Metal material intelligent continuous production device with local tissue regulation function and production method thereof

Abstract

The application discloses a kind of metal material intelligent continuous production device with local tissue regulation function and production method thereof, the metal material intelligent continuous production device includes computer control system, current output system, smelting and casting system, electric heating system, metal material processing system, defect on-line detection system, current micro-area tissue regulation system, the method of the present application, through the collaborative work of defect on-line detection device and current micro-area tissue regulation device, realize the detection and instant regulation of plate strip organization.This method can on-line monitoring and dynamic regulation to metal materials without affecting the overall production process, ensure the quality control of products in each link, greatly reduce the rework and scrap rate caused by defects.At the same time, the method is suitable for different kinds and specifications of metal materials, and can be customized according to specific needs, to meet the diversified industrial production needs.

Description

Technical Field

[0001] This invention belongs to the field of metal material forming technology, and specifically relates to an intelligent and continuous device for controlling the local microstructure of metal materials and its preparation method. Background Technology

[0002] With the rapid development of modern industry, the demand for various high-performance materials is constantly increasing. Wide-width alloy sheets and strips, due to their excellent mechanical properties and wide range of applications, such as aerospace, automotive manufacturing, and construction engineering, have become important basic materials. However, during production and processing, alloy sheets and strips often encounter problems such as localized compositional inhomogeneity, severe segregation, and the inability to control the microstructure in specific areas according to requirements, seriously affecting the mechanical properties and service life of the material. Therefore, how to effectively control the microstructure and improve the overall quality of alloy sheets and strips has become an urgent technical challenge to be solved.

[0003] The production of alloy strips typically involves processes such as smelting, casting, solution treatment, hot rolling, cold rolling, and heat treatment. These processes inevitably lead to various structural defects and material losses. For example, during smelting and casting, uneven alloy composition and inconsistent cooling rates can easily result in porosity. During rolling, microcracks are prone to occur under high temperature and pressure. These problems can lead to losses when moving to the next process. Furthermore, during heat treatment, inaccurate temperature control can cause stress concentration within the material or result in the same microstructure throughout the process. Currently, many methods exist for preparing and processing high-performance metallic materials, primarily focusing on the overall material preparation process, while research on the microstructure control process is scarce. Patent CN111424224B discloses a method for preparing high-strength, high-toughness, conductive copper alloy strips. This method employs a process route of "solution treatment—cold rolling—electric pulse heat treatment—cold rolling—aging treatment," resulting in a fine and uniform matrix grain structure, high-density dislocations, and dispersed precipitates, significantly improving the alloy's mechanical properties. However, this method is limited by the furnace cavity size, long heat treatment time, and low production efficiency of traditional heat treatment processes. Furthermore, because the entire alloy is treated, only a single and uniformly distributed microstructure can be obtained. Patent CN110343993A discloses a surface treatment method and application for cemented carbide, which involves carburizing or nitriding the alloy surface to effectively improve its mechanical properties. However, this process requires a high alloy thickness; if the substrate thickness is too thin, the coating structure will be loose, leading to coating failure or coating penetration. Patent CN117358754A discloses a method for preparing composite copper-based metal strips. This method involves coating a tin-based or aluminum-based material layer onto the graphene layer of the composite metal strip before pressing and rolling. This allows for a good bond between the graphene layer coated on the copper substrate strip surface and the composite copper-based metal material. The prepared material does not experience graphene layer peeling or breakage during use, exhibits good material uniformity, and effectively improves the conductivity of the resulting composite copper-based metal strip. However, this process has certain requirements on the thickness of the substrate, and the graphene coating is easily damaged and detached when it is squeezed during the composite process, which reduces the mechanical properties and service life of the material. At the same time, the process is relatively complex and has a long process, which increases equipment and labor costs.

[0004] In summary, by addressing the problems existing in current technologies and developing an intelligent, large-width alloy sheet / strip continuous local microstructure control device and method, the quality and reliability of alloy materials can be significantly improved, production costs reduced, and production efficiency increased. Furthermore, this will provide crucial technical support and assurance for the production and application of high-performance alloy materials. This technology is not only applicable to traditional industrial fields such as aerospace, automotive manufacturing, and construction engineering, but can also be extended to emerging high-tech fields such as new energy, electronic information, and medical devices, demonstrating broad application prospects and economic benefits, and driving the development of materials science and engineering technology. Summary of the Invention

[0005] To address the shortcomings mentioned above, the first objective of this invention is to provide an intelligent continuous production device for metal materials with local microstructure control capabilities. The local microstructure control device for metal materials provided by this invention uses an online defect detection device to detect minute defects on the surface and inside of the processed metal material in real time. It also uses a current-controlled microstructure control device to precisely regulate the microstructure during heating aging, recrystallization, and crack repair. Furthermore, it performs localized heat treatment using high-energy current, while ensuring the flatness of the plate and strip surface. This device not only significantly improves product quality and consistency but also reduces raw material waste, significantly increases production efficiency, lowers production costs, and enhances the overall performance of the product, making it suitable for large-scale industrial production.

[0006] The second objective of this invention is to provide an intelligent continuous production method for metallic materials with localized microstructure control capabilities. Through the coordinated operation of an online defect detection device and a current-based microstructure control device, the microstructure of sheet and strip materials can be detected and controlled in real time. This method enables online monitoring and dynamic control of metallic materials without affecting the overall production process, ensuring quality control at each stage and significantly reducing rework and scrap rates caused by defects. Furthermore, this method is applicable to different types and specifications of metallic materials and can be customized to meet diverse industrial production needs.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] This invention discloses an intelligent continuous production device for metallic materials with local microstructure regulation function. The intelligent continuous production device for metallic materials includes a computer control system, a current output system, a melting and casting system, an electric heating system, a metallic material processing system, an online defect detection system, and a current micro-area microstructure regulation system.

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

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

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

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

[0013] The current micro-area processing system includes a current probe located at the rear end of the online defect detection system. The current probe applies a micro-area current to the defect area of ​​the workpiece to repair the defect area and applies a micro-area current to the workpiece to regulate the microstructure.

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

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

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

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

[0018] In a further preferred embodiment, the power supply in the current output system consists of a high-frequency low-peak current type and a low-frequency high-peak current type.

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

[0020] In a further preferred embodiment, the melting apparatus comprises an insulating protective sleeve, a graphite crucible, an induction coil, a mechanical stirrer, a graphite electrode, and an atmosphere protection device; the induction coil is surrounded by the outside of the graphite crucible and is used to melt the metal raw material in the graphite crucible to obtain a melt; the mechanical stirrer is used to stir the melt; the graphite electrode is connected to the graphite crucible and provides pulse current to the graphite crucible through an external pulse power supply; and the atmosphere protection device is used to provide atmosphere protection for the melt in the graphite crucible.

