Metal material intelligent continuous production device with local structure regulation and control function and production method of metal material intelligent continuous production device

Abstract

The invention discloses a metal material intelligent continuous production device with a local structure regulation and control function and a production method thereof, and the metal material intelligent continuous production device comprises a computer control system, a current output system, a smelting and casting system and an electric heating system, according to the method, through cooperative work of the defect online detection system and the current micro-area structure regulation and control system, detection and immediate regulation and control of plate and strip structures are achieved. According to the method, on the premise that the whole production process is not affected, online monitoring and dynamic regulation and control can be carried out on the metal material, quality control of products in all links is ensured, and the reworking rate and the rejection rate caused by defects are greatly reduced. Meanwhile, the method is suitable for metal materials of different types and specifications, customized regulation and control can be carried out according to specific requirements, and diversified industrial production requirements are met.

Description

Technical Field

[0001] The present invention belongs to the technical field of metal material forming, and in particular relates to an intelligent and continuous metal material local tissue control device and a preparation method thereof. Background Art

[0002] With the rapid development of modern industry, the demand for various high-performance materials is increasing. Wide-width alloy plates and strips have become important basic materials due to their excellent mechanical properties and wide application fields, such as aerospace, automobile manufacturing, construction engineering, etc. However, during the production and processing process, alloy plates and strips often have problems such as local uneven composition, severe segregation, and the inability to adjust the microstructure in specific areas according to demand, which seriously affects the mechanical properties and service life of the material. Therefore, considering the national development strategy, achieving the major goals of national resource security and the dual carbon strategy, breaking through foreign technology blockades, and preventing the occurrence of strangulation, how to effectively regulate the microstructure and improve the overall quality of alloy plates and strips has become a technical problem that needs to be solved urgently.

[0003] The production of alloy plates and strips usually includes processes such as smelting, casting, solution treatment, hot rolling, cold rolling and heat treatment. In these processes, various organizational defects and material losses will inevitably occur. For example, during the smelting and casting process, the composition distribution of the alloy is uneven, the cooling rate is inconsistent, and pores are easily formed. During the rolling process, microcracks are prone to occur in the material under high temperature and high pressure. These problems will cause losses when entering the next process; in addition, during the heat treatment process, due to inaccurate temperature control, it may also cause internal stress concentration of the material or obtain the same microstructure during the heat treatment process. At present, there are many preparation and processing methods for high-performance metal materials, which mainly focus on the research of overall material preparation, and there are few studies on the micro-region organization control process of the material. Patent No. CN111424224B discloses a method for preparing a high-strength and high-toughness conductive copper alloy strip. The method adopts the process route of "solid solution-cold rolling-electric pulse heat treatment-cold rolling-aging treatment" to enable the alloy to obtain a matrix with fine and uniform grains, high-density dislocations and dispersed distribution of precipitation phases, which greatly improves the mechanical properties of the alloy. However, on the one hand, this method is limited by the size of the furnace chamber in the traditional heat treatment process, the heat treatment time is long, and the production efficiency is low; on the other hand, since the alloy is treated as a whole, only a single and evenly distributed organization can be obtained. Patent No. CN110343993A discloses a hard alloy surface treatment method and application. The method adopts carburizing or nitriding treatment on the alloy surface, which can effectively improve the mechanical properties of the alloy surface. However, this process has high requirements on the thickness of the alloy. If the thickness of the substrate is too thin, the coating structure will be loose, resulting in coating failure or coating penetration. Patent CN117358754A discloses a method for preparing a composite copper-based metal strip. The method can make the graphene layer coated on the surface of the copper substrate strip and the composite copper-based metal material better combined by coating a tin-based or aluminum-based material layer on the graphene layer of the composite metal plate and strip and then pressing and rolling. The prepared material will not peel off or break the graphene layer during use, and the material has good uniformity, which effectively improves the conductivity of the obtained composite copper-based metal strip. However, this process has certain requirements on the thickness of the substrate, and the graphene coating is easily damaged and falls off when squeezed during the composite process, thereby reducing the mechanical properties and service life of the material. At the same time, the process is relatively complex and the process is long, which increases equipment costs and labor costs.

[0004] In summary, how to solve the problems existing in the existing technology and develop an intelligent large-width alloy plate and strip continuous local organization control device and method can significantly improve the quality and reliability of alloy materials, reduce production costs, and improve production efficiency, and will provide important technical support and guarantee for the production and application of high-performance alloy materials. This technology is not only applicable to traditional industrial fields such as aerospace, automobile manufacturing and construction engineering, but can also be extended to emerging high-tech fields such as new energy, electronic information and medical equipment. It has broad application prospects and economic benefits, and promotes the development of materials science and engineering technology. Summary of the invention

[0005] In order to solve the deficiencies in the above background, the first purpose of the present invention is to provide an intelligent continuous production device for metal materials with local organization control function. The local organization control device for metal materials provided by the present invention detects tiny defects on the surface and inside of the processed metal materials in real time by setting up an online defect detection device, and can accurately control microstructures such as heating aging, recrystallization and crack repair through the current micro-area organization control device, and perform local heat treatment through high-energy current, while ensuring the flatness of the surface of the plate and strip. The device of the present invention can not only significantly improve the quality and consistency of the product, but also reduce the waste of raw materials, significantly improve production efficiency, reduce production costs, and improve the comprehensive performance of the product, and can be used for industrial-scale production.

[0006] The second purpose of the present invention is to provide an intelligent and continuous production method for metal materials with local organizational regulation function, which realizes the detection and immediate regulation of the sheet and strip organization through the coordinated work of an online defect detection device and a current micro-area organizational regulation device. This method can monitor and dynamically regulate metal materials online without affecting the overall production process, ensure the quality control of products in all links, and significantly reduce the rework and scrap rate caused by defects. At the same time, this method is suitable for metal materials of different types and specifications, and can be customized and regulated according to specific needs to meet the diverse needs of industrial production.

[0007] In order to achieve the above object, the present invention provides the following technical solutions:

[0008] The present invention provides an intelligent continuous production device for metal materials with a local organization control function, the intelligent continuous production device for metal materials comprising a computer control system, a current output system, a smelting and casting system, an electric heating system, a metal material processing system, an online defect detection system, and a current micro-area organization control system;

[0009] The smelting and casting system is used to smelt and cast metal raw materials to obtain ingots;

[0010] The electric heating system is located at the rear end of the smelting and casting system and is used to preheat the ingot.

[0011] The metal material processing system is located at the rear end of the electric heating system and is used to process the preheated ingot to obtain a processed part.

[0012] The online defect detection system is located at the rear end of the metal material processing device and is used to perform online defect detection on the processed workpiece;

[0013] The current micro-area processing system includes a current probe, which is located at the rear end of the defect online detection system, and applies micro-area current to the defect area of ​​the workpiece through the current probe to repair the structure of the defect area and to regulate the microstructure of the workpiece by applying micro-area current to the workpiece;

[0014] The current output system is used to provide output current for the current micro-area processing device and the metal material processing system;

[0015] The computer control system is connected to other systems and is used to control other systems.

[0016] In a preferred solution, the computer control system is used to receive and process electrical signals from other systems, and send precise control instructions to each system based on pre-entered process parameters of metal materials and real-time feedback information on the quality of processed parts to ensure coordinated operation of the device.

[0017] In a preferred embodiment, the output current form of the current output system is selected from direct current, alternating current, constant current, and pulse current, preferably pulse current.

[0018] Further preferably, the power supply in the current output system consists of a high-frequency low-peak current type and a low-frequency high-peak current type.

[0019] In a preferred embodiment, the smelting and casting system includes a smelting device, a cooling device, and a bending device. The smelting device is used to melt the metal raw material to obtain a melt. The cooling device is connected to the smelting device and is used to cool and crystallize the melt obtained in the smelting device to obtain an ingot. The bending device is used to convert the ingot from a vertical direction to a horizontal direction.

[0020] Further preferably, the smelting device consists of an insulating protective sleeve, a graphite crucible, an induction coil, a mechanical stirrer, a graphite electrode, and an atmosphere protection device; the induction coil is wrapped around the outside of the graphite crucible, and is used to melt the metal raw material in the graphite crucible to obtain a melt, the mechanical stirrer is used to stir the melt, the graphite electrode is connected to the graphite crucible, and provides a pulse current to the graphite crucible through an external pulse power supply, and the atmosphere protection device is used to provide atmosphere protection for the melt in the graphite crucible.

[0021] Further preferably, the mechanical agitator is made of stainless steel-graphite coated material.

