Preparation technology and application of aluminum alloy materials

Abstract

The present invention discloses a preparation process for an aluminum alloy material and its application, belonging to the field of aluminum alloy technology. The process includes the steps of smelting, filtration, casting, homogenization treatment, extrusion molding, solution quenching, and stretching and straightening. During the filtration process, a composite filter plate containing special components such as boron carbide, illite, and lithium feldspar is used to effectively remove inclusions from the aluminum liquid. Compared with the existing technology, the aluminum alloy material prepared by this process exhibits excellent tensile properties and fracture toughness, and is suitable for use in fields such as automotive parts. The present invention not only improves the performance of aluminum alloy materials, but also provides a new technical path for the industrial production of aluminum alloys.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum alloys, and in particular to a preparation process of an aluminum alloy material and applications thereof. Background Art

[0002] With the rapid development of modern industry, the requirements for material performance are increasing day by day. In particular, in the fields of aerospace, automobile manufacturing, rail transportation, etc., the demand for lightweight, high-strength, and corrosion-resistant aluminum alloy materials is growing. Aluminum alloys have become an indispensable key material in these fields due to their low density, high strength, good processing properties, and excellent corrosion resistance.

[0003] However, traditional aluminum alloys have limitations in terms of mechanical properties and corrosion resistance. For example, their strength and corrosion resistance at high temperatures are often insufficient to meet increasingly demanding application requirements. Furthermore, aluminum alloys are prone to inclusions and pores during the melting and casting processes, defects that can severely impact the material's mechanical properties and service life. Therefore, developing new aluminum alloys and their preparation processes to improve their overall performance has become a research hotspot in materials science.

[0004] Melting and filtration are crucial steps in the preparation of aluminum alloys. Traditional filtration methods, such as using single-layer ceramic filter plates or simple physical filtration, often fail to effectively remove non-metallic inclusions and gases from the aluminum alloy melt, resulting in poor final product performance. Furthermore, the high-temperature stability and mechanical strength of existing filter materials are insufficient to meet the demands of high-performance aluminum alloy preparation.

[0005] To address these issues, researchers have conducted extensive research and exploration to find more effective filtration technologies and materials. For example, efforts have been made to improve the mechanical properties and corrosion resistance of aluminum alloys by introducing microalloying elements, improving heat treatment processes, and employing new filter media. While these studies have achieved some progress, further research and development is still needed to fully enhance the performance of aluminum alloys.

[0006] Chinese invention patent CN114921698A discloses a low-coarse-grained aluminum alloy profile and a preparation method thereof; the low-coarse-grained aluminum alloy profile comprises, by weight percentage, 0.62% to 0.68% silicon, 0.81% to 1.13% manganese, 1.37% to 1.46% magnesium, 0.73% to 0.91% iron, 0.17% to 0.35% chromium, 0.11% to 0.21% titanium, 0.07% to 0.13% copper, 0.12% to 0. 0.27% zinc, 0.08%-0.15% tin, 0.1%-0.25% vanadium, 0.09%-0.18% barium, and the balance aluminum. By selecting suitable metal raw materials, the aluminum alloy profile of this invention improves the machinability of the aluminum alloy profile and suppresses grain growth during the extrusion process. The preparation method and raw materials of this invention reduce the coarse grain rings produced during the extrusion process and improve the quality of the aluminum profile. However, the mechanical properties and corrosion resistance of the aluminum alloy profile prepared in this way still need to be improved. Summary of the Invention

[0007] In response to the above problems, the present invention aims to provide a new aluminum alloy material preparation process, which effectively removes non-metallic inclusions and gases in the aluminum alloy melt by using a specific composite filter plate, thereby significantly improving the purity and quality of the aluminum alloy.

[0008] In order to achieve the above-mentioned object of the invention, the present invention adopts the following technical solutions:

[0009] A preparation process of an aluminum alloy material is as follows, in parts by weight:

[0010] Step 1, adding 970-980 parts of aluminum ingots into a smelting furnace, setting the temperature of the smelting furnace at 650-800°C, and when the charge temperature rises to the set value and begins to melt, sequentially adding 1-3 parts of iron, 0.8-1.2 parts of manganese and 0.8-1.2 parts of chromium powder, and then adding 8-10 parts of magnesium ingots, 0.5-1 parts of zinc ingots, 0.8-1.2 parts of titanium ingots, 2-3 parts of copper ingots and 4-6 parts of polysilicon, and finally adding 0.1-0.3 parts of gadolinium, 0.2-0.4 parts of lanthanum ingots, 0.2-0.4 parts of cerium ingots, and 0.1-0.3 parts of praseodymium ingots, stirring evenly until the materials are completely melted to obtain an alloy solution;

[0011] Step 2: Filter the alloy solution obtained in step 1 using a composite filter plate to obtain a solution to be used;

[0012] Step 3: Casting the standby liquid prepared in step 2 into an aluminum rod, and then allowing it to stand to be cast into a billet;

[0013] Step 4: placing the blank prepared in step 3 in a homogenization treatment device; keeping the blank warm; and performing homogenization treatment to obtain a homogenized aluminum alloy ingot.

