Manufacturing method of salt-corrosion-resistant cable fixing clamp

Abstract

The invention discloses a manufacturing method of a salt-corrosion-resistant cable fixing clamp, which comprises the following steps of: uniformly mixing rare earth oxide, an aluminum raw material, Fe, Cu, Mg and Ce elements, and pressing to form blocks or particles with fixed shapes; putting the blocks or particles into a high-temperature reaction furnace, taking out after reaction, cooling, and crushing to obtain an initial product; carrying out refining and alloying treatment on the initial product to obtain a rare earth aluminum alloy raw material, and processing the rare earth aluminum alloy raw material into a fixing clamp shape; performing anti-corrosion spraying on the surface of the fixing clamp, performing salt corrosion resistance detection, entering the next step if the salt corrosion resistance detection is qualified, and performing anti-corrosion spraying again if the salt corrosion resistance detection is unqualified; injection molding is conducted on the surface of the fixing clamp to form an insulator, anti-corrosion machining is conducted on the surface of the insulator, salt corrosion resistance detection is conducted, qualified products are output to a finished product area, and anti-corrosion machining is conducted again if unqualified products are detected. The cable fixing clamp disclosed by the invention has excellent salt corrosion resistance, can meet the fixing requirements of coastal cables, and ensures the safety and reliability of the coastal cables in use.

Description

Technical Field

[0001] The invention belongs to the technical field of cable fixing clamp materials, and in particular relates to a method for manufacturing a salt corrosion resistant cable fixing clamp. Background Art

[0002] In marine, coastal or other high-salinity environments, cables and their fixings are easily corroded by salt spray and seawater, causing corrosion and damage, which in turn affects the performance and safety of the cables.

[0003] A Chinese patent application with application number CN201410248523.8 discloses a cable clamp for power transmission and transformation cable engineering and a preparation method thereof, wherein the clamp comprises a combined body, a rubber pad, a spring, a bolt, a flat pad, a nut and a waist-shaped hole, wherein the combined body is composed of two independent units symmetrically connected together, wherein each independent unit has a semicircular connecting hole at the bottom and a groove with a "U" shape in lateral projection at the top, and waist-shaped holes are respectively processed on both sides of the connecting hole on each independent unit, so that the hole spacing of the bolt can be adjusted within a certain size; the two independent units are connected by bolts to form a clamping mechanism, wherein the bolt passes through the waist-shaped hole, and the end of the bolt is provided with a spring and connected to the nut, and the bolt and spring are used for flexible fixation, and the fixing performance is better than that of ordinary mechanical direct-contact cable clamps, but the cable clamp has not undergone special anti-salt corrosion treatment, and its metal parts are prone to rust, resulting in failure of the fixing clamp, and is not suitable for high-salinity environments. The Chinese patent application number CN201210408043.4 discloses a resin-based composite material for cable brackets or clamps and a preparation method thereof, characterized in that it is made of the following raw materials in weight percentage: 191 resin 10-30%, styrene 6-20%, initiator 0.1-0.8%, lubricant 0.5-3%, filler 60-85%, anti-aging agent 0.1-1%, and reinforcing fiber 8-16%. The preparation method thereof is: weighing the raw materials according to the weight ratio; adding the raw materials into a container in the order of adding 191 resin, reinforcing fiber, filler, lubricant, anti-aging agent, styrene and initiator, maintaining the temperature at 60-100 degrees and the rotation speed at 800-2000r / min, mixing the raw materials; discharging; pouring and curing. This invention adopts advanced and reasonable ingredient design to prepare a resin-based composite material for cable brackets or clamps, but the corrosion resistance and aging resistance of the composite material are poor, which cannot meet the fixation requirements of coastal cables. Its components may age and crack after long-term use, resulting in failure of the fixing clamps and loosening or even falling off of the cables, which will not only affect the normal operation of the cables, but may also cause safety hazards. Summary of the invention

[0004] In order to solve the above problems, the present invention provides a method for manufacturing a salt-corrosion resistant cable fixing clamp, which can prepare a cable fixing clamp with excellent salt-corrosion resistant performance, meet the fixing requirements of coastal cables, and ensure safety and reliability in use.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] A method for manufacturing a salt corrosion resistant cable fixing clamp comprises the following steps:

[0007] S1: mixing rare earth oxide, aluminum raw material, Fe, Cu, Mg and Ce elements uniformly in a mixing container, and pressing the mixed raw materials to form blocks or particles with a fixed shape;

[0008] S2: putting the block or particle obtained in step S1 into a high-temperature reaction furnace for aluminothermic reduction reaction, taking out and cooling after the reaction, and then crushing to obtain a primary product;