[0021] In a further preferred embodiment, the mechanical stirrer is made of stainless steel-graphite coated material.

[0022] In a further preferred embodiment, the cooling device includes a guide pipe and a water-cooled crystallizer. The guide pipe is connected to the outlet of the graphite crucible, and the melt in the graphite crucible flows into the water-cooled crystallizer through the guide pipe for cooling and crystallization to obtain an ingot.

[0023] In a further preferred embodiment, the water-cooled crystallizer comprises a mold and cooling water channels disposed on the outside of the mold. The number of cooling water channels decreases gradually from top to bottom, forming an "inverted T-shaped" cooling zone, wherein the ratio of the number of adjacent cooling water channels is 3:2 to 1.5. In this invention, by making the number of cooling water channels located on the outside of the mold gradually decrease from top to bottom, the amount of cooling water applied to the outside of the mold also gradually decreases from top to bottom, forming an "inverted T-shaped" cooling zone with a temperature gradient from rapid cooling to full cooling. Thus, this invention obtains an ingot with a temperature gradient, i.e., a columnar crystal structure, through the water-cooled crystallizer.

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

[0025] In a preferred embodiment, the electric heating system comprises two graphite plates arranged vertically, positioned above and below the ingot during operation. A robotic arm controls the fit between the two graphite plates and the ingot.

[0026] In a preferred embodiment, the metal material processing system includes processing equipment A and processing equipment B connected in sequence, as well as a current application device. Processing equipment A is used for hot processing of preheated ingots, processing equipment B is used for cold processing of the processed material obtained from hot processing, and the current application device includes a current delivery electrode, through which current is provided during cold processing of the processed material, preferably a pulsed current.

[0027] In a further preferred embodiment, both processing equipment A and processing equipment B are selected from one of rolling mills, drawing equipment, forging equipment, and extrusion equipment, with rolling mills being the preferred option.

[0028] Taking a rolling mill as an example, in this invention, rolling mill A performs ordinary rolling, the purpose of which is to perform hot rolling of alloy strip to eliminate defects generated during casting and to significantly reduce the size of the alloy. Then, it enters rolling mill B for cold rolling, the purpose of which is to obtain high-density dislocations in the processed billet and to reduce the risk of cracking of the processed billet by utilizing the electroplastic effect. Current is applied to the processed billet through electrodes to maintain a uniform electric field distribution and a good crystal structure in the processed billet during the processing, thereby improving the quality and performance of the processed billet.

[0029] In a further preferred embodiment, the current application device uses a high-frequency low-peak current, and the positive and negative poles of the high-frequency low-peak current are in direct contact with the upper and lower rollers of the processing area of ​​the processing equipment B.

[0030] In a preferred embodiment, the online defect detection system includes a high-precision image sensor and a data analysis module, used to detect minute defects on the surface and inside of the workpiece in real time, and to feed the defect information back to the computer control system.

[0031] In a further preferred embodiment, the high-precision image sensor comprises a non-destructive testing device and an image acquisition device. The non-destructive testing device includes one of an ultrasonic flaw detector, a magnetic particle flaw detector, and an electromagnetic eddy current flaw detector, preferably a magnetic particle flaw detector. The magnetic particle flaw detector includes a base, a support plate, a fiber brush, a magnetic suspension box, an electric brush, and a testing table.

[0032] Further optimization involves using a magnetic suspension fluid composed of magnetic powder, oil-based liquid, and fluorescent powder, applied to the surface of the workpiece in a horizontal zigzag pattern.

[0033] In actual operation, a magnetic suspension liquid is applied to the surface of the workpiece, and the surface of the workpiece is irradiated with ultraviolet light to continuously acquire surface images of the workpiece within the detection area. The acquired images are then fed back to the data analysis module through an image acquisition device. Based on the surface images acquired by the image acquisition module, surface and internal defects of the workpiece are determined, and the identified defects are marked.

[0034] In a preferred embodiment, the current micro-area processing system includes current probe 1, current probe 2, current copper plate 1, current copper plate 2, cable fixing copper ring 1, cable fixing copper ring 2; a three-axis displacement platform, and a fixed platform.

[0035] The rear end of the current-carrying copper plate 1 is connected to the cable-fixing copper ring 1, and the front end is equipped with current probe 1; the rear end of the current-carrying copper plate 2 is connected to the cable-fixing copper ring 2, and the front end is equipped with current probe 2; the cable-fixing copper ring 1 and the cable-fixing copper ring 2 are respectively connected to the positive and negative terminals of the power supply in the current output system.

[0036] The fixed platform consists of a support and a table at the top of the support. A limit plate is provided above the table. Current copper plate 1 is located above the table and below the limit plate, allowing it to move freely on the Y-axis and be limited to a certain position on the X-axis. Current copper plate 2 is fixed above the three-axis displacement platform and can move along the X, Y, and Z axes as the three-axis displacement platform moves. Current copper plate 2 and the three-axis displacement platform are located below the table. During operation, current probe 1 and current probe 2 are respectively positioned above and below the workpiece, and are controlled to be centered vertically.

[0037] In a further preferred embodiment, the shape of the head surface of current probe 1 and current probe 2 is selected from one of the following: circular, conical, cross-shaped, and straight, and the size of the head surface is 0.01 mm. 2 ~10cm 2 Preferably 0.01mm 2 ~1cm 2 A further preferred value is 0.01mm. 2 ~1mm 2 .

[0038] In a further preferred embodiment, the accuracy range of the triaxial displacement platform is 0 to 0.1 mm.

[0039] In this invention, current probe 1 and current probe 2 are respectively positioned above or below the workpiece after defect detection. Based on the identified defect, current is applied to the defect location by current probe 1 and current probe 2 to repair the defect. A three-axis displacement platform is used to move current probe 1 and current probe 2 precisely, applying current only to the defect location. The head surfaces of current probe 1 and current probe 2 are the contact surfaces with the workpiece. The treatment of specific defect areas is achieved through probes of specific shapes and sizes.

[0040] In a preferred embodiment, the intelligent continuous production device for metal materials further includes a water-cooling circulation system, which is located at the rear end of the processing equipment A in the metal material processing system and is used to cool the processed waste material that has been heat-treated by the processing equipment A.

[0041] In a preferred embodiment, the intelligent continuous production device for metal materials further includes a cooling system located at the rear end of the current micro-area processing device. The cooling system includes a spray gun, which is used to cool the defect area after the current micro-area processing device has applied current.

[0042] In a preferred embodiment, the intelligent continuous production device for metal materials further includes a temperature monitoring and control device, which consists of several thermocouple temperature sensors. The thermocouple temperature sensors are used to monitor the temperature in real time during the continuous production process and feed it back to the computer control system.

