Corrosion-resistant and high-performance aluminum alloy cable material as well as preparation method and application thereof

Abstract

The invention discloses a corrosion-resistant and high-performance aluminum alloy cable material as well as a preparation method and application thereof, and relates to the technical field of aluminum alloy preparation. The component formula of the conductor is Al-xMg-ySi-zNi-mCe-nSc-qY, x is larger than or equal to 0.05 and smaller than or equal to 0.3, y is larger than or equal to 0.6 and smaller than or equal to 1.4, z is smaller than or equal to 0.35, m is larger than or equal to 0.01 and smaller than or equal to 0.2, n is larger than or equal to 0.03 and smaller than or equal to 0.2, q is larger than or equal to 0.04 and smaller than or equal to 0.1, iron is a main impurity element in the alloy, and the content of the iron is not larger than 0.1%. The aluminum alloy cable material with excellent mechanical properties (the tensile strength is larger than or equal to 122 MPa, and the elongation is larger than or equal to 14%), electrical properties (the conductivity is larger than or equal to 62% IACS) and corrosion resistance (the maximum IGC depth is smaller than 100 micrometers) is prepared by adopting the technological method of flame direct injection smelting, synchronous water quenching pull casting, cold forming machining and non-isothermal aging synchronous heat treatment, and the aluminum alloy cable material is suitable for aluminum alloy cables. The method is short in technological process, good in cable quality, high in corrosion resistance and wide in application prospect.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy preparation technology, and in particular to a corrosion-resistant, high-performance aluminum alloy cable material, its preparation method, and its application. Background Technology

[0002] The research and application of novel corrosion-resistant aluminum alloy cables have demonstrated significant value in multiple dimensions, including power transmission, economic efficiency, and ecological sustainability. This not only reflects innovative breakthroughs in materials science but also represents a crucial path to address resource constraints and promote the construction of a green energy system. Against the backdrop of the global cable industry's development towards high reliability, long lifespan, and full-cycle cost control, corrosion-resistant cables have become a rigid requirement for laying cables in harsh environments such as industrial buildings, coastal areas, chemical industrial parks, and new energy power plants. Their performance directly affects power grid safety and operational efficiency.

[0003] Compared to the limitations of traditional pure aluminum cables, such as weak creep resistance and poor flexibility, aluminum alloy cables achieve a comprehensive performance improvement by introducing alloying elements such as rare earth, magnesium, copper, and silicon into the aluminum matrix, combined with advanced compaction and annealing technologies. Of particular note is the significant enhancement of the cable's adaptability to harsh environments through the corrosion-resistant aluminum alloy design. Its surface can form a dense and self-healing oxide film, which, combined with the micro-alloying effect of rare earth elements, significantly improves its resistance to chemical and electrochemical corrosion. In corrosive environments containing sulfur and humidity, it outperforms pure aluminum and even some copper materials, thereby extending the cable's service life under complex operating conditions and providing crucial material support for high-risk corrosion scenarios such as coastal wind power, cross-sea bridges, and underground integrated pipe corridors.

[0004] In terms of mechanical and connection performance, aluminum alloy cables also perform excellently. Taking the AA8000 series as an example, its creep resistance is 300% higher than that of pure aluminum, effectively alleviating the problem of connection loosening caused by temperature fluctuations and reducing the risk of increased contact resistance and overheating. At the same time, its good flexibility and lightweight characteristics make laying more convenient and reduce the requirements for supporting structures accordingly.

[0005] In terms of economic benefits, aluminum alloy cables offer significant cost advantages. Aluminum resources are abundant and its price is far lower than copper, resulting in procurement costs that are 15-60% lower than copper cables with equivalent electrical performance. Furthermore, the lighter weight saves 20-40% on installation and transportation costs. From a life-cycle perspective, its excellent corrosion resistance and creep resistance reduce system maintenance frequency and long-term operating costs, with an expected service life of over 40 years. Its overall economic efficiency is outstanding, making it particularly suitable for power infrastructure with stringent requirements for long-term reliable operation.

