RU2388583C2 - Method to produce clad material and device to this end - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention can be used to prepare clad material, in particular for vehicles heat exchangers. In compliance with proposed method, to prepare substrate material, ingot is produced by melting and casting. To prepare surface material, ingot is produced by melting and casting the metal that differs from that of substrate material. Surface material ingot is arranged to preset position on one or both sides of substrate material ingot to produce multi-layer material. Cladding is effected by hot rolling. Surface material can produced by cutting made ingot to ensure certain thickness. Surface material can be composed of multiple layers.

EFFECT: higher process efficiency due to easier control over surface state and clad material layer, good adhesion between clad material layers.

28 cl, 14 dwg

Description

Technical field

The present invention relates to a method for manufacturing a clad material used in vehicle heat exchangers or the like, and to a device for manufacturing it.

State of the art

Basically, as the clad materials in the manufacture of heat exchangers used in intercoolers, oil coolers, radiators, condensers, evaporators and radiators of the vehicle interior heater or the like, surface materials applied by rolling are used. For example, Patent Document 1 describes a well-known method for manufacturing a typical clad material for heat exchangers, comprising the following steps: first, the aluminum alloy for the base material and the aluminum alloy for the surface material are melted and continuously cast (consumable anode and filler in Patent Document 1), then if necessary, heat treatment is carried out in order to homogenize. Accordingly, in order to obtain a predetermined thickness, the aluminum alloy ingots used as the surface material are hot rolled (see steps S11a and S11b in FIG. 14, note that heat treatment to homogenize is indicated as “homogenization heating”). After that, the aluminum alloy ingot used as the base material and the hot-rolled plates for the surface material (element for the surface material) are superposed (see step S12 in FIG. 14) and then hot rolled (clad by hot rolling: see step S13 in FIG. 14) in accordance with a conventional method to obtain clad material.

Patent Document 1: Publication of Unexamined Japanese Patent Application No. 2005-232507 (paragraphs 0037, 0039 and 0040).

SUMMARY OF THE INVENTION

Problems Solved by the Invention

However, a typical clad material made using the methods described above has the following disadvantages:

(1) Since a hot rolled plate is used for the surface material, the number of hot rolling operations during the manufacture of clad material increases, which leads to a decrease in production efficiency.

(2) The surface layer is removed from the ingot for the base material using a milling machine or the like, as a result of which its surfaces acquire properties corresponding to this type of processing. On the other hand, the surfaces of the hot-rolled plate used for the surface material are formed as a result of rolling, in which specific lines oriented on the rolling direction appear on them. Accordingly, there is a difference in the state of the surface between the ingot for the base material and the hot-rolled plate for the surface material, so there is a problem of possible deterioration of the adhesion between the base material and the surface material when they are superposed and clad by hot rolling. To improve the adhesion between the base material and the surface material, cladding requires rolling in several passes with the application of a small pressure, which leads to a decrease in production efficiency.

(3) When using hot-rolled material as an element for a surface material, the surface condition and flatness (in particular, flatness in the length direction) of the hot-rolled element is controlled only by means of hot-rolling rolls, while on the surface of the hot-rolled plate due to such rolling an oxide film occurs, and therefore it is difficult to control the surface condition and flatness of such a rolled plate, which leads to such a deterioration of adhesion between the main material series and surface material that cannot be prevented.

(4) The deterioration of adhesion between the base material and the surface material leads to the following attendant problems: the production efficiency of the clad elements is reduced; a predetermined clad speed cannot be provided; quality decreases with the occurrence of such deviations as the formation of captivity; and due to poor adhesion, corrosion resistance is reduced.

The present invention has been made taking into account the above problems and its main objective is to propose a method for manufacturing clad material and a device for its manufacture, using which high production efficiency is ensured, it is easy to control the surface condition and flatness of the element for the surface material and adhesion is unlikely to deteriorate.

Problem Solving Tools

In order to solve the above problems, according to a first aspect of the present invention, there is provided a method for manufacturing a clad material consisting of a base material and one or more surface materials superimposed on one or both sides of said base material, comprising the steps of: preparing a clad material, for which respectively at the stage of preparing the base material, an ingot is prepared for the base material made by melting and casting the metal used in as the main material, and at the stage of preparing the surface material, an ingot for the surface material is prepared by melting and casting the metal used as the surface material, which differs from the main material in the content of components; overlap is performed, for which the ingot for the surface material is placed as the surface material in a predetermined position on one or both sides of the ingot for the base material in order to produce a multilayer material; and perform cladding by hot rolling, for which a laminated material is rolled to obtain a clad material.

When the clad material is made using such operations, hot rolling in the manufacture of an element for a surface material is not necessary, since an ingot for the surface material is used as an element for the surface material (surface material). Thus, it is possible to reduce the number of hot rolling operations, and it is possible to reduce the complexity of the process steps, as well as to easily control the surface condition and flatness of the clad material compared to the conventional method for manufacturing the clad material, in which hot rolling is performed in the manufacture of the surface material. In addition to this, since the ingot for the surface material is superimposed on the ingot for the base material, the surface conditions of the two ingots are identical, which leads to improved adhesion. Moreover, in connection with improved adhesion, rolling in several passes is not required at the cladding stage by hot rolling.

Preferably, in the step of preparing the surface material, at least one of the surface materials is made in a cutting step in which the ingot for the surface material made by melting and casting is cut to obtain a predetermined thickness.

When the clad material is made using such operations, since cut surface material is used as the surface material, it is not necessary to reduce the thickness of the surface material by hot rolling as in the case of conventional clad material, therefore, the number of hot rolling operations can be reduced and labor costs can be reduced by the implementation of the technological stages, as well as with ease to control the surface condition and flatness of the clad material according to knowledge of the usual way of making clad material.

In a preferred case, an ingot for a surface material made by melting and casting is further subjected to heat treatment to homogenize before the cutting step. When the clad material is made using such operations, internal stresses in the ingot for the surface material are eliminated, which leads to improved flatness of the cut surface material and improved adhesion between the base material and the surface material.

In the preferred case, at the stage of cutting the ingot for the surface material is cut parallel to the mounting surface of the ingot, which is placed horizontally. When the clad material is made using such operations, the influence of the weight of the cut piece or geometry distortion is minimized (for example, by the force arising from the fall of the cut piece), therefore, the flatness of the cut surface material is improved, which leads to improved adhesion between the base material and the surface material.

In the preferred case, at the stage of preparation of the base material, the manufactured ingot for the base material is subjected to at least one of the following: cutting and heat treatment for the purpose of homogenization. When the clad material is made using such operations, the surface condition and flatness of the ingot for the base material are improved, which leads to improved adhesion between the base material and the surface material.

In a preferred case, at the stage of preparing the surface material, the manufactured surface material is subjected to at least one of the following: cutting and heat treatment to homogenize. When the clad material is made using such operations, the surface condition and flatness of the surface material are improved, which leads to improved adhesion between the base material and the surface material.

Preferably, at least one of the surface materials has a flatness of at least 1 mm per 1 m in the length direction. When the clad material is made using such operations, it is possible to further improve the flatness of the surface material, maintaining it at a level no worse than a predetermined value, which leads to improved adhesion between the base material and the surface material.

Preferably, at least one of the surface materials has an arithmetic mean value (Ra) of the surface roughness in the range from 0.05 to 1.0 μm. When the clad material is fabricated using such operations, it is unlikely that a gap will occur between the base material and each of the surface materials, resulting in even greater grip improvement.

Preferably, the thickness of the ingot for the base material is in the range of 200 to 700 mm, and the thickness of the surface material is in the range of 3 to 200 mm. When the clad material is made using such operations, it is possible to appropriately adjust the clad speed by setting the thickness of the ingot for the base material and the laminated plate for the surface material in certain ranges.

Preferably, the metal used as the base material and the metal used as the surface material are aluminum or aluminum alloys. When the clad material is manufactured using such operations, due to the fact that the metal used as the base material and the metal used as the surface material are aluminum or aluminum alloys, machinability at each stage is improved, adhesion between the base material is improved. and surface material, and cladding speed can be suitably adjusted.

Preferably, the surface material consists of a plurality of layers, and at least one of the layers of the surface material is made using the step of preparing the surface material.

In the preferred case, after the cutting step, the surface of the chopped surface material having a predetermined thickness is further subjected to a surface finish. When a surface material is manufactured using such operations, the surface condition and flatness of the surface material are improved, which leads to improved adhesion between the base material and the surface material. Moreover, pressure connectivity is improved, which leads to a reduction in the number of passes for pressure connection.

In the preferred case, the surface finish is performed using one or more methods selected from the following: cutting, grinding and polishing. When a surface material is manufactured using such operations, the surface condition and flatness of the surface material are improved, which leads to improved adhesion between the base material and the surface material. Moreover, pressure connectivity is improved, which leads to a reduction in the number of passes for pressure connection.

In a preferred case, the method for manufacturing the clad material further includes a cold rolling step, wherein cold rolling is performed after the hot rolling step.

In a preferred case, at least one layer of the surface material is a filler; the filler is positioned so that it is on the outer surface of the clad material; and at least one layer of surface material, including a filler, is made in the preparation step of the surface material.

In a preferred case, the surface material comprises a filler and an intermediate material sandwiched between the base material and the filler; the filler is positioned so that it is on the outer surface of the clad material; and at least one layer of surface material, including a filler and an intermediate material, is made in the preparation step of the surface material.

Preferably, the clad material consists of a base material and surface materials superimposed on both sides of the base material; at least one layer of surface materials on one side of the base material is a filler, and at least one layer of surface materials on the other side of the base material is a consumable material, and the filler and consumable material are positioned so that they are on an outer surface on each side of the base material; and at least one layer of surface materials, including a filler, and at least one layer of surface materials, including a consumable material, are made at the stage of preparation of the surface material, respectively.

