A continuous roll-casting forming device and method for a shape-controllable foam metal plate

Abstract

This invention belongs to the field of foam metal forming technology, specifically relating to a shape-controllable foam metal sheet continuous casting and rolling forming equipment and method. The equipment includes a melt chute, a melt processing device, a gas supply device, a detection device, a casting and rolling device, and a blowing device. The blowing device is located at the bottom of the foaming cavity and directly below the casting and rolling device. The internal pore structure of the blowing device is gradient-distributed along the width and / or length of the roll gap, continuously blowing a group of bubbles into the pre-formed molten metal inside the foaming cavity. In this invention, the solid coating forming process, the foam core layer foaming process, and the composite interface bonding process are carried out simultaneously. The macroscopic structure of the solid coating, the microscopic structure of the composite interface, and the mesoscopic structure of the foam core layer can be reasonably controlled through structural parameters and process parameters. This is beneficial for the synergistic regulation of macroscopic-microscopic-mesoscopic structural performance and the metallurgical bonding of high-temperature in-situ high-strength composite interface, realizing the continuous near-net-shape forming of various wide-width foam metal sheets.

Description

Technical Field

[0001] This invention belongs to the field of foam metal forming technology, specifically relating to a shape-controllable foam metal sheet continuous casting and rolling forming equipment and method. Background Technology

[0002] Foamed metal sandwich materials achieve interfacial bonding between the solid coating and the foam core layer through special forming technology. Typical products include foamed metal sandwich panels and foamed metal sandwich tubes. They have the characteristics of low density, high specific stiffness, and high specific strength. They can give full play to the excellent functional properties of foamed metal itself, while improving its defects such as low strength and difficulty in connection. They are a typical new type of composite material with integrated structure and function, which can meet the performance requirements of extreme service environments and has extremely high research value and broad application prospects.

[0003] Currently, the manufacturing processes of foam metal sandwich panels can be divided into physical connection principles and metallurgical connection principles based on the type of composite interface bonding. Physical connection principles refer to achieving a physical bond between the solid cladding layer and the foam core layer through techniques such as adhesive bonding and bolted connections. While the process is simple, it is severely limited in practical applications. In adhesive bonding, the adhesive is often an organic compound, which is prone to melting and deterioration under high temperature and corrosive conditions, thus preventing heat treatment and also facing the problem of service aging. Through holes in threaded connections not only affect mechanical properties but also cause stress concentration and corrosion during service. Metallurgical connection principles refer to achieving a metallurgical bond between the foam core layer and the solid cladding layer through techniques such as powder metallurgy, welding, and melt foaming. Powder metallurgy involves mixing metal powder with foaming agent powder, preparing composite preforms through molding, cladding-composite rolling, and powder hot pressing, and finally heating and foaming to obtain the foam metal sandwich material. This method can produce complex components, but the process is complex and the yield is low. Welding methods include brazing, friction stir welding, and laser welding, which can produce large-sized products, but are limited to the interface bonding process of semi-finished products. Melt foaming uses mechanical stirring to introduce thickeners and foaming agents into the melt, which is then injected into a solid coating. The foaming agent decomposes in situ to generate gas, creating a foam core layer and achieving interfacial bonding. Currently, this is the most promising method for achieving integrated molding; however, the rising of bubbles during casting makes controlling the uniformity of cell size and distribution difficult, and it also presents significant challenges in continuous molding.

[0004] As the application fields of foamed metal sandwich panels continue to expand, extreme service environments such as bending, impact, fatigue, and high temperature place stringent demands on the properties of the component metals, interfacial bonding performance, and circumferential uniformity of both. Furthermore, a good interfacial bonding effect is a prerequisite for their interaction. Currently, the continuous forming process for wide-width products faces prominent problems such as low interfacial bonding strength, uncontrollable cell structure, and poor performance uniformity. Forming technologies such as adhesive bonding, bolted connection, powder metallurgy, welding, and melt foaming have promoted the development and application of foamed metal sandwich panels, but they face serious challenges in further improving production efficiency and product quality. Addressing the service performance requirements of wide-width foamed metal sandwich panels, including miniaturized cell structure, customized cell distribution, interfacial metallurgical bonding, and uniform microstructure and properties, developing a highly efficient, shape-controllable continuous near-net-shape forming technology has become an industry challenge and an international research hotspot. Summary of the Invention

[0005] This invention addresses the above-mentioned problems by providing a shape-controllable foam metal sheet continuous casting and rolling forming equipment and method.

[0006] To achieve the above objectives, the present invention employs the following technical solution:

[0007] A shape-controllable foam metal sheet continuous casting and rolling forming equipment includes a melt chute, a melt processing device, an air supply device, a detection device, a casting and rolling device, and an air blowing device.

[0008] The inner cavity of the melt chute is sealed and the outer wall is embedded with a heating device for temperature control. The melt chute includes a casting cavity, a connecting cavity and a foaming cavity. The melt processing device and the detection device are arranged above the casting cavity. The melt processing device is used to prepare pre-formed molten metal and pour the pre-formed molten metal into the casting cavity through a sealed interface. The detection device is used to detect the liquid level height of the pre-formed molten metal inside the casting cavity and provide feedback to adjust the pouring flow rate of the melt processing device to achieve a constant liquid level height in the casting cavity.

[0009] The casting and rolling device includes a transmission system, a pressing system, a main frame, a casting and rolling roll system, and a contoured side seal. The casting and rolling roll system is located inside the main frame and includes two sets of die-shaped casting and rolling rolls and bearing seats. The die-shaped casting and rolling rolls are internally circulated with cooling water and have a gradient die pattern on their surface. The surface of the die-shaped casting and rolling rolls is coated with a heat-insulating coating with the same thickness distribution. The heat-insulating coating is used to control the uniformity of cooling capacity of the die-shaped casting and rolling rolls along their axial direction with the solidification point height as the target. The transmission system is used to drive the die-shaped casting and rolling rolls to rotate. The pressing system is used to control the relative position between the die-shaped casting and rolling rolls, thereby achieving the purpose of controlling the roll gap. The two die-shaped casting and rolling rolls together form a gradient cross-section roll gap, and together with the air blowing cavity located below and the contoured side seals located at both ends, they form a casting and rolling zone. An adjustable arc-shaped gap is left between the die-shaped casting and rolling rolls and the air blowing cavity.

[0010] The gas supply device provides compressed gas to the blowing device, which is located at the bottom of the foaming cavity and directly below the casting and rolling device. The internal pore structure of the blowing device is gradient-distributed along the width and / or length of the roll gap, continuously blowing bubble groups into the pre-formed molten metal inside the foaming cavity to form a pre-formed molten metal containing gradient-distributed bubble groups. When the pre-formed molten metal containing gradient-distributed bubble groups passes through the casting and rolling zone, it is simultaneously subjected to rapid solidification and rolling deformation by the casting and rolling rolls, forming a spatial gradient structure foam metal plate with gradient fibrous pores.

[0011] Furthermore, it also includes a pressurizing device. The compressed gas provided by the gas supply device enters the upper part of the casting cavity through a sealed interface after passing through the pressurizing device, and applies downward extrusion pressure to the precast molten metal inside the casting cavity. The detection device can also be used to detect the extrusion pressure inside the casting cavity, thereby providing feedback to adjust the output pressure of the pressurizing device and achieve a constant extrusion pressure in the casting cavity.

