Study On Experiments And Process Of Al And Al-Mg Alloy Wire By CASTEX

Our country has large abundant of resource of Aluminum alloy which has been widely used in many aspects. With the relative scarcity of copper resources, the aluminum and aluminum alloy alternative to pure copper conductive material has become a tendency. The Continuous Casting and Extrusion is an energy saving, efficient, relatively small investment in equipment technology, will significantly reduce the cost of rod, wire of aluminum and aluminum alloys if it could be successfully applied in commercial. At the same time, its property is better than Continuous Casting and Rolling. So the Continuous Casting and Extrusion process has the most important practical significance for the development and application of the aluminum alloy. This paper is based on the theory of Continuous Casting and Extrusion and elected the pure aluminum and aluminum alloy as object. The technology of CASTEX process and metal’s flowing are studied, and the appropriate selection and preliminary research on the purification of molten and quantitative casting equipment of the producing line of CASTEX are taken, the corresponding transformation of the CASTEX equipment and CASTEX process parameters are optimized in this paper. Making the systematic analysis of the cause of the broken in the drawing process and the white spots on the surface of aluminum pole, the following results:(1) By the CASTEX theoretical analysis and experimental research, NEU laboratory of the CASTEX squeeze on the basis of the experimental equipment(DZJ300), by the frequency control, and the transformation of the wheel system, cooling system transformation, increase of quantitative gating system, and programmable control technology(PLC), quantify the CASTEX process parameters and process control to ensure the stability of the continuous solidification and forming process for aluminum and aluminum-magnesium alloy conductive material testing and product test providers a good equipment conditions.(2) Through the CASTEX force calculation and experimental studies, and comprehensive evaluation on the basic of products organization, performance, production and energy consumption, the optimum condition of the CASTEX prepared by Al and Al-3Mg wire are:the wheel speed of in the CASTEX process of Al-Mg wire in10r/min, the gap between roll and boot is0.7mm, pouring temperature is from675℃to685℃, the best cooling method is online cooled-water; however, the Al is that the speed is14r/min, the gap is0.9mm, pouring temperature is from720℃to740℃, and the best cooling method is also online cooled-water. Above-mentioned optimization results ensure that the CASTEX can carry out smoothly, the cycle crack will not emerge on the surface of products, and the mechanical and electrical resistance of products will meet the requirements, and reduce the energy consumption, save the power energy, under the premise of higher qualifying speeds.(3) In order to improve production efficiency, the mode structure is designed for porosity. In this regard, the mobility of the metal was analyzed. Due to the presence of dead zone and the temperature difference lead to the mobility of metal uneven. So, in order to improve the mobility of metal, the unequal length size band is taken into designing in the CASTEX process. At the same time, enlarge the size of micro-extrusion by the way of mold expansion mode, the extrusion deformation, further refine the grain structure, obtain the Al and Al-3Mg wire which has the best mechanical properties. They are that:the tensile strength of Al wire is90Mpa, the percentage of elongation is35%, and the hardening exponent is0.21; while the Al-3Mg is that the tensile strength of Al-3Mg wire is126Mpa, the percentage of elongation is36%, and the hardening exponent is0.26. Due to the Al and Al-3Mg wire products by CASTEX have good plasticity, the hardening exponent is high (the percentage of elongation of the pole by the continuous casting and rolling is18%, the hardening exponent is0.08), so it is fit for the following-up process of drawing by the large deformation. At the same time, the conductivity index of Al and Al-3Mg wire are accord with the corresponding requirements of the electrician aluminum wire standard.(4) In order to coordinate with the drawing process of CCA wire, research the combination of Cu-Al interface and the distribution patterns of pore and impurity in the aluminum pole. When the pore and impurity is found in the pole, it can cause broken wire in the process of drawing. The purification of molten is the most important link in the manufacturing technique process of Al and Al-3Mg lead. Therefore, the appropriate selection and preliminary research on the melt purification equipment increase the drawing property of products. At the same time, research on the phenomenon of white spots on the surface of CCA wire, and show that the phenomenon of white spots is caused by the galvanic corrosion of CCA wire after pitting corrosion.