[0022] Further preferably, the cooling device comprises a guide tube and a water-cooled crystallizer, the guide tube is connected to the liquid outlet of the graphite crucible, and the melt in the graphite crucible flows into the water-cooled crystallizer through the guide tube for cooling and crystallization to obtain an ingot.

[0023] Further preferably, the water-cooled crystallizer is composed of a mold and cooling water channels arranged on the outside of the mold, and the number of the cooling water channels decreases from top to bottom to form an "inverted T-shaped" cooling zone, wherein the ratio of the number of adjacent cooling water channels is 3:2 to 1.5. In the present invention, by decreasing the number of cooling water channels located on the outside of the mold from top to bottom, the amount of cooling water applied to the outside of the water mold decreases from top to bottom to form an "inverted T-shaped" cooling zone with a temperature gradient from fast cooling to full cooling, so that the present invention obtains an ingot with a temperature gradient, i.e., a columnar crystal structure, through a water-cooled crystallizer.

[0024] In a preferred embodiment, the bending device is composed of three rollers, and the three rollers are externally connected to a power source.

[0025] In a preferred solution, the electric heating system comprises two graphite pressing sheets, which are arranged vertically and located above and below the ingot respectively during operation. The degree of fit between the two graphite pressing sheets and the ingot is controlled by a mechanical arm.

[0026] According to a preferred embodiment, the metal material processing system comprises a processing device A, a processing device B and a current applying device connected in sequence, wherein the processing device A is used to perform hot processing on a preheated ingot, and the processing device B is used to perform cold processing on the processed blank obtained by hot processing, and the current applying device comprises a current delivery electrode, which provides current, preferably a pulse current, during cold processing of the processed blank.

[0027] Further preferably, the processing equipment A and the processing equipment B are both selected from a rolling mill, a drawing equipment, a forging equipment, and an extrusion equipment, preferably a rolling mill.

[0028] Taking the processing equipment as a rolling mill as an example, in the present invention, rolling mill A performs ordinary rolling, and its working purpose is to perform hot rolling processing on alloy plates and strips, eliminate defects generated in the casting process, and significantly reduce the size of the alloy, and then enter rolling mill B for cold rolling processing, the purpose of which is to make the processed billet obtain high-density dislocations, and at the same time utilize the electroplastic effect to reduce the risk of cracking of the processed billet. Current is applied to the processed billet through electrodes, so that the processed billet maintains a uniform electric field distribution and a good crystal structure during the processing process, thereby improving the quality and performance of the processed billet.

[0029] Further preferably, the current applying device uses a high-frequency, low-peak current, and the positive and negative poles of the high-frequency, low-peak current are directly in contact with the upper and lower rollers in the processing area of ​​the processing equipment B.

[0030] Preferably, the online defect detection system comprises a high-precision image sensor and a data analysis module, which are used to detect tiny surface and internal defects of the workpiece in real time and feed back the defect information to the computer control system.

[0031] Further preferably, the high-precision image sensor is composed of a nondestructive testing device and an image acquisition device, wherein the nondestructive testing device includes one of an ultrasonic flaw detection device, a magnetic particle flaw detection device, and an electromagnetic eddy current flaw detection device, preferably a magnetic particle flaw detection device, and the magnetic particle flaw detection device includes a base, a support plate, a fiber brush, a magnetic suspension box, an electric brush, and a detection table.

[0032] In a further embodiment, the magnetic suspension is composed of magnetic powder, oil-based liquid and fluorescent powder, and is coated on the surface of the workpiece in a transverse zigzag shape.

[0033] In the actual operation process, the magnetic suspension is coated on the surface of the workpiece, and the surface of the workpiece is irradiated with ultraviolet rays to continuously obtain the surface image of the workpiece in the detection area; and the acquired image is fed back to the data analysis module through the image acquisition device, and the surface and internal defects of the workpiece are determined based on the surface image acquired by the image acquisition module, and the determined defects are marked.

[0034] In a preferred solution, the current micro-area processing system comprises current probe No. 1, current probe No. 2, current copper plate No. 1, current copper plate No. 2, cable fixing copper ring No. 1, cable fixing copper ring No. 2; a three-axis displacement platform, a fixed platform;

[0035] The rear end of the current copper plate No. 1 is connected to the cable fixing copper ring No. 1, and the front end is provided with a current probe No. 1; the rear end of the current copper plate No. 2 is connected to the cable fixing copper ring No. 2, and the front end is provided with a current probe No. 2; the cable fixing copper ring No. 1 and the cable fixing copper ring No. 2 are respectively connected to the positive pole and the negative pole of the power supply in the current output system,

[0036] The fixed platform is composed of a support and a table located at the top of the support, a limit plate is arranged above the table, and the current copper plate No. 1 is located above the table and below the limit plate, so that it can move freely on the Y axis and move with a limit on the X axis; the current copper plate No. 2 is fixed above the three-axis displacement platform, and the current copper plate No. 2 can move on the X, Y, and Z axes as the three-axis displacement platform moves; the current copper plate No. 2 and the three-axis displacement platform are located below the table, and when working, the current probe No. 1 and the current probe No. 2 are respectively arranged above and below the workpiece, and the current probe No. 1 and the current probe No. 2 are controlled to be centered in the vertical direction.

[0037] Further preferably, the shape of the head surface of the current probe No. 1 and the current probe No. 2 is selected from one of a circle, a cone, a cross, and a straight line, and the size of the head surface is 0.01 mm 2 ~10cm 2 , preferably 0.01 mm 2 ~1cm 2 , and further preferably 0.01 mm 2 ~1mm 2 .

[0038] Further preferably, the accuracy range of the three-axis displacement platform is 0 to 0.1 mm.

[0039] In the present invention, current probe No. 1 and current probe No. 2 are respectively arranged above or below the workpiece that has been defect-detected, and according to the identified defects, current is applied to the defects through current probe No. 1 and current probe No. 2 to repair the defects, and the three-axis displacement platform is used to move to promote the precise movement of current probe No. 1 and current probe No. 2, and current is only applied to the defects. The head surfaces of current probe No. 1 and current probe No. 2 are the contact surfaces with the workpiece, and the processing of specific defect areas is achieved through probes of specific shapes and sizes.

[0040] Preferably, the intelligent continuous production device for metal materials also includes a water cooling circulation system, which is arranged at the rear end of the processing equipment A of the metal material processing system and is used to cool the processed scraps after the heat processing of the processing equipment A.

[0041] Preferably, the intelligent continuous production device for metal materials further comprises a cooling system, wherein the cooling system is located at the rear end of the current micro-area processing device, and the cooling system comprises a spray gun, and the spray gun is used to cool the defective area after the current micro-area processing device applies current to the defective area.

[0042] According to a preferred solution, the intelligent continuous production device for metal materials further comprises a temperature monitoring and control device, wherein the temperature detection and control device is composed of a plurality of thermocouple temperature sensors, and the thermocouple temperature sensors are used for real-time monitoring of the temperature during the continuous production process and feeding back to the computer control system.

[0043] According to a preferred embodiment, the intelligent continuous production device for metal materials further comprises a traction system, which comprises a traction rod and a guide copper plate; wherein the guide copper plate is in contact with the melt, and under the action of the traction rod, the melt flows into the water-cooled crystallizer through the guide pipe at a certain traction speed for cooling to obtain an ingot, and the subsequent ingot continues to pass through other systems in sequence under the traction of the traction system.

[0044] The present invention discloses an intelligent continuous production method of metal materials with local tissue regulation function. The intelligent continuous production device of metal materials is used to firstly melt and cast the metal raw materials to obtain ingots, preheat the ingots, and then process the preheated ingots to obtain processed parts. Online defect detection is performed on the processed parts to identify defective areas, and micro-area current is applied to the defective areas to repair the defects.

[0045] In a preferred embodiment, the metal material is selected from any one of copper alloy, titanium alloy, magnesium alloy, aluminum alloy and iron alloy.

[0046] In a preferred embodiment, the shape of the metal material is selected from a group consisting of a plate, a strip, a wire, a tube, and a special-shaped material.

[0047] According to a preferred solution, before smelting, the initial information of the metal material and the instruction parameter information are first input into the computer control system.

[0048] The initial information and instruction information of the metal material include the type of raw materials, the quality of raw materials, the melting point temperature and boiling point temperature of the raw materials, the heating rate during smelting, the holding temperature, the holding time, the mechanical stirring speed, the melt viscosity, the pulse frequency, the pulse current, the metal liquid flow rate, the temperature gradient simulation parameters of the cooling system, the cooling water flow rate, the rolling deformation, the roll speed, the traction speed, the roll gap size, etc.