[0006] As the core material of cables, aluminum alloys directly determine transmission efficiency and operational safety. Traditional manufacturing processes include smelting and alloying, casting, hot working, cold deformation, and heat treatment. Based on pure aluminum ingots (≥99.7%), intermediate alloys are added, and the mixture is smelted at 720-750℃. It is then purified by sodium-free refining agents and argon blowing, supplemented by ultrasonic or ceramic filtration to improve melt quality. Subsequently, billets are obtained through continuous casting and rolling (initial rolling 480-520℃, final rolling 250-300℃) or hot extrusion (410-450℃). Cold drawing is a key step in improving strength, with a pass reduction rate controlled at 15-20%. In recent years, techniques involving intense plastic deformation (such as continuous ECAE) have also been introduced to further refine the grain size. Finally, the microstructure and properties are controlled through aging treatment (such as single-stage aging at 270-340℃ for 20-40 hours, or double-stage aging process) and finished product annealing (330-370℃ for 1-3 hours) to ensure that the cable material has both high strength and excellent conductivity. However, existing corrosion-resistant aluminum alloy cable manufacturing technology has the disadvantages of long production process and poor corrosion resistance.

[0007] Aluminum alloy cables are an ideal choice for smart grids and various demanding applications. In smart grid construction, their lightweight characteristics reduce laying costs and complexity, while their corrosion resistance directly ensures the high reliability of energy transmission and monitoring systems during long-term operation. Furthermore, in applications with extremely high corrosion resistance requirements, such as new energy power plants, industrial buildings, and humid or sulfur-containing environments, they demonstrate a longer service life and lower maintenance requirements compared to traditional materials. The development and promotion of corrosion-resistant cables not only responds to the urgent need for cable durability in specific engineering scenarios but also drives the growth of related manufacturing and R&D activities, promoting the overall technological upgrading and industrial structure optimization of the cable industry. Summary of the Invention

[0008] To address the above shortcomings, this invention provides a corrosion-resistant, high-performance aluminum alloy cable material, its preparation method, and its application, solving the problems of long production processes and poor corrosion resistance in existing corrosion-resistant aluminum alloy cable manufacturing technologies. The specific technical solution is as follows: A method for preparing a corrosion-resistant, high-performance aluminum alloy cable material, wherein the nominal composition of the aluminum alloy cable material is Al-xMg-ySi-zNi-mCe-nSc-qY, wherein 0.05≤x≤0.3, 0.6≤y≤1.4, z≤0.35, 0.01≤m≤0.4, 0.03≤n≤0.2, and 0.04≤q≤0.1; The method for preparing the aluminum alloy cable material includes: Step S1, Ingredients: Weigh each raw material component according to the mass ratio; Step S2, direct flame injection smelting: Place each raw material component in a smelting furnace and smelt it using direct flame injection; Step S3, Refining: Add refining agent to the smelting furnace for refining; Step S4, Synchronous Water Quenching Casting: The refined melt is transferred into a buffer furnace. The bottom of the buffer furnace is equipped with an aluminum alloy wire rod forming mold. The mold is made of high-strength graphite, steel, other heat-resistant metals or alloys. The aluminum alloy wire rod forming mold has a through hole. The center line of the through hole is parallel to the bottom of the buffer furnace. One end of the through hole is connected to the melt inside the buffer furnace, and the other end leads to the outside of the buffer furnace. The height difference between the molten liquid level in the buffer furnace and the center line of the through hole of the aluminum alloy wire rod forming mold is maintained, while the furnace temperature is controlled to be kept at 690-710 ℃. Then, the opening of the mold through hole is opened, and the aluminum alloy liquid flows slowly from one end of the mold through hole to the other end. The aluminum alloy liquid that just flows out is instantly and rapidly water-quenched to form a wire rod. While water-quenching and casting, the cooled end of the wire rod is wound around an automatic take-up machine. The rotation speed of the take-up machine is controlled so that the wire rod is slowly pulled out from the through hole of the mold to obtain the aluminum alloy wire rod. Step S5, cold forming process: The aluminum alloy wire rod is cold rolled and cold drawn to obtain a hardened aluminum alloy wire; Step S6, Non-isothermal aging synchronous heat treatment: The hard aluminum alloy conductor is subjected to non-isothermal aging (NIA) synchronous treatment. The specific process is as follows: the aging start temperature is 95-120℃, the heating rate is 15-25℃ / h, the final temperature is 200-250℃, and it is taken out at the target temperature and immediately cooled in cold water to obtain the corrosion-resistant, high-performance aluminum alloy cable material.

