Fatigue resistant cable, fatigue resistant aluminum alloy monofilament and method of making same, wire

Abstract

The application relates to the technical field of cables, in particular to an anti-fatigue cable, an anti-fatigue aluminum alloy monofilament, a preparation method thereof and a wire. The preparation method of the anti-fatigue cable comprises the following steps: twisting a plurality of anti-fatigue aluminum alloy monofilaments to obtain a core, and wrapping the core with an insulation layer to obtain the anti-fatigue cable; wherein the preparation method of the anti-fatigue aluminum alloy monofilament comprises the following steps: melting an aluminum alloy base material to obtain an aluminum alloy melt; sequentially performing refining degassing treatment, slagging treatment and standing heat preservation treatment on the aluminum alloy melt to obtain a first melt; mixing and melting the first melt with a refiner, controlling the melt temperature to be 700 DEG C-740 DEG C, standing heat preservation for 20 min-40 min to obtain a second melt; and sequentially performing casting treatment, rolling treatment, forming treatment and aging treatment on the second melt to obtain the anti-fatigue aluminum alloy monofilament. The cable has excellent tensile strength, electrical performance and anti-fatigue property.

Description

Technical Field

[0001] This application relates to the field of cable technology, and in particular to fatigue-resistant cables, fatigue-resistant aluminum alloy monofilaments and their preparation methods, and conductors. Background Technology

[0002] The global energy transition towards green and low-carbon technologies is accelerating, creating an urgent need for power cables and conductors to improve efficiency, reduce losses, and conserve resources. Advances in materials science provide core support for power grid upgrades. Aluminum alloys, with their excellent conductivity and lightweight properties, have become a preferred material for ultra-high voltage and smart grid construction, such as power cables and conductors. Aluminum alloy core cables, aluminum alloy core stranded wires, and all-aluminum alloy stranded wires offer significant advantages over traditional copper core cables, aluminum core cables, and aluminum stranded wires.

[0003] Among them, aluminum alloy core cables, aluminum alloy core stranded wires, and all-aluminum alloy stranded wires have both excellent conductivity and high tensile strength. They can carry a larger current for the same cross-section, effectively increasing transmission capacity. They can adapt to various complex environments and reduce the maintenance cost throughout the entire life cycle. Therefore, they are widely used in ultra-high voltage transmission lines.

[0004] However, due to the low elastic modulus of aluminum alloy materials, aluminum alloy core wires are prone to elastic-plastic deformation during long-term operation due to their own weight, icing load, alternating wind load, etc., which can damage the structural stability of cables and conductors, leading to fatigue damage of cables and conductors, affecting the safety and reliability of power transmission, and shortening the service life of cables and conductors.

[0005] Therefore, there is an urgent need for a type of cable and conductor that can improve toughness while ensuring conductivity and tensile strength. Summary of the Invention

[0006] Based on this, this application provides a fatigue-resistant cable, an aluminum alloy monofilament and its preparation method, and a conductor that combine excellent tensile strength, electrical properties and fatigue resistance.

[0007] The technical solution to the above-mentioned technical problems in this application is as follows.

[0008] The first aspect of this application provides a method for preparing a fatigue-resistant cable, comprising the following steps: using multiple fatigue-resistant aluminum alloy monofilaments to obtain a core, and wrapping the core with an insulation layer to obtain a fatigue-resistant cable; wherein, the method for preparing the fatigue-resistant aluminum alloy monofilaments includes the following steps:

[0009] An aluminum alloy substrate is provided, which, by weight percentage, comprises the following components:

[0010] Mg: 0.60%~0.70%, Si: 0.65%~0.75%, Fe: 0.05%~0.15%, Cu: 0.05%~0.10%, B: 0.005%~0.015%, Ce: 0.03%~0.10%, Y: 0.03%~0.10%, total impurity elements ≤0.04%, balance Al;

[0011] The above-mentioned aluminum alloy substrate is melted to obtain an aluminum alloy melt;

[0012] The above-mentioned aluminum alloy melt was subjected to refining and degassing treatment, slag removal treatment, and static heat preservation treatment in sequence to obtain the first melt.

[0013] The first melt is mixed and melted with a refining agent, and the melt temperature is controlled at 700℃~740℃. The mixture is held at this temperature for 20min~40min to obtain the second melt. The refining agent is mainly composed of the following components by mass percentage: Ti: 4.5%~5.5%, C: 0.8%~1.2%, total impurity elements ≤0.5%, and the balance is Al.

[0014] The second melt was subjected to casting, rolling, wire drawing and aging treatment in sequence to obtain fatigue-resistant aluminum alloy monofilament.

[0015] The above-mentioned method for preparing fatigue-resistant cables involves using multiple fatigue-resistant aluminum alloy monofilaments to form the core, and then wrapping the core with an insulation layer to obtain the fatigue-resistant cable. The preparation method for the fatigue-resistant aluminum alloy monofilaments first involves melting an aluminum alloy substrate. The aluminum alloy monofilament substrate includes a specific proportion of Mg, Si, Fe, Cu, B, Ce, and Y. The specific proportions of Si and Mg effectively improve the tensile strength of the aluminum alloy conductor, while B further refines the grain size and improves high-temperature stability. The specific proportions of Ce and Y, combined with the interaction between these components, effectively enhance the strength of the aluminum alloy monofilament. Then, refining and degassing treatment, slag removal treatment, and settling treatment are performed to obtain a first melt. A refining agent is then added and mixed with the melt to obtain a second melt. Finally, the second melt is sequentially subjected to casting, rolling, wire drawing, and aging treatment to obtain the fatigue-resistant aluminum alloy monofilament. In this process, a grain refiner containing Al, Ti, and C is added during the smelting process. By controlling the specific ratio of the grain refiner, it is made to be uniformly dispersed in the melt, which refines the grain size of the aluminum alloy, inhibits grain growth, and improves the microstructure of the material. Combined with the specific element ratio of the aluminum alloy monofilament substrate and smelting process conditions, the material's lightweight and fatigue resistance are synergistically improved, enhancing its fatigue resistance and mechanical stability while also achieving higher conductivity to meet the high-performance requirements of cables.