[0049] The production method of the present invention adopts automated control throughout the entire process. The high-performance computer control system sends corresponding instructions to other system components to carry out digital control of the metal material processing process, precise regulation of the material microstructure and fine repair of the surface quality. In particular, it integrates functions such as detection, positioning, organizational regulation, defect repair and quality assessment to achieve a continuous and efficient metal material processing process.

[0050] In a preferred embodiment, the smelting process is to heat the metal raw material to a temperature of Ts+(50-100)°C to obtain a melt, and then keep it warm at Ts+(30-80)°C. During the warming process, mechanical stirring and application of electric pulses are performed simultaneously.

[0051] Further preferably, during the smelting, the parameters of the electric pulse applied are: pulse current frequency 10-600 Hz, current density 1-100 A / cm 3 .

[0052] Further preferably, during the smelting, the mechanical stirring speed is controlled at 1-400 r / min.

[0053] In the present invention, the metal raw material is placed in a crucible in a smelting system, the top cover is put on, and Ar gas is introduced for atmosphere protection; the metal raw material is heated by the instruction parameters issued by a high-performance computer control system, and when the insulation temperature is reached, the high-energy electric pulse output system is first rotated to the two gears of "pulse electricity" and "low-frequency high-peak current type", and the pulse current begins to be introduced. During the insulation process, the melt is subjected to dual treatments of mechanical stirring and electric pulse treatment to improve the composition and organizational uniformity of the material. At the same time, during the entire smelting process, atmosphere protection is applied to reduce the increase of oxides on the surface of the melt; after the insulation is completed, the top plug rod is opened, and the melt is directed into the cooling device below the crucible through the guide tube by a traction rod for directional solidification, and then a bending process is performed.

[0054] In a preferred embodiment, the casting process is as follows: the melt is continuously cast from top to bottom through a water-cooled crystallizer having an "inverted T-shaped" cooling zone at a pulling speed of 0.01 to 1 m / min to obtain an ingot.

[0055] After heat preservation, the melt obtained is introduced into the "inverted T-shaped" cooling zone under the furnace body by the traction system for rapid solidification, forming a grain structure that grows along the temperature gradient. During the cooling process, the edge temperature of the solid-liquid mixture is controlled not to be lower than the core temperature, forming a meniscus-shaped temperature distribution from the solid phase to the liquid phase. Since the edge temperature of the solid-liquid mixture is not lower than the core temperature, the alloy plate and strip obtained by the contact and solidification of the melt and the ingot copper plate does not produce casting defects such as orange peel. Subsequently, the solidified ingot is pulled out by the traction rod system and successively enters the bending device, and then is rapidly heated by subsequent electric current, which, on the one hand, promotes the recovery of the recrystallization process and refines the grains; on the other hand, the precipitated phase produced by the melt during the solidification process is fully dissolved back into the matrix to form a supersaturated solid solution, thereby improving the processing performance of the material.

[0056] The preferred solution is that the process of processing the preheated ingot is to first perform hot processing and then cold processing with the assistance of electric pulses. The parameters of the hot processing are: temperature: 0.8~0.85Tm, single-pass deformation amount is 0~30%, and the total deformation amount is 50~90%; cold processing parameters: single-pass deformation amount is 0~20%, and the total deformation amount is 50~90%.

[0057] Further preferably, the hot working is selected from one of hot rolling, hot drawing, hot forging, hot rotary forging, hot radial forging, hot extrusion, and hot upsetting, preferably hot rolling, and the cold working is selected from one of cold rolling, cold drawing, cold forging, cold rotary forging, cold radial forging, cold extrusion, and cold upsetting, preferably cold rolling.

[0058] Further preferably, during the cold processing, the electric pulse parameters are: pulse voltage: 6 to 12 V; output current: 200 to 1000 A; pulse frequency: 5000 to 20000 Hz, and processing time: 0.01 to 300 s.

[0059] The preheated ingot is passed through the processing system by the traction system and is subjected to hot rough rolling by the rolling mill A. It is then quenched to form a uniform supersaturated solid solution and then subjected to electric current fine rolling by the rolling mill B. The composite process of "hot rough rolling + electric current fine rolling" can enable the plate and strip rolling process to be carried out more quickly, and the second set of electric pulse rolling processes can effectively reduce the impact of the rolling process on the surface quality of the plate and strip.

[0060] In a preferred embodiment, the process of identifying defect areas through online defect detection is as follows: continuously acquiring surface images of the workpiece within the detection area through a nondestructive testing device; and feeding back the acquired images to a data analysis module through an image acquisition device, determining the surface and internal defects of the workpiece based on the surface images acquired by the image acquisition module, and identifying the determined defects.

[0061] Further preferably, the defects include pores, microcracks, and stress concentration, wherein stress concentration usually occurs at the bend.

[0062] According to a preferred solution, the process of applying micro-area current to the defect area is as follows: current probe No. 1 and current probe No. 2 of the current micro-area processing device are respectively moved to a marked defect area of ​​the metal material, a current is applied once within the area range of the current probe, and then the current probe is moved to apply current to the next area range of the current probe until the marked defect is processed.

[0063] Further preferably, when the defects are pores and cracks, the parameters of the current applied to the defect area are: pulse voltage: 6~12V; output current: 2000~5000A; pulse frequency: 50~2000Hz; when the defect is stress concentration, the parameters of the current applied to the defect area are: pulse voltage: 6~12V; output current: 2000~3000A; pulse frequency: 50~2000Hz.

[0064] The preferred solution is to apply micro-area current to the defect-repaired metal material for tissue regulation. When performing tissue regulation, the target tissue structure is first designed, and according to the designed target tissue structure, the entire metal material is scanned by micro-area current, or micro-area current scanning is performed in a targeted manner.

[0065] Further preferably, the process of applying micro-area current to the defect-repaired metal material for tissue regulation is as follows: according to the designed target tissue structure, current probe No. 1 and current probe No. 2 of the current micro-area processing device are respectively moved to a certain tissue regulation area of ​​the metal material, and a current is applied once within the area of ​​the current probe, and then the current probe is moved to apply current to the next current probe area until the tissue regulation area is processed. The parameters of the micro-area current are: pulse voltage: 6~12V; output current: 500~2000A; pulse frequency: 50~2000Hz, and processing time: 0.01~300s.

[0066] Principles and advantages

[0067] The processing method of the present invention adopts automatic control throughout the whole process. The high-performance computer control system sends corresponding instructions to other system components to carry out digital control of the processing process of large-width alloy plates and strips, precise regulation of the material microstructure, and fine repair of the surface quality. In particular, the detection, positioning, organization regulation, defect repair and quality assessment functions are integrated into one, so as to realize a continuous and efficient alloy plate and strip processing process. In the present invention, the metal raw material is placed in the melting chamber of the electric pulse melting system, and the melt is subjected to dual treatment of mechanical stirring and electric pulse treatment during the insulation process to improve the composition and organizational uniformity of the material. At the same time, during the entire melting process, atmosphere protection is applied to reduce the increase of oxides on the surface of the melt; after insulation, the melt obtained is introduced by the traction system into the "inverted T-shaped" cooling zone below the furnace body for rapid solidification to form a grain structure growing along the temperature gradient. During the cooling process, the edge temperature of the solid-liquid mixture is controlled not to be lower than the core temperature, forming a meniscus-shaped temperature distribution from the solid phase to the liquid phase. Since the edge temperature of the solid-liquid mixture is not lower than the core temperature, the alloy plate and strip obtained by the contact and solidification of the melt and the ingot copper plate does not produce casting defects such as orange peel. Subsequently, the solidified alloy plate and strip are pulled out by the traction rod system and successively enter the bending device and the induction coil area. The casting speed of the alloy plate and strip is controlled by the high-performance computer system to regulate the microstructure of the alloy plate and strip, introduce a large number of dislocations, and combine with the subsequent rapid heating of the current, on the one hand, to promote the recovery recrystallization process and refine the grains; on the other hand, the precipitated phase generated by the melt during the solidification process is fully dissolved back into the matrix to form a supersaturated solid solution and improve the processing performance of the material.