[0009] Further, in step S1, the ingredients are: low-iron industrial pure aluminum is weighed according to the mass ratio as the aluminum alloy base material, the industrial pure aluminum is industrial pure aluminum with an Fe mass percentage of no more than 0.1%, Si, Mg, Ni, Ce, Sc, Y aluminum-based master alloys or elements are weighed as alloying agents, and hexachloroethane is used as a refining agent; these industrial pure aluminum, aluminum-based master alloys or elements can be in the form of blocks, granules, powders or profiles.

[0010] Further, in step S2, the direct flame injection smelting involves placing the low-iron aluminum ingot from step S1 into a smelting furnace, introducing a mixture of natural gas and air into the furnace, igniting it, and directly injecting the high-temperature gas generated by the flame onto the surface of the material for heating. After the temperature is raised to 700-720℃ and the material is completely melted, it is kept at that temperature for 5-10 minutes. Then, alloying agents of Si, Mg, Ni, Ce, Sc, and Y are added in sequence. Each time an alloying agent is added, the mixture is stirred for 3-5 minutes and allowed to stand for 10-15 minutes.

[0011] Further, in step S3, the refining process involves adding the refining agent hexachloroethane (C2Cl6) to the smelting furnace. The amount of hexachloroethane added is 0.2-0.6% of the total mass of the alloy. After stirring for 5-10 minutes and letting it stand for 10-15 minutes, the slag is removed.

[0012] Furthermore, in step S4, the refined melt is transferred into a buffer furnace, where the temperature of the melt is controlled at 700-720°C by the flame generated by the combustion of natural gas and air.

[0013] Furthermore, in step S4, the diameter of the aluminum alloy rod is 6-12mm.

[0014] Furthermore, in step S5, the cold rolling passes are ≥10 times and the deformation is ≥85%; the cold drawing passes are ≥5 times and the deformation is ≥15%.

[0015] The present invention also provides a corrosion-resistant, high-performance aluminum alloy cable material.

[0016] The present invention also provides a cable containing the corrosion-resistant, high-performance aluminum alloy cable material obtained by the above preparation method.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention employs a process matching the Al-xMg-ySi-zNi-mCe-nSc-qY aluminum alloy formulation, consisting of "flame direct injection melting → simultaneous water quenching casting → cold forming → non-isothermal aging simultaneous heat treatment." Through the synergistic effect of these processes, under suitable process parameters, uniformly distributed fine precipitated phases are formed in the aluminum alloy cable material matrix, thereby improving the strength of the aluminum alloy while achieving high corrosion resistance. Testing shows that the aluminum alloy cable material of this invention has a tensile strength ≥122MPa, elongation ≥14%, conductivity ≥62%IACS, and a maximum IGC depth <100μm, providing important technical support for the development of energy-saving, corrosion-resistant, and high-efficiency high-performance aluminum alloy cable material manufacturing technology.

[0018] 2. This invention employs trace alloying elements such as Ni, Ce, Sc, and Y, which, while controlling the morphology, particle size, and dispersibility of the second phase, effectively refine the grains of the aluminum alloy. The cold forming process increases the dislocation density within the alloy and reduces the nucleation energy of the aluminum alloy and the second phase, resulting in a significantly refined grain structure in the cable material after simultaneous heat treatment with non-isothermal aging annealing, thus achieving better mechanical properties.

[0019] 3. This invention employs non-isothermal aging annealing (NIA), achieving rational performance control through a combination of different cooling rates and starting points within a continuous temperature range. The grain boundary structure of NIA alloys is similar to that of isothermal aging alloys, but the grain boundary particles are discontinuous, and there are no obvious grain boundary precipitates, thus improving the alloy's corrosion resistance. The resulting high corrosion resistance (maximum IGC depth ≤ 100 μm) will demonstrate a significant corrosion resistance effect compared to traditional aluminum alloy cable materials in heavily polluted industrial environments caused by harmful gas emissions, as well as in the unique marine environments surrounding the ocean. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0021] Figure 1 This is a flowchart illustrating the manufacturing process of the aluminum alloy cable material according to the present invention. Figure 2 This is a flowchart of the non-isothermal aging treatment process for aluminum alloy cable materials according to the present invention; Figure 3 The tensile strength and elongation of the aluminum alloy cable materials prepared in Examples 1-5 and Comparative Examples 1-7 of this invention are shown in the figure. Figure 4 The conductivity diagrams are of the aluminum alloy cable materials prepared in Examples 1-5 and Comparative Examples 1-7 of this invention. Figure 5 The maximum IGC depth of the aluminum alloy cable materials prepared in Examples 1-5 and Comparative Examples 1-7 of this invention is shown in the diagram. Figure 6 This is a schematic diagram of the process of simultaneous water quenching and casting of the aluminum alloy molten material after entering the buffer furnace according to the present invention. Detailed Implementation

[0022] The specific embodiments of the present invention will be described in detail below, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments.

