Aluminium extrusion yog ib qho tseem ceeb ntawm cov yas tsim cov txheej txheem hauv kev lag luam txhuas ua cov saw hlau. Nws tsim architectural thiab industrial profiles nrog predefined cross-sectional duab thiab qhov ntev los ntawm kev siv axial siab rau aluminium alloy billets kom yuam lawv los ntawm cov kab noj hniav tuag. This process features high material utilization, high forming efficiency and dense product microstructure, and its products are widely used in construction, rail transit, new energy vehicles, electrical and electronics, aerospace and other fields. Qhov sib txuam ntawm cov txheej txheem extrusion tsis thiab cov txheej txheem tswj ncaj qha txiav txim siab txog microstructure, txhua yam khoom, qhov tseeb qhov tseeb thiab qhov zoo ntawm extruded profiles, uas yog ib qho kev xav ntawm cov tub ntxhais kev muaj peev xwm ntawm txhuas ua lag luam.
I. Core Extrusion txheej txheem ntws thiab cov txuas tseem ceeb
Aluminium extrusion yog txheej txheem txheej txheem nrog ntau txheej txheem kev sib koom tes, uas tuaj yeem muab faib ua peb theem: billet pretreatment, extrusion forming, thiab kev kho tom qab extrusion. Cov txheej txheem precision ntawm txhua qhov txuas sib koom ua ke txiav txim siab cov khoom lag luam kawg.
1. Cov txheej txheem Billet Pretreatment
(1) Homogenization kev kho mob
Thaum lub sij hawm ib nrab nruam casting, aluminium alloy ingots yog nquag mus rau microstructure defects xws li intracranular segregation, coarse thib ob theem thiab concentrated nyob rau hauv kev ntxhov siab. Direct extrusion yuav ua rau tsis sib xws deformation tsis kam, tsis zoo nto thiab kev ua haujlwm loj hloov pauv. Homogenization kev kho mob muaj xws li cua sov lub billet rau ib tug kub hauv qab lub solidus kab thiab tuav nws ntev (rau 6xxx series alloys, feem ntau 540 ~ 580 degree, tuav rau 4 ~ 12 teev). Nws tshem tawm cov kev sib cais sib cais los ntawm atomic diffusion, thiab dissolves thiab precipitates coarse intermetallic tebchaw, ho txhim kho lub plasticity thiab deformation uniformity ntawm billet, uas yog qhov yuav tsum tau ua ntej kom ntseeg tau tias extrusion zoo.
(2) Billet thiab Tuag Preheating
Cov cua kub cua sov yuav tsum tau teem raws li cov txheej txheem alloy: 460 ~ 530℃rau 6xxx wrought aluminium alloys, thiab 400 ~ 480℃rau 7xxx high-strength aluminium alloys. Lub hauv paus ntsiab lus yog los xyuas kom meej zoo plasticity ntawm cov hlau thaum tsis txhob overburning. Lub caij no, lub thawv extrusion thiab tuag yuav tsum tau preheated synchronously. Qhov kub ntawm qhov tuag feem ntau yog 10 ~ 30℃qis dua qhov kub thiab txias, kom txo tau qhov kev nce siab ntawm kev ua haujlwm thiab tuag thermal shock tshwm sim los ntawm qhov kub thiab txias.
2. Extrusion txheej txheem
Raws li cov hlau ntws thiab cov yam ntxwv kev ntxhov siab, cov txheej txheem extrusion tseem ceeb tau muab faib ua peb pawg, hloov mus rau qhov sib txawv ntawm cov khoom muag:
Direct Extrusion: Cov txheej txheem siv dav tshaj plaws. Lub billet txav mus rau pem hauv ntej nrog lub extrusion qia, thiab cov hlau ntws kev taw qhia yog zoo ib yam nrog lub extrusion qia. Nws nta kev ua haujlwm yooj yim thiab hloov pauv yooj yim, tab sis muaj kev sib txhuam loj ntawm lub thawv ntim, thiab muaj qee qhov sib txawv hauv microstructure thiab cov khoom ntawm lub taub hau thiab tus Tsov tus tw ntawm qhov profile.
Indirect Extrusion: Cov tuag txav synchronously nrog lub extrusion qia. Tsis muaj tus txheeb ze zawv zawg ntawm cov hlau thiab lub thawv extrusion, uas ua rau tsis muaj kev sib txhuam tsis zoo, tsis sib xws deformation thiab qis extrusion quab yuam. Nws yog haum rau high-strength alloys thiab high-precision industrial profiles, tab sis cov khoom siv yog complex thiab tus nqi tu yog siab.