[0043] In a preferred embodiment, the intelligent continuous production device for metal materials further includes a traction system, which includes a traction rod and a copper ingot guide plate. The copper ingot guide plate contacts the molten material, and under the action of the traction rod, the molten material flows through the guide pipe into the water-cooled crystallizer at a certain traction speed to obtain an ingot. Subsequent ingots continue to pass through other systems in sequence under the traction of the traction system.

[0044] This invention discloses an intelligent continuous production method for metal materials with localized structure regulation function. Using the intelligent continuous production device for metal materials, the metal raw materials are first melted and cast to obtain ingots. The ingots are then preheated, and the preheated ingots are processed to obtain processed parts. The processed parts are subjected to online defect detection to identify defect areas, and micro-currents are applied to the defect areas to repair the defects.

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

[0046] In a preferred embodiment, the shape of the metal material is selected from one of the following: sheet metal, strip metal, wire metal, pipe metal, and profile metal.

[0047] In a preferred embodiment, before the smelting process, the initial information of the metal material and the instruction parameter information are first entered into the computer control system.

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

[0049] The production method of this invention adopts fully automated control. The high-performance computer control system issues corresponding instructions to other system components to digitally control the processing of metal materials, precisely regulate the microstructure of materials, and finely repair the surface quality. In particular, it integrates functions such as detection, positioning, microstructure regulation, defect repair, and quality assessment into one, realizing a continuous and efficient metal material processing process.

[0050] In a preferred embodiment, the smelting process involves heating the metal raw material to a temperature of Ts+(50~100)℃ to obtain a melt, and then holding it at Ts+(30~80)℃. During the holding process, mechanical stirring and the application of electrical pulses are carried out simultaneously.

[0051] In a further preferred embodiment, during the melting process, the parameters of the applied electrical pulse are: pulse current frequency 10–600 Hz, current density 1–100 A / cm². 3 .

[0052] In a further preferred embodiment, the mechanical stirring speed is controlled between 1 and 400 r / min during the melting process.

[0053] In this invention, the metal raw material is placed in a crucible in the melting system, covered with a top cap, and Ar gas is introduced for atmosphere protection. The metal raw material is heated according to the command parameters issued by the high-performance computer control system. When the holding temperature is reached, the high-energy electric pulse output system is rotated to either "pulse current" or "low-frequency high-peak current type" to begin supplying pulse current. During the holding process, the melt undergoes both mechanical stirring and electric pulse treatment to improve the uniformity of the material's composition and structure. Simultaneously, atmosphere protection is applied throughout the melting process to reduce the increase of oxides on the melt surface. After the holding period, the top plug is opened, and the melt is guided through a guide pipe into a cooling device below the crucible for directional solidification, followed by bending.

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

[0055] After heat treatment, the resulting melt is introduced into an inverted T-shaped cooling zone below the furnace by a traction system for rapid solidification, forming a grain structure that grows along a temperature gradient. During the cooling process, the temperature at the edges of the solid-liquid mixture is controlled to be no lower than the temperature at the center, resulting in a meniscus-shaped temperature distribution with the solid phase convex to the liquid phase. Because the temperature at the edges of the solid-liquid mixture is no lower than the temperature at the center, the alloy strip and plate formed by the solidification of the melt in contact with the ingot copper plate do not exhibit casting defects such as orange peel. Subsequently, the solidified ingot is pulled out by a traction rod system and successively enters a bending device. Then, it is rapidly heated by a subsequent current, which on the one hand promotes the recovery recrystallization process and refines the grains; on the other hand, it simultaneously allows the precipitates generated during the solidification process to fully dissolve back into the matrix, forming a supersaturated solid solution and improving the material's machinability.

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

[0057] In a further preferred embodiment, the hot working is selected from one of hot rolling, hot drawing, hot forging, hot rotary forging, hot radial forging, hot extrusion, and hot upsetting, preferably hot rolling; the cold working is selected from one of cold rolling, cold drawing, cold forging, cold rotary forging, cold radial forging, cold extrusion, and cold upsetting, preferably cold rolling.

[0058] In a further preferred embodiment, during the cold processing, the electrical pulse parameters are: pulse voltage: 6-12V; output current: 200-1000A; pulse frequency: 5000-20000Hz; and processing time: 0.01-300s.

[0059] The preheated ingot is transported by a traction system through a processing system and hot rough rolling in mill A. It is then quenched to form a uniform supersaturated solid solution and then finely rolled by current in mill B. The combined process of "hot rough rolling + current fine rolling" enables faster strip rolling, and the second set of electric pulse rolling processes can effectively reduce the impact of the rolling process on the surface quality of the strip.

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

[0061] Further preferred, the defects include porosity, microcracks, and stress concentration. Stress concentration typically occurs at bends.

[0062] In the preferred embodiment, the process of applying micro-current to the defect area is as follows: the current probe 1 and the current probe 2 of the current micro-area processing device are moved to a certain marked defect area of ​​the metal material, and a current is applied once within the area of ​​the current probe. Then the current probe is moved to apply current to the area of ​​the next current probe until the marked defect is processed.

[0063] Further preferred, when the defect is a pore or crack, the parameters of the current applied to the defect area are: pulse voltage: 6-12V; output current: 2000-5000A; pulse frequency: 50-2000Hz; when the defect is a stress concentration, the parameters of the current applied to the defect area are: pulse voltage: 6-12V; output current: 2000-3000A; pulse frequency: 50-2000Hz.

[0064] A preferred approach involves applying microcurrents to the defect-repaired metallic material for microstructural modulation. During microstructural modulation, a target microstructure is first designed, and based on this design, a microcurrent scan is performed on the entire metallic material, or a targeted microcurrent scan is performed.

[0065] A further preferred method involves applying micro-area current to the defect-repaired metal material for tissue regulation, as follows: Based on the designed target tissue structure, current probes 1 and 2 of the current micro-area processing device are moved to a specific tissue regulation area of ​​the metal material. A current is applied once within the area of ​​the current probe, and then the current probe is moved to apply current to the next current probe area until the tissue regulation area is completely processed. The parameters of the micro-area current are: pulse voltage: 6–12V; output current: 500–2000A; pulse frequency: 50–2000Hz; and processing time: 0.01–300s.