[0012] Furthermore, it also includes a rectifying device, which is located at the bottom of the foaming cavity and directly below the casting and rolling device. The air blowing device is located inside the rectifying device, and the rectifying device has two flow channels on both sides along the axis of the die-cut casting and rolling roll. The pre-formed molten metal enters the interior of the rectifying device through the two flow channels. After being blown by the air blowing device, the pre-formed molten metal containing gradient bubble groups is formed. A flow gap of pre-formed molten metal without gradient bubble groups is left between the outer wall of the rectifying device and the inner wall of the foaming cavity. The top of the rectifying device is not lower than the top of the foaming cavity and an arc-shaped gap is left between it and the die-cut casting and rolling roll. The shapes of the air blowing device and the rectifying device are the same as the shape of the gradient section roll gap.

[0013] Furthermore, it also includes an uncoiling device. There are two uncoiling devices, which are installed above the casting and rolling device and symmetrically arranged on both sides of the tapered section roll gap. They are used for constant tension uncoiling of different strips. After the strip is uncoiled by the uncoiling device, it is tightly wrapped around the adjacent die-cut casting and rolling rolls for half a turn, and then passes through the arc-shaped gap between the die-cut casting and rolling rolls and the air blowing cavity to enter the casting and rolling zone. Afterward, it leaves through the tapered section roll gap, completing the rolling and compounding with the pre-made molten metal.

[0014] A method for continuous casting and rolling of shape-controllable foam metal sheets includes the following steps:

[0015] S1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device, heated to temperature T1 to melt and held at the temperature, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and held at the temperature to prepare a pre-formed metal melt that meets the requirements of foaming stability.

[0016] S2; Adjust installation dimensions: Adjust the position of the casting roll system, set the gradient section roll gap size H0, and adjust the arc gap between the die-shaped casting roll and the foaming cavity to 0mm. The casting roll system, the contour side seal, and the foaming cavity together form the casting zone.

[0017] S3; Stable and uniform pouring: The gas supply device is turned on to generate compressed gas, preheat the melt chute to temperature T3, and pour the precast molten metal into the pouring cavity through the melt processing device. After flowing through the connected cavity, it enters the foaming cavity. The liquid level height inside the pouring cavity is detected by the detection device, and the pouring flow rate of the melt processing device is adjusted accordingly to achieve a constant liquid level height.

[0018] S4; Continuous dynamic casting: Start the casting and rolling device, and the compressed gas enters the pre-made molten metal through the micron or nano-scale internal pores of the blowing device to form a gradient bubble group. Then it gradually rises and enters the casting and rolling zone surrounded by the casting and rolling roll system, the contour side seal and the foaming cavity.

[0019] S5; Continuous casting and rolling: A pre-formed molten metal containing gradient bubble clusters is simultaneously subjected to rapid solidification and rolling deformation by a die-cut casting roll within the casting and rolling zone. The highest point of the boundary between the solidification zone and the rolling zone within the casting and rolling zone is called the solidification point, and the distance between the solidification point and the plane containing the axis of the die-cut casting roll is the solidification point height L. KP The degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a gradually changing cross-section foam metal plate with gradient fibrous pore characteristics, and achieving continuous forming after reaching a stable state.

[0020] The nominal radius of the casting roll is R0, the size of the foam metal sheet is equal to the roll gap size H0 of the gradient section, and the solidification point is L. KP The cross-sectional width H at the location KPThe calculation method is as follows The equation governing the degree of flattening during the transformation of spherical pores into fibrous structures is δ = (H KP -H0) / H KP ×100%, therefore, by adjusting the freezing point height L KP It can achieve the regulation of fibrous pore characteristics.

[0021] A method for continuous casting and rolling of shape-controllable foam metal sheets includes the following steps:

[0022] A1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device, heated to temperature T1 to melt and held at the temperature, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and held at the temperature to prepare a pre-formed metal melt that meets the requirements of foaming stability.

[0023] A2; Adjusting installation dimensions: Adjust the position of the casting roll system, set the gradient section roll gap size H0, adjust the arc gap between the die-shaped casting roll and the foaming cavity to 0mm, the casting roll system, the contour side seal and the foaming cavity together form the casting zone, install the rectifier, and set the width of the pre-molten metal without gradient bubble groups and the width of the pre-molten metal with gradient bubble groups before entering the casting zone;

[0024] A3; Stable reverse extrusion: The gas supply device is turned on to generate compressed gas, preheating the melt chute to temperature T3. The precast molten metal is poured into the casting cavity through the melt processing device. After flowing through the connecting cavity, it enters the foaming cavity. The detection device is used to detect the internal gas pressure and liquid level of the casting cavity, and the output pressure of the booster device and the casting flow rate of the melt processing device are adjusted accordingly to achieve constant extrusion pressure and liquid level.

[0025] A4; Dynamic foaming and confluence: When the casting and rolling device is started, the compressed gas passes through the micron or nano-sized internal pores of the blowing device and enters the pre-formed molten metal to form a gradient bubble group. Then, it enters the casting and rolling zone through the inside of the rectifier. At the same time, the pre-formed molten metal without gradient bubble group between the rectifier and the foaming cavity enters the casting and rolling zone under the reverse extrusion pressure of the casting cavity and converges with the pre-formed molten metal containing gradient bubble group inside the casting and rolling zone.

[0026] A5; Continuous casting and rolling: Through the rapid solidification and rolling combined action of the die-shaped casting rolls in the casting and rolling zone, the pre-formed molten metal without gradient bubble clusters solidifies and deforms into a solid cladding layer with a thickness of H1, while the pre-formed molten metal containing gradient bubble clusters solidifies and deforms into a foam core layer with a thickness of H2. The solid cladding layer and the foam core layer achieve a composite interface metallurgical bond. The highest point of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called the solidification point, and the distance between the solidification point and the plane containing the axis of the die-shaped casting roll is the solidification point height L. KPThe degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a gradually changing cross-section foam metal sandwich panel with gradient fibrous pore characteristics, and achieving continuous forming after reaching a stable state.

[0027] The nominal radius of the casting roll is R0. The dimensions of the foam metal sandwich panel are equal to the roll gap dimension H0 of the gradient section, including the thickness of the two solid cladding layers H1 and the thickness of the foam core layer H2, i.e., H0 = 2H1 + H2, and the solidification point is L. KP The cross-sectional width H at the location KP The calculation method is as follows The equation governing the degree of flattening during the transformation of spherical pores into fibrous structures is δ = (H KP -H2) / H KP ×100%, therefore, by adjusting the freezing point height L KP It can achieve the regulation of fibrous pore characteristics.

[0028] A method for continuous casting and rolling of shape-controllable foam metal sheets includes the following steps:

[0029] B1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device, heated to temperature T1 to melt and held at the temperature, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and held at the temperature to prepare a pre-formed metal melt that meets the requirements of foaming stability.

[0030] B2; Adjusting Installation Dimensions: Adjust the position of the casting roll system, set the gradient section roll gap size H0, and adjust the arc-shaped gap between the die-casting roll and the foaming cavity to be the thickness H of strip A. S1 And the thickness H of strip B S2 The casting and rolling roll system, the contour side seal and the foaming cavity together form the casting and rolling zone. A rectifier is installed to set the width of the pre-molten metal without gradient bubble clusters and the width of the pre-molten metal with gradient bubble clusters before entering the casting and rolling zone.