[0016] In some embodiments, the above-described method for preparing fatigue-resistant aluminum alloy monofilaments satisfies one or more of the following conditions:

[0017] (1) The mass ratio of Mg to Si is 1:0.90~1.10;

[0018] (2) The mass ratio of Ce to Y is 1:0.90~1.10;

[0019] (3) The mass ratio of the above-mentioned refining agent to the total mass of the above-mentioned Ce and the above-mentioned Y is 1.5~2.0:1.

[0020] In some embodiments, the aluminum alloy substrate comprises the following components by weight percentage:

[0021] Mg: 0.60%~0.62%, Si: 0.65%~0.68%, Fe: 0.05%~0.08%, Cu: 0.05%~0.06%, B: 0.005%~0.015%, Ce: 0.03%~0.05%, Y: 0.03%~0.045%, total impurity elements ≤0.04%, balance Al.

[0022] In some embodiments, the above-described method for preparing fatigue-resistant aluminum alloy monofilaments satisfies one or more of the following conditions:

[0023] (1) During the melting process of the above aluminum alloy substrate, the melting temperature is 700℃~740℃;

[0024] (2) The temperature for refining and degassing is 750℃~780℃;

[0025] (3) The refining and degassing process includes the following steps: inert gas is introduced into the above aluminum alloy melt for 15 min to 25 min, and at the same time, a refining agent is added for refining and degassing.

[0026] In some embodiments, the amount of the refining agent added is 1.5 kg / t to 2 kg / t.

[0027] In some embodiments, the above-described method for preparing fatigue-resistant aluminum alloy monofilaments satisfies one or more of the following conditions:

[0028] (1) The temperature for static heat preservation treatment is 750℃~780℃, and the time is 30min;

[0029] (2) The conditions for casting treatment include: casting treatment at 690℃~710℃, and cooling with cooling water at 35℃~45℃, so that the temperature of the ingot is controlled at 410℃~430℃.

[0030] (3) The aging treatment temperature is 140℃~160℃ and the time is 6h~8h;

[0031] (4) The above-mentioned aluminum alloy substrates include AlFe20 alloy, AlB3 alloy, Mg99.90 alloy, AlSi20 alloy, AlCu50 alloy, AlRE10 alloy and AlY10 alloy.

[0032] In another aspect, this application provides an anti-fatigue cable, which is prepared using the above-described method for preparing an anti-fatigue cable.

[0033] Another aspect of this application provides a method for preparing fatigue-resistant aluminum alloy monofilaments, comprising the following steps:

[0034] An aluminum alloy substrate is provided, which, by weight percentage, comprises the following components:

[0035] Mg: 0.60%~0.70%, Si: 0.65%~0.75%, Fe: 0.05%~0.15%, Cu: 0.05%~0.10%, B: 0.005%~0.015%, Ce: 0.03%~0.10%, Y: 0.03%~0.10%, total impurity elements ≤0.04%, balance Al;

[0036] The aluminum alloy substrate is melted to obtain an aluminum alloy melt;

[0037] The aluminum alloy melt is subjected to refining and degassing treatment, slag removal treatment, and static heat preservation treatment in sequence to obtain the first melt.

[0038] The first melt is mixed and melted with a refining agent, and the melt temperature is controlled at 700℃~740℃ and kept at that temperature for 20min~40min to obtain a second melt. The refining agent is mainly composed of the following components by mass percentage: Ti: 4.5%~5.5%, C: 0.8%~1.2%, total impurity elements ≤0.5%, and the balance is Al.

[0039] The second melt is subjected to casting, rolling, wire drawing and aging treatment in sequence to obtain fatigue-resistant aluminum alloy monofilament.

[0040] Another aspect of this application provides a fatigue-resistant aluminum alloy monofilament, which is prepared using the above-described method for preparing fatigue-resistant aluminum alloy monofilament.

[0041] This application also provides a conductor comprising the aforementioned fatigue-resistant aluminum alloy monofilament. Detailed Implementation

[0042] Reference will now be made to detailed embodiments of this application, one or more of which are described below. Each example is provided for explanation and not for limitation of this application. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to this application without departing from its scope or spirit. For example, features described or illustrated as part of one embodiment may be used in another embodiment to produce further embodiments.

[0043] Therefore, this application is intended to cover such modifications and variations falling within the scope of the appended claims and their equivalents. Other objects, features, and aspects of this application are disclosed in or will be apparent from the following detailed description. It will be understood by those skilled in the art that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of this application.

[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.

[0045] The terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element preceded by the phrase “comprising one…” does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. The indefinite articles “a” and “an” preceding an element or component in this application are not restrictive in terms of the quantity (i.e., the number of times) of the element or component. Therefore, “an” or “a” should be interpreted as including one or at least one, and singular elements or components also include plural forms, unless the quantity clearly refers only to the singular. “A plurality” means at least two, such as two, three, etc., unless otherwise expressly specified.

[0046] The weights of the relevant components mentioned in the embodiments of this application can refer not only to the specific content of each component, but also to the proportional relationship between the weights of the components. Therefore, any scaling up or down of the content of the relevant components according to the embodiments of this application is within the scope disclosed in the embodiments of this application. Specifically, the weights mentioned in the embodiments of this application can be well-known units of mass in the chemical industry, such as μg, mg, g, and kg.