[0068] The traction system is used to pass the plate and strip processing system, and the plate and strip are hot rough rolled by the first set of rollers, then quenched to form a uniform supersaturated solid solution, and then passed through the second set of rollers for electric current fine rolling. Through the composite process of "hot rough rolling + electric current fine rolling", the plate and strip rolling process can be carried out more quickly, and the second set of electric pulse rolling process can effectively reduce the impact of the rolling process on the surface quality of the plate and strip. As the alloy plate and strip enter the online defect detection system, the magnetic suspension is evenly coated on the surface of the workpiece in a horizontal zigzag shape through a fiber brush, and then the real-time surface detection and internal micro-defect detection of the workpiece are carried out online through the platform. The defect information is fed back to the high-performance computer control system in the form of visual electrical signals for processing and issuing instructions to the electric pulse micro-area defect repair system. The pulse current is accurately guided to the defective area through a high-precision positioning device, and electric pulses are used for micro-area heating and repair. Electric pulse defect repair is performed to quickly eliminate the defects, and then electric pulse aging or electric pulse recrystallization is performed on the target area according to the designed microstructure composition to obtain high-quality metal materials, especially high-quality large-width alloy plates and strips.

[0069] Compared with the prior art, the present invention has the following beneficial effects:

[0070] 1) Compared with the traditional production equipment and process of alloy plates and strips, the present invention provides an intelligent and continuous production device for metal materials with local organization control function. By introducing an automated control system and precise local processing technology, it realizes the efficient elimination of local defects of wide alloy plates and strips. The present invention uses a high-performance computer system to monitor and control the metal materials in real time from smelting, cooling and solidification, bending, recrystallization, hot rolling, electric pulse rolling, online defect detection and current micro-area organization control and other key steps to ensure the accuracy and quality of local defect elimination, avoid the problems of material unevenness and poor surface quality caused by macro segregation in traditional methods, and reduce the generation of micro cracks. It enables metal materials to be precisely designed according to organizational characteristics, greatly reducing the production cycle, reducing energy consumption and material waste, and significantly improving production efficiency and economic benefits.

[0071] 2) The present invention also provides an intelligent and continuous production method for metal materials with local organizational regulation function, which adopts a fully automated control system, and monitors and adjusts the processing parameters of the entire alloy plate and strip in real time through a high-performance computer system to ensure the accuracy and consistency of micro-organization regulation. In the process of electric pulse smelting, electric pulse smelting and mechanical stirring are combined to prevent the uneven composition of the alloy due to poor diffusion ability, and reduce the occurrence of casting defects. At the same time, the electric heating system effectively avoids grain coarsening and stress concentration phenomena, and adopts a process combining hot rolling + electric pulse rolling to achieve rapid deformation of the plate and strip, improve rolling efficiency, and improve the mechanical properties and surface quality of the plate and strip during rolling. Finally, electric pulse micro-organization regulation is used to achieve "point-to-point" microstructure precision design and rapid repair of microcracks. Compared with existing manual or semi-automatic repair methods, the present invention has high efficiency, high precision and low cost, which greatly improves the overall quality and market competitiveness of the product.

[0072] 3) The intelligent continuous production device of metal materials with local organizational regulation function of the present invention has high flexibility and scalability. Through the modular design of the entire production and processing process, the present invention can adapt to various complex production conditions according to the complex process parameters of different alloy types, plate specifications and organizational types. Whether it is a microstructure type with complex morphology or surface defects, the present invention can provide a corresponding design scheme, which not only eliminates the original defects, but also obtains a better organizational structure, significantly improving the ductility, fatigue resistance and corrosion resistance of the material. In addition, the integration of online detection, finishing and precise design functions improves the continuity and automation level of the production process. The present invention is particularly suitable for aerospace, automobile manufacturing and high-end equipment manufacturing fields with high strength and high reliability requirements, and has broad application prospects and market potential. BRIEF DESCRIPTION OF THE DRAWINGS

[0073] Figure 1 It is a structural schematic diagram of an intelligent continuous production device for metal materials with local tissue control function of the present invention, in which: a high-performance computer control system 1#, a high-energy current output system 2#, a smelting and casting system 3#, an electric heating system 4#, a plate and strip processing system 5#, a water cooling circulation system 6#, an online defect detection system 7#, the current micro-area processing system 8#, and a cooling system 9#.

[0074] Figure 2 The metal material after defect repair in Example 3.

[0075] Figure 3 Schematic diagram of the current micro-area processing system. In the figure, 81, current copper plate No. 1; 82, current input connector for installing current probe 1; 83, current output connector for installing current probe 2; 84, three-axis displacement platform; 85, fixed platform; 86, infrared thermometer; 87, current copper plate No. 2; 88, cable fixing copper ring No. 1; 89, cable fixing copper ring No. 2. DETAILED DESCRIPTION

[0076] The present invention is described in detail below with reference to the accompanying drawings.

[0077] like Figure 1 As shown, it is an intelligent continuous production device of metal materials with local tissue regulation function according to this specific embodiment, including a high-performance computer control system 1#, a high-energy current output system 2#, a smelting and casting system 3#, an electric heating system 4#, a plate and strip processing system 5#, a water cooling circulation system 6#, an online defect detection system 7#, the current micro-area processing system 8#, a cooling system 9#, a temperature monitoring and control device (not shown), and a traction system (not shown).

[0078] The current in the current output system includes direct current, alternating current, constant current, and pulse current, preferably pulse current, and pulse current covers high-frequency low-peak current and low-frequency high-peak current.

[0079] The smelting and casting system includes a smelting device, a cooling device, and a bending device. The smelting device is used to melt metal raw materials to obtain a melt. The cooling device is connected to the smelting device and is used to cool and crystallize the melt obtained in the smelting device to obtain an ingot. The bending device is used to convert the ingot from a vertical direction to a horizontal direction.

[0080] Furthermore, the smelting device is composed of an insulating protective sleeve, a graphite crucible, an induction coil, a mechanical stirrer, a graphite electrode, and an atmosphere protection device; the induction coil is wrapped around the outside of the graphite crucible, and is used to melt the metal raw material in the graphite crucible to obtain a melt, the mechanical stirrer is used to stir the melt, the graphite electrode is connected to the graphite crucible, and provides a pulse current to the graphite crucible through an external pulse power supply, and the atmosphere protection device is used to provide atmosphere protection for the melt in the graphite crucible.

[0081] Furthermore, the mechanical agitator is made of stainless steel-graphite coated material.

[0082] Furthermore, the cooling device comprises a guide tube and a water-cooled crystallizer, wherein the guide tube is connected to the liquid outlet of the graphite crucible, and the melt in the graphite crucible flows through the guide tube into the water-cooled crystallizer for cooling and crystallization to obtain an ingot.

[0083] Furthermore, the water-cooled crystallizer consists of a mold and cooling water channels arranged on the outside of the mold, and the number of cooling water channels decreases gradually from top to bottom to form an "inverted T-shaped" cooling zone, in which the ratio of the number of adjacent cooling water channels is 3:2 to 1.5.

[0084] The bending device is composed of three rollers, and the three rollers are externally connected to a power source.

[0085] The electric heating system comprises two graphite pressing sheets, which are distributed up and down and are respectively located above and below the ingot during operation. The degree of fit between the two graphite pressing sheets and the ingot is controlled by a mechanical arm.

[0086] The metal material processing system includes a processing device A connected in sequence, a processing device B and a current applying device, wherein the processing device A is used to perform hot processing on the preheated ingot, and the processing device B is used to perform cold processing on the processed blank obtained by hot processing, and the current applying device includes a current delivery electrode, which provides current, preferably a pulse current, during cold processing of the processed blank.

[0087] Further preferably, the processing equipment A and the processing equipment B are both selected from a rolling mill, a drawing equipment, a forging equipment, and an extrusion equipment, preferably a rolling mill.

[0088] Furthermore, the current applying device adopts a high-frequency, low-peak current, and the positive and negative electrodes of the high-frequency, low-peak current directly contact the upper and lower rollers in the processing area of ​​the processing equipment B.

[0089] Preferably, the online defect detection system comprises a high-precision image sensor and a data analysis module, which are used to detect tiny surface and internal defects of the workpiece in real time and feed back the defect information to the computer control system.

[0090] Further preferably, the high-precision image sensor is composed of a nondestructive testing device and an image acquisition device, wherein the nondestructive testing device includes one of an ultrasonic flaw detection device, a magnetic particle flaw detection device, and an electromagnetic eddy current flaw detection device, preferably a magnetic particle flaw detection device, and the magnetic particle flaw detection device includes a base, a support plate, a fiber brush, a magnetic suspension box, an electric brush, and a detection table.

