Production process of aviation carbon magnesium alloy composite material

Abstract

The invention belongs to the technical field of aviation carbon magnesium-gold composite materials, and discloses a production process of an aviation carbon magnesium-gold composite material, the aviation carbon magnesium-gold composite material researched and developed by the invention breaks through the technical monopoly of the global material industry on melt alloying of high-melting-point / nanoscale carbon fiber series, titanium series and boron series elements and a magnesium-based low-melting-point substrate, and the production process is simple and easy to implement. And the technical revolution from powder pressing to direct smelting is realized, and the method is a milestone-type achievement in the field of magnesium-based alloy materials. The aluminum alloy is light in weight, high in strength, high in toughness, resistant to corrosion and balanced in casting adaptability in five dimensions, can comprehensively replace traditional high-end aluminum alloys (AZ7075, 6061, ADC12 and the like), common magnesium alloys and light-weight stainless steel in the fields of aerospace, military industry, new energy automobiles, high-end equipment manufacturing and the like, and meanwhile solves the mass production problem and the cost pain point of a traditional technology in the industry. Downstream application scenes realize full-field full coverage, and the method has an unlimited development potential.

Description

Technical Field

[0001] This invention belongs to the field of aerospace carbon magnesium gold composite material technology, and specifically relates to a production process for aerospace carbon magnesium gold composite material. Background Technology

[0002] High-performance lightweight magnesium-aluminum composite structural materials are the core basic materials for the lightweight upgrading of high-end equipment. Carbon-based materials (graphite powder, carbon fiber) have a melting point of over 3000℃, which is much larger than that of magnesium-aluminum substrates with a melting point of only about 600℃. Achieving effective carbon infiltration at low temperatures has been a world-class problem that has not been solved in the global materials field for a long time.

[0003] Currently, both domestic and international industries use powder pressing to combine carbon-based elements with magnesium-aluminum matrices, and there is still no technological breakthrough in low-temperature melting and carburizing. Furthermore, traditional magnesium alloys have fatal defects such as easy ignition, extremely poor corrosion resistance, and easy surface scratches and damage. Ordinary magnesium-aluminum alloys have low tensile and bending strength, difficulty in achieving both rigidity and flexibility, and insufficient elongation. Although traditional high-end aluminum alloys (such as A356) and die-cast aluminum alloys (such as ADC12) have acceptable strength, their elongation and lightweight performance are not good. Although titanium-aluminum alloys have certain corrosion resistance, their overall performance still cannot meet the stringent requirements of high-end fields such as aerospace.

[0004] Meanwhile, traditional processes often use titanium-aluminum master alloys, which have poor compatibility when combined with carbon-based materials. This leads to problems such as easy agglomeration of nanoparticles, high-temperature oxidation and burn-off of magnesium and aluminum, low production efficiency, and low mass production yield, making it difficult to meet the multiple core requirements of high-end fields for materials with high strength, high toughness, high corrosion resistance, lightweight, and controllable processes. To overcome these technical bottlenecks, this invention pioneers a low-temperature melting and carburizing process, optimizes the master alloy system, and prepares aerospace-grade carbon-magnesium-gold composite material with globally leading comprehensive performance. Summary of the Invention

[0005] The purpose of this invention is to provide an aerospace-grade carbon-magnesium alloy composite material and its production process. It pioneers a low-temperature melting and carburizing technology, overcoming the world-class challenge of melting and infiltrating with ultra-large melting point differences. Graphite powder and carbon fiber are used as core raw materials for preparing the carbon-aluminum master alloy, replacing the titanium-aluminum master alloy with a titanium-boron master alloy, and precisely adding rare earth purification elements. Through core methods such as precise temperature control, long-term heat preservation and stirring, and precise process regulation, homogeneous fusion and in-situ dispersion of each reinforcing phase with the magnesium-aluminum matrix are achieved, completely solving the fatal defects of traditional magnesium alloys, such as easy ignition, easy corrosion, and easy breakage. Simultaneously, the material possesses ultra-high tensile and bending strength, excellent rigidity and flexibility, high elongation, extreme lightweight, and superior corrosion resistance. Furthermore, the process is controllable and highly producible, meeting the large-scale application needs of high-end fields such as aerospace and military, creating a globally unique high-performance lightweight composite structural material.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: a production process of aerospace carbon-magnesium-gold composite material, characterized in that it includes step S1, low-temperature melting, in an inert gas atmosphere, aerospace carbon-magnesium-gold composite material matrix raw material, carbon-aluminum master alloy, titanium-boron master alloy, and carbon material that has been surface-treated and ultrasonically dispersed are put into a melting equipment for low-temperature melting, the melting temperature is controlled at 650-750℃, and a homogeneous fused alloy melt is obtained.