Isothermal Extrusion: Los ntawm presetting lub axial kub gradient ntawm lub billet thiab tswj lub extrusion ceev nyob rau hauv lub sij hawm ntawm lub sij hawm, cov hlau kub nyob rau hauv lub deformation cheeb tsam yog khaws cia tas li. Nws tag nrho daws qhov sib txuas ntawm qhov tsis sib xws ntawm qhov nrawm thiab qhov kub thiab txias, thiab paub txog cov qauv microstructure thiab cov khoom raws li qhov ntev ntawm qhov profile. Nws yog cov txheej txheem tseem ceeb rau high-end industrial profiles.
Lub ntsiab parameter ntawm txheej txheem extrusion yog qhovextrusion ratio(qhov piv ntawm qhov sib npaug ntawm qhov chaw ntawm lub thawv extrusion mus rau qhov chaw hla ntu ntawm qhov profile), uas qhia txog qib ntawm deformation. Qhov sib piv extrusion ntawm architectural profiles feem ntau yog 20 ~ 50, thiab cov txheej txheem kev lag luam tuaj yeem ncav cuag 50 ~ 100. Tsis txaus extrusion piv yuav ua rau tsis muaj zog grain refinement nyhuv thiab tsis muaj zog, thaum ntau npaum li cas yog txwv los ntawm cov khoom tonnage thiab tuag lub zog.
3. Cov txheej txheem kho tom qab Extrusion
(1) On-line Quenching
Qhov kub ntawm qhov profile tawm hauv qhov tuag yog ze rau qhov kev kho mob kub, yog li nws yuav tsum tau txias thiab quenched tam sim ntawd kom cov ntsiab lus alloy yaj nyob rau hauv lub txhuas matrix nyob rau hauv ib tug supersaturated lub xeev, tsim tej yam kev mob rau ntxiv dag zog rau lub hnub nyoog. Cov txheej txheem cua txias tau muab faib ua peb pawg: cua txias, dej cua txias thiab dej txias, sib xws rau cov khoom sib txawv:
T5 Temper: Txais cov cua txias los yog dej pos huab cua txias nrog cov cua txias nruab nrab, ua ke nrog cov khoom qub tom qab, nws muaj qhov zoo sib xws thiab yog siv dav hauv kev tsim vaj tsev zoo nkauj.
T6 Temper: Txais cov dej sov los yog cov dej tsis muaj zog quenching nrog cov cua txias ceev thiab cov kev daws teeb meem txaus, nws muaj zog dua tom qab kev laus thiab siv rau kev lag luam kev lag luam.
Tus nqi cua txias yuav tsum phim cov alloy muaj pes tsawg leeg: tsis txaus cua txias yuav ua rau ntxov ntxov nag lossis daus ntawm theem ob thiab txo cov hnub nyoog ntxiv zog; Cov cua txias ntau dhau yuav yooj yim ua kom muaj kev ntxhov siab loj hauv sab hauv, ua rau deformation thiab tawg ntawm qhov profile.
(2) Stretch Straightening thiab tiav
Lub quenched profile muaj qhov seem sab hauv kev ntxhov siab thiab khoov / twisting tsis xws luag. Lub tensile deformation ntawm 0.5% ~ 2% yog siv los ntawm ib lub stretcher kom tshem tawm kev ntxhov siab thiab kho qhov ncaj thiab qhov tseeb. Tom qab ntawd, qhov ntev-ntev sawing, kev laus laus, thiab kev kho saum npoo (anodizing, electrophoretic txheej, hmoov txheej, thiab lwm yam) yog ua raws li qhov yuav tsum tau ua.
(3) Artificial Aging
Artificial aging yog cov txheej txheem tseem ceeb ntawm cov cua kub ntawm qhov profile mus rau qhov kub thiab txias, kom cov kua dej supersaturated precipitates nano-scale ntxiv dag zog rau theem, txhim kho lub zog. Cov txheej txheem xws li: T5 kev laus ntawm 6063 alloy ntawm 170 ~ 180℃rau 6 ~ 8 teev; T6 kev laus ntawm 6061 alloy ntawm 175℃rau 8 ~ 10 teev. Kev tswj xyuas meej ntawm kev laus kub thiab lub sijhawm yog lub hauv paus ntsiab lus los kho qhov sib txuam ntawm lub zog thiab plasticity.
