CN112662902B - Production method of high-plasticity high-corrosion-resistance aluminum alloy for automobile - Google Patents
Production method of high-plasticity high-corrosion-resistance aluminum alloy for automobile Download PDFInfo
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Abstract
The invention discloses a production method of high-plasticity high-corrosion-resistance aluminum alloy for automobiles, which comprises the following steps: (1) putting the raw materials into a melting furnace for melting to form an aluminum melt; (2) carrying out deslagging operation and component regulation and control on the aluminum melt in a melting furnace, and transferring the aluminum melt to a holding furnace after the deslagging operation and the component regulation and control are finished; (3) refining and standing the aluminum melt in a holding furnace, and then discharging the aluminum melt from the holding furnace; (4) the aluminum melt flows out of the heat preservation furnace, and reaches a casting crystallizer platform after being fed with aluminum-titanium-boron wires on line, dehydrogenated on line and filtered on line; (5) solidifying the aluminum melt into an aluminum alloy rod in a crystallizer; (6) homogenizing the aluminum alloy rod; (7) and cooling the aluminum alloy rod to room temperature, and cutting to length. The aluminum alloy material prepared by the method has better plasticity and corrosion resistance.
Description
Technical Field
The invention relates to a production method of high-plasticity high-corrosion-resistance aluminum alloy for automobiles.
Background
The micro-channel aluminum flat tube for the automobile heat exchange system is required for more than 4.5 ten thousand tons every year. The micro-channel aluminum flat tube is prepared from aluminum alloy, but the current aluminum alloy can not meet the requirements of the micro-channel aluminum flat tube on the properties of strength, plasticity, corrosion resistance and the like.
Disclosure of Invention
The invention aims to provide a production method for improving the plasticity and corrosion resistance of an aluminum alloy material for an automobile heat exchange system, and the specific technical scheme is as follows:
the production method of the high-plasticity high-corrosion-resistance aluminum alloy for the automobile comprises the following steps:
(1) comprises aluminum ingot, aluminum reclaimed material and AlMn20Master alloy and AlTi10Putting raw materials including the intermediate alloy into a melting furnace for melting to form an aluminum melt;
(2) carrying out deslagging operation and component regulation and control on the aluminum melt in a melting furnace, and transferring the aluminum melt to a holding furnace after the deslagging operation and the component regulation and control are finished;
(3) refining and standing the aluminum melt in a holding furnace, and then discharging the aluminum melt from the holding furnace;
(4) the aluminum melt flows out of the holding furnace, and reaches a casting crystallizer platform after online feeding of aluminum-titanium-boron wires, online dehydrogenation and online filtration;
(5) solidifying the aluminum melt into an aluminum alloy rod in a crystallizer;
(6) feeding the aluminum alloy rod into a homogenizing furnace for homogenizing treatment;
(7) after the homogenization treatment is finished, the aluminum alloy rod is sent into a cooling furnace to be cooled to room temperature, and then the aluminum alloy rod is cut to length;
the aluminum alloy rod comprises the following components in percentage by mass:
in the application, the alloy composition breaks through the composition design of the traditional 3-series wrought aluminum alloy, and on the basis of the national standard 3003 mark, the Ti content is increased, the Cu content is reduced, and the corrosion resistance of the alloy is improved. The Ti content is increased to 0.1-0.15 wt% from the national standard of less than or equal to 0.05 wt%, and the Cu content is reduced to less than or equal to 0.05 wt% from the national standard of 0.05-0.2 wt%.
The element content of the 3003 series aluminum alloy is shown in the following table (GB/T3190-:
the existence of the copper element can obviously reduce the corrosion resistance of the aluminum alloy bar, and the content of the copper element is reduced so as to reduce the corrosion caused by the copper element. After titanium reaches a certain content, the potential difference of different positions of the aluminum alloy rod can be balanced, the pitting corrosion can be converted into the strip corrosion, after the aluminum rod is extruded into the micro-channel flat tube for the automobile heat exchange system, the flat tube is small in size, the wall of the flat tube is as thin as 0.15mm, the pitting corrosion easily forms corrosion holes penetrating through the wall of the flat tube to cause product scrapping, and the service life of the product is prolonged due to the even corrosion flat tube wall of the strip corrosion.