[0047] Unless otherwise shown or indicated in the operational embodiments, all figures used to represent the amounts, physicochemical properties, etc., of ingredients in the specification and claims are to be understood to be adjusted by the term "about" in all cases. For example, therefore, unless stated to the contrary, the numerical parameters listed in the foregoing specification and appended claims are approximations, and those skilled in the art can appropriately modify these approximations to obtain the desired characteristics by utilizing the teachings disclosed herein. The use of numerical ranges indicated by endpoints includes all numbers within that range and any range within that range; for example, 1 to 5 includes 1, 1.1, 1.3, 1.5, 2, 2.75, 3, 3.80, 4, and 5, etc.

[0048] One embodiment of this application provides a method for preparing an anti-fatigue cable, comprising the following steps: using multiple anti-fatigue aluminum alloy monofilaments to obtain a core, wrapping the core with an insulation layer to obtain an anti-fatigue cable; wherein, the method for preparing the anti-fatigue aluminum alloy monofilaments comprises the following steps S100 to S500.

[0049] Step S100: Provide an aluminum alloy substrate, which, by mass percentage, comprises the following components:

[0050] Mg: 0.60%~0.70%, Si: 0.65%~0.75%, Fe: 0.05%~0.15%, Cu: 0.05%~0.10%, B: 0.005%~0.015%, Ce: 0.03%~0.10%, Y: 0.03%~0.10%, total impurity elements ≤0.04%, balance Al.

[0051] Step S200: Melt the above aluminum alloy substrate to obtain an aluminum alloy melt.

[0052] Step S300: The above aluminum alloy melt is subjected to refining and degassing treatment, slag removal treatment, and static heat preservation treatment in sequence to obtain the first melt.

[0053] Step S400: Mix and melt the first melt with the refining agent, control the melt temperature at 700℃~740℃ and keep it at that temperature for 20min~40min to obtain the second melt. The refining agent is mainly composed of the following components by mass percentage: Ti: 4.5%~5.5%, C: 0.8%~1.2%, total impurity elements ≤0.5%, and the balance is Al.

[0054] Step S500: The second melt is subjected to casting, rolling, wire drawing and aging treatment in sequence to obtain fatigue-resistant aluminum alloy monofilament.

[0055] The above-mentioned method for preparing fatigue-resistant cables involves using multiple fatigue-resistant aluminum alloy monofilaments to form the core, and then wrapping the core with an insulation layer to obtain the fatigue-resistant cable. The preparation method for the fatigue-resistant aluminum alloy monofilaments first involves melting an aluminum alloy substrate, which includes a specific proportion of Mg, Si, Fe, Cu, B, Ce, and Y. The specific proportions of Si and Mg effectively improve the tensile strength of the aluminum alloy conductor, while B further refines the grain size and improves high-temperature stability. The specific proportions of Ce and Y, combined with the interaction between these components, effectively enhance the strength of the aluminum alloy monofilaments. Then, refining and degassing treatment, slag removal treatment, and settling treatment are performed to obtain a first melt. A refining agent is then added and mixed with the melt to obtain a second melt. Finally, the second melt is sequentially subjected to casting, rolling, wire drawing, and aging treatments to obtain the fatigue-resistant aluminum alloy monofilaments. In this process, a grain refiner containing Al, Ti, and C is added during the smelting process. By controlling the specific ratio of the grain refiner, it is made to uniformly disperse the grain refiner in the melt, refine the grain size of the aluminum alloy, inhibit grain growth, and improve the microstructure of the material. Combined with the specific element ratio of the aluminum alloy monofilament substrate and smelting process conditions, the material's lightweight and fatigue resistance are synergistically improved, enhancing its fatigue resistance and mechanical stability while also achieving higher conductivity, making it suitable for cable production applications.

[0056] In some embodiments, the core is made by twisting together multiple fatigue-resistant aluminum alloy monofilaments.

[0057] It is understood that, by mass percentage, the aluminum alloy substrate contains, but is not limited to, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, or 0.70% Mg; 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, or 0.75% Si; and 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, or 0.15% Fe. Cu includes, but is not limited to, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, or 0.10%; B includes, but is not limited to, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%, 0.010%, 0.011%, 0.012%, 0.013%, 0.014%, or 0.015%; Ce includes, but is not limited to, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, or 0.10%; and Y includes, but is not limited to, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, or 0.10%. In some examples, any two of these point values ​​can be used as endpoints within a range, and the same applies below. It can also be understood that the above-mentioned aluminum alloy substrate may include other components.

[0058] The above melt temperature range is "700℃~740℃", which means the minimum and maximum values ​​of the range of 700℃~740℃, as well as every value between the minimum and maximum values. Specific examples include, but are not limited to, the point values ​​in the embodiments and the following point values: 700℃, 701℃, 702℃, 703℃, 704℃, 705℃, 706℃, 707℃, 708℃, 709℃, 710℃, 711℃, 712℃, 713℃, 714℃, 715℃, 716℃, 717℃, 718℃, 719℃, 720℃, 721℃, 722℃, 723℃, 724℃, 725℃, 726℃, 727℃, 728℃, 729℃, 730℃, 731℃, 732℃, 733℃, 734℃, 735℃, 736℃, 737℃, 738℃, 739℃, or 740℃, or a range consisting of any two of these values. For example, this includes: 700℃~730℃.

[0059] The settling time is set within the range of 20 min to 40 min, which includes the minimum and maximum values ​​within this range, as well as every value between these values. Specific examples include, but are not limited to, the point values ​​in the embodiments and the following point values: 20 min, 21 min, 22 min, 23 min, 24 min, 25 min, 26 min, 27 min, 28 min, 29 min, 30 min, 31 min, 32 min, 33 min, 34 min, 35 min, 36 min, 37 min, 38 min, 39 min, 40 min, or any range of any two of these values. For example, 20 min to 30 min is included.

[0060] In some embodiments, the mass ratio of Mg to Si is 1:0.90 to 1.10. For example, the mass ratio can be 1:0.90, 1:0.91, 1:0.92, 1:0.93, 1:0.94, 1:0.95, 1:0.96, 1:0.97, 1:0.98, 1:0.99, 1:1.00, 1:1.01, 1:1.02, 1:1.03, 1:1.04, 1:1.05, 1:1.06, 1:1.07, 1:1.08, 1:1.09, or 1:1.10.