II. Mechanism of Process Parameters on Microstructure thiab Properties
Cov txheej txheem extrusion yog txheej txheem kub deformation nrog ntau qhov sib txuas ntawm qhov kub, ceev thiab deformation. Cov txheej txheem tsis kawg txiav txim siab txog microstructure thiab cov khoom ntawm qhov profile los ntawm kev hloov pauv tus cwj pwm recrystallization thiab nag lossis daus ntawm theem ob.
1. Kub Parameter
Ua kom lub billet kub yuav txhim kho cov yas yas thiab txo cov deformation tsis kam, uas yog qhov tsim nyog rau kev tsim cov ntu ntu. Txawm li cas los xij, thaum qhov kub siab tshaj qhov tseem ceeb, nws yuav ua rau cov nplej coarsening, ntau dhau recrystallization, thiab txawm tias overburning tsis xws luag, ua rau lub pob tsuas zoo li poob ntawm cov khoom siv kho tshuab. Nyob rau tib lub sij hawm, cov yas deformation ua hauj lwm thaum lub sij hawm extrusion yuav hloov mus rau hauv tshav kub, ua rau tuag tawm kub ntawm qhov profile ho siab tshaj qhov pib billet kub. Qhov ceev ntawm extrusion ceev, qhov pom tseeb ntawm qhov kub nce, uas yog qhov nyuaj ntawm kev tswj cov txheej txheem.
2. Extrusion ceev
Lub extrusion ceev yuav tsum tau dynamically matched nrog kub: ceev ceev heev yuav ua rau concentrated deformation tshav kub, nto defects xws li tearing thiab txiv kab ntxwv tev ntawm lub profile, thiab loj kub sib txawv ntawm cov tub ntxhais thiab nto, uas yuav ua rau uneven microstructure thiab zog; qeeb qeeb qeeb yuav ua rau cov khoom siv qis qis, thiab qhov profile nyob twj ywm hauv qhov kub thiab txias rau lub sijhawm ntev, uas yog qhov yooj yim rau recrystallized grain loj hlob. Kev lag luam feem ntau siv cov tswv yim zoo sib xws ntawm "tsis tshua muaj kub + ceev extrusion" lossis "siab kub + qeeb extrusion", thiab sib txuas isothermal extrusion tshuab kom ua tiav qhov sib npaug ntawm kev ua haujlwm thiab zoo.
3. Deformation degree
Raws li cov yas deformation txoj kev xav, nce qhov sib piv extrusion yuav ua rau kom cov dislocation ceev, txhawb dynamic recrystallization, refine lub grain qauv, thiab txhim kho cov khoom ntawm lub zog thiab plasticity ntawm cov profile. Thaum qhov sib piv extrusion tsawg dua 10, cov txiaj ntsig zoo ntawm cov nplej tsis pom tseeb, thiab cov pob zeb ntxhib pob zeb tsis zoo yuav tshwm sim; ntau extrusion piv yuav ua rau ib tug ntse nce nyob rau hauv extrusion quab yuam, uas yog txwv los ntawm cov khoom tonnage thiab tuag lub zog.
4. Quenching thiab Aging Regime
Lub quenching txias tus nqi ncaj qha txiav txim siab txog qib ntawm kev kho cov tshuaj: qhov ceev ntawm qhov txias txias, qhov siab dua qhov concentration ntawm cov tshuaj supersaturated, thiab qhov ntau dispersed lub zog theem precipitated tom qab laus, ua rau muaj zog dua. Rau 6xxx series alloys, qhov tseem ceeb ntawm qhov txias txias yog li 1 ~ 5℃/ s. Hauv qab no tus nqi, Mg₂Si theem precipitates ua ntej thiab poob lub zog ntxiv zog.
Cov txheej txheem kev laus txiav txim siab cov nag lossis daus ntawm cov theem ntxiv: kev laus qis ua rau cov nag lossis daus tsis txaus ntawm cov theem ntxiv thiab tsis muaj zog; Peak aging ncav cuag lub siab tshaj plaws lub zog tab sis nrog tsawg plasticity; over-aging ua rau coarsening ntawm ntxiv dag zog rau theem, txo lub zog thiab txhim kho plasticity. Cov kev tswj hwm zoo yuav tsum raug xaiv raws li cov khoom lag luam xav tau.
