Conductor and method for producing a conductor, cable

Abstract

The application relates to the technical field of wires, in particular to a wire and a preparation method thereof and a cable. The wire comprises a plurality of aluminum alloy monofilaments which are twisted with each other; the aluminum alloy monofilament comprises the following components in percentage by mass: Mg 0.3%-0.5%, Si 0.1%-0.4%, Fe 0.1%-0.25%, Cu 0.015%-0.025%, Ce 0.05%-0.1%, Y 0.02%-0.06%, B 0.001%-0.008%, Ti 0.01%-0.05%, and the balance is Al. The wire has excellent mechanical properties and electrical conductivity.

Description

Technical Field

[0001] This application relates to the field of conductor technology, and in particular to conductors and their preparation methods, and cables. Background Technology

[0002] In the field of power cable conductors and wires, aluminum alloys have become a core material to replace copper cores due to their advantages such as light weight, corrosion resistance, and low cost. They are widely used in power transmission, urban power grids, and industrial power distribution. Aluminum alloy wires typically need to meet both high conductivity and medium-to-high strength requirements. High conductivity reduces transmission losses and improves power transmission efficiency; medium-to-high strength ensures good tensile strength and creep resistance during stranding, laying, and operation, thereby mitigating problems such as wire breakage and deformation.

[0003] In the traditional aluminum alloy material manufacturing process, there is a significant trade-off between the conductivity and strength of aluminum alloy materials: if impurity elements such as Fe and Si are added to improve strength, these elements are prone to forming coarse and brittle phases at grain boundaries, disrupting the continuity of the aluminum matrix, greatly increasing electron scattering, and thus reducing conductivity; if the impurity content is strictly controlled in pursuit of high conductivity, the tensile strength of the aluminum alloy will be reduced, failing to meet the structural load-bearing requirements of the conductor.

[0004] Therefore, the traditional methods for manufacturing wires and cables still need to be improved. Summary of the Invention

[0005] Based on this, one or more embodiments of this application provide a conductor with low resistivity, high tensile strength and elongation, a method for preparing the conductor, and a cable thereof.

[0006] According to a first aspect of the embodiments of this application, a wire is provided, the wire comprising multiple aluminum alloy monofilaments twisted together;

[0007] By mass percentage, aluminum alloy monofilament comprises the following components: Mg 0.3%~0.5%, Si 0.1%~0.4%, Fe 0.1%~0.25%, Cu 0.015%~0.025%, Ce 0.05%~0.1%, Y 0.02%~0.06%, B 0.001%~0.008%, Ti 0.01%~0.05%, with the balance being Al.

[0008] In some embodiments, the wire satisfies at least one of the following characteristics:

[0009] (1) The mass ratio of Mg to Si is 1:(1~1.3);

[0010] (2) The mass ratio of Ce to Y is 1:(0.5~1);

[0011] (3) The mass ratio of B to Ti is 1:(4.5~7).

[0012] In some embodiments, the aluminum alloy monofilament comprises, by mass percentage, the following components: Mg 0.35%~0.45%, Si 0.3%~0.4%, Fe 0.1%~0.2%, Cu 0.018%~0.022%, Ce 0.07%~0.09%, Y 0.03%~0.05%, B 0.004%~0.005%, Ti 0.02%~0.03%, with the balance being Al.

[0013] In some embodiments, the aluminum alloy monofilament satisfies at least one of the following characteristics:

[0014] (1) The elongation of the aluminum alloy monofilament is ≥5%;

[0015] (2) The tensile strength of the aluminum alloy monofilament is ≥250MPa;

[0016] (3) The conductivity of aluminum alloy monofilament is ≥59% IACS.

[0017] According to a second aspect of the embodiments of this application, a method for preparing a wire is provided, comprising the following steps:

[0018] Aluminum alloy monofilaments are prepared by providing raw materials according to the above-mentioned composition of aluminum alloy monofilaments.

[0019] Aluminum alloy monofilaments are stranded to prepare conductors.

[0020] In some embodiments, the preparation of aluminum alloy monofilaments includes the following steps:

[0021] The raw materials are melted to obtain an alloy melt;

[0022] The alloy melt is subjected to refining, casting, rolling, drawing and aging treatments in sequence to obtain aluminum alloy monofilaments.

[0023] The raw materials for preparing aluminum alloy monofilaments include grain refiners; grain refiners include aluminum-boron master alloys and aluminum-titanium-boron master alloys.

[0024] In some embodiments, the step of preparing the aluminum alloy monofilament satisfies at least one of the following characteristics:

[0025] (1) The melting temperature is 700℃~740℃;

[0026] (2) The refining temperature is 750℃~780℃;

[0027] (3) Based on the total mass of the alloy melt, the amount of refining agent added during the refining process is 1.5 kg / t to 2 kg / t;

[0028] (4) The casting temperature is 690℃~710℃;

[0029] (5) The cooling water pressure for the casting process is 0.06MPa~0.08MPa;

[0030] (6) The cooling water temperature for the casting process is 35℃~45℃;

[0031] (7) The outlet temperature of the casting ingot after casting is 410℃~430℃.

