JP2020190132A - Building component including aluminum plate-like structure, repairing water discharge drain, and manufacturing method of the same - Google Patents

Abstract

To provide a building component including an aluminum plate-like structure with less work hardening in a cut surface vicinity, a repairing water discharge drain and a manufacturing method of the same.SOLUTION: In a building material including an aluminum plate-like structure, the aluminum plate-like structure has purity of 99.99 wt% or more, and has a cut surface and a surface adjacent to the cut surface. As to at least a part of the cut surface, a work hardening rate of a cut surface vicinity expressed by the following formula (1) is 110% or less. "an average value of Vickers hardness of four points on the surface that are selected at random at points within 0.3 mm from a boundary between the surface and the cut surface"/"an average value of Vickers hardness of four points on the surface that are selected at random at points within 10.0 mm from the boundary"×100 (1).SELECTED DRAWING: Figure 1

Description

The present invention relates to building members including aluminum plate-like structures, repair drainage drains, and methods for manufacturing them.

Aluminum is widely used as a building member, for example, a building member for repairing a building. Examples of such a building member include the following repair drainage drains.

A drainage drain is usually provided on the rooftop, etc. in order to collect rainwater that has fallen on the flat part of the building such as the rooftop, flat roof, corridor, balcony, etc. Has been done.

The drainage drain includes a drainage drain for vertical drainage that allows rainwater to flow into a gutter or the like provided under the rooftop, and a drainage for horizontal drainage that draws rainwater into a gutter or the like provided next to the rooftop or the like. There is a drain.

The drainage drain is usually made of a material such as cast iron, stainless steel, or aluminum, and some of them are painted by baking finish or the like, and are fixed to the rooftop or the like by various methods.

However, with the passage of time, the drainage drain itself deteriorates, the contact area where the drainage drain is fixed on the roof, etc. is eroded, and rainwater does not flow normally to the tub, etc., or the drainage drain The area around the drain may become dirty, or water may leak from the corroded part of the drainage drain.

In order to repair such a deteriorated drainage drain and the vicinity of the drainage drain, for example, as disclosed in Patent Document 1, a repair drainage drain is widely used. FIG. 2 shows an example of the repair drainage drain. As shown in FIG. 2, the repair drainage drain 20 has a hole in the substantially central portion of the plate-shaped structure 22, and a hollow tube 24 extends from the hole to one side of the plate-shaped structure 22. .. FIG. 3 shows a schematic cross-sectional view of the drainage drain base before the repair drainage drain is installed, and FIG. 4 shows a schematic cross-sectional view of the drainage drain base on which the repair drainage drain is installed. As shown in FIG. 3, the drainage drain base 32 before the repair drainage drain is installed has, for example, a flat portion 34 and a recessed portion 36, and an existing drain pipe 38 having a drainage port 30 is arranged. As shown in FIG. 4, the hollow pipe 24 is inserted into the existing drain pipe 38 of the drainage drain to be repaired, and the plate-shaped structure 22 is hit with a hammer or the like to bring the plate-shaped structure 22 to the drainage drain base 32. The drainage drain can be repaired by adapting it to the shape of and making it adhere to it. Therefore, there is a need for a plate-like structure 22 that easily deforms and adheres to the shape of the drainage drain base 32 (that is, has high base followability).

A repair drainage drain using aluminum is used as such a plate-like structure. For example, Patent Document 2 discloses a plate-like structure of a repair drainage drain containing an aluminum metal mesh and the aluminum metal mesh coated with rubber.

Patent Document 3 discloses a structure using industrial pure aluminum as a plate-like structure of a repair drainage drain.

Japanese Unexamined Patent Publication No. 2014-101634 Japanese Unexamined Patent Publication No. 2012-202048 JP-A-2015-59333

An aluminum plate-like structure used for a building member such as a repair drainage drain is manufactured by subjecting an aluminum rolled plate to outer circumference cutting such as shear cutting or press working to form an opening by pressing or the like. , The cut surface formed by a method using mechanical force such as shear cutting or press working is work-hardened in the vicinity thereof, and the flexibility in the vicinity of the cut surface is reduced. Therefore, when a building member using an aluminum plate-like structure is used for repairing a building or the like, if the building member is to be deformed according to the shape of the building, it is difficult to deform the vicinity of the cut surface hard. Yes, or the vicinity of the cut surface may be damaged.

The present invention has been made in view of such a situation, and an object of the present invention is to provide a building member including an aluminum plate-like structure having a small work hardening near a cut surface, a repair drainage drain, and a method for manufacturing the same. That is.

Aspect 1 of the present invention is
A building member including an aluminum plate-like structure.
The aluminum plate-like structure contains Fe, Si and Cu, and has a purity of 99.99% by mass or more.
The aluminum plate-like structure has a cut portion and a surface adjacent to the cut surface.
A building member having a work hardening rate of 110% or less in the vicinity of the cut surface represented by the following equation (1) for at least a part of the cut surface.

(Mean value of four Vickers hardnesses randomly selected within 0.3 mm from the boundary between the surface and the cut surface) ÷ (Randomly selected at a position 10.0 mm from the boundary) Average value of Vickers hardness at 4 selected locations on the surface) × 100 (1)

Aspect 2 of the present invention is the building member according to Aspect 1, wherein the purity is 99.997% by mass or more.

Aspect 3 of the present invention is the building member according to Aspect 1 or 2, wherein the aluminum plate-like structure is a tempering material.

Aspect 4 of the present invention is the building member according to any one of Aspects 1 to 3 in which the work hardening rate is 110% or less for all of the cut surfaces.

Aspect 5 of the present invention is the building member according to any one of aspects 1 to 4, wherein at least a part of the cut surface defines an opening.