By adopting partial aluminum reclaimed materials as raw materials, the cost of the aluminum alloy rod can be reduced, and the micro-channel aluminum flat tubes scrapped from leftover materials of the aluminum alloy rod and the like can be used as the aluminum reclaimed materials.
Further, impurities and hydrogen can reduce the corrosion resistance of the alloy, and in order to improve the corrosion resistance of the alloy, the prior art and equipment in the industry are integrated, and process optimization is carried out on the basis, and five-stage purification treatment and three-stage dehydrogenation treatment are carried out on the aluminum melt;
primary purification and primary dehydrogenation: in the step (2), a slag-aluminum separating agent is blown into an aluminum melt by using first argon gas, and slag removal operation is carried out; the purity of the argon is more than or equal to 99.999 percent by volume, and the argon carries the hydrogen in the aluminum melt out of the aluminum liquid through the physical adsorption effect. The slag-aluminum separating agent mainly comprises a mixture of salts such as sodium chloride, potassium chloride, sodium fluoroaluminate and the like, and is used for bringing impurities in an aluminum melt to the surface of aluminum liquid and removing the impurities by slagging off with a special tool;
secondary purification and secondary dehydrogenation: in the step (3), blowing a refining agent into the aluminum melt by using second argon gas to carry out refining operation; the refining agent mainly comprises a mixture of salts such as sodium chloride, potassium chloride and the like, and is used for bringing impurities and alkali metals in an aluminum melt to the surface of the aluminum liquid and removing the impurities and the alkali metals by using a special tool;
third-stage purification: in the step (2), in the process of transferring the aluminum melt from the melting furnace to the heat preservation furnace, the residual aluminum liquid in the melting furnace is used for keeping heavy metals which are not alloyed with the aluminum in the melting furnace, in the step (3), in the process of transferring the aluminum melt from the heat preservation furnace to the casting platform, the residual aluminum liquid in the heat preservation furnace is used for keeping heavy metals in the heat preservation furnace;
three-stage dehydrogenation: in the step (4), the aluminum melt passes through a dual-rotor online degassing box, and third argon is blown into the aluminum melt through two rotating silicon nitride rotors, so that the hydrogen content in the aluminum melt is reduced to be below 0.12mL/100g Al; the rotating speed of the silicon nitride rotor is 500-550 rpm;
four-stage purification: in the step (4), the aluminum melt passes through the ceramic filter plate through the plate-type filter box, and impurities larger than 50 microns are blocked by the filter plate;
five-stage purification: in the step (4), the aluminum melt passes through the tubular filter and passes through the ceramic filter tube group, and impurities larger than 5 mu m are blocked by the filter tube group.
Through the steps, the purity of the product reaches the highest level, the metallographic cleanliness detection reaches one level, the corrosion resistance of the product is improved, and the service life of the micro-channel flat tube is doubled.
Further, the microstructure uniformity of the alloy determines the plasticity of the alloy, and in order to improve the plasticity of the alloy, an oil-gas slip casting method and an isothermal casting technology are adopted. The high-quality aluminum alloy rod with fine grains and uniform microstructure is obtained.
In the step (4), the aluminum melt flows out of the holding furnace and passes through a degassing box, and the degassing box contains 1-2t of aluminum liquid of the previous furnace. The degassing box is provided with an electric heating device which can heat up and preserve the temperature of the aluminum liquid. The temperature of the aluminum liquid in the degassing box is set to be 10-20 ℃ higher than that of the aluminum liquid in the holding furnace so as to compensate the temperature drop of the aluminum melt flowing from the holding furnace to the casting platform in the initial casting stage, and the temperature consistency of the aluminum liquid in the casting platform in the whole casting process is achieved.