[0023] Example 1 The manufacturing process of Al-0.2Mg-1.2Si-0.3Ni-0.02Ce-0.1Sc-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0024] The preparation steps of this conductor are as follows: Step S1: Weigh 409.68 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 23.36 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, 1.6 kg of Al-6Ce master alloy, 6 kg of Al-8Sc master alloy, 5.76 kg of Al-5Y master alloy, and 0.96 kg of hexachloroethane.

[0025] Step S2: Direct Flame Injection Melting The low-iron aluminum ingot from step S1 is placed in a pilot-scale smelting furnace. A mixture of natural gas and air is introduced into the furnace, and the flame generated by ignition heats the material. The temperature is raised to 720 ℃ and the material is completely melted. The temperature is then maintained for 5 minutes. Alloying agents of Mg, Si, Ni, Ce, Sc and Y are added in sequence. Each time an alloying agent is added, the mixture is stirred for 3 minutes and then allowed to stand for 10 minutes.

[0026] Step S3: Refining Add hexachloroethane (C2Cl6) from step S1 to the smelting furnace, stir for 5 minutes, let stand for 10 minutes, then remove slag. Next, open the outlet of the smelting furnace to allow the melt to flow into a buffer furnace. In the buffer furnace, the melt temperature is controlled at 720℃ by the flame generated from the combustion of natural gas and air. Figure 6 As shown, the bottom of the buffer furnace is provided with an aluminum alloy wire rod forming mold, and the aluminum alloy wire rod forming mold is provided with a through hole. The center line of the through hole is parallel to the bottom of the buffer furnace. One end of the through hole is connected to the melt inside the buffer furnace, and the other end leads to the outside of the buffer furnace.

[0027] Step S4: Synchronous water quenching and casting The height difference between the molten metal surface in the buffer furnace and the centerline of the through hole in the aluminum alloy wire rod forming mold is maintained, while the furnace temperature is controlled to be kept at 690-710℃. Then, the opening of the mold through hole is opened, allowing the molten aluminum alloy to slowly flow from one end of the mold through hole to the other end due to the pressure difference generated by the height difference of the liquid surface, forming a wire rod with a diameter of 6-12mm. The part of the aluminum alloy wire rod that just flows out is instantly and rapidly water-quenched. At the same time as water quenching casting, the cooled end of the wire rod is wound around an automatic take-up machine. The rotation speed of the take-up machine is controlled to slowly pull the wire rod out of the mold through hole, so as to achieve the purpose of synchronous water quenching casting, and obtain the aluminum alloy wire rod.

[0028] Step S5: Cold forming process The aluminum alloy rod obtained in step S4 is subjected to cold rolling and cold drawing, with 14 cold rolling passes and ≥8 cold drawing passes, thereby preparing aluminum alloy cable material in the hard state (Y state).

[0029] Step S6: Non-isothermal aging heat treatment The aluminum alloy cable material obtained in step S5 is subjected to aging treatment, specifically, the aluminum alloy cable material is treated according to the following settings: the initial aging temperature is set at 100℃, the heating rate is 20℃ / h, and the final temperature is 220℃. At the target temperature, it is removed and immediately cooled in cold water to produce a high-performance aluminum alloy cable material.

[0030] Example 2 The manufacturing process of Al-0.2Mg-1.2Si-0.3Ni-0.02Ce-0.1Sc-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0031] The preparation steps of this conductor are as follows: Step S1: Weighing, this step is exactly the same as in Example 1.

[0032] Step S2: Direct Flame Injection Melting The low-iron aluminum ingot from step S1 is placed in a pilot-scale smelting furnace. A mixture of natural gas and air is introduced into the furnace, and the flame generated by ignition heats the material. The temperature is raised to 710°C until the material is completely melted, and then held at that temperature for 8 minutes. Alloying agents of Mg, Si, Ni, Ce, Sc, and Y are added in sequence. Each time an alloying agent is added, the mixture is stirred for 4 minutes and then allowed to stand for 12 minutes.

