Production method of heterogeneous metal composite material

Abstract

The invention belongs to the technical field of dissimilar metal composite plate production, and particularly relates to a dissimilar metal composite material production method which comprises the following steps: S1, preparing a stainless steel composite blank pouring mold; s2, a vibration pouring equipment box is prepared; s3, a vibration pouring base is prepared; s4, pouring and assembling operation; s5, preheating treatment; s6, pouring and forming; s7, cooling treatment; and S8, subsequent processing. By innovatively designing a double-layer mold structure and a vibration pouring process, composite assembly of dissimilar metal is directly completed in the steelmaking pouring process, the production process is greatly simplified, energy consumption and production cost are reduced, meanwhile, the bonding strength of a composite interface and the product percent of pass are remarkably improved, and efficient and high-quality production of the dissimilar metal composite material is achieved.

Description

Technical Field

[0001] This invention belongs to the field of heterogeneous metal composite plate production technology, specifically relating to a method for producing heterogeneous metal composite materials. Background Technology

[0002] Heterogeneous metal composites achieve a combination of properties that cannot be achieved by combining two or more metals with different physical and chemical properties, thus finding increasingly widespread application in modern industry. Currently, the mainstream production process for heterogeneous metal composites in the industry is hot rolling composite. The typical process is as follows: metal billets corresponding to the substrate and the cladding are smelted and prepared separately; the two billets are pretreated by surface grinding and polishing; then the billets are assembled and welded and sealed; air between the billets is removed by vacuuming; finally, they are sent to a heating furnace and heated to the rolling temperature, and the composite forming of the two metals is achieved through multiple hot rolling passes.

[0003] However, traditional hot-rolled composite processes suffer from several insurmountable technical drawbacks: First, the production process is lengthy and cumbersome, requiring the substrate and cladding to undergo multiple independent processes such as smelting, ingot casting, billet preparation, and rolling. Surface pretreatment before assembly alone requires milling, polishing, and other fine machining, resulting in a production cycle of 15-20 days per 100 tons and extremely low production efficiency. Second, energy and resource consumption are enormous. The metal billet generates significant energy losses during multiple heating and rolling processes, with unit product energy consumption reaching 800-1000 kWh / ton. Simultaneously, the metal material loss rate during surface pretreatment reaches 15-20%, leading to severe resource waste. Third, product quality stability is poor. Weld defects are prone to occur during billet assembly welding, and incomplete vacuuming can lead to the formation of an oxide layer at the composite interface, severely affecting the bonding strength and resulting in a product qualification rate of only 70-80%. Fourth, the applicability is limited. For the combination of dissimilar metals with poor metallurgical compatibility, such as titanium plates and steel, traditional hot-rolling processes cannot achieve effective composite bonding and cannot flexibly adapt to the needs of products with different thicknesses.

[0004] To address the aforementioned issues, the industry has attempted to develop alternative processes such as explosive bonding and brazing bonding, but both have significant shortcomings: explosive bonding relies on the impact force generated by explosive explosions to achieve metal bonding, resulting in low production safety, difficulty in controlling product dimensional accuracy, and special requirements for production sites, leading to substantial environmental pollution; brazing bonding uses brazing filler metals for metal connection, which consumes less energy, but the bonding strength at the composite interface is only 100-150 MPa, far from meeting the requirements of heavy-duty operating conditions. Therefore, developing a simplified, low-energy-consumption, high-quality, and widely applicable method for producing heterogeneous metal composite materials has become an urgent technical challenge in this field. Summary of the Invention

[0005] To address the problems of low production efficiency, high energy consumption, poor quality stability, and serious resource waste in existing heterogeneous metal composite material production processes, the core objective of this invention is to provide a production method for heterogeneous metal composite materials. This method, through an innovative design of a double-layer mold structure and a vibration casting process, directly completes the composite assembly of heterogeneous metals during steelmaking casting, significantly simplifying the production process, reducing energy consumption and production costs, while simultaneously significantly improving the bonding strength of the composite interface and the product qualification rate, achieving efficient and high-quality production of heterogeneous metal composite materials.

[0006] The specific technical solution adopted by this invention is as follows:

[0007] A method for producing a heterogeneous metal composite material includes the following steps:

[0008] S1. Prepare a stainless steel composite billet casting mold, the casting mold including an inner mold and an outer mold. The inner mold is made of 30mm thick stainless steel bent into a U-shaped plate by a fully automatic integrated bending machine. The ends of the U-shaped plate are processed with special bevels. The outer mold is made of 30mm thick high manganese steel and bent into a U-shaped part with lugs. The two U-shaped parts are joined together in a Harvard shape and connected by bolts. The inner cavity of the outer mold is 50-60mm larger than the outer cavity of the inner mold. 60x60mm angle steels are inserted side by side inside the inner cavity of the outer mold. The openings of the angle steels face the inner wall of the high manganese steel outer mold.

[0009] S2. Prepare a vibration casting equipment box. The equipment box is made of carbon steel for the base shell. The shell is lined with high-grade refractory material. The shell has two holes for installing a hot and cold air injection device. The air outlet of the hot and cold air injection device corresponds to the angle steel area of ​​the outer mold.

[0010] S3. Prepare a vibratory casting base. The upper surface of the base is machined with positioning steps according to the outer dimensions of the vibratory casting equipment box. Two vibrators are fixedly installed at the bottom of the base. The vibration frequency of the vibrators can be adjusted in the range of 50-200Hz.

