铝板带轧制工艺原理(中英文)

1TheMechanicsoftheAluminumSheetRollingProcess铝板带轧制工艺机理2TheMechanicsoftheAluminumSheetRollingProcess铝板带轧制工艺机理Index索引1.Preamble导言2.Casting2.铸造(i)Description(i)描述(ii)MetalFilter(ii)金属过滤器(iii)CastingMachines(iii)铸造机(iv)ContinuousCasters(iv)连续铸造机3.Scalping3.铣削(i)Surface(i)表面(ii)Edge(ii)边(iii)HeadandTails(iii)头和尾4.PreheatingandHomogenizing4.加热和均热5.Hotlines5.热轧线(i)HotlinetableGeometry3(i)热轧线辊道几何学(ii)Configuration(ii)配置(iii)Hotmillrollroughness(iii)热轧机轧制粗糙度(iv)Rollgrinding(iv)磨辊(v)Scratchbrushes(v)钢丝刷6.Hotrolling6.热轧7.Coldrolling7.冷轧(i)Reductions(i)压下量(ii)Shape(ii)形状(iii)Surfacefinish(iii)表面光洁度FourthAnnualHiarcMeetingOctober16-18,1996Toronto,Canada第四届Hiarc年会1996年10月16日到18日多伦多，加拿大Themechanismofthealuminumsheetrollingprocess铝板带轧制工艺机理1.Preamble1.导言Duringtherollingofaluminumsheet,particularlyhotrollingmanyproblemsmayarise.Thereisfrequentlyaninitialtendencytoascribemanyofthesetothecoolant.Someoftheissuesinthecircumstancesarenotcoolantrelated.Thispaperdescribesthetreatmentofaluminumfromcastingtocoldrollinginanattempttogivesomeinsightintothemanyproblemsthatcanariseintherollingprocess.铝板带轧制过程中，尤其是热轧，会出现很多问题。经常性的最初倾向是，把这些问题的多数归因于冷却液。一些问题所处的环境与冷却液无关．此文件描述了从铸造到冷轧的铝处理方法，试图就轧制过程中可能会出现的许多问题给出一些深刻的见解。42.Casting2.铸造(i)Description(i)描述Forthepurposesofrollingsheetorplateasopposedtoextruding,aluminumismainlycastbytheV.D.C.orverticaldirectchillprocesswhichproducelargeblockofupto30inchesthicksuitableforrolling,ortoalesserextentmaybeproducedbycontinuouscastingwhichmakescoilwithametalthicknessofbetweenal/4”to3/4”.轧制铝带材或铝板的目的，不允许有挤压，铝主要是由立式直冷铸造机铸造的，立式直冷铸造机可生产适用于轧制厚度达30英寸的大铝块，或在较小程度上也可通过连续铸造生产厚度在l/4到3/4英寸之间的卷材。Themoltenmetalwhichisusedforcastingmaybeanyoneofseriesofalloyfrom1xxxthrough2,3,4,5,6to7xxx.Themostcommonare1xxx'swhicharelargelypurewithminoralloyingandareusedforfoilstock,to3xxx’susedextensivelyas3004forbodystockto5xxx'sas5182forcanendstockand5086asahightensilesheet.Series2xxxand6xxxareheattreatableandbesidesmagnesiumhavehigherconcentrationsofcopper.The7xxxseriesalloyswithsignificantzincareusedinsomeplacesforarmourplate.用于铸造的熔化金属可以是从1XXX到7XXX的任何一系列合金。最普通的是1XXX系列，它的纯度很高、合金很少，被用作铝箔原料；3xxx系列如3004大量用于罐体坯料；5xxx系列如5182用于罐盖料以及5086用于高强度拉伸板。2xxx和6xxx系列可进行热处理，除了镁之外，还含较高浓度的铜。7xxx系列含有大量的锌，用于需要装甲板的地方。Themeltingpointformostalloysfallswithintherange1125to1215oF8or610to660oC)大多数合金的熔点在1125到1215oF或610～660oC范围内。Duringthemeltingandcastingoperationdueattentionmustbepaidtotwoparameters.在熔铸操作过程中必须关注两个参数。