[0014] Step 5: Extruding the aluminum alloy ingot prepared in step 4 in an extruder to obtain a 6-series modified alloy profile;

[0015] Step 6: subjecting the 6 series modified alloy profile prepared in step 5 to an online solution quenching treatment at a temperature of 500-560° C., using an online quenching device to implement three cooling methods: strong wind, spraying, and water cooling, followed by an aging treatment to obtain a T6 state aluminum alloy;

[0016] Step 7: stretching and straightening the T6 aluminum alloy prepared in step 6 with a stretching amount of 1-5% to obtain an aluminum alloy material;

[0017] The preparation method of the composite filter plate is as follows, in parts by weight:

[0018] S1, 70-90 parts of boron carbide, 70-90 parts of illite, 80-120 parts of lithium feldspar, 40-60 parts of bentonite, 80-120 parts of aluminum hydroxide, 400-600 parts of black corundum, 15-25 parts of mica powder, and 15-25 parts of quartz powder are mixed and ball-milled, and two-level particle size composite powders are screened out, with particle sizes of 40-90 μm and 1-30 μm, respectively. 80-120 parts of the composite powders of different particle sizes are respectively taken and mixed with 30-50 parts of water, 15-25 parts of phosphoric acid, 0.5-2 parts of sodium carboxymethyl cellulose, and 0.4-0.6 parts of zinc stearate to obtain large-particle size ceramic slurry and small-particle size ceramic slurry;

[0019] S2, immersing the polyurethane foam in the large-particle ceramic slurry for 5 to 15 minutes, taking out the foam, and pressing the excess slurry with a roller press to obtain a composite foam;

[0020] S3, placing the combined foam body in a vacuum drying oven, drying at 90-100° C. for 10-20 minutes, pouring a small-particle ceramic slurry on the combined foam body, and after the slurry stops flowing out, squeezing out the excess slurry with a roller press, transferring the body to a drying oven and drying it for 10-20 minutes, repeating the pouring and drying operation 1-3 times to obtain a preform;

[0021] S4. Dry the preform at 100-130°C for 4-6 hours, transfer it into a kiln, heat it to 300-500°C at a rate of 1-3°C / min, maintain it for 0.5-2 hours, continue heating it to 1400-1500°C at a rate of 1-3°C / min, keep it at that temperature for 1-3 hours, then naturally cool it to room temperature, cut it, and polish it to obtain a composite filter plate.

[0022] In the step 3, the mixture is allowed to stand at 660-770° C. for 0.5-2 hours.

[0023] In step 4, the temperature is kept at 530-580° C. for 6-8 hours.

[0024] In the extrusion molding process in step 5, the aluminum alloy ingot is heated to 500-560°C with a temperature gradient of 6-8°C, the extrusion barrel temperature is 400-450°C, the extrusion die temperature is 460-500°C, and the extrusion speed is 4-6 m / min.

[0025] The polyurethane foam is modified polyurethane foam.

[0026] The preparation method of the modified polyurethane foam is as follows, in parts by weight:

[0027] 10-30 parts of polyoxyethyl glycerol ether, 10-30 parts of polytetramethylene glycol, 50-70 parts of polyethylene glycol, 1-3 parts of water, 0.4-0.6 parts of di-n-butyltin diisooctanoate and 0.8-1.2 parts of hydroxy silicone oil are mixed in a beaker, and the mixture is stirred at 30-50°C for 4-6 minutes to form a uniform mixed solution. 8-12 parts of sodium polyacrylate and 25-35 parts of 1,6-hexamethylene diisocyanate are quickly added to the mixed solution, and the mixture is poured into a pre-prepared mold to ensure that the foam completely fills the space in the mold. Stirring is started, and then the mixture is allowed to stand for 8-12 minutes. The filled mold is placed in an oven at 80-120°C for 1-3 hours of curing treatment, and then taken out, cooled and demolded to obtain a modified polyurethane foam. The size of the modified polyurethane foam is 300-400×300-400×20-80 mm.

[0028] The aluminum alloy material is used in automobile accessories.

[0029] Preferably, the aluminum alloy material is used in a sunroof motor, an instrument panel or a battery tray.