Preferably, the clad material consists of a base material and surface materials superimposed on both sides of the base material; the surface material on one side of the base material contains a filler and an intermediate material that is sandwiched between the base material and the filler, and at least one layer of surface materials on the other side of the base material is a consumable material, and the filler and consumable material are positioned in such a way so that they are on the outer surface on each side of the base material; and at least one layer of surface materials, including filler and intermediate material, and at least one layer of surface materials, including consumable material, are made in the preparation step of the surface material, respectively.

In order to solve the above problems, according to a second aspect of the present invention, there is provided a device for manufacturing a surface material, which is a device for manufacturing a surface material used in a clad material consisting of a base material and one or more layers of surface materials superimposed on one or more sides of the main material, and this device contains a casting tool, a melting metal, used as a surface material that differs tsya from the basic material of the component content, and the surface of pourable material; ingot cutting means, a cutting ingot for a surface material cast by a casting means; and transportation means transporting an ingot for a surface material between said means, wherein the ingot cutting means is a cutting means cutting an ingot for a surface material to obtain a predetermined thickness.

When using such a device for manufacturing a surface material, an ingot for a surface material is cast using a casting means and cut into a predetermined thickness using a cutting means, which is an ingot cutting means. In this case, the ingot for the surface material is transported between the aforementioned means by means of a transportation means.

In a preferred case, the cutting means is a means slicing an ingot for a surface material arranged horizontally parallel to the mounting surface of said ingot.

When using such a device for manufacturing a surface material, the ingot for the surface material is cast using a casting means and cut to obtain a predetermined thickness parallel to the mounting surface of the said ingot placed horizontally using a cutting means, which is an ingot cutting means. In this case, the ingot for the surface material is transported between the aforementioned means by means of a transportation means.

In a preferred case, the apparatus for manufacturing a surface material further includes a surface finisher that finishes the surface of the surface material having a predetermined thickness that is cut by means of cutting ingots.

When using such a device for manufacturing a surface material, an ingot for a surface material is cast using a casting means and cut into a predetermined thickness using a cutting means, which is an ingot cutting means. In this case, a surface material having a predetermined thickness that is cut by means of cutting ingots is subjected to a surface finish using means of surface finishing, and an ingot for a surface material or surface material is transported between said means by means of a conveyance.

In a preferred case, the apparatus for manufacturing a surface material is further provided with a heat treatment means for homogenizing, performing a heat treatment for the purpose of homogenizing an ingot for a surface material cast using a casting means. When using such a device for manufacturing a surface material, an ingot for a surface material cast by means of a casting is subjected to heat treatment for the purpose of homogenization by means of a heat treatment means for the purpose of homogenization.

In a preferred case, the ingot cutting means includes a cutting means and a cutting means cutting off the front and back parts of the ingot for the surface material to obtain a predetermined thickness. When using such a device for manufacturing a surface material, the ingot for the surface material has a predetermined length due to cutting off the front and back parts thereof using cutting means, and is cut to obtain a predetermined thickness using the cutting means.

In order to solve the above problems, according to a third aspect of the present invention, there is provided a surface material for a clad material, which is a surface material for a clad material, which is used in a method for manufacturing a clad material according to the first aspect of the present invention, characterized in that this surface material for the clad material from one or more layers; each layer of surface material is made of metal that differs from the base material in the content of components; and at least one layer of the surface material has a cast microstructure when this material is applied on one or more sides of the base material.

When the surface material has such a structure, it is easy to control the surface condition and flatness, since at least one layer of this material has a cast microstructure. As a result, when the base material and the surface material are superimposed on each other, a gap is unlikely to occur between the base material and the surface material, or between the surface materials, which leads to improved adhesion and bonding under pressure. In particular, since the surfaces of the base material and the surface material that overlap each other are identical in crystal structure, the adhesion between them can be improved. In addition, due to the improved adhesion, it is possible to improve the pressure connection in the cladding step by hot rolling both materials and to reduce the number of passes for pressure connection, which leads to an increase in output and an increase in production efficiency. In addition to this, it is not necessary to produce surface material by hot rolling as in the case of conventional clad material, therefore, it is possible to reduce the number of hot rolling operations and to reduce labor costs when performing technological steps. Moreover, since hot rolling is not performed, the thickness of the oxide film is reduced, which leads to improved adhesion between the base material and the surface material. As a result, the corrosion resistance of the clad material can be improved.

Preferably, the surface material consists of a 1000 series aluminum alloy complying with JIS (Japan Industrial Standard) or various aluminum alloys not specified in the JIS standard. Examples of aluminum alloys not listed in the JIS standard include: Al-Mn system, Al-Mn-Cu system, Al-Mn-Si system, Al-Mn-Cu-Si system, Al-Mn-Mg system, Al-Mn-Mg-Cu, Al-Mn-Mg-Si system, Al-Mn-Mg-Cu-Si system, Al-Zn system, Al-Mg-Zn system, Al-Si-Zn system, Al- Si-Mn-Zn, Al-Si-Mg-Zn system, Al-Si-Mn-Mg-Zn system, Al-Mn-Zn system, Al-Mn-Si-Zn system, Al-3-10 Si alloy and Al-3-10 alloy Si-Zn. Such aluminum alloys may additionally contain 0.05% -0.3% Sc, 0.05% -0.3% Zr, 0.05% -0.3% Ti or 0.001% -0.1% Sr. When the surface material has such a structure, its workability can be improved, therefore, the cladding speed can be appropriately controlled in the manufacture of the clad material, and the adhesion between the base material and the surface material can be further improved when they are superimposed.

Preferably, at least one layer of the surface material has a cast microstructure, and its thickness is in the range from 10 to 250 mm. When the surface material has such a structure, it is possible to appropriately control the cladding speed in the manufacture of the clad material by setting the thickness of the surface material having a cast microstructure in a certain range.

According to a fourth aspect of the present invention, there is provided a method of manufacturing a clad material consisting of a base material and two or more surface materials superimposed on one another on one or both sides of said base material, comprising the steps of: preparing a base material, for which an ingot for the base material is made by melting and casting the metal used as the main material; preparing a surface material, for which an ingot for a surface material is made by melting and casting a metal used as a surface material, which differs from the metal used as the base material, in terms of the content of components; preparing a rolled plate for a surface material, for which a rolled plate for a surface material is made by subsequent hot rolling of an ingot for a surface material; overlay is performed, for which a multilayer material is made by placing an ingot for a surface material and a laminated plate for a surface material as surface materials in a predetermined position on one or both sides of the ingot for the base material; and perform cladding by hot rolling, for which a laminated material is rolled to obtain a clad material.

When the clad material is made using such operations, hot rolling is not required in the manufacture of the surface material element, since an ingot for the surface material is used as one of several elements for the surface material (surface materials). Thus, it is possible to reduce the number of hot rolling operations in the manufacture of several elements for a surface material in comparison with the conventional method for manufacturing clad material, which makes it easy to control the surface condition and flatness of the clad material, as well as to reduce labor costs when performing technological steps. In addition to this, since the ingot for the surface material is superimposed on the ingot for the base material, the surface conditions of the two ingots are identical, which leads to improved adhesion. Moreover, in connection with improved adhesion, rolling in several passes is not required at the cladding stage by hot rolling. In addition, due to the fact that a hot-rolled plate is used as an element for a surface material, a surface material and a device for manufacturing this material can be used as used in a conventional method for manufacturing a clad material.

Preferably, the thicknesses of the ingot for the surface material and the hot rolled plate for the surface material are in the range of 3 to 200 mm.

Effect of the invention

According to the method for manufacturing the clad material according to the first aspect of the present invention, due to the reduction in the number of hot rolling operations in the manufacture of the clad material, it is easy to control the surface condition and flatness of the element for the surface material (surface material), and also provide high production efficiency, resulting in clad material can be made for which adhesion between the main mother is unlikely scarlet and surface material. In addition to this, since there is no need for rolling in several passes, it is possible to produce clad material with high production efficiency.

According to a device for manufacturing a surface material according to the second aspect of the present invention, the surface material is made by cutting by means of a cutting means, therefore, it is not necessary to reduce the thickness of this material by hot rolling, as in the case of conventional clad material, as a result of which labor costs can be reduced when performing technological steps, if not used hot rolling in the manufacture of surface material. In addition, it is possible to produce clad material in which surface condition and flatness can be easily controlled, the thickness of the oxide film can be reduced, the adhesion is less likely to occur when the surface material is applied to the base material, and there is high corrosion resistance.

As regards the surface material for manufacturing the clad material according to the third aspect of the present invention, it can be noted that since at least one layer of the surface material has a cast microstructure, adhesion is unlikely to occur when the surface material is applied to the base material, whereby it can be made clad material with excellent grip and ensure high production efficiency. In addition, since it is not necessary to produce the surface material by hot rolling, as in the case of conventional clad material, it is possible to obtain a clad material from which surface condition and flatness can be easily controlled, the thickness of the oxide film can be reduced, and adhesion is less likely to deteriorate between the base material and the surface material; and there is high corrosion resistance, and it is also possible to reduce the number of hot rolling operations in comparison with the conventional method of manufacturing clad material, as a result of which it is possible to reduce labor costs when performing technological steps.

According to a method for manufacturing a clad material according to the fourth aspect of the present invention, since a hot-rolled plate for a surface material is used as one of the elements for the surface material (surface materials), a clad material can be obtained from which the surface condition and flatness can be easily controlled. the probability of deterioration of adhesion between the main material and the surface material, as well as the high efficiency of its production . In addition, it is possible to produce clad material with low cost.