[0032] In some embodiments, the step of preparing the aluminum alloy monofilament satisfies at least one of the following characteristics:

[0033] (1) The entry temperature of the rolling process is 490℃~520℃;

[0034] (2) The rolling mill speed for the rolling process is 340 rpm to 360 rpm;

[0035] (3) The temperature for wire drawing is 30℃~45℃;

[0036] (4) The aging treatment temperature is 160℃~180℃ and the time is 8h~10h.

[0037] In some embodiments, the step of preparing the aluminum alloy monofilament satisfies at least one of the following characteristics:

[0038] (1) The temperature of the emulsion during the rolling process is 47℃~50℃;

[0039] (2) The pressure of the emulsion during the rolling process is 0.03MPa~0.04MPa.

[0040] According to a third aspect of the embodiments of this application, a cable is provided, comprising the above-described conductor or a conductor prepared by the above-described conductor preparation method.

[0041] Compared with traditional technologies, this application has the following advantages:

[0042] In the conductive wire of this application, the aluminum alloy monofilament contains components in a specific ratio. Mg and Si, as the main alloying elements, significantly improve the tensile strength and hardness of the aluminum alloy monofilament. Fe works synergistically with Si and Ce, combining with excess Si to form fine, dispersed ternary compounds, reducing the risk of grain boundary embrittlement. Fe also acts as a second phase particle, enhancing the toughness and strength of the aluminum alloy and promoting grain refinement through recrystallization. Furthermore, Mg and Si have minimal impact on conductivity, maintaining high conductivity while improving strength. Ce and Y, as composite rare earth elements, synergistically purify grain boundaries, inhibit the formation of coarse precipitates, refine grains, and reduce the negative impact of solid solution strengthening on conductivity. B and Ti combine to form the efficient grain refinement system, TiB2, with dispersed TiB2 particles significantly improving microstructure uniformity and conductivity stability. These elements, along with Cu, Y, B, and Ti, work together to produce an aluminum alloy monofilament with low resistivity and high tensile strength and elongation. This improves the electrical performance and overall tensile strength of conductors and cables, better meeting their structural load-bearing requirements. Detailed Implementation

[0043] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, a detailed description of specific embodiments of this application is provided. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0044] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. Unless otherwise specifically stated, all raw materials, reagents, instruments, and equipment used in this application are commercially available or can be prepared by existing methods.

[0045] In this application, the terms "multiple", "various", "multiple times", "multi-dimensional", etc., unless otherwise specified, refer to a quantity greater than or equal to 2. For example, "one or more" means one or more than or equal to two.

[0046] The terms “combinations of,” “any combination of,” and “any combination of” used in this article include all suitable combinations of any two or more of the listed items.

[0047] In this document, the term "suitable" as used in phrases such as "suitable combination," "suitable method," and "any suitable method" refers to the ability to implement the technical solution of this application, solve the technical problem of this application, and achieve the expected technical effect of this application.

[0048] In this application, terms such as "further," "even further," and "particularly" are used to describe purposes and indicate differences in content, but should not be construed as limiting the scope of protection of this application.

[0049] In this application, the terms "first aspect," "second aspect," "third aspect," "fourth aspect," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or quantity, nor should they be construed as implicitly indicating the importance or quantity of the indicated technical features. Moreover, "first," "second," "third," "fourth," etc., serve only as a non-exhaustive enumeration and should be understood not to constitute a closed limitation on quantity.

[0050] In this application, the technical features described in an open-ended manner include both closed technical solutions consisting of the listed features and open technical solutions that include the listed features.

[0051] In this application, numerical intervals (i.e., numerical ranges) are involved. Unless otherwise specified, the selected numerical distributions within the aforementioned numerical intervals are considered continuous and include the two endpoints (i.e., the minimum and maximum values) of the numerical range, as well as every value between these two endpoints. Unless otherwise specified, when a numerical interval refers only to integers within that interval, it includes the two endpoint integers of the numerical range, as well as every integer between the two endpoints. In this document, this is equivalent to directly listing every integer. For example, if t is an integer selected from 1 to 10, it means that t is any integer selected from the group of integers consisting of 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Furthermore, when multiple ranges are provided to describe features or characteristics, these ranges can be merged. In other words, unless otherwise specified, the ranges disclosed herein should be understood to include any and all subranges to which they are included.

[0052] Unless otherwise specified, the temperature parameters in this application are permitted to be either constant-temperature treatment or variations within a certain temperature range. It should be understood that the constant-temperature treatment allows temperature fluctuations within the precision range of the instrument control, such as ±5℃, ±4℃, ±3℃, ±2℃, or ±1℃.

[0053] In this application, "room temperature" or "normal temperature" generally refers to 4℃~35℃, for example, 20℃±5℃. In some embodiments of this application, "room temperature" or "normal temperature" refers to 10℃~30℃. In some embodiments of this application, "room temperature" or "normal temperature" refers to 20℃~30℃.

[0054] In this application, %(w / w) and wt% both represent weight percentage, %(v / v) refers to volume percentage, and %(w / v) refers to mass-volume percentage.

[0055] Some embodiments of this application provide a wire comprising multiple intertwined aluminum alloy monofilaments;

[0056] By mass percentage, aluminum alloy monofilament comprises the following components: Mg 0.3%~0.5%, Si 0.1%~0.4%, Fe 0.1%~0.25%, Cu 0.015%~0.025%, Ce 0.05%~0.1%, Y 0.02%~0.06%, B 0.001%~0.008%, Ti 0.01%~0.05%, with the balance being Al.

