum monofilaments, and the detection results are shown in Table 1.
TABLE 1
The above embodiments are described in detail with respect to the technical solution of the present invention. It is obvious that the invention is not limited to the described embodiments. Based on the embodiments of the present invention, those skilled in the art can make various changes thereto, but any changes equivalent or similar to the present invention are within the scope of the present invention.
Claims (8)
1. The high-conductivity and high-corrosion-resistance aluminum monofilament is characterized by comprising the following components in percentage by mass: 0.06-0.08% of Ce, 0.02-0.03% of Ga, 0.10-0.25% of Fe, less than or equal to 0.22% of Si, less than or equal to 0.001% of Ti, the balance of Al and unavoidable impurities, wherein the content of each element in the unavoidable impurity elements is less than or equal to 0.005%, the total amount of the unavoidable impurities is less than or equal to 0.02%, and the mass ratio of Ga to Ce is 0.20-0.40, the production process of the aluminum monofilament comprises the following steps:
(1) Smelting aluminum liquid: loading an aluminum ingot with the purity of more than 99.7% into a hearth of a smelting furnace, heating the furnace body to 760-800 ℃, adding Al-Fe intermediate alloy, al-Si intermediate alloy and Al-Cu intermediate alloy after the aluminum ingot is melted, and then cooling the obtained aluminum alloy melt to 740-760 ℃ to obtain a primary alloyed aluminum melt;
(2) Vacuum smelting: the aluminum cerium intermediate alloy and the Ga block are put into a vacuum smelting furnace, vacuum refining and purification are carried out at the temperature of 1300-1500 ℃ to obtain a secondary alloyed aluminum alloy melt;
(3) Refining in a converter: transferring the primary alloyed aluminum melt obtained in the step (1) to a heat preservation furnace, filtering the melt on line, adding a blocky hexachloroethane refining agent into the primary alloyed aluminum melt in the heat preservation furnace, degassing and deslagging the melt in the furnace, controlling the temperature of the melt to be 720-750 ℃, and standing;
(4) And (3) submerged injection refining: the secondary alloyed aluminum alloy melt obtained in the step (2) is submerged into the lower part of the liquid level of the primary alloyed aluminum melt through a graphite pipe, then a rotary jetting degassing device is adopted to carry out online degassing on the mixed melt, high-purity argon or nitrogen is used as a degassing medium, the hydrogen content in the melt after degassing is not more than 0.10ml/100gAl, the temperature of the melt is adjusted to be 710-730 ℃, and the melt is kept stand for 45min;
(5) Continuous casting and rolling: casting the melt obtained in the step (4) into a wheel type crystallizer for continuous casting to form a casting blank with the sectional area of 1800-2600mm, then continuously rolling the casting blank in a continuous rolling unit to obtain a round rod blank with the diameter of 9-12mm, and then rolling by adopting an automatic wire winding device to obtain an aluminum round rod blank;
(6) Drawing and scraping: and (3) selecting an alloy steel drawing die with hard nitriding surface treatment, drawing the aluminum round rod blank obtained in the step (5) on a sliding wire drawing machine to obtain an aluminum monofilament with the diameter of 1.5-5.0mm, and carrying out single-pass scraping on the drawn aluminum monofilament by adopting an alloy steel scraping die, wherein the final-pass drawing dimensional accuracy requirement is +/-0.02 mm.
2. The aluminum monofilament according to claim 1, wherein the aluminum monofilament has a white corrosion product observed with naked eyes for the first time after 96 hours of the neutral salt spray test and a calculated corrosion rate of 1.11-1.16 mg/dm.d after 720 hours, as compared to the GB/T10125-2012 salt spray test (NSS-720 hours) test analysis.
3. The aluminum monofilament according to claim 1, wherein the finished aluminum monofilament has an electrical conductivity of 36.77-37.00MS/m, a tensile strength Rm of 135-145MPa, and an elongation after break of 12.5-14%.
4. The process for producing aluminum monofilaments of claim 1 wherein the in-line filtration of step (3) uses a dual stage ceramic foam filter plate having a pore size of 30/50PPI.
5. The process for producing aluminum monofilaments according to claim 1, wherein the degassing time in step (4) is 10min/200kgAl.
6. The process for producing aluminum monofilaments according to claim 1, wherein the continuous casting setting process parameters in the step (5) are casting temperature 710-730 ℃, casting speed 10-14m/min, cooling water temperature 10-40 ℃, cooling water pressure 0.45-0.60MPa, and casting blank rolling temperature 500-520 ℃.
7. The process for producing aluminum monofilaments according to claim 1, wherein the drawing speed in step (6) is 6-8m/s, the shaved thickness is 0.02-0.05mm, and the shaved speed is 8-10m/min.
8. A high conductivity, high corrosion resistant aluminum wire comprising the high conductivity, high corrosion resistant aluminum monofilament of claim 1.
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