Brief Description of the Drawings

1A-1C are diagrams illustrating a flowchart of methods for manufacturing a clad material according to a first embodiment of the present invention.

2 is a diagram illustrating a flowchart in a method for manufacturing a clad material according to a second embodiment of the present invention.

Figa-Fig.3D are cross sections illustrating the structure of the clad material according to the present invention.

4 is a diagram illustrating in general terms a step for preparing a base material or a step for preparing a surface material.

5 is a diagram illustrating in general terms a step for preparing a base material or a step for preparing a surface material.

6 is a diagram illustrating in general terms a step of preparing a base material or a step of preparing a surface material.

7A and 7B are diagrams illustrating in general terms a method of cutting an ingot.

8A is a diagram illustrating the structure of a laminate when applied.

8B is a diagram illustrating in general terms a hot rolling cladding step.

9A and 9B are diagrams illustrating flowcharts in methods for manufacturing a clad material for heat exchangers according to a third embodiment of the present invention.

10A-10F are cross-sectional views illustrating the structure of a clad material for use in heat exchangers according to a third embodiment of the present invention.

11 is a perspective view of a clad material according to the present invention.

12 is a diagram illustrating an apparatus for manufacturing a surface material according to the present invention.

13 is a diagram illustrating another embodiment of a device for manufacturing a surface material according to the present invention.

14 is a diagram illustrating a flowchart in a conventional method for manufacturing a clad material.

Reference designations:

S1a - the stage of preparation of the main material;

S1b is the step of preparing the surface material;

S1c is the step of rolling the surface material;

S2a and S2b are the overlay step;

S3 - clad hot rolling;

1a, 1b, 1c and 1d — clad material;

2 - the main material;

3 and 4 - surface material;

17, 25, 34 and 35 - ingot (ingot for the main material, ingot for the surface material).

Preferred Embodiments

Next, a method of manufacturing a clad material corresponding to the present invention will be described in detail with reference to the accompanying drawings. Of the referenced drawings, FIGS. 1A, 1B, 1C, and FIG. 2 are diagrams illustrating a flowchart in methods for manufacturing a clad material; Figa-Fig 3D are cross sections illustrating the structure of the clad material; 4 to 7 are diagrams illustrating in general terms a step for preparing a base material or a step for preparing a surface material; Figa is a diagram illustrating the structure of the multilayer material when applied; and FIG. 8B is a diagram generally illustrating a hot rolling cladding step.

A method of manufacturing a clad material in accordance with the present invention can be used in any cladding as long as the clad material consists of a base material and one or more surface materials that are applied on one or both sides of the base material, as a result of which such clad material. In this case, the number of layers of the clad material is not limited to anything, and this method can preferably be used for a two-layer clad material 1 a, in which one side of the base material 2 is coated with one surface material 3, as shown in FIG. 3A; a three-layer clad material 1b in which both sides of the base material 2 are respectively coated with two surface materials 3 and 3, as shown in FIG. 3B; a three-layer clad material 1c, in which one side of the base material 2 is coated with two surface materials 3 and 3, as shown in figs; and a three-layer clad material 1d in which both sides of the base material 2 are respectively coated with a surface material 3 and a conventional surface material 4 (a surface material made of a rolled plate), as shown in FIG. 3D; and so on. However, there is no need to say that the method can be advantageously applied to a clad material having even more layers, namely to a clad material containing four or more layers.

In the clad material according to the present invention, the metal used as the base material and the metal used as the surface material differ from each other in the content of the components. Metals differing in the content of components include metals of the same type, differing in the content of components, and metals of various types, differing in the content of components.

By metals of the same type, differing in the content of components, we mean metals in which the basis is metals of the same type, and the content of components is different. As regards metals such as clad material for heat exchangers, this category includes cases where the metal for the base material is an aluminum alloy of the Al-Mn 3000 series, while the metal for the surface material is an aluminum alloy of the Al-Mn 4000 series ( metal for filler as a surface material), aluminum alloy of the Al-Zn-Mn system of the 7000 series (metal for consumable material as a surface material) or pure aluminum of the 1000 series (metal for the intermediate material as a surface material). As an alternative to the metals of the same type, differing in the content of the components, there are cases when the main material is Al-0.5Si-0.5Cu-1.1Mn-0.4Mg, while the surface material is Al-0, 5Si-0.5Cu-1.1Mn, or the main material is an alloy of the 3000 series, such as Al-0.5Si-0.5Cu-1.1Mn, while the surface material is Al-0.5Si-0, 1Cu-1.1Mn or Al-0.5Si-0.1Cu-1.1Mn-2.5Zn. In addition to this, as the clad material for canned food in this category, the case also corresponds to the case when the metal for the main material is an aluminum alloy of the Al-Mn 3000 series or an aluminum alloy of the Al-Mq 5000 series, while the metal for the surface material is pure aluminum of the 1000 series. Further, as a product with a polished coating, this category also corresponds to the case when the metal for the main material is an aluminum alloy of the Al-Cu system of the 2000 series, while llom surface material is pure aluminum 1000 series.

Under the metals of a different type, differing in the content of the components, we mean metal materials in which the basis is metals of a different type. An example of such metallic materials is a metal containing a copper alloy or steel instead of an aluminum alloy. The content of the components in the metals mentioned above can be suitably adjusted according to the application of the clad material and the like.

The following describes in detail the options for a method of manufacturing a clad material of the present invention.

1. The first option

According to a first embodiment of the present invention, a method for manufacturing a clad material is a method for manufacturing a clad material consisting of a base material and one or more surface materials that are applied on one or both sides of the base material, and using this method, for example, clad materials 1a are made , 1b and 1c shown in figa - figs. As shown in FIGS. 1A to FIG. 1C, a method for manufacturing a clad material according to a first embodiment of the present invention includes the following steps: a step for preparing a clad material consisting of a step for preparing a base material S1a and a step for preparing a surface material S1b; overlay step S2a; and hot rolling clad step S3. Each of these steps will be described below.

Clad material preparation step

The step of preparing the clad material is the step of preparing the ingot for the base material made in step S1a of preparing the base material and the ingot for the surface material made in step S1b of preparing the surface material. In the preparation step of the clad material, either an ingot for the base material or an ingot for the surface material may be prepared first, or both steps S1a and S1b may be prepared in advance and performed simultaneously.

(1) Step for preparing base material S1a

In step S1a of preparing the base material, the metal used as the base material is melted and poured, whereby an ingot for the base material is manufactured. In this case, the metal used as the base material is a metal, the content of the components in which is indicated earlier. In the preferred case, the ingot is made using the semi-continuous casting method, which will be described later. However, the possible options are not limited to the method of semi-continuous casting and in the manufacture of, for example, clad material, in which the base material has a small thickness, you can apply the method of casting a flat billet (slab) of small thickness, a two-roll casting method or a method of cutting flat billets. In addition to this, the width and length of the ingot for the base material are not particularly limited; however, from the point of view of production efficiency, the width is preferably selected in the range from 1000 to 2500 mm, and the length is preferably selected in the range from 3000 to 10000 mm.

Semi-continuous casting method

In the semi-continuous casting method, the casting tool 10 shown in FIG. 4 is used, in which the molten metal M (in this case, the metal used as the main material) is poured from above into the water-cooled metal mold 11 with an open bottom, and the solidified metal is continuously removed from the bottom of this mold 11 to obtain an ingot 17 (in this case, an ingot for the base material) having a predetermined thickness T1. In this case, the molten metal M is fed into a water-cooled mold 11 using a reservoir 12, a nozzle 13, a float 14 and a meniscus 15. The molten metal M supplied to the water-cooled mold 11 hardens by contacting the inner wall of this mold, which is cooled by cooling water W, and becomes a hardened layer 16. The ingot 17 (ingot for the base material) can be produced continuously provided that cooling water W is supplied in the direct spray mode onto the surface of the hardened layer 16 of bottom area of the water-cooled mold 11.

In this case, the thickness T1 of the ingot for the base material is preferably in the range from 200 to 700 mm. If the thickness T1 is outside this range, the clad speed in the manufacture of the clad material may be unacceptable. In addition, if necessary and appropriately, before applying the ingot for the surface material (to be considered later) to the ingot for the base material, using at least one of the following can be performed using a grinding machine: processing associated with the removal of the surface layer (on figa and 1B is indicated as removal of the surface layer), in order to remove the crystallized substance and oxide formed on the surface of the ingot, and heat treatment to homogenize (on figa and 1B indicated as homogenization heating).

When processing associated with the removal of the surface layer, you can get the main material, the flatness of which is not worse than 1 mm per 1 m in the direction along the length, preferably not worse than 0.5 mm, with an appropriate assessment of flatness, and the surface roughness, expressed by the arithmetic mean value (Ra) is in the range from 0.05 to 1.5 microns, preferably from 0.1 to 0.7 microns. When flatness is outside the specified range, adhesion in the clad material may be impaired. If the surface roughness is below the lower limit of the specified range, clad material is difficult to process. If the surface roughness is above the upper limit of the specified range, adhesion in clad material may be impaired. When performing heat treatment for the purpose of homogenization, internal stresses in the ingot for the base material are eliminated, which leads to an improvement in the flatness of the base material. In this case, the temperature and the heat treatment period for the purpose of homogenization are not particularly limited; however, the treatment temperature is preferably selected in the range of 350 ° C. to 600 ° C., and the processing period is preferably selected in the range of 1 to 10 hours.