[0009] S3: refining and alloying the primary product obtained in step S2 to obtain a rare earth aluminum alloy raw material, and processing the rare earth aluminum alloy raw material into a fixed clip shape;

[0010] S4: Anti-corrosion spraying is performed on the surface of the fixing clip obtained in step S3, and salt corrosion resistance test is performed on the surface of the fixing clip after spraying. If the test is qualified, the next step is performed, and if the test is unqualified, anti-corrosion spraying is performed again;

[0011] S5: The surface of the fixed clamp after spraying is injection molded to form an insulator. After the injection molding is completed, the surface of the insulator is subjected to anti-corrosion processing, and the surface of the insulator is tested for salt corrosion resistance. If the test is qualified, it is output to the finished product area. If the test is unqualified, the anti-corrosion processing is performed again.

[0012] Furthermore, in step S1, the rare earth oxide is one or a mixture of lanthanum oxide, cerium oxide, praseodymium oxide, neodymium oxide, and yttrium oxide.

[0013] Furthermore, in step S2, the temperature of the high temperature reaction furnace is 700-800°C.

[0014] Furthermore, in step S3, the rare earth aluminum alloy raw material contains the following metal elements in percentage by mass: Al 80-90%, Fe 0.25-1%, Cu 0.1-0.4%, Mg 0.05-0.2%, Ce 0.1-0.3%.

[0015] Furthermore, in step S5, one of polystyrene, nylon and polyethylene is used to form an insulator by injection molding on the surface of the fixing clip.

[0016] Furthermore, in step S5, a composite coating is sprayed on the surface of the fixing clip by combining thermal spraying and cold spraying to complete the injection molding.

[0017] Furthermore, the specific process of spraying the composite coating on the surface of the fixing clip is: thoroughly clean and pretreat the surface of the fixing clip to remove impurities, then apply a layer of primer, spray an anti-salt corrosion layer, an insulating layer and a hard layer on the primer in sequence, and finally apply a layer of topcoat, and dry and cure after the coating is completed.

[0018] Furthermore, in steps S4 and S5, during the salt corrosion resistance test, if the product fails the test twice in a row, the product is output to the defective product area.

[0019] Furthermore, in steps S4 and S5, the specific process of salt corrosion resistance testing is: placing the product to be tested in a salt spray environment of a set concentration, observing the surface corrosion of the product after 48 hours, and preliminarily judging the salt corrosion resistance by comparing the sample status before and after the test, and conducting chemical analysis on the product to detect whether its chemical composition and content meet the requirements.

[0020] Furthermore, in the process of observing the corrosion on the product surface, the appearance of the sample is checked by visual inspection and touch to see if there are scratches, bubbles, or discoloration defects on the product to be tested, and the size of the product to be tested is compared with the standard size to ensure that the error is within the tolerance range.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. The present invention provides a method for manufacturing a salt corrosion resistant cable fixing clamp. Through aluminothermic reduction reaction, rare earth oxides are fully mixed with aluminum, Fe, Cu, Mg and Ce elements to form a rare earth aluminum alloy with excellent performance. This alloy is not only high in strength and corrosion resistant, but also has good thermal stability and electrical conductivity, and is very suitable for use in environments with severe salt spray corrosion such as oceans and coastal areas. The raw materials are pressed to form blocks or particles, and the subsequent processing into the shape of a fixing clamp can flexibly adjust the shape and size of the product to meet the needs of different installation environments and cable specifications. In the entire process, from raw material mixing to pressing and forming, to aluminothermic reduction reaction and cooling and crushing, it is continuous and efficient, which can greatly improve production efficiency; anti-corrosion spraying and insulator injection molding on the surface of the fixing clamp can effectively enhance the anti-corrosion performance of the product, especially in a high salinity environment, which can greatly extend the service life of the product; in addition, multiple salt corrosion resistance tests are set in the process to ensure that each process meets the quality requirements, and the final output product has stable performance and reliability, and by optimizing the production process, energy consumption and waste emissions are reduced, which meets the requirements of modern industrial production for environmental protection and energy saving.

[0023] 2. In the present invention, one of polystyrene, nylon and polyethylene is used to form an insulator by injection molding on the surface of the fixing clamp. Polystyrene, nylon and polyethylene are all excellent insulating materials, which can effectively isolate the cable from the external environment, prevent current leakage or short circuit, and ensure the safe operation of the cable. The insulators molded by these materials have high mechanical strength, wear resistance and impact resistance, which can protect the cable fixing clamp from physical damage and extend the service life; polystyrene, nylon and polyethylene have good chemical stability and can resist the corrosion of chemical substances such as acid and alkali, especially in corrosive environments such as salt spray, which can maintain long-term stability and reliability, and are easy to injection mold, and can accurately produce insulators that match the shape of the fixing clamp, ensuring good assembly accuracy and appearance quality; in addition, polystyrene, nylon and polyethylene are all widely used materials with relatively low production costs, which helps to reduce the production cost of the entire cable fixing clamp and improve the market competitiveness of the product.