[0011] S4. For the pouring and assembly operation, the vibratory pouring equipment box is hoisted and placed on the positioning step of the vibratory pouring base to ensure that there are no gaps at the joint. Then, the inner mold is hoisted and inserted into the equipment box and positioned and fixed.

[0012] S5. Preheating treatment: Turn on the hot air blower of the hot and cold air injection device and continuously deliver hot air to the inner mold through the angle steel area to preheat the inner mold to 1000-1200℃. During the preheating process, keep the vibrator running at a low frequency and set the vibration frequency to 50-80Hz.

[0013] S6. Casting and forming: Molten iron at a temperature of 1500-1600℃ is poured uniformly into the inner mold box at a rate of 10-15 kg / s. During casting, the vibrator frequency is adjusted to 120-180 Hz and run continuously. S7. Cooling treatment: After casting, the hot air fan is turned off and the cold air fan is turned on immediately. Cold air is delivered to the inner mold through the angle steel area for forced cooling. The cooling rate is controlled at 5-10℃ / s. Cooling and vibration are stopped when the temperature of the composite billet drops below 300℃.

[0014] S8. Subsequent processing: The cooled composite material billet is hoisted out and sent to the billet production line to be billeted to the preset size. Then, it is produced into a finished heterogeneous metal composite plate through hot rolling and cold rolling processes.

[0015] The heterogeneous metal composite material consists of a substrate and a cladding plate. The substrate is selected from carbon steel, low alloy steel, stainless steel 201, and 4-series stainless steel. The cladding plate is selected from stainless steel 304, stainless steel 316, stainless steel 321, and titanium plate.

[0016] In a preferred embodiment, the U-shaped plate of the inner mold described in step S1 undergoes systematic surface treatment and performance optimization before bending. First, it is degreased by immersing in a 5-8% sodium hydroxide solution at 60-80°C for 20-30 minutes to remove surface oil. Then, it is acid-washed with a 15-20% nitric acid solution at room temperature for 10-15 minutes to remove oxide scale. Finally, it is rinsed with clean water and dried for later use. The bending process is performed using a WC67Y-300T / 4000 CNC hydraulic bending machine. The bending radius is precisely controlled within 15-25mm, and the wall thickness reduction at the bend is ≤1mm. The special bevel is processed using a combination of plasma cutting and grinding, with a bevel angle of 30-45°, a bevel depth of 10-15mm, and a bevel surface roughness Ra≤3.2μm. The bevel edge is free of burrs and collapse defects. After the bending and beveling are completed, the dimensions of the U-shaped plate are checked, and the deviations in length, width, and height are all controlled within ±1mm. At the same time, ultrasonic flaw detection is used to inspect the internal quality of the bend.

[0017] In a preferred embodiment, the high-manganese steel mentioned in step S1 is ZGMn13 type wear-resistant high-manganese steel, and the final chemical composition is precisely controlled by weight percentage as follows: C 1.0-1.4%, Mn 10-14%, Si 0.3-1.0%, P ≤0.07%, S ≤0.03%, Cr 0.2-0.5%, Ni 0.1-0.3%. The high-manganese steel is subjected to water toughening treatment before cutting. The process is to heat to 1050-1100℃, hold for 2-3 hours, and then quickly water quench, with a cooling rate ≥30℃ / s. After treatment, the high-manganese steel has a tensile strength ≥800MPa, an impact toughness ≥150J / cm², and a hardness ≤220HB. The cutting is carried out using a CNC plasma cutting machine with a cutting accuracy of ±0.5mm.

[0018] In a preferred embodiment, the angle steel mentioned in step S1 is selected from Q235B low-carbon structural steel, with specifications of 60×60×5mm. Its mechanical properties must meet the following requirements: tensile strength ≥375MPa, yield strength ≥235MPa, elongation ≥26%. Before installation, the angle steel must undergo a complete surface pretreatment process, including degreasing, immersion in a 5% sodium carbonate solution at 50℃ for 15 minutes, sandblasting to remove rust (rust removal grade Sa2.5, surface roughness Ra40-80μm), and phosphating to form a 2-5μm phosphate film. To enhance the bonding strength with the adhesive; the spacing between angle steels is uniformly set to 30-50mm, and the parallelism error between adjacent angle steels is ≤1mm; the high-temperature resistant adhesive is an inorganic adhesive with alumina and silicon dioxide as the main components, with a room temperature bonding strength ≥10MPa, a bonding strength ≥5MPa at 1000℃, and a service temperature range of -50℃ to 1600℃. The adhesive coating thickness is uniformly controlled to 2-3mm, and after coating, it is cured at 150-200℃ for 2-3 hours. After curing, the adhesive layer is free of bubbles and cracks.

[0019] In a preferred embodiment, the high-grade refractory material mentioned in step S2 is a high-purity alumina hollow sphere brick with an Al2O3 content ≥95%, a bulk density of 1.8-2.2 g / cm³, a room temperature compressive strength ≥80 MPa, a high temperature flexural strength ≥15 MPa at 1400℃, an upper limit of service temperature ≤1800℃, and a thermal conductivity (1000℃) ≤0.8 W / (m·K). The refractory mortar is selected from high-alumina refractory mortar, and its chemical composition by weight percentage is Al2O3. The refractory material has a composition of 65-75%, SiO2 20-30%, Fe2O3 ≤ 2%, a refractoriness of ≥ 1750℃, and a room temperature compressive strength of ≥ 10MPa. The refractory material and the carbon steel shell are laid using a staggered joint method, with a thickness of 80-120mm, a joint width of 2-3mm, and a joint fullness of ≥ 98%. After laying, the refractory material is naturally cured for more than 72 hours. The carbon steel shell is made of Q345B low-alloy high-strength steel with a plate thickness of 16-20mm. Welding is performed using carbon dioxide gas shielded welding with ER50-6 welding wire. The welded joints are ultrasonically tested and meet the Class I requirements of GB / T 11345-2013 standard, with no welding defects.

