高压电力电缆皱纹铝护套的挤制

从产品的结构设计、铝杆选用、模具设计、产品制造等方面进行论述,重点介绍采用铝杆挤制铝护套的结构设计、产品制造过程中关键技术的控制,确保产品满足质量要求。

连续包覆挤铝技术在超高压电缆中的应用

不同于传统的焊接皱纹铝护套,新型连续包覆挤铝技术不仅产量高,而且能够生产真正的连续无缝护层。主要介绍了连续包覆挤铝技术的原理及其在超高压交联聚乙烯(XLPE)绝缘电力电缆皱纹铝护套生产中的应用,着重分析在铝护套挤制过程中连续包覆挤铝工艺的关键控制要点,针对其经常出现的问题提出了相应的解决方法及预防措施。连续包覆挤铝技术是一种非常实用的生产技术,其工艺优点明显,有着非常广阔的应用前景。

铝挤压锭半连续铸造工艺研究和发展

简述了各种铝挤压锭半连续铸造工艺的研究和发展。重点介绍了国外热顶铸造发展情况和国内热顶铸造研究成果，阐明了热顶铸造的优越性。

铝挤型散热片正面避位加工工艺分析与夹具设计

针对髙精度、易变形的铝挤型散热片完成多个部位的局部加工,设计出快捷、操作简便、保证加工质量的专用型夹具,方 便零件能够大批量生产,提髙生产效率,为企业谋取较大的盈利？

无缝平滑铝套电缆的设计及应用

根据连续包覆挤铝技术生产无缝铝套的原理,在焊接平滑铝套电缆生产工艺基础上,创新设计了无缝平滑铝套电缆产品及生产工艺,从结构、机械性能及安装应用等方面对无缝平滑铝套电缆进行试验分析,结果表明设计的无缝平滑铝套电缆具有制作工艺先进、产品性能优良、应用效果良好、市场前景广阔等优势。

Refinement and consolidation of pure Al particles by equal channel angular pressing and torsion

Consolidation of pure Alpowder was conducted at 200 ℃ by equal channel angular pressing and torsion （ECAPT） method. The grain refinement and consolidation behavior were deeply investigated by scan electronic microscopy （SEM） and transmission electronic microscopy （TEM）. The density, hardness and room temperature compression properties of the deformed samples were measured. The experiment results show that ECAPT is an effective method of consolidating powders at relatively low temperatures. Pure A1 particles are successfully consolidated into dense bulk material after 4 passes of ECAPT at 200 ℃. The consolidated material possesses fine grain structure and excellent mechanical properties. The refinement and consolidation mechanisms were analyzed. ECAPT is a promising method to produce the high-performance bulk materials from particles.

Uniaxial compressive behavior of equal channel angular pressing Al at wide temperature and strain rate range

Uniaxial compressive experiments of ultrafine-grained Al fabricated by equal channel angular pressing(ECAP) method were performed at wide temperature and strain rate range. The influence of temperature on flow stress, strain hardening rate and strain rate sensitivity was investigated experimentally. The results show that both the effect of temperature on flow stress and its strain rate sensitivity of ECAPed Al is much larger than those of the coarse-grained Al. The temperature sensitivity of ultrafine-grained Al is comparatively weaker than that of the coarse-grained Al. Based on the experimental results, the apparent activation volume was estimated at different temperatures and strain rates. The forest dislocation interactions is the dominant thermally activated mechanism for ECAPed Al compressed at quasi-static strain rates, while the viscous drag plays an important role at high strain rates.

Extrusion force analysis of aluminum pipe fabricated by CASTEX using expansion combination die

To determine the extrusion force of pipe fabricated by continuous casting and extrusion (CASTEX) using an expansion combination die, the metallic expansion combination die was divided into diversion zone, expansion zone, flow dividing zone, welding chamber, and sizing zone, and the corresponding stress formulae in various zones were established using the slab method. The deformation zones of CASTEX groove were divided into liquid and semisolid zone, solid primary gripping zone, and solid gripping zone, and the formulae of pipe extrusion forces were established. Experiments were carried out on the self-designed CASTEX machine to obtain the aluminum pipe and measure its extrusion force using the expansion combination die. The experimental results of radial extrusion force for aluminum pipe are in good agreement with the calculated ones.

Force analysis and experimental study of pure aluminum and Al-5%Ti-1%B alloy continuous expansion extrusion forming process

The deformation zone of CONFORM extrusion was divided into primary gripping zone,gripping zone,conical expansion chamber zone,cylindrical zone and sizing zone of die,and corresponding force equilibrium equations were established using the Slab method.The deformation force formulae of CONFORM machine at any wrapping angle with an expansion chamber were obtained.Experiment on pure aluminum and Al-5%Ti-1%B alloy was conducted on the CONFORM machine self-designed.The resistance to deformation of Al-5%Ti-1%B alloy at the deformation temperature of 400℃ and the strain rate of 3.07 s-1 was measured to be 50 MPa using Gleeble-1500 thermal simulation machine.The calculation results of deformation forces for CONFORM process with an expansion chamber for pure aluminum and Al-5%Ti-1%B alloy were given.The experimental CONFORM radial force is in agreement with the radial force obtained by theoretical formula.

