Method for manufacturing salt corrosion resistant cable fixing clamp

Abstract

The present invention discloses a method for manufacturing a salt corrosion resistant cable clamp, comprising the following steps: uniformly mixing rare earth oxide, aluminum raw material, Fe, Cu, Mg and Ce elements and then pressing to form a block or particle with a fixed shape; placing the block or particle in a high-temperature reactor, taking it out and cooling it after the reaction is completed, and crushing it to obtain a primary product; refining and alloying the primary product to obtain a rare earth aluminum alloy raw material, which is then processed into a fixed clamp shape; performing anti-corrosion spraying on the surface of the fixed clamp and conducting a salt corrosion resistance test, and proceeding to the next step if qualified, and performing anti-corrosion spraying again if unqualified; injection molding the surface of the fixed clamp to form an insulator, performing anti-corrosion processing on the surface of the insulator, and conducting a salt corrosion resistance test, and outputting it to a finished product area if qualified, and performing anti-corrosion processing again if unqualified. The cable clamp of the present invention has excellent salt corrosion resistance, can meet the fixing requirements of coastal cables, and ensure its safety and reliability in use.

Description

Technical Field

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

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

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

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

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

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

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

[0008] S2: placing the blocks or particles obtained in step S1 into a high-temperature reactor for aluminothermic reduction reaction. After the reaction is complete, the blocks or particles are taken out for cooling, and then crushed to obtain a primary product.

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

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

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

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

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

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

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

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

[0017] Furthermore, the specific process of spraying the composite coating on the surface of the fixing clip is: thoroughly cleaning and pre-treating the surface of the fixing clip to remove impurities, then applying a layer of primer, spraying the anti-salt corrosion layer, insulating layer and hard layer on the primer in sequence, and finally applying a layer of topcoat, and drying and curing after the coating is completed.

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

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

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

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

[0022] The present invention provides a method for manufacturing a salt-corrosion-resistant cable clamp. Through an aluminothermic reduction reaction, rare earth oxides are fully mixed with aluminum, Fe, Cu, Mg, and Ce elements to form a rare earth aluminum alloy with excellent performance. This alloy not only has high strength and corrosion resistance, but also excellent thermal stability and electrical conductivity, making it ideal for use in environments with severe salt spray corrosion, such as marine and coastal areas. Pressing the raw materials into blocks or granules and then processing them into the clamp shape allows for flexible adjustment of the product's shape and size to meet the requirements of different installation environments and cable specifications. The entire process, from raw material mixing to pressing and forming, to aluminothermic reduction reaction, and cooling and crushing, is continuous and efficient, significantly improving production efficiency. Anti-corrosion spraying and insulator injection molding on the clamp surface effectively enhance the product's corrosion resistance, particularly in high-salinity environments, significantly extending its service life. Multiple salt corrosion resistance tests are implemented throughout the process to ensure that each step meets quality requirements. The final product exhibits stable performance and reliability. Furthermore, by optimizing the production process, energy consumption and waste emissions are reduced, meeting the environmental and energy conservation requirements of modern industrial production.

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

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

[0025] 4. In the present invention, the high-temperature reactor temperature is 700-800°C. At this temperature, the reducing power of aluminum is sufficient to reduce rare earth oxides, while avoiding the safety risks and increased energy consumption that may be caused by excessively high temperatures. Furthermore, within this temperature range, the rate of the aluminothermic reduction reaction is moderate, neither slowing down due to excessively low temperatures nor causing runaway reactions due to excessively high temperatures. However, temperatures above 800°C may increase thermal stress in the reactor, increasing safety risks.

[0026] 5. In the present invention, the rare earth oxide is one or a mixture of lanthanum oxide, cerium oxide, praseodymium oxide, neodymium oxide, and yttrium oxide. Lanthanum oxide is an important rare earth oxide that can significantly improve the performance of aluminum alloys by reacting with other metal elements to improve the strength and heat resistance of the alloy. Cerium oxide is a common oxide form of the rare earth element cerium and is often used as an additive in aluminum alloys to enhance the mechanical properties of the alloy, especially under high temperature conditions. Praseodymium oxide is also an oxide of the rare earth element and helps improve the oxidation resistance and corrosion resistance of aluminum alloys. Neodymium oxide is an oxide of the rare earth element neodymium. The use of yttrium oxide in aluminum alloys can improve their high-temperature performance and oxidation resistance. As important additives, rare earth oxides play a vital role in the production of rare earth aluminum alloys. Lanthanum oxide, cerium oxide, praseodymium oxide, neodymium oxide, and yttrium oxide are all common rare earth oxides, each with unique chemical and physical properties. They can be used alone or in combination to improve the performance of aluminum alloys. BRIEF DESCRIPTION OF THE DRAWINGS

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

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

[0029] Example 1

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

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

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

[0033] S2: placing the blocks or particles obtained in step S1 into a high-temperature reactor for aluminothermic reduction reaction. After the reaction is completed, the blocks or particles are taken out for cooling, and then crushed to obtain a primary product. In this embodiment, the temperature of the high-temperature reactor is 750° C.