[0024] 3. In the present invention, in the surface injection molding step of the fixing clip, the coating material can be tightly bonded to the surface of the fixing clip by combining the hot spraying method and the cold spraying method to form a dense protective film, which effectively isolates the fixing clip from the external environment, thereby improving its corrosion resistance, especially in corrosive environments such as salt spray, which can greatly extend the service life of the fixing clip. The hot spraying method melts the spraying material at high temperature to form a metallurgical bond with the surface of the fixing clip, while the cold spraying method tightly bonds the coating material at room temperature through high-speed impact. The combination of the two ensures the bonding strength of the coating and avoids the influence of high temperature on the performance of the fixing clip substrate. Compared with traditional coating methods, hot spraying and cold spraying technologies can reduce material waste and harmful emissions, and are more environmentally friendly. Combining the two advanced spraying technologies, a new type of composite coating can be developed to improve the market competitiveness of the fixing clip. In addition, by combining hot spraying and cold spraying, multi-layer coatings with different functions can be formed on the surface of the fixing clip, such as a wear-resistant layer, an insulating layer, and an anti-corrosion layer.

[0025] 4. In the present invention, the temperature of the high-temperature reactor is 700-800°C. At this temperature, the reduction ability of aluminum is sufficient to reduce rare earth oxides, while avoiding the safety risks and increased energy consumption that may be caused by excessively high temperatures. Moreover, within this temperature range, the rate of the aluminothermic reduction reaction is moderate, and the reaction will not be slow due to too low a temperature, nor will the reaction be out of control due to too high a temperature. At the same time, a temperature higher than 800°C may increase the thermal stress of the reactor, increasing safety risks.

[0026] 5. In the present invention, the rare earth oxide is one or a mixture of lanthanum oxide, cerium oxide, praseodymium oxide, neodymium oxide, and yttrium oxide. Among them, lanthanum oxide is an important rare earth oxide, which can significantly improve the performance of aluminum alloys by being used in them. It can improve the strength and heat resistance of the alloy by reacting with other metal elements; cerium oxide is a common oxide form of the rare earth element cerium, which is often used as an additive for aluminum alloys, and it can enhance the mechanical properties of the alloy, especially under high temperature conditions; praseodymium oxide is also an oxide of rare earth elements, which helps to improve the oxidation resistance and corrosion resistance of aluminum alloys; neodymium oxide is an oxide of the rare earth element neodymium, and the application of yttrium oxide in aluminum alloys can improve its high temperature performance and oxidation resistance; rare earth oxides, as important additives, play a vital role in the production of rare earth aluminum alloys. Among them, lanthanum oxide, cerium oxide, praseodymium oxide, neodymium oxide, and yttrium oxide are all common rare earth oxides, each of which has unique chemical and physical properties and can be used alone or in combination to improve the performance of aluminum alloys. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 The present invention provides a flow chart of a method for manufacturing a salt corrosion resistant cable fixing clamp. DETAILED DESCRIPTION

[0028] The following is in conjunction with the preferred embodiment and with reference to the attached Figure 1 , the present invention is further described. The endpoints and any values ​​of the ranges disclosed in the present invention are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values; for numerical ranges, the endpoint values ​​of each range, the endpoint values ​​of each range and individual point values, and the individual point values ​​can be combined with each other to obtain one or more new numerical ranges, and these numerical ranges should be regarded as specifically disclosed herein; the materials, reagents, etc. used in the following examples, unless otherwise specified, can be obtained from commercial channels; the experimental methods in the following examples, unless otherwise specified, are all conventional methods.

[0029] Example 1

[0030] This embodiment provides a method for manufacturing a salt corrosion resistant cable fixing clamp. Figure 1 As shown, the following steps are included:

[0031] S1: Evenly mix rare earth oxides, aluminum raw materials, Fe, Cu, Mg and Ce elements in a mixing container, and press the mixed raw materials to form blocks or particles with a fixed shape; the rare earth oxides are a mixture of lanthanum oxide, cerium oxide and praseodymium oxide.