[0061] Understandably, in Al-Mg-Si alloy conductor materials, Mg and Si, as the main alloying elements, play a strengthening role in the matrix. This application controls the Mg / Si ratio to be 1:0.90~1.10, which can promote the precipitation of the β'' phase (Mg2Si precursor precipitate), making it smaller in size and more dispersed in distribution, and can also reduce the number of dissolved Mg atoms in the matrix, thereby enabling the alloy to obtain higher electrical conductivity.

[0062] In some embodiments, the mass ratio of Ce to Y is 1:0.90 to 1.10. For example, the mass ratio can be 1:0.90, 1:0.91, 1:0.92, 1:0.93, 1:0.94, 1:0.95, 1:0.96, 1:0.97, 1:0.98, 1:0.99, 1:1.00, 1:1.01, 1:1.02, 1:1.03, 1:1.04, 1:1.05, 1:1.06, 1:1.07, 1:1.08, 1:1.09, or 1:1.10.

[0063] In some embodiments, the mass ratio of the refining agent to the total mass of Ce and Y is 1.5 to 2.0:1. For example, the mass ratio can be 1.50:1, 1.51:1, 1.52:1, 1.53:1, 1.54:1, 1.55:1, 1.56:1, 1.57:1, 1.58:1, 1.59:1, 1.60:1, 1.61:1, 1.62:1, 1.63:1, 1.64:1, 1.65:1, 1.66:1, 1.67:1, 1.68:1, 1.69:1, 1.70:1, 1.71... :1, 1.72:1.73:1, 1.74:1, 1.75:1, 1.76:1, 1.77:1, 1.78:1, 1.79:1, 1.80:1, 1.81:1, 1.82:1, 1.83:1, 1.84:1, 1.85:1, 1.86:1, 1.87:1, 1.88:1, 1.89:1, 1.90:1, 1.91:1, 1.92:1, 1.93:1, 1.94:1, 1.95:1, 1.96:1, 1.97:1, 1.98:1, 1.99:1, or 2.00:1.

[0064] In one specific example, the above-mentioned refining agent includes AlTi5C1 refining agent.

[0065] It is understandable that fatigue crack propagation in aluminum alloys is regulated by microstructure factors such as grain size, precipitate type and morphology, and grain boundary characteristics. Grain refinement reduces the alloy's resistance to fatigue crack propagation, while grain boundaries can alter the crack propagation path and rate. Optimizing the material's microstructure by adding Al, Ti, and C-containing refiners can increase dislocation slip resistance, and the increased number of grain boundaries can effectively hinder crack propagation, thereby improving the alloy's fatigue performance. Furthermore, Al, Ti, and C-containing refiners can form highly thermally stable multi-scale strengthening phases coherent with the aluminum matrix, promoting the directional formation of grain boundaries, subgrain boundaries, and dislocations after hot extrusion and multi-pass drawing, inhibiting high-temperature dynamic and static recrystallization, and significantly improving the alloy's tensile and fatigue strength without sacrificing electrical conductivity. More importantly, these multi-scale strengthening phases exhibit excellent thermal stability, showing no significant coarsening or growth at 300℃, and even inducing the precipitation of the main strengthening phase, reducing the concentration of dissolved Mg and Si atoms, and improving the alloy's electrical conductivity.

[0066] In some embodiments, the aluminum alloy substrate comprises the following components by weight percentage:

[0067] Mg: 0.60%~0.62%, Si: 0.65%~0.68%, Fe: 0.05%~0.08%, Cu: 0.05%~0.06%, B: 0.005%~0.015%, Ce: 0.03%~0.05%, Y: 0.03%~0.045%, total impurity elements ≤0.04%, balance Al.

[0068] It is understandable that the Fe content in the above-mentioned components increases the formation of primary particles, thereby reducing the amount of free Si that leads to grain boundary brittleness. As the Fe content increases, the hindering effect of excess Si on electron transport in the alloy is reduced, thus improving the alloy's electrical conductivity. Therefore, controlling the composition of the aluminum alloy substrate within the above-mentioned ratio range can further improve the alloy's toughness and strength, resulting in excellent tensile strength, electrical conductivity, and fatigue resistance, meeting the long-term service requirements of cables.

[0069] In some embodiments, during the melting process of the aluminum alloy substrate, the melting temperature is 700℃~740℃. For example, the temperature can be 700℃, 701℃, 702℃, 703℃, 704℃, 705℃, 706℃, 707℃, 708℃, 709℃, 710℃, 711℃, 712℃, 713℃, 714℃, 715℃, 716℃, 717℃, 718℃, 719℃, 720℃, 721℃, 722℃, 723℃, 724℃, 725℃, 726℃, 727℃, 728℃, 729℃, 730℃, 731℃, 732℃, 733℃, 734℃, 735℃, 736℃, 737℃, 738℃, 739℃, or 740℃.

[0070] In some embodiments, the refining and degassing treatment temperature is 750°C to 780°C. For example, the temperature can be 750°C, 751°C, 752°C, 753°C, 754°C, 755°C, 756°C, 757°C, 758°C, 759°C, 760°C, 761°C, 762°C, 763°C, 764°C, 765°C, 766°C, 767°C, 768°C, 769°C, 770°C, 771°C, 772°C, 773°C, 774°C, 775°C, 776°C, 777°C, 778°C, 779°C, or 780°C.

[0071] In some embodiments, the refining and degassing treatment includes the following steps: introducing an inert gas with a flow rate of 1.5 L / min to 2.5 L / min into the above-mentioned aluminum alloy melt for 15 min to 25 min, while adding a refining agent to carry out the refining and degassing treatment.

[0072] In some embodiments, the inert gas includes one or more of nitrogen or argon.