[0020] In a preferred embodiment, the vibrator in step S3 is a VB series variable frequency electromagnetic vibrator. The rated power of a single vibrator is 1.5-3kW, the excitation force is 5-10kN, and it can be continuously and steplessly adjusted within the range of 50-200Hz via a frequency converter control cabinet. The vibration amplitude is 0.5-2mm, and the amplitude stability error is ≤±5%. The vibration base is integrally cast from QT450-10 ductile iron, and the chemical composition of the casting, by weight percentage, is C 3.4-3.8%, Si 2.2-2.8%, Mn ≤0.6%, P ≤0.07%, S ≤0.03%, Mg ≤0.07%, Mg ... The internal stress of the casting is eliminated by aging treatment at 200-250℃ for 4-6 hours. The flatness error of the positioning step on the upper surface of the base is ≤0.2mm / m. The shock-absorbing rubber pad at the bottom of the base is made of nitrile rubber with a Shore hardness of 60-70HA, tensile strength ≥15MPa, elongation at break ≥300%, temperature resistance range of -40℃ to 120℃, and thickness of 20-30mm. It is fixed to the base by countersunk bolts with a bolt preload torque of 80-100N·m.

[0021] In a preferred embodiment, the preheating process in step S5 employs a PLC fully automatic closed-loop temperature control system. Six K-type thermocouples distributed at both ends and the middle of the mold collect temperature data in real time, with a measurement range of 0-1800℃ and an accuracy of ±1℃. The specific control logic for the segmented heating method is as follows: From room temperature to 500℃, the heating rate is set to 50℃ / min. This stage rapidly removes adsorbed moisture and residual oil from the mold surface, preventing porosity defects during casting. From 500℃ to 800℃, the heating rate is reduced to 30℃ / min for slow temperature release. Thermal stress caused by temperature changes in the mold is prevented from causing micro-cracks; during the target temperature stage from 800℃ to 1000-1200℃, the heating rate is further reduced to 20℃ / min, and the temperature difference is controlled within ±10℃; after reaching the target temperature, it is held for 20-30 minutes, and the temperature fluctuation range during the holding period is ≤±5℃; throughout the preheating process, the vibrator maintains a low frequency of 50-80Hz, and promotes the conduction of heat inside the mold through slight vibration. Temperature data is transmitted to the central control system in real time and recorded and archived to form a complete preheating process curve for easy quality traceability.

[0022] In a preferred embodiment, the molten iron in step S6 is made of high-quality carbon structural steel, and its chemical composition by weight percentage needs to be precisely controlled as follows: C 0.15-0.25%, Si 0.15-0.35%, Mn 0.45-0.80%, Cr ≤0.25%, Ni ≤0.25%, Cu ≤0.25%, P ≤0.035%, S ≤0.035%, Al ≤0.035%, and Sodium ≤0.035%. The iron content is ≥0.015%, with the remainder being Fe and unavoidable impurities. Composition control ensures good fluidity and solidification properties in the molten iron. Before casting, the molten iron must undergo refining in an LF refining furnace. The refining process includes: adding 0.5-1.0% (by weight) of CaO-Al2O3 composite slagging agent to the molten iron for 15-20 minutes to remove non-metallic inclusions; using an aluminum-manganese-titanium composite deoxidizer at a rate of 0.2-0.5 kg / ton of steel to ensure an oxygen content ≤20 ppm; after refining, the gas content of the molten iron must be strictly controlled to H≤2 ppm and N≤50 ppm. Non-metallic inclusions must be rated at grade ≤1.5 according to GB / T 10561-2005. The temperature of the molten iron is monitored in real-time using an infrared thermometer to ensure a stable casting temperature of 1500-1600℃ with temperature fluctuations ≤±20℃.

[0023] In a preferred embodiment, the cooling process in step S7 employs an intelligent segmented cooling strategy, consisting of a closed-loop control system comprised of a surface infrared thermometer, insertion thermocouples, a variable frequency air cooler, and a PLC controller. Specifically, the cooling method is as follows: in the high-temperature stage (300-800℃), the cooling rate is controlled at 10℃ / s. During this stage, rapid cooling refines the grain structure of the composite material, improving its strength and hardness. In the medium-low temperature stage below 800℃, the cooling rate is reduced to 5℃ / s. Slow cooling effectively reduces the temperature difference between the surface and core of the billet, lowering thermal stress. To prevent cracking of the composite interface, the system calculates the temperature difference between the surface and the core in real time during the cooling process. When the temperature difference approaches 50℃, the system adjusts the air volume and speed of the air cooler to ensure that the temperature difference is controlled within 50℃ throughout the process. The air cooler is a scroll-type refrigeration unit with a cooling power of 30-60kW and a cold air outlet temperature of 5-15℃. The airflow is evenly applied to the mold surface through the airflow channel formed by the angle steel. When the overall temperature of the composite material blank drops below 300℃, the system shuts down the air cooler and vibrator sequentially after a 10-minute delay to avoid residual stress caused by a sudden drop in temperature.

