A high-strength aluminum alloy profile and a method for manufacturing the same

Abstract

This invention provides a high-strength aluminum alloy profile and its manufacturing method. The aluminum alloy material is a non-standard alloy design. Through specific alloy raw material design and preparation method matching the alloy raw material, the obtained aluminum alloy profile has the advantages of smooth surface and high strength. Using the aluminum alloy profile to prepare aluminum alloy photovoltaic frames can effectively reduce the weight of the aluminum alloy photovoltaic frames and reduce production costs while ensuring high mechanical strength. The high-strength photovoltaic frame is more stable and reliable during use.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy profile technology, specifically to a high-strength aluminum alloy profile and its manufacturing method. Background Technology

[0002] Photovoltaic modules, or solar cell modules, are mainly composed of crystalline silicon cells, EVA, tempered glass, backsheets, frames, and cell boxes. Photovoltaic frames primarily include steel frames, aluminum alloy frames, and composite material frames. Among these, aluminum alloy photovoltaic frames, as the key frame material for fixing and sealing photovoltaic modules, have become the most widely used frame material due to their significant advantages such as lightweight, corrosion resistance, high strength, and recyclability, achieving a penetration rate of over 95% in the photovoltaic module market. However, with the rapid development of the photovoltaic industry, cost control has become a key factor for the industry's continued progress. Aluminum alloy photovoltaic frames account for approximately 10% of the cost of photovoltaic modules. This relatively high cost percentage undoubtedly drives up the overall cost of photovoltaic modules to some extent, thus impacting the large-scale adoption and market competitiveness of the photovoltaic industry.

[0003] Cost structure analysis of aluminum alloy photovoltaic frames reveals that raw material costs account for approximately 89% of the total cost, while processing costs account for about 11%. This high proportion of raw materials keeps production costs high, squeezing profit margins for manufacturers and hindering the healthy development of the industry. Currently, aluminum alloy photovoltaic frames primarily use 6000 series aluminum alloys, with 6063, 6005, and 6005A being common types. To reduce costs, the industry often reduces raw material input by thinning the wall thickness, but this leads to a decrease in the mechanical properties of the photovoltaic frame, failing to meet the stress requirements of photovoltaic modules under different installation conditions. Furthermore, the traditional structural design of aluminum alloy photovoltaic frames results in significant weight, with a single frame typically weighing 2309.39 grams, further increasing raw material consumption and transportation costs. Additionally, the traditional method of connecting the long and short sides of the frame using stamping and riveting means that when the cross-sectional structure is optimized for weight reduction, the internal cavity disappears, rendering the original connection method ineffective. Moreover, the structural changes alter the stress distribution, making safety difficult to guarantee.

[0004] Therefore, in the production process of aluminum alloy photovoltaic frames, reducing raw material costs and product weight while ensuring the strength and safety of the photovoltaic frame products is of great practical significance for promoting the sustainable development of the photovoltaic industry. Summary of the Invention

[0005] In view of this, the present invention provides a high-strength aluminum alloy profile and its manufacturing method. The aluminum alloy material is a non-standard alloy design. Through specific alloy raw material design and preparation method matching the alloy raw material, the obtained aluminum alloy profile has the advantages of smooth surface and high strength. Using the aluminum alloy profile to prepare aluminum alloy photovoltaic frames can effectively reduce the weight of aluminum alloy photovoltaic frames and reduce production costs while ensuring high mechanical strength. The high-strength photovoltaic frame is more stable and reliable during use.

[0006] The technical solution of the present invention is as follows: A high-strength aluminum alloy profile, comprising the following components by weight percentage: Cu 0.3-0.35wt%, Fe 0.13wt%, Mg 0.64-0.72wt%, Mn 0.05wt%, Si 0.57-0.61wt%, Cr 0.05wt%, Zn 0.02wt%, Ti 0.03wt%, individual impurities ≤0.05wt%, total impurities ≤0.15wt%, balance Al.

[0007] Preferably, the high-strength aluminum alloy profile comprises the following components by weight percentage: Cu 0.33wt%, Fe 0.13wt%, Mg 0.66wt%, Mn 0.05wt%, Si 0.59wt%, Cr 0.05wt%, Zn 0.02wt%, Ti 0.03wt%, individual impurities ≤0.05wt%, total impurities ≤0.15wt%, balance Al.