[0073] In some embodiments, the amount of the refining agent added is 1.5 kg / t to 2 kg / t. For example, the amount added can be 1.5 kg / t, 1.6 kg / t, 1.7 kg / t, 1.8 kg / t, 1.9 kg / t, or 2.0 kg / t.

[0074] In some embodiments, the static heat preservation treatment is carried out at a temperature of 750°C to 780°C for a time of 25 min to 35 min. For example, the temperature can be 750°C, 751°C, 752°C, 753°C, 754°C, 755°C, 756°C, 757°C, 758°C, 759°C, 760°C, 761°C, 762°C, 763°C, 764°C, 765°C, 766°C, 767°C, 768°C, 769°C, 770°C, 771°C, 772°C, 773°C, 774°C, 775°C, 776°C, 777°C, 778°C, 779°C, or 780°C, and the time can be 25 min, 26 min, 27 min, 28 min, 29 min, 30 min, 31 min, 32 min, 33 min, 34 min, or 35 min.

[0075] In some embodiments, the casting process includes casting at 690°C to 710°C and cooling with cooling water at 35°C to 45°C, so that the temperature of the ingot is controlled at 410°C to 430°C.

[0076] In some embodiments, the aging treatment temperature is 140℃~160℃, and the time is 6h~8h. For example, the temperature can be 140℃, 141℃, 142℃, 143℃, 144℃, 145℃, 146℃, 147℃, 148℃, 149℃, 150℃, 151℃, 152℃, 153℃, 154℃, 155℃, 156℃, 157℃, 158℃, 159℃, or 160℃, and the time can be 6h, 6.5h, 7h, 7.5h, or 8h.

[0077] In some embodiments, the aluminum alloy substrate includes AlFe20 alloy, AlB3 alloy, Mg99.90 alloy, AlSi20 alloy, AlCu50 alloy, AlRE10 alloy, and AlY10 alloy.

[0078] In some embodiments, the diameter of the fatigue-resistant aluminum alloy monofilament is 3.0 mm to 4.0 mm.

[0079] Another embodiment of this application provides a fatigue-resistant cable, which is prepared using the above-described method for preparing fatigue-resistant cables.

[0080] The surface of the aforementioned specific wire core is coated with an insulation layer using an extrusion process. After curing, cooling, and testing, the finished cable is obtained. The insulation layer is made of an insulating material suitable for power transmission, ensuring the cable's insulation performance and service life.

[0081] Another embodiment of this application provides a method for preparing fatigue-resistant aluminum alloy monofilament, including the following steps S100 to S500.

[0082] Step S100: Provide an aluminum alloy substrate, which, by mass percentage, comprises the following components:

[0083] Mg: 0.60%~0.70%, Si: 0.65%~0.75%, Fe: 0.05%~0.15%, Cu: 0.05%~0.10%, B: 0.005%~0.015%, Ce: 0.03%~0.10%, Y: 0.03%~0.10%, total impurity elements ≤0.04%, balance Al.

[0084] Step S200: Melt the above aluminum alloy substrate to obtain an aluminum alloy melt.

[0085] Step S300: The above aluminum alloy melt is subjected to refining and degassing treatment, slag removal treatment, and static heat preservation treatment in sequence to obtain the first melt.

[0086] Step S400: Mix and melt the first melt with the refining agent, control the melt temperature at 700℃~740℃ and keep it at that temperature for 20min~40min to obtain the second melt. The refining agent is mainly composed of the following components by mass percentage: Ti: 4.5%~5.5%, C: 0.8%~1.2%, total impurity elements ≤0.5%, and the balance is Al.

[0087] Step S500: The second melt is subjected to casting, rolling, wire drawing and aging treatment in sequence to obtain fatigue-resistant aluminum alloy monofilament.

[0088] The aforementioned fatigue-resistant aluminum alloy monofilaments are used in conductors and cables, possessing excellent tensile strength, electrical properties, and fatigue resistance.

[0089] Another embodiment of this application provides a fatigue-resistant aluminum alloy monofilament, which is prepared by the above-described method for preparing fatigue-resistant aluminum alloy monofilament.

[0090] The mechanical properties, electrical properties, and fatigue resistance of the aforementioned fatigue-resistant aluminum alloy monofilaments are significantly improved. Specifically, the elongation of the aluminum alloy monofilaments can reach a minimum of 7.0%, far exceeding the minimum elongation of 3.0% required by GB / T 23308-2009 for alloy round wires. The strength can reach over 315 MPa, the electrical conductivity can reach 55.25% IACS (20℃), and the tensile fatigue performance reaches 120 MPa (3×10⁻⁶). 7 (More than once) to enhance the reliability of conductors and cables in processing, installation and complex application scenarios, extend service life and reduce the replacement and maintenance costs of conductors and cables.

[0091] Another embodiment of this application provides a conductor comprising the aforementioned fatigue-resistant aluminum alloy monofilament.

[0092] In some embodiments, the conductor is made by twisting together the aforementioned fatigue-resistant aluminum alloy monofilaments.

[0093] The fatigue-resistant aluminum alloy monofilaments prepared above are stranded according to the design specifications to obtain a conductor that meets the requirements of power transmission. The tension is controlled to be uniform during the stranding process to ensure the conductor structure is stable and the performance is consistent.

[0094] The present application will be described in further detail below with reference to specific embodiments, but the embodiments of the present application are not limited thereto.

[0095] Example 1

[0096] (1) Chemical composition ratio by mass percentage: Mg: 0.60%, Si: 0.65%, Fe: 0.05%, Cu: 0.05%, B: 0.005%, Ce: 0.03%, Y: 0.03%, total content of other impurity elements: 0.03%, Al: balance, the weight ratio of Mg to Si is 1:1.08 (0.60:0.65), and the weight ratio of Ce to Y is 1:1.00 (0.03:0.03). Weigh each raw material accurately according to the above chemical composition and ratio. The raw material is selected as high-purity aluminum ingot (specific model is Al99.70) and corresponding alloy element raw materials. After heating and melting the aluminum ingot (melting temperature is 720℃), AlFe20 alloy, AlB3 alloy, Mg99.90 alloy, AlSi20 alloy, AlCu50 alloy, AlRE10 alloy and AlY10 alloying materials are added at 740℃ to obtain aluminum alloy melt.