[0031] B3; Constant tension unwinding: Two unwinding devices unwind coils of thickness H at constant tension. S1 Strip A and thickness H S2 Strip B is uncoiled, and strips A and B are closely attached to the adjacent die-casting rolls. After half a turn, they pass through the arc-shaped gap between the die-casting rolls and the foaming cavity and enter the casting zone. When they leave the tapered section roll gap, there is a gap H3 between strips A and B.

[0032] B4; Stable reverse extrusion: The gas supply device is turned on to generate compressed gas, preheat the melt chute to temperature T3, and pour the pre-made molten metal into the casting cavity through the melt processing device. After flowing through the connecting cavity, it enters the foaming cavity. The detection device is used to detect the gas pressure and liquid level inside the casting cavity, and the output pressure of the booster device and the pouring flow rate of the melt processing device are adjusted accordingly to achieve constant extrusion pressure and liquid level.

[0033] B5; Dynamic foaming confluence: When the casting and rolling device is started, the compressed gas passes through the micron or nano-sized internal pores of the blowing device and enters the pre-formed molten metal to form a gradient bubble group. Then, it enters the casting and rolling zone through the inside of the rectifier. At the same time, the pre-formed molten metal without gradient bubble group between the rectifier and the foaming cavity enters the casting and rolling zone under the reverse extrusion pressure of the casting cavity. It converges with the pre-formed molten metal containing gradient bubble group and the strip A and strip B containing pre-impregnated coating inside the casting and rolling zone.

[0034] B6; Continuous casting and rolling: Strips A and B with pre-impregnated coatings, pre-molten metal without gradient bubble clusters, and pre-molten metal with gradient bubble clusters are simultaneously subjected to rapid solidification and rolling by the die-cut casting rolls in the casting and rolling zone to achieve composite interface metallurgical bonding; the pre-molten metal without gradient bubble clusters solidifies and deforms into a solid coating layer of thickness H1, and the pre-molten metal with gradient bubble clusters solidifies and deforms into a foam core layer of thickness H2; the highest point of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called the solidification point, and the distance between the solidification point and the plane containing the axis of the die-cut casting roll is the solidification point height L. KP The degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a gradually changing cross-section foam metal sandwich panel with gradient fibrous pore characteristics, and achieving continuous forming after reaching a stable state.

[0035] The nominal radius of the casting roll is R0, and the dimensions of the foam metal sandwich panel are equal to the tapered section roll gap dimension H0, including the strip thickness H. S1 Strip thickness B S2 The thickness of the two solid overlay layers H1 and the thickness of the foam core layer H2, i.e., H0 = H S1 +H S2 +2H1+H2, freezing point L KP The cross-sectional width H at the location KP The calculation method is as follows The equation governing the degree of flattening during the transformation of spherical pores into fibrous structures is δ = (H KP -H2) / H KP ×100%, therefore, by adjusting the freezing point height L KP It can achieve the regulation of fibrous pore characteristics.

[0036] Compared with the prior art, the present invention has the following advantages:

[0037] In this invention, the solid coating forming process, the foam core layer foaming process, and the composite interface bonding process are carried out simultaneously. The macroscopic structure of the solid coating, the microscopic structure of the composite interface, and the mesoscopic structure of the foam core layer can be reasonably controlled through structural parameters and process parameters. This is conducive to the coordinated regulation of macroscopic-microscopic-mesoscopic structural performance and the metallurgical bonding of high-temperature in-situ high-strength composite interface, realizing the continuous near-net-shape forming of various wide-width foam metal sheets. It has many advantages such as high efficiency, short process, and low energy consumption.

[0038] The present invention has a compact and reasonable structure. The uncoiling device directly forms a tension control unit with the die casting roll to realize constant tension uncoiling of the strip. Furthermore, the low temperature strip is in contact with the high temperature die casting roll for heat transfer. The lower temperature of the die casting roll is conducive to increasing the casting speed, while the higher temperature of the strip is conducive to promoting interfacial bonding. In addition, the pre-impregnated coating on the surface of the strip can further promote the formation of metallurgical bonding at the composite interface.

[0039] This invention controls the shape of the roll gap by adjusting the gradient shape of the die-casting roll and the corresponding thickness distribution of the surface heat insulation coating, thereby achieving axial heat and mass transfer regulation of the die-casting roll with the solidification point height as the target. It can prepare foam metal boards with different gradient cross-sectional shapes.

[0040] This invention controls the solidification point height by adjusting structural parameters such as the diameter of the die-casting roll and the size of the foaming cavity, as well as process parameters such as the casting speed and pouring temperature, thereby changing the bubble cell shape from spherical to fibrous and precisely controlling the geometric structure of the fibrous bubble cell.

[0041] This invention can change the distribution pattern of gradient-distributed bubble groups by altering the internal pore structure of the blowing device along the width and / or length of the roll gap. By changing the flow gap of the pre-fabricated molten metal without gradient bubble groups between the outer wall of the rectifier and the inner wall of the foaming cavity, the ratio between the foam core layer and the solid coating can be adjusted. By changing the blowing flow rate of the blowing device, the porosity of the foam core layer can be changed.

[0042] This invention has a wide range of applications. The pure metal or alloy raw materials can be aluminum, copper, lead, magnesium, zinc, iron, nickel, titanium, or stainless steel, etc. By changing the structure of the device, various products such as heterogeneous foam metal sandwich panels, homogeneous foam metal sandwich panels, and foam metal can be prepared. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the structure of the present invention;

[0044] Figure 2 This is a schematic diagram of the casting and rolling apparatus and the uncoiling apparatus of the present invention;

[0045] Figure 3 This is a cross-sectional view of the present invention along the axial direction of the die-casting roll;

[0046] Figure 4 This is a cross-sectional view of the present invention along the radial direction of the die-casting roll;

[0047] Figure 5 This is a schematic diagram showing the distribution of the die-shaped casting roll and the surface heat-insulating coating of the present invention;

[0048] Figure 6 This is a schematic diagram of the structure of the tapered cross-section roll gap of the present invention;

[0049] Figure 7 This is a schematic diagram of the air blowing device of the present invention;

[0050] Figure 8 This is a schematic diagram of the rectifier device of the present invention;

[0051] Figure 9 This is a schematic diagram of the casting and rolling zone structure during the preparation of elemental foam metal plates according to the present invention.

[0052] Figure 10 This is a schematic diagram of the structure of the elemental foam metal plate prepared according to the present invention;

[0053] Figure 11 This is a schematic diagram of the casting and rolling zone structure during the preparation of homogeneous foam metal sandwich panels according to the present invention.

[0054] Figure 12 This is a schematic diagram of the structure of the homogeneous foam metal sandwich panel prepared according to the present invention;

[0055] Figure 13 This is a schematic diagram of the casting and rolling zone structure during the preparation of heterogeneous foam metal sandwich panels according to the present invention.

[0056] Figure 14 This is a schematic diagram of the heterogeneous foam metal sandwich panel prepared according to the present invention.