[0091] Furthermore, the magnetic suspension is composed of magnetic powder, oil-based liquid and fluorescent powder, and is coated on the surface of the workpiece in a horizontal zigzag shape.

[0092] The current micro-area processing device comprises current probe No. 1, current probe No. 2, current copper plate No. 1, current copper plate No. 2, cable fixing copper ring No. 1, cable fixing copper ring No. 2; a three-axis displacement platform and a fixed platform;

[0093] The rear end of the current copper plate No. 1 is connected to the cable fixing copper ring No. 1, and the front end is provided with a current probe No. 1; the rear end of the current copper plate No. 2 is connected to the cable fixing copper ring No. 2, and the front end is provided with a current probe No. 2; the cable fixing copper ring No. 1 and the cable fixing copper ring No. 2 are respectively connected to the positive pole and the negative pole of the power supply in the current output system,

[0094] The fixed platform is composed of a support and a table located at the top of the support, a limit plate is arranged above the table, and the current copper plate No. 1 is located above the table and below the limit plate, so that it can move freely on the Y axis and move with a limit on the X axis; the current copper plate No. 2 is fixed above the three-axis displacement platform, and the current copper plate No. 2 can move on the X, Y, and Z axes as the three-axis displacement platform moves; the current copper plate No. 2 and the three-axis displacement platform are located below the table, and when working, the current probe No. 1 and the current probe No. 2 are respectively arranged above and below the workpiece, and the current probe No. 1 and the current probe No. 2 are controlled to be centered in the vertical direction.

[0095] The shape of the head surface of the current probe No. 1 and the current probe No. 2 is selected from one of a circle, a cone, a cross, and a straight line, and the size of the head surface is 0.01 mm2 ~10cm 2 , preferably 0.01 mm 2 ~1cm 2 , and further preferably 0.01 mm 2 ~1mm 2 .

[0096] The accuracy range of the three-axis displacement platform is 0 to 0.1 mm.

[0097] The water cooling circulation system is arranged at the rear end of the processing equipment A of the metal material processing system, and is used to cool the processed scraps that have been heat-processed by the processing equipment A.

[0098] The cooling system is located at the rear end of the current micro-area processing device. The cooling system includes a spray gun, which is used to cool the defective area after the current micro-area processing device applies current.

[0099] The temperature monitoring and control device is composed of a plurality of thermocouple temperature sensors, and the thermocouple temperature sensors are used to monitor the temperature in the continuous production process in real time and feed back to the computer control system.

[0100] The traction system includes a traction rod and a copper plate for ingot ingot; the copper plate for ingot ingot ingot contacts the melt, and under the action of the traction rod, the melt flows into the water-cooled crystallizer through the guide pipe at a certain traction speed for cooling to obtain an ingot, and the subsequent ingot continues to pass through other systems in sequence under the traction of the traction system. The specific operation includes the following steps:

[0101] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0102] (1) Data entry. Before smelting, the initial information of the metal material is entered into the high-performance computer control system, including the type of raw materials, the quality of raw materials, the melting point and boiling point of the raw materials, the heating rate during smelting, the insulation temperature, the insulation time, the mechanical stirring speed, the melt viscosity, the pulse frequency, the pulse current, the metal liquid flow rate, the cooling system temperature gradient simulation parameters, the cooling water flow rate, the roll speed, the traction speed, the roll gap size, etc.

[0103] (2) Material preparation. Before heating, close the plug at the bottom of the crucible, and put the metal raw materials into the crucible in order from low to high melting points according to the designed composition and quality. Close the top cover and introduce Ar gas for atmosphere protection. The gas flow rate is 15-20 L / min. After about 3-5 minutes, reduce the gas flow rate to 5-10 L / min, and continue to introduce argon protective gas to ensure that the entire smelting process is under atmosphere protection.

[0104] (3) Electric pulse melting. The melting command (heating speed 20-150℃ / min, insulation temperature 25-1800℃, insulation time 1-60min) is issued by the high-performance computer control system. The induction coil in the electric pulse melting system starts to heat the melting chamber. When the insulation temperature is reached, the mechanical stirrer in the center of the melting chamber (stirring speed: 1-400r / min) and the pulse power supply (the power supply is adjusted to "pulse power" and "low frequency high peak current type", pulse current: 1-100A / cm 3 , pulse current frequency: 10~600Hz) to accelerate the dispersion of the melt. After the insulation is completed, the plug at the bottom of the crucible is opened by the robotic arm, and the traction rod is passed through the cooling device on the outside of the bottom of the crucible (cooling water flow rate 200~1000L / h,, from top to bottom, the ratio of the adjacent water channel is reduced by 3:2~1.5, and the top rod head is inserted into the groove at the bottom of the crucible to connect with the metal liquid. According to the set traction speed (0.01~1m / min), the metal melt is pulled out to the bending device below.

[0105] (4) Strip processing. The high-performance computer control system issues a heating command (heating speed 20-150°C / min, insulation temperature 0.8-0.85Tm), and the graphite electrode at the front end of the strip processing device begins to heat the processing area with electric current. Then, the traction rod is used to pull the plate ingot from the bending device into the induction coil for insulation for 1-30 minutes. After the insulation is completed, it enters the "hot rolling + electric pulse rolling" area at the middle and rear ends. The hot rolling deformation is controlled at 50-90%. After the hot rolling is completed, electric pulse fine rolling processing is immediately carried out (the deformation of the finishing pass is less than 20%, the total deformation is 50-90%, the pulse voltage is: 6-12V; the output current is: 200-1000A; the pulse frequency is 5000-20000Hz, and the processing time is 0.01-300s).

[0106] (5) Defect detection: After the strip is processed, the plate and strip enter the online defect detection system for quality inspection. The magnetic particle inspection method is adopted, and the suspension (magnetic powder, oil-based liquid and fluorescent powder are mixed in a ratio of 3:10:1) is applied to the surface of the plate and strip in a horizontal "zigzag" shape using a fiber brush. The surface is observed and sampled through the detection table, and the image signal is fed back to the high-performance computer system for recording, and the corresponding signal is input and transmitted to the electric pulse micro-area defect repair system to determine the surface and internal defects of the processed parts, and the determined defects are marked.

[0107] (6) Defect repair: Move current probe No. 1 and current probe No. 2 of the current micro-area processing device to a marked defect area of ​​the metal material respectively, apply current once within the area range of the current probe, and then move the current probe to apply current to the next area range of the current probe until the marked defects are processed. When the defects are pores and cracks, the parameters of the current applied to the defect area are: pulse voltage: 6~12V; output current: 2000~5000A; pulse frequency: 50~2000Hz; when the defect is stress concentration, the parameters of the current applied to the defect area are: pulse voltage: 6~12V; output current: 2000~3000A; pulse frequency: 50~2000Hz.

[0108] (7) Tissue control: Finally, optionally, the process of applying micro-area current to the defect-repaired metal material for tissue control is as follows: according to the designed target tissue structure, the current probe No. 1 and the current probe No. 2 of the current micro-area processing device are respectively moved to a certain tissue control area of ​​the metal material, and a current is applied once within the area of ​​the current probe. Then, the current probe is moved to apply current to the next current probe area until the tissue control area is processed. The parameters of the micro-area current are: pulse voltage: 6~12V; output current: 500~2000A; pulse frequency: 50~2000Hz, and processing time: 0.01~300s.

[0109] It will be further described below in conjunction with embodiments.

[0110] Example 1

[0111] Taking Cu-Ni-Sn alloy as an example, the following steps are included:

[0112] (1) Data entry. Before smelting, the initial information of the alloy plate and strip was entered into the high-performance computer control system, including the type of raw materials (Cu-9Ni-6Sn), the mass fraction of raw materials (Cu: 85wt%, Ni: 9wt%, Sn: 6wt%), the melting point temperature of raw materials (Cu: 1083℃, Ni: 1455℃, Sn: 232℃), the heating rate during smelting (50℃ / min), the holding temperature (1150℃), the holding time (5min), the mechanical stirring speed (200r / min), the pulse frequency (400Hz), the pulse current (50A / cm 3 ), cooling water flow rate (300L / h), traction speed (0.5m / min), etc.

[0113] (2) Material preparation. Before heating, close the plug at the bottom of the crucible, and put the metal raw materials into the crucible in order from low to high melting points according to the designed composition and quality. Close the top cover and introduce Ar gas for atmosphere protection. The gas flow rate is 15L / min. After about 5 minutes, reduce the gas flow rate to 10L / min, and continue to introduce argon protective gas to ensure that the entire smelting process is under atmosphere protection.