[0032] In this embodiment, the aluminum raw material is alumina. By fully mixing rare earth oxide, aluminum raw material, and Fe, Cu, Mg, and Ce elements in a mixing container, the uniformity of the alloy composition can be ensured, thereby obtaining a product with uniform performance; the mixed raw materials are pressed to form blocks or particles with a fixed shape, which is conducive to the uniformity of the aluminum thermal reduction reaction and also facilitates subsequent heating and reaction control;

[0033] S2: putting the block or particle obtained in step S1 into a high-temperature reaction furnace for aluminothermic reduction reaction, taking out and cooling after the reaction is completed, and then crushing to obtain a primary product; in this embodiment, the temperature of the high-temperature reaction furnace is 750° C.;

[0034] The aluminothermic reduction reaction of the present invention can be used to reduce rare earth elements at high temperature or at low temperature, with more selectivity and greater operating space. At the same time, the generated alloy components are relatively pure, which helps to reduce energy consumption and production costs. After the reaction is completed, the reaction product is taken out from the high-temperature reactor for cooling, and then crushed to obtain a primary product. The cooling step ensures the completion of the reaction, and the crushing makes the subsequent refining and alloying treatment more efficient.

[0035] S3: refining and alloying the primary product obtained in step S2 to obtain a rare earth aluminum alloy raw material, and processing the rare earth aluminum alloy raw material into a fixed clip shape; this step can remove impurities, adjust the alloy composition, ensure that the alloy reaches the required performance indicators, and process the alloy into a fixed clip shape, thereby increasing the applicability and diversity of the product and meeting specific application requirements; the rare earth aluminum alloy raw material contains the following metal elements in mass percentage: Al 85%, Fe 0.25%, Cu 0.1%, Mg 0.2%, Ce 0.2%; the mechanical properties of the rare earth aluminum alloy material are: yield strength ≥140MPa; tensile strength ≥220MPa; conductivity ≥61.8%IACS;

[0036] The addition of rare earth elements can greatly improve the strength and hardness of aluminum alloys, while maintaining the lightweight characteristics of aluminum alloys. This allows rare earth aluminum alloys to reduce the weight of the fixing clips while maintaining structural stability, thereby reducing the cost of mass production of fixing clips. Rare earth elements can effectively improve the corrosion resistance of aluminum alloys, allowing them to be used in harsh environments, especially in environments with severe salt spray corrosion such as oceans and coastal areas, showing excellent durability. They can also improve the high-temperature performance of aluminum alloys, making their performance more stable and reliable in high-temperature environments, and less prone to deformation or damage. In addition, rare earth aluminum alloys have good plasticity and machinability, and are easy to cut, weld, bend, and other processing, which enables them to meet the needs of various complex shapes and structures.

[0037] S4: Anti-corrosion spraying is performed on the surface of the fixing clip obtained in step S3, and salt corrosion resistance test is performed on the surface of the fixing clip after spraying. If the test is qualified, the next step is entered, and if the test is unqualified, anti-corrosion spraying is performed again; anti-corrosion spraying can effectively improve the corrosion resistance of the product and extend the service life, especially in marine or high humidity environments, and salt corrosion resistance test of the fixing clip can ensure the reliability of the product in harsh environments and improve product quality assurance;

[0038] S5: The surface of the fixed clamp after spraying is injection molded with polystyrene material to form an insulator. After the injection molding is completed, the surface of the insulator is subjected to anti-corrosion processing, and the surface of the insulator is tested for salt corrosion resistance. If the test is qualified, it will be output to the finished product area. If the test is unqualified, the anti-corrosion processing will be performed again;

[0039] In this embodiment, a composite coating is sprayed on the surface of the fixing clip by combining hot spraying and cold spraying to complete the injection molding; hot spraying and cold spraying techniques can make the coating material tightly bonded to the surface of the fixing clip, forming a dense protective film, effectively isolating the contact between the fixing clip and the external environment, thereby improving its corrosion resistance, especially in corrosive environments such as salt spray, which can greatly extend the service life of the fixing clip. The hot spraying method melts the spraying material at high temperature to form a metallurgical bond with the surface of the fixing clip, while the cold spraying method makes the coating material tightly bonded at room temperature by high-speed impact. The combination of the two can not only ensure the bonding strength of the coating, but also avoid the influence of high temperature on the performance of the fixing clip substrate. Compared with traditional coating methods, hot spraying and cold spraying techniques can reduce material waste and harmful emissions, and are more environmentally friendly. Combining the two advanced spraying technologies, a new type of composite coating can be developed to improve the market competitiveness of the fixing clip. In addition, by combining hot spraying and cold spraying, multi-layer coatings with different functions can be formed on the surface of the fixing clip, such as wear-resistant layers, insulating layers, and anti-corrosion layers.