III. Cov txheej txheem tswj meej meej rau Core Performance Indicators
Kev tswj hwm ntawm aluminium extruded khoom tsom rau plaub qhov loj me: cov khoom siv kho tshuab, qhov tseeb qhov tseeb, qhov zoo ntawm qhov chaw, thiab kev tiv thaiv corrosion & hluav taws xob conductivity.
1. Mechanical Property Control
Mechanical zog (lub zog tensile, yield zog, elongation tom qab tawg) yog cov cim tseem ceeb ntawm industrial profiles. Txoj kev tswj tag nrho cov txheej txheem suav nrog:
Composition Source Control: Precisely tswj cov ntsiab lus ntawm ntxiv dag zog rau cov hlau, xws li tswj tag nrho cov ntsiab lus ntawm Mg thiab Si thiab Mg / Si piv nyob rau hauv 6xxx series alloys los xyuas kom meej txaus tsim ntawm Mg₂Si ntxiv dag zog rau theem; nruj me ntsis tswj impurity ntsiab xws li Fe thiab Cu kom tsis txhob nkig theem txo plasticity.
Homogenization txaus: Ua kom muaj kev sib xyaw ua ke thiab microstructure ntawm billet thiab tshem tawm cov kev hloov pauv hauv zos.
Extrusion txheej txheem Matching: Tswj qhov tsim nyog extrusion kub thiab extrusion piv los xyuas kom meej txaus dynamic recrystallization thiab grain refinement.
Quenching-aging Closed-Loop Control: Xyuas kom lub quenching cua txias npaum li cas raws li tus qauv, thiab precisely tswj qhov kub thiab txias uniformity thiab tuav lub sij hawm ntawm lub aging furnace kom ua tau zoo nag lossis daus ntawm ntxiv dag zog rau theem.
2. Dimensional Accuracy Control
Qhov tseeb qhov tseeb ntawm aluminium profiles cuam tshuam los ntawm ntau yam xws li tuag, khoom siv thiab txheej txheem. Cov ntsiab lus tswj muaj xws li:
Tuag qhov ntev: Txais kev ua haujlwm siab precision thiab daim iav polishing, tsim tsim nyog bearing av ntev thiab porthole qauv los them rau qhov sib txawv ntawm cov hlau khiav ceev.
Txheej txheem dimension: Stabilize extrusion kub thiab ceev kom tsis txhob hla-sectional deformation tshwm sim los ntawm qhov tsis sib xws txaus tus nqi; tswj lub stretching npaum li cas ntawm stretch straightening los tiv thaiv seem deviation.
Khoom Dimension: Xyuas kom meej qhov tseeb ntawm lub extruder thiab qhov ncaj ntawm cov kev taw qhia rail kom txo tau qhov sib tw thiab khoov los ntawm cov cuab yeej clearance.
Qhov tseeb qhov tseeb ntawm high-end industrial profiles tuaj yeem ncav cuag qib IT6 ~ IT7, ua tau raws li qhov yuav tsum tau ua ntawm kev sib dhos precision.
3. Kev Tswj Xyuas Qhov Zoo
Cov teeb meem tshwm sim muaj xws li khawb, qhov, streaks, hlwv, thiab lwm yam. Cov kev tiv thaiv tseem ceeb thiab kev tswj xyuas yog:
Txhim kho cov metallurgical zoo ntawm billets kom txo tau qhov tsis xws luag xws li pores thiab inclusions.
Tuav lub thawv extrusion thiab tuag tsis tu ncua, ntxuav cov khib nyiab ntawm qhov chaw thiab cov khoom siv txhuas, thiab khaws cov av bearing tuag rau hauv daim iav.
Optimize qhov sib piv ntawm extrusion ceev thiab kub kom tsis txhob nto tearing tshwm sim los ntawm cov hlau ntws ntau dhau.
Ua kom zoo rau cov qauv kev xa tawm ntawm lub rooj tawm thiab lub txaj txias kom txo tau cov khoom khawb.
4. Corrosion Resistance thiab hluav taws xob Conductivity Control
Corrosion tsis kam: Txo qhov nyiam ntawm electrochemical corrosion los ntawm kev tswj lub uniformity ntawm grain qauv thiab txo cov ntxhib theem ob; ua ke nrog kev kho deg xws li anodizing thiab electrophoretic txheej, cov ntsev tsuag tsis kam thiab acid-base kuj tuaj yeem txhim kho tau zoo.