In aspect 6 of the present invention, the aluminum plate-like structure is a substantially quadrangular shape having a side of 200 mm or more and 600 mm or less or a substantially circular shape having a diameter of 200 mm or more and 600 mm or less, and the opening is a substantially circular shape having a diameter of 30 mm or more and 200 mm or less. The building member according to the fifth aspect.

Aspect 7 of the present invention is a repair drainage drain which is a building member according to aspect 5 or 6, and one end of a hollow pipe is formed into the aluminum plate-like structure so as to communicate fluid with the opening. It is a fixed repair drainage drain.

Aspect 8 of the present invention is the repair drainage drain according to aspect 7, wherein one end of the aluminum hollow pipe, which is the hollow pipe, is welded to the aluminum plate-like structure.

Aspect 9 of the present invention is a method for manufacturing a building member including an aluminum plate-like structure.
The process of preparing a rolled aluminum plate with a purity of 99.99% by mass or more, and
A method for manufacturing a building member, which includes a cutting process of cutting at least a part of the rolled aluminum plate by laser cutting to obtain the aluminum plate-like structure.

Aspect 10 of the present invention is the method for manufacturing a building member according to aspect 9, wherein the purity is 99.997% by mass or more.

Aspect 11 of the present invention is the construction according to aspect 9 or 10, which includes an annealing step of holding the rolled aluminum plate or the aluminum plate-like structure at a temperature of 300 ° C. or higher and 600 ° C. or lower for 1 hour or more and 24 hours or less. It is a method of manufacturing a member.

Aspect 12 of the present invention is the method for manufacturing a building member according to any one of aspects 9 to 11, wherein in the cutting process, all cutting of the rolled aluminum plate is performed by laser cutting.

Aspect 13 of the present invention is the method for manufacturing a building member according to any one of aspects 9 to 12 for obtaining two or more of the aluminum plate-like structures from one of the rolled aluminum plates in the cutting process.

Aspect 14 of the present invention is the method for manufacturing a building member according to any one of aspects 9 to 13 in which an opening is provided in the aluminum plate-like structure by laser cutting in the cutting process.

Aspect 15 of the present invention is the aluminum having a substantially quadrangular shape having a side of 200 mm or more and 600 mm or less or a substantially circular shape having a diameter of 200 mm or more and 600 mm or less and the opening having a diameter of 30 mm or more and 200 mm or less in the cutting process. The method for manufacturing a building member according to aspect 14, wherein a plate-shaped structure is obtained.

Aspect 16 of the present invention is a method for manufacturing a repair drainage drain, which is a building member according to any one of aspects 9 to 15, and is hollow so as to allow fluid communication with the opening in the aluminum plate-like structure. It is a method of manufacturing a repair drainage drain including a hollow pipe fixing step of fixing one end of a pipe.

In aspect 17 of the present invention, in the hollow pipe fixing step, an aluminum hollow pipe is used as the hollow pipe, and the aluminum plate-like structure and one end of the aluminum hollow pipe are welded to each other. The method for manufacturing a repair drainage drain according to the 16th aspect, wherein one end of the aluminum hollow pipe is fixed to the aluminum plate-like structure.

Aspect 18 of the present invention is the method for manufacturing a repair drainage drain according to aspect 17, wherein the welding is laser welding.

INDUSTRIAL APPLICABILITY The present invention provides a building member including an aluminum plate-like structure having a small work hardening in the vicinity of a cut surface, a repair drainage drain, and a method for manufacturing the same.

FIG. 1 is a schematic plan view showing an example of an aluminum plate-like structure. FIG. 2 is a schematic perspective view showing an example of the repair drainage drain. FIG. 3 is a schematic cross-sectional view showing an example of a drainage drain base. FIG. 4 is a schematic cross-sectional view showing an example of a state in which the hollow pipe of the repair drainage drain is inserted into the inside of the drainage drain pipe.

1. 1. Building members including an aluminum plate-like structure The building members according to the embodiment of the present invention are
Including aluminum plate-like structure,
The purity is 99.99% by mass or more,
The aluminum plate-like structure has a cut portion and a surface adjacent to the cut surface.
It is a building member having a work hardening rate of 110% or less in the vicinity of the cut surface represented by the following equation (1) for at least a part of the cut surface.

(Mean value of Vickers hardness at 4 locations on the surface randomly selected within 0.3 mm from the boundary between the surface and the cut surface) ÷ (Randomly selected at a position 10.0 mm from the boundary) Average value of Vickers hardness at 4 selected locations on the above surface) x 100 (1)

As the building member according to the embodiment of the present invention, in addition to using high-purity aluminum having excellent flexibility, at least a part of the rolled aluminum plate is cut by laser cutting to produce an aluminum plate-like structure. As a result, work hardening in the vicinity of the cut surface formed by laser cutting is reduced. Therefore, when the building member according to the embodiment of the present invention is deformed, the vicinity of the cut surface is easily deformed and is not easily damaged. Hereinafter, the building member according to the embodiment of the present invention will be described more specifically by taking the repair drainage drain as an example as the building member according to the embodiment of the present invention.

Conventionally, it has been proposed that industrial pure aluminum is applied as a plate-like structure of a repair drainage drain. However, since such industrial pure aluminum is produced by an electrolysis method such as the Hall-Héroult method, the purity is usually about 99% by mass, that is, it contains an impurity element close to 1% by mass. For example, the purity of the JIS standard alloy number A1100 is about 99% by mass, and the purity of A1050 is about 99.5% by mass.
In addition, in the mass percent notation indicating purity, N, which is an acronym for nine, is added after the number of 9s consecutive from the beginning, for example, 99.99 mass% of purity is described as "4N", and is referred to as "four nines". I may call it. Aluminum with a purity of 4N may be described as "4N-Al".

Pure aluminum having a purity of about 99% by mass usually contains about 1% by mass of impurity elements.