[0114] (3) Electric pulse melting. The melting command is issued by the high-performance computer control system, and the induction coil in the electric pulse melting system starts to heat the melting chamber. When the insulation temperature is reached, the mechanical stirrer and pulse power supply in the center of the melting chamber are turned on at the same time (the power supply is adjusted to "pulse electricity" and "low-frequency high-peak current type") to accelerate the dispersion of the melt. After the insulation is completed, the plug at the bottom of the crucible is opened by the robotic arm, and the traction rod is passed through the cooling device on the outside of the bottom of the crucible. The top rod head is inserted into the groove at the bottom of the crucible and connected to the molten metal. The molten metal is pulled out to the bending device below according to the set traction speed.

[0115] (4) Strip processing. The high-performance computer control system issues a heating command (heating speed 50°C / min, insulation temperature 820°C), and the induction coil at the front end of the electric pulse strip processing device begins to heat the processing area. Then, the traction rod is used to pull the plate ingot from the bending device into the induction coil for insulation for 10 minutes. After the insulation is completed, it enters the "hot rolling + electric pulse rolling" area at the middle and rear ends. The single deformation of hot rolling is controlled at 30%, and the total deformation is 50%. After the hot rolling is completed, the electric pulse fine rolling process is immediately carried out (the single deformation of fine rolling is 10%, the total deformation is 70%, the pulse voltage is: 8V; the output current is: 400A; the pulse frequency is 15000Hz, and the processing time is 60s).

[0116] (5) Defect detection: After the electric pulse strip processing is completed, the plate and strip enter the defect online detection system for quality inspection. The magnetic particle inspection method is adopted, and the suspension (magnetic powder, oil-based liquid and fluorescent powder are mixed in a ratio of 3:10:1) is applied to the surface of the plate and strip in a horizontal "Z" shape using a fiber brush. The surface is observed and sampled through the detection table, and the image signal is fed back to the high-performance computer system for recording, and the corresponding signal is input and transmitted to the electric pulse micro-area defect repair system to determine whether the surface of the processed part has a number of pores and microcracks, and the determined defects are marked.

[0117] (6) Defect repair: Move current probe No. 1 and current probe No. 2 of the current micro-area processing device to a marked defect area of ​​the metal material respectively, apply current once within the area of ​​the current probe, and then move the three-dimensional mobile platform of the current micro-area processing device in three different directions, X, Y, and Z, and move the current probe to apply current to the next current probe area until the marked defect is processed. The defect repair pulse voltage is: 12V; the output current is: 2000A; the pulse frequency is 1500Hz, and the processing time is 10s.

[0118] (7) Microstructure control: After the defect is repaired, the three-dimensional mobile platform is used to control the movement of current probe No. 1 and current probe No. 2 in three different directions, X, Y, and Z, to control the microstructure of the entire material (pulse voltage: 8 V; output current: 800 A; pulse frequency: 1000 Hz, processing time: 30 s).

[0119] Corresponding performance:

[0120] Hardness: 375HV

[0121] Tensile strength: 1180MPa

[0122] Elongation: 8.8%

[0123] Example 2

[0124] Taking Cu-Ni-Sn alloy as an example, the following steps are included:

[0125] (1) Data entry. Before smelting, the initial information of the alloy plate and strip was entered into the high-performance computer control system, including the type of raw materials (Cu-6Ni-6Sn), the mass fraction of raw materials (Cu: 88wt%, Ni: 6wt%, Sn: 6wt%), the melting point temperature of raw materials (Cu: 1083℃, Ni: 1455℃, Sn: 232℃), the heating rate during smelting (50℃ / min), the holding temperature (1150℃), the holding time (5min), the mechanical stirring speed (200r / min), the pulse frequency (400Hz), the pulse current (50A / cm3), the cooling water flow rate (300L / h), the pulling speed (0.5m / min), etc.

[0126] (2) Material preparation. Before heating, close the plug at the bottom of the crucible, and put the metal raw materials into the crucible in order from low to high melting points according to the designed composition and quality. Close the top cover and introduce Ar gas for atmosphere protection. The gas flow rate is 15L / min. After about 5 minutes, reduce the gas flow rate to 10L / min, and continue to introduce argon protective gas to ensure that the entire smelting process is under atmosphere protection.

[0127] (3) Electric pulse melting. The melting command is issued by the high-performance computer control system, and the induction coil in the electric pulse melting system starts to heat the melting chamber. When the insulation temperature is reached, the mechanical stirrer and pulse power supply in the center of the melting chamber are turned on at the same time (the power supply is adjusted to "pulse electricity" and "low-frequency high-peak current type") to accelerate the dispersion of the melt. After the insulation is completed, the plug at the bottom of the crucible is opened by the robotic arm, and the traction rod is passed through the cooling device on the outside of the bottom of the crucible. The top rod head is inserted into the groove at the bottom of the crucible and connected to the molten metal. The molten metal is pulled out to the bending device below according to the set traction speed.

[0128] (4) Strip processing. The high-performance computer control system issues a heating command (heating speed 50°C / min, insulation temperature 850°C). The induction coil at the front end of the electric pulse strip processing device starts to heat the processing area. Then, the traction rod is used to pull the plate ingot from the bending device into the induction coil for insulation for 10 minutes. After the insulation is completed, it enters the "hot rolling + electric pulse rolling" area at the middle and rear ends. The hot rolling deformation is controlled at 30%. After the hot rolling is completed, the electric pulse fine rolling process is immediately carried out (the finishing deformation is 20%, the pulse voltage is: 6V; the output current is: 300A; the pulse frequency is 20000Hz, and the processing time is 60s).

[0129] (5) Defect detection: After the electric pulse strip processing is completed, the plate and strip enter the defect online detection system for quality inspection. The magnetic particle inspection method is adopted, and the suspension (magnetic powder, oil-based liquid and fluorescent powder are mixed in a ratio of 3:10:1) is applied to the surface of the plate and strip in a horizontal "Z" shape using a fiber brush. The surface is observed and sampled through the detection table, and the image signal is fed back to the high-performance computer system for recording, and the corresponding signal is input and transmitted to the electric pulse micro-area defect repair system to determine whether the surface of the processed part has a number of pores and microcracks, and the determined defects are marked.

[0130] (6) Defect repair: Move current probe No. 1 and current probe No. 2 of the current micro-area processing device to a marked defect area of ​​the metal material respectively, apply current once within the area of ​​the current probe, and then move the three-dimensional mobile platform of the current micro-area processing device in three different directions, X, Y, and Z, and move the current probe to apply current to the next current probe area until the marked defect is processed. The defect repair pulse voltage is: 12V; the output current is: 1000A; the pulse frequency is 1200Hz, and the single-point processing time is 10s.

[0131] (7) Microstructure control: After the defect is repaired, the three-dimensional mobile platform is used to control the movement of current probe No. 1 and current probe No. 2 in three different directions, X, Y, and Z, to control the microstructure of the entire material. The pulse voltage is 8 V; the output current is 600 A; the pulse frequency is 1000 Hz, and the single-point processing time is 30 s.

[0132] Corresponding performance:

[0133] Hardness: 355HV

[0134] Tensile strength: 1024MPa

[0135] Elongation: 12.3%

[0136] Example 3

[0137] Taking Cu-Ni-Co-Si alloy as an example, the following steps are included:

[0138] (1) Data entry. Before smelting, the initial information of the alloy plate and strip was entered into the high-performance computer control system, including the type of raw materials (Cu-6Ni-6Sn), the mass fraction of raw materials (Cu: 96.9wt%, Ni: 1.1wt%, Co: 1.4wt%, Si: 0.6wt%), the melting point temperature of the raw materials (Cu: 1083℃, Ni: 1455℃, Co: 1495℃, Si: 1410℃), the heating rate during smelting (50℃ / min), the holding temperature (1180℃), the holding time (5min), the mechanical stirring speed (400r / min), the pulse frequency (500Hz), the pulse current (30A / cm3), the cooling water flow rate (200L / h), the pulling speed (0.3m / min), etc.

[0139] (2) Material preparation. Before heating, close the plug at the bottom of the crucible, and put the metal raw materials into the crucible in order from low to high melting points according to the designed composition and quality. Close the top cover and introduce Ar gas for atmosphere protection. The gas flow rate is 15L / min. After about 5 minutes, reduce the gas flow rate to 10L / min, and continue to introduce argon protective gas to ensure that the entire smelting process is under atmosphere protection.