[0097] (2) The above aluminum alloy melt is refined at 760°C. Nitrogen gas at 2.0L / min is introduced and a refining agent is added at the same time. The amount of refining agent added is 1.8kg / t. The refining is carried out twice, each time for no less than 15 minutes, with an interval of no less than 5 minutes between each time. The slag is scraped from the liquid surface to the outside and then stopped at the furnace door for 10-20 seconds before being removed. After scraping the slag, the temperature of the aluminum liquid is controlled at 760°C and left to stand for 30 minutes to obtain the first melt.

[0098] (3) After the first melt is left to stand for 40 minutes, it is filtered through a 40-mesh ceramic filter plate. The filtered melt is mixed and melted with a refining agent. The refining agent contains 4.5% Ti, 0.8% C, 0.4% impurity elements, and Al: balance. The weight ratio of AlTi5C1 to (Ce+Y) is 1.5:1 (i.e., the amount of AlTi5C1 is 0.09%). The melt temperature is controlled at 720℃ and left to stand for 30 minutes to obtain the second melt.

[0099] (4) The second melt is cast at 700°C. The cooling water system of the casting machine is cooled at 0.07 MPa and the temperature of the cooling water is controlled at 40°C. The ingot temperature is controlled at 425°C. The ingot is then heated to raise the ingot temperature to 510°C. The rolling mill speed is slowly adjusted to 350 rpm. The aluminum alloy rod with a nominal diameter of 9.5 mm is rolled out. After rolling, the aluminum alloy rod is cooled by cooling water so that the rod temperature is controlled at ≤100°C. During the rolling of the aluminum alloy rod, the temperature of the emulsion (mainly mineral oil and nonionic surfactant) is controlled at 48°C and the pressure of the emulsion is controlled at 0.03 MPa to obtain the aluminum alloy rod.

[0100] (5) The aluminum alloy rod obtained by rolling is drawn by a wire drawing machine to obtain an intermediate aluminum alloy monofilament with a nominal diameter of 3.60 mm.

[0101] (6) The obtained intermediate aluminum alloy monofilament is placed in an aging furnace and aged at 150°C for 8 hours to obtain fatigue-resistant aluminum alloy monofilament.

[0102] (7) Multiple fatigue-resistant aluminum alloy monofilaments are twisted together to prepare a wire core. The insulation layer is wrapped around the wire core to obtain a fatigue-resistant cable.

[0103] Example 2

[0104] Example 2 is basically the same as Example 1, except that the chemical composition ratios in steps (1) and (3) are different, and the aging treatment in step (6) is different. Specifically:

[0105] (1) Chemical composition ratio by mass percentage: Mg: 0.62%, Si: 0.68%, Fe: 0.08%, Cu: 0.06%, B: 0.010%, Ce: 0.05%, Y: 0.045%, total content of other impurity elements: 0.025%, Al: balance, the weight ratio of Mg to Si is 1:1.10 (0.62:0.68), and the weight ratio of Ce to Y is 1:0.90 (0.05:0.045); each raw material is accurately weighed according to the above chemical composition and ratio, and high-purity aluminum ingots and corresponding alloying element raw materials are selected. The melting temperature of aluminum ingots and the temperature at which alloying elements are added are different. Specifically, the aluminum ingots are heated and melted (melting temperature is 730℃), and then alloying materials are added at 730℃ to obtain aluminum alloy melt.

[0106] The chemical composition ratio of the refining agent in step (3) is different. Specifically, the refining agent contains 4.8% Ti, 0.9% C, 0.35% impurity elements, and the balance is Al. The weight ratio of AlTi5C1 to (Ce+Y) is 1.6:1 (i.e., the amount of AlTi5C1 used is 0.152%). The melt temperature and holding time are controlled differently. Specifically, the melt temperature is controlled at 730℃ and held for 25 minutes to obtain the second melt.

[0107] The aging temperature in step (6) is different. Specifically, the intermediate aluminum alloy monofilament is placed in an aging furnace and aged at 160°C for 8 hours to obtain fatigue-resistant aluminum alloy monofilament.

[0108] The remaining steps and parameters are the same as in Example 1.

[0109] Example 3

[0110] Example 3 is basically the same as Example 1, except that the chemical composition ratio in step (1) is different. The specific chemical composition ratio by mass percentage is as follows: Mg: 0.70%, Si: 0.75%, Fe: 0.15%, Cu: 0.1%, Ce: 0.1%, Y: 0.1%, total content of other impurity elements: 0.03%, Al: balance, the weight ratio of Mg to Si is 1:1.07 (0.7:0.75), and the weight ratio of Ce to Y is 1:1.00 (0.1:0.1). Each raw material is accurately weighed according to the above chemical composition and ratio. The raw materials are high-purity aluminum ingots and corresponding alloy element raw materials.

[0111] The remaining steps and parameters are the same as in Example 1.

[0112] Example 4

[0113] Example 4 is basically the same as Example 1, except that the amount of refining agent added in step (3) is different, as follows:

[0114] (3) After the first melt is left to stand for 40 minutes, it is filtered through a 40-mesh ceramic filter plate. The filtered melt is mixed and melted with a refining agent. The refining agent contains 5.5% Ti, 1.2% C, 0.4% impurity elements, and Al: balance. The weight ratio of AlTi5C1 to (Ce+Y) is 2.0:1 (i.e., the amount of AlTi5C1 is 0.12%), and the second melt is obtained.

[0115] The remaining steps and parameters are the same as in Example 1.