[0057] In the diagram, the components are: 1. Melt chute; 2. Melt processing device; 3. Gas supply device; 4. Pressurization device; 5. Detection device; 6. Casting and rolling equipment; 7. Air blowing device; 8. Rectifying device; 9. Uncoiling device; 101. Casting cavity; 102. Connecting cavity; 103. Foaming cavity; 601. Transmission system; 602. Pressing system; 603. Main frame; 604. Casting and rolling roll system; 605. Contouring side seal; 6041. Cutter roll; 6042. Bearing seat; 801. Side flow channels; H0. Roll gap size; H1. Solid coating thickness; H2. Foam core layer thickness; H3. Strip A thickness. S1 Strip thickness B—H S2 Freezing point height - L KP Freezing point L KPThe cross-sectional width at H KP Degree of flattening—δ. Detailed Implementation

[0058] To further illustrate the technical solution of the present invention, the present invention will be further described below through embodiments.

[0059] Example 1

[0060] Continuous casting and rolling of elemental foam metal sheets

[0061] A shape-controllable foam metal sheet continuous casting and rolling forming equipment includes a melt chute 1, a melt processing device 2, an air supply device 3, a detection device 5, a casting and rolling device 6, and an air blowing device 7.

[0062] The inner cavity of the melt chute 1 is sealed and a heating device is embedded in the outer wall for temperature control. The melt chute 1 includes a casting cavity 101, a connecting cavity 102 and a foaming cavity 103. The melt processing device 2 and the detection device 5 are arranged above the casting cavity 101. The melt processing device 2 is used to prepare pre-formed molten metal and pour the pre-formed molten metal into the casting cavity 101 through a sealed interface. The detection device 5 is used to detect the liquid level height of the pre-formed molten metal inside the casting cavity 101 and provide feedback to adjust the pouring flow rate of the melt processing device 2 to achieve a constant liquid level height in the casting cavity 101.

[0063] The casting and rolling device 6 includes a transmission system 601, a pressing system 602, a main frame 603, a casting roll system 604, and a contour side seal 605. The casting roll system 604 is disposed inside the main frame 603 and includes two sets of die-shaped casting rolls 6041 and bearing seats 6042. The die-shaped casting rolls 6041 are internally circulated with cooling water and have gradually changing die patterns on their surfaces. A heat-insulating coating with the same thickness distribution is coated on the surface of the die-shaped casting rolls 6041. The heat-insulating coating is used to control the die-shaped casting rolls 6041 based on the solidification point height. 41. The uniformity of cooling capacity along its axial direction, the transmission system 601 is used to drive the die casting roll 6041 to rotate, the pressing system 602 is used to control the relative position between the die casting rolls 6041, thereby achieving the purpose of controlling the roll gap, the two die casting rolls 6041 together form a gradually changing cross section roll gap, and together with the air blowing cavity 303 located below and the contoured side seals 605 located at both ends, they form a casting and rolling area, and an adjustable arc-shaped gap is left between the die casting roll 6041 and the air blowing cavity 303;

[0064] The gas supply device 3 provides compressed gas to the blowing device 7, which is located at the bottom of the foaming cavity 103 and directly below the casting and rolling device 6. The internal pore structure of the blowing device 7 is gradient-distributed along the width and / or length of the roll gap, continuously blowing bubble groups into the pre-formed molten metal inside the foaming cavity 103 to form a pre-formed molten metal containing gradient-distributed bubble groups. When the pre-formed molten metal containing gradient-distributed bubble groups passes through the casting and rolling zone, it is simultaneously subjected to rapid solidification and rolling deformation by the casting and rolling rolls, forming a spatial gradient structure foam metal plate with gradient fibrous pores.

[0065] A method for continuous casting and rolling of shape-controllable foam metal sheets includes the following steps:

[0066] S1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device 2, heated to temperature T1 to melt and kept at the temperature, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and kept at the temperature to prepare a pre-formed metal melt that meets the foaming stability requirements.

[0067] S2; Adjust installation dimensions: Adjust the position of the casting roll system 604, set the gradient section roll gap size H0, and adjust the arc gap between the die-shaped casting roll 6041 and the foaming cavity 103 to 0mm. The casting roll system 604, the contour side seal 605 and the foaming cavity 103 together form the casting area.

[0068] S3; Stable and uniform pouring: The gas supply device 3 is turned on to generate compressed gas, preheat the melt chute 1 to temperature T3, and pour the precast molten metal into the pouring cavity 101 through the melt processing device 2. After flowing through the connecting cavity 102, it enters the foaming cavity 103. The detection device 5 is used to detect the liquid level height inside the pouring cavity 101, and the pouring flow rate of the melt processing device 2 is adjusted accordingly to achieve a constant liquid level height.

[0069] S4; Continuous dynamic casting: Start the casting and rolling device 6. After the compressed gas passes through the micron or nano-level internal pores of the blowing device 7, it enters the pre-made molten metal to form a gradient bubble group. Then it gradually rises and enters the casting and rolling zone enclosed by the casting and rolling roll system 604, the contour side seal 605 and the foaming cavity 103.

[0070] S5; Continuous casting and rolling: The pre-formed molten metal containing gradient bubble clusters is simultaneously subjected to rapid solidification and rolling deformation by the die-cut casting roll 6041 in the casting and rolling zone. The highest point of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called the solidification point. The distance between the solidification point and the plane containing the axis of the die-cut casting roll 6041 is the solidification point height L. KPThe degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a gradually changing cross-section foam metal plate with gradient fibrous pore characteristics, and achieving continuous forming after reaching a stable state.

[0071] The nominal radius of the casting roll is R0, the size specification H2 of the foam metal board is equal to the roll gap size H0 of the gradient section, and the solidification point is L. KP The cross-sectional width H at the location KP The calculation method is as follows The equation governing the degree of flattening during the transformation of spherical pores into fibrous structures is δ = (H KP -H0) / H KP ×100%, therefore, by adjusting the freezing point height L KP It can achieve the regulation of fibrous pore characteristics.

[0072] A schematic diagram of the casting and rolling zone structure in this method is shown below. Figure 9 As shown, a gradient cross-section elemental foam metal plate with gradient fibrous pore characteristics is prepared, such as... Figure 10 As shown.

[0073] Example 2

[0074] Homogeneous foam metal sandwich panels are continuously cast and rolled.

[0075] A shape-controllable foam metal sheet continuous casting and rolling forming equipment includes a melt chute 1, a melt processing device 2, an air supply device 3, a pressurizing device 4, a detection device 5, a casting and rolling device 6, an air blowing device 7, and a rectifier 8.

[0076] The inner cavity of the melt chute 1 is sealed and a heating device is embedded in the outer wall for temperature control. The melt chute 1 includes a casting cavity 101, a connecting cavity 102 and a foaming cavity 103. The melt processing device 2 and the detection device 5 are arranged above the casting cavity 101. The melt processing device 2 is used to prepare pre-formed molten metal and pour the pre-formed molten metal into the casting cavity 101 through a sealed interface. The compressed gas provided by the gas supply device 3 enters the upper part of the casting cavity 101 through the sealed interface after passing through the pressurization device 4, and applies downward extrusion pressure to the pre-formed molten metal inside the casting cavity 101. The detection device 5 includes a pressure sensor and a liquid level sensor for detecting the extrusion pressure and liquid level of the casting cavity 101, and feeding back to adjust the output pressure of the pressurization device 4 and the pouring flow rate of the melt processing device 2 to achieve constant extrusion pressure and liquid level of the casting cavity 101.