[0007] By adopting the above technical solution, magnesium and aluminum matrices are fed into a melting equipment, heated to a low-temperature range for melting and uniform stirring. A mixture of titanium-boron master alloy, carbon-boron compound, and magnesium-aluminum special melting agent, along with rare earth purification elements, are added sequentially. After a period of holding and stirring, a carbon-aluminum master alloy prepared from graphite powder and carbon fiber, along with carbon materials, is added. Through precise temperature control, prolonged holding and stirring, and precise adjustment of process parameters, high-melting-point carbon elements and the magnesium-aluminum matrix are fully and homogeneously fused. The mixture is continuously held and stirred until the liquid phase is uniform, resulting in a homogeneously fused melt. High-purity inert protective gas is used throughout the melting process. The melting equipment is a medium-frequency induction melting furnace, and the melting crucible is made of high-purity graphite material. This process avoids magnesium and aluminum oxidation and burn-off, improving the overall performance of the materials.

[0008] Low-temperature smelting has overcome the world-class challenge of melting and carburizing carbon-based materials (graphite powder and carbon fiber, melting point exceeding 3000℃) with the large melting point difference between them and the magnesium-aluminum matrix (melting point approximately 600℃). This breakthrough enables efficient carbon melting and carburizing at low temperatures, and the resulting material completely eliminates the defects of traditional magnesium alloys, such as flammability, corrosion, and susceptibility to scratches and breakage. Graphite powder and carbon fiber are the core raw materials for preparing carbon-aluminum master alloys, which enable the effective introduction of carbon into the magnesium-aluminum matrix.

[0009] This material has fine grains and a dense structure. The reinforcing phases are homogeneously fused with the magnesium-aluminum matrix and dispersed in situ. It has ultra-high tensile and bending strength, excellent rigidity and flexibility, high elongation, extreme corrosion resistance and lightweight properties. Its elongation far exceeds that of A356 aluminum alloy, and its corrosion resistance can reach the level of no corrosion reaction in a flowing water environment for 24 hours.

[0010] The aerospace-grade carbon-magnesium-gold composite material of the present invention is a novel composite material.

[0011] Aerospace: The core application scenarios of the material of this invention are clearly positioned in high-end fields such as aerospace and military industry, which are different from ordinary civilian magnesium-aluminum alloys. At the same time, the material can meet the core design requirements of high-end equipment such as lightweight, high mechanical performance and resistance to extreme environments.

[0012] Carbon: The core strengthening system of this invention is carbon-based material strengthening, with graphite powder and carbon fiber as the core carbon source. Low-temperature melting and infiltration are achieved by preparing carbon-aluminum intermediate alloys, and a core strengthening structure with a two-carbon three-dimensional network distribution is formed. This is the key technical feature of this invention that breaks through the problem of melting and infiltration with ultra-large melting point difference.

[0013] Magnesium: This indicates that the composite material of the present invention uses magnesium-aluminum alloy as the core matrix. Relying on the extreme lightweight characteristics of magnesium-based materials, it achieves the core advantage of a material density of 1.96 g / cm³, which is 34% lighter than traditional high-end aluminum alloys. It is the core base for achieving lightweight materials.

[0014] "Gold" is a general term for alloy materials, referring specifically to the carbon-titanium-magnesium-aluminum multi-element molten alloy obtained by the low-temperature smelting process of this invention. This distinguishes it from composite powders prepared by powder pressing, reflecting the revolutionary technological feature of direct smelting in this invention. A further feature of this invention is that the carbon material is one or more of graphite powder and carbon fiber.

[0015] A further provision of the present invention is that the carbon material is a mixture of graphite powder and carbon fiber, and the carbon material is ultrasonically dispersed after surface modification treatment, wherein the surface modification treatment is a coating or grafting treatment adapted to the type of carbon material.

[0016] A further provision of the present invention is that, in step S1, the aerospace carbon-magnesium-gold composite material matrix raw material, by weight, comprises 60-80 parts magnesium, 25-35 parts aluminum, 3-8 parts carbon-aluminum master alloy, 3-8 parts titanium-boron master alloy, 0.3-2 parts carbon-boron compound, 0.05-0.5 parts rare earth purification element, and 0.05-0.5 parts carbon material, wherein the rare earth purification element is one or both of scandium and yttrium.

[0017] A further provision of the present invention is that, in step S1, the matrix raw materials of the aerospace carbon-magnesium-gold composite material include, by weight, 65-75 parts magnesium, 28-32 parts aluminum, 4-6 parts carbon-aluminum master alloy, 4-6 parts titanium-boron master alloy, 0.8-1 parts carbon-boron compound, 0.1-0.3 parts rare earth purification elements, and 0.1-0.3 parts carbon materials.

[0018] A further setting of the present invention is as follows: In step S1, magnesium and aluminum are put into a smelting device, heated to 650-750°C to melt and stir evenly, and titanium-boron master alloy, a mixture of carbon-boron compound and smelting agent, and rare earth purification elements are added in sequence. After being kept warm and stirred for a period of time, carbon-aluminum master alloy and carbon material that has been surface treated and ultrasonically dispersed are added. The mixture is kept warm and stirred for 4-12 hours to obtain a homogeneous fused alloy melt.

[0019] A further feature of the present invention is that, in step S1, the smelting agent is a magnesium-aluminum specific smelting agent.