[0116] Example 5

[0117] Example 5 is basically the same as Example 1, except that the smelting process in step (3) is different, as follows:

[0118] (3) After the first melt is left to stand for 40 minutes, it is filtered through a 40-mesh ceramic filter plate. The filtered melt is mixed and melted with a refining agent. The refining agent contains 4.8% Ti, 0.9% C, 0.35% impurity elements, and Al: balance. The weight ratio of AlTi5C1 to (Ce+Y) is 1.6:1 (i.e., the amount of AlTi5C1 is 0.152%). The melt temperature is controlled at 700℃ and left to stand for 20 minutes to obtain the second melt.

[0119] The remaining steps and parameters are the same as in Example 1.

[0120] Example 6

[0121] Example 6 is basically the same as Example 1, except that the smelting process in step (3) is different, as follows:

[0122] (3) After the first melt is left to stand for 40 minutes, it is filtered through a 40-mesh ceramic filter plate. The filtered melt is mixed and melted with a refining agent. The refining agent contains 4.8% Ti, 0.9% C, 0.35% impurity elements, and Al: balance. The weight ratio of AlTi5C1 to (Ce+Y) is 1.6:1 (i.e., the amount of AlTi5C1 is 0.152%). The melt temperature is controlled at 740℃ and left to stand for 40 minutes to obtain the second melt.

[0123] The remaining steps and parameters are the same as in Example 1.

[0124] Comparative Example 1

[0125] Comparative Example 1 is basically the same as Example 1, except that: no refining agent is added in step (3). The specific steps are as follows:

[0126] (3) After the first melt is left to stand for 40 minutes, it is filtered through a 40-mesh ceramic filter plate. The melt temperature is controlled at 720℃ and kept at the temperature for 30 minutes to obtain the second melt.

[0127] The remaining steps and parameters are the same as in Example 1.

[0128] Comparative Example 2

[0129] Comparative Example 2 is basically the same as Example 1, except that the ratio of the refining agent in step (3) is different, as follows:

[0130] (3) After the first melt is left to stand for 40 minutes, it is filtered through a 40-mesh ceramic filter plate. The filtered melt is mixed and melted with a refining agent. The refining agent contains 3.0% Ti, 0.5% C, 0.4% impurity elements, and Al: balance. The weight ratio of AlTi5C1 to (Ce+Y) is 1.0:1 (i.e., the amount of AlTi5C1 is 0.06%).

[0131] The remaining steps and parameters are the same as in Example 1.

[0132] Comparative Example 3

[0133] Comparative Example 3 is basically the same as Example 1, except that the smelting process in step (3) is different, as follows:

[0134] (3) After the first melt is left to stand for 40 minutes, it is filtered through a 40-mesh ceramic filter plate. The filtered melt is mixed and melted with a refining agent. The refining agent contains 4.5% Ti, 0.8% C, 0.4% impurity elements, and Al: balance. The weight ratio of AlTi5C1 to (Ce+Y) is 1.5:1 (i.e., the amount of AlTi5C1 is 0.09%). The melt temperature is controlled at 680℃ and left to stand for 15 minutes to obtain the second melt.

[0135] The remaining steps and parameters are the same as in Example 1.

[0136] Performance testing:

[0137] 1. The resistivity of the fatigue-resistant aluminum alloy monofilament in the fatigue-resistant cables prepared in each embodiment and comparative example was tested, specifically according to GB / T 3048.2-2007 Electrical Performance Test Methods for Wires and Cables Part 2: Resistivity Test of Metallic Materials.

[0138] 2. The tensile strength of the fatigue-resistant aluminum alloy monofilaments in the fatigue-resistant cables prepared in each embodiment and comparative example was tested, specifically according to GB / T 4909.3-2009 Bare Wire Test Methods Part 3: Tensile Test.

[0139] 3. The elongation of the fatigue-resistant aluminum alloy monofilaments in the fatigue-resistant cables prepared in each embodiment and comparative example was tested, specifically using GB / T 4909.3-2009 Bare Wire Test Methods Part 3: Tensile Test.

[0140] 4. The tensile-tensile fatigue properties of the fatigue-resistant aluminum alloy monofilaments in the fatigue-resistant cables prepared in each embodiment and comparative example were tested, specifically using the axial force control method of fatigue testing of metallic materials (GB / T 3075-2021). The results are shown in Table 1.

[0141] Table 1. Performance test results of aluminum alloy monofilaments in each embodiment and comparative example.

[0142]

[0143] As shown in Table 1, compared with the comparative example, the fatigue-resistant aluminum alloy monofilament produced by the technical solution of this application has better tensile strength, electrical properties and fatigue resistance, and can be stably used in the production of conductors and cables, ensuring the stable quality of products produced in subsequent processes.

[0144] This application, through the synergistic effect of alloying elements and reasonable process parameters, significantly improves the mechanical properties, electrical properties, and fatigue resistance of the obtained fatigue-resistant aluminum alloy monofilament. Specifically, the elongation of the aluminum alloy monofilament can reach a minimum of 7.0%, far exceeding the minimum elongation of 3.0% required by GB / T 23308-2009 for alloy round wire; the strength can reach over 315 MPa; the conductivity can reach 55.25% IACS (20℃), i.e., the resistivity does not exceed 31.20 nΩ·m; and the tensile-tensile fatigue performance reaches 120 MPa (3×10⁻⁶). 7 (More than once) to enhance the reliability of conductors and cables in processing, installation and complex application scenarios, extend service life and reduce conductor replacement and maintenance costs.

[0145] The aluminum alloy rods described in this application are produced using a continuous casting and rolling process. The casting and rolling temperatures and speeds, as well as the cooling water temperature and pressure, are strictly controlled to ensure that the aluminum alloy rods have a uniform microstructure, reduce the impact of defects on conductivity, and possess excellent mechanical properties, thereby guaranteeing the stable quality of subsequent conductor and cable production products.

[0146] 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.