[0066] Principles and advantages

[0067] The processing method of this invention employs fully automated control. A high-performance computer control system issues corresponding instructions to other system components, enabling digital control of the processing of wide alloy strips and plates, precise regulation of the material's microstructure, and refined surface quality repair. In particular, it integrates functions such as detection, positioning, microstructure control, defect repair, and quality assessment into a single unit, achieving a continuous and efficient alloy strip and plate processing process. In this invention, the metal raw material is placed in the melting chamber of an electric pulse melting system. During the holding process, the melt undergoes dual treatment of mechanical stirring and electric pulse processing, improving the uniformity of the material's composition and microstructure. Simultaneously, a protective atmosphere is applied throughout the melting process to reduce the increase of oxides on the melt surface. After holding, the resulting melt is introduced by a traction system into a "T-shaped" cooling zone below the furnace for rapid solidification, forming a grain structure that grows along the temperature gradient. During the cooling process, the temperature at the edges of the solid-liquid mixture is controlled to be no lower than the temperature at the center, forming a meniscus-shaped temperature distribution convex from the solid phase to the liquid phase. Because the temperature at the edges of the solid-liquid mixture is no lower than the temperature at the center, the alloy strip obtained by solidification of the melt in contact with the ingot copper plate does not produce casting defects such as orange peel. Subsequently, the solidified alloy strip is pulled out by a traction rod system and successively enters the bending device and induction coil area. The casting speed of the alloy strip is controlled by a high-performance computer system to regulate the microstructure of the alloy strip, introducing a large number of dislocations. Combined with subsequent rapid heating with current, this promotes the recovery recrystallization process and refines the grains. At the same time, it allows the precipitates generated during the solidification process of the melt to fully dissolve back into the matrix, forming a supersaturated solid solution and improving the processing performance of the material.

[0068] The strip material is traction-driven through the strip processing system. It undergoes hot roughing through the first set of rolls, followed by quenching to form a uniform supersaturated solid solution. Then, it is subjected to current fine rolling through the second set of rollers. This composite process of "hot roughing + current fine rolling" allows for faster strip rolling, and the second set of electric pulse rolling technology effectively reduces the impact of the rolling process on the surface quality of the strip material. As the alloy strip enters the online defect detection system, a magnetic suspension is evenly applied to the surface of the workpiece using a fiber brush in a zigzag pattern. The platform then performs real-time surface and internal micro-defect detection, feeding the defect information back to the high-performance computer control system as visual electrical signals. This system then issues commands to the electrical pulse micro-area defect repair system, which uses a high-precision positioning device to accurately guide the pulse current to the defect area. The electrical pulse is then used for micro-area heating and repair, resulting in rapid defect elimination. Based on the designed microstructure, the target area is then subjected to electrical pulse aging or electrical pulse recrystallization to obtain high-quality metallic materials, especially high-quality, large-width alloy strips.

[0069] Compared with the prior art, the beneficial effects of the present invention are:

[0070] 1) Compared with traditional alloy sheet and strip production equipment and processes, this invention provides an intelligent continuous production device for metallic materials with local microstructure control capabilities. By introducing an automated control system and precise local processing techniques, it achieves efficient elimination of local defects in wide alloy sheet and strip materials. This invention uses a high-performance computer system to monitor and control multiple key steps of the metallic material production process in real time, including melting, cooling and solidification, bending, recrystallization, hot rolling, electric pulse rolling, online defect detection, and current-controlled microstructure regulation. This ensures the accuracy and quality of local defect elimination, avoiding problems such as material inhomogeneity and poor surface quality caused by macroscopic segregation that may occur in traditional methods, and reducing the generation of microcracks. This allows for precise design of metallic materials based on their microstructure characteristics, significantly reducing production cycles, lowering energy consumption and material waste, and significantly improving production efficiency and economic benefits.

[0071] 2) This invention also provides an intelligent continuous production method for metallic materials with local microstructure control capabilities. It employs a fully automated control system, using a high-performance computer system to monitor and adjust the processing parameters of the entire alloy sheet / strip in real time, ensuring the precision and consistency of microstructure control. During the electro-pulse melting process, a combination of electro-pulse melting and mechanical stirring is used to prevent uneven composition due to poor diffusion capacity of the alloy, reducing casting defects. Simultaneously, the electric heating system effectively avoids grain coarsening and stress concentration. The combination of hot rolling and electro-pulse rolling enables rapid deformation of the sheet / strip, improving rolling efficiency and enhancing the mechanical properties and surface quality of the sheet / strip during rolling. Finally, electro-pulse microstructure control enables precise "point-to-point" microstructure design and rapid microcrack repair. Compared with existing manual or semi-automated repair methods, this invention offers high efficiency, high precision, and low cost, significantly improving the overall product quality and market competitiveness.

[0072] 3) This invention provides an intelligent continuous production device for metallic materials with local microstructure regulation capabilities, exhibiting high flexibility and scalability. Through modular design of the entire production process, this invention can adapt to various complex production conditions based on complex process parameters for different alloy types, plate specifications, and microstructure types. Whether dealing with complex microstructure types or surface defects, this invention provides corresponding design solutions, not only eliminating existing defects but also achieving a superior microstructure, significantly improving the material's ductility, fatigue resistance, and corrosion resistance. Furthermore, the integration of online detection, trimming, and precise design functions enhances the continuity and automation level of the production process. This invention is particularly suitable for fields requiring high strength and high reliability, such as aerospace, automotive manufacturing, and high-end equipment manufacturing, and has broad application prospects and market potential. Attached Figure Description

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

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

[0075] Figure 3 Schematic diagram of the current micro-area processing system. In the diagram, 81, current copper plate 1; 82, current input connector for installing current probe 1; 83, current output connector for installing current probe 2; 84, three-axis displacement platform; 85, fixed platform; 86, infrared thermometer; 87, current copper plate 2; 88, cable fixing copper ring 1; 89, cable fixing copper ring 2. Detailed Implementation

[0076] The present invention will now be described in detail with reference to the accompanying drawings.

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

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

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

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

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

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

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

[0084] The bending device consists of three rollers, which are externally connected to a power source.

[0085] The electric heating system includes two graphite plates, which are arranged vertically above and below the ingot during operation. A robotic arm controls the fit between the two graphite plates and the ingot.

[0086] The metal material processing system includes processing equipment A and processing equipment B connected in sequence, as well as a current application device. Processing equipment A is used for hot processing of preheated ingots, and processing equipment B is used for cold processing of the processed material obtained from hot processing. The current application device includes a current delivery electrode, through which current is provided during the cold processing of the processed material, preferably a pulsed current.

[0087] In a further preferred embodiment, both processing equipment A and processing equipment B are selected from one of rolling mills, drawing equipment, forging equipment, and extrusion equipment, with rolling mills being the preferred option.

[0088] Furthermore, the current application device uses a high-frequency low-peak current, and the positive and negative poles of the high-frequency low-peak current are in direct contact with the upper and lower rollers of the processing area of ​​the processing equipment B.