[0057] The conductor of this application comprises multiple intertwined aluminum alloy monofilaments. Mg and Si elements are the main alloying elements in the aluminum alloy monofilaments, which can significantly improve its mechanical properties such as tensile strength and hardness, while retaining high conductivity. Fe element can work synergistically with Si and Ce elements to combine with excess Si to form fine and dispersed ternary compounds, reducing the risk of grain boundary embrittlement. At the same time, as a second phase particle, it can improve the toughness and strength of the aluminum alloy and promote grain refinement during recrystallization. Moreover, Mg and Si elements have little impact on conductivity, thus maintaining high conductivity while improving strength.

[0058] In some embodiments, the composition of the aluminum alloy monofilament also includes impurity elements.

[0059] Furthermore, the content of impurity elements is ≤0.04%. It is understood that impurity elements are not essential elements, but are introduced from the raw materials or smelting process.

[0060] As an example, the mass percentage of Mg can be 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, or any value within the range formed by any two of the above points.

[0061] Furthermore, the mass percentage of Mg is 0.35% to 0.45%.

[0062] As an example, the mass percentage of Si can be 0.1%, 0.15%, 0.2%, 0.25%, 0.3%, 0.35%, 0.4%, or any value within the range formed by any two of the above points.

[0063] Furthermore, the mass percentage of Si is 0.3% to 0.4%.

[0064] As an example, the mass percentage of Fe can be 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, or any value within the range formed by any two of the above points.

[0065] Furthermore, the mass percentage of Fe is 0.1% to 0.2%.

[0066] Understandably, an appropriate amount of Fe can synergistically interact with Si and Ce, combining with excess Si to form fine, dispersed ternary compounds, reducing the risk of grain boundary embrittlement. Simultaneously, as second-phase particles, it enhances the toughness and strength of the aluminum alloy and promotes recrystallization and grain refinement. Furthermore, excessive Fe does not disrupt the uniformity of the microstructure by forming coarse, brittle compounds. Moreover, the grain refiner of this application enables a more uniform distribution of elements in the alloy, thereby promoting the synergistic effect of Fe with other elements and achieving a balance between strength, plasticity, and electrical conductivity.

[0067] As an example, the mass percentage of Cu can be 0.015%, 0.016%, 0.017%, 0.018%, 0.019%, 0.02%, 0.021%, 0.022%, 0.023%, 0.024%, 0.025%, or any value within the range formed by any two of the above points.

[0068] Furthermore, the mass percentage of Cu is 0.018% to 0.022%.

[0069] As an example, the mass percentage of Ce can be 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, or any value within the range formed by any two of the above point values.

[0070] Furthermore, the mass percentage of Ce is 0.07% to 0.09%.

[0071] As an example, the mass percentage of Y can be 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, or any value within the range formed by any two of the above point values.

[0072] Furthermore, the mass percentage of Y is 0.03% to 0.05%.

[0073] As an example, the mass percentage of B can be 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, or any value within the range formed by any two of the above point values.

[0074] Furthermore, the mass percentage of B is 0.004% to 0.005%.

[0075] As an example, the mass percentage of Ti can be 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, or any value within the range formed by any two of the above points.

[0076] Furthermore, the mass percentage of Ti is 0.02% to 0.03%.

[0077] In some embodiments, the mass ratio of Mg to Si is 1:(1~1.3).

[0078] As an example, the mass ratio of Mg to Si can be 1:1, 1:1.1, 1:1.2, 1:1.3, or any value within the range of any two of the above ratios.

[0079] It is understandable that Mg and Si, as the main alloying elements in aluminum alloy monofilaments, can significantly strengthen the aluminum alloy matrix. Furthermore, the mass ratio of Mg to Si also has a significant impact on the alloy's microstructure and properties. Specifically, this application controls the mass ratio of Mg to Si within the aforementioned range, which is more conducive to promoting the precipitation of age-hardening phases, resulting in finer phase sizes and more dispersed distribution. Simultaneously, it reduces excessive Si segregation at grain boundaries, avoids grain boundary catalysis, and achieves higher conductivity while maintaining strength.

[0080] In some embodiments, the mass ratio of Ce to Y is 1:(0.5~1).

[0081] As an example, the mass ratio of Ce to Y can be 1:0.5, 1:0.6, 1:0.7, 1:0.8, 1:0.9, 1:1, or any value within the range of any two of the above ratios.

[0082] Understandably, the proper combination of Ce and Y can leverage the synergistic modification effect of rare earth elements. On the one hand, it can purify the melt and remove harmful impurities; on the other hand, it can suppress the precipitation of coarse phases at grain boundaries, refine grains, and improve grain boundary bonding. This enhances strength and plasticity while minimizing adverse effects on conductivity. If the Y content is too low, the synergistic purification and refining effect of rare earth elements is poor, and coarse precipitates are prone to appear, leading to a decrease in strength, plasticity, and conductivity. If the Y content is too high, excessive rare earth elements are prone to segregation at grain boundaries, forming high-resistivity phases, increasing electron scattering, significantly reducing conductivity, and potentially causing abnormal grain growth, resulting in deterioration of mechanical properties.