As described above, when repairing the deteriorated drainage drain, the repaired drainage drain is deformed and used so that the repaired drainage drain is in close contact with each other according to the shape of the drainage drain and its surroundings. Pure industrial aluminum having a purity of about 99% by mass contains a large amount of impurity elements, so that it has high strength, and it is difficult for the plate material to follow the substrate by tapping with a hammer or the like. Furthermore, even when a tempering material with low strength among industrial pure aluminum is used, it is hard to deform due to its high strength compared to lead, which is widely used as a material for repair drainage drainage, and it is also strong due to work hardening. Is easy to rise, so it is difficult to sufficiently plastically deform it to follow the drain base. Therefore, we focused on the need for a material that has low strength, high plastic deformability, and is difficult to work harden.

As a result of diligent studies, the present inventors have made it important to use a high-purity aluminum material having a purity of 99.99% by mass or more (4N or more) as a material for the aluminum plate-like structure in order to solve the above-mentioned problems. I found that.
That is, in the building member according to the embodiment of the present invention, the purity of the aluminum plate-like structure is 99.99% by mass or more. As a result, the strength of the aluminum plate-like structure can be suppressed, plastic deformation can be facilitated, and the increase in strength due to work hardening can be reduced.

Regarding the purity of high-purity aluminum, high-purity refined aluminum is used to suppress the ingress of impurities and melt casting is performed. Once a high-purity aluminum ingot is obtained, it is then subjected to homogeneous heat treatment and rolling. It is widely known that the purity does not substantially change even after undergoing processing such as surface milling and cutting, and heat treatment after processing. Therefore, it is widely known that when manufacturing an aluminum plate-shaped structure, the purity of aluminum measured in any of the steps may be used as the purity of the finally obtained aluminum plate-shaped structure. Further, even when a raw material whose composition is known in advance is used and the invasion of impurities is suppressed and melt casting is performed, the composition of the raw material may be widely used as the purity of the finally obtained aluminum plate-like structure. Are known.

As an impurity element of high-purity aluminum, typical elements are iron (Fe), silicon (Si), copper (Cu), manganese (Mn), magnesium (Mg), titanium (Ti), and boron (B). , Chromium (Cr), gallium (Ga), nickel (Ni), vanadium (V), zinc (Zn) and zirconium (Zr) are known to be 13 elements. Among these 13 elements, it is known that the amounts of Fe, Cu and Si are particularly large.
Therefore, the purity of high-purity aluminum may be determined by using the total content of Fe, Cu, and Si. That is, the purity [mass%] of high-purity aluminum may be set to (100- (total content of Fe, Cu, and Si [mass%]). For example, the total content of Fe, Cu, and Si is 0. The purity of high-purity aluminum when it is 01% by mass or less may be 99.99% or more (4N or more).

For the measurement of the content of the above 13 elements, a known analytical method capable of ensuring measurement accuracy may be used. For example, it may be determined by glow discharge mass spectrometry (GD-MS) or solid-state emission spectroscopic analysis.

In the building member according to the embodiment of the present invention, the purity of the aluminum plate-like structure is preferably 99.997% by mass or more (4N7 or more), more preferably 99.999% by mass or more (5N or more), and further preferably. It is 99.9997% by mass or more (5N7 or more), more preferably 99.99999% by mass or more (6N or more). By further limiting the total content of the impurity elements Fe, Si and Cu, the strength of the aluminum plate-like structure can be made smaller, plastic deformation can be made easier, and work hardening can be further suppressed. Therefore, for example, when the building member according to the present invention is a repair drainage drain, its workability can be further improved.

The mechanism by which the higher the purity of aluminum is, the more the strength improvement due to work hardening can be suppressed is not clear, but it is speculated as follows. That is, in the case of a general metal having a high impurity concentration, when crystal defects called dislocations are introduced during processing, the movement of dislocations is suppressed by the impurity element (that is, pinned) and accumulated. Dislocations become difficult to move, that is, work hardening occurs. On the other hand, when the purity of aluminum is 99.99% by mass or more, the amount of impurity elements is significantly smaller than that of general metals, so that the effect of suppressing (pinning) the movement of dislocations by the impurity elements is small. Therefore, it is considered that work hardening is unlikely to occur.

Further, in the building member according to the embodiment of the present invention, the aluminum plate-like structure has a purity of 99.99% by mass or more, so that in addition to being able to suppress a decrease in flexibility due to work hardening, it also has excellent corrosion resistance. Can have. Therefore, for example, when the building member according to the embodiment of the present invention is a repair drainage drain, it is less likely to deteriorate even when exposed to rainwater for a long time. Such an effect of improving corrosion resistance can be more prominently exhibited by further increasing the purity. Therefore, from the viewpoint of obtaining the effect of corrosion resistance, the purity is preferably 99.997% by mass or more, more preferably 99.999% by mass or more, still more preferably 99.9997% by mass or more, still more preferably 99.9999% by mass. % Or more.

In the building member according to the embodiment of the present invention, the aluminum plate-like structure may be a tempering material. By using the tempering material, the processing strain introduced in the rolling process at the time of manufacturing is alleviated and the flexibility is improved. Therefore, for example, when the building member according to the embodiment of the present invention is a repair drainage drain, the aluminum plate-like structure becomes easier to adhere to the shape of the repaired portion of the drainage drain, and the workability of the repair drainage drain is improved. Can be improved.

As described above, when the high-purity aluminum material is used, the flexibility of the aluminum plate-like structure can be ensured. However, since high-purity aluminum has low breaking strength and is easily broken, it may be difficult to deform the vicinity of the cut surface hard due to the slight effect of work hardening due to the cutting process only by using high-purity aluminum material. The vicinity of the surface may be damaged. Therefore, as a result of diligent studies, the present inventors have conducted laser cutting to cut at least a part of the aluminum plate in addition to using a high-purity aluminum material having a small increase in strength due to work hardening as described above. It has been found that it is important to reduce work hardening in the vicinity of the cut surface formed by laser cutting by producing an aluminum plate-like structure in order to solve the above-mentioned problems.
That is, in the building member according to the embodiment of the present invention, the aluminum plate-like structure has a cut surface and a surface adjacent to the cut surface, and at least a part of the cut surface is represented by the following equation (1). The work hardening rate near the cut surface is 110% or less.