In the step (4), the aluminum-titanium-boron wire is added into the aluminum melt between the holding furnace and the degassing box to play a role in refining grains, so that the average grain size of the product is reduced to be below 80 mu m. And (3) allowing the aluminum melt to flow out of the heat preservation furnace, wherein the time for the aluminum melt to reach the casting platform is 4-6min, adding an aluminum-titanium-boron wire into the aluminum melt between the heat preservation furnace and the degassing box, and giving sufficient reaction time to the aluminum-titanium-boron, so that the grain refining effect is better. The Al-Ti-B wire may be Ti5B0.2The addition of the aluminum-titanium-boron wire ensures that the Ti content reaches 0.004-0.006 wt% of the product quality.
In the step (5), in the process of crystallizing the aluminum melt into the aluminum bar, the aluminum melt is not directly contacted with the graphite ring of the crystallizer, and a layer of air cushion and oil film are established between the aluminum melt and the graphite ring, so that the whole casting and crystallizing process is in a good thermal balance state, and the microstructure of the alloy is homogenized. The conventional process is broken through, the casting speed (the casting speed at the initial stage is 143mm/min, and the casting speed at the stable stage is 137mm/min) which is faster than that at the stable stage is adopted at the initial stage of casting, so that the aluminum bar enters a gas-sliding state earlier, the removal amount of the head of the aluminum bar is reduced, and the yield is increased.
Through the steps, the average grain size of the aluminum bar is reduced to be below 80 mu m, the thickness of the segregation layer is reduced to be below 200 mu m, the microstructure is uniform, the plasticity (the plasticity refers to the processing performance of the aluminum bar) is improved, and the production efficiency of extruding the micro-channel flat tube by the aluminum bar is improved by 20%.
In order to eliminate the stress generated in the aluminum bar by rapid cooling in the casting stage and reduce the segregation in the crystal, the aluminum bar is homogenized.
In the step (6), the homogenizing treatment process sequentially comprises a temperature rising section, a maintaining section, a temperature reducing section and a heat preservation section, wherein the temperature of the maintaining section is 4-8 ℃ higher than that of the heat preservation section. Setting the temperature rise period to be 3h, the temperature of the maintaining period to be 605 ℃, the time to be 1h, the temperature reduction period to be 20min, and the temperature of the heat preservation period to be 600 ℃, and the time to be 10 h. Because the temperature of the furnace gas is higher than the temperature of the aluminum bar, the temperature of the aluminum bar can reach the heat preservation temperature at the fastest speed and the aluminum bar can not be over-burnt through the arrangement of the holding section.
In the step (6), the circulating fan circulates the hot air in the homogenizing furnace, and the circulating fan rotates forwards and backwards alternately to enable the hot air in the homogenizing furnace to flow in a reciprocating and circulating mode. The circulating fan rotates in a single direction, the time difference of the aluminum bars at different positions in the homogenizing furnace reaching the heat preservation temperature of minus 5 ℃ is close to 3 hours, the circulating fan rotates in a positive and negative mode alternately, and the time difference of the aluminum bars at different positions in the homogenizing furnace reaching the heat preservation temperature of minus 5 ℃ is shortened to 1 hour.
Through the steps, the residual stress in the aluminum bar is eliminated, the segregation in the crystal is reduced, and the uniformity and the consistency of the aluminum bar are enhanced.
By the method, the plasticity and the corrosion resistance of the aluminum alloy for the automobile can be effectively improved, the production efficiency of the micro-channel flat tube for the automobile heat exchange system made of the aluminum bar is improved by 20%, the corrosion resistance of the micro-channel flat tube is improved by one time, and the leakage time of the SWAAT salt spray test is improved to 5000h from 2000 h.
Description of the drawings:
FIG. 1 is a flow chart of the present invention.
FIG. 2 is a view of a homogenization process
FIG. 3 is a temperature curve diagram of points where the temperature of the aluminum bar in the homogenizing furnace is the fastest and the temperature of the aluminum bar is the slowest when the circulating fan rotates forward and backward alternately.
FIG. 4 is a temperature curve diagram of the point where the temperature of the aluminum bar in the homogenizing furnace is the fastest and the slowest when the circulating fan rotates in one direction.