[0040] In this embodiment, the specific process of spraying the composite coating on the surface of the fixing clip is: thoroughly cleaning and pre-treating the surface of the fixing clip to remove impurities such as oil, dust, etc., then applying a layer of primer, spraying the anti-salt corrosion layer, insulating layer and hard layer on the primer in sequence, and finally applying a layer of topcoat, and drying and curing after the coating is completed. Specifically, the intermediate steps include: surface cleaning and pre-treatment: using a solvent to clean the surface of the fixing clip, remove impurities such as oil, old paint layer, dust, etc., and perform grinding or sandblasting to increase the bonding strength between the coating and the surface of the fixing clip. Applying primer: uniformly applying a layer of primer on the surface of the cleaning and pre-treated fixing clip, the primer can improve the adhesion of the coating and provide a preliminary anti-corrosion function. Spraying anti-salt corrosion layer: using thermal spraying technology to spray a layer of corrosion-resistant material, such as zinc or aluminum-based coating, on the primer to provide additional anti-corrosion protection. Spraying insulation layer: using cold spraying technology to spray a layer of insulating material, such as ceramic or special plastic, to form an insulation layer of the fixing clip. Spraying hard layer: Use thermal spraying technology again to spray hard materials such as tungsten carbide or aluminum oxide to increase the wear resistance and impact resistance of the surface of the fixing clip. Applying topcoat: Apply a layer of topcoat on top of the multi-layer coating. The topcoat can provide a final protective layer to prevent environmental factors from corroding the composite coating. Drying and curing treatment: Place the coated fixing clip in an appropriate temperature and environment for drying and curing to ensure that the coating is fully combined with the surface of the fixing clip to form a stable composite coating. Quality inspection: After the coating is cured, the coating of the fixing clip is checked for quality, including the thickness, uniformity and adhesion of the coating. Salt corrosion resistance test: Perform salt corrosion resistance test on the coating to ensure that the coating meets the corrosion resistance requirements. Post-processing: If necessary, post-processing of the coating, such as heat treatment, can be performed to further enhance the performance of the coating;

[0041] The present invention forms an insulator by injection molding on the surface of the fixing clip, thereby providing electrical isolation for the fixing frame and increasing the safety and functionality of the product. In addition, a layer of coating with an anti-corrosion function is coated on the surface of the insulator, which can block the direct contact between salt mist and plastic, thereby preventing the salt mist from corroding the plastic. Repeated inspection and correction of the anti-corrosion spraying and insulator processing in the entire process embodies the strict control of product quality, while avoiding the influx of unqualified products into the market and reducing resource waste.

[0042] In steps S4 and S5 of this embodiment, during the salt corrosion resistance test, if the product fails the test twice in a row, it will be output to the defective product area. In the production process, quality control is a crucial link, especially for processing steps such as coatings that have a direct impact on performance. If the product fails the test twice in a row, it is reasonable to classify it as a defective product, which helps to ensure the quality of the final product. In this embodiment, the specific process of salt corrosion resistance testing is:

[0043] Initial inspection: After the coating is sprayed, the first quality inspection is carried out, including coating thickness, uniformity, adhesion and corrosion resistance;

[0044] Analysis of test results: If the test results show that the product does not meet the quality standards, record detailed non-conformity information;

[0045] Rework or repair: Based on the unqualified test results, decide whether to rework or repair the product;

[0046] Secondary testing: Conduct a second test on the reworked or repaired product to verify the effectiveness of the repair measures;

[0047] Continuous non-conformity treatment: If the product still fails the second test, it is confirmed as a defective product, isolated and transferred to the defective product area;

[0048] Defective product review: Review defective products to determine whether they can be further reworked or repaired, or whether they need to be scrapped;

[0049] In this embodiment, the product is placed in a salt spray environment of a set concentration. After 48 hours, the surface corrosion of the product is observed. By comparing the sample states before and after the test, the salt corrosion resistance is preliminarily judged. Then, the product is chemically analyzed to detect whether its chemical composition and content meet the requirements. The specific detection steps are as follows:

[0050] Sample preparation: Ensure that the surface coating of the fixing clamp is uniform and has no obvious defects, clean the sample surface, and remove contaminants that may affect the test results;

[0051] Salt spray test machine preparation: Prepare the salt spray test machine;

[0052] Set the salt spray environment: According to the relevant standards of ASTM B117, set the salt water concentration, temperature and spray pressure in the salt spray test machine;

[0053] Sample placement: Place the fixing clamp in the salt spray test machine to ensure that the sample is in the correct position so that the salt spray can evenly contact the sample surface;

[0054] Start the test: start the salt spray test machine and expose the fixing clamp to the set salt spray environment;

[0055] Observe the corrosion conditions: After the set time interval of 48 hours, take out the samples, observe and record the surface corrosion conditions;

[0056] Evaluation of anti-salt corrosion performance: By comparing the sample status before and after the test, the anti-salt corrosion performance of the fixing clip is evaluated, and whether there are corrosion, bubbles, and peeling defects;