If the temperature of the heat treatment for homogenization is below 350 ° C, then the internal stresses are eliminated to a lesser extent, and the homogenization of the dissolved element, which is segregated during casting, is insufficient, as a result of which the effect of the heat treatment that is supposed to be performed will be small. On the other hand, if the temperature of heat treatment for the purpose of homogenization is higher than 600 ° C, the so-called burning occurs, in which part of the surface of the ingot dissolves, which is possibly the cause of defects on the surface of the clad material. If the treatment period is less than 1 hour, the elimination of internal stresses occurs to a lesser extent, and homogenization may be insufficient. In terms of production efficiency, the treatment period should preferably be 10 hours or less.

(2) Step for preparing surface material S1b

In the preparation step S1b of the surface material, the metal used as the surface material, which differs from the metal used as the base material, is melted and cast according to the content of the components, as a result of which one or more ingots for the surface material are made. The ingot for a surface material manufactured here is in some cases applied in a predetermined position on one or more sides of the base material as a surface material as it is, or in other cases, before being applied in a predetermined position on one or more sides of the base material as a surface material, an ingot for the surface material is pre-cut. In this case, the metal used as the surface material is a metal, the content of the components in which is indicated above. As for the casting method, it is preferable to cast a flat billet of small thickness or the twin roll casting method shown in FIGS. 5 and 6, respectively, and as for the cutting method, it is preferable to cut the flat billet shown in FIG. 7A and 7B. However, the casting method is not limited to the aforementioned method of casting a flat billet of small thickness or the two-roll casting method, and, for example, a semi-continuous casting method can be used. The width and length of the ingot for the surface material are not particularly limited; however, the width is preferably selected in the range of 1000 to 2500 mm, and the length is preferably selected in the range of 3000 to 10000 mm. Next will be considered a method of casting a flat billet of small thickness, a two-roll casting method and a method of cutting a flat billet.

The method of casting a flat workpiece of small thickness

When implementing the method of casting a flat billet of small thickness, the casting means 20 shown in FIG. 5 is used, in which the molten metal M (in this case, the metal used as a surface material) is poured sideways into a metal water-cooled mold 21 with an open side section, and hardened metal is continuously removed from the side portion of this mold 21 to produce an ingot 25 (in this case, an ingot for a surface material) having a predetermined thickness. In this case, the molten metal M is fed into the water-cooled mold 21 using a reservoir 22 connected to the mold through the refractory material 23. The molten metal M supplied to the water-cooled mold 21 hardens by contacting the inner wall of this mold, which is cooled by cooling water W, and becomes a hardened layer 26. The ingot 25 (ingot for a surface material) can be produced continuously provided that cooling water W is supplied in a direct spray mode to the hardened surface second layer 26 of a water cooled region of the lateral portion of the mold 21. In this case, the thickness T2 of the ingot surface material is preferably in the range of from 3 to 200 mm. If the thickness T2 is outside this range, the cladding speed in the manufacture of the clad material may be unacceptable. FIG. 5 shows a casting means 20 with a horizontal outlet, however, a vertical type casting means can be used in which the production takes place in a vertical direction.

Two roll casting method

As shown in FIG. 6, the twin-roll casting method is a casting method in which rolls opposed to each other are used as rotating molds, in this method casting means 30 including a pair of rolls 33 and 33, a lateral stop 31 are used mounted on the sides of this pair of rolls, and cooling means (not shown, however, is usually installed inside the rolls 33 and 33), which cools said rolls. The molten metal M (in this case, the metal used as the surface material) is fed into the gap between the outer peripheral surfaces of the rotating rolls 33 and 33 from the nozzle 32 located in the side of the side stop 31, and it is possible to continuously produce an ingot 34 (in this case ingot for surface material) having a predetermined thickness T3, provided that the rolls 33 and 33 are cooled using cooling means that is turned on immediately after the molten metal M is fed. In this case, t the thickness T3 of the ingot for the surface material is preferably in the range of 3 to 200 mm. If the thickness T3 is outside this range, the clad speed in the manufacture of clad material may be unacceptable. Figure 6 shows the tool 30 casting with a horizontal outlet, however, you can apply the means of casting a vertical type, in which the output occurs in the vertical direction. In addition, a tape or a drum may be used as a rotating mold in a casting means.

The method of cutting a flat workpiece

As shown in FIG. 7, when implementing the method of cutting a flat workpiece in step S1b of preparing a surface material, an ingot 17 (25) made using a semi-continuous casting method or a method for casting a flat workpiece of small thickness using a band-cutting machine (not shown) is cut. to produce an ingot 35 for a surface material having a predetermined thickness T4. An ingot 35 for a surface material made by cutting becomes a surface material. In this case, the thickness T4 of the ingot 35 for the surface material is preferably in the range of 3 to 200 mm. If the thickness T4 is outside this range, the clad speed in the manufacture of the clad material may be unacceptable. As shown in figv, the ingot 17 (25), which is placed horizontally, is preferably cut parallel to the mounting surface 35A of this ingot. Here, the mounting surface 35a means the surface of the ingot 17 (25) for the surface material in contact with the table of the cutting machine. With this cutting of the ingot, the influence of the weight of the cut piece or geometry distortion is minimized (for example, under the action of the force arising from the fall of the cut piece), so the flatness of the cut surface material can be improved. As for the cutting method, the ingot can be cut using a circular edging machine or using a laser or water.

As shown in FIG. 1C, the ingot 17 (25) made using the casting method described above can, if necessary and properly, be subjected to heat treatment to homogenize (shown in FIG. 1C as homogenizing heating) before cutting the ingot. When performing heat treatment for the purpose of homogenization, internal stresses in the ingot 17 (25) are eliminated and the flatness of the cut surface material is further improved. The temperature and the heat-treatment period for the purpose of homogenization are not particularly limited; however, the treatment temperature is preferably selected in the range of 350 ° C. to 600 ° C., and the processing period is preferably selected in the range of 1 to 10 hours.

If the temperature of the heat treatment for homogenization is below 350 ° C, then the internal stresses are eliminated to a lesser extent, and the homogenization of the dissolved element, which is segregated during casting, is insufficient, as a result of which the effect of the heat treatment that is supposed to be performed will be small. On the other hand, if the temperature of the heat treatment for homogenization is higher than 600 ° C, the so-called burning occurs, at which part of the surface of the ingot dissolves, which is possibly the cause of defects on the surface of the clad material used for the heat exchanger. If the treatment period is less than 1 hour, the elimination of internal stresses occurs to a lesser extent, and homogenization may be insufficient. In terms of production efficiency, the treatment period should preferably be 10 hours or less.

Before applying to the above-described ingot for the base material an ingot for a surface material using a grinding machine, at least one of the following can be applied if necessary and properly applied to this ingot for a surface material manufactured using the methods described above: associated with the removal of the surface layer (in FIGS. 1A, 1B and 1C is indicated as removal of the surface layer) in order to remove crystallized material and oxide formed on the surface of the layer itka, and heat treatment for the purpose of homogenization (on figa, 1B and 1C is indicated as homogenization heating). With this cutting and processing, associated with the removal of the surface layer, it is possible to obtain an ingot for a surface material, the flatness of which is not worse than 1 mm per 1 m in the length direction, preferably not worse than 0.5 mm, with an appropriate assessment of flatness and roughness surface, expressed by arithmetic mean value (Ra), is in the range from 0.05 to 1.5 microns, preferably from 0.1 to 1.0 microns. When flatness is outside the specified range, adhesion in the clad material may be impaired. If the surface roughness is below the lower limit of the specified range, clad material is difficult to process. If the surface roughness is above the upper limit of the specified range, adhesion in clad material may be impaired. When performing heat treatment for the purpose of homogenization, internal stresses in the ingot for the surface material are eliminated, which leads to an additional improvement in the flatness of the base material. In this case, the temperature and the heat treatment period for the purpose of homogenization are not particularly limited; however, the treatment temperature is preferably selected in the range of 350 ° C. to 600 ° C., and the processing period is preferably selected in the range of 1 to 10 hours.

If the temperature of the heat treatment for homogenization is lower than 350 ° C, then the internal stresses are eliminated to a lesser extent, and the homogenization of the dissolved element that segregates during casting is insufficient, as a result of which the effect of the heat treatment that is supposed to be performed will be small. On the other hand, if the temperature of heat treatment for the purpose of homogenization is higher than 600 ° C, the so-called burning occurs, in which part of the surface of the ingot dissolves, which is possibly the cause of defects on the surface of the clad material. If the treatment period is less than 1 hour, the elimination of internal stresses occurs to a lesser extent, and homogenization may be insufficient. In terms of production efficiency, the treatment period should preferably be 10 hours or less.

As for the surface finish, a cutting method can be used, for example, end milling, diamond cutting; a grinding method, for example surface treatment with a grinding stone or the like; as well as a polishing method, for example, using a polishing wheel; however, surface finishing methods are not limited to the following.

Using such a surface material 35, it is possible to obtain a clad material for a heat exchanger whose corroding depth does not exceed 60 μm during subsequent verification, which is the following: CASS test (Copper-Accelerated Salt-Spray - accelerated salt fog test) for 1500 hours (neutral salt spray test according to JIS Z 2371) as a test for evaluating resistance to external corrosion, and an immersion test for 2000 hours (Na ⁺ : 118 ppm, ppm, parts per million), Cl ^- : 58 ppm million, SO ₄ ^2- : 60 ppm, Cu ²⁺ : 1 ppm, Fe ³⁺ : 30 ppm) at 80 ° C as a test for evaluating resistance to internal corrosion.

Using the manufacturing method described above, it is possible to obtain at least one layer 35 of a surface material, and the other layer (s) to be made using a well-known method.