[0008] The design principles of the above alloy components are as follows: In this invention, Si and Mg form the Mg2Si strengthening phase, which is the main strengthening element of aluminum alloy. Controlling the Si content to 0.57-0.61wt% can ensure the formation of sufficient strengthening phase while avoiding surface defects caused by excessive Si. In this invention, Mg and Si form a Mg2Si phase with a reasonable ratio, ensuring a balance between the strength and plasticity of the alloy. Excessive Mg will lead to a decrease in the toughness of the alloy, while insufficient Mg will result in poor strengthening effect. Therefore, the Mg content is controlled at 0.64-0.72 wt%. In this invention, the addition of Cu can improve the strength and corrosion resistance of the alloy. By controlling the Cu content to 0.3-0.35 wt%, the strengthening effect can be enhanced, while avoiding the problem of poor alloy processing performance due to excessive Cu. In this invention, Mn and Cr can refine the grains. By controlling the content of Mn and Cr, the strength and stress corrosion resistance of the alloy can be improved while ensuring the plasticity of the alloy. In this invention, Fe is an unavoidable impurity element, which is controlled at 0.13 wt% to reduce the formation of harmful phases and ensure the processing performance and surface quality of the alloy. In this invention, the addition of Zn and Ti can further optimize the microstructure of the alloy and improve its overall performance.

[0009] The manufacturing method of the above-mentioned high-strength aluminum alloy profiles includes the following processes: homogenization of aluminum rods, extrusion, quenching, stretching and straightening, artificial aging, surface treatment, and packaging and inspection.

[0010] Preferably, the aluminum rod is homogenized by homogenizing it at 550-570℃ for 5.5-6.5 hours to eliminate component segregation and microstructure inhomogeneity within the aluminum rod, thereby improving subsequent processing performance and product quality stability.

[0011] Preferably, the aluminum rod is homogenized at 560°C for 6 hours.

[0012] Preferably, the extrusion includes a preparation stage and an extrusion molding stage; The preparation phase involves the following process: The aluminum rods are heated using an induction heating furnace at a temperature of 460±20℃ for 1 hour to ensure good plasticity. Preheat the extrusion cylinder to 400±20℃ 2 hours in advance to avoid uneven extrusion stress caused by excessive temperature difference between the aluminum rod and the extrusion cylinder. Preheat the mold and keep it at 440-480℃ for 3-4 hours to ensure uniform mold temperature and reduce mold wear and surface defects of the profile during extrusion. Extrusion molding involves placing the prepared aluminum rods onto the extrusion machine for extrusion molding. The temperature of the aluminum rods, extrusion cylinder, and die is checked every hour to ensure stable extrusion process parameters.

[0013] Preferably, the mold is preheated at 460°C for 3.5 hours.

[0014] Preferably, the quenching is performed by air-cooling quenching to cool the extruded profile, with a quenching cooling rate ≥200℃ / min. Rapid cooling ensures the supersaturation of the solid solution in the alloy, laying the foundation for subsequent age hardening.

[0015] Preferably, the quenching cooling rate is 220℃ / min.

[0016] Preferably, the stretching and straightening is carried out under the condition that the profile temperature is <50℃, and the stretching amount is 0.5-1%; the stretched and straightened profile is cut to length, and the allowable deviation of the cutting length is 0-5mm, to ensure that the dimensional accuracy of the profile meets the assembly requirements.

[0017] Preferably, the stretching amount is 0.7%.

[0018] Preferably, the artificial aging process involves loading the sawn profiles into a material frame, with 4 frames of profiles being aged per furnace. The artificial aging conditions are: holding at 200±5℃ for 2.5-3.5 hours. After artificial aging, the profiles are removed from the furnace and cooled to room temperature. The hardness of the profiles is then tested according to the drawing requirements to ensure that the profile strength meets the standards.

[0019] Preferably, the surface treatment involves transferring the aged profiles to the surface treatment workshop, where they undergo sandblasting, oxidation top discharge, oxidation middle control, and oxidation bottom discharge processes in sequence to make the aluminum alloy profiles smooth and improve their corrosion resistance and appearance quality. Each frame of profiles should be filled out with a production accompanying card as required, and each layer should guarantee 28 profiles to facilitate orderly production in the sandblasting process. Packaging inspection involves conducting a final inspection of the surface-treated profiles. Once the inspection is passed, the profiles are packaged according to the packaging operation instructions, awaiting further processing or shipment.

[0020] The aluminum alloy profile manufacturing process of this invention has clear parameters and strong operability. Strict process standards and quality control measures have been formulated for each process, from aluminum rod homogenization, extrusion, quenching to aging and surface treatment, to ensure stable and consistent product quality. At the same time, the process is environmentally friendly and controllable. Pollutants are treated by supporting facilities and discharged in compliance with national green production requirements.