[0140] (3) Electric pulse melting. The melting command is issued by the high-performance computer control system, and the induction coil in the electric pulse melting system starts to heat the melting chamber. When the insulation temperature is reached, the mechanical stirrer and pulse power supply in the center of the melting chamber are turned on at the same time (the power supply is adjusted to "pulse electricity" and "low-frequency high-peak current type") to accelerate the dispersion of the melt. After the insulation is completed, the plug at the bottom of the crucible is opened by the robotic arm, and the traction rod is passed through the cooling device on the outside of the bottom of the crucible. The top rod head is inserted into the groove at the bottom of the crucible and connected to the molten metal. The molten metal is pulled out to the bending device below according to the set traction speed.

[0141] (4) Strip processing. The high-performance computer control system issues a heating command (heating speed 50°C / min, insulation temperature 920°C), and the induction coil at the front end of the electric pulse strip processing device begins to heat the processing area. Then, the traction rod is used to pull the plate ingot from the bending device into the induction coil for insulation for 10 minutes. After the insulation is completed, it enters the "hot rolling + electric pulse rolling" area at the middle and rear ends. The hot rolling deformation is controlled at 50%. After the hot rolling is completed, the electric pulse fine rolling process is immediately carried out (the finishing deformation is 30%, the pulse voltage is: 6V; the output current is: 200A; the pulse frequency is 20000Hz, and the processing time is 60s).

[0142] (5) Defect detection + defect repair. After the electric pulse strip processing is completed, the plate and strip enter the defect online detection system for quality inspection. The magnetic particle inspection method is adopted, and the fiber brush is used to adhere the suspension (magnetic powder, oil-based liquid and fluorescent powder are mixed in a ratio of 3:10:1) to apply the plate and strip surface in a horizontal "Z" shape. The surface is observed and sampled through the detection table, and the image signal is fed back to the high-performance computer system for recording, and the corresponding signal is input and transmitted to the electric pulse micro-area defect repair system. According to the instructions, the high-precision positioning device is controlled to move along three different directions of X, Y, and Z, and the micro-area heater is controlled to select a circular, elliptical, linear or zigzag pulse probe to repair the defective area of ​​the plate and strip (the pulse voltage is: 12V; the output current is: 1000A; the pulse frequency is 800Hz, and the processing time is 10s).

[0143] Corresponding performance:

[0144] Hardness: 220HV

[0145] Tensile strength: 760MPa

[0146] Elongation: 8.2%

[0147] Comparative Example 1

[0148] This comparative example cancels defect detection, taking Cu-Ni-Sn alloy as an example, includes the following steps:

[0149] (1) Data entry. Before smelting, the initial information of the alloy sheet and strip was entered into the high-performance computer control system, including the type of raw materials (Cu-9Ni-6Sn), the mass fraction of raw materials (Cu: 85wt%, Ni: 9wt%, Sn: 6wt%), the melting point temperature of raw materials (Cu: 1083℃, Ni: 1455℃, Sn: 232℃), the heating rate during smelting (50℃ / min), the holding temperature (1150℃), the holding time (5min), the mechanical stirring speed (200r / min), the pulse frequency (400Hz), the pulse current (50A / cm3), the cooling water flow rate (300L / h), the pulling speed (0.5m / min), etc.

[0150] (2) Material preparation. Before heating, close the plug at the bottom of the crucible, and put the metal raw materials into the crucible in order from low to high melting points according to the designed composition and quality. Close the top cover and introduce Ar gas for atmosphere protection. The gas flow rate is 15L / min. After about 5 minutes, reduce the gas flow rate to 10L / min, and continue to introduce argon protective gas to ensure that the entire smelting process is under atmosphere protection.

[0151] (3) Electric pulse melting. The melting command is issued by the high-performance computer control system, and the induction coil in the electric pulse melting system starts to heat the melting chamber. When the insulation temperature is reached, the mechanical stirrer and pulse power supply in the center of the melting chamber are turned on at the same time (the power supply is adjusted to "pulse electricity" and "low-frequency high-peak current type") to accelerate the dispersion of the melt. After the insulation is completed, the plug at the bottom of the crucible is opened by the robotic arm, and the traction rod is passed through the cooling device on the outside of the bottom of the crucible. The top rod head is inserted into the groove at the bottom of the crucible and connected to the molten metal. The molten metal is pulled out to the bending device below according to the set traction speed.

[0152] (4) Strip processing. The high-performance computer control system issues a heating command (heating speed 50°C / min, insulation temperature 820°C), and the induction coil at the front end of the electric pulse strip processing device begins to heat the processing area. Then, the traction rod is used to pull the plate ingot from the bending device into the induction coil for insulation for 10 minutes. After the insulation is completed, it enters the "hot rolling + electric pulse rolling" area at the middle and rear ends. The single deformation of hot rolling is controlled at 30%, and the total deformation is 50%. After the hot rolling is completed, the electric pulse fine rolling process is immediately carried out (the single deformation of fine rolling is 10%, the total deformation is 70%, the pulse voltage is: 8V; the output current is: 400A; the pulse frequency is 15000Hz, and the processing time is 60s).

[0153] (5) Current micro-area structure control. After the electric pulse strip processing is completed, the plate and strip enter the defect online detection system without quality inspection, but directly continue to enter the electric pulse micro-area. According to the instructions, the high-precision positioning device is controlled to move along three different directions of X, Y, and Z, and the micro-area heater is controlled to select circular, elliptical, linear or zigzag pulse probes to control the microstructure of the entire plate and strip surface (pulse voltage: 8V; output current: 800A; pulse frequency: 1000Hz, processing time: 30s).

[0154] Corresponding performance:

[0155] Hardness: 375HV

[0156] Tensile strength: 650MPa

[0157] Elongation: 2.3%.

Claims

1. An intelligent continuous production device for metal materials with local tissue regulation function, characterized in that: The intelligent continuous production device for metal materials includes a computer control system, a current output system, a smelting and casting system, an electric heating system, a metal material processing system, an online defect detection system, and a current micro-area organization control system; The smelting and casting system is used to smelt and cast metal raw materials to obtain ingots; The electric heating system is located at the rear end of the smelting and casting system and is used to preheat the ingot. The metal material processing system is located at the rear end of the electric heating system and is used to process the preheated ingot to obtain a processed part. The online defect detection system is located at the rear end of the metal material processing device and is used to perform online defect detection on the processed workpiece; The current micro-area processing system includes a current probe, which is located at the rear end of the defect online detection system, and applies micro-area current to the defect area of ​​the workpiece through the current probe to repair the structure of the defect area and to regulate the microstructure of the workpiece by applying micro-area current to the workpiece; The current output system is used to provide output current for the current micro-area processing device and the metal material processing system; The computer control system is connected to other systems and is used to control other systems.

2. According to claim 1, a metal material intelligent continuous production device with local tissue regulation function is characterized by: The computer control system is used to receive and process electrical signals from other systems, and send precise control instructions to each system based on pre-entered process parameters of metal materials and real-time feedback information on the quality of processed parts to ensure coordinated operation of the device; The output current form of the current output system is selected from direct current, alternating current, constant current, and pulse current. The power supply in the current output system is composed of a high-frequency low-peak current type and a low-frequency high-peak current type.

3. The intelligent continuous production device for metal materials with local tissue regulation function according to claim 1 is characterized in that: The smelting and casting system comprises a smelting device, a cooling device, and a bending device. The smelting device is used to smelt metal raw materials to obtain a melt. The cooling device is connected to the smelting device and is used to cool and crystallize the melt obtained in the smelting device to obtain an ingot. The bending device is used to convert the ingot from a vertical direction to a horizontal direction. The smelting device is composed of an insulating protective sleeve, a graphite crucible, an induction coil, a mechanical stirrer, a graphite electrode, and an atmosphere protection device; the induction coil is surrounded by the outside of the graphite crucible and is used to smelt the metal raw material in the graphite crucible to obtain a melt, the mechanical stirrer is used to stir the melt, the graphite electrode is connected to the graphite crucible, and a pulse current is provided to the graphite crucible through an external pulse power supply, and the atmosphere protection device is used to provide atmosphere protection for the melt in the graphite crucible; The mechanical stirrer is made of stainless steel-graphite coated material; The cooling device comprises a guide pipe and a water-cooled crystallizer, wherein the guide pipe is connected to the liquid outlet of the graphite crucible, and the melt in the graphite crucible flows into the water-cooled crystallizer through the guide pipe for cooling and crystallization to obtain an ingot; The water-cooled crystallizer is composed of a mold and cooling water channels arranged outside the mold, the number of the cooling water channels decreases from top to bottom to form an "inverted T-shaped" cooling zone, wherein the ratio of the number of adjacent cooling water channels is 3:2 to 1.5; The bending device is composed of three rollers, and the three rollers are externally connected to a power source.