(3) Overlay step S2a

As shown in FIG. 8A, in the overlay step S2a, by placing one ingot 25, 34 and 35 (17) for the surface material (17) or two or more ingots for the surface material (not shown) in a predetermined position on one or both sides (not shown) ingot 17 (25, 34 and 35) for the base material manufactured in the steps described above, obtain a multilayer material 36. Here, by "predetermined position" refers to the position corresponding to the construction of the clad material as the product obtained, for example, for the placement of the base material 2 and the surface material 3 in the clad materials 1a, 1b and 1c shown in FIGS. 3A to 3C. As for the application method, a known method is used, for example, a method in which both end sections of the ingot 17 ( 25, 34 and 35) for the base material and the ingot 25, 34 and 35 (17) for the surface material are pulled together by the bandage 37. Other methods can be used, for example, fixing by welding.

(4) Clad step by hot rolling

As shown in FIG. 8B, the clad material 1a in the clad step S3 by hot rolling is obtained by hot rolling the laminate 36 after cutting the brace 37. In this case, the known rolling method is used as the hot rolling method. As the rolling mill used, FIG. 8B shows a four-roll rolling mill; however, a twin roll mill or a rolling mill having four or more rolls that are not shown may be used. To obtain a clad material 1a with a predetermined thickness, a rolling means 40 is used, comprising one stand with rolls, which is shown in FIG. 8B; however, to repeat the hot rolling operations, a rolling means comprising several stands with rolls that is not shown can be used.

The clad material made in this way can subsequently and if necessary be subjected to cold rolling, heat treatment (annealing), deformation removal, or aging or the like using conventional methods to obtain the required mechanical properties and the like, or it can be processed to obtain a specific shape, or can be cut to obtain a certain size. An example is cold rolling, which is carried out under the condition that the degree of compression during rolling is from 30% to 99%; intermediate annealing, which is performed between the stages of cold rolling; and final annealing, which is performed after the final cold rolling step and which is carried out in a continuous furnace or a batch furnace at a temperature of from 200 ° C to 500 ° C for 0 to 10 hours; however, such processing or a set of steps is not limited to that given, and it is possible to perform this processing or a set of steps with a suitable change of parameters, provided that they provide the desired effect (mechanical properties).

2. The second option

Below will be considered a second variant of the method of manufacturing a clad material proposed by the present invention. According to a second embodiment of the present invention, a method for manufacturing a clad material is a method for manufacturing a clad material consisting of a base material and two or more surface materials that are laid on one or both sides of the base material, and using this method, for example, a clad material 1d is made in which the surface material 3 is superimposed on one side of the base material 2, and the surface material 4 is superimposed on the other side of this base material 2, as shown in Fig. 3D. As shown in FIG. 2, a method for manufacturing a clad material according to a second embodiment of the present invention includes the following steps: a step for preparing a clad material, consisting of a step for preparing a base material S1a, a step for preparing a surface material S1b, and a step for rolling the surface material S1c; overlay step S2b; and hot rolling clad step S3. In this case, the surface material 3 in the manufactured clad material is obtained from an ingot for the surface material manufactured in the surface material preparation step S1b using the following steps (superposition step S2 and hot rolling clad step S3), and the surface material 4 is obtained from the rolled plate for the surface material manufactured in step S1c of rolling the surface material using the following steps. Since the surface material preparation step S1a, the surface material preparation step S1b, and the hot rolling clad step S3 are similar to the corresponding steps of the first embodiment of the present invention described above, the discussion will be omitted, therefore, the surface material hot rolling step S1c and the application step S2b will be discussed below. .

Preparation stage

The preparation step is the step of preparing the ingot for the base material produced in step S1a of preparing the base material, the ingot for the surface material produced in step S1b of preparing the surface material, and the rolled plate for the surface material manufactured in step S1c of rolling the surface material. In the preparation step, any of the following can be first made and prepared: an ingot for a base material, an ingot for a surface material and a laminated plate for a surface material, or two or three stages, a step for preparing a base material S1a, a step for preparing a surface material S1b and a rolling step S1c surface material can be prepared in advance and performed simultaneously.

Stage rolling surface material S1c

At the stage of rolling the surface material, the metal used as the surface material, which differs from the metal used as the base material, is melted and cast according to the content of the components, as a result of which an ingot for the surface material is made, after which the ingot for the surface material is further subjected to hot rolling as a result of which one or more laminated plates for a surface material are manufactured. It should be noted that the surface material at this stage is a metal, the content of components in which is indicated above. As for the casting method, semi-continuous casting and the method of casting a flat workpiece of small thickness, as described previously, are preferred. In addition, the ingot for the surface material may be subjected to at least one of the following: processing associated with the removal of the surface layer and heat treatment for the purpose of homogenization (in Fig. 2, respectively, are indicated as removal of the surface layer and homogenization heating). As for the hot rolling method, the known rolling method is performed in the same manner as in the cladding step by hot rolling. The rolling mill used is similar to that used in the cladding step by hot rolling. The thickness of the laminated plate for the surface material is preferably in the range from 3 to 200 mm, if this thickness is outside the specified range, the clad speed in the manufacture of the clad material may be unacceptable.

Overlay Step S2b

In step S2b, an overlay (not shown) by placing one or more ingots for a surface material and a laminated plate for a surface material made in the previous steps, at predetermined positions on one or both sides of the ingot for the base material made in the previous steps, obtain a multilayer material. Here, “predetermined positions” are understood to mean positions corresponding to the construction of the clad material as the product obtained, for example, corresponding to the placement of the base material 2, surface material 3 and surface material 4 in the clad material 1d shown in FIG. 3D. Alternatively, a design is possible in which the surface material 3 and the surface material 4 are superimposed on one side of the base material 2. As regards the superposition method, a known method can be used, for example, a method in which both end sections of the ingot are for the base material, the ingot for the surface the material and the rolled plate for the surface material are tightened with a bandage, or the method of fixation by welding.

It is preferable that each of the gaps resulting from the application of the components does not exceed a maximum of 10 mm, preferably 5 mm.

The clad material made in this way can subsequently and if necessary be subjected to cold rolling, heat treatment (annealing), deformation removal, or aging or the like using conventional methods to obtain the required mechanical properties and the like, or it can be processed to obtain a specific shape, or can be cut to obtain a certain size in the same way as in the first embodiment of the present invention.

3. The third option

Below will be described a third variant of the method of manufacturing a clad material proposed by the present invention. From the referenced drawings, FIGS. 9A and 9B are diagrams illustrating a flowchart for manufacturing methods of clad material for heat exchangers, and FIG. 10 is a cross-sectional view illustrating structures of clad material for heat exchangers.

As shown in FIGS. 9A and 9B, in the method for manufacturing a clad material for heat exchangers according to the present invention, the base material and the surface material that is applied to the base material are made in step S1a of manufacturing the base material, which is the step of preparing the base material, and step S1b of manufacturing the surface material, which is the step of preparing the surface material. Further, a multilayer material is made by placing the surface material on the base material in a predetermined position in the superposition step S2, after which this multilayer material is subjected to heat treatment to homogenize in the heat treatment step S2-1 to homogenize. After performing the aforementioned step S2-1, the hot rolling processing is carried out in the hot rolling step S3, and then the cold rolling is carried out in the cold rolling step S4.

First, either the surface material or the base material can be manufactured and prepared, or the base material preparation step S1a and the surface material preparation step S1b can be arranged in advance and performed simultaneously.

If the clad material is a clad material for heat exchangers, then each layer of the surface material is divided into filler 7, consumable material 8 and intermediate material 9 in accordance with their functions. First, a typical structure of a clad material for heat exchangers will be described.

For the clad material used in heat exchangers, the surface material is used as follows: one or more layers of this surface material are applied on one or more sides of the base material, while the number of layers of the surface material in such a clad material is not limited. As examples for the layers of the surface material, the following can be cited: FIG. 10A shows a two-layer clad material 5a for heat exchangers, in which one layer of filler 7 is applied as a clad to the base material 6; 10B shows a three-layer clad material 5b for heat exchangers in which one layer of filler 7 is applied on each side of the base material 6 as a cladding; Fig. 10C shows a three-layer clad material 5 c for heat exchangers, in which, on one side of the base material 6, a filler layer 7 is applied as a cladding, and on the other side of the base material 6, a layer of consumable material 8 is applied; 10D shows a three-layer clad material 5d for heat exchangers in which, on one side of the base material 6, a layer of intermediate material 9 and a filler layer 7 are applied as a cladding; 10E shows a four-layer clad material 5e for heat exchangers, in which, on one side of the base material 6, a layer of intermediate material 9 and a layer of filler 7 are applied as a cladding, and on the other side of the base material 6, a layer of consumable material 8 is applied as a cladding; and FIG. 10F shows a five-layer clad material for heat exchangers in which layers of the intermediate material 9 and layers of filler 7 are superimposed on both sides of the base material 6.

However, there is no need to say that it is possible to profitably use clad material for heat exchangers, consisting of six or more layers (not shown), in which the number of layers of the surface material (filler, consumable material and intermediate material) can be further increased.

According to the present invention, each layer of the surface material consists of a metal used as a surface material, which differs from the base material in the content of the components. Examples of metals used as a surface material include, for example, an aluminum alloy, a copper alloy, steel (an iron alloy), or the like. Preferably, the above surface materials are comprised of a JIS 1000 series aluminum alloy, or various aluminum alloys not specified in the JIS standard. Examples of aluminum alloys not listed in the JIS standard include: Al-Mn system, Al-Mn-Cu system, Al-Mn-Si system, Al-Mn-Cu-Si system, Al-Mn-Mg system, Al-Mn-Mg-Cu, Al-Mn-Mg-Si system, Al-Mn-Mg-Cu-Si system, Al-Zn system, Al-Mg-Zn system, Al-Si-Zn system, Al- Si-Mn-Zn, Al-Si-Mg-Zn system, Al-Si-Mn-Mg-Zn system, Al-Mn-Zn system, Al-Mn-Si-Zn system, Al-3-10 Si alloy, Al-3-10 alloy Si-Zn, etc. Such aluminum alloys may additionally contain 0.05% -0.3% Sc, 0.05% -0.3% Zr, 0.05% -0.3% Ti or 0.001% -0.1% Sr.