[0030] In the aluminum alloy material preparation process of the present invention, the functions of various substances are as follows:

[0031] Aluminum ingots, as the main raw material of aluminum alloy, provide aluminum elements and are the basis of aluminum alloy.

[0032] Elements such as silicon, iron, copper, manganese, magnesium, chromium, zinc and titanium are added as alloying elements in specific chemical composition ratios to improve the mechanical properties, corrosion resistance and processing properties of aluminum alloys.

[0033] Rare earth elements such as gadolinium, lanthanum, cerium and praseodymium, as microalloying elements, can refine the grains of aluminum alloys and improve the strength and toughness of the alloys.

[0034] Composite filter plates are used to filter impurities and non-metallic inclusions from alloy solutions to improve the purity and performance of aluminum alloys.

[0035] Boron carbide acts as hard particles in the composite filter plate to improve the wear resistance and hardness of the filter plate.

[0036] Illite is an aluminum-containing silicate mineral used in the preparation of composite filter plates to improve the chemical stability of the filter plates.

[0037] Lithium feldspar provides the aluminosilicate component in the composite filter plate and helps form the skeleton structure of the filter plate.

[0038] Aluminum hydroxide aids in the bonding and sintering of the particles.

[0039] Black corundum provides high hardness and wear resistance in composite filter plates.

[0040] Mica powder and quartz powder are used as filling materials in the composite filter plate to adjust the porosity and strength of the filter plate.

[0041] Phosphoric acid aids in the bonding and sintering of the particles.

[0042] Sodium carboxymethyl cellulose and zinc stearate are used as additives in the preparation of composite filter plates to improve the rheological properties of the slurry and enhance the mechanical strength of the filter plates.

[0043] In the method for preparing the modified polyurethane foam of the present invention, the functions of the various substances are as follows:

[0044] Polyethylene glycol, as another polyol, also participates in the reaction with isocyanate, affecting the physical properties of the foam and increasing the flexibility and elongation of the foam.

[0045] In the preparation of polyurethane foam, the role of water is to react with isocyanate to generate carbon dioxide gas. This gas acts as a foaming agent in the foam formation process, forming the porous structure of the foam.

[0046] Di-n-butyltin diisooctanoate is a catalyst used to accelerate the polymerization reaction between isocyanate and polyol, increase the reaction rate, and thus affect the formation speed and quality of foam.

[0047] Hydroxy silicone oil is usually used as a surfactant to help improve the surface properties of foam, reduce surface defects, and improve the uniformity and stability of foam.

[0048] As a high molecular compound, sodium polyacrylate plays a reinforcing role in foam and can improve the mechanical strength and stability of foam.

[0049] Hexamethylene diisocyanate, a type of isocyanate, is another key raw material for the preparation of polyurethane foam. It reacts with polyols to form polyurethane, forming the hard segment of the foam and providing mechanical strength and thermal stability.

[0050] Polyoxyethylene glycerol ether is a nonionic surfactant with excellent water solubility, dispersibility, and emulsification properties. When combined with polytetramethylene glycol ether, it forms a more uniform and dense foam structure, thereby improving the mechanical strength and chemical stability of the modified polyurethane foam. Polytetramethylene glycol ether itself is a high-molecular-weight polyether known for its excellent flexibility and elasticity, and is commonly used in the preparation of high-performance polyurethane materials. The introduction of polyoxyethylene glycerol ether enhances the foam's elasticity and compression resistance, which are critical for maintaining the structural integrity of the filter plate. This combination may also improve the foam's pore structure, allowing the ceramic slurry to form a more uniform and dense coating on the foam surface, thereby improving the filter plate's compressive strength and thermal shock resistance. Furthermore, the addition of polyoxyethylene glycerol ether may enhance the foam's wettability, allowing the ceramic slurry to be more evenly applied to the foam surface, further enhancing the uniformity and density of the coating. In summary, the compounding of polyoxyethyl glycerol ether and polytetramethylene ether not only improves the physical properties of modified polyurethane foam, but also enhances its chemical stability and wettability. These factors work together to improve the performance of the composite filter plate, thereby improving the mechanical properties of the aluminum alloy material.

[0051] The combination and interaction of these substances enable the aluminum alloy preparation process to produce aluminum alloy products with excellent properties. By precisely controlling the proportions of these substances and the processing technology, the properties of aluminum alloys can be optimized to meet the needs of specific industrial applications.

[0052] Compared with the existing technology, it has the following beneficial effects:

[0053] 1) By using a special composite filter plate and introducing rare earth elements, the preparation process of the present invention effectively removes inclusions and gases from the aluminum alloy melt, thereby improving the purity of the aluminum alloy and enhancing the tensile properties and fracture toughness of the material.