[0077] The casting and rolling device 6 includes a transmission system 601, a pressing system 602, a main frame 603, a casting roll system 604, and a contour side seal 605. The casting roll system 604 is disposed inside the main frame 603 and includes two sets of die-shaped casting rolls 6041 and bearing seats 6042. The die-shaped casting rolls 6041 are internally circulated with cooling water and have gradually changing die patterns on their surfaces. A heat-insulating coating with the same thickness distribution is coated on the surface of the die-shaped casting rolls 6041. The heat-insulating coating is used to control the die-shaped casting rolls 6041 based on the solidification point height. 41. The uniformity of cooling capacity along its axial direction, the transmission system 601 is used to drive the die casting roll 6041 to rotate, the pressing system 602 is used to control the relative position between the die casting rolls 6041, thereby achieving the purpose of controlling the roll gap, the two die casting rolls 6041 together form a gradually changing cross section roll gap, and together with the air blowing cavity 303 located below and the contoured side seals 605 located at both ends, they form a casting and rolling area, and an adjustable arc-shaped gap is left between the die casting roll 6041 and the air blowing cavity 303;

[0078] The gas supply device 3 provides compressed gas to the gas blowing device 7. The gas blowing device 7 and the rectifier 8 are located at the bottom of the foaming cavity 103 and below the casting and rolling equipment 6. The gas blowing device 7 is located inside the rectifier 8, and the rectifier 8 has two flow channels 801 on both sides along the axis of the die casting roll 6041. The preformed molten metal enters the interior of the rectifier 8 through the two flow channels 801. The internal pore structure of the gas blowing device 7 is gradient distributed along the width direction and / or length direction of the roll gap. After the gas blowing device 7 blows gas, it forms a preformed molten metal containing gradient bubble groups. There is a flow gap of preformed molten metal without gradient bubble groups between the outer wall of the rectifier 8 and the inner wall of the foaming cavity 103. The top of the rectifier 8 is not lower than the top of the foaming cavity 103 and there is an arc-shaped gap between it and the die casting roll 6041. The shapes of the gas blowing device 7 and the rectifier 8 are the same as the shape of the gradient cross section roll gap.

[0079] The blowing device 7 blows gradient bubble groups into the interior of the precast molten metal. The precast molten metal containing gradient bubble groups enters the casting and rolling zone through the interior of the rectifier 8. At the same time, the precast molten metal without gradient bubble groups between the rectifier 8 and the foaming cavity 103 enters the casting and rolling zone under the extrusion pressure of the casting cavity 101. The precast molten metal containing gradient bubble groups and the precast molten metal without gradient bubble groups are simultaneously subjected to the rapid solidification and rolling combined action of the casting and rolling rolls in the casting and rolling zone to achieve metallurgical bonding. After solidification, the gradient bubble groups extend along the rolling direction, changing from spherical to fibrous, forming a gradually changing cross-section foam metal sandwich panel with gradient fiber pore characteristics.

[0080] A method for continuous casting and rolling of shape-controllable foam metal sheets includes the following steps:

[0081] A1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device 2, heated to temperature T1 to melt and kept at the temperature, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and kept at the temperature to prepare a pre-formed metal melt that meets the requirements of foaming stability.

[0082] A2; Adjusting installation dimensions: Adjust the position of the casting roll system 604, set the gradient section roll gap size H0, adjust the arc gap between the die-shaped casting roll 6041 and the foaming cavity 103 to 0mm, the casting roll system 604, the contour side seal 605 and the foaming cavity 103 together form the casting and rolling zone, install the rectifier 8, and set the width of the pre-molten metal without gradient bubble group and the width of the pre-molten metal with gradient bubble group before entering the casting and rolling zone;

[0083] A3; Stable reverse extrusion: The gas supply device 3 is turned on to generate compressed gas, preheating the melt chute 1 to temperature T3. The precast molten metal is poured into the casting cavity 101 through the melt processing device 2. After flowing through the connecting cavity 102, it enters the foaming cavity 103. The detection device 5 is used to detect the internal gas pressure and liquid level of the casting cavity 101, and the output pressure of the pressurizing device 4 and the pouring flow rate of the melt processing device 2 are adjusted accordingly to achieve constant extrusion pressure and liquid level.

[0084] A4; Dynamic foaming and confluence: When the casting and rolling device 6 is started, the compressed gas passes through the micron or nanometer-level internal pores of the blowing device 7 and enters the pre-formed molten metal to form a gradient bubble group. Then, it enters the casting and rolling zone through the inside of the rectifier device 8. At the same time, the pre-formed molten metal without gradient bubble group between the rectifier device 8 and the foaming cavity 103 enters the casting and rolling zone under the reverse extrusion pressure of the casting cavity 101 and converges with the pre-formed molten metal containing gradient bubble group inside the casting and rolling zone.

[0085] A5; Continuous casting and rolling forming: Through the rapid solidification and rolling combined action of the die-shaped casting roll 6041 in the casting and rolling zone, the pre-formed molten metal without gradient bubble clusters solidifies and deforms into a solid coating layer with a thickness of H1, and the pre-formed molten metal containing gradient bubble clusters solidifies and deforms into a foam core layer with a thickness of H2. The solid coating layer and the foam core layer achieve a composite interface metallurgical bond. The highest point of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called the solidification point, and the distance between the solidification point and the plane containing the axis of the die-shaped casting roll 6041 is the solidification point height L. KP The degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a homogeneous foam metal sandwich panel with a gradient cross-section and gradient fibrous pore characteristics. After reaching a stable state, continuous forming is achieved.

[0086] The nominal radius of the casting roll is R0. The dimensions of the foam metal sandwich panel are equal to the roll gap dimension H0 of the gradient section, including the thickness of the two solid cladding layers H1 and the thickness of the foam core layer H2, i.e., H0 = 2H1 + H2, and the solidification point is L. KP The cross-sectional width H at the location KP The calculation method is as follows The equation governing the degree of flattening during the transformation of spherical pores into fibrous structures is δ = (H KP -H2) / H KP ×100%, therefore, by adjusting the freezing point height L KP It can achieve the regulation of fibrous pore characteristics.

[0087] A schematic diagram of the casting and rolling zone structure in this method is shown below. Figure 11 As shown, a homogeneous foam metal sandwich panel with a gradient cross-section and gradient fibrous pore characteristics is prepared, such as... Figure 12 As shown.

[0088] Example 3

[0089] Heterogeneous foam metal sandwich panel continuous casting and rolling

[0090] A shape-controllable foam metal sheet continuous casting and rolling forming equipment includes a melt chute 1, a melt processing device 2, an air supply device 3, a pressurizing device 4, a detection device 5, a casting and rolling device 6, an air blowing device 7, a rectifier device 8, and an uncoiling device 9.

[0091] The inner cavity of the melt chute 1 is sealed and a heating device is embedded in the outer wall for temperature control. The melt chute 1 includes a casting cavity 101, a connecting cavity 102 and a foaming cavity 103. The melt processing device 2 and the detection device 5 are arranged above the casting cavity 101. The melt processing device 2 is used to prepare pre-formed molten metal and pour the pre-formed molten metal into the casting cavity 101 through a sealed interface. The compressed gas provided by the gas supply device 3 enters the upper part of the casting cavity 101 through the sealed interface after passing through the pressurization device 4, and applies downward extrusion pressure to the pre-formed molten metal inside the casting cavity 101. The detection device 5 is used to detect the extrusion pressure and liquid level of the casting cavity 101, and adjust the output pressure of the pressurization device 4 and the pouring flow rate of the melt processing device 2 to achieve constant extrusion pressure and liquid level of the casting cavity 101.

