A process for the production of an aluminium alloy profile

Abstract

The application relates to the technical field of aluminum profile machining, and particularly discloses a production process of an aluminum alloy profile, which comprises the following steps: extruding and molding an aluminum alloy ingot to obtain a long-strip-shaped profile, at least one side surface of the long-strip-shaped profile is provided with a groove along the length direction, and the groove bottom width is greater than the groove opening width; the obtained long-strip-shaped profile is cut according to the required length to obtain a single-section profile; a steel pipe with an organic coating on the surface is embedded into the groove of the single-section profile, the steel pipe is adhered to the groove bottom surface after being extruded and deformed by a stamping mechanism, a core pipe inside the single-section profile is formed, and the aluminum alloy profile is obtained. The aluminum profile obtained by the machining process has good mechanical strength, and the bending performance and fatigue performance are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of aluminum profile processing technology, and in particular to a production process for aluminum alloy profiles. Background Technology

[0002] Aluminum alloy profiles are widely used in door and window structures due to their advantages such as light weight, corrosion resistance, and good machinability. However, traditional aluminum alloy profiles still have the following shortcomings in practical applications: Although aluminum alloy profiles have excellent lightweight characteristics, their strength and rigidity are relatively weak. When bearing external loads (such as wind pressure, opening and closing forces), they are prone to deformation and warping, affecting the stability and sealing of doors and windows. Moreover, stress concentration often occurs at the corners, connection points, and areas of high-strength wall in aluminum alloy profiles, leading to damage and failure in these parts during long-term use.

[0003] To address the aforementioned shortcomings, existing technologies include using composite molding to combine aluminum alloy profiles with other high-strength materials in areas requiring reinforcement. For example, Chinese patent CN116809679A discloses a method of stamping steel tubing onto the inclined side arm of an aluminum profile to create a mating fit with the aluminum profile, thereby enhancing the impact resistance of the aluminum profile. While this solution provides a new approach to improving the performance of aluminum profiles, it still faces some application challenges. For instance, there is a poor compatibility between the surface of the steel tubing and the surface of the aluminum alloy profile. Additionally, the different coefficients of thermal expansion between aluminum alloy and steel may lead to stress problems, loosening and deformation between materials, and electrochemical corrosion issues when temperatures change.

[0004] Therefore, overcoming the above problems and providing an aluminum alloy profile with better mechanical properties, good matching performance, and good stability has become one of the urgent technical problems to be solved. Summary of the Invention

[0005] In view of this, the present invention proposes a production process for aluminum alloy profiles, aiming to improve the structural strength and stability of aluminum profiles through process improvement.

[0006] The technical solution of this invention is achieved as follows: This invention provides a manufacturing process for aluminum alloy profiles, the process steps of which include:

[0007] Step 1: The aluminum alloy ingot is extruded to form a long strip profile. At least one side of the long strip profile has a groove along its length, and the bottom width of the groove is greater than the opening width of the groove.

[0008] Step 2: Cut the long strip of profile obtained in Step 1 into single sections according to the required length;

[0009] Step 3: Insert a steel pipe with an organic coating into the groove of the single-section profile. After being squeezed and deformed by a stamping mechanism, the steel pipe is made to fit with the bottom of the groove to form the core tube inside the single-section profile, thus obtaining an aluminum alloy profile.

[0010] In some embodiments, the organic coating includes a polyurethane layer, and the thickness of the organic coating is 100-400 μm.

[0011] In some embodiments, the organic coating further includes an epoxy layer located at the bottom of the polyurethane layer, the epoxy layer having a thickness of 30-50 μm.

[0012] In some embodiments, step two, after obtaining the single-section profile, further includes machining honing texture in the groove.

[0013] In some embodiments, the honing texture has a depth of 5-50 μm, a texture spacing of 50-100 μm, and an intersection angle of 20-45°.

[0014] In some embodiments, after honing the grooves, the process further includes coating the grooves with nano-graphite powder, the nano-graphite powder having a particle size of 5-20 μm.

[0015] In some implementations, the angle between the two side walls of the groove and the bottom surface is less than 90°.

[0016] In some embodiments, both sides of the groove are provided with flanges, the distance between the flanges on both sides is less than the width of the groove opening, and the angle between the lower surface of the flange and the bottom surface of the groove is 30-45°.

[0017] In some embodiments, the steel pipe has a circular cross-section, the outer diameter of the steel pipe does not exceed the distance between the two flanges, and the distance from the end of the flange to the bottom of the groove is 1 / 2 of the steel pipe radius.