The specific implementation mode is as follows:
the technical solution of the present invention is further specifically described below by way of examples.
(1) 19t of aluminum ingot with the purity of 99.7 wt%, 10t of cleaned aluminum reclaimed material and AlMn20Intermediate alloy 1.2t, AlTi10And (3) putting 0.35t of the intermediate alloy into a melting furnace, and heating and melting to form an aluminum melt. The total weight is about 30.55t, and the reclaimed materials account for 32.7 percent.
(2) After the aluminum materials are completely melted, stirring the aluminum melt for 3min, uniformly blowing 25kg of slag aluminum separating agent into the aluminum liquid of the melting furnace through first argon for 5min, and then removing scum on the surface of the aluminum liquid.
In this embodiment, the purity of the first argon gas is greater than or equal to 99.999% by volume, and the slag-aluminum separating agent is a mixture of salts such as sodium chloride, potassium chloride, sodium fluoroaluminate, and the like.
Regulating and controlling the components of the aluminum melt to meet the standard, tilting the melting furnace after the temperature is raised to a first set temperature, transferring the aluminum melt to a holding furnace, and leaving 1t of aluminum liquid in the melting furnace. In this embodiment, the first set temperature is 755 ℃, and the temperature of molten aluminum in the holding furnace after the converter is 745 ℃.
(3) 25kg of refining agent was blown into the holding furnace aluminum melt with a second argon gas using an HD2000 furnace side refining system for 40 min. After refining, removing dross on the surface of the aluminum liquid, then keeping the temperature of the aluminum liquid in the heat preservation furnace at 720-730 ℃, and standing for 20-30 min.
In this example, the purity of the second argon gas is not less than 99.999% by volume, and the refining agent is a mixture of salts such as sodium chloride and potassium chloride.
(4) And (3) tilting the holding furnace, wherein the aluminum melt flows out of the holding furnace and sequentially passes through the wire feeder, the degassing box, the plate-type filter box and the tubular filter and then reaches the casting crystallizer platform.
When the aluminum melt enters the degassing box, the wire feeding machine is started to feed the aluminum-titanium-boron wire Ti5B0.2Continuously adding into the aluminum melt between the holding furnace and the degassing tank,the wire feeding speed is 350mm/min, and the adding amount of the aluminum-titanium-boron wire increases the titanium content in the aluminum melt by 0.005 wt%.
The temperature of the aluminum melt in the degassing tank was 740 ℃. In this embodiment, the degassing tank is a dual-rotor online degassing tank. The temperature of the aluminum liquid in the degassing box is 10-20 ℃ higher than that of the aluminum liquid in the holding furnace, so as to compensate the temperature drop of the aluminum liquid flowing from the holding furnace to the casting platform at the initial casting stage, and the temperature consistency of the platform aluminum liquid in the whole casting process is achieved. After casting, 1t of aluminum liquid is remained in the heat preservation furnace.
When the aluminum melt enters the degassing box, two silicon nitride rotors of the degassing box enter a working state, and third argon is sent into the aluminum melt, wherein the rotating speed of the silicon nitride rotors is 550rpm/min, and the flow of the third argon is 40L/min.
A ceramic filter plate is arranged in the plate-type filter box, the aluminum melt passes through the 50-mesh ceramic filter plate, and impurities larger than 50 microns are intercepted by the ceramic filter plate.
The ceramic filter tube is arranged in the tubular filter, the aluminum melt passes through the ceramic filter tube with the precision of less than or equal to 5 microns, and impurities larger than 5 microns are intercepted by the ceramic filter tube, so that the cleanliness of the aluminum melt is ensured.
(5) And the aluminum melt subjected to online treatment enters a runner of the casting platform, and is filled into each crystallizer through the runner for casting to form the aluminum alloy rod.
In this embodiment, the aluminum melt reaches the casting platform after passing through the tube filter, and is blocked by the gate plate in the flow channel, and the liquid level of the aluminum liquid starts to be raised. Before this, the cooling water system of the casting machine was already turned on.