[0021] An aluminum alloy photovoltaic frame is made of the aforementioned high-strength aluminum alloy profile. The aluminum alloy photovoltaic frame includes two long frames, two short frames, and four corner brackets. The long and short frames are connected by the corner brackets to form a rectangular frame structure.

[0022] Preferably, the long border and the short border are connected by corner brackets; The long frame includes a bottom edge A, a side edge A, and a clamping part A; The short frame includes a bottom edge B, a side edge B, and a clamping part B; The corner bracket includes connecting edge A and connecting edge B. The inner side of connecting edge A is connected to the outer side of side edge A, and the inner side of connecting edge B is connected to the outer side of side edge B.

[0023] Preferably, a reinforcing block is provided at the connection point of the connecting edge A and the connecting edge B of the corner bracket to improve the overall robustness of the photovoltaic frame.

[0024] Preferably, the connecting edge A and the side edge A are connected by self-piercing rivets, and the connecting edge B and the side edge B are connected by self-piercing rivets. Self-piercing rivets do not require pre-punching and can directly penetrate the profile for riveting. The connection firmness is 30% higher than that of ordinary stamped rivets, and the riveting process can be automated and has high repeatability, which is suitable for the assembly requirements of new structural frame.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The high-strength aluminum alloy profile of the present invention achieves a balance between high strength and good processing performance and a smooth surface through non-standard alloy composition design and precise manufacturing process; the high-strength aluminum alloy profile has a tensile strength ≥320MPa, a yield strength ≥280MPa, and an elongation after fracture ≥8%, which is significantly improved in strength compared with traditional 6xxx series aluminum alloy profiles, and can meet the usage requirements of photovoltaic frames under complex stress conditions.

[0026] 2. The photovoltaic frame is made using the aluminum alloy profile of the present invention. Under the premise of ensuring strength and safety, the weight of a single frame is reduced to 2020.80 grams, a weight reduction of 12.5%. This effectively reduces the amount of aluminum alloy raw materials used, lowers the proportion of raw material costs in the total cost, reduces product transportation costs, and increases the profit margin of the manufacturing enterprise.

[0027] 3. In response to the assembly requirements of the new structural frame, this invention uses self-piercing rivets as the connection method. This connection method does not require pre-punching, has high assembly efficiency, strong connection, and is suitable for connection of different materials, solving the problem that the traditional stamping riveting method cannot be applied in the new structural frame; the reinforcing block design at the corner code connection further improves the overall stability of the frame. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 The phase diagram is for the high-strength aluminum alloy profile of Example 1.

[0030] Figure 2 The temperature-phase content relationship diagram is shown for the high-strength aluminum alloy profile of Example 1.

[0031] Figure 3 This is the phase diagram of the aluminum alloy profile in Example 2.

[0032] Figure 4 This is a temperature-phase content relationship diagram for the aluminum alloy profile in Example 2.

[0033] Figure 5 This is the phase diagram of the aluminum alloy profile in Example 3.

[0034] Figure 6 This is a temperature-phase content relationship diagram for the aluminum alloy profile in Example 3.

[0035] Figure 7 This is a schematic diagram of the long border structure in Example 6.

[0036] Figure 8 This is a schematic diagram of the short border structure in Example 6.

[0037] Figure 9 This is a schematic diagram of the corner code in Example 6.

[0038] Figure 10 This is a schematic diagram of the structure along the long side of Comparative Example 1.

[0039] Figure 11 This is a schematic diagram of the short side of Comparative Example 1.

[0040] Figure 12 This is a schematic diagram of the structure of a corner code for comparison 1.

[0041] In the diagram, 1-long frame, 101-bottom edge A, 102-side edge A, 103-clamping part A, 1031-cuboid frame, 1032-anti-slider A, 1033-anti-slider B, 2-short frame, 201-bottom edge B, 202-side edge B, 203-clamping part B, 3-corner bracket, 301-connecting edge A, 302-connecting edge B, 4-reinforcing block. Detailed Implementation

[0042] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions of this invention will be clearly and completely described below in conjunction with the embodiments of this invention. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this invention.