[0089] In a preferred embodiment, the online defect detection system includes a high-precision image sensor and a data analysis module, used to detect minute defects on the surface and inside of the workpiece in real time, and to feed the defect information back to the computer control system.

[0090] In a further preferred embodiment, the high-precision image sensor comprises a non-destructive testing device and an image acquisition device. The non-destructive testing device includes one of an ultrasonic flaw detector, a magnetic particle flaw detector, and an electromagnetic eddy current flaw detector, preferably a magnetic particle flaw detector. The magnetic particle flaw detector includes a base, a support plate, a fiber brush, a magnetic suspension box, an electric brush, and a testing table.

[0091] Furthermore, the magnetic suspension fluid is composed of magnetic powder, oil-based liquid and fluorescent powder, and is applied to the surface of the workpiece in a horizontal zigzag pattern.

[0092] The current micro-area processing device includes current probe 1, current probe 2, current copper plate 1, current copper plate 2, cable fixing copper ring 1, cable fixing copper ring 2; a three-axis displacement platform, and a fixed platform.

[0093] The rear end of the current-carrying copper plate 1 is connected to the cable-fixing copper ring 1, and the front end is equipped with current probe 1; the rear end of the current-carrying copper plate 2 is connected to the cable-fixing copper ring 2, and the front end is equipped with current probe 2; the cable-fixing copper ring 1 and the cable-fixing copper ring 2 are respectively connected to the positive and negative terminals of the power supply in the current output system.

[0094] The fixed platform consists of a support and a table at the top of the support. A limit plate is provided above the table. Current copper plate 1 is located above the table and below the limit plate, allowing it to move freely on the Y-axis and be limited to a certain position on the X-axis. Current copper plate 2 is fixed above the three-axis displacement platform and can move along the X, Y, and Z axes as the three-axis displacement platform moves. Current copper plate 2 and the three-axis displacement platform are located below the table. During operation, current probe 1 and current probe 2 are respectively positioned above and below the workpiece, and are controlled to be centered vertically.

[0095] The head surface shape of current probe 1 and current probe 2 is selected from one of the following: circular, conical, cross-shaped, and straight. The size of the head surface is 0.01mm.2 ~10cm 2 Preferably 0.01mm 2 ~1cm 2 A further preferred value is 0.01mm. 2 ~1mm 2 .

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

[0097] The water-cooling circulation system is located at the rear end of the processing equipment A in the metal material processing system, and is used to cool the processed waste material that has been heat-treated by the processing equipment A.

[0098] The cooling system, located at the rear end of the current micro-area processing device, includes a spray gun for cooling the defect area after it has been treated by the current micro-area processing device.

[0099] The temperature monitoring and control device consists of several thermocouple temperature sensors, which are used to monitor the temperature in real time during continuous production and feed it back to the computer control system.

[0100] The traction system includes a traction rod and a copper ingot guide plate. The copper ingot guide plate contacts the molten material, and under the action of the traction rod, the molten material flows at a certain traction speed through a guide pipe into a water-cooled crystallizer for cooling to obtain an ingot. Subsequent ingots continue to be tractioned by the traction system and pass through other systems sequentially. The specific operation includes the following steps:

[0101] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

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

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

[0104] (3) Electro-pulse melting. Upon receiving melting commands from a high-performance computer control system (heating rate 20–150℃ / min, holding temperature 25–1800℃, holding time 1–60min), the induction coil in the electro-pulse melting system begins heating the melting cavity. When the holding temperature is reached, the mechanical stirrer in the center of the melting cavity (stirring speed: 1–400 r / min) and the pulse power supply (power supply adjusted to "pulse power" and "low frequency high peak current type" settings, pulse current: 1–100 A / cm²) are simultaneously activated. 3 (Pulse current frequency: 10~600Hz) to accelerate the dispersion of the melt. After the holding time is completed, the robotic arm opens the plug at the bottom of the crucible, and at the same time, the traction rod passes through the cooling device on the outside of the bottom of the crucible (cooling water flow rate 200~1000L / h, decreasing in a gradient from top to bottom according to the ratio of adjacent water channels 3:2~1.5), and the top rod head is inserted into the groove at the bottom of the crucible to connect with the molten metal. According to the set traction speed (0.01~1m / min), the molten metal is pulled out into the bending device below.

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

[0106] (5) Defect Detection: After the strip is processed, it enters the online defect detection system for quality inspection. Magnetic particle testing is used, and a suspension (magnetic powder, oil-based liquid, and fluorescent powder are mixed in a ratio of 3:10:1) is applied to the surface of the strip in a horizontal zigzag pattern using a fiber brush. The surface is observed and sampled through the inspection station, and the image signal is fed back to the high-performance computer system for recording. The corresponding signal is then input into the electrical pulse micro-area defect repair system to determine the surface and internal defects of the processed part, and the determined defects are marked.

[0107] (6) Defect Repair: Move the current probe 1 and current probe 2 of the current micro-area processing device to a marked defect area of ​​the metal material, apply a current once within the area of ​​the current probe, and then move the current probe to apply a current to the area of ​​the next current probe until the marked defect is repaired. When the defect is a porosity or crack, the parameters of the current applied to the defect area are: pulse voltage: 6-12V; output current: 2000-5000A; pulse frequency: 50-2000Hz. When the defect is a stress concentration, the parameters of the current applied to the defect area are: pulse voltage: 6-12V; output current: 2000-3000A; pulse frequency: 50-2000Hz.

[0108] (7) Tissue Regulation: Finally, optionally, the process of applying micro-area current to regulate the tissue of the defect-repaired metal material is as follows: According to the designed target tissue structure, the current probe 1 and the current probe 2 of the current micro-area processing device are moved to a certain tissue regulation area of ​​the metal material, and a current is applied once within the area of ​​the current probe. Then, the current probe is moved to apply current to the area of ​​the next current probe until the tissue regulation area is completely processed. The parameters of the micro-area current are: pulse voltage: 6~12V; output current: 500~2000A; pulse frequency: 50~2000Hz; processing time: 0.01~300s.

[0109] The following examples will provide further details.

[0110] Example 1

[0111] Taking Cu-Ni-Sn alloys as an example, the steps include:

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

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

[0114] (3) Electro-pulse melting. Upon receiving a melting command from the high-performance computer control system, the induction coil in the electro-pulse melting system begins heating the melting chamber. When the holding temperature is reached, the mechanical stirrer in the center of the melting chamber and the pulse power supply (adjusted to either "pulse power" or "low-frequency high-peak current type") are simultaneously activated to accelerate the dispersion of the melt. After holding, the robotic arm opens the plug at the bottom of the crucible, and simultaneously, the traction rod passes through the cooling device on the outside of the crucible bottom, with the top end inserted into the groove at the bottom of the crucible to connect with the molten metal. The molten metal is pulled out to the bending device below according to the set traction speed.