[0083] In some embodiments, the mass ratio of B to Ti is 1:(4.5~7).

[0084] As an example, the mass ratio of B to Ti can be 1:4.5, 1:4.6, 1:4.7, 1:4.8, 1:4.9, 1:5, 1:5.1, 1:5.2, 1:5.3, 1:5.4, 1:5.5, 1:5.6, 1:5.7, 1:5.8, 1:5.9, 1:6, 1:6.1, 1:6.2, 1:6.3, 1:6.4, 1:6.5, 1:6.6, 1:6.7, 1:6.8, 1:6.9, 1:7, or any value within the range formed by any two of the above ratios.

[0085] Understandably, a proper ratio of B to Ti can preferentially form fine and dispersed TiB2 particles, preventing excessive Ti dissolution in the aluminum matrix or the formation of coarse Ti-Al phases. This ensures efficient grain refinement while maximizing the retention of high conductivity in the aluminum alloy, achieving a balance between grain refinement and conductivity. If the Ti content is too high, excess Ti will dissolve into the aluminum matrix, significantly increasing resistivity and decreasing conductivity. It also easily forms coarse TiAl3 phases, impairing plasticity. If the B content is too high, excess B easily forms boride agglomerates, losing its grain-refining effect, resulting in uneven microstructure and decreased strength and electrical stability.

[0086] In some embodiments, the elongation of the aluminum alloy monofilament is ≥5%.

[0087] In some embodiments, the tensile strength of the aluminum alloy monofilament is ≥250MPa.

[0088] In some embodiments, the conductivity of the aluminum alloy monofilament is ≥59% IACS.

[0089] The conductor of this application has excellent mechanical and electrical properties, and it has good reliability in processing, installation and complex working conditions, which can extend its service life and reduce maintenance costs.

[0090] Some embodiments of this application also provide a method for preparing a wire, comprising the following steps: providing raw materials according to the above-described composition of aluminum alloy monofilament, and preparing aluminum alloy monofilament;

[0091] Aluminum alloy monofilaments are stranded to prepare conductors.

[0092] In some embodiments, the preparation of aluminum alloy monofilaments includes the following steps:

[0093] The raw materials are melted to obtain an alloy melt;

[0094] Aluminum alloy monofilaments are obtained by sequentially refining, casting, rolling, drawing, and aging the alloy melt.

[0095] In some embodiments, the raw materials for preparing aluminum alloy monofilaments include grain refiners; the grain refiners include aluminum-boron master alloys and aluminum-titanium-boron master alloys.

[0096] In some embodiments, the raw materials for preparing aluminum alloy monofilaments also include aluminum ingots, aluminum-iron master alloys, aluminum-boron master alloys, magnesium ingots, aluminum-silicon master alloys, aluminum-copper master alloys, aluminum-rare earth master alloys, aluminum-yttrium master alloys, and aluminum-titanium-boron master alloys.

[0097] It is understandable that the aluminum element in the composition of aluminum alloy monofilament mainly comes from aluminum ingots; magnesium element comes from magnesium ingots; silicon element comes from aluminum-silicon master alloys; iron element comes from aluminum-iron master alloys; copper element comes from aluminum-copper master alloys; cerium element comes from aluminum-rare earth master alloys; yttrium element comes from aluminum-yttrium master alloys; boron element comes from aluminum-boron master alloys and aluminum-titanium-boron master alloys; and titanium element comes from aluminum-titanium-boron master alloys.

[0098] In the aforementioned aluminum alloy monofilament, aluminum-boron master alloy and aluminum-titanium-boron master alloy are used as grain refiners. Their synergistic effect achieves grain refinement and improves the strength of the aluminum alloy while simultaneously imparting excellent electrical conductivity to the monofilament. Specifically, the aluminum-boron master alloy promotes the preferential formation of TiB2 particles from Ti in the aluminum-titanium-boron master alloy, reducing the amount of Ti dissolved in the aluminum matrix, decreasing the formation of Ti-Al intermetallic compounds, and improving the uniformity of TiB2 phase distribution in the melt, reducing agglomeration tendency, and increasing refinement efficiency. Meanwhile, the influence of boron (B) on the conductivity of the aluminum alloy is relatively small and will not impair the conductivity of the aluminum alloy monofilament.

[0099] In some embodiments, the step of obtaining the alloy melt includes: melting aluminum ingots to obtain aluminum liquid; heating to 700°C~740°C, and sequentially adding aluminum-iron master alloy, aluminum-boron master alloy, magnesium ingot, aluminum-silicon master alloy, aluminum-copper master alloy, aluminum rare earth master alloy, aluminum-yttrium master alloy and aluminum-titanium-boron master alloy to the aluminum liquid, mixing them evenly to obtain the alloy melt.

[0100] It should be noted that when adding intermediate alloys to molten aluminum, the next alloy should be added only after the previous alloy has completely melted. By adding the raw materials in stages, the alloying elements in the melt can be dissolved more thoroughly and evenly.

[0101] In some embodiments, the drawing temperature is 30°C to 45°C.