[0043] Example 1 A high-strength aluminum alloy profile, comprising the following components by weight percentage: Cu 0.33wt%, Fe 0.13wt%, Mg 0.66wt%, Mn 0.05wt%, Si 0.59wt%, Cr 0.05wt%, Zn 0.02wt%, Ti 0.03%, single impurity 0.05wt%, total impurities 0.15wt%, balance Al; The manufacturing method of the above-mentioned high-strength aluminum alloy profiles is as follows: Step 1: Homogenize the aluminum rod. The aluminum rod was homogenized at 560℃ for 6 hours to eliminate component segregation and microstructure inhomogeneity inside the aluminum rod, thereby improving subsequent processing performance and product quality stability. Step two, extrusion, includes the preparation stage and extrusion molding; The preparation phase consists of the following steps: The aluminum rods are heated using an induction heating furnace at a temperature of 460℃ for 1 hour to ensure good plasticity. Preheat the extrusion cylinder to 400℃ 2 hours in advance to avoid uneven extrusion stress caused by excessive temperature difference between the aluminum rod and the extrusion cylinder. The mold is preheated and kept at 460℃ for 3.5 hours to ensure uniform mold temperature and reduce mold wear and surface defects of the profile during extrusion. Extrusion molding involves placing the prepared aluminum rods onto the extrusion machine for extrusion molding. The temperature of the aluminum rods, extrusion cylinder, and die is checked every hour to ensure the extrusion effect. Step 3, quenching. The extruded profiles were cooled by air-cooled quenching at a rate of 220℃ / min. Rapid cooling ensured the supersaturation of the solid solution in the alloy, laying the foundation for subsequent age hardening. Step four, stretching and straightening. After the profile cools to 45℃, perform tensile straightening with a stretching amount of 0.7%. Then, the stretched and straightened profiles are cut to length, with a permissible deviation of 0-5mm in the cutting length, to ensure that the dimensional accuracy of the profiles meets the assembly requirements. Step 5, manual processing time. The sawn profiles are loaded into the material frame, and four frames of profiles are aged per furnace. The artificial aging conditions are: heat preservation at 200℃ for 3 hours; After artificial aging, the profiles are removed from the furnace and cooled to room temperature. The hardness of the profiles is then tested according to the drawing requirements to ensure that the strength of the profiles meets the standards. Step six, surface treatment. After aging, the profiles are transferred to the surface treatment workshop, where they undergo sandblasting, oxidation top discharge, oxidation middle control, and oxidation bottom discharge processes in sequence to make the aluminum alloy profiles smooth and improve their corrosion resistance and appearance quality. Each frame of profiles should be filled out with a production tracking card as required, and each layer should guarantee 28 profiles to facilitate orderly production of the sandblasting process; Step 7, Packaging Inspection After surface treatment, the profiles undergo a final inspection. Once the inspection is passed, they are packaged according to the packaging operation instructions and await further processing or shipment. The profile has a tensile strength of 367 MPa, a yield strength of 295 MPa, and an elongation after fracture of 10.5%. Example 2 The difference from Example 1 is that the element content of the high-strength aluminum alloy profile is different. In the high-strength aluminum alloy profile of Example 2, the weight percentage of Mg element is 0.64%, and the rest is the same as in Example 1.

[0044] Example 3 The difference from Example 1 is that the element content of the high-strength aluminum alloy profile is different. In the high-strength aluminum alloy profile of Example 3, the weight percentage of Mg element is 0.72%, and the rest is the same as in Example 1.

[0045] The profiles obtained in Examples 1, 2, and 3 were subjected to performance tests, and the results are shown in Table 1 below: Table 1 Performance test results of Examples 1, 2 and 3