[0018] In some embodiments, the wall thickness of the steel pipe does not exceed 1 mm.

[0019] The present invention has the following advantages over the prior art:

[0020] This invention significantly improves the strength and rigidity of aluminum profiles by embedding steel tubes inside them, enhancing their resistance to deformation under external loads and improving their stability and load-bearing capacity. At the same time, the application of an organic coating on the surface of the steel tube effectively solves the new problem of matching between aluminum alloy and steel tube, avoiding friction and loosening between the two materials. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a cross-sectional view of an aluminum alloy profile according to one embodiment of the present invention;

[0023] Figure 2 This is a cross-sectional view of an aluminum alloy profile according to one embodiment of the present invention;

[0024] Figure 3 This is a schematic diagram of the aluminum alloy profile forming process according to one embodiment of the present invention;

[0025] Figure 4 This is a cross-sectional view of the steel pipe used in the aluminum alloy profile according to one embodiment of the present invention.

[0026] In the diagram: 1-long strip profile, 11-groove, 2-steel pipe, 3-organic coating, 31-polyurethane layer, 32-epoxy layer, 12-flange. Detailed Implementation

[0027] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0028] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0029] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the embodiments of this invention pertain. If any definition stated in this section is contrary to or otherwise inconsistent with a definition stated in a patent, patent application, published patent application, or other publication incorporated herein by reference, the definitions listed here shall prevail over those incorporated herein by reference.

[0031] Unless otherwise specified, the methods used in the following embodiments are conventional methods. Unless otherwise specified, the materials, reagents, and instruments used are conventional materials, reagents, and instruments in the art, and can be obtained commercially by those skilled in the art.

[0032] When a quantity, concentration, or other value or parameter is expressed as a range, a preferred range, or a range defined by a series of upper and lower preferred values, this should be understood as specifically disclosing all ranges formed by any pair of any upper or preferred value with any lower or preferred value, regardless of whether the range is disclosed individually. For example, when the range “1 to 5” is disclosed, the described range should be interpreted as including ranges “1 to 4”, “1 to 3”, “1 to 2”, “1 to 2 and 4 to 5”, “1 to 3 and 5”, etc. When numerical ranges are described herein, unless otherwise stated, the range is intended to include its endpoints and all integers and fractions within that range. In this specification and claims, range definitions may be combined and / or interchanged, unless otherwise stated, these ranges include all subranges contained therein.

[0033] like Figure 1 As shown, combined with Figure 2-4 The manufacturing process of aluminum alloy profiles according to one embodiment of the present invention includes the following steps:

[0034] S1. Aluminum alloy ingot is extruded and formed to obtain a long strip profile 1. At least one side surface of the long strip profile 1 is provided with a groove 11 along the length direction. The width of the bottom surface of the groove 11 is greater than the opening width of the groove 11.

[0035] S2. Cut the long strip profile 1 obtained in S1 into single-section profiles according to the required length.

[0036] S3. Insert a steel pipe 2 with an organic coating 3 into the groove 11 of the single-section profile. After being squeezed and deformed by a stamping mechanism, the steel pipe 2 is attached to the bottom surface of the groove 11 and kept relatively fixed, forming the core tube inside the single-section profile, and obtaining an aluminum alloy profile.

[0037] In the above embodiments, the opening width of the groove 11 is smaller than the bottom width. After being extruded and deformed by the stamping mechanism, the steel pipe 2 adapts to the shape of the bottom surface of the groove 11 and is thus limited to the bottom surface of the groove 11. After stamping, the surface of the steel pipe 2 can completely fit with the bottom surface of the groove 11, thereby forming a composite structure to enhance the mechanical strength of the aluminum alloy profile. Moreover, compared with the prior art of directly using steel pipes, the steel pipe 2 in this application has an organic coating 3 on its surface. The organic coating 3 can play an elastic buffering role, avoiding stress concentration and loosening or over-tightening caused by thermal expansion. At the same time, it can also avoid friction between the two materials, extend service life, and improve stability.

[0038] In some embodiments, the organic coating 3 includes a polyurethane layer 31, and the thickness of the organic coating 3 is 100-400 μm.

[0039] In the above embodiments, the organic coating 3 not only increases the adhesion between the steel pipe and the aluminum alloy profile, but also provides a buffer layer, effectively solving the stress problem caused by the different coefficients of thermal expansion of the two materials. The coating thickness of 100-400μm ensures sufficient buffering and protection.

[0040] In some embodiments, the organic coating 3 further includes an epoxy layer 32, which is located at the bottom of the polyurethane layer 31 and has a thickness of 30-50 μm.