(Mean value of Vickers hardness at 4 locations on the surface randomly selected within 0.3 mm from the boundary between the surface and the cut surface) ÷ (Randomly selected at a position 10.0 mm from the boundary) Average value of Vickers hardness at 4 selected locations on the above surface) x 100 (1)

On the surface of the aluminum plate-like structure, a position within 0.3 mm (hereinafter, sometimes referred to as "near the cut surface") from the boundary (hereinafter, may be referred to as "cut end") is due to cutting. Since it is easily affected by work hardening, it is selected as a typical position indicating the hardness of the work-hardened part by cutting. On the other hand, on the surface of the aluminum plate-like structure, the position 10.0 mm from the cut end is not affected by work hardening due to cutting, so it is selected as a representative position indicating the hardness of the part that has not been work hardened. doing. That is, the work hardening rate in the vicinity of the cut surface represented by the above equation (1) indicates the degree of work hardening by cutting, and the lower the work hardening rate by cutting, the smaller the work hardening by cutting.

In the building member according to the embodiment of the present invention, the cut surface of the aluminum plate-shaped structure may define a part or all of the outer peripheral portion of the aluminum plate-shaped structure in the surface direction, and the cut surface of the aluminum plate-shaped structure may be defined. An opening may be defined. In one embodiment of the invention, the aluminum plate-like structure has a surface and an outer peripheral portion and an opening defined by a cut surface adjacent to the surface.

The work hardening rate in the vicinity of the cut surface is preferably 108% or less, more preferably 105% or less. By further reducing the work hardening rate in the vicinity of the cut surface, the strength in the vicinity of the cut surface can be further reduced, plastic deformation can be facilitated, and damage in the vicinity of the cut surface can be less likely to occur. Therefore, for example, when the building member according to the present invention is a repair drainage drain, its workability can be further improved.

The Vickers hardness is a value measured according to JIS Z 2244: 2009, and the diagonal length of the depression remaining on the surface after pushing the diamond indenter of a regular square pyramid into the surface of the aluminum plate-like structure and releasing the test force. Calculate from the above.
JIS Z 2244: 2009 stipulates that the hardness symbol is changed according to the test force. In the embodiment of the present invention, as the Vickers hardness, for example, the Vickers hardness HV0.01 when the test force is 0.01 kgf (= 0.0981N) may be used.
In addition, the test force may be appropriately selected in consideration of other measurement conditions. For example, as described in JIS Z2244: 2009, the thickness and test force of the test piece are adjusted so that the thickness of the test piece (that is, the aluminum plate-like structure) is 1.5 times or more the diagonal length of the indentation. You may choose. As a suitable example of the test force, 0.001 to 0.05 kgf is used when the thickness of the aluminum plate-like structure is 300 μm or more, and 0.005 to 0.01 kgf is used when the thickness of the aluminum plate-like structure is less than 300 μm. Can be mentioned. The indentation size can be adjusted by the test force and the hardness of the test piece.

The building member according to the embodiment of the present invention has a work hardening rate in the vicinity of the cut surface for at least a part of the cut surface of the aluminum plate-shaped structure, that is, for a part of all the cut surfaces of the aluminum plate-shaped structure. It may be 110% or less. For example, the cut surface in the vicinity of the cut surface having a work hardening rate of 110% or less may define a part or all of the outer peripheral portion of the aluminum plate-like structure, or may define an opening. When the work hardening rate near the cut surface that defines the opening is 110% or less, for example, when the building member according to the embodiment of the present invention is a repair drainage drain, when the repair drainage drain is constructed, the vicinity of the opening is constructed. It is possible to facilitate plastic deformation and prevent damage in the vicinity of the opening.

In the building member according to the embodiment of the present invention, it is preferable that the work hardening rate in the vicinity of the cut surface is 110% or less for all of the cut surfaces. As a result, the strength can be made smaller over the entire vicinity of the cut surface, plastic deformation can be made easier, and damage in the vicinity of the cut surface can be less likely to occur.

In the building member according to the embodiment of the present invention, the shape of the aluminum plate-shaped structure is not particularly limited as long as it is plate-shaped, and when the aluminum plate-shaped structure has an opening, the shape of the opening is particularly limited. Not done. For example, the aluminum plate-like structure may be a substantially quadrangular shape having a side of 200 mm or more and 600 mm or less or a substantially circular shape having a diameter of 200 mm or more and 600 mm or less, and an opening having a diameter of 30 mm or more and 200 mm, depending on the application and design of the building member. It may be the following substantially circular shape. Building members including such an aluminum plate-like structure are suitable as a repair drainage drain.

In the building member according to the embodiment of the present invention, the plate thickness of the aluminum plate-like structure is preferably 0.3 mm or more, more preferably 0.5 mm or more, still more preferably 0.7 mm or more. As a result, for example, when the building member according to the embodiment of the present invention is a repair drainage drain, the aluminum plate-like structure is less likely to be damaged when the repair drainage drain is constructed, and water leakage due to corrosion due to rainwater or the like is more likely to occur. It is less likely to occur.
The plate thickness of the aluminum plate-like structure is preferably 2.0 mm or less, more preferably 1.8 mm or less, and further preferably 1.5 mm or less. As a result, for example, when the building member according to the embodiment of the present invention is a repair drainage drain, it becomes easier to secure the flexibility of the aluminum plate-like structure, and the workability of the repair drainage drain can be improved. It will be easy.