[0020] A further provision of the present invention is that, in step S1, the inert gas is high-purity argon, the melting equipment is a medium-frequency induction melting furnace, and the crucible used for melting is made of high-purity graphite. Low-temperature melting is carried out under an inert protective gas atmosphere. The melting equipment is a medium-frequency induction melting furnace, and the melting crucible is made of high-purity graphite. Homogeneous fusion of each element with the magnesium-aluminum matrix is ​​achieved through precise temperature control, long-term heat preservation and stirring, and precise adjustment of process parameters.

[0021] A further feature of the present invention is that it includes step S2, molding, precisely controlling the molding temperature, and ensuring that the pouring temperature is consistent with the melting temperature.

[0022] By adopting the above technical solutions, the molding temperature is precisely controlled, and the pouring temperature is kept consistent with the melting temperature. The homogeneous fused melt is poured at the corresponding melting temperature. The die casting process is adopted, and the mold is professionally preheated. With appropriate pouring pressure and cooling rate, the aerospace carbon magnesium gold composite material is molded, ensuring that the material has a dense structure and stable performance, and achieving a perfect balance between rigidity and flexibility.

[0023] A further feature of this invention is that the prepared aerospace-grade carbon-magnesium-gold composite material has a grain size of 20 μm, an in-situ dispersed distribution of carbon boron compound nanophases, and a three-dimensional network distribution of carbon fibers and graphite powder. The core performance indicators of the alloy are: tensile strength 610 MPa, flexural strength 670 MPa, elongation 12.0%, impact toughness 18 J / cm, Vickers hardness 185 HV, and density 1.85 g / cm³.

[0024] The beneficial effects of this invention are: 1. Core technological bottlenecks in the materials industry: The melting point difference between titanium (melting point 1668℃), carbon (graphite powder melting point > 3600℃, carbon fiber temperature resistance > 2000℃), and boron carbon (B4C melting point 2350℃) and magnesium (melting point 650℃) and aluminum (melting point 660℃) exceeds 3000℃, posing a smelting challenge due to the large melting point difference. Furthermore, graphite powder and boron carbon are powder materials, which are prone to agglomeration and have poor interfacial bonding with the metal matrix. Magnesium and aluminum are easily burned off at conventional smelting temperatures, and high-melting-point elements cannot be melted or homogeneously distributed. Moreover, the industry requires a conventional titanium infiltration process that takes tens of hours to significantly improve production efficiency.

[0025] To overcome the aforementioned technical bottlenecks, this invention independently developed a low-temperature melting alloying core process. Through precise temperature gradient control, melt atmosphere regulation, element introduction timing design, and synergistic use of a dedicated flux and ultrasonic dispersion, homogeneous fusion and in-situ dispersion of titanium, carbon fiber + graphite powder (dual carbon), carbon boron compounds, and a magnesium-based substrate are achieved at a magnesium-aluminum smelting temperature of approximately 700℃. Simultaneously, efficient titanium infiltration is achieved, eliminating the need for the industry's conventional titanium infiltration process that takes tens of hours, thus increasing production efficiency by more than a hundredfold. This technological breakthrough represents a disruptive achievement in the field of magnesium-based alloy materials, reaching the pinnacle of industry smelting technology.

[0026] 2. The aerospace-grade carbon-magnesium-gold composite material of the present invention forms a precisely synergistic strengthening system among its various elements, and the core strengthening logic is as follows: Carbon-titanium-aluminum alloy: The secondary infiltration into the magnesium-aluminum base alloy achieves homogeneous fusion through a low-temperature melting process, refining the alloy grains to 20m and constructing the core substrate for the mechanical properties of the alloy, significantly improving the strength and toughness of the matrix; at the same time, it replaces the traditional titanium infiltration process that takes tens of hours, greatly improving production efficiency, and forms a dual-base reinforcement of metallic phase + carbon phase with the carbon-based phase.

[0027] Carbon fiber + graphite powder (dual carbon synergy): After surface modification and ultrasonic dispersion, a three-dimensional network in-situ dispersed distribution is achieved under low-temperature melting. Carbon fiber forms a macroscopic load-bearing skeleton, and graphite powder fills the matrix gaps. The two work together to achieve efficient load transfer, prevent intergranular slip and microcrack propagation, and significantly improve the tensile, bending strength and impact toughness of the alloy. At the same time, a dense carbon passivation film is formed on the alloy surface to optimize corrosion resistance.

[0028] Boron carbon compounds (B4C): Nanoscale boron carbon phases are uniformly dispersed in the matrix, significantly improving the Vickers hardness and wear resistance of the alloy by utilizing their high hardness and high wear resistance. Simultaneously, the boron carbon phase forms a strong metallurgical bond with the magnesium-aluminum matrix, further suppressing intergranular deformation and enhancing the alloy's resistance to deformation and high-temperature stability. The precise addition of rare earth purification elements thoroughly purifies the magnesium-aluminum melt, eliminating performance defects caused by impurities, inhibiting the precipitation of brittle phases, and ensuring the stability and consistency of alloy performance. Furthermore, these elements act as interfacial bridges, forming chemical bonds between the metal matrix and the carbon / boron phases, significantly improving interfacial bonding strength and maximizing the modifying effect of each reinforcing phase.