If filler 7 and consumable material 8 are used, they are placed on the outside on each of the surfaces of the base material, respectively.

Surface preparation step

In step S1b of preparing the surface material, as shown in FIG. 9, one or more layers of surface material are made which are to be applied on one or both sides of the base material used in the manufacture of the clad material for heat exchangers. Step S1b includes a melting step in which the metal used as a surface material is smelted, which differs from the base material in component content; a casting step in which a metal used as a surface material is molten, molten in a melting step, and an ingot for a surface material is made; and a cutting step in which an ingot for a surface material is cut to obtain a predetermined thickness in order to produce at least one layer of the surface material. If necessary, after the casting step, heat treatment for homogenization can be performed (described below), and after the cutting step, surface finishing can be performed (Fig. 9 - removal of the surface layer), which is described below.

Melting stage

At the melting stage, the metal used as a surface material is smelted, which differs from the base material in the content of the components. If the clad materials 5a-5f for heat exchangers contain a filler 7 as the metal used for the surface material, then an aluminum alloy of the Al-Si system of the 4000 series can be used as filler 7. In this case, the alloys of the Al-Si system also include an alloy containing Zn except Si. For example, as alloys of the Al-Si system, you can use an alloy of the Al-7-13 Si system (% by mass) and an alloy of the Al-7-13 Si system (% by mass) - 2-7 Zn (% by mass) or like that. However, Al-Si system alloys are not limited to the above, and any alloy can be used as a filler.

If clad materials 5c and 5e for heat exchangers contain consumable material 8 as the metal used for the surface material, then aluminum alloy system Al-Mn 3000 series or aluminum alloy system Al-Zn-Mg 7000 series, as well as aluminum alloy system Al-Zn. In this case, Al-Zn alloys include an alloy further comprising Mn and Si other than Zn. For example, as alloys of the Al-Zn system, you can use an alloy of the Al-1-7 Zn system (% by weight), an alloy of the Al-0.5-1.2 Mn system (% by weight) - 0.5-1.2 Si (% by mass) - 2-6 Zn (% by mass) and an alloy of the Al-0.8-1.2 Si system (% by mass) - 2-6 Zn (% by mass). However, alloys of the Al-Zn system are not limited to the above, and any alloy can be used as a consumable material.

If the clad materials 5d-5f for heat exchangers contain an intermediate material 9 as the metal used for the surface material, then as an intermediate material 9, you can use pure aluminum of the 1000 series or aluminum alloy system Al-Zn-Mg 7000 series or the like, and you can also use aluminum alloy system Al-Mn. In this case, alloys of the Al-Mn system include an alloy additionally containing Cu, Si and Ti in addition to Mn. For example, as alloys of the Al-Mn system, you can use an alloy of the Al-0.5-1.2 Mn system (% by weight) - 0.5-1.2 Cu (% by weight) - 0.5-1.2 Si (% by mass) and alloy of the Al-0.5-1.2 Mn system (% by mass) - 0.5-1.2 Cu (% by mass) - 0.5-1.2 Si (% by mass) mass) -0.05-0.3 Ti (% by mass). However, alloys of the Al-Mn system are not limited to, and any alloy used as an intermediate material can be used. The regulation of the content of the components in the above metals can be carried out properly in accordance with the scope or the like for clad material.

The intermediate material 9 is used to prevent the penetration of the filler 7 into the base material 6, which occurs, for example, during brazing of clad material.

Casting stage

A consideration of the casting step will be omitted since this step is similar to that described for the first embodiment of the present invention.

Cutting stage

An examination of the cutting step will be omitted since this step is similar to that described for the first embodiment of the present invention.

Stage of preparation of the main material

As shown in FIG. 9, the preparation step S1a of the base material includes a melting step in which the metal used as the base material is melted; and a casting step in which an ingot for a base material is manufactured by casting a metal used as a base material that has been melted in a melting step. At least one of the following can be performed: finishing the surface (in Fig. 1 - removing the surface layer) and heat treatment to homogenize. Here, consideration of each of these steps will be omitted, since they are similar to those described for the first embodiment of the present invention.

Overlay Stage

Here, consideration of the overlay step will be omitted, since this step is similar to that described for the first embodiment of the present invention.

The step of heat treatment to homogenize

The multilayer material 36 made in the overlay step S2 is heat treated to homogenize (step S2-1) to obtain a homogenized structure and soften this material to perform hot rolling in an efficient manner.

Hot Rolling Stage

Here, consideration of the hot rolling step S3 will be omitted since this step is similar to that described for the first embodiment of the present invention.

Cold Rolling Stage

Here, consideration of the cold rolling step S4 will be omitted since this step is similar to that described for the first embodiment of the present invention.

As mentioned above, according to the method of manufacturing a clad material in accordance with the present invention, it is possible to improve the flatness and smoothness of the surface material, since it is easy to control the state of its surface and flatness, which further leads to a decrease in the thickness of the oxide film. Thanks to improved adhesion and improved pressure connectivity, it is possible to reduce the number of passes for pressure connection, which leads to an increase in output and an increase in production efficiency. In addition, a gap is unlikely to occur between the base material and each of the layers of the surface material, which leads to improved corrosion resistance.

4. The fourth option

A consideration of a method for manufacturing a clad material in accordance with a fourth embodiment of the present invention will be omitted since this method is similar to a method for manufacturing a clad material in accordance with a second embodiment of the present invention, except that at least one layer of the surface material has a cast structure.

Each layer of the surface material according to the present invention consists of a metal used as a surface material, which differs from the base material in the content of the components. An example of a metal used as a surface material is aluminum alloy, copper alloy, steel (iron alloy), etc., and in the preferred case, an aluminum alloy of a series 1000, series 3000, series 4000 or series 7000, corresponding to JIS standard.

As shown in FIG. 11, in the manufacture of the clad material, it is necessary that at least one layer of the surface material 35 (surface material 35) have a cast structure when this material is applied on one (not shown) or both sides of the base material 26, which has a cast structure. In this case, the base material 26 is obtained by cutting the ingot 17 for the base material shown in FIG. 4 to obtain a predetermined length. Since at least one layer of the surface material 35 (surface material 35a) has a cast structure, the adhesion between the base material 26 and the surface material 35a is improved. Therefore, in the hot rolling step of both materials (see FIG. 8B), pressure connectivity is improved and the number of passes for pressure connection is reduced, which leads to an increase in output and an increase in production efficiency. Moreover, it is possible to obtain a clad material with excellent corrosion resistance. 11 shows an example in which one layer of surface material 35 is placed on each side of the base material 26, respectively. If several layers of surface material 35 are placed on one or both sides of the base material 26, then the layer adjacent to the base material 26 or surface material 35 may be a layer (surface material) having a cast structure. However, from the point of view of adhesion and pressure coupling for the base material 26 and the surface material 35, it is preferable that the layer of the surface material adjacent to the base material 26 have a cast structure.

In the surface material of the present invention, it is preferable that the layers of the surface material (surface material 35b) different from the layer having a cast structure (surface material 35a) consist of layers having a cast structure in order to improve adhesion between the base material 26 and the surface material 35, or between layers (not shown) of surface material 35; however, the layers of the surface material may consist of a layer having a texture after rolling, which is obtained by hot rolling and is used as a surface material for conventional clad material. The thickness (T4 in FIG. 7) of the layer (surface material 35a) having a cast structure is preferably in the range of 10 to 250 mm. If the thickness is outside this range, the clad speed in the manufacture of clad material may be unacceptable.

Preferably, the surface material 35 of the present invention contains a layer (surface material 35a) having a cast structure, and the surface roughness of this material 35, expressed as an arithmetic mean value (Ra), is in the range from 0.05 to 1.0 μm, preferably from 0.1 to 0.7 μm. If the surface roughness is below the lower limit of the specified range, clad material is difficult to process. Otherwise, if the surface roughness is above the upper limit of the specified range, a small gap occurs between the base material 26 and the surface material 35a, resulting in deterioration of pressure connectivity and adhesion, resulting in poor adhesion in the clad material. Preferably, the flatness of the layer (surface material 35a) having a cast structure is no worse than 1 mm per 1 m in the length direction, most preferably no worse than 0.5 mm per 1 m. When the flatness is outside the specified range, between the main material 26 and each of the surface materials 35 (not shown) there is a small gap, resulting in deterioration of pressure connectivity and adhesion, which leads to poor adhesion in the clad material.

Using such a surface material 35, it is possible to produce a clad material whose corroding depth does not exceed 60 μm during a subsequent test, which is as follows: CASS test for 1,500 hours (test with the spray of neutral salt JIS Z 2371) as a test for evaluation resistance to external corrosion and immersion testing for 2000 hours (Na ⁺ : 118 ppm, Cl ^- : 58 ppm, SO ₄ ^2- : 60 ppm, Cu ²⁺ : 1 ppm, Fe ^{3 +:} 30 ppm) at 80 ° C as a test for evaluating resistance to VNU renney corrosion.

Preferably, the layer (surface material 35b), which is different from the layer (surface material 35a) having a cast structure, is also made using the method described above; however, this layer can be made using a known method using conventional melting, casting, removing the surface layer (heating to homogenize) and hot rolling. Surface materials 35a and 35b can be made using a method of casting flat billets of small thickness or a two-roll casting method instead of cutting a flat billet.