[0057] Chemical analysis: Chemical analysis of samples is performed to detect whether the chemical composition and content of the coating meet the product specification requirements;

[0058] Data Recording: Record all observed corrosion conditions and chemical analysis results;

[0059] Performance evaluation: Based on the recorded data and pre-set performance standards, evaluate whether the salt corrosion resistance of the fixing clip meets the standards;

[0060] Disqualified product handling: If the anti-salt corrosion performance of the fixing clip does not meet the standard, it will be transferred to the defective product area according to the defective product handling process, and the cause analysis and subsequent handling will be carried out;

[0061] Qualification confirmation: If the salt corrosion resistance of the fixing clip meets the requirements, continue with the subsequent production process;

[0062] Report preparation: Prepare detailed test reports including test conditions, observations, chemical analysis data and final evaluation conclusions;

[0063] Continuous improvement: Based on the test results, evaluate whether the current coating process needs to be improved to improve the product's anti-salt corrosion performance.

[0064] In this embodiment, in the process of observing the corrosion of the product surface, the appearance of the sample is checked by visual inspection and touch to check whether there are defects such as scratches, bubbles, discoloration, etc., and then the size of the product is measured using a measuring tool and compared with the standard size to ensure that it is within the tolerance range. In the process of observing the corrosion of the product surface, it is a comprehensive and effective method to use visual inspection and touch inspection and use measuring tools for comprehensive evaluation. This method can not only directly observe the appearance defects of the product, but also ensure the accuracy and compliance of the product through dimensional measurement. First, visual inspection of the appearance of the sample is an intuitive and fast method. It can find obvious surface defects such as scratches, bubbles, and discoloration. These defects are often the initial signs of corrosion or other surface damage. Therefore, timely discovery and treatment are of great significance to prevent further corrosion. At the same time, visual inspection can also find other possible problems, such as uneven coating, color difference, etc., which are important factors affecting product quality and appearance. Secondly, touch inspection can further verify the results of visual inspection. By feel, the roughness and unevenness of the product surface can be judged. The subtle changes, these changes may be caused by corrosion, wear or improper processing, so touch inspection is another verification of the appearance quality of the product. In addition to visual and tactile inspections, measuring the product dimensions using measuring tools is also a necessary step. By comparing with the standard dimensions, it can be ensured that the product is within the tolerance range and thus meets the use requirements. If the product dimension exceeds the tolerance range, then even if there is no obvious corrosion or defects on the surface, there may be structural or performance problems that require further investigation and processing.

[0065] Example 2

[0066] This embodiment provides a method for manufacturing a salt corrosion resistant cable fixing clamp, comprising the following steps:

[0067] S1: Mixing rare earth oxide, aluminum raw material, Fe, Cu, Mg and Ce elements uniformly in a mixing container, and pressing the mixed raw materials to form blocks or particles with a fixed shape; the rare earth oxide is neodymium oxide.

[0068] S2: putting the block or particle obtained in step S1 into a high-temperature reaction furnace for aluminothermic reduction reaction. After the reaction is completed, taking it out and cooling it, and then crushing it to obtain a primary product. In this embodiment, the temperature of the high-temperature reaction furnace is 700° C.

[0069] S3: refining and alloying the primary product obtained in step S2 to obtain a rare earth aluminum alloy raw material, and processing the rare earth aluminum alloy raw material into a fixed clip shape; the rare earth aluminum alloy raw material contains the following metal elements in mass percentage: Al 80%, Fe 1%, Cu 0.4%, Mg 0.1%, Ce 0.1%; the mechanical properties of the rare earth aluminum alloy material are: yield strength ≥134MPa; tensile strength ≥215MPa; electrical conductivity ≥63.2%IACS;

[0070] S4: Anti-corrosion spraying is performed on the surface of the fixing clip obtained in step S3, and salt corrosion resistance test is performed on the surface of the fixing clip after spraying. If the test is qualified, the next step is performed, and if the test is unqualified, anti-corrosion spraying is performed again;

[0071] S5: The surface of the sprayed fixing clip is injection molded with nylon material to form an insulator. After the injection molding is completed, the surface of the insulator is subjected to anti-corrosion processing, and the surface of the insulator is tested for salt corrosion resistance. If the test is qualified, it will be output to the finished product area. If the test is unqualified, the anti-corrosion processing will be performed again;

[0072] In this embodiment, a composite coating is sprayed on the surface of the fixing clip by combining hot spraying and cold spraying to complete the injection molding; the specific process of spraying the composite coating on the surface of the fixing clip is: thoroughly cleaning and pre-treating the surface of the fixing clip to remove impurities, then applying a layer of primer, spraying an anti-salt corrosion layer, an insulating layer and a hard layer on the primer in sequence, and finally applying a layer of topcoat, and drying and curing after the coating is completed;