[0024] In a preferred embodiment, in step S8, the billet mill is a four-high reversible billet mill with a work roll diameter of 500-600mm, a support roll diameter of 1200-1400mm, a rated rolling force of 1000-1500kN, and a rolling speed adjustable within the range of 0.5-2m / s. The billet rolling temperature is strictly controlled at 800-1000℃, and the billet rolling process uses 3-5 passes, with the reduction rate decreasing with each pass. The final thickness tolerance of the billet after billet rolling is controlled to be ±0.5mm. The hot rolling process uses a six-high hot rolling mill with a rolling temperature of 900-1100℃ and a total reduction rate of 60-80%. Multiple rolling passes refine the grains and densify the microstructure of the composite material. After hot rolling, the oxide scale on the surface of the sheet is removed by high-pressure water descaling. The cold rolling process uses an 18-roll precision cold rolling mill with a rolling temperature of room temperature and a total reduction rate of 30-50%. Rolling oil is used for lubrication and cooling during the rolling process. The kinematic viscosity (40℃) of the rolling oil is 10-15 mm² / s, and the flash point is ≥180℃. The final product is straightened, trimmed, and polished. After straightening, the flatness error is ≤0.2 mm / m, the trimming accuracy is ±1 mm, the surface roughness Ra is ≤1.6 μm, and the dimensional accuracy meets the Class A requirements of GB / T708-2016 standard.

[0025] The technical effects achieved by this invention are as follows:

[0026] The production process is greatly simplified and efficiency is significantly improved: This invention innovatively completes the composite billet assembly of dissimilar metals directly during the steelmaking and casting process, eliminating more than 10 processes such as smelting, casting, billet opening, surface polishing, welding, and vacuuming of the substrate and cladding plate in the traditional hot rolling process. The production cycle is shortened by more than 60%, and the production efficiency is increased by 3-5 times. Actual production verification shows that the traditional process requires 15-20 days to produce 100 tons of composite plates, while this invention can complete the process in only 5-7 days, greatly improving production efficiency.

[0027] Significantly reduced energy consumption and costs: Eliminating energy-intensive processes such as repeated heating and rolling of metal billets reduces energy consumption per unit product from 800-1000 kWh / ton in traditional processes to 250-350 kWh / ton, a reduction of 50-70%. At the same time, the simplification of surface pretreatment processes reduces the metal material loss rate from 15-20% to below 5%, saving 100-150 kg of metal material per ton of product. Combined with the reduction in energy consumption, the production cost per unit product is reduced by more than 40%, giving it a strong competitive edge in the market.

[0028] The product quality is stable and reliable: the double-layer mold structure design and positioning pin fixation effectively avoid welding defects and mold displacement problems in traditional processes; the application of vibration casting and segmented temperature control technology eliminates the oxide layer and internal pores of the composite interface, and the bonding strength of the composite interface reaches more than 300MPa, which is 1.5-2 times that of the traditional hot rolling process; at the same time, segmented preheating and cooling control reduces the internal stress of the billet, and the product qualification rate increases from 70-80% in the traditional process to more than 95%, and the quality stability is greatly improved.

[0029] With a wide range of applications and high flexibility, it can realize the composite molding of various dissimilar metals such as carbon steel, low alloy steel, stainless steel, and titanium plates to meet the performance requirements of different industries. By adjusting process parameters such as preheating temperature and casting temperature, it can be adapted to the production of products with different thicknesses and specifications. It can efficiently produce thin plates of a few millimeters to medium and thick plates of tens of millimeters, and its product adaptability is extremely strong. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the process flow for a method of producing a heterogeneous metal composite material according to the present invention.

[0031] Figure 2 This is a schematic diagram of a method for producing a heterogeneous metal composite material according to the present invention. Detailed Implementation

[0032] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0033] Example 1: Production of 201 / 304 stainless steel composite plate (for food machinery)

[0034] This embodiment addresses the requirements of food processing machinery for corrosion resistance and hygiene of materials. A dissimilar metal composite plate is produced with a base material of stainless steel 201 and a cover plate of stainless steel 304. The specific steps are as follows:

[0035] S1. Mold Preparation: The inner mold is made of 30mm thick 201 stainless steel plate. Before bending, it undergoes solution treatment (holding at 1080℃ for 45 minutes followed by water quenching), then degreases by immersion in 5% sodium hydroxide solution at 70℃ for 25 minutes, removes rust by pickling in 20% nitric acid solution at room temperature for 12 minutes, rinses with clean water, and dries at 120℃. A U-shaped plate with a bending radius of 20mm is formed using a WC67Y-300T / 4000 bending machine. The end edge is machined with a special bevel of 35° and a depth of 12mm, and the bevel surface is ground to Ra2.8μm. The outer mold is made of 30mm thick ZGMn13 high manganese steel (composition: C 1.2%, Mn 12%, Si 0.6%, P 0.05%, S 0.02%, Cr 0.4%, Ni 0.2%). After being water-cooled at 1080℃ for 3 hours, it is cut and bent. The two U-shaped parts are spliced ​​together and connected with M24 bolts. The inner cavity is 55mm larger than the inner mold. Q235B 60×60×5mm angle steel is fixed inside the inner cavity at 40mm intervals, using alumina-based adhesive, and cured at 180℃ for 2.5 hours.