[0054] 2) The optimized heat treatment process and addition of microalloying elements in the present invention improve the corrosion resistance of the aluminum alloy, making it more suitable for applications requiring high corrosion resistance, such as automotive parts.

[0055] 3) The use of the modified polyurethane foam of the present invention and the specific composite filter plate preparation process make the filter plate have higher compressive strength and thermal shock resistance, thereby being more effective in filtering aluminum alloy melts, further improving the overall performance of the aluminum alloy material. DETAILED DESCRIPTION

[0056] Main sources of substances:

[0057] Commercially available polyurethane foam: thermal conductivity (room temperature): 0.035, grade: B1, elongation at break: 11%, specifications: 350×350×50mm.

[0058] Polyoxyethyl glycerol ether: average molecular weight 850.

[0059] Polyethylene glycol: average molecular weight 600, average hydroxyl value 192.

[0060] Sodium polyacrylate, average molecular weight is 1500.

[0061] Polytetramethylenetetramethylene ether, average molecular weight is 1000.

[0062] Polyether 210, average hydroxyl value 110mgKOH / g.

[0063] Tetrameric 1,2-propylene glycol, average molecular weight 250.

[0064] Trihydroxy polyoxypropylene ether, average molecular weight 3000.

[0065] The remaining raw materials in the examples and comparative examples of the present invention are all commercially available products.

[0066] The design idea of ​​the present invention is to provide a new type of aluminum alloy material preparation process. By using a composite filter plate containing specific components, non-metallic inclusions and gases in the aluminum alloy melt can be effectively removed, thereby improving the purity and quality of the aluminum alloy. At the same time, rare earth elements are introduced for micro-alloying, and specific heat treatment and processing techniques are adopted to obtain aluminum alloy materials with excellent mechanical properties and corrosion resistance, meeting the demand for high-performance aluminum alloy materials in fields such as automobile manufacturing. Example 1

[0067] A preparation process of aluminum alloy material is as follows:

[0068] Step 1: Add 976.7 kg of aluminum ingots to a smelting furnace and set the temperature of the smelting furnace at 700 ° C. When the charge temperature rises to the set value and begins to melt, add 2 kg of iron, 1 kg of manganese and 1 kg of chromium powder in sequence, then add 9 kg of magnesium ingots, 0.8 kg of zinc ingots, 1 kg of titanium ingots, 2.5 kg of copper ingots and 5 kg of polysilicon, and finally add 0.2 kg of gadolinium, 0.3 kg of lanthanum ingots, 0.3 kg of cerium ingots and 0.2 kg of praseodymium ingots. Stir evenly until the materials are completely melted to obtain an alloy solution.

[0069] Step 2: Filter the alloy solution obtained in step 1 using a double-stage ceramic filter plate, wherein the mesh numbers of the double-stage ceramic filter plate are 40 mesh and 60 mesh respectively, to obtain a solution to be used after filtration;

[0070] Step 3: Cast the standby solution prepared in step 2 into an aluminum rod, and then let it stand at 710° C. for 1 hour to cast it into a billet;

[0071] Step 4: placing the blank prepared in step 3 in a homogenization treatment device; keeping the temperature at 550° C. for 7 hours; performing homogenization treatment to obtain a homogenized aluminum alloy ingot;

[0072] Step 5: Extruding the aluminum alloy ingot prepared in step 4 in an extruder. During the extrusion process, the aluminum alloy ingot is heated to 530° C., the temperature gradient is 7° C., the extrusion barrel temperature is 430° C., the extrusion die temperature is 480° C., and the extrusion speed is 5 m / min to obtain a 6-series modified alloy profile.

[0073] Step 6: The 6 series modified alloy profile prepared in step 5 is subjected to online solution quenching treatment at a treatment temperature of 520° C. The online quenching device realizes three cooling methods: strong wind, spraying, and water cooling, and then performs aging treatment to obtain T6 state aluminum alloy;

[0074] Step 7: The T6 aluminum alloy prepared in step 6 is stretched and straightened with a stretching amount of 2% to obtain an aluminum alloy material. Example 2

[0075] A preparation process of aluminum alloy material is as follows:

[0076] Step 1: Add 976.7 kg of aluminum ingots to a smelting furnace and set the temperature of the smelting furnace at 700 ° C. When the charge temperature rises to the set value and begins to melt, add 2 kg of iron, 1 kg of manganese and 1 kg of chromium powder in sequence, then add 9 kg of magnesium ingots, 0.8 kg of zinc ingots, 1 kg of titanium ingots, 2.5 kg of copper ingots and 5 kg of polysilicon, and finally add 0.2 kg of gadolinium, 0.3 kg of lanthanum ingots, 0.3 kg of cerium ingots and 0.2 kg of praseodymium ingots. Stir evenly until the materials are completely melted to obtain an alloy solution.