[0046] Combined with Table 1 and Figures 1-6 It can be seen that: First, as the Mg content increases, the equilibrium peak mass fraction and room temperature equilibrium precipitation of the core age-strengthening phase Mg2Si increase simultaneously, and the complete solution temperature rises accordingly. Specifically, in Example 2 (0.64% Mg), the peak Mg2Si content is approximately 0.78 wt% and the complete solution temperature is approximately 515 °C; in Example 1 (0.66% Mg), the peak Mg2Si content is approximately 0.82 wt% and the complete solution temperature is approximately 520 °C; and in Example 3 (0.72% Mg), the peak Mg2Si content is approximately 0.92 wt% and the complete solution temperature is approximately 530 °C. When the Mg content fluctuates within the range of 0.64-0.72 wt%, it has almost no effect on the content and precipitation-dissolution temperature of Fe-based brittle impurity phases such as AlFeSi-α, AlFeSi-β, and Al3Fe. This proves that these harmful phases are determined only by the content of Fe and Si elements and are not affected by small adjustments in the Mg content within this range. In other words, the Mg content is the core variable that regulates the precipitation-dissolution behavior of the Mg2Si core strengthening phase in the aluminum alloy of this system; Secondly, both high and low Mg content will reduce the tensile strength, yield strength and elongation after fracture of the profile, indicating that the Mg content has a significant impact on the mechanical properties of aluminum alloy profiles; the profile provided in Example 1 has the best mechanical properties, indicating that the alloy composition ratio in Example 1 is more reasonable and can better balance strength and plasticity. In terms of strength, the Mg content in Example 2 is relatively low, resulting in a slightly lower total amount of Mg2Si generated. Under the same aging process, the number of strengthening phases that can participate in the dispersed precipitation is limited, leading to insufficient aging strengthening effect and the lowest tensile and yield strengths among the three. In Example 3, the Mg content is relatively high. Although the theoretical peak content of Mg2Si is the highest, the coarse room temperature equilibrium precipitates in the as-cast state are difficult to completely dissolve during the homogenization process. After aging, they are prone to forming coarse precipitates, which reduces the strengthening effect. In contrast, the 0.66wt% Mg ratio in Example 1 ensures sufficient strengthening phase content and achieves dispersed precipitation during the aging process, ultimately achieving the optimal strength performance of 367MPa tensile strength and 295MPa yield strength. From a plasticity perspective, the excess Mg-induced brittle phase and coarse primary Mg2Si phase in Example 3 disrupt the continuity of the aluminum matrix, significantly reducing the alloy's plasticity, resulting in the lowest elongation after fracture among the three. Due to insufficient strengthening phase, Example 2 exhibits weak matrix solid solution strengthening, and its plasticity is also lower than that of Example 1. The composition ratio of Example 1 avoids the precipitation of excessive brittle phases and ensures matrix continuity through uniform aging precipitation, achieving a high elongation after fracture of 10.5%, thus achieving the optimal balance between high strength and high plasticity. Then, in Example 2, the Mg content is low and the solid solution temperature of Mg2Si is even lower. Under the same 560℃ homogenization process, local oversolution and uneven structure are likely to occur, and surface micro-defects are likely to be generated during the extrusion process. In Example 3, the Mg content was too high, and the temperature for complete solid solution of Mg2Si was raised to 530℃. Although solid solution could be achieved by homogenization at 560℃, the dissolution rate of the coarse phase in the as-cast state was slow, and the 6-hour homogenization time was insufficient to completely eliminate it. The residual hard and brittle phase caused surface defects. In Example 1, the Mg ratio was perfectly matched with the homogenization and extrusion processes. Homogenization could achieve complete solid solution of the reinforcing phase, and the extrusion temperature was within the high plasticity range of the alloy, resulting in excellent microstructure uniformity. No surface scratches were caused by hard and brittle phases during the extrusion process, and the optimal surface roughness Ra=0.6μm was finally obtained, which was significantly better than that of Example 2 and Example 3, where the Mg content deviated from the optimal value. It is evident that fluctuations in Mg content affect the uniformity of the alloy microstructure, which in turn determines the surface quality after extrusion molding. Finally, the preparation process of the present invention has a high degree of synergistic compatibility with the composition ratio of Example 1, which can fully release the potential of alloy performance; Among them, the homogenization process, the 560℃×6h homogenization regime used in Example 1, is much higher than the complete solid solution temperature of 520℃ for Mg2Si, which can fully eliminate component segregation and allow Mg and Si elements to be completely dissolved in the aluminum matrix, laying a sufficient supersaturation foundation for subsequent aging strengthening. The extrusion process, with an extrusion temperature of 460°C, falls precisely within the high plasticity range of the alloy in Example 1 (most of the reinforcing phase is dissolved in solid solution, and no abnormal precipitation of brittle phases), ensuring uniform plasticity of the aluminum rod and good extrusion formability. However, the results for Examples 2 and 3 are slightly worse, with a slight decrease in forming quality compared to Example 1. The aging process, with an artificial aging regime of 200℃×3h, precisely matches the optimal dispersion precipitation range of Mg2Si in Example 1, maximizing the aging enhancement effect.