[0073] In steps S4 and S5 of this embodiment, during the salt corrosion resistance test, if the product fails the test twice in a row, it will be output to the defective product area. The specific process of the salt corrosion resistance test is as follows: the product to be tested is placed in a salt spray environment of a set concentration. After a certain period of time, the appearance of the sample is checked by visual inspection and touch to check whether the product to be tested has scratches, bubbles, or discoloration defects, and the size of the product to be tested is compared with the standard size to ensure that the error is within the tolerance range. By comparing the sample states before and after the test, the salt corrosion resistance performance is preliminarily judged, and the product is chemically analyzed to detect whether its chemical composition and content meet the requirements.

[0074] Example 3

[0075] This embodiment provides a method for manufacturing a salt corrosion resistant cable fixing clamp, comprising the following steps:

[0076] S1: Mixing rare earth oxide, aluminum raw material, Fe, Cu, Mg and Ce elements uniformly in a mixing container, and pressing the mixed raw materials to form blocks or particles with a fixed shape; the rare earth oxide is a mixture of lanthanum oxide, cerium oxide and yttrium oxide.

[0077] S2: putting the block or particle obtained in step S1 into a high-temperature reaction furnace for aluminothermic reduction reaction. After the reaction is completed, taking out and cooling, and then crushing to obtain a primary product. In this embodiment, the temperature of the high-temperature reaction furnace is 800° C.

[0078] S3: refining and alloying the primary product obtained in step S2 to obtain a rare earth aluminum alloy raw material, and processing the rare earth aluminum alloy raw material into a fixed clip shape; the rare earth aluminum alloy raw material contains the following metal elements in mass percentage: Al 90%, Fe 0.5%, Cu 0.2%, Mg 0.05%, Ce 0.3%; the mechanical properties of the rare earth aluminum alloy material are: yield strength ≥156MPa; tensile strength ≥238MPa; electrical conductivity ≥61.3%IACS;

[0079] S4: Anti-corrosion spraying is performed on the surface of the fixing clip obtained in step S3, and salt corrosion resistance test is performed on the surface of the fixing clip after spraying. If the test is qualified, the next step is performed, and if the test is unqualified, anti-corrosion spraying is performed again;

[0080] S5: The surface of the fixed clamp after spraying is injection molded with polyethylene material to form an insulator. After the injection molding is completed, the surface of the insulator is subjected to anti-corrosion processing, and the surface of the insulator is tested for salt corrosion resistance. If the test is qualified, it will be output to the finished product area. If the test is unqualified, the anti-corrosion processing will be performed again;

[0081] In this embodiment, a composite coating is sprayed on the surface of the fixing clip by combining hot spraying and cold spraying to complete the injection molding; the specific process of spraying the composite coating on the surface of the fixing clip is: thoroughly cleaning and pre-treating the surface of the fixing clip to remove impurities, then applying a layer of primer, spraying an anti-salt corrosion layer, an insulating layer and a hard layer on the primer in sequence, and finally applying a layer of topcoat, and drying and curing after the coating is completed;

[0082] In steps S4 and S5 of this embodiment, during the salt corrosion resistance test, if the product fails the test twice in a row, it will be output to the defective product area. The specific process of the salt corrosion resistance test is as follows: the product to be tested is placed in a salt spray environment of a set concentration. After a certain period of time, the appearance of the sample is checked by visual inspection and touch to check whether the product to be tested has scratches, bubbles, or discoloration defects, and the size of the product to be tested is compared with the standard size to ensure that the error is within the tolerance range. By comparing the sample states before and after the test, the salt corrosion resistance performance is preliminarily judged, and the product is chemically analyzed to detect whether its chemical composition and content meet the requirements.

[0083] Wherein, the rare earth oxide can also be selected from one or a mixture of lanthanum oxide, cerium oxide, praseodymium oxide, neodymium oxide, and yttrium oxide; in step S4, the raw materials for anticorrosive spraying can be selected from organic coatings such as epoxy resin, polyurethane, perchlorethylene, phenolic resin, etc., and the anticorrosive spraying process is an existing process technology; in step S5, the anticorrosive processing is a conventional process, including selecting a suitable anticorrosive coating according to the material of the substrate, the use environment, the anticorrosive requirements, etc. The coating can be an organic coating (such as epoxy resin, polyurethane) or an inorganic coating (such as inorganic zinc-rich paint, glass flake coating). The anticorrosive coating is evenly applied to the surface of the substrate using an appropriate coating method (such as brushing, spraying, dipping, etc.). During the coating process, attention should be paid to the thickness and uniformity of the coating to avoid missing coating, sagging, etc. After the coating is applied, it is cured according to the type of coating and the curing conditions. The curing method can be natural drying, heating curing, etc. During the curing process, attention should be paid to controlling the temperature and time to ensure that the coating is completely cured. After curing is completed, the coating is inspected to check whether it is flat, smooth, free of bubbles, cracks and other defects. At the same time, adhesion tests and corrosion resistance tests can also be carried out to ensure that the anti-corrosion performance of the coating meets the requirements.