[0033] Step S3: Refining Add hexachloroethane (C2Cl6) from step S1 to the smelting furnace, stir for 8 minutes, let stand for 12 minutes, then skim off the slag. Next, open the outlet of the smelting furnace to allow the melt to flow into the buffer furnace. In the buffer furnace, the melt temperature is controlled at 710℃ by the flame generated from the combustion of natural gas and air. Figure 6 As shown, the bottom of the buffer furnace is provided with an aluminum alloy wire rod forming mold, and the aluminum alloy wire rod forming mold is provided with a through hole. The center line of the through hole is parallel to the bottom of the buffer furnace. One end of the through hole is connected to the melt inside the buffer furnace, and the other end leads to the outside of the buffer furnace.

[0034] Step S4: Synchronous water quenching and casting The height difference between the molten metal surface in the buffer furnace and the centerline of the through hole in the aluminum alloy wire rod forming mold is maintained, while the furnace temperature is controlled to be kept at 700 ℃. Then, the opening of the mold through hole is opened, allowing the molten aluminum alloy to slowly flow from one end of the mold through hole to the other end by means of the pressure difference generated by the height difference of the liquid surface, forming a wire rod with a diameter of 8 mm. The part of the aluminum alloy wire rod that just flows out is instantly and rapidly water-quenched. At the same time as water quenching casting, the cooled end of the wire rod is wound around an automatic take-up machine. The rotation speed of the take-up machine is controlled to slowly pull the wire rod out of the mold through hole, so as to achieve the purpose of synchronous water quenching casting, and obtain the aluminum alloy wire rod.

[0035] Step S5: Cold forming process The aluminum alloy rod obtained in step S4 is subjected to cold rolling and cold drawing, with 12 cold rolling passes and 6 cold drawing passes, thereby preparing aluminum alloy cable material in the hard state (Y state).

[0036] Step S6: Non-isothermal aging heat treatment The aluminum alloy cable material obtained in step S5 is subjected to aging treatment, specifically, the aluminum alloy cable material is treated according to the following settings: the initial aging temperature is set at 100℃, the heating rate is 15℃ / h, and the final temperature is 200℃. At the target temperature, it is removed and immediately cooled in cold water to produce a high-performance aluminum alloy cable material.

[0037] Example 3 The manufacturing process of Al-0.2Mg-1.2Si-0.1Ni-0.02Ce-0.1Sc-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0038] The preparation steps of this conductor are as follows: Step S1: Weigh 425.68 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 23.36 kg of Al-20Si master alloy, 8 kg of Al-6Ni master alloy, 1.6 kg of Al-6Ce master alloy, 6 kg of Al-8Sc master alloy, 5.76 kg of Al-5Y master alloy, and 0.96 kg of hexachloroethane.

[0039] The other preparation steps are exactly the same as in Example 1.

[0040] Example 4 The manufacturing process of Al-0.2Mg-1.2Si-0.3Ni-0.02Ce-0.2Sc-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0041] The preparation steps of this conductor are as follows: Step S1: Weigh 403.68 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 23.36 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, 1.6 kg of Al-6Ce master alloy, 12 kg of Al-8Sc master alloy, 5.76 kg of Al-5Y master alloy, and 0.96 kg of hexachloroethane.

[0042] The other preparation steps are exactly the same as in Example 1.

[0043] Example 5 The manufacturing process of aluminum alloy cable material (Al-0.2Mg-1.2Si-0.3Ni-0.02Ce-0.1Sc-0.02Y) is as follows: Figure 1 As shown.

[0044] The preparation steps of this conductor are as follows: Step S1: Weigh 413.52 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 23.36 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, 1.6 kg of Al-6Ce master alloy, 6 kg of Al-8Sc master alloy, 1.92 kg of Al-5Y master alloy, and 0.96 kg of hexachloroethane.

[0045] The other preparation steps are exactly the same as in Example 1.

[0046] Comparative Example 1 The manufacturing process of Al-0.2Mg-1.6Si-0.3Ni-0.02Ce-0.1Sc-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0047] This comparative example aims to examine the effect of alloy formulation on alloy properties. The alloy formulation uses a Si content exceeding the scope of the claims, specifically a Si content of 1.6% by mass in the alloy. Compared with Example 1, except for the different ingredient preparation in step S1, all other preparation process parameters are exactly the same.