[0036] S2. Equipment Box Preparation: The carbon steel outer shell is made of 18mm thick Q345B steel, welded with ER50-6 welding wire, and passes ultrasonic flaw detection (Level I). The interior is constructed with 100mm thick alumina hollow spherical bricks (Al2O3 content 96%, bulk density 2.0g / cm³), using high-alumina refractory mortar with staggered joints, mortar joints 2.5mm, and cured for 72 hours. A hot and cold air injection device is installed; the hot air generator has a power of 80kW, the cold air generator has a power of 50kW, and the switching valve response time is 0.8s.

[0037] S3. Base preparation: A positioning step is machined on the QT450-10 ductile iron base. Two VB series variable frequency electromagnetic vibrators with an excitation force of 8kN are installed at the bottom. A 25mm thick nitrile rubber shock-absorbing pad is set, and the bolt pre-tightening torque is 90N·m.

[0038] S4. Assembly: The equipment box is hoisted to the base step with a levelness error of 0.08mm / m; the inner mold is fixed by high-temperature alloy positioning pins (fitting gap 0.15mm) with an overall dimensional verification error of ±0.8mm.

[0039] S5. Preheating: The PLC temperature control system is adopted, with 6 K-type thermocouples for temperature measurement. The temperature is increased in stages: room temperature → 500℃ (50℃ / min) → 800℃ (30℃ / min) → 1100℃ (20℃ / min), and the temperature is maintained for 25 minutes. The vibrator runs at a low frequency of 60Hz, and the temperature difference between the inside and outside of the mold is ≤8℃.

[0040] S6. Casting: Molten iron composition (wt%): C 0.20%, Si 0.25%, Mn 0.60%, Cr 0.20%, Ni 0.20%, Cu 0.20%, P 0.03%, S 0.03%, Al 0.02%. After LF refining, H 1.8ppm, N 45ppm, and non-metallic inclusions grade 1.0. Molten iron at 1550℃ is cast at a rate of 12kg / s at a 20° angle, with the vibrator set to 150Hz.

[0041] S7. Cooling: Switch the air cooler within 1 second after casting. Cool at 8℃ / s for 300-800℃ and at 5℃ / s for below 800℃. Monitor the temperature difference in real time to ≤45℃. Stop cooling and vibration when the billet temperature drops to 280℃.

[0042] S8. Subsequent processing: The billet is rolled to 25mm thickness at 900℃ using a four-roll mill with a rolling force of 1200kN; hot-rolled at 1000℃ (total reduction rate 70%); cold-rolled at room temperature (total reduction rate 40%); straightened, trimmed, and polished with a 1000-grit abrasive wheel.

[0043] Finished product testing: Composite interface bonding strength 320MPa, surface roughness Ra1.2μm, flatness error ≤0.15mm / m, salt spray corrosion resistance meets the 1000h rust-free requirement in GB / T 10125-2021 standard, fully meeting the requirements for use in food machinery.

[0044] Example 2: Production of Q235 carbon steel / TA2 titanium plate composite plate (for chemical equipment)

[0045] This embodiment addresses the requirements of chemical equipment for corrosion resistance and strength by producing a dissimilar metal composite plate with a base material of Q235 carbon steel and a cladding plate of TA2 titanium. The steps are as follows:

[0046] S1. Mold Preparation: The inner mold is made of 30mm thick TA2 titanium plate. Surface treatment includes: immersion in 6% sodium hydroxide solution at 80℃ for 30min for degreasing, pickling in 15% nitric acid solution at room temperature for 15min for rust removal, drying, and solution treatment at 1050℃ for 60min. The bending radius is 18mm, the bevel is 40° with a depth of 14mm, and the slope surface Ra is 3.0μm. The outer mold is made of high-manganese steel with the following composition: C 1.3%, Mn 13%, Si 0.8%, P 0.06%, S 0.025%. It undergoes water toughening treatment at 1100℃ for 2.5h. The inner cavity is 50mm larger than the inner layer, and the angle steel spacing is 35mm.

[0047] S2. Equipment box preparation: outer shell 20mm thick Q345B steel, refractory material masonry thickness 110mm, hot air generator power 100kW, cold air generator power 60kW.

[0048] S3. Base preparation: Vibrator excitation force 10kN, damping pad thickness 30mm.

[0049] S4. Assembly: The locating pin fit clearance is 0.2mm, and the overall dimensional error is ±1mm.

[0050] S5. Preheating: Target temperature 1050℃, keep warm for 30 minutes, vibrator running at 70Hz.

[0051] S6. Casting: The molten iron composition is the same as that of Q235, with H2ppm and N50ppm after LF refining. The molten iron at 1580℃ is cast at a speed of 14kg / s and at a 30° angle, with the vibrator running at 160Hz.

[0052] S7. Cooling: Cooling rate of 7℃ / s for 300-800℃, 5℃ / s for below 800℃, and temperature difference control ≤50℃.

[0053] S8. Subsequent processing: billet temperature 950℃, rolling force 1500kN, billet thickness 22mm; hot rolling temperature 950℃, total reduction rate 65%; cold rolling reduction rate 35%, finished product polished to Ra1.4μm.

[0054] Finished product testing: Composite interface bonding strength 290MPa, titanium plate coating thickness uniformity error ≤0.3mm, hydrochloric acid corrosion resistance meets the requirements of GB / T 10125-2021 standard, suitable for corrosion-resistant working conditions of chemical equipment.