5. A variant of the device for the manufacture of surface material

Below with reference to the accompanying drawings will be described in detail a device for the manufacture of surface material. Of the referenced drawings, FIG. 12 is a diagram illustrating a device for manufacturing surface materials 50, and FIG. 13 is a diagram illustrating another embodiment of a device for manufacturing surface materials 50.

5.1 Device for the manufacture of surface material

As shown in FIG. 12, a device 50a for manufacturing a surface material 50 is a device for manufacturing a surface material 3 used in a clad material consisting of a base material 2 and one or more layers of surface material 3 that are applied on one or both sides of the base 2. The device 50a for manufacturing the surface material 50 includes a casting means 51a for casting the surface material 3 by melting the metal used in honors surface material different from the base material 2 on the content components; ingot cutting means 52 for cutting an ingot 3 ′ for a surface material; and transport means 53 for transporting an ingot 3 ′ for a surface material between said means. The ingot cutting means 52 may be a cutting means 52a that cuts an ingot 3 ′ for a surface material to obtain a predetermined thickness, or the ingot cutting means 52 may include a cutting means 52a and a cutting means 52b for cutting the front and back of the ingot 3 'for a surface material to obtain a predetermined length. In addition, as necessary, the ingot cutting means 52 may be provided with homogenizing heat treating means 54 used in performing the heat treating to homogenize the ingot 3 'for the surface material cast by the casting means 51a.

Each of the means will be described below.

Casting agent

The casting means 51a is, for example, a semi-continuous casting device in which molten metal used as a surface material, which differs from the main material in the content of the components, is poured from above, and the hardened metal is continuously removed from the bottom of the water-cooled mold to form an ingot 3 'of a surface material having a predetermined thickness.

Homogenizing heat treatment

The homogenizing heat treating means 54 is used when performing the heat treatment to homogenize the ingot 3 'for a surface material in order to eliminate internal stresses and to ensure homogenization of the inner structure of this ingot if necessary. When performing heat treatment for the purpose of homogenization, the internal stresses in the ingot 3 'for the surface material are eliminated, which leads to an improvement in the flatness of the cut surface material 3.

Ingot Cutting Tool

The ingot cutting means 52 is used when cutting the ingot 3 'for a surface material cast using the casting means 51a, and this means 52 may be a cutting means 52b or may include a cutting means 52b and a cutting means 52a.

Cutting tool

The cutting means 52a is used to cut the front and back parts of the ingot 3 ′ for surface material using a band-cutting machine in the length direction so that the surface material ingot 3 ′ has a predetermined length. When cutting the ingot in this way, it is possible to remove a recess or protrusion that occurs in the front or rear of the ingot 3 'for the surface material, which allows to obtain smooth surfaces in these parts of the said ingot. In addition to the band saw of the band saw, you can use the circular saw of a circular edger, pressurized water or a laser, etc .; however, cutting tools are not limited to these. In addition, when the base material 2 and the surface material 3 are superimposed on each other, the ingot 3 'for the surface material is cut from the sides, which will be described later.

Cutting tool

The cutting means 52b cuts an ingot 3 'for a surface material cast using the casting means 51a to obtain a predetermined thickness using, for example, a band saw. A band saw is an endless tape that cuts during rotation. The ingot 3 'for the surface material can be cut as follows: place the cutting edge of the band saw in the immediate vicinity of the front or rear ends of this ingot, bring the saw blade into rotation for cutting by the said cutting edge of the ingot, then move the cutting tool 52b in the opposite direction, respectively back or front ends of the ingot. By repeating the described operation, an ingot 3 ′ for a surface material is cut to obtain a predetermined thickness, and it is possible to produce a plurality of layers of the surface material 3. An ingot 3 ′ for a surface material can be cut to obtain a predetermined thickness by moving the ingot itself, while 52b slicing will remain in a fixed position.

In the preferred case, the ingot 3 'for the surface material is cut parallel to the mounting surface of this ingot, which is placed horizontally. Here, the mounting surface means the surface of the ingot 3 'for a surface material in contact with the table of the cutting means. With this cutting of the ingot, the influence of the weight of the cut piece or geometry distortion is minimized (for example, under the action of the force arising from the fall of the cut piece, etc.), so the flatness of the cut surface material can be improved.

The thickness of the cut surface material 3 is preferably in the range of 10 to 250 mm. If the thickness of the cut surface material 3 is outside this range, the clad speed in the manufacture of the clad material may be unacceptable. Moreover, the cutting edge of the band saw may have not one, but two or more cutting edges. By creating several cutting edges at the cutting edge of a band saw, it is possible to increase the efficiency of cutting an ingot 3 'for a surface material. The band saw used in the cutting means 52b may be of conventional construction, but a circular saw, pressurized water, a laser or the like can be used as a cutting tool; however, the tools used for slicing are not limited to these.

When cutting an ingot 3 'for a surface material, either the cutting of the front and back parts of the ingot using the cutting means 52a can be performed first, or the ingot can be cut using the cutting means 52b. In this case, the cutting means 52a described above and the cutting means 52b are made as different devices; however, cutting the front and back parts of the ingot 3 'for the surface material and cutting the ingot 3' for the surface material can be performed using one device.

Means of transportation

The transport means 53 is used in transporting an ingot 3 'for a surface material between the above-described casting means 51a, the cutting means 52a and the cutting means 52b; however, the transport means 53 may transport an ingot 3 ′ for a surface material or a surface material 3 and between other means. As transport means 53, a device equipped with a conveyor belt or conveyor, or the like can be used; however, this tool is not limited to the above, and a tool may be used in which the ingot 3 ′ for the surface material or the surface material 3 is moved using their suspension on a cable, chain, or using vacuum.

5.2 Another device for the manufacture of surface material

Below, an example will be described modifications of the device for the manufacture of surface materials. As shown in FIG. 13, the apparatus 50c for the manufacture of surface materials is a apparatus for the manufacture of surface materials 3 used in a clad material consisting of a base material 2 and one or more layers of surface material 3 that are laid on one or more sides of the base material 2. A device for manufacturing the surface material 3 includes a casting means 51a for casting the surface material 3 by melting the metal used as e skin material, which differs from the main material content components; ingot cutting means 52 for cutting an ingot 3 ′ for a surface material; surface finishing means 55 for surface finishing; and transport means 53 for transporting an ingot 3 ′ for a surface material or surface material 3 between said means. The ingot cutting means 52 may be a cutting means 52b that cuts an ingot 3 ′ for a surface material to obtain a predetermined thickness. Alternatively, the ingot cutting means 52 may include a cutting means 52b and a cutting means 52a for producing an ingot with a predetermined length by cutting the front and back portions of the ingot 3 'for a surface material. If necessary, the ingot cutting means 52 may be provided with homogenizing heat treating means 54 used in performing the heat treatment to homogenize the ingot 3 'for a surface material cast by the casting means 51a.

Each of the means will be described below. Moreover, consideration of the casting means 51a, the heat treatment means 54 for the purpose of homogenization, the cutting means 52a and the cutting means 52b will be omitted since they are similar to those described above.

Means of transportation

The transport means 53 is used in transporting the ingot 3 ′ for a surface material or surface material 3 between the above-described casting means 51a, the cutting means 52a and the cutting means 52b; however, the conveyance means may transport an ingot 3 ′ for a surface material and a surface material 3 between other means. As a means of transportation, you can use a device equipped with a conveyor belt or roller table or the like; however, this tool is not limited to the above, and a tool may be used in which the ingot 3 ′ for the surface material or the surface material 3 is moved using their suspension on a cable, chain, or using a vacuum or the like. The surface material 3 is transported after the ingot 3 ′ for the surface material is cut to obtain a predetermined thickness using a band-cutting machine, using the “suspension” of the cut surface material 3 in a vacuum, and then transporting it to the work surface finishing means. The surface material 3 can be transported to the desktop of the surface finishing means by moving this material on the transportation means 53.

Surface Finisher

The surface finisher is used to finish the surface of the surface material 3 cut by means of the cutting means 52b. The surface material 3 moved by the conveying means 53 described above is subjected to a surface finish using the surface finisher 55. After the surface material 3 is turned over with the aid of the overturning means, the reverse side of this material can be subjected to the surface finishing. As a surface finish, you can use the cutting method, for example cutting with an end mill, cutting with a diamond tool; a grinding method in which the surface is treated with a grinding stone or the like; as well as a polishing method, for example, using a polishing wheel or the like; however, surface finishing methods are not limited to the following. As a surface finish, you can use a combination of several methods, for example, in a situation when the surface layer is removed after cutting.

Using the above-described device 50a or 50c for the manufacture of surface materials, at least one layer of surface material 3 can be obtained, while another layer or layers can be obtained using a conventional device for the manufacture of surface materials.

Below will be described a device for the manufacture of clad materials 50, which uses the above device 50a or 50c for the manufacture of surface materials. An apparatus for manufacturing clad materials 50 includes the apparatus 50a or 50c described above for making surface materials; a device for manufacturing basic materials 2, consisting of a casting means 51b for melting and casting metal for a base material that is different from a surface material, and a cutting means 52b for treating an ingot 3 'for a base material cast using the casting means 51b , with obtaining a predetermined length by cutting the ingot 3 'in length; superimposing means (not shown) intended to produce a multilayer material by superposing the surface material 3 and the base material 2 on top of each other; and hot rolling means (not shown) for hot rolling said laminate.

Device for the manufacture of surface material

In this case, a device 50a or 50c for manufacturing a surface material will not be considered, since this device is similar to that described previously.