4. The intelligent continuous production device for metal materials with local tissue regulation function according to claim 1 is characterized in that: The electric heating system comprises two graphite pressing sheets, which are distributed up and down and are respectively located above and below the ingot during operation; The metal material processing system comprises a processing device A and a processing device B connected in sequence and a current applying device, wherein the processing device A is used to perform hot processing on the preheated ingot, and the processing device B is used to perform cold processing on the processed blank obtained by hot processing, and the current applying device comprises a current transmission electrode, through which current is provided during the cold processing of the processed blank. The processing equipment A and the processing equipment B are both selected from a rolling mill, a drawing equipment, a forging equipment, and an extrusion equipment. The current applying device adopts high-frequency low-peak current, and the positive and negative electrodes of the high-frequency low-peak current are directly in contact with the upper and lower rollers in the processing area of ​​the processing equipment B.

5. The intelligent continuous production device for metal materials with local tissue regulation function according to claim 1 is characterized in that: The online defect detection system includes a high-precision image sensor and a data analysis module, which is used to detect small surface and internal defects of the workpiece in real time and feed back the defect information to the computer control system; The high-precision image sensor is composed of a non-destructive testing device and an image acquisition device, wherein the non-destructive testing device includes one of an ultrasonic flaw detection device, a magnetic particle flaw detection device, and an electromagnetic eddy current flaw detection device. The current micro-area processing system comprises current probe No. 1, current probe No. 2, current copper plate No. 1, current copper plate No. 2, cable fixing copper ring No. 1, cable fixing copper ring No. 2; a three-axis displacement platform and a fixed platform; The rear end of the current copper plate No. 1 is connected to the cable fixing copper ring No. 1, and the front end is provided with a current probe No. 1; the rear end of the current copper plate No. 2 is connected to the cable fixing copper ring No. 2, and the front end is provided with a current probe No. 2; the cable fixing copper ring No. 1 and the cable fixing copper ring No. 2 are respectively connected to the positive pole and the negative pole of the power supply in the current output system, The fixed platform is composed of a support and a table located at the top of the support, a limit plate is arranged above the table, and the current copper plate No. 1 is located above the table and below the limit plate, so that it can move freely on the Y axis and move within a limit limit on the X axis; the current copper plate No. 2 is fixed above the three-axis displacement platform, and the current copper plate No. 2 can move on the X, Y, and Z axes with the movement of the three-axis displacement platform; the current copper plate No. 2 and the three-axis displacement platform are located below the table, and when working, the current probe No. 1 and the current probe No. 2 are respectively arranged above and below the workpiece, and the current probe No. 1 and the current probe No. 2 are controlled to be centered in the vertical direction; The shape of the head surface of the current probe No. 1 and the current probe No. 2 is selected from one of a circle, a cone, a cross, and a straight line, and the size of the head surface is 0.01 mm 2 ~10cm 2 , preferably 0.01 mm 2 ~1cm 2 , and further preferably 0.01 mm 2 ~1mm 2 ; The accuracy range of the three-axis displacement platform is 0 to 0.1 mm.

6. An intelligent continuous production device for metal materials with local tissue regulation function according to any one of claims 1 to 5, characterized in that: The intelligent continuous production device for metal materials further comprises a water cooling circulation system, which is arranged at the rear end of the processing equipment A of the metal material processing system and is used to cool the processed waste material after the heat processing of the processing equipment A; The intelligent continuous production device for metal materials further comprises a cooling system, the cooling system is located at the rear end of the current micro-area processing device, the cooling system comprises a spray gun, and the spray gun is used to cool the defective area after the current micro-area processing device applies current treatment; The intelligent continuous production device for metal materials also includes a temperature monitoring and control device, which is composed of a plurality of thermocouple temperature sensors, and the thermocouple temperature sensors are used to monitor the temperature in the continuous production process in real time and feed back to the computer control system; The intelligent continuous production device for metal materials also includes a traction system, which includes a traction rod and a guide copper plate; the guide copper plate is in contact with the melt, and under the action of the traction rod, the melt flows into the water-cooled crystallizer through the guide pipe at a certain traction speed for cooling to obtain an ingot, and the subsequent ingot continues to pass through other systems in turn under the traction of the traction system.

7. An intelligent and continuous production method of metal materials with local tissue regulation function, characterized in that: By using the intelligent continuous production device for metal materials as described in any one of claims 1 to 6, the metal raw materials are first smelted and cast to obtain ingots, the ingots are preheated, and then the preheated ingots are processed to obtain processed parts, defects of the processed parts are detected online to identify defective areas, and micro-area current is applied to the defective areas to perform defect repair.

8. The intelligent continuous production method of metal materials with local tissue regulation function according to claim 7, characterized in that: The metal material is selected from any one of copper alloy, titanium alloy, magnesium alloy, aluminum alloy and iron alloy; The shape of the metal material is selected from one of a plate, a strip, a wire, a tube, and a special-shaped material; Before the smelting, the initial information of the metal material and the instruction parameter information are first input into the computer control system; The smelting process is to heat the metal raw material to a temperature of Ts+(50-100)°C to obtain a melt, and then keep it warm at Ts+(30-80)°C. During the warming process, mechanical stirring and electric pulse application are performed simultaneously. During the smelting, the parameters of the electric pulse applied are: pulse current frequency 10-600 Hz, current density 1-100 A / cm 3 ; During the smelting, the mechanical stirring speed is controlled at 1-400 r / min; The casting process is as follows: the melt is continuously casted from top to bottom through a water-cooled crystallizer having an "inverted T-shaped" cooling zone at a pulling speed of 0.01 to 1 m / min to obtain an ingot; The process of processing the preheated ingot is to first perform hot processing and then perform cold processing with the assistance of electric pulses. The parameters of the hot processing are: temperature: 0.8-0.85Tm, single-pass deformation amount of 0-30%, total deformation amount of 50-90%; cold processing parameters: single-pass deformation amount of 0-20%, total deformation amount of 50-90%; The hot working is selected from one of hot rolling, hot drawing, hot forging, hot rotary forging, hot radial forging, hot extrusion and hot upsetting; the cold working is selected from one of cold rolling, cold drawing, cold forging, cold rotary forging, cold radial forging, cold extrusion and cold upsetting. During the cold processing, the electric pulse parameters are: pulse voltage: 6-12V; output current: 200-1000A; pulse frequency: 5000-20000Hz, and processing time: 0.01-300s.

9. The intelligent continuous production method of metal materials with local tissue regulation function according to claim 7, characterized in that: The process of marking the defect area by online defect detection is as follows: continuously acquiring the surface image of the workpiece in the detection area by a nondestructive testing device; feeding the acquired image back to a data analysis module by an image acquisition device, determining the surface and internal defects of the workpiece according to the surface image acquired by the image acquisition module, and marking the determined defective location; The defects include pores, microcracks, and stress concentration; The process of applying micro-area current to the defective area is as follows: the current probe No. 1 and the current probe No. 2 of the current micro-area processing device are respectively moved to a marked defective area of ​​the metal material, a current is applied once within the area range of the current probe, and then the current probe is moved to apply current to the next area range of the current probe until the marked defect is processed; When the defects are pores and cracks, the parameters of the current applied to the defect area are: pulse voltage: 6~12V; output current: 2000~5000A; pulse frequency: 50~2000Hz; when the defect is stress concentration, the parameters of the current applied to the defect area are: pulse voltage: 6~12V; output current: 2000~3000A; pulse frequency: 50~2000Hz.

10. The intelligent continuous production method of metal materials with local tissue regulation function according to claim 7 or 9, characterized in that: Organizing and regulating the applied micro-area current of the defect-repaired metal material; The process of applying micro-area current to the defect-repaired metal material for tissue regulation is as follows: according to the designed target tissue structure, the current probe No. 1 and the current probe No. 2 of the current micro-area processing device are respectively moved to a certain tissue regulation area of ​​the metal material, and a current is applied once within the area range of the current probe, and then the current probe is moved to apply current to the next current probe area range until the tissue regulation area is processed. The parameters of the micro-area current are: pulse voltage: 6~12V; output current: 500~2000A; pulse frequency: 50~2000Hz, and processing time: 0.01~300s.

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