[0055] This invention innovatively completes the composite billet assembly of dissimilar metals directly during the steelmaking and casting process, eliminating more than 10 steps in the traditional hot rolling process, including smelting, ingot casting, billet preparation, surface polishing, welding, and vacuuming of the substrate and cladding plate. This shortens the production cycle by more than 60% and increases production efficiency by 3-5 times. Actual production verification shows that while the traditional process requires 15-20 days to produce 100 tons of composite plates, this invention can complete the process in only 5-7 days, significantly improving production efficiency. It eliminates energy-intensive processes such as repeated heating and rolling of metal billets, reducing energy consumption per unit product from 800-1000 kWh / ton in the traditional process to 250-350 kWh / ton, a reduction of 50-70%. Simultaneously, the simplified surface pretreatment process reduces the metal material loss rate from 15-20% to below 5%, saving 100-150 kg of metal material per ton of product. Combined with the reduced energy consumption, the energy consumption per unit product... Production costs are reduced by more than 40%, giving it a strong market competitiveness. The double-layer mold structure design and locating pin fixation effectively avoid welding defects and mold displacement problems found in traditional processes. The application of vibration casting and segmented temperature control technology eliminates the oxide layer and internal porosity of the composite interface, achieving a composite interface bonding strength of over 300MPa, which is 1.5-2 times that of traditional hot rolling processes. Simultaneously, segmented preheating and cooling control reduce internal stress in the billet, increasing the product qualification rate from 70-80% in traditional processes to over 95%, significantly improving quality stability. It can achieve composite molding of various dissimilar metals such as carbon steel, low alloy steel, stainless steel, and titanium plates, meeting the performance requirements of different industries. By adjusting process parameters such as preheating temperature and casting temperature, it can adapt to the production of products with different thicknesses, efficiently producing everything from thin plates of a few millimeters to medium-thick plates of tens of millimeters, demonstrating extremely strong product adaptability.

[0056] The above description is merely a preferred embodiment of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described or explained in this invention are implemented according to conventional methods in the art unless otherwise specified or limited.

Claims

1. A method for producing a heterogeneous metal composite material, characterized in that: Includes the following steps: S1. Prepare a stainless steel composite billet casting mold, the casting mold including an inner mold and an outer mold. The inner mold is made of 30mm thick stainless steel bent into a U-shaped plate by a fully automatic integrated bending machine. The ends of the U-shaped plate are processed with special bevels. The outer mold is made of 30mm thick high manganese steel and bent into a U-shaped part with lugs. The two U-shaped parts are joined together in a Harvard shape and connected by bolts. The inner cavity of the outer mold is 50-60mm larger than the outer cavity of the inner mold. 60x60mm angle steels are inserted side by side inside the inner cavity of the outer mold. The openings of the angle steels face the inner wall of the high manganese steel outer mold. S2. Prepare a vibration casting equipment box. The equipment box is made of carbon steel for the base shell. The shell is lined with high-grade refractory material. The shell has two holes for installing a hot and cold air injection device. The air outlet of the hot and cold air injection device corresponds to the angle steel area of ​​the outer mold. S3. Prepare a vibratory casting base. The upper surface of the base is machined with positioning steps according to the outer dimensions of the vibratory casting equipment box. Two vibrators are fixedly installed at the bottom of the base. The vibration frequency of the vibrators can be adjusted in the range of 50-200Hz. S4. For the pouring and assembly operation, the vibratory pouring equipment box is hoisted and placed on the positioning step of the vibratory pouring base to ensure that there are no gaps at the joint. Then, the inner mold is hoisted and inserted into the equipment box and positioned and fixed. S5. Preheating treatment: Turn on the hot air blower of the hot and cold air injection device and continuously deliver hot air to the inner mold through the angle steel area to preheat the inner mold to 1000-1200℃. During the preheating process, keep the vibrator running at a low frequency and set the vibration frequency to 50-80Hz. S6. Casting and forming: Molten iron at a temperature of 1500-1600℃ is poured uniformly into the inner mold box at a rate of 10-15 kg / s. During casting, the vibrator frequency is adjusted to 120-180 Hz and run continuously. S7. Cooling treatment: After casting, the hot air fan is turned off and the cold air fan is turned on immediately. Cold air is delivered to the inner mold through the angle steel area for forced cooling. The cooling rate is controlled at 5-10℃ / s. Cooling and vibration are stopped when the temperature of the composite billet drops below 300℃. S8. Subsequent processing: The cooled composite material billet is hoisted out and sent to the billet production line to be billeted to the preset size. Then, it is produced into a finished heterogeneous metal composite plate through hot rolling and cold rolling processes. The heterogeneous metal composite material consists of a substrate and a cladding plate. The substrate is selected from carbon steel, low alloy steel, stainless steel 201, and 4-series stainless steel. The cladding plate is selected from stainless steel 304, stainless steel 316, stainless steel 321, and titanium plate.