[0048] Step S1: Weigh 400.08 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 32.96 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, 1.6 kg of Al-6Ce master alloy, 6 kg of Al-8Sc master alloy, 5.76 kg of Al-5Y master alloy, and 0.96 kg of hexachloroethane.

[0049] Comparative Example 2 The manufacturing process of Al-0.2Mg-0.4Si-0.3Ni-0.02Ce-0.1Sc-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0050] This comparative example aims to examine the effect of alloy formulation on alloy properties. The alloy formulation uses a Si content lower than the scope of the claims, i.e., Si is formulated at a mass percentage of 0.4% in the alloy. Compared with Example 1, except for the different ingredients in step S1, all other preparation process parameters are exactly the same.

[0051] Step S1: Weigh 428.88 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 4.16 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, 1.6 kg of Al-6Ce master alloy, 6 kg of Al-8Sc master alloy, 5.76 kg of Al-5Y master alloy, and 0.96 kg of hexachloroethane.

[0052] Comparative Example 3 The manufacturing process of Al-0.2Mg-1.2Si-0.3Ni aluminum alloy cable material is as follows: Figure 1 As shown.

[0053] This comparative example aims to examine the effect of alloy formulation on alloy properties. No rare earth elements (Ce, Sc, Y) were added to the alloy formulation, and the proportions of other alloying elements in the alloy were exactly the same as in Example 1. Compared with Example 1, except for the different ingredient preparation in step S1, the rest of the preparation process was exactly the same.

[0054] Step S1: Weigh 423.04 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 23.36 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, and 0.96 kg of hexachloroethane.

[0055] Comparative Example 4 The manufacturing process of Al-0.2Mg-1.2Si-0.3Ni-0.02Ce-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0056] The preparation steps of this conductor are as follows: Step S1: Weigh 415.68 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 23.36 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, 1.6 kg of Al-6Ce master alloy, 5.76 kg of Al-5Y master alloy, and 2.4 kg of hexachloroethane.

[0057] Except for the lack of Sc in the raw materials, the other raw material ratios and preparation steps are exactly the same as in Example 1.

[0058] Comparative Example 5 The manufacturing process of Al-0.2Mg-1.2Si-0.3Ni-0.02Ce-0.1Sc aluminum alloy cable material is as follows: Figure 1 As shown.

[0059] The preparation steps of this conductor are as follows: Step S1: Weigh 415.44 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 23.36 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, 1.6 kg of Al-6Ce master alloy, and 2.4 kg of hexachloroethane.

[0060] Except for the lack of Y in the raw material, the other raw material ratios and preparation steps are exactly the same as in Example 1.

[0061] Comparative Example 6 The manufacturing process of Al-0.2Mg-1.2Si-0.3Ni-0.1Sc-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0062] The preparation steps of this conductor are as follows: Step S1: Weigh 411.28 kg of industrial pure aluminum, 9.60 kg of Al-10Mg master alloy, 23.36 kg of Al-20Si master alloy, 24 kg of Al-6Ni master alloy, 6 kg of Al-8Sc master alloy, 5.76 kg of Al-5Y master alloy, and 0.96 kg of hexachloroethane.

[0063] Except for the lack of Ce in the raw materials, the other raw material ratios and preparation steps are exactly the same as in Example 1.

[0064] Comparative Example 7 The manufacturing process of Al-0.2Mg-1.2Si-0.3Ni-0.02Ce-0.1Sc-0.06Y aluminum alloy cable material is as follows: Figure 1 As shown.

[0065] The preparation steps of this conductor are as follows: Step S1: Weighing, this step is exactly the same as in Example 1.

[0066] Step S2: Direct flame smelting, which is exactly the same as in Example 1.

[0067] Step S3: Refining, which is exactly the same as in Example 1.

[0068] Step S4: Synchronous water quenching and casting, this step is exactly the same as in Example 1.

[0069] Step S5: Cold forming process, which is exactly the same as in Example 1.

[0070] Step S6: Isothermal aging heat treatment The aluminum alloy cable material obtained in step S5 is subjected to aging annealing treatment, that is, the aluminum alloy cable material is heated to 260 ℃, held at that temperature for 6 h, and then cooled in the furnace.