[0115] (4) Strip processing. The heating command (heating rate 50℃ / min, holding temperature 820℃) issued by the high-performance computer control system starts to heat the area to be processed by the induction coil at the front end of the electric pulse strip processing device. Then, the traction rod is used to pull the slab from the bending device into the induction coil for holding for 10 minutes. After holding, it enters the "hot rolling + electric pulse rolling" area at the middle and rear ends. The deformation of a single hot rolling is controlled at 30%, and the total deformation is 50%. After hot rolling, the electric pulse fine rolling is performed immediately (the deformation of a single fine rolling is 10%, and the total deformation is 70%; the pulse voltage is 8V; the output current is 400A; the pulse frequency is 15000Hz; and the processing time is 60s).

[0116] (5) Defect Detection: After the electrical pulse strip processing is completed, the strip enters the online defect detection system for quality inspection. Magnetic particle testing is used, employing a fiber brush to adhere a suspension (magnetic powder, oil-based liquid, and fluorescent powder in a 3:10:1 ratio) to the strip surface in a transverse zigzag pattern. The surface is observed and sampled through a detection table, and the image signal is fed back to the high-performance computer system for recording. The corresponding signal is then transmitted to the electrical pulse micro-area defect repair system to identify several pores and microcracks on the surface of the processed part, and the identified defects are marked.

[0117] (6) Defect Repair: Move the current probe 1 and current probe 2 of the current micro-area processing device to a certain marked defect area of ​​the metal material. Apply a current once within the area of ​​the current probe. Then, move the current probe in three different directions (X, Y, Z) through the three-dimensional moving platform of the current micro-area processing device. Apply current to the area of ​​the next current probe until the marked defect is repaired. The defect repair pulse voltage is 12V; the output current is 2000A; the pulse frequency is 1500Hz; and the processing time is 10s.

[0118] (7) Tissue control: After the defect is repaired, continue to use the three-dimensional moving platform to control the movement of current probe 1 and current probe 2 in three different directions (X, Y, Z) to perform micro-tissue control on the entire material (pulse voltage: 8V; output current: 800A; pulse frequency: 1000Hz; processing time: 30s).

[0119] Corresponding performance:

[0120] Hardness: 375HV

[0121] Tensile strength: 1180MPa

[0122] Elongation: 8.8%

[0123] Example 2

[0124] Taking Cu-Ni-Sn alloys as an example, the steps include:

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

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

[0127] (3) Electro-pulse melting. Upon receiving a melting command from the high-performance computer control system, the induction coil in the electro-pulse melting system begins heating the melting chamber. When the holding temperature is reached, the mechanical stirrer in the center of the melting chamber and the pulse power supply (adjusted to either "pulse power" or "low-frequency high-peak current type") are simultaneously activated to accelerate the dispersion of the melt. After holding, the robotic arm opens the plug at the bottom of the crucible, and simultaneously, the traction rod passes through the cooling device on the outside of the crucible bottom, with the top end inserted into the groove at the bottom of the crucible to connect with the molten metal. The molten metal is pulled out to the bending device below according to the set traction speed.

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

[0129] (5) Defect Detection: After the electrical pulse strip processing is completed, the strip enters the online defect detection system for quality inspection. Magnetic particle testing is used, employing a fiber brush to adhere a suspension (magnetic powder, oil-based liquid, and fluorescent powder in a 3:10:1 ratio) to the strip surface in a transverse zigzag pattern. The surface is observed and sampled through a detection table, and the image signal is fed back to the high-performance computer system for recording. The corresponding signal is then transmitted to the electrical pulse micro-area defect repair system to identify several pores and microcracks on the surface of the processed part, and the identified defects are marked.

[0130] (6) Defect Repair: Move the current probe 1 and current probe 2 of the current micro-area processing device to a certain marked defect area of ​​the metal material. Apply a current once within the area of ​​the current probe. Then, move the current probe in three different directions (X, Y, Z) through the three-dimensional moving platform of the current micro-area processing device. Apply current to the area of ​​the next current probe until the marked defect is repaired. The defect repair pulse voltage is 12V; the output current is 1000A; the pulse frequency is 1200Hz; and the single-point processing time is 10s.

[0131] (7) Organizational control: After the defect is repaired, the three-dimensional moving platform is used to control the movement of current probe 1 and current probe 2 in three different directions (X, Y, Z) to perform micro-organic control on the entire material. The pulse voltage is 8V; the output current is 600A; the pulse frequency is 1000Hz; and the single-point processing time is 30s.

[0132] Corresponding performance:

[0133] Hardness: 355HV

[0134] Tensile strength: 1024MPa

[0135] Elongation: 12.3%

[0136] Example 3

[0137] Taking Cu-Ni-Co-Si alloys as an example, the steps include:

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

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

[0140] (3) Electro-pulse melting. Upon receiving a melting command from the high-performance computer control system, the induction coil in the electro-pulse melting system begins heating the melting chamber. When the holding temperature is reached, the mechanical stirrer in the center of the melting chamber and the pulse power supply (adjusted to either "pulse power" or "low-frequency high-peak current type") are simultaneously activated to accelerate the dispersion of the melt. After holding, the robotic arm opens the plug at the bottom of the crucible, and simultaneously, the traction rod passes through the cooling device on the outside of the crucible bottom, with the top end inserted into the groove at the bottom of the crucible to connect with the molten metal. The molten metal is pulled out to the bending device below according to the set traction speed.

[0141] (4) Strip processing. The heating command issued by the high-performance computer control system (heating rate 50℃ / min, holding temperature 920℃) starts the induction coil in the front end of the electric pulse strip processing device to heat the area to be processed. Then, the traction rod is used to pull the slab from the bending device into the induction coil for holding for 10 minutes. After the holding is completed, it enters the "hot rolling + electric pulse rolling" area in the middle and rear end. The hot rolling deformation is controlled at 50%. After the hot rolling is completed, the electric pulse fine rolling processing is carried out immediately (fine rolling deformation is 30%, pulse voltage is 6V; output current is 200A; pulse frequency is 20000Hz, processing time is 60s).

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

[0143] Corresponding performance:

[0144] Hardness: 220HV

[0145] Tensile strength: 760MPa

[0146] Elongation: 8.2%

[0147] Comparative Example 1

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

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

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

[0151] (3) Electro-pulse melting. Upon receiving a melting command from the high-performance computer control system, the induction coil in the electro-pulse melting system begins heating the melting chamber. When the holding temperature is reached, the mechanical stirrer in the center of the melting chamber and the pulse power supply (adjusted to either "pulse power" or "low-frequency high-peak current type") are simultaneously activated to accelerate the dispersion of the melt. After holding, the robotic arm opens the plug at the bottom of the crucible, and simultaneously, the traction rod passes through the cooling device on the outside of the crucible bottom, with the top end inserted into the groove at the bottom of the crucible to connect with the molten metal. The molten metal is pulled out to the bending device below according to the set traction speed.