2. The method for producing a heterogeneous metal composite material according to claim 1, characterized in that: The U-shaped plate of the inner mold described in step S1 undergoes systematic surface treatment and performance optimization before bending. First, it is degreased by immersing in a 5-8% sodium hydroxide solution at 60-80℃ for 20-30 minutes to remove surface oil. Then, it is acid-washed with a 15-20% nitric acid solution at room temperature for 10-15 minutes to remove oxide scale. Finally, it is rinsed with clean water and dried for later use. The bending process is performed using a WC67Y-300T / 4000 CNC hydraulic bending machine, with a bending radius of half... The diameter is precisely controlled within 15-25mm, and the wall thickness reduction at the bend is ≤1mm. The special bevel is processed using a combination of plasma cutting and grinding. The bevel angle is 30-45°, the bevel depth is 10-15mm, the bevel surface roughness Ra≤3.2μm, and there are no burrs or collapse defects on the bevel edge. After the bending and beveling are completed, the dimensions of the U-shaped plate are checked. The deviations in length, width, and height are all controlled within ±1mm. At the same time, ultrasonic flaw detection is used to detect the internal quality at the bend.

3. The method for producing a heterogeneous metal composite material according to claim 2, characterized in that: The high-manganese steel mentioned in step S1 is ZGMn13 type wear-resistant high-manganese steel. The final chemical composition is precisely controlled by weight percentage as follows: C 1.0-1.4%, Mn 10-14%, Si 0.3-1.0%, P ≤0.07%, S ≤0.03%, Cr 0.2-0.5%, Ni 0.1-0.3%. The high-manganese steel is subjected to water toughening treatment before cutting. The process is to heat to 1050-1100℃, hold for 2-3 hours and then quickly water quench, with a cooling rate ≥30℃ / s. After treatment, the high-manganese steel has a tensile strength ≥800MPa, an impact toughness ≥150J / cm², and a hardness ≤220HB. The cutting is carried out using a CNC plasma cutting machine with a cutting accuracy of ±0.5mm.

4. The method for producing a heterogeneous metal composite material according to claim 3, characterized in that: The angle steel mentioned in step S1 is made of Q235B low-carbon structural steel with a specification of 60×60×5mm. Its mechanical properties must meet the following requirements: tensile strength ≥375MPa, yield strength ≥235MPa, and elongation ≥26%. Before installation, the angle steel must undergo a complete surface pretreatment process, including degreasing, immersion in a 5% sodium carbonate solution at 50℃ for 15 minutes, sandblasting to remove rust (rust removal grade Sa2.5, surface roughness Ra40-80μm), and phosphating to form a 2-5μm phosphate film to enhance adhesion. The bonding strength of the adhesive; the spacing between angle steels is uniformly set to 30-50mm, and the parallelism error between adjacent angle steels is ≤1mm; the high-temperature resistant adhesive is an inorganic adhesive with alumina and silicon dioxide as the main components, with a bonding strength of ≥10MPa at room temperature and ≥5MPa at 1000℃, and a service temperature range of -50℃ to 1600℃. The adhesive coating thickness is uniformly controlled to 2-3mm, and after coating, it is cured at 150-200℃ for 2-3h. After curing, the adhesive layer is free of bubbles and cracks.

5. The method for producing a heterogeneous metal composite material according to claim 4, characterized in that: The premium refractory material mentioned in step S2 is a high-purity alumina hollow sphere brick with an Al2O3 content ≥95%, a bulk density of 1.8-2.2 g / cm³, a room temperature compressive strength ≥80 MPa, a high temperature flexural strength ≥15 MPa at 1400℃, an upper limit of service temperature ≤1800℃, and a thermal conductivity (1000℃) ≤0.8 W / (m·K). The refractory mortar is a high-alumina refractory mortar with a chemical composition of Al2O3 by weight percentage. The refractory material is 65-75% refractory material, SiO2 20-30% refractory material, Fe2O3 ≤2% refractory material, refractoriness ≥1750℃, and room temperature compressive strength ≥10MPa. The refractory material and the carbon steel shell are laid using a staggered joint method, with a thickness of 80-120mm, a joint width of 2-3mm, and a joint fullness of ≥98%. After laying, the refractory material is naturally cured for more than 72 hours. The carbon steel shell is made of Q345B low alloy high strength steel with a plate thickness of 16-20mm. Welding is performed using carbon dioxide gas shielded welding with ER50-6 welding wire. The welded joints are ultrasonically tested and meet the Class I requirements of GB / T11345-2013 standard, with no welding defects.

6. The method for producing a heterogeneous metal composite material according to claim 5, characterized in that: The vibrator used in step S3 is a VB series variable frequency electromagnetic vibrator. The rated power of a single vibrator is 1.5-3kW, and the excitation force is 5-10kN. It can be continuously and steplessly adjusted within the range of 50-200Hz via a frequency converter control cabinet. The vibration amplitude is 0.5-2mm, and the amplitude stability error is ≤±5%. The vibration base is integrally cast from QT450-10 ductile iron. The chemical composition of the casting, by weight percentage, is C 3.4-3.8%, Si 2.2-2.8%, Mn ≤0.6%, P ≤0.07%, S ≤0.03%, Mg ≤0.07%, Mg ... The internal stress of the casting is eliminated by aging treatment at 200-250℃ for 4-6 hours. The flatness error of the positioning step on the upper surface of the base is ≤0.2mm / m. The shock-absorbing rubber pad at the bottom of the base is made of nitrile rubber with a Shore hardness of 60-70HA, tensile strength ≥15MPa, elongation at break ≥300%, temperature resistance range of -40℃ to 120℃, and thickness of 20-30mm. It is fixed to the base by countersunk bolts with a bolt preload torque of 80-100N·m.