Effect of process parameters on sheath forming of continuous extrusion sheathing of aluminum

The effect of flow passage length in the die cavity and extrusion wheel velocity on the shape of aluminum sheath during the continuous extrusion sheathing process was analyzed by using finite element methods based on software DEFORM 3D and experimentally validated. The results show that by increasing the flow passage length, the velocity of metal at the cross-section of sheath tends toward uniformity, the values of the bending angles of sheath gradually approach the ideal value of zero and the cross-section exhibits a better shape. The extrusion wheel velocity has negligible effects on the bending shape and cross-section of the sheath product when a long flow passage is used.

Influence of twist extrusion process on consolidation of pure aluminum powder in tubes by equal channel angular pressing and torsion

In comparison with the conventional equal channel angular pressing（ECAP） process,a comprehensive study of influence of twist extrusion（TE） process on consolidating pure aluminum powder in tubes（PITs） by equal channel angular pressing and torsion（ECAPT） was conducted via three-dimensional（3D） finite element simulation,experimental investigation and theoretical analysis.Simulation results revealed that during the consolidation of aluminum powder particles by ECAPT,TE process played a significant role of back pressure.Due to the torsional shear and high hydrostatic pressure exerted by twist channel,both the magnitude and homogeneity of the effective strain were increased markedly.After one pass of ECAPT process using a square channel with an inner angle of 90° and a twist slope angle of 36.5° at 200℃,commercial pure aluminum powder particles were successfully consolidated to nearly full density.Simulation and experimental results showed good agreement.In the microstructure observations,grains were greatly refined.At the same time,porosities were effectively eliminated by shrinking in size and breaking into small ones.Microhardness test indicated that strain distribution of ECAPT-processed billet was more homogeneous with respect to the ECAP-processed one.All these improvements may be attributed to the extreme intense shear strain induced during ECAPT and the increase in self-diffusion coefficient of aluminum due to the back pressure exerted by TE process.

Strain rate-dependent high temperature compressive deformation characteristics of ultrafine-grained pure aluminum produced by ECAP

To explore the effect of strain rate ε on the high temperature deformation characteristics of ultrafine-grained materials, the deformation and damage features as well as microstructures of ECAP-treated pure Al at different temperatures T and strain ratesε were systematically studied through compression tests and microscopic observations. The increase in ε eliminates strain softening at T≤473 K, and largely enhances the yield strength and flow stress at 473?573 K. The shear deformation dominates the plastic deformation of ECAP-treated Al. Many cracks along shear bands (SBs) are formed at T≥473 K and secondary SBs basically disappear at 1×10?3 s?1; however, at 1×10?2 s?1, cracks are only observed at temperature below 473 K, and secondary SBs become clearer at T≥473 K. The microstructures of ECAP-treated Al mainly consist of sub-grains (SGs). The increase in ε inhibits the SG growth, thus leading to the increases both in yield strength and flow stress at high temperatures.

采用CAXA软件简易设计型线绞合导体

随着"以铝节铜"政策的贯彻,国家相关行业对铝合金芯电力电缆的制造、应用逐渐成熟,作为该类电缆核心的铝合金芯导体的质量至关重要。为实现提高载流量、减少电缆外径等技术目标,部分制造企业对各工序做了大量的技术研究,本文主要从采用CAXA软件设计型线导体的过程进行相关技术阐述。

Microstructures and mechanical properties of semi-solid squeeze casting ZL104 connecting rod

Semi-solid squeeze casting（SSSC） and liquid squeeze casting（LSC） processes were used to fabricate a ZL104 connecting rod, and the influences of the process parameters on the microstructures and mechanical properties were investigated. Results showed that the tensile strength and elongation of the SSSC-fabricated rod were improved by 22% and 17%, respectively, compared with those of the LSC-fabricated rod. For SSSC, the average particle size（APS） and the shape factor（SF） increased with the increase of re-melting temperature（Tr）, whereas the tensile strength and elongation increased first and then decreased. The APS increased with increasing the mold temperature（Tm）, whereas the SF increased initially and then decreased, which caused the tensile strength and elongation to increase initially and then decrease. The APS decreased and the SF increased as squeezing pressure（ps） increased, and the mechanical properties were enhanced. Moreover, the optimal Tr, ps and Tm are 848 K, 100 MPa and 523 K, respectively.

Influences of electric-hydraulic chattering on backward extrusion process of 6061 aluminum alloy

The possibility of the electric-hydraulic chattering technology and its application in the cold extrusion were presented.The conventional and electric-hydraulic chattering assisted backward extrusion processes were performed on 6061 aluminum alloy billets at room temperature.The experimental results showed that 5.65% reduction in the extrusion load was attained if the die and ejector were vibrated at a frequency of 100 Hz and amplitude of 0.013 mm in the longitudinal direction.The friction coefficient at the billet and tool system interface determined from the finite element analysis（FEA） decreased from 0.2 without chattering to 0.1 with application of electric-hydraulic chattering.The higher values of instantaneous velocity and direction change of material flow were achieved during the chattering assisted backward extrusion process.The strain distribution of the chattering assisted backward extrusion billet revealed lower maximum strain and smoother strain distribution in comparison with that produced by the conventional extrusion method.