[0102] As an example, the temperature for wire drawing can be 30℃, 31℃, 32℃, 33℃, 34℃, 35℃, 36℃, 37℃, 38℃, 39℃, 40℃, 41℃, 42℃, 43℃, 44℃, 45℃, or any value within the range of any two of the above values.

[0103] This application uses a low temperature of 30℃~45℃ for wire drawing. Compared with the traditional high temperature wire drawing, it can avoid grain growth and coarsening of precipitates during processing, maintain a fine and uniform structure, and reduce conductivity loss caused by work hardening. At the same time, low temperature wire drawing can reduce surface oxidation and damage, improve the surface quality and dimensional accuracy of single filaments, and take into account both processability and final product performance.

[0104] In some of these embodiments, the melting temperature is 700°C to 740°C.

[0105] As an example, the melting temperature can be 700℃, 705℃, 710℃, 715℃, 720℃, 725℃, 730℃, 735℃, 740℃, or any value within the range formed by any two of the above points.

[0106] In some embodiments, the refining process is carried out at a temperature of 750°C to 780°C.

[0107] As an example, the refining temperature can be 750℃, 755℃, 760℃, 765℃, 770℃, 775℃, 780℃, or any value within the range formed by any two of the above points.

[0108] In some embodiments, the amount of refining agent added during the refining process is 1.5 kg / t to 2 kg / t, based on the total mass of the alloy melt.

[0109] As an example, based on the total mass of the alloy melt, the amount of refining agent added during the refining process can be 1.5 kg / t, 1.6 kg / t, 1.7 kg / t, 1.8 kg / t, 1.9 kg / t, 2.0 kg / t, or any value within the range formed by any two of the above points.

[0110] In some embodiments, refining is carried out using a refining agent and nitrogen.

[0111] Understandably, using refining agents and nitrogen in synergistic degassing can effectively remove hydrogen, solid inclusions, and soluble impurities from molten aluminum, thereby improving melt purity, reducing casting and processing defects, and providing a uniform and stable aluminum alloy melt for subsequent processes.

[0112] In some embodiments, the refining process is performed two or more times.

[0113] Furthermore, each refining process should last no less than 15 minutes.

[0114] Furthermore, the interval between each refining step should be no less than 5 minutes.

[0115] In some embodiments, after refining, the aluminum alloy melt is further subjected to slag removal. Further, after slag removal, the temperature of the aluminum alloy melt is controlled at 750°C to 780°C, and it is allowed to stand for 30 to 40 minutes.

[0116] In some embodiments, after refining and before casting, the following step is further included: filtering the molten aluminum alloy. Further, the filter plate used for filtering is 50-70 mesh. More specifically, it is 60 mesh.

[0117] In some embodiments, the casting temperature is 690°C to 710°C.

[0118] As an example, the casting temperature can be 690℃, 691℃, 692℃, 693℃, 694℃, 695℃, 696℃, 697℃, 698℃, 699℃, 700℃, 701℃, 702℃, 703℃, 704℃, 705℃, 706℃, 707℃, 708℃, 709℃, 710℃, or any value within the range formed by any two of the above points.

[0119] In some embodiments, the cooling water pressure for the casting process is 0.06 MPa to 0.08 MPa.

[0120] As an example, the cooling water pressure for the casting process can be 0.06MPa, 0.07MPa, 0.08MPa, or any value within the range formed by any two of the above points.

[0121] In some embodiments, the cooling water temperature for the casting process is 35°C to 45°C.

[0122] As an example, the cooling water temperature for the casting process can be 35℃, 36℃, 37℃, 38℃, 39℃, 40℃, 41℃, 42℃, 43℃, 44℃, or 45℃, or any value within the range formed by any two of the above points.

[0123] In some embodiments, the ingot outlet temperature during the casting process is 410°C to 430°C.

[0124] As an example, the outlet temperature of the ingot during the casting process can be 410℃, 411℃, 412℃, 413℃, 414℃, 415℃, 416℃, 417℃, 418℃, 419℃, 420℃, 421℃, 422℃, 423℃, 424℃, 425℃, 426℃, 427℃, 428℃, 429℃, or 430℃, or any value within the range formed by any two of the above points.

[0125] In this application, the casting temperature refers to the temperature of the aluminum alloy ingot during the crystallization and solidification process; the cooling water temperature refers to the temperature of the cooling water before it enters the cooling system; the cooling water pressure refers to the water supply pressure of the cooling water in the crystallizer or spray pipe; and the ingot outlet temperature refers to the surface temperature of the ingot when it leaves the crystallizer and enters the secondary water cooling zone.

[0126] In some embodiments, the entry temperature of the rolling process is 490°C to 520°C.

[0127] As an example, the entry temperature of the rolling process can be 490℃, 495℃, 500℃, 505℃, 510℃, 515℃, 520℃, or any value within the range formed by any two of the above points.

[0128] In some embodiments, the mill speed for the rolling process is 340 rpm to 360 rpm.

[0129] As an example, the mill speed for rolling can be 340 rpm, 345 rpm, 350 rpm, 355 rpm, 360 rpm, or any value within the range formed by any two of the above points.

[0130] In some embodiments, the temperature of the emulsion during the rolling process is 47°C to 50°C.

[0131] As an example, the temperature of the emulsion during the rolling process can be 47°C, 48°C, 49°C, 50°C, or any value within the range formed by any two of the above points.