7. The method for producing a heterogeneous metal composite material according to claim 6, characterized in that: In step S5, the preheating process employs a PLC fully automatic closed-loop temperature control system. Six K-type thermocouples distributed at both ends and the middle of the mold collect temperature data in real time, with a measurement range of 0-1800℃ and an accuracy of ±1℃. The specific control logic for the segmented heating method is as follows: From room temperature to 500℃, the heating rate is set to 50℃ / min. This stage rapidly removes adsorbed moisture and residual oil from the mold surface, preventing porosity defects during casting. From 500℃ to 800℃, the heating rate is reduced to 30℃ / min, slowly releasing the heat generated by the mold. The thermal stress generated by the sudden change prevents the formation of microcracks; during the target temperature stage from 800℃ to 1000-1200℃, the heating rate is further reduced to 20℃ / min, and the temperature difference is controlled within ±10℃; after reaching the target temperature, the temperature is held for 20-30 minutes, and the temperature fluctuation range during the holding period is ≤±5℃; throughout the preheating process, the vibrator maintains a low frequency of 50-80Hz, and the slight vibration promotes the conduction of heat inside the mold. The temperature data is transmitted to the central control system in real time and recorded and archived to form a complete preheating process curve, which facilitates quality traceability.

8. The method for producing a heterogeneous metal composite material according to claim 7, characterized in that: In step S6, the molten iron is made of high-quality carbon structural steel, and its chemical composition by weight percentage must be precisely controlled as follows: C 0.15-0.25%, Si 0.15-0.35%, Mn 0.45-0.80%, Cr ≤0.25%, Ni ≤0.25%, Cu ≤0.25%, P ≤0.035%, S ≤0.035%, Al ≤0.035%, and Sodium ≤0.035%. The iron content is ≥0.015%, with the remainder being Fe and unavoidable impurities. Composition control ensures good fluidity and solidification properties in the molten iron. Before casting, the molten iron must undergo refining in an LF refining furnace. The refining process includes: adding 0.5-1.0% (by weight) of CaO-Al2O3 composite slagging agent to the molten iron for 15-20 minutes to remove non-metallic inclusions; using an aluminum-manganese-titanium composite deoxidizer at a rate of 0.2-0.5 kg / ton of steel to ensure an oxygen content ≤20 ppm; after refining, the gas content of the molten iron must be strictly controlled to H≤2 ppm and N≤50 ppm. Non-metallic inclusions must be rated at grade ≤1.5 according to GB / T 10561-2005. The temperature of the molten iron is monitored in real-time using an infrared thermometer to ensure a stable casting temperature of 1500-1600℃ with temperature fluctuations ≤±20℃.

9. A method for producing a heterogeneous metal composite material according to claim 8, characterized in that: In step S7, the cooling process employs an intelligent segmented cooling strategy, consisting of a closed-loop control system comprised of a surface infrared thermometer, insertion thermocouples, a variable frequency air cooler, and a PLC controller. Specifically, the cooling method is as follows: in the high-temperature stage (300-800℃), the cooling rate is controlled at 10℃ / s. During this stage, rapid cooling refines the grain structure of the composite material, improving its strength and hardness. In the medium-low temperature stage below 800℃, the cooling rate is reduced to 5℃ / s. Slow cooling effectively reduces the temperature difference between the surface and core of the billet, lowers thermal stress, and prevents the composite from becoming too compact. Interface cracking; during the cooling process, the temperature difference between the surface and the core is calculated in real time. When the temperature difference approaches 50℃, the system adjusts the air volume and speed of the air cooler to ensure that the temperature difference is controlled within 50℃ throughout the process. The air cooler uses a scroll-type refrigeration unit with a cooling power of 30-60kW and a cold air outlet temperature of 5-15℃. The airflow is evenly applied to the mold surface through the airflow channel formed by the angle steel. When the overall temperature of the composite material blank drops below 300℃, the system delays for 10 minutes and then shuts down the air cooler and vibrator in sequence to avoid residual stress caused by a sudden drop in temperature.

10. A method for producing a heterogeneous metal composite material according to claim 9, characterized in that: In step S8, a four-high reversible billet mill is used for the billet forming process. The working roll diameter is 500-600mm, the support roll diameter is 1200-1400mm, the rated rolling force is 1000-1500kN, and the rolling speed can be adjusted within the range of 0.5-2m / s. The billet rolling temperature is strictly controlled at 800-1000℃. The billet forming process uses 3-5 passes, with the reduction rate decreasing with each pass. The final thickness tolerance of the billet after forming is controlled to be ±0.5mm. The hot rolling process uses a six-high hot rolling mill with a rolling temperature of 900-1100℃ and a total reduction rate of 60-80%. The composite material undergoes multiple rolling passes to refine its grains and densify its structure. After hot rolling, the oxide scale on the surface of the sheet is removed using high-pressure water descaling. The cold rolling process uses an 18-roll precision cold rolling mill at room temperature with a total reduction of 30-50%. Rolling oil is used for lubrication and cooling during the rolling process. The kinematic viscosity (40℃) of the rolling oil is 10-15 mm² / s, and the flash point is ≥180℃. The final product undergoes straightening, edge trimming, and surface polishing. After straightening, the flatness error is ≤0.2 mm / m, the edge trimming accuracy is ±1 mm, the surface roughness Ra is ≤1.6 μm, and the dimensional accuracy meets the Class A requirements of GB / T 708-2016 standard.

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