[0029] Rare earth elements: Precise addition at the percentile level achieves a dual core function: First, it thoroughly purifies the magnesium-aluminum melt, eliminates performance defects caused by impurities, inhibits the precipitation of brittle phases, and ensures the stability and consistency of alloy performance; Second, as an interface bridging agent, it forms rare earth-OC / rare earth-OB chemical bonds between the metal matrix and the carbon / boron phases, greatly improving the interfacial bonding strength and maximizing the modifying effects of titanium, double carbon, and carbon boron.

[0030] This invention, which researches and develops aerospace-grade carbon-magnesium alloy composite material, breaks the global materials industry's technological monopoly on the melting alloying of high-melting-point / nanoscale carbon fiber, titanium-based, and boron-based elements with a low-melting-point magnesium-based substrate. It represents a technological revolution from powder pressing to direct melting, marking a milestone in the field of magnesium-based alloy materials. With a balanced performance across five dimensions—lightweight, high strength, high toughness, corrosion resistance, and casting compatibility—it can comprehensively replace traditional high-end aluminum alloys (AZ7075, 6061, ADC12, etc.), ordinary magnesium alloys, and lightweight stainless steel in aerospace, military, new energy vehicles, and high-end equipment manufacturing. Simultaneously, it solves the mass production challenges and cost pain points of traditional industry processes, achieving full coverage of downstream applications and possessing unlimited development potential.

[0031] The aerospace-grade carbon-magnesium alloy composite material prepared by this invention achieves a five-dimensional balance in terms of lightweight, high strength, high toughness, corrosion resistance, and casting compatibility. All core properties surpass those of military-grade AZ7075 aluminum alloy. With a density of only 1.85 g / cm³, it is 34% lighter than traditional high-end aluminum alloys, has 2.5 times better corrosion resistance, a 95% casting qualification rate, retains 92% of its strength after welding, and reduces tool wear rate by 25% during machining. It can completely replace traditional high-end aluminum alloys, ordinary magnesium alloys, and lightweight stainless steel in aerospace, military, new energy vehicles, and high-end equipment manufacturing.

[0032] The production process of this invention is simple to operate and highly controllable, solving the mass production problems and cost pain points of traditional processes. It has a high raw material utilization rate, a mass production qualification rate of 95%, and can achieve large-scale and standardized production. It covers all downstream application scenarios. In the field of new energy vehicles alone, it has a substitution space of hundreds of billions of yuan in China. It also has huge potential for industrial application in aerospace, military, and high-end equipment manufacturing. Detailed Implementation

[0033] Example 1: A production process for aerospace carbon-magnesium-gold composite material, including step S1, low-temperature melting. Under an inert gas atmosphere, 60 parts by weight of magnesium and 25 parts by weight of aluminum are added to a melting device, heated to 650-750℃ to melt and stir evenly. Then, 3 parts of titanium-boron master alloy, 0.3 parts of a mixture of carbon-boron compound and appropriate amount of melting agent, and 0.05 parts of rare earth purification element are added sequentially. After holding and stirring at the temperature for a period of time, 3 parts of carbon-aluminum master alloy and 0.05 parts of carbon material that has been surface-treated and ultrasonically dispersed are added. The temperature is held and stirred for another 4 hours to obtain a homogeneous fused alloy melt.

[0034] The flux used is a magnesium-aluminum specific flux. The inert gas is high-purity argon, the melting equipment is a medium-frequency induction melting furnace, and the crucible used for melting is made of high-purity graphite. The carbon material is a mixture of graphite powder and carbon fiber. The carbon material is ultrasonically dispersed after surface modification treatment. The surface modification treatment is a coating or grafting treatment adapted to the type of carbon material.

[0035] S2. Molding: The alloy melt is poured at 700℃ using a die-casting process. The mold is preheated, and the pouring is carried out under appropriate pressure and cooling rate to complete the molding of the aerospace carbon magnesium gold composite material.

[0036] Example 2: A production process for aerospace carbon-magnesium-gold composite material, including step S1, low-temperature melting, in an inert gas atmosphere, 65 parts by weight of magnesium and 28 parts by weight of aluminum are added to a melting device, heated to 750°C to melt and stir evenly, 4 parts of titanium-boron master alloy, 0.8 parts of a mixture of carbon-boron compound and appropriate amount of melting agent, and 0.1 parts of rare earth purification element are added sequentially, and after holding and stirring for a period of time, 4 parts of carbon-aluminum master alloy and 0.1 parts of graphite powder carbon material that has been surface treated and ultrasonically dispersed are added, and the process is continued to hold and stir for 8 hours to obtain a homogeneous fused alloy melt.

[0037] The flux used is a special flux for magnesium and aluminum. The inert gas is high-purity argon. The melting equipment is a medium-frequency induction furnace. The crucible used for melting is made of high-purity graphite. The carbon material is graphite powder.