Hluav taws xob conductivity: Rau txhuas profiles rau hluav taws xob conduction, nws yog tsim nyog los tswj cov ntsiab lus ntawm impurity ntsiab thiab txo lattice distortion; Nyob rau tib lub sijhawm, tsis txhob coarsening ntawm theem ob tshwm sim los ntawm kev laus dhau, thiaj li ua kom qhov sib npaug ntawm cov conductivity thiab lub zog.
IV. Common Quality Defects and Prevention Solutions
| Hom kev puas tsuaj | Core Ua | Kev Tiv Thaiv & Tswj Kev daws teeb meem |
|---|---|---|
| Nto blisters / peeling | Pores thiab shrinkage kab noj hniav nyob rau hauv billets; residual roj los yog txhuas chips nyob rau hauv extrusion thawv | Txhim kho billet casting zoo; ntxuav lub thawv extrusion thiab tuag ua ntej extrusion; tswj billet cua sov kub kom tsis txhob overburning |
| Coarse grain nplhaib / grain coarsening | Extrusion kub heev; me me extrusion piv; tsis txaus deformation degree | Txo qhov kub thiab txias; nce extrusion ratio; optimize extrusion ceev kom inhibit recrystallization grain loj hlob |
| Unqualified mechanical zog | Tsis txaus quenching txias tus nqi; deviation ntawm aging regime; kev cais cais | Ua kom quenching txias siv; calibrate kub uniformity ntawm aging rauv; xyuas kom txaus billet homogenization |
| Profile twisting / dabtsi yog khoov | Tsis tsim nyog tsim ntawm tuag bearing av; tsis sib npaug hlau ntws tus nqi; tsis tsim nyog stretch straightening | Optimize tuag portholes thiab bearing av; kho extrusion kub thiab ceev; precisely tswj stretching npaum li cas thiab kev taw qhia |
| Nto khawb / rub cov cim | Hnav ntawm tuag bearing av; tawv protrusions ntawm qhov rooj tawm thiab lub txaj txias | Polish lossis hloov tuag tsis tu ncua; ntxuav qhov chaw sib cuag ntawm cov khoom siv conveying; optimize tso tawm cov qauv qhia |
V. Kev Lag Luam Technology Development Trends
Nrog rau kev kho dua tshiab ntawm kev thov los ntawm high-end downstream manufacturing, aluminium extrusion tshuab txuas ntxiv hloov mus rau qhov siab precision, kev ua haujlwm siab, qis carbonization thiab kev txawj ntse.
Integrated Extrusion ntawm Loj Complex Hla-SectionKev thov los ntawm cov teb xws li lub zog tshiab lub tsheb chassis thiab kev tsheb ciav hlau tsheb thauj mus los txhawb kev nrov ntawm 10,000-tuj loj-tonnage extruders, paub txog kev sib koom ua ke ntawm cov phab ntsa loj nyias nyias, qhov khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob khoob
Extrusion Technology rau High-Strength thiab High-Toughness AlloysKev tawg ntawm kev siv tshuab extrusion rau 7xxx, 2xxx high-strength aluminium alloys thiab aluminium-lithium alloys txhawb nqa lub teeb yuag ntawm aerospace thiab lub zog tshiab tsheb. Cov teeb meem tseem ceeb nyob hauv kev tswj deformation tawg thiab txhim kho microstructure uniformity. Indirect extrusion, isothermal extrusion, gradient cua sov thiab lwm yam thev naus laus zis tau dhau los ua qauv tsim.
Intelligent Extrusion Production LinesLos ntawm cov ntxaib digital, on-line infrared ntsuas kub ntsuas, ntsuas qhov pom qhov pom thiab lwm yam thev naus laus zis, lub sijhawm kaw-loop tswj qhov ntsuas extrusion yog pom tau; ua ke nrog AI algorithm los ua kom zoo dua tus qauv tsim thiab cov txheej txheem tsis sib xws, phau ntawv sim thiab kev ua yuam kev raug txo, thiab cov txiaj ntsig thiab kev tsim khoom tau zoo dua qub.
Ntsuab thiab Tsawg-Carbon Extrusion txheej txheemTxhawb kev txuag hluav taws xob xws li electromagnetic induction cua sov thiab pov tseg cov cua sov kom txo tau lub zog siv hauv cov txheej txheem extrusion; tsim cov txheej txheem luv luv-ntws extrusion, tshem tawm cov kab hluav taws xob reheating txuas, thiab ncaj qha siv cov khib nyiab pov tseg rau extrusion, uas tuaj yeem txo qis kev siv hluav taws xob ntau dua 30%.