2. 2. Repair drainage drain The repair drainage drain according to the embodiment of the present invention is one aspect of the building member according to the embodiment of the present invention, and is a hollow pipe so as to communicate fluidly with an opening provided in an aluminum plate-like structure. One end is fixed to the aluminum plate-like structure.

The repair drainage drain according to the embodiment of the present invention can be sufficiently plastically deformed when the aluminum plate-like structure is deformed to match the shape of the repaired portion, and can be easily brought into close contact with the shape of the repaired portion. In addition, the vicinity of the cut surface can be easily plastically deformed, and damage in the vicinity of the cut surface can be prevented from occurring.

The material of the hollow tube is not particularly limited, and the hollow tube may be made of resin, or may be made of a spirally wound metal or a metal mesh coated with resin. These hollow pipes are preferably flexible, and in that case, for example, even if the existing drain pipe has a bent portion, the hollow pipe is easily deformed according to the shape of the bent portion, so that the hollow pipe is hollow. It becomes easier to insert the pipe into the existing drain pipe.
When the hollow tube is made of resin or a metal or metal mesh wound in a spiral shape is coated with resin, one end of the hollow tube is formed into an aluminum plate-like structure by, for example, an adhesive. It may be fixed.

Further, the hollow tube may be an aluminum hollow tube. The chemical composition of the aluminum hollow tube may be the same as or different from that of the aluminum plate-like structure.
I. By using an aluminum hollow pipe as the hollow pipe, corrosion resistance is improved, and the repair drainage drain is less likely to deteriorate even when exposed to rainwater for a long time.
When the hollow tube is an aluminum hollow tube, one end of the aluminum hollow tube may be welded to an aluminum plate-like structure.

3. 3. Method for manufacturing building member including aluminum plate-shaped structure The method for manufacturing building member including aluminum plate-shaped structure according to the embodiment of the present invention is as follows.
The process of preparing an aluminum rolled plate having a purity of 99.99% by mass or more, and
It includes a cutting process of cutting at least a part of an aluminum rolled plate by laser cutting to obtain an aluminum plate-like structure.
Hereinafter, each step will be described.

(1) Step of preparing a rolled aluminum plate A rolled aluminum plate having a purity of 99.99% by mass or more is prepared.

The method for preparing the rolled aluminum plate is not particularly limited, but for example,
A process for producing a rolled material made of an aluminum material having a purity of 99.99% by mass or more, and
An aluminum rolled plate may be prepared by a method including a rolling step of rolling a rolled material to obtain an aluminum rolled plate.

(1-1) Step of Producing Rolled Material A rolled material made of an aluminum material having the above-mentioned composition can be obtained by, for example, the following method. That is, an ingot having a predetermined shape is produced from the molten metal dissolved in high-purity aluminum obtained by the purification method described later while suppressing the invasion of impurities. After that, a rolled material can be obtained by cutting the ingot into a predetermined shape. The method for producing the rolled material is not limited to the above-mentioned method, and conventionally known methods (for example, die casting, extrusion, etc.) may be used. Further, a step of heat-treating the rolled material (homogenization heat treatment step) may be included.

Examples of the method for purifying high-purity aluminum include a segregation method and a three-layer electrolysis method.

The segregation method is a purification method that utilizes the segregation phenomenon during solidification of molten aluminum, and a plurality of methods have been put into practical use. One form of the segregation method is to pour molten aluminum into the container, heat the molten aluminum at the top while rotating the container, and solidify the purified aluminum from the bottom while stirring. By the segregation method, high-purity aluminum having a purity of 99.99% by mass or more can be obtained.

In the three-layer electrolysis method, pure aluminum having a relatively low purity (for example, a grade of JIS-H2102 having a purity of 99.9% by mass) is charged into the Al—Cu alloy layer to form an anode in a molten state. This is a method in which an electrolytic bath containing, for example, aluminum fluoride and barium fluoride is placed on it to deposit high-purity aluminum on the cathode.
By the three-layer electrolysis method, high-purity aluminum having a purity of 99.999% by mass or more can be obtained. Further, the concentration of Fe in aluminum can be relatively easily suppressed to 10 mass ppm (0.001 mass%) or less.

The segregation method and the three-layer electrolysis method have been described as examples of the purification method for high-purity aluminum, but the purification method for high-purity aluminum is not limited to these, and known methods such as band melt purification method and ultra-high vacuum dissolution purification method are available. Other methods and combinations thereof may be used.

The purity of the rolled aluminum plate is preferably 99.997% by mass or more, more preferably 99.999% by mass or more, still more preferably 99.9997% by mass or more, and even more preferably 99.9999% by mass or more.

(1-2) Rolling Step for Obtaining Rolled Aluminum Plate The rolling step is a step of rolling the obtained rolled material, for example, a step of rolling with a rolling processing rate of 90% or more. The rolling processing ratio referred to here is the value obtained by subtracting the thickness of the final plate obtained by rolling from the thickness of the rolled material (that is, the thickness before rolling) (that is, the thickness reduced by rolling). Percentage of the value divided by the thickness of the material,
Rolling rate (%) = [(Thickness before rolling-Thickness after rolling) ÷ Thickness before rolling] x 100
Is calculated by. For example, if a rolled material having a thickness of 10 mm is rolled into a plate material having a thickness of 1 mm, the rolling processing rate is 90%.

It is preferable that the rolled material is rolled a plurality of times to obtain the final plate thickness. The higher the rolling process rate, the higher the production efficiency in many cases. Therefore, the rolling process rate is preferably 90% or more. Since the higher the rolling rate is, the more preferable it is, no upper limit is set.

The rolling method may be either cold rolling or hot rolling. Hot rolling and cold rolling can be combined. For example, among the rolling processes performed a plurality of times, hot rolling may be performed at the initial stage and cold rolling may be performed at the latter half.