[0047] Example 4 A high-strength aluminum alloy profile, comprising the following components by weight percentage: Cu 0.3wt%, Fe 0.13wt%, Mg 0.66wt%, Mn 0.05wt%, Si 0.57wt%, Cr 0.05wt%, Zn 0.02wt%, Ti 0.03%, individual impurities ≤0.05wt%, total impurities 0.15wt%, balance Al; The manufacturing method of the above-mentioned high-strength aluminum alloy profiles is as follows: Step 1: Homogenize the aluminum rod. The aluminum rod was homogenized at 550℃ for 6.5 hours to eliminate component segregation and microstructure inhomogeneity inside the aluminum rod, thereby improving subsequent processing performance and product quality stability. Step two, extrusion, includes the preparation stage and extrusion molding; The preparation phase consists of the following steps: The aluminum rods are heated using an induction heating furnace at a temperature of 440℃ for 1 hour to ensure good plasticity. Preheat the extrusion cylinder to 380℃ 2 hours in advance to avoid uneven extrusion stress caused by excessive temperature difference between the aluminum rod and the extrusion cylinder. The mold is preheated and kept at 440℃ for 4 hours to ensure uniform mold temperature and reduce mold wear and surface defects of the profile during extrusion. Extrusion molding involves placing the prepared aluminum rods onto the extrusion machine for extrusion molding, and checking the temperature of the aluminum rods, extrusion cylinder, and mold every hour. Step 3, quenching. The extruded profiles were cooled by air-cooled quenching at a rate of 200℃ / min. Rapid cooling ensured the supersaturation of the solid solution in the alloy, laying the foundation for subsequent age hardening. Step four, stretching and straightening. The process is carried out at a profile temperature of 40℃ with a stretching amount of 0.5%. The stretched and straightened profiles are then cut to length with a permissible deviation of 0-5mm to ensure that the dimensional accuracy of the profiles meets the assembly requirements. Step 5, manual processing time. The sawn profiles are loaded into the material frame, and 4 frames of profiles are aged per furnace. The artificial aging conditions are: heat treatment at 195℃ for 3.5 hours. After artificial aging, the profiles are removed from the furnace and cooled to room temperature. The hardness of the profiles is then tested according to the drawing requirements to ensure that the strength of the profiles meets the standards. Step six, surface treatment. After aging, the profiles are transferred to the surface treatment workshop, where they undergo sandblasting, oxidation top discharge, oxidation middle control, and oxidation bottom discharge processes in sequence to make the aluminum alloy profiles smooth and improve their corrosion resistance and appearance quality. Each frame of profiles should be filled out with a production tracking card as required, and each layer should guarantee 28 profiles to facilitate orderly production of the sandblasting process; Step 7, Packaging Inspection After surface treatment, the profiles undergo a final inspection. Once the inspection is passed, they are packaged according to the packaging operation instructions and await further processing or shipment.

[0048] Example 5 A high-strength aluminum alloy profile, comprising the following components by weight percentage: Cu 0.35wt%, Fe 0.13wt%, Mg 0.66wt%, Mn 0.05wt%, Si 0.61wt%, Cr 0.05wt%, Zn 0.02wt%, Ti 0.03%, individual impurities ≤0.05wt%, total impurities 0.15wt%, balance Al; The manufacturing method of the above-mentioned high-strength aluminum alloy profiles is as follows: Step 1: Homogenize the aluminum rod. The aluminum rod was homogenized at 570℃ for 5.5 hours to eliminate component segregation and microstructure inhomogeneity inside the aluminum rod, thereby improving subsequent processing performance and product quality stability. Step two, extrusion, includes the preparation stage and extrusion molding; The preparation phase consists of the following steps: The aluminum rods are heated using an induction heating furnace at a temperature of 480℃ for 1 hour to ensure good plasticity. Preheat the extrusion cylinder to 420℃ 2 hours in advance to avoid uneven extrusion stress caused by excessive temperature difference between the aluminum rod and the extrusion cylinder. The mold is preheated and kept at 480℃ for 3 hours to ensure uniform mold temperature and reduce mold wear and surface defects of the profile during extrusion. Extrusion molding involves placing the prepared aluminum rods onto the extrusion machine for extrusion molding, and checking the temperature of the aluminum rods, extrusion cylinder, and mold every hour. Step 3, quenching. The extruded profiles were cooled by air-cooled quenching at a rate of 240℃ / min. Rapid cooling ensured the supersaturation of the solid solution in the alloy, laying the foundation for subsequent age hardening. Step four, stretching and straightening. The process is carried out at a profile temperature of 48℃ with a stretching amount of 1%. The profiles after stretching and straightening are then cut to length with a permissible deviation of 0-5mm to ensure that the dimensional accuracy of the profiles meets the assembly requirements. Step 5, manual processing time. The sawn profiles are loaded into the material frame, and four frames of profiles are aged per furnace. The artificial aging conditions are: heat treatment at 205℃ for 2.5 hours; after artificial aging, the material is removed from the furnace and cooled to room temperature, and the hardness of the profile is tested according to the drawing requirements to ensure that the strength of the profile meets the standards. Step six, surface treatment. After aging, the profiles are transferred to the surface treatment workshop, where they undergo sandblasting, oxidation top discharge, oxidation middle control, and oxidation bottom discharge processes in sequence to make the aluminum alloy profiles smooth and improve their corrosion resistance and appearance quality. Each frame of profiles should be filled out with a production tracking card as required, and each layer should guarantee 28 profiles to facilitate orderly production of the sandblasting process; Step 7, Packaging Inspection After surface treatment, the profiles undergo a final inspection. Once the inspection is passed, they are packaged according to the packaging operation instructions and await further processing or shipment.