[0132] In some embodiments, the pressure of the emulsion during the rolling process is 0.03 MPa to 0.04 MPa.

[0133] As an example, the pressure of the emulsion during the rolling process can be 0.03MPa, 0.031MPa, 0.032MPa, 0.033MPa, 0.034MPa, 0.035MPa, 0.036MPa, 0.037MPa, 0.038MPa, 0.039MPa, or 0.04MPa, or any value within the range formed by any two of the above points.

[0134] In some embodiments, the aging treatment is carried out at a temperature of 160°C to 180°C for 8 hours to 10 hours.

[0135] As an example, the aging treatment temperature can be 160℃, 161℃, 162℃, 163℃, 164℃, 165℃, 166℃, 167℃, 168℃, 169℃, 170℃, 171℃, 172℃, 173℃, 174℃, 175℃, 176℃, 177℃, 178℃, 179℃, or 180℃, or any value within the range formed by any two of the above points. The aging treatment time can be 8h, 9h, or 10h, or any value within the range formed by any two of the above points.

[0136] In the preparation method described in this application, the synergistic effect of specific alloying elements and reasonable process parameters significantly improves the mechanical and electrical properties of the prepared aluminum alloy monofilaments and wires. By controlling the casting and rolling temperatures, speeds, cooling water temperatures, and pressures, the aluminum alloy monofilaments exhibit uniform microstructure and fewer internal defects, providing stable raw materials for subsequent wire drawing and aging treatments, and ensuring good consistency in the performance of the final products.

[0137] Some embodiments of this application also provide an aluminum alloy monofilament as described above.

[0138] In some embodiments, the aluminum alloy monofilament comprises, by mass percentage, the following components: Mg 0.3%~0.5%, Si 0.1%~0.4%, Fe 0.1%~0.25%, Cu 0.015%~0.025%, Ce 0.05%~0.1%, Y 0.02%~0.06%, B 0.001%~0.008%, Ti 0.01%~0.05%, with the balance being Al.

[0139] It is understood that in the aluminum alloy monofilament provided in this application, the various elements work together and cooperate to give it advantages such as low resistivity, high tensile strength and elongation.

[0140] Some embodiments of this application also provide a method for preparing aluminum alloy monofilament as described above.

[0141] In some embodiments, the method for preparing aluminum alloy monofilament includes the aluminum alloy monofilament preparation steps in the above-described method for preparing conductors.

[0142] Some embodiments of this application also provide a cable, including the above-described conductor or a conductor prepared by the above-described conductor preparation method.

[0143] In some embodiments, the cable includes conductors and an insulating layer covering the surface of the conductors.

[0144] The present application will be further described below with reference to specific embodiments and comparative examples, but these should not be construed as limiting the scope of protection of the present application. Unless otherwise specified, the raw materials involved in the following specific embodiments are all commercially available, the instruments used are all commercially available, and the processes involved are conventionally selected by those skilled in the art unless otherwise specified.

[0145] Example 1

[0146] By mass percentage, the aluminum alloy monofilament in this embodiment comprises: Mg: 0.4%, Si: 0.4%, Fe: 0.18%, Cu: 0.02%, Ce: 0.08%, Y: 0.04%, B: 0.0045%, Ti: 0.027%, with other impurity elements totaling ≤0.04% and Al as the balance.

[0147] The mass ratio of Mg to Si is 1:1, the mass ratio of Ce to Y is 1:0.5, and the mass ratio of B to Ti is 1:6.

[0148] (1) Raw material smelting: Provide Al, AlFe20 (aluminum-iron master alloy with 20wt% iron content), AlB3 (aluminum-boron master alloy with 3wt% boron content), Mg99.90 (magnesium ingot with 99.90% purity), AlSi20 (aluminum-silicon master alloy with 20wt% silicon content), AlCu50 (aluminum-copper master alloy with 50wt% copper content), AlRE10 (aluminum-rare earth master alloy with 10wt% rare earth content), and AlY10 (yttrium) according to the composition of the aluminum alloy monofilament. Raw materials for preparation include 10wt% aluminum-yttrium master alloy and AlTi5B1 (aluminum-titanium-boron master alloy with 5wt% titanium and 1wt% boron content). First, industrial pure aluminum ingots with a purity ≥99.7% are placed in a melting furnace and heated to melt. After the aluminum liquid is completely melted, the temperature is adjusted to 720℃. AlFe20, AlB3, Mg99.90, AlSi20, AlCu50, AlRE10, AlY10, and AlTi5B1 are added in sequence and stirred evenly to obtain the alloy melt.

[0149] (2) Refining treatment: The temperature of the alloy melt is raised to 765℃ and refined by a combination of refining agent and nitrogen. The amount of refining agent added is 1.8Kg / t based on the total mass of the alloy melt. The refining is carried out in two stages, each refining for 18 minutes, with an interval of 8 minutes between the two refining stages. When removing slag, it is slowly gathered from the inside of the liquid surface towards the furnace door, paused for 15 seconds at the furnace door, and then slowly removed. After removing slag, the temperature of the alloy melt is kept at 765℃ and left to stand for 35 minutes.