Hydrogen氢Firstlyhydrogenwhichisabsorbedbythemetalwithincreasedsolubilitythemoltenmetaltemperatureincrease.Asthemoltenmetalcoolsanydissolvedhydrogenwillcomeoutofsolutionandformssmallbubblesinthesolidifiedmetalcalledocclusions.0ntherollingsurfacedefectsresult.首先，氢被金属吸收增加，其溶解性随熔铸金属温度升高而升高。熔铸金属冷却时，氢会从溶液中挥发出来，在凝固的金属上形成小气泡被称作吸留物，这种吸留物会影响轧制表面质量，成为表面缺陷。AluminumOxide氧化铝Secondlythepresenceofaluminumoxidewhichformsreadilyinoxygenandofcourseinair.第二，氧化铝的存在，氧化铝在氧气中形成，当然在空气中也形成。Aluminumoxidecanexistinanysizeparticlescalledinclusions.Consideringthatthethinnestfoilrolledisabout0.2thousandthofaninch(5.5microns)andthatthethicknessofadrawnandironedaluminumcanwallisaboutthisthicknesstheninclusionoverabouthalfthissizeareunacceptable.氧化铝能够以任何尺寸的颗粒存在，称之为夹杂物。考虑到最薄的轧制铝箔的厚度大约是5千分之0.2英寸（5.5微米）并且拉深铝罐壁的厚度大约也是这个厚度，那么，如果夹杂物的厚度超过此尺寸的一半将不能被接受。(ii)MetalFilters金属过滤器Figure1showstheoutlineofthetwomostcommonaluminumfiltersusedtoremovehydrogenandassistintheextractionofaluminumoxidefromthemoltenmetal.图1显示了两种最普通的用于除去氢和帮助从金属熔化物中除去氧化铝的铝过滤器的外形图。GasFilters气体过滤器OneiscalledaSNIFpreviouslymadebyUnionCarbideandtheotheranAlpurmadebyPechiney(Alcoahasasimilarunitcalleda622).Thesefilteralloperateonthesamebasis,thatispassingshearedbubblesofArgonGaswith2%to3%ofchlorinethroughthemoltenmetal.Thisshouldextractanyhydrogentolessthan0.2milliliters(ccs)per100gramsofmetal(infacttomuchlessthanthisisstandard)andliftsahighpercentageofallaluminumoxidetothesurfaceofthefilterswhereitcanbeskimmedoff.一个被称之为SNIF，先前由UnionCarbide制造，另一个叫Alpur,由Pechiney生产（Alcoa拥有类似装置，叫做622）。所有这些过滤器操作基理相同：将氩气及浓度为2％到3％的氯的混合气泡通过金属熔化物。这将取出金属中的氢，使之少于每100克0.2毫升（ccs）的氢（实际上甚至可以比这标准更少），及提升所有氧化铝到过滤器的表层位置，然后可以撇去。CeramicFoamFiltersInadditiontotheabovetypeoffiltermostplantsuseaCFF(ceramicfoamfilter)oraTKR(aluminumoxideorsiliconcarbide)filterasafinalfilter.Thefirstisaprobabilityfilterinthesensethatitisselfblindingwhilethesecondisapositivescreen.陶瓷泡沫过滤器除了以上类型的过滤器，大多数工厂使用CFF(陶瓷泡沫过滤器)或TKR（氧化铝或碳化硅）型过滤器作为最终选择。CFF(陶瓷泡沫过滤器)是一种几率性过滤器（因为它本身是一些盲管），而TKR（氧化铝或碳化硅）是一种绝对的过滤器。6ThemostcommonCFF’saremadebySeleeandFosecowhileTKRfilterswhichwerefirstdevelopedbyKeiserAluminumarewidelyusedandmarketedunderthatnameinJapan.最常见的CFF过滤器由Selee和Foseco生产制造，而TKR过滤器最先由Keiser铝业公司研制，并在日本被广泛使用和以此冠名销售。Theeffectivenessoftheabovetypeofarrangementisthatintheworld’sbiggestproductwhichiscanbodystocktheoccurrenceofwhatiscalledsplitflangesduringthebodymakingprocess,hasgonefrom1in10,000in1980toabout!in1,000,000aswespeak.上述类型配置的效果是，对于世界上最大用量的罐体料产品中出现的问题，被称为罐体制造过程的开裂问题，像我们说的那样，已经从1980年的1/10,000降到目前的1/1,000,000。Anoteofcautionhoweverisappropriate,andthatis,thatnotallrollingplantshavethesefacilities.In