When the liquid level of the aluminum melt reaches 90mm, the flashboard is lifted, and the aluminum liquid is simultaneously filled into each crystallizer of the platform. After the mold was filled with the molten aluminum, the dummy bar head began to descend and the casting began after a holding time of 14 seconds.
The initial casting speed was 143mm/min, the casting speed started to decrease at a constant speed when the casting length reached 125mm, and the casting speed reached 137mm/min when the casting length reached 165mm, at which time the aluminum alloy rods had entered a gas-slip state. Thereafter, the casting speed was maintained at 137mm/min until the end of casting.
(6) After casting, the aluminum alloy rod is lifted out of the casting well and then transferred to a homogenizing furnace for homogenizing treatment. The air temperature in the homogenizing furnace sequentially passes through the temperature raising section, the holding section, the temperature lowering section and the heat preservation section, please refer to fig. 2.
In this embodiment, the temperature raising period is 3 hours, the temperature maintaining period is 605 ℃, the time maintaining period is 1 hour, the temperature lowering period is 20min, the temperature maintaining period is 600 ℃, and the time maintaining period is 10 hours.
The circulating fan alternately rotates forward and backward in the heating section and the holding section by taking half an hour as a period, and alternately rotates forward and backward in the cooling section and the heat preservation section by taking one hour as a period.
The temperature of the aluminum bars at different positions in the homogenizing furnace is monitored by a furnace temperature tracker, and the monitoring result shows that the time difference of the aluminum bars of the whole batch reaching the heat preservation temperature of minus 5 ℃ is not more than 1 h.
(7) And after the homogenization treatment is finished, sending the aluminum alloy rod into a cooling furnace to be cooled to room temperature, and then carrying out fixed length cutting. And in a cooling furnace, air cooling is performed for 20min, water mist cooling is performed for 40min, and finally water cooling is performed to room temperature.
(8) The aluminum alloy bar is cut to length by sawing, and is sampled for detection, and the average grain size is less than 80 mu m. The product composition contains 0.12 wt% of titanium element and 0.01 wt% of copper element.
(9) The circulating fan rotates in a single direction in a positive and negative rotation ratio alternately, so that the temperature uniformity of the aluminum bar in the homogenizing furnace is obviously improved. The following table shows temperature data of points which enable the circulating fan to rotate in a positive and negative direction and rotate in a single direction alternately, and enable the aluminum bar in the homogenizing furnace to be heated up most quickly and heated up most slowly respectively. Fig. 3 and 4 are graphs showing temperature changes of the aluminum bar.
The circulating fan rotates forward and backward alternately, the time for the aluminum bar to reach 595 ℃ at the fastest temperature rise point is 224min, the time for the aluminum bar to reach 595 ℃ at the slowest temperature rise point is 277min, and the difference between the two is 53 min.
The circulating fan rotates in one direction, the time for the aluminum bar to reach 595 ℃ at the fastest temperature rise point is 221min, the time for the aluminum bar to reach 595 ℃ at the slowest temperature rise point is 373min, and the difference between the two is 152 min.
(10) Compared with the aluminum bar purchased from our company, the aluminum bar manufactured by the embodiment has better plasticity (the plasticity refers to the processing performance of the aluminum bar), the micro-channel flat tube with the same model is extruded, on the premise of ensuring the product quality, the fastest extrusion speed of the aluminum bar purchased from our company is 70m/min, the fastest extrusion speed of the aluminum bar purchased from our company is 100m/min, the influence of other factors is integrated, and the production efficiency is improved by 20%.
(11) The corrosion resistance of the micro-channel flat tube extruded by the aluminum bar manufactured by the embodiment is higher than that of a common flat tube in the market. Carry out SWAAT salt spray test, ordinary flat pipe 2000h leaks, and the flat pipe of this embodiment can reach 5000h and not leak, and product life promotes more than the one time.