Microstructure and mechanical properties of Al-6Zn-2.5Mg-1.8Cu alloy prepared by squeeze casting and solid hot extrusion

Al-6Zn-2.5Mg-1.8Cu alloy ingots were prepared by squeeze casting under different specific pressures,and the fresh ingot with best mechanical properties was solid hot extruded.With the increase of the specific pressure from 0 to 250 MPa,the dendrites became round and small.Because the applied pressure increased the solid solubility of alloying elements,the number of MgZn2 phases decreased.When the specific pressure increased from 250 MPa to 350 MPa,the grain size increased.After solid hot extrusion,the a（Al） grains were refined obviously and the MgZn2 phases were uniformly dispersed in the microstructure.After solid hot extrusion,the ultimate tensile strength was 605.67 MPa and the elongation was 8.1%,which were improved about 32.22%and15.71%,respectively,compared with those of the metal mold casting alloy.The fracture modes of the billet prepared by the metal mold casting and by squeeze casting were intergranular and quasi-cleavage fractures,respectively,whereas,that of the solid hot extrusion was mainly dimple fracture.The refined crystalline strengthening was the main reason to improve the strength and elongation of alloy.

Effects of extrusion speed of continuous extrusion with double billets on welding performance of 6063 Al alloy

During continuous extrusion,the welds were formed at the confluence of two billets.Influences of extrusion wheel rotational speed on micromorphology and properties of welds of 6063 Al alloy were investigated through microstructure observation,tensile test,and SEM analyses.Welding parameters were analyzed using finite element simulation.Results indicated that metal welding was remarkably affected by oxide on outer surface of the double billets during continuous extrusion.Degree of oxide breakage on the welding surface increased due to the evident increase in effective strain rate with increasing extrusion speed.The high temperature induced by increased extrusion speed accelerated the formation of metallurgical bonding.A portion of weld seam lines slowly disappeared,and the proportion of the welding interface that failed to reach metallurgical bonding was also gradually reduced.Tensile strength and elongation of the weld specimen increased with the increase of extrusion speed.

Comparison of experimental methods to evaluate seam welds quality in extruded profiles

The wedge and bulge expansion tests were compared in the assessment of the seam welds strength in a tubular profile extruded at two ram speeds.In the wedge test,the expansion was determined by moving a conical punch into the tube until the specimen fracture.In the bulge test,a hydrostatic tensile stress state was applied by expanding the specimen with an internal rubber plug.The two methodologies were compared in terms of load and hoop strain at fracture and by detecting the fracture morphology and location.Then,the effect of a number of design parameters was investigated in order to evaluate the robustness of the standard testing conditions.For both tests,ductile fractures appeared in the seam welds location,but the bulge test was more robust and conservative with respect to the wedge test,showing less scattered data.Thus,the performances of a second die for the tube profile,designed to optimize the seam welds quality,have been successfully assessed by the bulge test and results compared to those achieved by a novel numerical quality index,coming to a final good matching.

Corrosion resistance of aluminum alloy AA7022 wire fabricated by friction stir extrusion

Friction stir extrusion(FSE)is known as an innovative manufacturing technology that makes it possible to directly produce wire via consolidation and extrusion of metal chips or solid billets.In this study,wire samples were produced using aluminum alloy AA7022 machining chips by the use of the FSE.To this end,the microstructures and mechanical properties of the base material(BM)and the extruded samples were investigated.The corrosion resistance of the given samples was also determined using potentiodynamic polarization technique.The results showed that the samples manufactured at higher rotational speeds possessed good surface quality,the process temperature and the grain size similarly increased following the rise in rotational speed,and the mechanical properties consequently decreased.Using the FSE led to crystallite refinement,increase in volume fraction of grain boundaries,as well as re-distribution of precipitates affecting corrosion resistance.Furthermore,the findings of the corrosion tests revealed that the produced samples by the FSE had adequate corrosion resistance and the growth in die rotation rate augmented current density and subsequently reduced corrosion resistance.

Grain refinement and mechanical properties of pure aluminum processed by accumulative extrusion bonding

Ultrafine-grained aluminum processed by a new severe plastic deformation technique, accumulative extrusion bonding (AEB), was investigated. Microstructural characterization indicated good interfacial bonding and an average grain size of ~440 nm was obtained after six passes. Tensile testing revealed that the strength reached the maximum value of 195 MPa and the total elongation exceeded 16% after five passes. The hardness was also significantly improved and almost reached saturation after the first pass. SEM fractography of AEB-processed specimens after tensile test showed that failure mode was shear ductile fracture with elongated shallow dimples. Comparison with conventional accumulative roll bonding indicates that this new AEB technique is more effective in refining grain and improving mechanical properties of the specimens.