[0092] The casting and rolling device 6 includes a transmission system 601, a pressing system 602, a main frame 603, a casting roll system 604, and a contour side seal 605. The casting roll system 604 is disposed inside the main frame 603 and includes two sets of die-shaped casting rolls 6041 and bearing seats 6042. The die-shaped casting rolls 6041 are internally circulated with cooling water and have gradually changing die patterns on their surfaces. A heat-insulating coating with the same thickness distribution is coated on the surface of the die-shaped casting rolls 6041. The heat-insulating coating is used to control the die-shaped casting rolls 6041 based on the solidification point height. 41. The uniformity of cooling capacity along its axial direction, the transmission system 601 is used to drive the die casting roll 6041 to rotate, the pressing system 602 is used to control the relative position between the die casting rolls 6041, thereby achieving the purpose of controlling the roll gap, the two die casting rolls 6041 together form a gradually changing cross section roll gap, and together with the air blowing cavity 303 located below and the contoured side seals 605 located at both ends, they form a casting and rolling area, and an adjustable arc-shaped gap is left between the die casting roll 6041 and the air blowing cavity 303;

[0093] There are two uncoiling devices 9, which are installed above the casting and rolling device 6 and symmetrically arranged on both sides of the gradient section roll gap. They are used for constant tension uncoiling of different strips. After the strip is uncoiled by the uncoiling device 9, it is tightly wrapped around the adjacent die-shaped casting roll 6041 for half a turn, and then passes through the arc-shaped gap between the die-shaped casting roll 6041 and the air blowing cavity 303 to enter the casting and rolling zone. Afterwards, it leaves through the gradient section roll gap, completing the rolling composite with the pre-made molten metal.

[0094] The gas supply device 3 provides compressed gas to the gas blowing device 7. The gas blowing device 7 and the rectifier 8 are located at the bottom of the foaming cavity 103 and below the casting and rolling equipment 6. The gas blowing device 7 is located inside the rectifier 8, and the rectifier 8 has two flow channels 801 on both sides along the axis of the die casting roll 6041. The preformed molten metal enters the interior of the rectifier 8 through the two flow channels 801. The internal pore structure of the gas blowing device 7 is gradient distributed along the width direction and / or length direction of the roll gap. After the gas blowing device 7 blows gas, it forms a preformed molten metal containing gradient bubble groups. There is a flow gap of preformed molten metal without gradient bubble groups between the outer wall of the rectifier 8 and the inner wall of the foaming cavity 103. The top of the rectifier 8 is not lower than the top of the foaming cavity 103 and there is an arc-shaped gap between it and the die casting roll 6041. The shapes of the gas blowing device 7 and the rectifier 8 are the same as the shape of the gradient cross section roll gap.

[0095] Two uncoiling devices 9 uncoil strips A and B under transverse tension and feed them into the casting and rolling zone. An air blowing device 7 blows gradient bubble clusters into the pre-formed molten metal. The pre-formed molten metal containing gradient bubble clusters enters the casting and rolling zone through the interior of a rectifying device 8. Simultaneously, the pre-formed molten metal without gradient bubble clusters between the rectifying device 8 and the foaming cavity 103 enters the casting and rolling zone under the extrusion pressure of the casting cavity 101. The pre-formed molten metal containing gradient bubble clusters, the pre-formed molten metal without gradient bubble clusters, strip A, and strip B are simultaneously subjected to the combined effects of rapid solidification and rolling by the casting rolls in the casting and rolling zone, achieving metallurgical bonding. Furthermore, after solidification, the gradient bubble clusters extend along the rolling direction, changing from spherical to fibrous, forming a gradually changing cross-section foam metal sandwich panel with gradient fibrous pore characteristics.

[0096] A method for continuous casting and rolling of shape-controllable foam metal sheets includes the following steps:

[0097] B1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device 2, heated to temperature T1 to melt and kept at the temperature, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and kept at the temperature to prepare a pre-formed metal melt that meets the requirements of foaming stability.

[0098] B2; Adjusting installation dimensions: Adjust the position of the casting roll system 604, set the gradient section roll gap size H0, and adjust the arc gap between the die-cut casting roll 6041 and the foaming cavity 103 to be the thickness H of the strip A. S1 And the thickness H of strip B S2 The casting and rolling roll system 604, the contour side seal 605 and the foaming cavity 103 together form the casting and rolling zone. A rectifier 8 is installed to set the width of the pre-molten metal without gradient bubble clusters and the width of the pre-molten metal with gradient bubble clusters before entering the casting and rolling zone.

[0099] B3; Constant tension unwinding: Two unwinding devices 9 unwind the coils of thickness H at a constant tension. S1 Strip A and thickness H S2 Strip B is uncoiled, and strips A and B are wrapped around the adjacent die-cutting roll 6041 for half a turn and then pass through the arc-shaped gap between the die-cutting roll 6041 and the foaming cavity 103 to enter the casting and rolling zone. When leaving the tapered section roll gap, there is a gap H3 between strips A and strip B.

[0100] B4; Stable reverse extrusion: The gas supply device 3 is turned on to generate compressed gas, preheat the melt chute 1 to temperature T3, and pour the pre-made molten metal into the casting cavity 101 through the melt processing device 2. After flowing through the connecting cavity 102, it enters the foaming cavity 103. The detection device 5 is used to detect the gas pressure and liquid level inside the casting cavity 101, and the output pressure of the pressurizing device 4 and the pouring flow rate of the melt processing device 2 are adjusted accordingly to achieve constant extrusion pressure and liquid level.

[0101] B5; Dynamic foaming confluence: When the casting and rolling device 6 is started, the compressed gas passes through the micron or nanometer-level internal pores of the blowing device 7 and enters the pre-formed molten metal to form a gradient bubble group. Then, it enters the casting and rolling zone through the inside of the rectifier 8. At the same time, the pre-formed molten metal without gradient bubble group between the rectifier 8 and the foaming cavity 103 enters the casting and rolling zone under the reverse extrusion pressure of the casting cavity 101, and converges with the pre-formed molten metal containing gradient bubble group and the strip A and strip B containing pre-impregnated coating in the casting and rolling zone.

[0102] B6; Continuous casting and rolling forming: Strips A and B with pre-impregnated coatings, pre-molten metal without gradient bubble clusters, and pre-molten metal with gradient bubble clusters are simultaneously subjected to rapid solidification and rolling by the die-cut casting roll 6041 in the casting and rolling zone to achieve composite interface metallurgical bonding; the pre-molten metal without gradient bubble clusters solidifies and deforms into a solid coating layer with a thickness of H1, and the pre-molten metal with gradient bubble clusters solidifies and deforms into a foam core layer with a thickness of H2; the highest point of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called the solidification point, and the distance between the solidification point and the plane containing the axis of the die-cut casting roll 6041 is the solidification point height L. KP The degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a heterogeneous foam metal sandwich panel with gradient fibrous pore characteristics. After reaching a stable state, it achieves continuous forming.