[0071] Except for step S6, which is isothermal aging heat treatment, the other raw material ratios and preparation methods are the same as in Example 1.

[0072] The alloy formulations for each embodiment and comparative example are shown in Table 1: Table 1. Alloy formulations (kg) for the examples and comparative examples The main mechanical properties, electrical conductivity, and maximum IGC depth of the aluminum alloys obtained in the above embodiments and comparative examples are shown in Table 2: Table 2 shows the mechanical properties, electrical conductivity, and maximum IGC depth of the prepared aluminum alloy cable materials at room temperature (20℃). As shown in Table 2, Figure 3 , Figure 4 , Figure 5 As shown, under the conditions of scientific formulation and matching preparation process, the high-conductivity aluminum alloy cable materials in Examples 1-5 can simultaneously meet the requirements of GB / T30552-2014 in terms of mechanical and electrical properties.

[0073] Figure 3 The figures show the tensile strength and elongation of the aluminum alloy cable materials prepared in Examples 1-5 (Figures 1-5) and Comparative Examples 1-7 (Figures 6-13). The figures show that the soft tensile strength of the aluminum alloy cable materials in all examples is above 120 MPa, and the elongation is ≥14%, both of which are within the range specified by the national standard. However, the plasticity of Comparative Examples 1 and 3 is lower and does not meet the standard requirement (≥10%). Although the plasticity of Comparative Example 2 is higher, its tensile strength does not meet the standard requirement (≥98 MPa).

[0074] Figure 4 The figures show the conductivity of aluminum alloy cable materials prepared in Examples 1-5 (1-5 in the figures) and Comparative Examples 1-7 (6-13 in the figures) of the present invention. The figures show that the conductivity of aluminum alloy cable materials in all examples is ≥62% IACS, while the conductivity of Comparative Example 1 in the comparative examples is <61% IACS, which is not within the range specified by the standard (≥61% IACS).

[0075] Figure 5 The figures show the maximum IGC depth of the aluminum alloy cable materials prepared in Examples 1-5 (Figures 1-5) and Comparative Examples 1-7 (Figures 6-13) of the present invention. The figures show that the maximum IGC depth of the aluminum alloy cable materials in all examples is <100μm, while the maximum IGC depth of the aluminum alloy cable materials in the comparative examples is >150μm.

[0076] Furthermore, the corrosion resistance of this aluminum alloy cable material is significantly better than that of the comparative examples. Comparative Example 1, due to its excessively high Si content, resulted in a higher proportion of the second phase in the alloy, limiting its elongation and corrosion resistance, thus falling below the national standard. Comparative Example 2, due to its excessively low Si content, reduced the strengthening effect of the second phase, resulting in tensile strength that did not meet the national standard requirements; however, its higher Mg / Si ratio made it more corrosion-resistant than Comparative Example 1. Comparative Example 3, due to the absence of rare earth elements, reduced the grain-refining effect of the alloying elements, leading to slightly lower plasticity and a higher maximum IGC depth. Comparative Examples 3, 4, 5, and 6 demonstrate that only the combined effect of Ce, Sc, and Y can achieve superior mechanical and corrosion resistance. Comparative Example 7 shows that compared to isothermal aging heat treatment, the non-isothermal aging annealing treatment used in this invention provides better mechanical and corrosion resistance. In summary, the alloy cable materials prepared in the comparative examples cannot simultaneously meet the national standard requirements for aluminum alloy cable materials for cables in terms of tensile strength, elongation, and conductivity, or their corrosion resistance is relatively low.

[0077] The foregoing description of specific exemplary embodiments of the invention is for illustrative and explanatory purposes. These descriptions are not intended to limit the invention to the precise forms disclosed, and it will be apparent that many changes and variations can be made in accordance with the foregoing teachings. The exemplary embodiments were chosen and described in order to explain the specific principles of the invention and its practical application, thereby enabling those skilled in the art to implement and utilize various different exemplary embodiments of the invention, as well as various different choices and variations. The scope of the invention is intended to be defined by the claims and their equivalents.

Claims

1. A method for preparing a corrosion-resistant, high-performance aluminum alloy cable material, characterized in that, The nominal composition of the aluminum alloy cable material is Al-xMg-ySi-zNi-mCe-nSc-qY, where 0.05≤x≤0.3, 0.6≤y≤1.4, z≤0.35, 0.01≤m≤0.4, 0.03≤n≤0.2, and 0.04≤q≤0.