[0038] S2. Molding: The alloy melt is poured at 750℃ using a die-casting process. The mold is preheated, and the pouring is carried out under appropriate pressure and cooling rate to complete the molding of the aerospace carbon magnesium gold composite material.

[0039] Example 3: A production process for aerospace carbon-magnesium-gold composite material, including step S1, low-temperature melting, in an inert gas atmosphere, the aerospace carbon-magnesium-gold composite material matrix raw material and surface-treated and ultrasonically dispersed carbon material are put into a melting equipment for low-temperature melting, the melting temperature is controlled at 750°C, and a homogeneous fused alloy melt is obtained.

[0040] In an inert gas atmosphere, 75 parts by weight of magnesium and 32 parts by weight of aluminum are added to a melting equipment, heated to 720°C and stirred evenly. Then, 6 parts of titanium-boron master alloy, 1 part of a mixture of carbon-boron compound and appropriate amount of melting agent, and 0.3 parts of rare earth purification element are added in sequence. After holding and stirring at the temperature for a period of time, 6 parts of carbon-aluminum master alloy and 0.3 parts of carbon material that has been surface treated and ultrasonically dispersed are added. The mixture is then held and stirred for another 10 hours to obtain a homogeneous fused alloy melt.

[0041] The flux used is a special flux for magnesium and aluminum. The inert gas is high-purity argon, the melting equipment is a medium-frequency induction furnace, and the crucible used for melting is made of high-purity graphite. The carbon material is carbon fiber.

[0042] S2. Molding: The alloy melt is poured at 720℃ using a die-casting process. The mold is preheated, and the pouring is carried out under appropriate pressure and cooling rate to complete the molding of the aerospace carbon magnesium gold composite material.

[0043] Example 4: A production process for aerospace carbon-magnesium-gold composite material, including step S1, low-temperature melting, in an inert gas atmosphere, 80 parts by weight of magnesium and 35 parts of aluminum are added to a melting equipment, heated to 730°C to melt and stir evenly, 8 parts of titanium-boron master alloy, 2 parts of a mixture of carbon-boron compound and appropriate amount of melting agent, and 0.5 parts of rare earth purification element are added in sequence, and after holding and stirring for a period of time, 8 parts of carbon-aluminum master alloy and 0.5 parts of carbon material mixed with graphite powder and carbon fiber after surface treatment and ultrasonic dispersion are added, and the process is continued to hold and stir for 12 hours to obtain a homogeneous fused alloy melt.

[0044] The flux used is a magnesium-aluminum specific flux. The inert gas is high-purity argon, the melting equipment is a medium-frequency induction melting furnace, and the crucible used for melting is made of high-purity graphite. The carbon material is a mixture of graphite powder and carbon fiber. The carbon material is ultrasonically dispersed after surface modification treatment. The surface modification treatment is a coating or grafting treatment adapted to the type of carbon material.

[0045] S2. Molding: The alloy melt is poured at 730℃ using a die-casting process. The mold is preheated, and the pouring is carried out under appropriate pressure and cooling rate to complete the molding of the aerospace carbon magnesium gold composite material.

[0046] Table of core performance indicators of the aerospace-grade carbon-magnesium-gold composite material prepared by this invention Performance indicators unit Aerospace-grade carbon-magnesium composite materials Military-grade AZ7075 aluminum alloy Performance Exceeding Range Core performance characteristics tensile strength MPa 62010 52010 19% Dual carbon + carbon-boron synergistic strengthening, no brittle decay in strength at room / intermediate temperatures. flexural strength MPa 68010 61010 11% The carbon-boron phase suppresses intergranular slip and significantly improves resistance to deformation. elongation % 13.01.0 12.01.0 8% Rare earth elements bridge the carbon matrix and enhance the strength and plasticity of the composite material. Impact toughness J / cm 191 131 46% The dual-carbon three-dimensional network absorbs impact energy, maximizing fatigue resistance. Vickers hardness HV 1905 1655 15% The carbon-boron nanophase is dispersed, resulting in uniform hardness without soft spots. Corrosion resistance - 5% sulfuric acid only slightly oxidizes after 24 hours. 5% sulfuric acid pitting corrosion over 24 hours + thick oxide layer 2.5 times The combination of carbon and rare earth elements forms a double-layer passivation film, resulting in a significant improvement in corrosion resistance. density g / cm 1.85 2.80 34% weight loss Extremely lightweight design, world-leading load-bearing efficiency per unit volume Casting yield % 95 80 18% Low-temperature smelting process is suitable for large-scale mass production, and the yield is controllable. Welding performance - excellent generally 92% of the strength is retained after welding. Rare earth elements optimize grain boundary structure, resulting in no cracking or embrittlement after welding. Machinability - excellent middle Tool wear rate reduced by 25% The carbon-boron phase improves wear resistance and results in smooth cutting without tool sticking. Effects of the present invention Overcoming world-class technical challenges, the company pioneered a low-temperature melting and carburizing technology: achieving for the first time the low-temperature melting and carburizing of carbon-based materials (graphite powder and carbon fiber) at over 3000℃ with a magnesium-aluminum substrate at around 600℃. Abandoning the industry's traditional powder pressing method, the company achieved efficient and uniform introduction of carbon elements through a combination of graphite powder and carbon fiber to prepare carbon-aluminum master alloys, precise temperature control, and long-term heat preservation and stirring. This provides a brand-new technical path for carbon strengthening of magnesium-aluminum composite materials, and its technical level is globally leading.