[0103] The nominal radius of the casting roll is R0, and the dimensions of the foam metal sandwich panel are equal to the tapered section roll gap dimension H0, including the strip thickness H. S1 Strip thickness B S2 The thickness of the two solid overlay layers H1 and the thickness of the foam core layer H2, i.e., H0 = H S1 +H S2 +2H1+H2, freezing point L KP The cross-sectional width H at the location KP The calculation method is as follows The equation governing the degree of flattening during the transformation of spherical pores into fibrous structures is δ = (H KP -H2) / H KP ×100%, therefore, by adjusting the freezing point height L KPIt can achieve the regulation of fibrous pore characteristics.

[0104] A schematic diagram of the casting and rolling zone structure in this method is shown below. Figure 13 As shown, a heterogeneous foam metal sandwich panel with a gradient cross-section and gradient fibrous pore characteristics is prepared. Figure 14 As shown.

[0105] In the above three embodiments, foam metal plates with different gradient cross-sectional shapes can be prepared by adjusting the gradient shape of the die-casting roll 6041 and controlling the roll gap of the gradient cross-section. The solidification point position can be controlled, the degree of cell deformation can be changed, and the fibrous cell geometry can be adjusted by adjusting structural parameters such as the diameter of the die-casting roll 6041 and the size of the foaming cavity 103, as well as process parameters such as casting speed and pouring temperature. The distribution pattern of the gradient-distributed bubble group can be changed by altering the gradient distribution of the internal pore structure of the blowing device 7 along the width and / or length of the roll gap. The ratio between the foam core layer and the solid coating layer can be adjusted by changing the gap between the outer wall of the rectifier 8 and the inner wall of the foaming cavity 103. The porosity of the foam core layer can be changed by changing the air flow rate of the blowing device 7. The gas blown by the blowing device 7 is air, oxygen, etc., and the pure metal or alloy raw material can be aluminum, copper, lead, magnesium, zinc, iron, nickel, titanium, or stainless steel, etc.

[0106] The foregoing has shown and described the main features and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0107] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A shape-controllable foam metal sheet continuous casting and rolling forming equipment, characterized in that: It includes a melt chute (1), a melt processing device (2), a gas supply device (3), a detection device (5), a casting and rolling device (6), and a blowing device (7). The inner cavity of the melt chute (1) is sealed and the outer wall is embedded with a heating device for temperature control. The melt chute (1) includes a casting cavity (101), a connecting cavity (102) and a foaming cavity (103). The melt processing device (2) and the detection device (5) are arranged above the casting cavity (101). The melt processing device (2) is used to prepare pre-made metal melt and pour the pre-made metal melt into the casting cavity (101) through a sealed interface. The detection device (5) is used to detect the liquid level height of the pre-made metal melt inside the casting cavity (101) and adjust the pouring flow rate of the melt processing device (2) to achieve a constant liquid level height in the casting cavity (101). The casting and rolling device (6) includes a transmission system (601), a pressing system (602), a main frame (603), a casting roll system (604), and a contour side seal (605). The casting roll system (604) is located inside the main frame (603) and includes two sets of die-shaped casting rolls (6041) and bearing seats (6042). The die-shaped casting rolls (6041) are internally circulated with cooling water and have a gradient die pattern on their surface. The surface of the die-shaped casting rolls (6041) is coated with a heat-insulating coating with the same thickness distribution. The heat-insulating coating is used to control the die-shaped casting rolls with the solidification point height as the target. (6041) The cooling capacity uniformity along its axial direction, the transmission system (601) is used to drive the die casting roll (6041) to rotate, the pressing system (602) is used to control the relative position between the die casting rolls (6041) to achieve the purpose of controlling the roll gap, the two die casting rolls (6041) together form a gradually changing cross section roll gap, and together with the blowing cavity (303) located below and the contoured side seals (605) located at both ends, they form a casting and rolling area, and an adjustable arc gap is left between the die casting roll (6041) and the blowing cavity (303); The gas supply device (3) provides compressed gas to the blowing device (7). The blowing device (7) is located at the bottom of the foaming cavity (103) and directly below the casting and rolling device (6). The internal pore structure of the blowing device (7) is gradient distributed along the width and / or length of the roll gap. It continuously blows a group of bubbles into the pre-formed molten metal inside the foaming cavity (103) to form a pre-formed molten metal containing a gradient distribution of bubble groups. When the pre-formed molten metal containing a gradient distribution of bubble groups passes through the casting and rolling zone, it is simultaneously subjected to rapid solidification and rolling deformation by the casting and rolling rolls to form a foam metal plate with a spatial gradient structure of gradient fibrous pores.

2. The shape-controllable foam metal sheet continuous casting and rolling forming equipment according to claim 1, characterized in that: It also includes a pressurizing device (4). The compressed gas provided by the gas supply device (3) enters the upper part of the casting cavity (101) through the sealed interface after passing through the pressurizing device (4), and applies downward extrusion pressure to the precast molten metal inside the casting cavity (101). The detection device (5) can also be used to detect the extrusion pressure inside the casting cavity (101), thereby providing feedback to adjust the output pressure of the pressurizing device (4) and achieve a constant extrusion pressure in the casting cavity (101).

3. The shape-controllable foam metal sheet continuous casting and rolling forming equipment according to claim 2, characterized in that: It also includes a rectifier (8), which is located at the bottom of the foaming cavity (103) and directly below the casting and rolling device (6). The air blowing device (7) is located inside the rectifier (8), and the rectifier (8) has two flow channels (801) on both sides along the axis of the die-shaped casting and rolling roll (6041). The pre-formed molten metal enters the interior of the rectifier (8) through the two flow channels (801). After the air blowing device (7) blows air, it forms a pre-formed molten metal containing gradient bubble groups. There is a flow gap of pre-formed molten metal without gradient bubble groups between the outer wall of the rectifier (8) and the inner wall of the foaming cavity (103). The top of the rectifier (8) is not lower than the top of the foaming cavity (103) and there is an arc-shaped gap between it and the die-shaped casting and rolling roll (6041). The shapes of the air blowing device (7) and the rectifier (8) are the same as the shape of the gradient section roll gap.

4. The shape-controllable foam metal board continuous casting and rolling forming equipment according to claim 3, characterized in that: It also includes an uncoiling device (9), of which there are two, which are installed above the casting and rolling device (6) and symmetrically arranged on both sides of the gradient section roll gap. They are used for constant tension uncoiling of different strips. After the strip is uncoiled by the uncoiling device (9), it is wrapped around the adjacent die-shaped casting roll (6041) for half a turn, and then passes through the arc gap between the die-shaped casting roll (6041) and the air blowing cavity (303) to enter the casting and rolling zone. Then it leaves through the gradient section roll gap to complete the rolling composite with the pre-made molten metal.