(2) Cutting Process By laser cutting, at least a part of the rolled aluminum plate prepared as described above is cut to obtain an aluminum plate-like structure. By laser cutting at least a part of the rolled aluminum plate to produce an aluminum plate-like structure, work hardening in the vicinity of the cut surface formed by laser cutting can be reduced. That is, the aluminum plate-like structure has a work hardening rate of 110% or less in the vicinity of the cut surface of the cut surface formed by laser cutting. On the other hand, the cut surface formed by a method using mechanical force such as shear cutting or press working has work hardening in the vicinity thereof, and the work hardening rate in the vicinity of the cut surface is high.

As an embodiment in which at least a part of the rolled aluminum plate is laser-cut to produce an aluminum plate-like structure, a part or all of the outer peripheral portion of the aluminum plate-like structure in the surface direction is provided with an opening of the aluminum plate-like structure. It may be formed by laser cutting. The remaining outer circumference and / or opening that is not formed by laser cutting may be formed, for example, by press working.
More specifically, for example, the following aspects [a] to [f] can be mentioned.
[A] A part of the outer peripheral portion of the aluminum plate-shaped structure is formed by laser cutting, and the remaining outer peripheral portion is formed by press working.
[B] A part of the outer peripheral portion of the aluminum plate-shaped structure is formed by laser cutting, and the remaining outer peripheral portion and the opening are formed by press working.
[C] A part of the outer peripheral portion and the opening of the aluminum plate-shaped structure are formed by laser cutting, and the remaining outer peripheral portion is formed by press working.
[D] The entire outer peripheral portion of the aluminum plate-shaped structure is formed by press working, and the opening is formed by laser cutting.
[E] The entire outer peripheral portion of the aluminum plate-shaped structure is formed by laser cutting, and the opening is formed by press working.
[F] The entire outer peripheral portion and the opening of the aluminum plate-like structure are formed by laser cutting, that is, all the aluminum rolled plate is cut by laser cutting.

Aspect [f] is preferable because it is possible to obtain a building member having a work hardening rate in the vicinity of the cut surface of 110% or less for all of the cut surfaces. Further, the aspect [f] is preferable because the outer periphery and the opening of the aluminum plate-like structure can be collectively formed by laser cutting from the viewpoint of shortening the process.

In the cutting process, it is preferable to obtain an aluminum plate-like structure having a substantially quadrangular shape having a side of 200 mm or more and 600 mm or less or a substantially circular shape having a diameter of 200 mm or more and 600 mm or less and an opening having a diameter of 30 mm or more and 200 mm or less. If it is within the above dimensions, it is preferable because the processing difficulty with a general laser cutting machine is low and the handleability of the obtained aluminum plate-like structure is also good.

In the cutting process, it is preferable to obtain two or more aluminum plate-like structures from one aluminum rolled plate from the viewpoint of shortening the process.

Further, since laser cutting has higher processing accuracy than press working, it is possible to obtain an aluminum plate-like structure having high dimensional accuracy.

(3) Annealing Step The method for manufacturing a building member according to the embodiment of the present invention may include an annealing step of annealing an aluminum rolled plate or an aluminum plate-like structure. The annealing step may be applied to an aluminum rolled plate before the cutting step, or may be applied to an aluminum plate-like structure obtained by cutting an unannealed aluminum rolled plate in the cutting step. By the annealing step, the aluminum plate-like structure can be used as a tempering material.
By setting the annealing temperature to 300 ° C. or higher, an aluminum plate-like structure having more excellent flexibility can be obtained. On the other hand, by setting the temperature to 600 ° C. or lower, it is possible to suppress sticking between rolled aluminum plates or between aluminum plate-like structures during annealing, and a building member having good appearance quality can be obtained. Therefore, the annealing temperature is preferably 300 ° C. or higher, preferably 600 ° C. or lower.
Further, by setting the annealing time to 1 hour or more, a plate-like structure for repair drainage drain having more excellent flexibility can be obtained. Even if the annealing time is lengthened, there is no problem in characteristics, but from the viewpoint of cost, up to about 24 hours is sufficient. Therefore, the annealing time is preferably 1 hour or more, more preferably 3 hours or more, preferably 24 hours or less, and more preferably 12 hours or less.

4. Method for Manufacturing Repaired Drainage Drain The method for manufacturing the repaired drainage drain according to the embodiment of the present invention is one aspect of the method for manufacturing a building member according to the embodiment of the present invention. A hollow tube fixing step of fixing one end of the hollow tube so as to communicate is included.

When the hollow tube is made of resin or spirally wound metal or metal mesh as described above and coated with resin, for example, an adhesive or the like is used to cover one end of the hollow tube. It may be fixed to an aluminum plate-like structure.

When the hollow pipe is an aluminum hollow pipe as described above, welding, brazing, etc. can be mentioned as a method of joining (fixing) one end of the aluminum hollow pipe to the aluminum plate-like structure. .. The welding method is not particularly limited, and examples thereof include TIG welding, laser welding, MIG welding, and arc welding. Laser welding is preferable from the viewpoint of increasing the joint strength of the welded portion. Further, at the time of welding, a filler material having an appropriate composition may be used, if necessary.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to the Examples.