[0047] Completely solves the fatal defects of traditional magnesium alloys, achieving a qualitative leap in corrosion resistance: Through dual optimization of raw materials and processes, it completely solves the industry pain points of ordinary magnesium alloys, such as easy ignition, easy surface scratches and damage, and extremely poor corrosion resistance; the actual test results of this invention show that this type of alloy material can be left to stand in a flowing water environment for 24 hours without any corrosion reaction. The corrosion resistance of the aerospace carbon magnesium alloy composite material prepared by this invention is further improved, making it suitable for outdoor, marine, complex industrial and other corrosive environments.

[0048] With world-leading comprehensive mechanical properties, the material perfectly balances rigidity and flexibility: it possesses ultra-high tensile and bending strength, excellent rigidity and flexibility, and high elongation. Its elongation performance far exceeds that of traditional high-end aluminum alloys. The elongation of the optimized ADC12 titanium-carbon alloy, compared with the benchmark technology system, can be significantly improved, far exceeding the elongation level of A356 aluminum alloy. Its tensile, bending strength and rigidity meet the load-bearing requirements of high-end fields such as aerospace, while its flexibility adapts to the forming and use requirements of complex structural components, solving the performance contradiction of traditional materials that are strong but brittle and flexible but weak.

[0049] Ultimate lightweight design with world-leading load-bearing efficiency per unit volume: With magnesium and aluminum as the core matrix, combined with a precise ratio of carbon-based (graphite powder, carbon fiber) and titanium-boron-based reinforcing components, the material density is far lower than that of traditional high-end aluminum alloys and lightweight stainless steel, resulting in outstanding lightweight characteristics and a significant improvement in load-bearing efficiency per unit volume. This enables lightweight upgrades of equipment and enhances the payload, range, and mobility of equipment in aerospace, military, and new energy vehicle fields.

[0050] Optimized raw material system, improving both melting compatibility and production efficiency: Replacing the titanium-aluminum master alloy with a titanium-boron master alloy, and combining it with a carbon-aluminum master alloy prepared from graphite powder and carbon fiber, significantly improves the melting compatibility between the high-melting-point strengthening components and the low-melting-point magnesium-aluminum matrix, fundamentally solving the core problems of high fusion difficulty and uneven element dispersion in the original process; eliminating the need for the traditional long-time titanium infiltration process, greatly improving production efficiency, increasing raw material utilization, and significantly improving the mass production qualification rate.

[0051] Rare earth elements provide core strength, resulting in superior performance stability and interfacial bonding: Scandium / yttrium rare earth purification elements are the core confidential components, which have the dual functions of melt purification and interfacial bridging. They not only eliminate melt impurities and inhibit the precipitation of brittle phases, ensuring the stability and consistency of material batch performance, but also improve the interfacial bonding strength between the metal matrix and each reinforcing phase, allowing the modification effect of carbon-based (graphite powder, carbon fiber) and titanium-boron-based reinforcing components to be maximized.

[0052] Application scenarios and core alternative value The aerospace-grade carbon-magnesium alloy composite material prepared by this invention overcomes the world-class challenge of low-temperature melting and carburizing, boasting unique comprehensive performance globally. It possesses core advantages such as ultra-high mechanical properties, extreme corrosion resistance, lightweight, and a balance of rigidity and flexibility, completely resolving the performance limitations of traditional alloy materials. This aerospace-grade carbon-magnesium alloy composite material surpasses aerospace and military-grade AX7075 aluminum alloy in all aspects, reaching the theoretical upper limit of magnesium-based alloy systems. It exhibits a five-dimensional balance of lightweight, high strength, high toughness, corrosion resistance, and casting compatibility, and can comprehensively replace traditional high-end aluminum alloys (AZ7075, 6061, ADC12, etc.), ordinary magnesium alloys, and lightweight stainless steel in aerospace, military, new energy vehicles, and high-end equipment manufacturing fields. Simultaneously, it solves the mass production challenges and cost pain points of traditional industry processes, achieving full coverage of downstream application scenarios.

[0053] (I) Aerospace Field: Core Choice for Import Substitution of High-End Light Alloy Materials 1.1 Core Applications: Lightweight structural components for aircraft fuselages, cabin supports, aerospace auxiliary accessories, UAV fuselages / landing gear / wings, aero-engine peripheral accessories, satellite lightweight structural components, etc. Aerospace auxiliary accessories, satellite lightweight structural components, etc.; extreme lightweight design significantly improves equipment payload and endurance; ultra-high tensile and bending strength, and a combination of rigidity and flexibility make it suitable for extreme environments such as high altitudes, drastic temperature changes, and complex airspace; superior corrosion resistance solves the problems of high-altitude oxidation and outdoor storage corrosion.