Claims (3)
1. The production method of the high-plasticity high-corrosion-resistance aluminum alloy for the automobile is characterized by comprising the following steps of:
(1) comprises aluminum ingot, aluminum reclaimed material and AlMn20Master alloy and AlTi10Putting raw materials including the intermediate alloy into a melting furnace for melting to form an aluminum melt;
(2) carrying out deslagging operation and component regulation and control on the aluminum melt in a melting furnace, and transferring the aluminum melt to a holding furnace after the deslagging operation and the component regulation and control are finished;
(3) refining and standing the aluminum melt in a holding furnace, and then discharging the aluminum melt from the holding furnace;
(4) after flowing out of the heat preservation furnace, the aluminum melt is subjected to online dehydrogenation and online filtration by a degassing box and then reaches a casting crystallizer platform; setting the temperature of the molten aluminum in the degassing box to be 10-20 ℃ higher than that of the molten aluminum in the holding furnace, and adding an aluminum-titanium-boron wire into the molten aluminum between the holding furnace and the degassing box;
(5) solidifying the aluminum melt into an aluminum alloy rod in a crystallizer; in the process of crystallizing the aluminum melt into an aluminum bar, the aluminum melt is not directly contacted with a graphite ring of a crystallizer, and an air cushion and an oil film are established between the aluminum melt and the graphite ring;
in the process of crystallizing the aluminum melt into the aluminum bar, the casting speed is higher than that in the stable stage in the initial stage of casting, wherein the casting speed in the initial stage is 143mm/min, and the casting speed in the stable stage is 137 mm/min;
(6) feeding the aluminum alloy rod into a homogenizing furnace for homogenizing treatment; in the homogenizing treatment process, the device sequentially comprises a temperature rising section, a maintaining section, a temperature reduction section and a heat preservation section, wherein the temperature rising section is set to be 3 hours, the temperature of the maintaining section is 605 ℃, the time is 1 hour, the temperature reduction section is set to be 20 minutes, the temperature of the heat preservation section is 600 ℃, and the time is 10 hours;
(7) after the homogenization treatment is finished, the aluminum alloy rod is sent into a cooling furnace to be cooled to room temperature, and then the aluminum alloy rod is cut to length;
the aluminum alloy rod comprises the following components in percentage by mass: less than or equal to 0.1 percent of Si, less than or equal to 0.2 percent of Fe, less than or equal to 0.01 percent of Cu, 1.0 to 1.5 percent of Mn, less than or equal to 0.05 percent of Mg, less than or equal to 0.1 percent of Zn, 0.1 to 0.15 percent of Ti, less than or equal to 0.05 percent of the others, and the balance of Al;
the circulating fan circulates the hot air in the homogenizing furnace, and the circulating fan alternately rotates forwards and backwards to make the hot air in the homogenizing furnace flow in a reciprocating and circulating manner;
carrying out five-stage purification treatment and three-stage dehydrogenation treatment on the aluminum melt;
primary purification and primary dehydrogenation: in the step (2), a slag-aluminum separating agent is blown into an aluminum melt by using first argon gas, and slag removal operation is carried out;
secondary purification and secondary dehydrogenation: in the step (3), blowing a refining agent into the aluminum melt by using second argon gas to carry out refining operation;
third-stage purification: in the step (2), heavy metals are left in the melting furnace in the process of transferring the aluminum melt from the melting furnace to the heat preservation furnace, and in the step (3), the heavy metals are left in the heat preservation furnace in the process of transferring the aluminum melt from the heat preservation furnace to the casting platform;
three-stage dehydrogenation: in the step (4), the aluminum melt passes through a double-rotor online degassing box, and third argon is blown into the aluminum melt through two rotating silicon nitride rotors;
four-stage purification: in the step (4), the aluminum melt passes through the ceramic filter plate through the plate-type filter box, and impurities larger than 50 microns are blocked by the filter plate;
five-stage purification: in the step (4), the aluminum melt passes through the tubular filter and passes through the ceramic filter tube group, and impurities larger than 5 mu m are blocked by the filter tube group.
2. The production method according to claim 1,
in the raw materials, the mass percent of the aluminum reclaimed material is 30-40%.
3. The production method according to claim 1,
and (5) adopting an oil-gas slip casting method and an isothermal casting technology.
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