High-purity aluminum (4N-Al) having a purity of 99.99% by mass was prepared by the segregation method. High-purity aluminum (5N-Al, 6N-Al) having a purity of 99.999% by mass or more was prepared by a three-layer electrolysis method. The total content of Fe, Si and Cu of the high-purity aluminum measured by the solid-state luminescence analysis method is 0.01% by mass (4N-Al), 0.001% by mass (5N-Al), 0.0001% by mass. % (6N-Al), and the total content of other impurity elements (Ti, Mn, Mg, Ga, Ni, V, Zn, Cr, B, Zr) is 0.006% by mass (4N-Al). ), 0.0008 mass% (5N-Al), 0.0003 mass% (6N-Al).
A rolled material made of the above high-purity aluminum was prepared, and the rolled material was rolled from a thickness of 20 mm to room temperature to obtain an aluminum rolled plate having a thickness of 0.8 mm. The rolled aluminum plate is annealed at 430 ° C. for 6 hours, and then laser-cut to have a substantially circular opening with a diameter of 10 mm in the center of the aluminum plate-like structures A to C (length 60 mm ×) of Examples 1 to 3. Width 60 mm × plate thickness 0.8 mm) was obtained.
Further, in the same manner as described above, an aluminum rolled plate made of industrial pure aluminum (purity 99.5% by mass) was obtained. The rolled aluminum plate is annealed at 430 ° C. for 6 hours, and then laser-cut to have a substantially circular opening with a diameter of 10 mm in the center, and the aluminum plate-like structure D (length 60 mm × width 60 mm × plate) of Comparative Example 1 A thickness of 0.8 mm) was obtained.
Further, in the same manner as described above, rolled aluminum plates made of industrial pure aluminum (purity 99.5% by mass) and high-purity aluminum (4N-Al, 5N-Al, 6N-Al) were obtained. An aluminum plate of Comparative Examples 2 to 5 having a substantially circular opening with a diameter of 10 mm in the center by annealing the rolled aluminum plate at 430 ° C. for 6 hours, and then forming an opening by outer peripheral processing and press processing by shear cutting. Shaped structures E to H (length 60 mm × width 60 mm × plate thickness 0.8 mm) were obtained.

Aluminum plate structures A to H were randomly selected at a position 0.1 mm from the cut end of the opening with a test force of 0.01 kgf (= 0.0981N) according to JIS Z 2244: 2009. The Vickers hardness HV0.01 at four locations on the surface was measured, and the average value of the Vickers hardness HV0.01 at four locations was determined. In the measurement of Vickers hardness HV0.01, the Vickers hardness HV0.01 is calculated from the diagonal length of the indentation remaining on the surface after pushing the diamond indenter of a regular square pyramid into the surface of the aluminum plate-like structure and releasing the test force. did. The same measurement was performed at each position of 0.3 mm, 0.5 mm, 1.0 mm, 3.0 mm, 5.0 mm and 10.0 mm from the cut end, and the average Vickers hardness HV 0.01 was performed at each position. The value was calculated. Table 1 shows the average value of the Vickers hardness HV 0.01 at each position.
The work hardening rate was determined by dividing the average value of the Vickers hardness HV 0.01 at the position of 0.1 mm to 5.0 mm by the average value of the Vickers hardness HV 0.01 at the position of 10.0 mm. Table 2 shows the work hardening rate.

As can be seen from Table 1, the aluminum plate-like structures A to C and F to H of 4N-Al to 6N-Al of Examples 1 to 3 and Comparative Examples 3 to 5 have a distance of 0 from the cut end. The average value of the Vickers hardness HV0.01 at a position of .5 mm or more was less than 25.0, and the flexibility was high. The aluminum plate-like structures D and E having a purity of 99.5% by mass in Comparative Examples 1 and 2 have high strength due to the high content of impurity elements, and are at a position where the distance from the cut end is 0.5 mm or more. The average value of the Vickers hardness HV 0.01 was 25.0 or more, and the flexibility was low.
As can be seen from Table 2, the aluminum plate-like structures A to D of Examples 1 to 3 and Comparative Example 1 produced by laser cutting are cut portions located within 0.3 mm from the cut end of the opening. The work hardening rate in the vicinity was as low as 110% or less. On the other hand, the aluminum plate-like structures E to H of Comparative Examples 2 to 5 produced by press working have a work hardening rate of 110% in the vicinity of the cut portion located within 0.3 mm from the cut end of the opening. It was overpriced.

In order to evaluate the breaking strength in the vicinity of the cut end, the Eriksen value was obtained according to JIS Z 2247: 2006 "Eriksen test method". In the Ericssen test, a spherical jig having a diameter larger than the diameter of the opening of the aluminum plate-like structure is placed so as to be in contact with the entire circumference of the cut end of the opening, and the spherical jig is pushed toward the opening. The distance (Ericsen value) that the spherical jig moved before the crack was generated at the end of the cutting process was measured. Therefore, the higher the Eriksen value, the higher the breaking strength. The Eriksen values are shown in Table 3.

As can be seen from Table 3, the high-purity aluminum plate-like structures A to C of Examples 1 to 3 produced by laser cutting are the high-purity aluminum plate-like structures of Comparative Examples 3 to 5 produced by press working. Compared with the bodies F to H, the Elixin value was high and the breaking strength was excellent. The industrial pure aluminum aluminum plate-like structures D to E of Comparative Examples 1 and 2 had high strength due to the high content of impurity elements, and no cracks were observed.

In addition, the dimensional accuracy of the aluminum plate-like structure obtained by laser cutting and press working was evaluated as follows.

In both laser cutting and press working, the following four target dimensions were set in order to obtain a quadrangular aluminum plate-like structure centered on the opening. The "shortest straight line distance between the side and the opening" is an index indicating how accurately the opening is located at the center of the aluminum plate-like structure.
(Target dimension 1)
Outer circumference: 300.00 mm on a side
Opening: 52.50 mm in diameter
Shortest straight line distance between side and opening: 123.75mm
(Target size 2)
Outer circumference: 400.00 mm on a side
Opening: 52.50 mm in diameter
The shortest linear distance between the side and the opening: 173.75 mm
(Target size 3)
Outer circumference: 300.00 mm on a side
Opening: 45.00 mm in diameter
The shortest linear distance between the side and the opening: 127.50 mm
(Target dimension 4)
Outer circumference: 400.00 mm on a side
Opening: 45.00 mm in diameter
The shortest linear distance between the side and the opening: 177.50 mm

After obtaining an aluminum rolled plate in the same manner as in Example 2, the aluminum plate-like structure I of Example 4 has a target size of 1 and the aluminum plate-like structure J of Example 5 has a target size of 2 by laser cutting. Obtained.
Further, after obtaining an aluminum rolled plate in the same manner as in Comparative Example 4, the aluminum plate-like structure K of Comparative Example 6 and the target size 4 have the target size 3 by forming an opening by shear cutting and pressing. The aluminum plate-like structure L of Comparative Example 7 was obtained.