[0152] (4) Strip processing. The heating command (heating rate 50℃ / min, holding temperature 820℃) issued by the high-performance computer control system starts to heat the area to be processed by the induction coil at the front end of the electric pulse strip processing device. Then, the traction rod is used to pull the slab from the bending device into the induction coil for holding for 10 minutes. After holding, it enters the "hot rolling + electric pulse rolling" area at the middle and rear ends. The deformation of a single hot rolling is controlled at 30%, and the total deformation is 50%. After hot rolling, the electric pulse fine rolling is performed immediately (the deformation of a single fine rolling is 10%, and the total deformation is 70%; the pulse voltage is 8V; the output current is 400A; the pulse frequency is 15000Hz; and the processing time is 60s).

[0153] (5) Micro-area microstructure control. After the electrical pulse strip processing is completed, the strip enters the online defect detection system without quality inspection. Instead, it directly enters the electrical pulse micro-area. According to the instructions, the high-precision positioning device moves along three different directions, X, Y, and Z. The micro-area heater automatically selects circular, elliptical, linear, or zigzag pulse probes to perform microstructure control on the entire strip surface (pulse voltage: 8V; output current: 800A; pulse frequency: 1000Hz; processing time: 30s).

[0154] Corresponding performance:

[0155] Hardness: 375HV

[0156] Tensile strength: 650MPa

[0157] Elongation: 2.3%.

Claims

1. A metal material intelligent continuous production device with local tissue regulation function, characterized by: The metal material intelligent continuous production device comprises a computer control system, an electric current output system, a smelting and casting system, an electric heating system, a metal material processing system, an online defect detection system and an electric current micro-region structure regulation system. The smelting and casting system is used for smelting and casting metal raw materials to obtain ingots. The electric heating system is located at the rear end of the smelting and casting system and is used for preheating the ingots. The metal material processing system is located at the rear end of the electric heating system and is used for processing the preheated ingots to obtain processed pieces. The online defect detection system is located at the rear end of the metal material processing device and comprises a high-precision image sensor and a data analysis module and is used for online detection of defects of the processed pieces. The high-precision image sensor comprises a nondestructive testing device and an image acquisition device, wherein the nondestructive testing device comprises one of an ultrasonic flaw detection device, a magnetic particle flaw detection device and an electromagnetic eddy current flaw detection device. The electric current micro-region structure regulation system comprises an electric current probe which is located at the rear end of the online defect detection system and is used for repairing the structure of the defect region of the processed pieces and regulating the microstructure of the processed pieces by applying a micro-region electric current to the defect region of the processed pieces through the electric current probe. The electric current probe comprises an electric current probe No. 1 and an electric current probe No. 2, and the electric current micro-region structure regulation system further comprises an electric current copper plate No. 1, an electric current copper plate No. 2, a cable fixing copper ring No. 1, a cable fixing copper ring No. 2, a three-axis displacement platform and a fixed platform. The rear end of the electric current copper plate No. 1 is connected with the cable fixing copper ring No. 1, and the front end of the electric current copper plate No. 1 is provided with the electric current probe No.

1. The rear end of the electric current copper plate No. 2 is connected with the cable fixing copper ring No. 2, and the front end of the electric current copper plate No. 2 is provided with the electric current probe No.

2. The cable fixing copper ring No. 1 and the cable fixing copper ring No. 2 are respectively connected with the positive pole and the negative pole of the power supply in the electric current output system.

2. The intelligent continuous production device of metal materials with local tissue regulation function according to claim 1, characterized in that: The fixed platform comprises a support and a table top located at the uppermost position of the support. The upper end of the table top is provided with a limiting plate, the electric current copper plate No. 1 is located above the table top and below the limiting plate, and the electric current copper plate No. 1 can freely move on the Y axis and limit moves on the X axis. The electric current copper plate No. 2 is fixed above the three-axis displacement platform and can move on the X, Y and Z axes along with the movement of the three-axis displacement platform. The electric current copper plate No. 2 and the three-axis displacement platform are located below the table top, the electric current probe No. 1 and the electric current probe No. 2 are respectively arranged above and below the processed piece during work, and the electric current probe No. 1 and the electric current probe No. 2 are controlled to be centered in the vertical direction. The electric current output system is used for providing output electric current for the electric current micro-region structure regulation system and the metal material processing system. The computer control system is connected with other systems and is used for controlling other systems. The computer control system is used for receiving and processing electric signals from other systems and sending accurate control instructions to each system according to the pre-recorded process parameters of the metal material and the real-time feedback information of the quality of the processed pieces to ensure the coordinated operation of the device. The output electric current of the electric current output system is selected from one of direct current, alternating current, constant current and pulse current. The power supply in the current output system is composed of high-frequency low-peak current type and low-frequency high-peak current type. 3.The intelligent continuous production device of metal materials with local tissue regulation function according to claim 1, characterized in that: The smelting and casting system comprises a smelting device, a cooling device and a bending device, the smelting device is used for smelting metal raw materials to obtain a melt, the cooling device is connected with the smelting device and is used for cooling and crystallizing the melt obtained in the smelting device to obtain an ingot, and the bending device is used for converting the ingot from a vertical direction to a horizontal direction. The smelting device comprises an insulation protective sleeve, a graphite crucible, an induction coil, a mechanical stirrer, a graphite electrode and an atmosphere protection device, the induction coil is arranged outside the graphite crucible and is used for smelting metal raw materials in the graphite crucible to obtain a melt, the mechanical stirrer is used for stirring the melt, the graphite electrode is connected with the graphite crucible and provides pulse current for the graphite crucible through an external pulse power supply, and the atmosphere protection device is used for providing atmosphere protection for the melt in the graphite crucible. The mechanical stirrer is made of stainless steel-graphite clad material. The cooling device comprises a flow guide pipe and a water-cooled crystallizer, the flow guide pipe is connected with a liquid outlet of the graphite crucible, and the melt in the graphite crucible flows into the water-cooled crystallizer through the flow guide pipe to be cooled and crystallized to obtain an ingot. The water-cooled crystallizer comprises a mold and cooling water channels arranged outside the mold, the number of the cooling water channels decreases from top to bottom, forming a "inverted T-shaped" cooling area, and the number of adjacent cooling water channels is 3:2~1.