5. A method for continuous casting and rolling of shape-controllable foam metal sheets using the forming equipment described in claim 1, characterized in that: Includes the following steps: S1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device (2), heated to temperature T1 to melt and kept warm, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and kept warm to prepare a pre-formed metal melt that meets the foaming stability requirements. S2; Adjust installation dimensions: Adjust the position of the casting roll system (604), set the gradient section roll gap size H0, adjust the arc gap between the die-shaped casting roll (6041) and the foaming cavity (103) to 0mm, and the casting roll system (604), the contour side seal (605) and the foaming cavity (103) together form the casting area; S3; Stable and uniform pouring: The gas supply device (3) is turned on to generate compressed gas, preheat the melt chute (1) to temperature T3, and pour the precast metal melt into the pouring cavity (101) through the melt processing device (2). After flowing through the connecting cavity (102), it enters the foaming cavity (103). The liquid level height inside the pouring cavity (101) is detected by the detection device (5), and the pouring flow rate of the melt processing device (2) is adjusted to achieve a constant liquid level height. S4; Continuous dynamic casting: Start the casting and rolling device (6), and the compressed gas enters the pre-made metal melt through the micron or nano-level internal pores of the blowing device (7) to form a gradient bubble group, which then gradually rises and enters the casting and rolling zone formed by the casting and rolling roll system (604), the contour side seal (605) and the foaming cavity (103). S5; Continuous casting and rolling: The pre-formed molten metal containing gradient bubble clusters is simultaneously subjected to rapid solidification and rolling deformation by the die-cut casting roll (6041) in the casting and rolling zone. The highest point of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called the solidification point. The distance between the solidification point and the plane containing the axis of the die-cut casting roll (6041) is the solidification point height L. KP The degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a gradually changing cross-section foam metal plate with gradient fibrous pore characteristics, and achieving continuous forming after reaching a stable state.

6. A method for continuous casting and rolling of shape-controllable foam metal sheets using the forming equipment described in claim 3, characterized in that: Includes the following steps: A1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device (2), heated to temperature T1 to melt and kept warm, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and kept warm to prepare a pre-formed metal melt that meets the foaming stability requirements. A2; Adjust installation dimensions: Adjust the position of the casting roll system (604), set the gradient section roll gap size H0, adjust the arc gap between the die-shaped casting roll (6041) and the foaming cavity (103) to 0mm, the casting roll system (604), the contour side seal (605) and the foaming cavity (103) together form the casting and rolling zone, install the rectifier (8), and set the width of the pre-molten metal without gradient bubble group and the width of the pre-molten metal with gradient bubble group before entering the casting and rolling zone; A3; Stable reverse extrusion: The gas supply device (3) is turned on to generate compressed gas, preheat the melt chute (1) to temperature T3, and the precast metal melt is poured into the casting cavity (101) through the melt processing device (2). After flowing through the connecting cavity (102), it enters the foaming cavity (103). The detection device (5) is used to detect the internal gas pressure and liquid level of the casting cavity (101), and the output pressure of the booster device (4) and the casting flow rate of the melt processing device (2) are adjusted to achieve constant extrusion pressure and liquid level. A4; Dynamic foaming and confluence: When the casting and rolling device (6) is started, the compressed gas enters the pre-formed molten metal through the micron or nano-sized internal pores of the blowing device (7) to form a gradient bubble group. Then, it enters the casting and rolling zone through the inside of the rectifier (8). At the same time, the pre-formed molten metal without gradient bubble group between the rectifier (8) and the foaming cavity (103) enters the casting and rolling zone under the reverse extrusion pressure of the casting cavity (101) and converges with the pre-formed molten metal containing gradient bubble group inside the casting and rolling zone. A5； Continuous casting and rolling: Through the rapid solidification and rolling combined action of the die-shaped casting roll (6041) in the casting and rolling zone, the pre-formed molten metal without gradient bubble clusters solidifies and deforms into a solid coating layer with a thickness of H1, and the pre-formed molten metal containing gradient bubble clusters solidifies and deforms into a foam core layer with a thickness of H2. The solid coating layer and the foam core layer achieve a composite interface metallurgical bond. The highest point of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called the solidification point, and the distance between the solidification point and the plane containing the axis of the die-shaped casting roll (6041) is the solidification point height L. KP The degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a gradually changing cross-section foam metal sandwich panel with gradient fibrous pore characteristics, and achieving continuous forming after reaching a stable state.

7. A method for continuous casting and rolling of shape-controllable foam metal sheets using the forming equipment described in claim 4, characterized in that: Includes the following steps: B1; Pre-formed metal melt: Pure metal or alloy raw materials are added to the melt processing device (2), heated to temperature T1 to melt and kept warm, particles or powders are added to thicken the liquid metal melt, and then the temperature is lowered to temperature T2 and kept warm to prepare a pre-formed metal melt that meets the foaming stability requirements. B2; Adjusting installation dimensions: Adjust the position of the casting roll system (604), set the gradient section roll gap size H0, and adjust the arc gap between the die-shaped casting roll (6041) and the foaming cavity (103) to be the thickness H of the strip A. S1 And the thickness H of strip B S2 The casting and rolling roll system (604), the contour side seal (605) and the foaming cavity (103) together form the casting and rolling zone. A rectifier (8) is installed to set the width of the pre-molten metal without gradient bubble group and the width of the pre-molten metal with gradient bubble group before entering the casting and rolling zone. B3； Constant tension unwinding: Two unwinding devices (9) unwind the coils of thickness H with constant tension. S1 Strip A and thickness H S2 Strip B is uncoiled, and strip A and strip B are closely attached to the adjacent die-casting roll (6041) and after half a turn, they pass through the arc gap between the die-casting roll (6041) and the foaming cavity (103) and enter the casting and rolling zone. When leaving the tapered section roll gap, there is a gap H3 between strip A and strip B. B4; Stable reverse extrusion: The gas supply device (3) is turned on to generate compressed gas, preheat the melt chute (1) to temperature T3, and the precast metal melt is poured into the casting cavity (101) through the melt processing device (2). After flowing through the connecting cavity (102), it enters the foaming cavity (103). The gas pressure and liquid level inside the casting cavity (101) are detected by the detection device (5), and the output pressure of the booster device (4) and the pouring flow rate of the melt processing device (2) are adjusted to achieve constant extrusion pressure and liquid level. B5; Dynamic foaming confluence: Start the casting and rolling device (6), and the compressed gas enters the pre-formed molten metal through the micron or nano-scale internal pores of the blowing device (7) to form a gradient bubble group. Then, it enters the casting and rolling zone through the inside of the rectifier (8). At the same time, the pre-formed molten metal without gradient bubble group between the rectifier (8) and the foaming cavity (103) enters the casting and rolling zone under the reverse extrusion pressure of the casting cavity (101), and converges with the pre-formed molten metal containing gradient bubble group and the strip A and strip B containing pre-impregnated coating in the casting and rolling zone. B6； Continuous casting and rolling forming: Strips A and B with pre-impregnated coatings, pre-molten metal without gradient bubble clusters, and pre-molten metal with gradient bubble clusters are simultaneously subjected to rapid solidification and rolling by the die-cut casting roll (6041) in the casting and rolling zone to achieve composite interface metallurgical bonding; the pre-molten metal without gradient bubble clusters solidifies and deforms into a solid coating layer with a thickness of H1, and the pre-molten metal with gradient bubble clusters solidifies and deforms into a foam core layer with a thickness of H2; the highest point of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called the solidification point, and the distance between the solidification point and the plane containing the axis of the die-cut casting roll (6041) is the solidification point height L. KP The degree of bubble deformation is determined by the solidification of the gradient bubble group, which extends along the rolling direction after solidification, changing from spherical to fibrous, forming a gradually changing cross-section foam metal sandwich panel with gradient fibrous pore characteristics, and achieving continuous forming after reaching a stable state.

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