[0034] The aluminothermic reduction reaction of the present invention can be performed at either high temperature or low temperature to reduce rare earth elements, which provides more options and a wider operating space. Furthermore, the generated alloy components are relatively pure, which helps reduce energy consumption and production costs. After the reaction is completed, the reaction product is removed from the high-temperature reactor and cooled. After cooling, it is crushed to obtain a primary product. The cooling step ensures the completion of the reaction, while the crushing makes subsequent refining and alloying treatments more efficient.

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

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

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

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

[0039] In this embodiment, a composite coating is sprayed onto the surface of the retaining clip using a combination of thermal spraying and cold spraying to complete the injection molding process. Thermal spraying and cold spraying techniques allow the coating material to adhere tightly to the surface of the retaining clip, forming a dense protective film that effectively isolates the retaining clip from the external environment, thereby improving its corrosion resistance. This significantly extends the service life of the retaining clip, particularly in corrosive environments such as salt spray. Thermal spraying melts the spraying material at high temperatures, forming a metallurgical bond with the retaining clip surface, while cold spraying uses high-velocity impact to achieve a tight bond at room temperature. This combination of methods ensures the coating's bonding strength while minimizing the effects of high temperatures on the retaining clip's substrate properties. Compared to traditional coating methods, thermal spraying and cold spraying reduce material waste and harmful emissions, making them more environmentally friendly. Combining these two advanced spraying technologies allows the development of novel composite coatings, enhancing the market competitiveness of retaining clips. Furthermore, combining thermal spraying and cold spraying allows the formation of multi-layer coatings with diverse functions, such as wear-resistant, insulating, and anti-corrosion layers, on the retaining clip surface.

[0040] In this embodiment, the specific process for spraying the composite coating on the surface of the retaining clip is as follows: thoroughly clean and pre-treat the surface of the retaining clip to remove impurities such as oil, dust, etc., then apply a layer of primer. An anti-corrosion layer, an insulating layer, and a hard coating are sprayed sequentially over the primer. Finally, a topcoat is applied. After coating, the surface is dried and cured. Specifically, the intermediate steps include: Surface cleaning and pre-treatment: Cleaning the retaining clip surface with a solvent to remove impurities such as oil, old paint, and dust, followed by sanding or sandblasting to enhance the adhesion between the coating and the retaining clip surface. Applying primer: Applying a uniform layer of primer to the cleaned and pre-treated retaining clip surface. The primer improves the coating's adhesion and provides preliminary corrosion protection. Applying the anti-corrosion coating: Using thermal spraying technology, a corrosion-resistant material, such as a zinc or aluminum-based coating, is sprayed over the primer to provide additional corrosion protection. Applying the insulating layer: Using cold spraying technology, a layer of insulating material, such as ceramic or special plastic, is sprayed to form the retaining clip's insulating layer. Spraying a hard layer: Use thermal spraying technology again to spray hard materials such as tungsten carbide or aluminum oxide to increase the wear resistance and impact resistance of the surface of the fixing clip. Applying a topcoat: Apply a layer of topcoat on top of the multi-layer coating. The topcoat can provide a final protective layer to prevent environmental factors from corroding the composite coating. Drying and curing treatment: Place the coated fixing clip in an appropriate temperature and environment for drying and curing to ensure that the coating is fully combined with the surface of the fixing clip to form a stable composite coating. Quality inspection: After the coating is cured, the coating of the fixing clip is inspected for quality, including the thickness, uniformity and adhesion of the coating. Salt corrosion resistance test: Perform salt corrosion resistance test on the coating to ensure that the coating meets the corrosion resistance requirements. Post-processing: If necessary, post-processing of the coating, such as heat treatment, can be performed to further enhance the performance of the coating;

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

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

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

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

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

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

[0047] Continuous failure handling: If the product still fails the second test, it is confirmed as defective, isolated and moved to the defective product area;

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

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

[0050] Sample preparation: Ensure that the surface coating of the fixing clamp is uniform and free of obvious defects, clean the sample surface and remove contaminants that may affect the test results;

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

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

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

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

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

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

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

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

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

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

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

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

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

[0064] In this embodiment, during the observation of product surface corrosion, the sample's appearance is visually and tactilely inspected for defects such as scratches, bubbles, and discoloration. The product's dimensions are then measured using a measuring tool and compared to the standard dimensions to ensure they are within tolerance. This comprehensive assessment, using visual inspection, tactile inspection, and measuring tools, is a comprehensive and effective method for observing product surface corrosion. This method not only directly observes product appearance defects but also ensures product accuracy and conformity through dimensional measurement. First, visual inspection of the sample's appearance is an intuitive and rapid method. It can detect obvious surface defects such as scratches, bubbles, and discoloration. These defects are often early signs of corrosion or other surface damage, making timely detection and treatment crucial for preventing further corrosion. Visual inspection can also reveal other potential issues, such as uneven coating and color variations, which are important factors affecting product quality and appearance. Second, tactile inspection can further validate the results of visual inspection. By feel, subtle variations in surface roughness and unevenness can be detected. These variations may be caused by corrosion, wear, or improper processing, making tactile inspection an additional verification of product appearance quality. In addition to visual and tactile inspections, measuring the product dimensions using measuring tools is also a necessary step. By comparing with the standard dimensions, it can be ensured that the product is within the tolerance range and thus meets the use requirements. If the product dimensions are out of tolerance, then even if there is no obvious corrosion or defects on the surface, there may be structural or performance problems that require further investigation and treatment.