[0054] 1.2 Core Substitution Value: A core choice for import substitution of high-end lightweight alloy materials globally, reducing weight by more than 34% compared to traditional military aluminum alloys, significantly improving equipment payload, endurance, and flight performance; dual carbon (graphite powder, carbon fiber) + carbon boron synergistic reinforcement, resulting in superior corrosion resistance, impact resistance, fatigue resistance, and wear resistance, making it suitable for extreme environments such as high altitudes, drastic temperature changes, and complex airspace; the world's first low-temperature melting process enables large-scale mass production, meeting the bulk procurement needs of the aerospace industry.

[0055] 1.3 Market Demand: The global aerospace industry is clearly trending towards lightweighting and high-end upgrades, with a compound annual growth rate of 15% in demand for high-end light alloy materials; the domestic aerospace industry is developing rapidly, with an urgent need for import substitution of core materials, and the market capacity is continuously expanding.

[0056] (II) Military Equipment Sector: Core Supporting Materials for Lightweight Upgrading of Military Equipment 2.1 Core Applications: Core supporting materials for lightweight upgrades in military industry, applied to structural components of individual soldier tactical equipment, core components of military drones / armor vehicles, lightweight structural components of coastal / land defense equipment, etc.; extreme lightweighting improves the portability of individual soldier equipment and the mobility of military equipment; high strength, high impact resistance, and wear resistance are suitable for complex collision / vibration environments on the battlefield; water-grade corrosion resistance solves the rust problem of marine / outdoor military equipment, and there is no fire hazard of traditional magnesium alloys.

[0057] 2.2 Core Replacement Value: Extreme lightweight design significantly improves the portability of individual soldier equipment and the mobility of military equipment; high strength, high impact resistance, and high wear resistance are suitable for complex collision / vibration / wear environments on the battlefield; corrosion resistance solves the rust problem of outdoor / marine military equipment; mass production qualification rate of 95% can meet the needs of large-scale and standardized procurement of military equipment.

[0058] 2.3 Market Demand: The global trend of upgrading military equipment to be lightweight, high-end, and intelligent is inevitable. There is a strong demand for domestically produced and controllable new military materials. High-end lightweight alloy materials have become the core direction of military equipment support, and market demand continues to grow rapidly.

[0059] (III) New Energy Vehicle Sector: Core Materials for Lightweight Upgrading of Automobiles, with a Replacement Potential Worth Hundreds of Billions of Yuan 3.1 Core Applications: Core material for automotive lightweighting upgrades, with a market potential of hundreds of billions of yuan. It is applied to lightweight chassis structural components, battery pack brackets / shells, integrated die-cast parts for the central control system, door / seat frames, etc.; single-vehicle application can achieve significant weight reduction, directly improving the range of new energy vehicles and fundamentally solving range anxiety; its combination of rigidity and flexibility adapts to the long-term load-bearing and deformation requirements of complex road conditions, and its superior corrosion resistance solves the corrosion problem of core components such as battery packs and chassis, extending the service life of the entire vehicle.

[0060] 3.2 Core Replacement Value: Application in a single vehicle can reduce weight by 25-35kg, directly increasing the range of new energy vehicles by more than 15%, fundamentally addressing the industry pain point of range anxiety; its mechanical properties are superior to traditional aluminum alloys, meeting the long-term load-bearing requirements of high-speed driving and complex road conditions; its excellent casting and machining performance enables integrated die casting, significantly reducing automotive production processes and manufacturing costs; and its superior corrosion and wear resistance solves the problems of rust and wear in core components such as battery packs and chassis, extending the overall vehicle lifespan.

[0061] 3.3 Market Demand: The global new energy vehicle industry has entered a period of rapid development, and lightweighting is the core upgrade direction (industry consensus: for every 100kg reduction in weight, the range of new energy vehicles increases by about 10%). Traditional aluminum alloys can no longer meet the performance requirements of high-end models, and our products have become the core choice for lightweighting upgrades of new energy vehicles. The domestic market alone has a replacement potential of hundreds of billions of yuan.

[0062] (iv) High-end equipment manufacturing sector: Core components for lightweight upgrades of all types of equipment, with demand increasing by 20% annually. 4.1 Core Applications: Core supporting components for lightweight upgrades of all types of equipment, applied to industrial robot arms / joints, high-end CNC machine tool parts, lightweight structural components for marine engineering, corrosion-resistant parts for chemical equipment, etc.; extreme lightweighting improves equipment operating efficiency and reduces energy consumption; high elongation and a balance of rigidity and flexibility are suitable for the high-frequency movement requirements of components such as robotic arms; super corrosion resistance is suitable for complex corrosive environments such as marine and chemical industries; high hardness solves the wear resistance requirements of equipment.

[0063] 4.2 Core Replacement Value: Extreme lightweight design improves equipment operating efficiency and mobility while reducing energy consumption; high strength, high toughness, and high wear resistance meet the high-frequency, high-precision, and long-term operation requirements of equipment; corrosion resistance is suitable for complex corrosive environments such as marine, chemical, and outdoor environments; excellent machinability enables high-precision forming, meeting the precision requirements of high-end equipment.