[0041] In the above embodiments, the epoxy layer 32 is used to provide a transition structure. The epoxy layer 32 has a stronger bond with the steel. As a base layer, it can make the bond between the organic coating 3 and the steel pipe 2 higher, and the organic coating 3 has a better and more stable adhesion effect.

[0042] In some embodiments, step two, after obtaining a single profile section, further includes machining honing texture in the groove 11.

[0043] In the above embodiments, by processing honing texture on the inner surface of the groove 11, stress concentration can be significantly reduced, and the contact strength and fatigue resistance of the material surface can be improved. These honing textures can significantly increase the surface area of ​​the inner surface of the groove 11, thereby expanding the stress distribution area and reducing the stress value in the local stress concentration area. Moreover, by processing honing textures, regular texture paths can be formed on the inner surface of the groove 11. These texture paths can change the stress path, reduce the peak stress at the stress concentration point, and the textured surface provides more adhesion points, improving the bonding strength between the organic coating 3 and the groove 11. This adhesion effect will also reduce the destructive effect of stamping deformation on the organic coating 3 in step S3. Furthermore, honing textures can also eliminate the small defects generated on the inner surface of the groove 11 after extrusion molding, thereby reducing stress concentration points. Moreover, the complex surface morphology brought about by honing textures requires more energy to be consumed during the subsequent crack propagation process, thus slowing down the crack propagation speed.

[0044] In some embodiments, the honing texture has a depth of 5-50 μm, a texture spacing of 50-100 μm, and an intersection angle of 20-45°.

[0045] After optimizing the honing process parameters, the above-mentioned preferred parameter values ​​were obtained. A depth of 5-50μm is suitable for surface processing and can provide a significant stress dispersion effect. A texture spacing of 50-100μm is more suitable for the operating conditions of aluminum profiles; a cross angle of 20-45° brings a certain degree of complexity to the texture and a stress dispersion effect, which is beneficial to enhancing fatigue resistance.

[0046] In some embodiments, after honing, the process further includes coating the groove 11 with nano-graphite powder, wherein the nano-graphite powder has a particle size of 5-20 μm, and the nano-graphite powder on the surface is blown away after coating.

[0047] In the above embodiments, nano-graphite powder is mainly used to fill the texture grooves of the honing pattern. This operation can make the groove 11 still have a relatively smooth surface after the honing pattern is processed, thereby reducing the wear between the organic coating 3 and the honing pattern caused by deformation or load. At the same time, nano-graphite powder has a certain self-lubricating effect, further reducing friction loss. During the relative sliding process between the organic coating 3 and the groove 11, nano-graphite powder helps to form a uniform undercoat film at the interface, which can not only further improve the stress dispersion, but also protect the aluminum alloy surface.

[0048] In some embodiments, the angle between the two side walls of the groove 11 and the bottom surface is less than 90°.

[0049] In the above embodiments, the angles of the two side walls of the groove 11 are defined as acute angles, so that the steel pipe 2 after extrusion and bonding can be tightly attached to the bottom surface of the groove 11 with the size determined in advance, thus maintaining structural stability.

[0050] In some embodiments, both sides of the groove 11 are provided with flanges 12, the distance between the flanges 12 on both sides is less than the opening width of the groove 11, and the angle between the lower surface of the flange 12 and the bottom surface of the groove 11 is 30-45°.

[0051] In the above embodiments, the function of the flange 12 is to limit and guide the extrusion molding of the steel pipe 2, and further limit the extruded steel pipe 2 to maintain the stability of the steel pipe 2.

[0052] In some embodiments, the steel pipe 2 has a circular cross-section, the outer diameter of the steel pipe 2 does not exceed the distance between the two flanges 12, and the distance from the end of the flange 12 to the bottom surface of the groove is 1 / 2 of the steel pipe radius.

[0053] The flange size and position in the above embodiments are beneficial for the steel pipe 2 to fill the space between the bottom of the flange 12 and the bottom surface of the groove 11 during extrusion molding, thus avoiding unexpected deformation of the steel pipe 2 during extrusion.

[0054] In some embodiments, the wall thickness of the steel pipe 2 does not exceed 1 mm.

[0055] In the above embodiments, the steel pipe 2 needs to have a relatively stable and predictable deformation capacity, so the thickness should not be too large. At the same time, the strength improvement effect of the steel pipe 2 mainly depends on its structure. Too much thickness is not conducive to the lightweighting of aluminum alloy. Therefore, the preferred thickness is no more than 1 mm, preferably 0.1-0.8 mm, and more preferably 0.4 mm.