FIG. 1 is a schematic plan view of the aluminum plate-like structure 10.
In FIG. 1, x is the length of the side of the outer peripheral portion 12, y is the diameter of the opening 14, and z is the shortest straight line distance from the side of the outer peripheral portion 12 to the opening 14. To evaluate the dimensional accuracy of the aluminum plate-like structure 10 by comparing the absolute value of the difference between the measured lengths of x, y and z and the target dimension (hereinafter, may be referred to as “deviation amount”). Can be done.

For the aluminum plate-shaped structures I to L, x and z at four points and y at two points were measured, respectively, and the average values of x, y and z were obtained. The amount of deviation between the average value of x, y and z and the target dimension was obtained and the dimensional accuracy was evaluated. Table 4 shows the average values of x, y and z, and the amount of deviation.

As can be seen from the results in Table 4, the aluminum plate-like structures I and J of Examples 4 and 5 produced by laser cutting are the same as the aluminum plate-like structures K and L of Comparative Examples 6 and 7 produced by press working. In comparison, the amount of deviation was small and the dimensional accuracy was high.

10: Aluminum plate-shaped structure 12: Outer circumference 14: Opening 20: Repair drainage drain 22: Plate-shaped structure 24: Hollow pipe 30: Drainage port 32: Drainage drain base 34: Drainage drain base Flat part 36: Drainage Drain base recess 38: Existing drain pipe

Claims (18)

A building member including an aluminum plate-like structure.
The aluminum plate-like structure has a purity of 99.99% by mass or more and has a purity of 99.99% by mass or more.
The aluminum plate-like structure has a cut surface and a surface adjacent to the cut surface.
A building member having a work hardening rate of 110% or less in the vicinity of the cut surface represented by the following equation (1) for at least a part of the cut surface.

(Mean value of four Vickers hardnesses randomly selected within 0.3 mm from the boundary between the surface and the cut surface) ÷ (Randomly selected at a position 10.0 mm from the boundary) Average value of Vickers hardness at 4 selected locations on the surface) × 100 (1) The building member according to claim 1, wherein the purity is 99.997% by mass or more. The building member according to claim 1 or 2, wherein the aluminum plate-like structure is a tempering material. The building member according to any one of claims 1 to 3, wherein the work hardening rate is 110% or less for all of the cut surfaces. The building member according to any one of claims 1 to 4, wherein at least a part of the cut surface defines an opening. The building according to claim 5, wherein the aluminum plate-like structure is a substantially quadrangular shape having a side of 200 mm or more and 600 mm or less or a substantially circular shape having a diameter of 200 mm or more and 600 mm or less, and the opening is a substantially circular shape having a diameter of 30 mm or more and 200 mm or less. Element. The repair drainage drain, which is a building member according to claim 5 or 6, in which one end of a hollow pipe is fixed to the aluminum plate-like structure so as to communicate fluid with the opening. Drain. The repair drainage drain according to claim 7, wherein one end of the aluminum hollow pipe, which is the hollow pipe, is welded to the aluminum plate-like structure. A method for manufacturing building members including an aluminum plate-like structure.
The process of preparing an aluminum rolled plate having a purity of 99.99% by mass or more, and
A method for manufacturing a building member, which comprises a cutting process of cutting at least a part of the rolled aluminum plate by laser cutting to obtain the aluminum plate-like structure. The method for manufacturing a building member according to claim 9, wherein the purity is 99.997% by mass or more. The method for manufacturing a building member according to claim 9 or 10, further comprising an annealing step of holding the rolled aluminum plate or the aluminum plate-like structure at a temperature of 300 ° C. or higher and 600 ° C. or lower for 1 hour or more and 24 hours or less. The method for manufacturing a building member according to any one of claims 9 to 11, wherein in the cutting process, all cutting of the rolled aluminum plate is performed by laser cutting. The method for manufacturing a building member according to any one of claims 9 to 12, wherein in the cutting process, two or more aluminum plate-like structures are obtained from one rolled aluminum plate. The method for manufacturing a building member according to any one of claims 9 to 13, wherein an opening is provided in the aluminum plate-like structure by laser cutting in the cutting process. A claim for obtaining the aluminum plate-like structure having a substantially quadrangular shape having a side of 200 mm or more and 600 mm or less or a substantially circular shape having a diameter of 200 mm or more and 600 mm or less and an opening having a diameter of 30 mm or more and 200 mm or less in the cutting process. Item 14. The method for manufacturing a building member according to Item 14. The method for manufacturing a repair drainage drain, which is a building member according to any one of claims 9 to 15, wherein one of the hollow pipes communicates fluidly with the opening in the aluminum plate-like structure. A method for manufacturing a repair drainage drain, which includes a hollow pipe fixing step for fixing the end portion. In the hollow tube fixing step, an aluminum hollow tube is used as the hollow tube, and the aluminum plate-like structure and one end of the aluminum hollow tube are welded to form the aluminum plate-like structure. The method for manufacturing a repair drainage drain according to claim 16, wherein one end of the aluminum hollow pipe is fixed to the aluminum hollow pipe. The method for manufacturing a repair drainage drain according to claim 17, wherein the welding is laser welding.

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