5. The bending device comprises three rollers, and the three rollers are connected with a power supply.

4. The intelligent continuous production device for metal materials with local tissue regulation function according to claim 1, characterized in that: The electric heating system comprises two graphite pressing sheets, which are arranged in an upper and lower distribution mode and are located above and below the ingot during operation. The metal material processing system comprises sequentially connected processing equipment A and processing equipment B and a current application device, the processing equipment A is used for hot processing of the preheated ingot, the processing equipment B is used for cold processing of the processed material, and the current application device comprises a current delivery electrode for providing current during cold processing of the processed material. The processing equipment A and the processing equipment B are selected from one of a rolling mill, a drawing device, a forging device and an extrusion device. The current application device adopts high-frequency low-peak current, and the positive and negative electrodes of the high-frequency low-peak current are directly connected with upper and lower rollers of a processing area of the processing equipment B.

5. The metal material intelligent continuous production device with local tissue regulation function according to claim 1, characterized in that: The shape of the head surface of the current probe No. 1 and the current probe No. 2 is selected from one of a circle, a cone, a cross, and a single line, and the size of the head surface is 0.01 mm 2 10 cm 2 ; The precision range of the three-axis displacement platform is 0~0.1mm.

6. The intelligent continuous production device for metal materials with local tissue regulation function according to any one of claim 4, characterized in that: The metal material intelligent continuous production device further comprises a water-cooled circulation system, which is arranged at the rear end of the processing equipment A of the metal material processing system and is used for cooling the processed material processed by the processing equipment A. The metal material intelligent continuous production device further comprises a cooling system, which is arranged at the rear end of the current micro-zone tissue regulation system and comprises a spray gun for cooling the defect area processed by the current micro-zone tissue regulation system.

5. The metal material intelligent continuous production device with local tissue regulation function according to claim 1, characterized in that: The precision range of the three-axis displacement platform is 0~0.1mm. The metal material intelligent continuous production device further comprises a water-cooled circulation system, which is arranged at the rear end of the processing equipment A of the metal material processing system and is used for cooling the processed material processed by the processing equipment A. The metal material intelligent continuous production device further comprises a cooling system, which is arranged at the rear end of the current micro-zone tissue regulation system and comprises a spray gun for cooling the defect area processed by the current micro-zone tissue regulation system. The metal material intelligent continuous production device further comprises a temperature monitoring control device, the temperature monitoring control device is composed of a plurality of thermocouple temperature sensors, the thermocouple temperature sensors are used for real-time monitoring of the temperature in the continuous production process, and feedback to the computer control system; The metal material intelligent continuous production device further comprises a traction system, the traction system comprises a traction rod and an ingot copper plate; wherein the ingot copper plate is in contact with the melt, and the melt flows into the water-cooled crystallizer through the flow guide pipe at a certain traction speed under the action of the traction rod to obtain the cast ingot, and the subsequent cast ingot continues to pass through other systems in turn under the traction of the traction system.

7. A method for intelligent and continuous production of metal materials with local tissue regulation function, characterized in that: The metal material intelligent continuous production device of any one of claims 1-6 is applied, first, the metal raw material is melted and cast to obtain a cast ingot, the cast ingot is preheated, then the preheated cast ingot is processed to obtain a processed piece, the processed piece is subjected to online defect detection to mark the defect area, and the defect area is subjected to micro-area current to repair the defect.

8. The metal material intelligent continuous production method with local structure regulation function according to claim 7, characterized in that: The metal material is selected from any one of copper alloy, titanium alloy, magnesium alloy, aluminum alloy and iron alloy; The shape of the metal material is selected from one of plate, strip, wire, pipe and special-shaped material; Before melting, the initial information and instruction parameter information of the metal material are input into the computer control system; The melting process is that the metal raw material is heated to Ts+(50-100)℃ to obtain a melt, and then is kept at Ts+(30-80)℃, and mechanical stirring and electric pulse are applied simultaneously during the keeping process; The parameters of the electric pulse applied during the smelting are: pulse current frequency 10-600 Hz, current density 1-100 A / cm 2 ; The mechanical stirring speed is controlled at 1-400 r / min during melting; The casting process is that the melt passes through the water-cooled crystallizer with "inverted T-shaped" cooling zone from top to bottom at a traction speed of 0.01-1 m / min to obtain a cast ingot; The process of processing the preheated cast ingot is that hot working is first performed, and then cold working is performed under the assistance of electric pulse, the parameters during hot working are temperature: 0.8-0.85Tm, single-pass deformation amount: 0-30%, and total deformation amount: 50-90%, and the parameters during cold working are single-pass deformation amount: 0-20%, and total deformation amount: 50-90%; The hot working is selected from one of hot rolling, hot drawing, hot forging, hot rotary forging, hot radial forging, hot extrusion and hot upsetting, and the cold working is selected from one of cold rolling, cold drawing, cold forging, cold rotary forging, cold radial forging, cold extrusion and cold upsetting; The electric pulse parameters during cold working are pulse voltage: 6-12 V, output current: 200-1000 A, pulse frequency: 5000-20000 Hz, and processing time: 0.01-300 s.

9. The metal material intelligent continuous production method with local structure regulation function according to claim 7, characterized in that: The process of identifying the defect area by the online detection is: continuously acquiring the surface image of the workpiece in the detection area by the non-destructive testing device; and feeding the acquired image to the data analysis module by the image acquisition device, determining the surface and internal defects of the workpiece according to the surface image acquired by the image acquisition device, and identifying the determined defect area; The defects include pores, micro-cracks and stress concentration; The process of applying micro-current to the defect area is: moving the current probe No. 1 and the current probe No. 2 of the current micro-area organization regulation system to a certain identified defect area of the metal material respectively, applying current to the current probe area range once, then moving the current probe to apply current to the next current probe area range, and repeating the above process until the identified defect area is processed. When the defect is a pore or a crack, the parameters of the current applied to the defect area are: pulse voltage: 6-12V; output current: 2000-5000A; pulse frequency: 50-2000Hz; when the defect is stress concentration, the parameters of the current applied to the defect area are: pulse voltage: 6-12V; output current: 2000-3000A; pulse frequency: 50-2000Hz.

10. The intelligent continuous production method of metal material with local organization regulation function according to claim 7 or 9, characterized in that: The micro-current applied to the metal material after defect repair is subjected to organization regulation. The process of regulating the micro-current applied to the metal material after defect repair is: according to the designed target organization structure, moving the current probe No. 1 and the current probe No. 2 of the current micro-area organization regulation system to a certain organization regulation area of the metal material respectively, applying current to the current probe area range once, then moving the current probe to apply current to the next current probe area range, and repeating the above process until the organization regulation area is processed, and the parameters of the micro-current are: pulse voltage: 6-12V; output current: 500-2000A; pulse frequency: 50-2000Hz; and processing time: 0.01-300s.

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