[0150] (3) Casting process: After the alloy melt is allowed to stand, it is filtered through a 60-mesh ceramic filter plate and the temperature of the aluminum liquid is adjusted to 700℃ for casting. The water pressure of the casting machine cooling system is controlled at 0.07MPa, the cooling water temperature is 40℃, and the ingot outlet temperature is controlled at 420℃ to obtain the alloy ingot.

[0151] (4) Rolling process: The alloy ingot is heated in a frequency doubler heating system to raise the ingot entry temperature to 505℃, and the mill speed is adjusted to 350rpm for rolling. During the rolling process, the emulsion temperature is controlled at 48.5℃ and the emulsion pressure is controlled at 0.035MPa. After rolling, the ingot is cooled quickly with cooling water to control the rod temperature at 90℃, and an alloy rod with a nominal diameter of 9.5mm is obtained.

[0152] (5) Wire drawing: The rolled aluminum alloy rod is drawn at 35°C using a wire drawing machine to obtain an alloy single wire with a nominal diameter of 3.6 mm.

[0153] (6) Aging treatment: The obtained alloy monofilament is placed in an aging furnace at 170°C for 9 hours to obtain aluminum alloy monofilament.

[0154] (7) Make aluminum alloy monofilaments into wires.

[0155] Example 2

[0156] The composition is basically the same as in Example 1, except that the component ratio is different. The specific component ratio is as follows: Mg: 0.3%, Si: 0.3%, Fe: 0.1%, Cu: 0.015%, Ce: 0.05%, Y: 0.02%, B: 0.001%, Ti: 0.0045%, the total amount of other impurity elements is ≤0.04%, and Al is the balance.

[0157] The mass ratio of Mg to Si is 1:1, the mass ratio of Ce to Y is 1:0.4, and the mass ratio of B to Ti is 1:4.5.

[0158] The drawing temperature in step (5) is different. Specifically, the aluminum alloy rod obtained by rolling is drawn at 30°C through a wire drawing machine to obtain an alloy single wire with a nominal diameter of 3.6 mm.

[0159] The aging process in step (6) is different. Specifically, the alloy monofilament is placed in an aging furnace at 160°C for 9 hours to obtain an aluminum alloy monofilament.

[0160] Example 3

[0161] It is basically the same as Example 1, except that the mass ratio of Mg to Si is different, specifically 1:1.3.

[0162] In this embodiment, the amounts of magnesium ingots and aluminum-silicon master alloys in the raw materials are adjusted so that the composition of the aluminum alloy monofilament is Mg: 0.38%, Si: 0.4%, Fe: 0.18%, Cu: 0.02%, Ce: 0.08%, Y: 0.04%, B: 0.0045%, Ti: 0.027%, with the total amount of other impurity elements ≤0.04% and Al as the balance.

[0163] Example 4

[0164] It is basically the same as Example 1, except that the temperature of the drawing process is different; specifically, the temperature of the drawing process in Example 4 is 55°C.

[0165] Example 5

[0166] The process is basically the same as in Example 1, except that the mass percentage of Fe in the aluminum-magnesium-silicon alloy is different; specifically, the mass percentage of Fe in Example 5 is 0.25%.

[0167] Example 6

[0168] The process is basically the same as in Example 1, except that the mass ratio of Ce to Y is different, specifically 1:1. By adjusting the amount of aluminum rare earth master alloy and aluminum yttrium master alloy in the raw materials, the composition of the aluminum alloy monofilament is as follows: Mg: 0.4%, Si: 0.4%, Fe: 0.18%, Cu: 0.02%, Ce: 0.06%, Y: 0.06%, B: 0.0045%, Ti: 0.027%, with the total amount of other impurity elements ≤ 0.04%, and Al as the balance.

[0169] Example 7

[0170] The process is basically the same as in Example 1, except that the mass ratio of B to Ti is different, specifically 1:4.5. By adjusting the amount of aluminum rare earth master alloy and aluminum yttrium master alloy in the raw materials, the composition of the aluminum alloy monofilament is as follows: Mg: 0.4%, Si: 0.4%, Fe: 0.18%, Cu: 0.02%, Ce: 0.08%, Y: 0.04%, B: 0.008%, Ti: 0.036%, with the total amount of other impurity elements ≤0.04% and Al as the balance.

[0171] Example 8

[0172] The process is basically the same as in Example 1, except that AlTi5B1 refining agent is not added to the raw materials to make the composition of the aluminum alloy monofilament Mg: 0.4%, Si: 0.4%, Fe: 0.18%, Cu: 0.02%, Ce: 0.08%, Y: 0.04%, B: 0.0045%, with the total amount of other impurity elements ≤0.04% and Al as the balance.

[0173] Example 9

[0174] The process is basically the same as in Example 1, except that AlB3 refining agent is not added to the raw materials, so that the composition of the aluminum alloy monofilament is Mg: 0.4%, Si: 0.4%, Fe: 0.18%, Cu: 0.02%, Ce: 0.08%, Y: 0.04%, B: 0.0045%, Ti: 0.0027%, with the total amount of other impurity elements ≤0.04% and Al as the balance.

[0175] Comparative Example 1

[0176] It is basically the same as Example 1, except that the mass percentage of element B is different; specifically, it is 0.05 wt%.