Device for manufacturing the base material

Casting agent

In the casting means 51b, molten metal used as a base material that is melted in the melting step and prepared, for example, using a semi-continuous casting method and which differs from the surface material 3 in terms of component content, is poured from above and the solidified metal is continuously extracted from the bottom of the water-cooled mold with obtaining an ingot of base material having a predetermined thickness.

Cutting tool

The cutting means 52b is used to cut the ingot 2 ′ for the base material cast using the casting means 51b to obtain a predetermined size. As a cutting tool, a band saw, pressurized water, a laser or the like, as well as a circular saw, can be used; however, the tools used for slicing are not limited to these.

Overlay tool

The application tool allows you to get a multilayer material by placing the surface material 3 or several surface materials 3 on one or both sides of the base material 2, which is made at the above stage in a predetermined position. As for the overlay method, a known method is used, for example a method in which both end sections of the base material 2 and the surface material 3 are pulled together. Other methods can be used, for example, fixing by welding. The multilayer material thus obtained can, if necessary, be subjected to heat treatment to homogenize using heat treatment means 54 in order to remove internal stresses and facilitate hot rolling.

Hot Roller

Hot rolling

In the hot rolling step, the aforementioned bandage for fixing the laminate is cut and clad material is made by hot rolling of the laminate. As for the hot rolling method, a known rolling method is used. The rolling means used may be a two-roll rolling device or a rolling device with four or more rolls, as well as a four-roll rolling device. Hot rolling can be repeated to obtain a clad material having a predetermined thickness using a rolling tool provided with several groups of stands with rolls, as well as a rolling tool equipped with one group of stands with rolls.

Cold rolling

The clad material thus prepared is subsequently cold rolled if necessary. The cold rolling step can be performed, for example, provided that the reduction ratio is in the range from 30% to 99%.

The clad material, if necessary, can be subjected to heat treatment (annealing), deformation or aging or the like using conventional methods to obtain the required mechanical properties and the like, or it can be processed to obtain a certain shape, or it can be cut to getting a certain size. An example is annealing, including coarse annealing, which is performed before cold rolling, intermediate annealing, which is performed between the cold rolling steps, and final annealing, which is performed after the final cold rolling step, these annealing steps being carried out in a continuous furnace or batch furnaces at temperatures from 200 ° C to 500 ° C for 0 to 10 hours; however, such a set of steps or processing is not limited to that given, and there is no need to say that it is possible to perform this set of steps or processing with a suitable change of parameters, provided that they provide the desired benefit (mechanical properties).

As indicated above, in accordance with the device for the manufacture of surface materials proposed by the present invention, it is not necessary to reduce the thickness of the surface material by hot rolling as for conventional clad material, therefore, there is no need to use hot rolling in the manufacture of surface material, which reduces labor costs when performing technological steps. In addition, since it is easy to control the surface condition and flatness of the surface material, it is possible to improve the flatness and smoothness of the surface material, and, in addition, reduce the thickness of the oxide film. Further, when applying a surface material to the base material since adhesion and pressure connectivity between the base material and the surface material are improved, it is possible to reduce the number of passes during hot rolling, which leads to an increase in output and an increase in production efficiency. Moreover, a gap is unlikely to occur between the base material and each of the surface materials, resulting in improved corrosion resistance.

A method for manufacturing clad material and a device for making clad material has been described above; however, the description provided should not be construed as limiting the nature and scope of the present invention. The scope of the present invention should be determined only by the appended claims. In addition, a person skilled in the art should understand that many changes and modifications are possible that do not go beyond the essence and scope of the present invention, and these changes and modifications can also be used as embodiments of this invention.

Claims (28)

1. A method of manufacturing a clad material, consisting of a base material and one or more layers of a surface material superimposed on one or both sides of said base material, wherein
at the stage of preparing the base material, an ingot for the base material is made by melting and casting the metal used as the base material, and at the stage of preparing the surface material, an ingot for the surface material is made by melting and casting the metal used as the surface material, which is different from the base material according to the content of the components;
overlay is performed by placing the ingot for the surface material in a predetermined position on one or both sides of the ingot for the base material in order to produce a multilayer material; and
perform cladding by hot rolling, for which laminated material is rolled to obtain clad material. 2. The method according to claim 1, in which at the stage of preparing the surface material, at least one of the surface materials is subjected to cutting, in which the ingot for the surface material made by melting and casting is cut to obtain a predetermined thickness. 3. The method according to claim 2, in which the ingot for the surface material made by melting and casting is further subjected to heat treatment for homogenization before the cutting step. 4. The method according to claim 2, in which at the stage of cutting the ingot for the surface material is cut parallel to the mounting surface on which the ingot is placed horizontally. 5. The method according to claim 1, in which at the stage of preparation of the base material, the manufactured ingot for the base material is subjected to removal of the surface layer and / or heat treatment for homogenization. 6. The method according to claim 1, in which at the stage of preparation of the surface material, the manufactured surface material is subjected to removal of the surface layer and / or heat treatment for homogenization. 7. The method according to claim 1, in which at least one of the surface materials has a flatness of not more than 1 mm per 1 m in the length direction. 8. The method according to claim 1, in which at least one of the surface materials has an arithmetic mean value (Ra) of the surface roughness in the range from 0.05 to 1.0 μm. 9. The method according to claim 1, in which the thickness of the ingot for the base material is in the range from 200 to 700 mm, and the thickness of the surface material is in the range from 3 to 200 mm. 10. The method according to claim 1, wherein the metal used as the base material and the metal used as the surface material are aluminum or aluminum alloys. 11. The method according to claim 2, in which the surface material consists of many layers, at least one of which is made by cutting an ingot of the surface material. 12. The method according to claim 2, in which, after the cutting step, the surface of the chopped surface material having a predetermined thickness is further subjected to finishing. 13. The method according to item 12, in which the surface finish is performed using one or more methods selected from the group:
cutting, grinding and polishing. 14. The method according to claim 1, which further comprises a cold rolling step after the hot rolling step. 15. The method according to claim 11, in which in the manufacture of clad material intended for heat exchangers, at least one layer of surface material is a filler that is positioned so that it is on the outer surface of the clad material, at least one layer of surface material is made by cutting an ingot of surface material. 16. The method according to claim 11, in which in the manufacture of clad material intended for heat exchangers, the surface material contains a filler and an intermediate material placed between the main material and the filler, and the filler is positioned so that it is on the outer surface of the clad material, and in which at least one of the said layers of surface material is made by cutting an ingot. 17. The method according to claim 11, in which the clad material intended for heat exchangers consists of a base material and surface materials superimposed on both sides of the base material, wherein at least one layer of surface material on one side of the base material is the filler, and at least one layer of the surface material on the other side of the base material is a consumable material, and the filler and consumable are positioned so that they are on walked on the outer surface on each side of the base material, with at least one of said layers of surface material being made by cutting an ingot. 18. The method according to claim 11, in which the clad material intended for heat exchangers consists of a base material and surface materials superimposed on both sides of the base material, while the surface material on one side of the base material contains a filler and an intermediate material that is placed between the main material and the filler, and at least one layer of the surface material on the other side of the main material is a consumable material, while the filler and consumable Container material positioned so that they are located at the outer surface of each side of the base material, and at least one of said surface layer material is produced by cutting an ingot. 19. A device for manufacturing a surface material for a clad material manufactured by the method according to claim 1, containing
casting means, providing melting of the metal used as a surface material, which differs from the base material in the content of components, and its casting;
means for cutting ingots of surface material cast by means of a molding tool, including means for cutting an ingot for surface material to obtain a predetermined thickness;
means for transporting an ingot of surface material between said means. 20. The device according to claim 19, in which the means of cutting the ingot for the surface material is placed horizontally parallel to the mounting surface of the said ingot. 21. The device according to claim 19, which further comprises means for finishing the surface of a surface material having a predetermined thickness, which is cut using means of cutting ingots. 22. The device according to claim 19, which is further provided with heat treatment means for homogenizing the ingot for a surface material cast using a casting means. 23. The device according to claim 19, in which the means of cutting the ingots includes a means of cutting, cutting the front and back of the ingot with obtaining a predetermined length. 24. A surface material for a clad material consisting of a base material and one or more layers of surface material superimposed on one or both sides of the aforementioned base material, and manufactured by preparing the base material and surface material, applying the surface material in a predetermined position from one or both sides of the base material to obtain a multilayer material and cladding by hot rolling, which
consists of one or more layers;
each layer is made of metal that differs from the main material in the content of components and
at least one layer has a cast microstructure when this material is applied on one or both sides of the base material. 25. The surface material of claim 24, which is made of an aluminum alloy of a series 1000, a series 3000, a series 4000, or a series 7000, conforming to the JIS standard. 26. The surface material according to paragraph 24, in which at least one layer has a cast microstructure, and its thickness is in the range from 10 to 250 mm 27. A method of manufacturing a clad material, consisting of a base material and two or more layers of surface materials superimposed on one another from one or both sides of said base material, wherein
preparing the base material by making an ingot for the base material by melting and casting the metal used as the base material;
preparing a surface material by making an ingot for a surface material by melting and casting a metal used as a surface material that differs from the base material in terms of component content;
preparing a rolled plate for a surface material by subsequent hot rolling of an ingot for a surface material;
overlaying is performed by placing the ingot for the surface material and the rolled plate for the surface material in a predetermined position on one or both sides of the ingot for the base material; and
perform cladding by hot rolling of the multilayer material to obtain a clad material. 28. The method according to item 27, in which the thickness of the ingot for the surface material and the hot-rolled plate for the surface material are in the range from 3 to 200 mm

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