[0084] The present invention is suitable for adding a variety of rare earth elements, has good flexibility and adaptability, can adjust the alloy composition according to different application requirements, and also combines the traditional aluminum thermal reduction method and modern injection molding technology, reflecting the application of technological innovation in the preparation of new materials. From raw material mixing to final product output, the entire process involves multiple process steps, which helps to integrate the upstream and downstream industrial chains and improve production efficiency. By improving product performance and quality, the market competitiveness of the product is enhanced, which helps to open up a broader market. It can also improve the electrical conductivity and thermal conductivity of aluminum alloys, so that rare earth aluminum alloys have broad application prospects in the fields of electricity and electronics.

[0085] The above is only a preferred embodiment of the present invention. It should be pointed out that a person skilled in the art can make several modifications and improvements without departing from the inventive concept of the present invention, which all belong to the protection scope of the present invention.

Claims

1. A method for manufacturing a salt corrosion resistant cable fixing clamp, characterized in that: The following steps are involved: S1: mixing rare earth oxide, aluminum raw material, Fe, Cu, Mg and Ce elements uniformly in a mixing container, and pressing the mixed raw materials to form blocks or particles with a fixed shape; S2: putting the block or particle obtained in step S1 into a high-temperature reaction furnace for aluminothermic reduction reaction, taking out and cooling after the reaction, and then crushing to obtain a primary product; S3: refining and alloying the primary product obtained in step S2 to obtain a rare earth aluminum alloy raw material, and processing the rare earth aluminum alloy raw material into a fixed clip shape; S4: Anti-corrosion spraying is performed on the surface of the fixing clip obtained in step S3, and salt corrosion resistance test is performed on the surface of the fixing clip after spraying. If the test is qualified, the next step is performed, and if the test is unqualified, anti-corrosion spraying is performed again; S5: The surface of the fixed clamp after spraying is injection molded to form an insulator. After the injection molding is completed, the surface of the insulator is subjected to anti-corrosion processing, and the surface of the insulator is tested for salt corrosion resistance. If the test is qualified, it is output to the finished product area. If the test is unqualified, the anti-corrosion processing is performed again.

2. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 1, characterized in that: In step S1, the rare earth oxide is one or a mixture of lanthanum oxide, cerium oxide, praseodymium oxide, neodymium oxide, and yttrium oxide.

3. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 1, characterized in that: In step S2, the temperature of the high temperature reaction furnace is 700-800°C.

4. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 1, characterized in that: In step S3, the rare earth aluminum alloy raw material contains the following metal elements in percentage by mass: Al 80-90%, Fe 0.25-1%, Cu 0.1-0.4%, Mg 0.05-0.2%, Ce 0.1-0.3%.

5. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 1, characterized in that: In step S5, one of polystyrene, nylon and polyethylene is used for injection molding on the surface of the fixing clip to form an insulator.

6. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 1, characterized in that: In step S5, a composite coating is sprayed on the surface of the fixing clip by combining hot spraying and cold spraying to complete the injection molding.

7. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 6, characterized in that: The specific process of spraying the composite coating on the surface of the fixing clip is: thoroughly cleaning and pre-treating the surface of the fixing clip to remove impurities, then applying a layer of primer, spraying an anti-salt corrosion layer, an insulating layer and a hard layer on the primer in sequence, and finally applying a layer of topcoat, and drying and curing after the coating is completed.

8. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 1, characterized in that: In steps S4 and S5, during the salt corrosion resistance test, if the product fails the test twice in a row, it will be output to the defective product area.

9. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 1, characterized in that: In steps S4 and S5, the specific process of salt corrosion resistance testing is: place the product to be tested in a salt spray environment of a set concentration, observe the surface corrosion of the product after 48 hours, and preliminarily judge the salt corrosion resistance by comparing the sample status before and after the test. Perform chemical analysis on the product to detect whether its chemical composition and content meet the requirements.

10. The method for manufacturing a salt corrosion resistant cable fixing clamp according to claim 9, characterized in that: When observing the corrosion on the product surface, check the appearance of the sample by visual inspection and touch to see if there are scratches, bubbles, or discoloration defects on the product to be tested, and compare the size of the product to be tested with the standard size to ensure that the error is within the tolerance range.

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