[0077] Step 2: Filter the alloy solution obtained in step 1 using a composite filter plate to obtain a solution to be used;

[0078] Step 3: Cast the standby solution prepared in step 2 into an aluminum rod, and then let it stand at 710° C. for 1 hour to cast it into a billet;

[0079] Step 4: placing the blank prepared in step 3 in a homogenization treatment device; keeping the temperature at 550° C. for 7 hours; performing homogenization treatment to obtain a homogenized aluminum alloy ingot;

[0080] Step 5: Extruding the aluminum alloy ingot prepared in step 4 in an extruder. During the extrusion process, the aluminum alloy ingot is heated to 530° C., the temperature gradient is 7° C., the extrusion barrel temperature is 430° C., the extrusion die temperature is 480° C., and the extrusion speed is 5 m / min to obtain a 6-series modified alloy profile.

[0081] Step 6: The 6 series modified alloy profile prepared in step 5 is subjected to online solution quenching treatment at a treatment temperature of 520° C. The online quenching device realizes three cooling methods: strong wind, spraying, and water cooling, and then performs aging treatment to obtain T6 state aluminum alloy;

[0082] Step 7: The T6 aluminum alloy prepared in step 6 is stretched and straightened with a stretching amount of 2% to obtain an aluminum alloy material.

[0083] The preparation method of the composite filter plate is as follows:

[0084] S1, 80kg boron carbide, 80kg illite, 100kg lithium feldspar, 50kg bentonite, 100kg aluminum hydroxide, 500kg black corundum, 20kg mica powder, 20kg quartz powder were mixed and ball-milled, and two-level particle size composite powders were screened out, with particle sizes of 60μm and 20μm, respectively. 100kg of composite powders of different particle sizes were taken respectively with 40kg water, 20kg phosphoric acid, 1kg sodium carboxymethyl cellulose, and 0.5kg zinc stearate and stirred to obtain large-particle size ceramic slurry and small-particle size ceramic slurry;

[0085] S2, immersing the modified polyurethane foam in the large-particle ceramic slurry for 10 minutes, taking out the foam, and pressing the excess slurry with a roller press to obtain a composite foam;

[0086] S3, placing the composite foam body in a vacuum drying oven and drying it at 95° C. for 20 minutes, pouring a small-particle ceramic slurry on the composite foam body, and after the slurry stops flowing out, squeezing out the excess slurry with a roller press, transferring the body to a drying oven and drying it for 15 minutes, repeating the pouring and drying operation three times to obtain a preform;

[0087] S4. Dry the preform at 120°C for 5 hours, transfer it into a kiln, heat it to 400°C at a rate of 2°C / min, keep it for 1 hour, continue to heat it to 1450°C at a rate of 2°C / min, keep it at that temperature for 2 hours, then naturally cool it to room temperature, cut it, and grind it to obtain a composite filter plate.

[0088] The preparation method of the modified polyurethane foam is as follows:

[0089] Mix 40 kg of polyoxyethyl glycerol ether, 60 kg of polyethylene glycol, 2 kg of water, 0.5 kg of di-n-butyltin diisooctanoate and 1 kg of hydroxy silicone oil in a beaker, stir at 40 ° C for 5 minutes to form a uniform mixed solution, quickly add 10 kg of sodium polyacrylate and 30 kg of 1,6-hexamethylene diisocyanate to the mixed solution, pour it into a pre-prepared mold, ensure that the foam completely fills the space in the mold, start stirring, and then let it stand for 10 minutes. Place the filled mold in a 100 ° C oven for 1.5 hours of curing treatment, then take out, cool and demold to obtain modified polyurethane foam. The size of the modified polyurethane foam is 350×350×50 mm. Example 3

[0090] The preparation process of an aluminum alloy material is basically the same as that of Example 2, the only difference being the preparation method of the modified polyurethane foam.

[0091] The preparation method of the modified polyurethane foam is as follows:

[0092] Mix 40 kg of polyether 210, 60 kg of polyethylene glycol, 2 kg of water, 0.5 kg of di-n-butyltin diisooctanoate and 1 kg of hydroxy silicone oil in a beaker, stir at 40 ° C for 5 minutes to form a uniform mixed solution, quickly add 10 kg of sodium polyacrylate and 30 kg of 1,6-hexamethylene diisocyanate to the mixed solution, pour it into a pre-prepared mold, ensure that the foam completely fills the space in the mold, start stirring, and then let it stand for 10 minutes. Place the filled mold in a 100 ° C oven for 1.5 hours of curing treatment, then take out, cool and demold to obtain modified polyurethane foam. The size of the modified polyurethane foam is 350×350×50 mm.