[0056] Example 1

[0057] This embodiment provides an aluminum alloy profile with the following structure: Figure 1 As shown.

[0058] The product prepared by the above method has an organic coating 3, which includes a 30 μm epoxy layer 32 and a 70 μm polyurethane layer 31, but does not include honing texture and graphite powder.

[0059] Example 2

[0060] This embodiment provides an aluminum alloy profile with the following structure: Figure 1 As shown.

[0061] The material prepared by the above method has an organic coating 3, which includes a 30 μm epoxy layer 32 and a 70 μm polyurethane layer 31, and also includes honing texture. The honing texture parameters are: depth of 30 μm, texture spacing of 60 μm, and intersection angle of 30°.

[0062] Example 3

[0063] This embodiment provides an aluminum alloy profile with the following structure: Figure 1 As shown.

[0064] The material prepared by the above method has an organic coating 3, which includes a 30μm epoxy layer 32 and a 70μm polyurethane layer 31, and also includes a honing texture with the following parameters: depth of 30μm, texture spacing of 60μm, and cross angle of 30°. The material is also rich in nano-graphite powder with a particle size of 15μm.

[0065] Example 4

[0066] This embodiment provides an aluminum alloy profile with the following structure: Figure 2 As shown.

[0067] The product prepared by the above method has an organic coating 3, which includes a 30 μm epoxy layer 32 and a 70 μm polyurethane layer 31, but does not include honing texture and graphite powder.

[0068] Comparative Example

[0069] The difference from Example 1 is that the surface of the steel pipe 2 does not have an organic coating 3.

[0070] The bending modulus and bending fatigue tests were performed on the above embodiments and comparative examples respectively, and the test results of the embodiments were compared with those of the comparative examples. The data is shown in the table below:

[0071] Grouping Comparative Example Example 1 Example 2 Example 3 Example 4 Flexural modulus increment / % 0 1.5 6.6 6.5 2.4 Bending fatigue increment / % 0 10.8 18.4 22.9 10.6

[0072] It is easy to see that after the steel pipe with organic coating is extruded and composited, the bending fatigue effect of the profile is significantly improved, and the bending modulus is also improved to a certain extent. While adding organic coating, the honing texture processed on the inner surface of groove 11 can significantly improve the bending wooden beam and bending fatigue effect. The effect is even better when combined with nano graphite powder. The addition of flange also brings a certain improvement in mechanical effect.

[0073] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A manufacturing process for aluminum alloy profiles, characterized in that, Includes the following steps: Step 1: The aluminum alloy ingot is extruded to form a long strip profile. At least one side surface of the long strip profile has a groove along the length direction. The bottom width of the groove is greater than the opening width of the groove. The angle between the two side walls of the groove and the bottom surface is less than 90°. Both side walls of the groove are provided with flanges. The distance between the two flanges is less than the opening width of the groove. The angle between the lower surface of the flange and the bottom surface of the groove is 30-45°. Step 2: Cut the long strip of profile obtained in Step 1 into single sections according to the required length; Step 3: Insert a steel pipe with an organic coating into the groove of the single-section profile. The steel pipe has a circular cross-section and its outer diameter does not exceed the distance between the two flanges. The distance from the end of the flange to the bottom of the groove is 1 / 2 of the steel pipe radius. After being squeezed and deformed by a stamping mechanism, the steel pipe fits into the bottom of the groove to form the core tube inside the single-section profile, thus obtaining an aluminum alloy profile.

2. The manufacturing process of aluminum alloy profiles as described in claim 1, characterized in that, The organic coating includes a polyurethane layer, and the thickness of the organic coating is 100-400 μm.

3. The manufacturing process of aluminum alloy profiles as described in claim 2, characterized in that, The organic coating also includes an epoxy layer, which is located at the bottom of the polyurethane layer and has a thickness of 30-50 μm.

4. The manufacturing process of aluminum alloy profiles as described in claim 2, characterized in that, Step two, after obtaining the single-section profile, also includes machining honing texture in the groove.

5. The manufacturing process of aluminum alloy profiles as described in claim 4, characterized in that, The honing texture has a depth of 5-50 μm, a texture spacing of 50-100 μm, and an intersection angle of 20-45°.

6. The manufacturing process of aluminum alloy profiles as described in claim 4, characterized in that, After the honing process is completed, the method further includes coating the grooves with nano-graphite powder, wherein the particle size of the nano-graphite powder is 5-20μm.

7. The manufacturing process of aluminum alloy profiles as described in claim 1, characterized in that, The wall thickness of the steel pipe does not exceed 1 mm.

Images