[0049] The results of the profile testing for Examples 4 and 5 are shown in Table 2 below: Table 2 Performance test results of Examples 4 and 5

[0050] Example 6 Combination Figures 7-9 An aluminum alloy photovoltaic frame is provided, with the following dimensions: long frame 2031mm, short frame 1011mm, and corner bracket 35mm (single side). It is made from the high-strength aluminum alloy profile prepared in Example 1; It includes two long borders 1, two short borders 2, and four corner brackets 3; the long borders 1 and short borders 2 are connected by the corner brackets 3; Among them, the long frame 1, the short frame 2 and the corner bracket 3 are all made of aluminum alloy profiles prepared in Example 1; The long frame 1 includes a bottom edge A101, a side edge A102, and a clamping part A103; The short frame 2 includes a bottom edge B201, a side edge B202, and a clamping part B203; Corner code 3 includes connecting edge A301 and connecting edge B302. The inner side of connecting edge A301 is connected to the outer side of side edge A102, and the inner side of connecting edge B302 is connected to the outer side of side edge B202. A reinforcing block 4 is provided at the connection point of the connecting edge A301 and the connecting edge B302 of the corner bracket 3 to improve the sturdiness of the photovoltaic frame; Connecting edge A301 and side edge A102 are connected by self-piercing rivets, and connecting edge B302 and side edge B202 are connected by self-piercing rivets. The clamping part A103 and the clamping part B203 have the same structure. The clamping part A103 includes a U-shaped frame 1031, which is connected to the top surface of the side A102. The horizontal plate of the U-shaped frame 1031 is set at an angle; Anti-slip blocks A1032 and B1033 are provided on the upper horizontal plate of the C-shaped frame 1031; The anti-slip block A1032 is connected to the inverted bracket 1031 at a position close to the vertical plate of the inverted bracket 1031, and the anti-slip block A1032 is tilted downward. The anti-slip block B1033 is connected to the end of the horizontal plate, and the anti-slip block B1033 is set horizontally; The bottom end of anti-slip block A1032 and the bottom surface of anti-slip block B1033 are on the same horizontal plane; A hollow area is formed between anti-slip block A1032 and anti-slip block B1033; When the protective glass is installed into the clamping part A103 and the clamping part B203, a buffer area can be formed for the protective glass, reducing the probability of damage to the protective glass due to vibration or impact and extending the service life of the photovoltaic module; the long frame 1 and the short frame 2 are connected by the corner bracket 3 to form a photovoltaic frame. The aluminum alloy photovoltaic frame (including two long frames 1, two short frames 2, and four corner brackets 3) obtained by assembling the aluminum alloy profile prepared in Example 1 has a total weight of 2020.80 grams; the aluminum alloy photovoltaic frame has a smooth surface and high strength. Under the most risky installation method of 45° tilt and frontal 12-level wind force, the maximum stress of the photovoltaic frame is 200.8MPa and the minimum safety factor is 1.394 (profile yield strength 280 / 200.8), which meets the safety requirements for the use of photovoltaic modules.

[0051] Comparative Example 1 Existing photovoltaic frames are made of 6005 series aluminum alloy, which has a yield strength of 187 MPa; the structure is shown below. Figures 10-12 Given clamping parts A and B of the same length, width, and size, The total weight of the aluminum alloy photovoltaic frame (including two long frames, two short frames, and four corner brackets) in Comparative Example 1 is 2309.39 grams; The comparison shows that the aluminum alloy photovoltaic frame of Example 6 has a total weight reduction of 288.59 grams, or 12.5%, compared to the aluminum alloy photovoltaic frame of Comparative Example 1.

[0052] The photovoltaic frames of Example 6 and Comparative Example 1 were tested for weight and stress performance, and the results are shown in Table 3 below: Table 3 shows the test results of the photovoltaic frames in Example 6 and Comparative Example 1.