[0093] The preparation method of the composite filter plate is the same as that of Example 2. Example 4

[0094] The preparation process of an aluminum alloy material is basically the same as that of Example 2, the only difference being the preparation method of the modified polyurethane foam.

[0095] The preparation method of the modified polyurethane foam is as follows:

[0096] Mix 40 kg of tetrapropylene glycol, 60 kg of polyethylene glycol, 2 kg of water, 0.5 kg of di-n-butyltin diisooctanoate and 1 kg of hydroxy silicone oil in a beaker, stir at 40 ° C for 5 minutes to form a uniform mixed solution, quickly add 10 kg of sodium polyacrylate and 30 kg of 1,6-hexamethylene diisocyanate to the mixed solution, pour it into a pre-prepared mold, ensure that the foam completely fills the space in the mold, start stirring, and then let it stand for 10 minutes. Place the filled mold in a 100 ° C oven for 1.5 hours of curing treatment, then take out, cool and demold to obtain a modified polyurethane foam. The size of the modified polyurethane foam is 350×350×50 mm.

[0097] The preparation method of the composite filter plate is the same as that of Example 2. Example 5

[0098] The preparation process of an aluminum alloy material is basically the same as that of Example 2, the only difference being the preparation method of the modified polyurethane foam.

[0099] The preparation method of the modified polyurethane foam is as follows:

[0100] Mix 40 kg of polytetramethylene glycol, 60 kg of polyethylene glycol, 2 kg of water, 0.5 kg of di-n-butyltin diisooctanoate and 1 kg of hydroxy silicone oil in a beaker, stir at 40 ° C for 5 minutes to form a uniform mixed solution, quickly add 10 kg of sodium polyacrylate and 30 kg of 1,6-hexamethylene diisocyanate to the mixed solution, pour it into a pre-prepared mold, ensure that the foam completely fills the space in the mold, start stirring, and then let it stand for 10 minutes. Place the filled mold in a 100 ° C oven for 1.5 hours of curing treatment, then take out, cool and demold to obtain a modified polyurethane foam. The size of the modified polyurethane foam is 350×350×50 mm.

[0101] The preparation method of the composite filter plate is the same as that of Example 2. Example 6

[0102] The preparation process of an aluminum alloy material is basically the same as that of Example 2, the only difference being the preparation method of the modified polyurethane foam.

[0103] The preparation method of the modified polyurethane foam is as follows:

[0104] Mix 20 kg of polyoxyethyl glycerol ether, 20 kg of polytetramethylene glycol, 60 kg of polyethylene glycol, 2 kg of water, 0.5 kg of di-n-butyltin diisooctanoate and 1 kg of hydroxy silicone oil in a beaker, stir at 40 ° C for 5 minutes to form a uniform mixed solution, quickly add 10 kg of sodium polyacrylate and 30 kg of 1,6-hexamethylene diisocyanate to the mixed solution, pour it into a pre-prepared mold, ensure that the foam completely fills the space in the mold, start stirring, and then let it stand for 10 minutes. Place the filled mold in a 100 ° C oven for 1.5 hours of curing treatment, then take out, cool and demold to obtain modified polyurethane foam. The size of the modified polyurethane foam is 350×350×50 mm.

[0105] The preparation method of the composite filter plate is the same as that of Example 2.

[0106] Comparative Example 1

[0107] The preparation process of an aluminum alloy material is basically the same as that of Example 2, the only difference being the preparation method of the modified polyurethane foam.

[0108] The preparation method of the modified polyurethane foam is as follows:

[0109] Mix 40 kg of trihydroxy polyoxypropylene ether, 60 kg of polyethylene glycol, 2 kg of water, 0.5 kg of di-n-butyltin diisooctanoate and 1 kg of hydroxy silicone oil in a beaker, stir at 40 ° C for 5 minutes to form a uniform mixed solution, quickly add 10 kg of sodium polyacrylate and 30 kg of 1,6-hexamethylene diisocyanate to the mixed solution, pour it into a pre-prepared mold, ensure that the foam completely fills the space in the mold, start stirring, and then let it stand for 10 minutes. Place the filled mold in a 100 ° C oven for 1.5 hours of curing treatment, then take out, cool and demold to obtain modified polyurethane foam. The size of the modified polyurethane foam is 350×350×50 mm.

[0110] The preparation method of the composite filter plate is the same as that of Example 2.

[0111] Comparative Example 2

[0112] The preparation process of an aluminum alloy material is basically the same as that of Example 2, the only difference being that the modified polyurethane foam is replaced with commercially available polyurethane foam.