[0065] Example 2

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

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

[0068] S2: placing the blocks or particles obtained in step S1 into a high-temperature reactor for aluminothermic reduction reaction. After the reaction is completed, the blocks or particles are taken out for cooling and then crushed to obtain a primary product. In this embodiment, the temperature of the high-temperature reactor is 700° C.

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

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

[0071] S5: The surface of the sprayed fixing clamp is injection molded with nylon material to form an insulator. After the injection molding is completed, the surface of the insulator is subjected to anti-corrosion processing and salt corrosion resistance testing. The qualified ones are output to the finished product area. If the test fails, the anti-corrosion processing is performed again.

[0072] In this embodiment, a composite coating is sprayed on the surface of the fixing clip by combining hot spraying and cold spraying to complete the injection molding. The specific process of spraying the composite coating on the surface of the fixing clip is as follows: the surface of the fixing clip is thoroughly cleaned and pretreated to remove impurities, and then a layer of primer is applied. The salt corrosion protection layer, the insulating layer, and the hard layer are sprayed on the primer in sequence, and finally a layer of topcoat is applied. After the coating is completed, the coating is dried and cured.

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

[0074] Example 3

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

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

[0077] S2: placing the blocks or particles obtained in step S1 into a high-temperature reactor for aluminothermic reduction reaction. After the reaction is completed, the blocks or particles are taken out for cooling, and then crushed to obtain a primary product. In this embodiment, the temperature of the high-temperature reactor is 800° C.

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

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

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

[0081] In this embodiment, a composite coating is sprayed on the surface of the fixing clip by combining hot spraying and cold spraying to complete the injection molding. The specific process of spraying the composite coating on the surface of the fixing clip is as follows: the surface of the fixing clip is thoroughly cleaned and pretreated to remove impurities, and then a layer of primer is applied. The salt corrosion protection layer, the insulating layer, and the hard layer are sprayed on the primer in sequence, and finally a layer of topcoat is applied. After the coating is completed, the coating is dried and cured.

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

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

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

[0085] The above description is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this field, several variations and improvements can be made without departing from the creative concept of the present invention, which all fall within the scope of protection of the present invention.

Claims

1. A method for manufacturing a salt corrosion resistant cable clamp, characterized in that: The following steps are involved: S1: Mixing rare earth oxide, aluminum raw material, Fe, Cu, Mg and Ce elements uniformly in a mixing container, and pressing the mixed raw materials to form blocks or particles with a fixed shape; S2: placing the blocks or particles obtained in step S1 into a high-temperature reactor for aluminothermic reduction reaction. After the reaction is complete, the blocks or particles are taken out for cooling, and then crushed to obtain a primary product. S3: refining and alloying the primary product obtained in step S2 to obtain a rare earth aluminum alloy raw material, and processing the rare earth aluminum alloy raw material into a fixing clip shape; the rare earth aluminum alloy raw material contains the following metal elements in percentage by mass: Al 80-90%, Fe 0.25-1%, Cu 0.1-0.4%, Mg 0.05-0.2%, and Ce 0.1-0.3%; S4: Anti-corrosion spraying is performed on the surface of the fixing clip prepared in step S3, and the surface of the fixing clip after spraying is tested for salt corrosion resistance. If the test is qualified, the next step is performed; if the test is unqualified, the anti-corrosion spraying is performed again; S5: The surface of the fixed clamp after spraying is injection molded to form an insulator. After the injection molding is completed, the surface of the insulator is subjected to anti-corrosion processing and the surface of the insulator is tested for salt corrosion resistance. If the test is qualified, it is output to the finished product area. If the test is unqualified, the anti-corrosion processing is performed again.

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

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

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

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

6. The method for manufacturing a salt corrosion resistant cable clamp according to claim 5, characterized in that: The specific process of spraying the composite coating on the surface of the fixing clamp is as follows: the surface of the fixing clamp is thoroughly cleaned and pretreated to remove impurities, and then a layer of primer is applied. The anti-salt corrosion layer, the insulating layer and the hard layer are sprayed on the primer in sequence, and finally a layer of topcoat is applied. After the coating is completed, the surface is dried and cured.

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

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

9. The method for manufacturing a salt corrosion resistant cable clamp according to claim 8, characterized in that: When observing the surface corrosion of the product, check the appearance of the sample by visual inspection and touch to see if there are scratches, bubbles, or discoloration defects on the product to be tested. Compare the size of the product to be tested with the standard size to ensure that the error is within the tolerance range.

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