[0147] The embodiments described above are merely illustrative of several implementation methods of this application, intended to facilitate a detailed understanding of the technical solutions of this application, but should not be construed as limiting the scope of protection of the patent application. 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 scope of protection of this application. It should be understood that technical solutions obtained by those skilled in the art based on the technical solutions provided in this application through logical analysis, reasoning, or limited experimentation are all within the scope of protection of the appended claims. Therefore, the scope of protection of this patent application should be determined by the content of the appended claims, and the specification can be used to interpret the content of the claims.

Claims

1. A method for preparing a fatigue-resistant cable, characterized in that, The process includes the following steps: a wire core is prepared using multiple fatigue-resistant aluminum alloy monofilaments; an insulation layer is then wrapped around the wire core to obtain a fatigue-resistant cable; wherein the preparation method of the fatigue-resistant aluminum alloy monofilaments includes the following steps: An aluminum alloy substrate is provided, which, by weight percentage, comprises the following components: Mg: 0.60%~0.70%, Si: 0.65%~0.75%, Fe: 0.05%~0.15%, Cu: 0.05%~0.10%, B: 0.005%~0.015%, Ce: 0.03%~0.10%, Y: 0.03%~0.10%, total impurity elements ≤0.04%, balance Al; The aluminum alloy substrate is melted to obtain an aluminum alloy melt; The aluminum alloy melt is subjected to refining and degassing treatment, slag removal treatment, and static heat preservation treatment in sequence to obtain the first melt. The first melt is mixed and melted with a refining agent, and the melt temperature is controlled at 700℃~740℃ and kept at that temperature for 20min~40min to obtain a second melt. The refining agent is mainly composed of the following components by mass percentage: Ti: 4.5%~5.5%, C: 0.8%~1.2%, total impurity elements ≤0.5%, and the balance is Al. The second melt is subjected to casting, rolling, wire drawing and aging treatment in sequence to obtain fatigue-resistant aluminum alloy monofilament.

2. The method for preparing the fatigue-resistant cable as described in claim 1, characterized in that, The method for preparing the fatigue-resistant aluminum alloy monofilament satisfies one or more of the following conditions: (1) The mass ratio of Mg to Si is 1:0.90~1.10; (2) The mass ratio of Ce to Y is 1:0.90~1.10; (3) The mass ratio of the refining agent to the total mass of Ce and Y is 1.5~2.0:

1.

3. The method for preparing the fatigue-resistant cable according to any one of claims 1 to 2, characterized in that, The aluminum alloy substrate comprises the following components by weight percentage: Mg: 0.60%~0.62%, Si: 0.65%~0.68%, Fe: 0.05%~0.08%, Cu: 0.05%~0.06%, B: 0.005%~0.015%, Ce: 0.03%~0.05%, Y: 0.03%~0.045%, total impurity elements ≤0.04%, balance Al.

4. The method for preparing the fatigue-resistant cable according to any one of claims 1 to 2, characterized in that, The method for preparing the fatigue-resistant aluminum alloy monofilament satisfies one or more of the following conditions: (1) During the melting process of the aluminum alloy substrate, the melting temperature is 700℃~740℃; (2) The temperature for refining and degassing is 750℃~780℃; (3) The refining and degassing treatment includes the following steps: inert gas is introduced into the aluminum alloy melt for 15 min to 25 min, and at the same time, a refining agent is added for refining and degassing treatment.

5. The method for preparing the fatigue-resistant cable as described in claim 4, characterized in that, The amount of the refining agent added is 1.5 kg / t to 2 kg / t.

6. The method for preparing the fatigue-resistant cable according to any one of claims 1 to 2 and 5, characterized in that, The method for preparing the fatigue-resistant aluminum alloy monofilament satisfies one or more of the following conditions: (1) The temperature for static heat preservation treatment is 750℃~780℃, and the time is 30min; (2) The conditions for casting treatment include: casting treatment at 690℃~710℃, and cooling with cooling water at 35℃~45℃, so that the temperature of the ingot is controlled at 410℃~430℃. (3) The aging treatment temperature is 140℃~160℃ and the time is 6h~8h; (4) The aluminum alloy substrate includes AlFe20 alloy, AlB3 alloy, Mg99.90 alloy, AlSi20 alloy, AlCu50 alloy, AlRE10 alloy and AlY10 alloy.

7. A fatigue-resistant cable, characterized in that, The anti-fatigue cable is prepared using the method described in any one of claims 1 to 6.

8. A method for preparing fatigue-resistant aluminum alloy monofilament, characterized in that, Includes the following steps: An aluminum alloy substrate is provided, which, by weight percentage, comprises the following components: Mg: 0.60%~0.70%, Si: 0.65%~0.75%, Fe: 0.05%~0.15%, Cu: 0.05%~0.10%, B: 0.005%~0.015%, Ce: 0.03%~0.10%, Y: 0.03%~0.10%, total impurity elements ≤0.04%, balance Al; The aluminum alloy substrate is melted to obtain an aluminum alloy melt; The aluminum alloy melt is subjected to refining and degassing treatment, slag removal treatment, and static heat preservation treatment in sequence to obtain the first melt. The first melt is mixed and melted with a refining agent, and the melt temperature is controlled at 700℃~740℃ and kept at that temperature for 20min~40min to obtain a second melt. The refining agent is mainly composed of the following components by mass percentage: Ti: 4.5%~5.5%, C: 0.8%~1.2%, total impurity elements ≤0.5%, and the balance is Al. The second melt is subjected to casting, rolling, wire drawing and aging treatment in sequence to obtain fatigue-resistant aluminum alloy monofilament.

9. A fatigue-resistant aluminum alloy monofilament, characterized in that, The anti-fatigue aluminum alloy monofilament was prepared using the method described in claim 8.

10. A conductor, characterized in that, Including the fatigue-resistant aluminum alloy monofilament as described in claim 9.

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