[0113] Test Example 1

[0114] Mechanical properties testing

[0115] The aluminum alloy materials prepared in the examples and comparative examples of the present invention were subjected to tensile property tests at room temperature with reference to GB / T 16865-2023 “Test specimens and methods for tensile testing of wrought aluminum, magnesium, and their alloy products”.

[0116] The fracture toughness test of the aluminum alloy materials prepared in the examples of the present invention and the comparative examples was conducted with reference to GB / T 4161-2007 "Test method for plane strain fracture toughness KIC of metallic materials". The test results are shown in Table 1.

[0117] Table 1

[0118]

[0119] Test Example 2

[0120] The filter plates used in the above examples and comparative examples were tested for compressive strength at room temperature according to GB / T 4740-1999 “Test method for compressive strength of ceramic materials”.

[0121] Thermal shock resistance: Preheat the heating furnace to 800°C and keep it warm for 10 minutes. Then, move the filter plates used in the above examples and comparative examples into the furnace and keep them there for 30 minutes. Then, open the furnace door and quickly remove the filter plates from the furnace. Let them cool naturally in the air. Repeat this process 8 times and observe whether the filter plates have any cracks, flaking of the ceramsite, or breakage.

[0122] The test results are shown in Table 2.

[0123] Table 2

[0124]

[0125] It can be seen from the data in Tables 1 and 2 that the aluminum alloy material prepared in Example 6 has the best mechanical properties, and the obtained composite filter plate has excellent compressive strength and thermal shock resistance.

[0126] Composite filter plates play a key role in the production of aluminum alloys. They effectively remove non-metallic inclusions and gases from the aluminum alloy melt, improving its purity and quality. Specifically, the composite filter plates' multi-layered network structure and high porosity ensure thorough filtration of the molten aluminum as it flows through the plates, intercepting, adsorbing, and depositing inclusions, significantly reducing the impurity content in the aluminum alloy. This not only improves the mechanical properties and corrosion resistance of the castings, but also reduces casting defects such as pores and cracks, ultimately enhancing the overall performance and service life of the aluminum alloy.

[0127] Compared with commercially available polyurethane foam, modified polyurethane foam exhibits better performance in the preparation of aluminum alloy materials and composite filter plates, mainly because the surface of the modified polyurethane foam becomes rougher, providing more mechanical locking points, which can better grasp and retain the ceramic slurry. At the same time, the improvement in wettability means that the modified polyurethane foam can more evenly coat the ceramic slurry, so that the slurry forms a more uniform and denser coating on the surface of the foam. This uniform and dense coating helps to form a composite filter plate with higher compressive strength and thermal shock resistance. When this filter plate is used in the preparation of aluminum alloy materials, it can effectively remove more non-metallic inclusions and gases, thereby improving the purity and quality of the aluminum alloy, and ultimately resulting in aluminum alloy materials with better mechanical properties.

[0128] The aluminum alloy material prepared using polyoxyethyl glycerol ether in Example 2 has a composite filter plate with better mechanical properties and higher compressive strength and thermal shock resistance, mainly due to the characteristics of polyoxyethyl glycerol ether. Polyoxyethyl glycerol ether has good wettability and dispersibility, which allows the ceramic slurry to be more evenly covered on the foam surface when preparing modified polyurethane foam, forming a dense and uniform coating. In addition, polyoxyethyl glycerol ether has high chemical stability and mechanical strength, which can provide more mechanical interlocking points and improve the overall strength and thermal shock resistance of the composite filter plate. These advantages make the aluminum alloy material in Example 2 perform better in mechanical properties and filter plate performance.

[0129] In Example 6, the combination of polyoxyethylene glycerol ether and polytetramethylene glycol ether significantly improved the mechanical properties of the aluminum alloy and the compressive strength and thermal shock resistance of the composite filter plate. The excellent wettability and dispersibility of polyoxyethylene glycerol ether enabled the ceramic slurry to evenly coat the foam surface, forming a dense coating; while polytetramethylene glycol ether enhanced the mechanical strength and chemical stability of the foam. The synergistic effect of the two compounds significantly improved the adhesion and uniformity of the ceramic slurry and increased mechanical interlocking points, ultimately resulting in a composite filter plate and aluminum alloy with superior performance.