[0177] Comparative Example 2

[0178] It is basically the same as Example 1, except that the mass percentage of Si is different; specifically, it is 0.45 wt%.

[0179] Comparative Example 3

[0180] It is basically the same as Example 1, except that the mass percentage of Ce element is different; specifically, it is 0.2 wt%.

[0181] Comparative Example 4

[0182] It is basically the same as Example 1, except that the mass percentage of Cu is different; specifically, it is 0.04 wt%.

[0183] Performance testing: The resistivity of the aluminum alloy monofilaments prepared in the above examples and comparative examples was tested according to GB / T 3048.2-2007 "Test methods for electrical properties of wires and cables - Part 2: Test for resistivity of metallic materials"; the tensile strength and elongation of the aluminum alloy monofilaments prepared in the above examples and comparative examples were tested according to GB / T4909.3-2009 "Test methods for bare wires - Part 3: Tensile test"; the results are shown in Table 1.

[0184] Table 1. Performance test results of aluminum alloy monofilaments prepared in Examples 1-9 and Comparative Examples 1-4

[0185]

[0186] As shown in the table above, compared with Comparative Examples 1 to 4, the aluminum alloy monofilaments prepared in the Examples have better performance in all aspects, with conductivity ≥59%IACS, tensile strength ≥2250MPa, and elongation ≥5.2%. They have superior performance in all aspects, combining high conductivity and medium strength, which enables the conductors produced in subsequent processes to have better performance.

[0187] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0188] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A conductor, characterized in that, The conductor comprises multiple aluminum alloy monofilaments twisted together. The aluminum alloy monofilament comprises the following components by mass percentage: Mg 0.3%~0.5%, Si 0.1%~0.4%, Fe 0.1%~0.25%, Cu 0.015%~0.025%, Ce 0.05%~0.1%, Y 0.02%~0.06%, B 0.001%~0.008%, Ti 0.01%~0.05%, with the balance being Al.

2. The conductor according to claim 1, characterized in that, The conductor satisfies at least one of the following characteristics: (1) The mass ratio of Mg to Si is 1:(1~1.3); (2) The mass ratio of Ce to Y is 1:(0.5~1); (3) The mass ratio of B to Ti is 1:(4.5~7).

3. The conductor according to any one of claims 1 to 2, characterized in that, The aluminum alloy monofilament comprises the following components by mass percentage: Mg 0.35%~0.45%, Si 0.3%~0.4%, Fe 0.1%~0.2%, Cu 0.018%~0.022%, Ce 0.07%~0.09%, Y 0.03%~0.05%, B 0.004%~0.005%, Ti 0.02%~0.03%, with the balance being Al.

4. The conductor according to any one of claims 1 to 2, characterized in that, The aluminum alloy monofilament satisfies at least one of the following characteristics: (1) The elongation of the aluminum alloy monofilament is ≥5%; (2) The tensile strength of the aluminum alloy monofilament is ≥250MPa; (3) The conductivity of the aluminum alloy monofilament is ≥59% IACS.

5. A method for preparing a conductor, characterized in that, Includes the following steps: The aluminum alloy monofilament is prepared by providing the raw materials according to the composition of any one of claims 1 to 4; The aluminum alloy monofilaments are stranded to prepare the conductor.

6. The method for preparing the conductor according to claim 5, characterized in that, The preparation of aluminum alloy monofilaments includes the following steps: The raw materials are melted to obtain an alloy melt; The alloy melt is subjected to refining, casting, rolling, drawing and aging treatments in sequence to obtain the aluminum alloy single wire; The raw materials for preparing the aluminum alloy monofilament include grain refiners; the grain refiners include aluminum-boron master alloys and aluminum-titanium-boron master alloys.

7. The method for preparing the conductor according to claim 6, characterized in that, The steps for preparing aluminum alloy monofilaments must satisfy at least one of the following characteristics: (1) The melting temperature is 700℃~740℃; (2) The refining temperature is 750℃~780℃; (3) Based on the total mass of the alloy melt, the amount of refining agent added in the refining process is 1.5 kg / t to 2 kg / t; (4) The casting temperature is 690℃~710℃; (5) The cooling water pressure for the casting process is 0.06MPa~0.08MPa; (6) The cooling water temperature for the casting process is 35℃~45℃; (7) The outlet temperature of the ingot after the casting process is 410℃~430℃.

8. The method for preparing a conductor according to claim 6, characterized in that, The steps for preparing aluminum alloy monofilaments must satisfy at least one of the following characteristics: (1) The entry temperature of the rolling process is 490℃~520℃; (2) The mill speed for the rolling process is 340 rpm to 360 rpm; (3) The temperature of the wire drawing process is 30℃~45℃; (4) The aging treatment temperature is 160℃~180℃ and the time is 8h~10h.

9. The method for preparing a conductor according to any one of claims 6 to 8, characterized in that, The steps for preparing aluminum alloy monofilaments must satisfy at least one of the following characteristics: (1) The temperature of the emulsion in the rolling process is 47℃~50℃; (2) The pressure of the emulsion in the rolling process is 0.03MPa~0.04MPa.

10. A cable, characterized in that, The conductor includes the conductor prepared by any one of claims 1 to 4 or the conductor prepared by any one of claims 5 to 9.

Images