1. The method for preparing the aluminum alloy cable material includes: Step S1, Ingredients: Weigh each raw material component according to the mass ratio; Step S2, direct flame injection smelting: Place each raw material component in a smelting furnace and smelt it using direct flame injection; Step S3, Refining: Add refining agent to the smelting furnace for refining; Step S4, Synchronous water quenching casting: The refined melt is transferred into a buffer furnace. The bottom of the buffer furnace is provided with an aluminum alloy wire rod forming mold. The aluminum alloy wire rod forming mold is provided with a through hole. The center line of the through hole is parallel to the bottom of the buffer furnace. One end of the through hole is connected to the melt inside the buffer furnace, and the other end leads to the outside of the buffer furnace. The height difference between the molten liquid level in the buffer furnace and the center line of the through hole of the aluminum alloy wire rod forming mold is maintained, while the furnace temperature is controlled to be kept at 690-710 ℃. Then, the opening of the mold through hole is opened, and the aluminum alloy liquid flows slowly from one end of the mold through hole to the other end. The aluminum alloy liquid that just flows out is instantly and rapidly water-quenched to form a wire rod. While water-quenching and casting, the cooled end of the wire rod is wound around an automatic take-up machine. The rotation speed of the take-up machine is controlled so that the wire rod is slowly pulled out from the through hole of the mold to obtain the aluminum alloy wire rod. Step S5, cold forming process: The aluminum alloy wire rod is cold rolled and cold drawn to obtain a hardened aluminum alloy wire; Step S6, Non-isothermal aging synchronous heat treatment: The hard aluminum alloy conductor is subjected to non-isothermal aging synchronous treatment. The specific process is as follows: the aging start temperature is 95-120℃, the heating rate is 15-25℃ / h, the final temperature is 200-250℃, and it is taken out at the target temperature and immediately cooled in cold water to obtain the corrosion-resistant, high-performance aluminum alloy cable material.

2. The method for preparing a corrosion-resistant, high-performance aluminum alloy cable material according to claim 1, characterized in that, In step S1, the ingredients are: low-iron industrial pure aluminum is weighed according to the mass ratio as the aluminum alloy base material, Si, Mg, Ni, Ce, Sc, Y aluminum-based master alloys or elements are weighed as alloying agents, and hexachloroethane is weighed as a refining agent.

3. The method for preparing a corrosion-resistant, high-performance aluminum alloy cable material according to claim 1, characterized in that, In step S2, the direct flame injection smelting involves placing the low-iron aluminum ingot from step S1 into a smelting furnace, introducing a mixture of natural gas and air into the furnace, igniting it, and directly injecting the high-temperature gas generated by the flame onto the surface of the material for heating. After the material is completely melted at 700-720°C, it is held at that temperature for 5-10 minutes. Then, alloying agents of Si, Mg, Ni, Ce, Sc, and Y are added sequentially. Each time an alloying agent is added, the mixture is stirred for 3-5 minutes and allowed to stand for 10-15 minutes.

4. The method for preparing a corrosion-resistant, high-performance aluminum alloy cable material according to claim 1, characterized in that, In step S3, the refining process involves adding the refining agent into the smelting furnace, stirring for 5-10 minutes, letting it stand for 10-15 minutes, and then skimming off the slag.

5. The method for preparing a corrosion-resistant, high-performance aluminum alloy cable material according to claim 1, characterized in that, In step S4, the refined melt is transferred into a buffer furnace, where the temperature of the melt is controlled at 700-720°C by the flame generated by the combustion of natural gas and air.

6. The method for preparing a corrosion-resistant, high-performance aluminum alloy cable material according to claim 1, characterized in that, In step S4, the diameter of the aluminum alloy rod is 6-12mm.

7. The method for preparing a corrosion-resistant, high-performance aluminum alloy cable material according to claim 1, characterized in that, In step S5, the cold rolling passes are ≥10 times and the deformation is ≥85%; the cold drawing passes are ≥5 times and the deformation is ≥15%.

8. A corrosion-resistant, high-performance aluminum alloy cable material prepared by the method according to any one of claims 1-7.

9. A cable, characterized in that, It contains a corrosion-resistant, high-performance aluminum alloy cable material obtained by the method described in any one of claims 1-7.

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