Claims

1. A process for preparing an aluminum alloy material, comprising the following steps: melting an aluminum ingot, sequentially adding iron powder, manganese powder, and chromium powder, subsequently adding a magnesium ingot, a zinc ingot, a titanium ingot, a copper ingot, and polysilicon, and finally adding a gadolinium ingot, a lanthanum ingot, a cerium ingot, and a praseodymium ingot, stirring uniformly until the materials are completely melted to obtain an alloy solution; filtering, casting into aluminum rods, homogenizing, extruding, quenching, and stretching and straightening; characterized in that: The amounts of the raw materials are as follows: 970-980 parts by weight of aluminum ingot, 1-3 parts of iron powder, 0.8-1.2 parts of manganese powder, 0.8-1.2 parts of chromium powder, 8-10 parts of magnesium ingot, 0.5-1 parts of zinc ingot, 0.8-1.2 parts of titanium ingot, 2-3 parts of copper ingot, 4-6 parts of polysilicon, 0.1-0.3 parts of gadolinium ingot, 0.2-0.4 parts of lanthanum ingot, 0.2-0.4 parts of cerium ingot, and 0.1-0.3 parts of praseodymium ingot. Casting the aluminum rod is to cast the filtered aluminum alloy solution into an aluminum rod, and let it stand at 660-770° C. for 0.5-2 hours to obtain a billet; The filtration is carried out using a composite filter plate; the preparation method of the composite filter plate is as follows, in parts by weight: S1, 70-90 parts of boron carbide, 70-90 parts of illite, 80-120 parts of lithium feldspar, 40-60 parts of bentonite, 80-120 parts of aluminum hydroxide, 400-600 parts of black corundum, 15-25 parts of mica powder, and 15-25 parts of quartz powder are mixed and ball-milled, and two-level particle size composite powders are screened out, with particle sizes of 40-90 μm and 1-30 μm, respectively. 80-120 parts of the composite powders of different particle sizes are respectively taken and mixed with 30-50 parts of water, 15-25 parts of phosphoric acid, 0.5-2 parts of sodium carboxymethyl cellulose, and 0.4-0.6 parts of zinc stearate to obtain large-particle size ceramic slurry and small-particle size ceramic slurry; S2, immersing the modified polyurethane foam in the large-particle ceramic slurry for 5 to 15 minutes, taking out the foam, and pressing the excess slurry with a roller press to obtain a composite foam; S3, placing the combined foam body in a vacuum drying oven, drying at 90-100° C. for 10-20 minutes, pouring a small-particle ceramic slurry on the combined foam body, and after the slurry stops flowing out, squeezing out the excess slurry with a roller press, transferring the body to a drying oven and drying it for 10-20 minutes, repeating the pouring and drying operation 1-3 times to obtain a preform; S4, drying the preform at 100-130°C for 4-6 hours, transferring it to a kiln, heating it to 300-500°C at a rate of 1-3°C / min, maintaining it for 0.5-2 hours, and then heating it to 1400-1500°C at a rate of 1-3°C / min, keeping it at that temperature for 1-3 hours, and then naturally cooling it to room temperature, cutting it, and polishing it to obtain a composite filter plate; The preparation method of the modified polyurethane foam is as follows, in parts by weight: 10-30 parts of polyoxyethyl glycerol ether, 10-30 parts of polytetramethylene glycol, 50-70 parts of polyethylene glycol, 1-3 parts of water, 0.4-0.6 parts of di-n-butyltin diisooctanoate and 0.8-1.2 parts of hydroxy silicone oil are mixed in a beaker, and the mixture is stirred at 30-50°C for 4-6 minutes to form a uniform mixed solution. 8-12 parts of sodium polyacrylate and 25-35 parts of 1,6-hexamethylene diisocyanate are quickly added to the mixed solution, and the mixture is poured into a pre-prepared mold to ensure that the foam completely fills the space in the mold. Stirring is started, and then the mixture is allowed to stand for 8-12 minutes. The filled mold is placed in an oven at 80-120°C for curing treatment for 1-3 hours, and then taken out, cooled and demolded to obtain a modified polyurethane foam. The size of the modified polyurethane foam is 300-400×300-400×20-80 mm.

2. The process for preparing the aluminum alloy material according to claim 1, wherein: The homogenization treatment is to keep the billet at 530~580℃ for 6~8 hours to obtain an aluminum alloy ingot.

3. The process for preparing the aluminum alloy material according to claim 1, wherein: During the extrusion process, the aluminum alloy ingot is heated to 500~560℃ with a temperature gradient of 6~8℃, the extrusion barrel temperature is 400~450℃, the extrusion die temperature is 460~500℃, and the extrusion speed is 4~6m / min.

4. An aluminum alloy material, characterized in that: Prepared by the process according to any one of claims 1 to 3.

5. Application of the aluminum alloy material as claimed in claim 4 in automobile parts.

6. The use according to claim 5, characterized in that The automobile accessories are sunroof motors, instrument panels or battery trays.

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