[0053] As shown in Table 2, the photovoltaic frame of Example 6 maintains high strength and safety factor while significantly reducing weight, and its connection firmness is better than that of traditional frames, thus meeting the requirements for use of photovoltaic modules.

[0054] Tensile strength (MPa), tested according to GB / T 228.1-2021; Yield strength (MPa), GB / T 228.1-2021; Elongation after fracture (%), GB / T 228.1-2021; Surface roughness (Ra), GB / T 1031-2023.

[0055] Although the present invention has been described in detail with reference to preferred embodiments, it is not limited thereto. Various equivalent modifications or substitutions can be made to the embodiments of the present invention by those skilled in the art without departing from the spirit and essence of the invention, and such modifications or substitutions should all be within the scope of the present invention. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should also be covered within the protection scope of the present invention. Therefore, the protection scope of the present invention should be determined by the scope of the claims.

Claims

1. A high strength aluminum alloy shape characterized by, Includes the following components by weight percentage: Cu 0.3-0.35wt%, Fe 0.13wt%, Mg 0.64-0.72wt%, Mn 0.05wt%, Si 0.57-0.61wt%, Cr 0.05wt%, Zn 0.02wt%, Ti 0.03wt%, individual impurities ≤0.05wt%, total impurities ≤0.15wt%, balance Al.

2. The high-strength aluminum alloy profile as described in claim 1, characterized in that, The high-strength aluminum alloy profile comprises the following components by weight percentage: Cu 0.33wt%, Fe 0.13wt%, Mg 0.66wt%, Mn 0.05wt%, Si 0.59wt%, Cr 0.05wt%, Zn 0.02wt%, Ti 0.03wt%, individual impurities ≤0.05wt%, total impurities ≤0.15wt%, balance Al.

3. A method for manufacturing a high-strength aluminum alloy profile as described in claim 1, characterized in that, The process includes: homogenization of aluminum rods, extrusion, quenching, stretching and straightening, artificial aging, surface treatment, and packaging and inspection.

4. The manufacturing method of the high-strength aluminum alloy profile as described in claim 3, characterized in that, The aluminum rod is homogenized by homogenizing it at 550-570℃ for 5.5-6.5 hours.

5. The method for manufacturing high-strength aluminum alloy profiles as described in claim 3, characterized in that, The extrusion includes a preparation stage and an extrusion molding stage; The preparation phase involves the following process: The aluminum rods are heated by using an induction heating furnace to heat the homogenized aluminum rods at a temperature of 460±20℃ for 1 hour. Preheat the extrusion cylinder to 400±20℃ 2 hours in advance; Preheat the mold, and keep it at 440-480℃ for 3-4 hours; Extrusion molding involves placing the prepared aluminum rods onto the extrusion machine for extrusion molding, and checking the temperature of the aluminum rods, extrusion cylinder, and mold every hour.

6. The method for manufacturing high-strength aluminum alloy profiles as described in claim 3, characterized in that, The quenching process involves air-cooled quenching to cool the extruded profile, with a quenching cooling rate ≥200℃ / min.

7. The method for manufacturing high-strength aluminum alloy profiles as described in claim 3, characterized in that, The stretching and straightening is carried out under the condition that the profile temperature is <50℃, and the stretching amount is 0.5-1%.

8. The method for manufacturing high-strength aluminum alloy profiles as described in claim 3, characterized in that, The artificial aging process involves loading the sawn profiles into a material frame, with 4 frames of profiles being aged per furnace. The artificial aging conditions are: holding at 200±5℃ for 2.5-3.5 hours.

9. An aluminum alloy photovoltaic frame, characterized in that, It is made from the high-strength aluminum alloy profile described in claim 1 or 2; The aluminum alloy photovoltaic frame includes two long frames, two short frames, and four corner brackets. The long and short frames are connected by the corner brackets to form a rectangular frame structure. The long and short borders are connected by corner brackets; The long frame includes a bottom edge A, a side edge A, and a clamping part A; The short frame includes a bottom edge B, a side edge B, and a clamping part B; The corner bracket includes connecting edge A and connecting edge B. The inner side of connecting edge A is connected to the outer side of side edge A, and the inner side of connecting edge B is connected to the outer side of side edge B.

10. The aluminum alloy photovoltaic frame as described in claim 9, characterized in that, A reinforcing block is provided at the connection point of the connecting edge A and the connecting edge B of the corner bracket; The connecting edge A and the side edge A are connected by self-piercing rivets, and the connecting edge B and the side edge B are connected by self-piercing rivets.

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