[0064] 4.3 Market Demand: The global high-end equipment manufacturing industry is upgrading towards intelligence, lightweighting, and precision, with high-end light alloy materials becoming a core component. The market demand is growing at a compound annual growth rate of 20%, application scenarios are continuously expanding, and the market size is continuously increasing.

[0065] (V) Mid-to-high-end civilian manufacturing sector: core materials for consumption upgrade, market demand continues to sink. 5.1 Core Applications: High-end outdoor equipment, lightweight smart home, aviation models, high-end hardware accessories, bathroom structural components, high-end bicycle frames, etc.

[0066] 5.2 Core substitution value: Lightweight design improves the portability and user experience of civilian products; high strength, wear resistance, and corrosion resistance extend the product's lifespan; controllable mass production costs enable large-scale upgrading of mid-to-high-end civilian products, aligning with the trend of consumption upgrading.

[0067] 5.3 Market Demand: The trend of domestic consumption upgrading is clear, and the requirements for material performance of mid-to-high-end civilian products continue to increase. Lightweight, high-performance, and long-life alloy materials have become the mainstream demand in the market, and the application scenarios continue to expand, resulting in a huge market size.

Claims

1. A manufacturing process for aerospace-grade carbon-magnesium-gold composite materials, characterized in that: The process includes step S1, low-temperature melting, in which the aerospace carbon-magnesium-gold composite matrix raw material, carbon-aluminum master alloy, titanium-boron master alloy, and carbon material that has undergone surface treatment and ultrasonic dispersion are put into a melting equipment for low-temperature melting under an inert gas atmosphere. The melting temperature is controlled at 650-750℃ to obtain a homogeneous fused alloy melt.

2. The production process of an aerospace-grade carbon-magnesium alloy composite material according to claim 1, characterized in that: The carbon material is one or more of graphite powder and carbon fiber.

3. The production process of an aerospace-grade carbon-magnesium alloy composite material according to claim 1, characterized in that: The carbon material is a mixture of carbon fiber graphite powder and carbon fiber. The carbon material is ultrasonically dispersed after surface modification treatment. The surface modification treatment is a coating or grafting treatment adapted to the type of carbon material.

4. The production process of an aerospace-grade carbon-magnesium alloy composite material according to claim 1, characterized in that: In step S1, by weight, the matrix raw materials of the aerospace carbon magnesium gold composite material include 60-80 parts magnesium, 25-35 parts aluminum, 3-8 parts carbon aluminum master alloy, 3-8 parts titanium boron master alloy, 0.3-2 parts carbon boron compound, 0.05-0.5 parts rare earth purification element, and 0.05-0.5 parts carbon material, wherein the rare earth purification element is one or two of scandium and yttrium.

5. The production process of an aerospace-grade carbon-magnesium alloy composite material according to claim 4, characterized in that: In step S1, by weight, the matrix raw materials of the aerospace carbon magnesium gold composite material include 65-75 parts magnesium, 28-32 parts aluminum, 4-6 parts carbon aluminum master alloy, 4-6 parts titanium boron master alloy, 0.8-1 parts carbon boron compound, 0.1-0.3 parts rare earth purification elements, and 0.1-0.3 parts carbon materials.

6. The production process of an aerospace-grade carbon-magnesium alloy composite material according to claim 1, characterized in that: In step S1, magnesium and aluminum are put into a melting device, heated to 650-750℃ to melt and stir evenly. Then, titanium-boron master alloy, a mixture of carbon-boron compound and melting agent, and rare earth purification elements are added in sequence. After holding and stirring for a period of time, carbon-aluminum master alloy and carbon material that has been surface-treated and ultrasonically dispersed are added. The mixture is then held and stirred for 4-12 hours to obtain a homogeneous fused alloy melt.

7. The production process of an aerospace-grade carbon-magnesium alloy composite material according to claim 6, characterized in that: In step S1, the smelting agent is a magnesium-aluminum specific smelting agent.

8. The production process of an aerospace-grade carbon-magnesium alloy composite material according to any one of claims 1-7, characterized in that: In step S1, the inert gas is high-purity argon, the melting equipment is a medium-frequency induction melting furnace, and the crucible used for melting is made of high-purity graphite.

9. The production process of an aerospace-grade carbon-magnesium alloy composite material according to claim 1, characterized in that: This includes step S2, molding, and precise control of the molding temperature, ensuring that the pouring temperature is consistent with the melting temperature.

10. The production process of an aerospace-grade carbon-magnesium alloy composite material according to claim 1, characterized in that: The prepared aerospace-grade carbon-magnesium-gold composite material has a grain size of 20 μm, with in-situ dispersed distribution of carbon boron compound nanophases and a three-dimensional network distribution of carbon fibers and graphite powder. The core performance indicators of the alloy are: tensile strength 610 MPa, flexural strength 670 MPa, elongation 12.0%, impact toughness 18 J / cm, Vickers hardness 185 HV, and density 1.85 g / cm³.