Fabricated building aluminum alloy formwork lightweight integrated forming process

Abstract

The application discloses a lightweight integrated forming machining process for aluminum alloy templates for fabricated buildings, relates to the aluminum alloy plate machining technical field, and solves the problems of a plurality of traditional aluminum mold welding procedures, high self-weight, low precision, and poor adaptability. The process contains a front lightweight structure design and digital simulation. After rare earth micro-alloying smelting, semi-continuous ingot casting, and homogenization treatment, the template full structure is integrally formed through multi-directional composite extrusion. The process is matched with online staged quenching, one-time clamping numerical control machining, aging straightening, and nano composite coating treatment, combined with full-process digital twin management and control and full-life-cycle tracing. The process cancels the welding procedure, realizes double lightweight of materials and structures, improves forming precision and structural integrity, is suitable for robot construction and fabricated building full scenes, has low carbon environmental protection and high turnover, greatly improves production and construction efficiency, and reduces full-life-cycle cost.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy sheet processing technology, specifically to a lightweight integrated molding process for aluminum alloy formwork used in prefabricated buildings. Background Technology

[0002] With its core advantages such as high turnover rate, good concrete forming accuracy, 100% recyclability, and environmental friendliness, aluminum alloy formwork has gradually replaced traditional wooden and steel formwork, becoming a core supporting material for concrete pouring construction in prefabricated buildings. It has been applied on a large scale in standardized engineering projects such as high-rise residential buildings, affordable housing, and commercial complexes, and market demand continues to grow.

[0003] The current mainstream aluminum alloy template production process in the industry generally adopts the traditional process of "plate cutting - welding and splicing of frame and reinforcing ribs - multi-process dispersed machining - surface treatment", which has many difficult-to-solve industry pain points. Firstly, the high proportion of welding processes means that panels, longitudinal frames, reinforcing ribs, and end plates all require multiple welding steps to assemble, which easily leads to problems such as welding deformation, weld cracking, and residual stress concentration. This not only significantly reduces the overall structural integrity and service life of the formwork but also results in lengthy production processes, low production efficiency, and high labor and energy costs. Secondly, it is difficult to balance lightweighting and load-bearing capacity. Traditional processes are limited by material properties and structural design. To meet the load-bearing requirements of construction, redundant structural designs and thick base material walls are commonly used, resulting in a large self-weight of the formwork. On-site manual handling and installation are difficult, which restricts the improvement of construction efficiency. Thirdly, the forming and processing precision is insufficient. Multi-process decentralized clamping and processing easily leads to cumulative errors. It is difficult to stably control the dimensional accuracy, hole position accuracy, and assembly flatness of the formwork, making it unsuitable for the high precision requirements of plaster-free construction. At the same time, traditional surface treatment processes have problems such as high environmental pressure and insufficient upper limit of formwork turnover.

[0004] At the same time, with the rapid iteration of intelligent construction technology, prefabricated buildings have put forward higher requirements for the standardization, digitalization, functional integration, and automated construction adaptability of formwork. Traditional production processes cannot achieve digital traceability of the entire life cycle of formwork, nor can they adapt to the application needs of new scenarios such as construction robot construction and prefabricated decoration integration. The industry urgently needs to develop a new processing technology that can take into account lightweight, integrated molding, high precision, low carbon and environmental protection, and functional integration, to solve the core shortcomings of existing technologies and adapt to the upgrading and development needs of the prefabricated building industry. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a lightweight, integrated molding process for aluminum alloy formwork used in prefabricated buildings.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings, including conventional basic processes such as alloy batching and smelting, semi-continuous ingot casting, homogenization treatment, profile extrusion, CNC machining, aging treatment, and surface treatment. The lightweight structural design and digital simulation verification of the formwork are completed in the pre-process. Rare earth micro-alloying modification treatment is used in the smelting process. The extrusion process uses an integrated molding die to complete the integrated isothermal extrusion molding of the panel, frame, and reinforcing ribs. After extrusion, the process is completed online with graded quenching treatment. The CNC machining process completes the entire process of punching and milling in one clamping. After aging, the process is completed simultaneously with CNC precision straightening and residual stress elimination. The surface treatment process uses an integrated composite coating modification treatment. The entire process completes digital quality inspection and traceability.

[0007] Preferably, recycled aluminum alloy is used as the main raw material in the batching process. The composition of recycled aluminum is tested and directionally adjusted before smelting. The smelting process adopts rotary jet refining and multi-stage slag removal and degassing treatment. The composition and cleanliness of the melt are tested online before casting.

[0008] Preferably, the lightweight structural design adopts AI-driven topology optimization and equal strength design to complete the parametric modeling of the irregular cross section of the template, and completes the structural parameter verification through multi-physics finite element simulation, while simultaneously completing the mold flow simulation and structural optimization of the extrusion die.

[0009] Preferably, the isothermal extrusion adopts a multi-directional composite extrusion method that links horizontal and vertical processes, simultaneously completing the integrated forming of the longitudinal and transverse reinforcing ribs and end plates of the template. The extrusion process adopts zoned temperature control and adaptive closed-loop control of extrusion speed, and the dimensional accuracy is detected online in real time after extrusion molding.

[0010] Preferably, the CNC machining adopts an online linkage machining system for the extrusion line, which sequentially completes the entire process of fixed-length sawing, hole milling, and edge deburring. The machining process uses servo CNC positioning and machine vision closed-loop calibration, and the hole position and dimensional accuracy are simultaneously inspected online after machining is completed.

[0011] Preferably, the aging treatment adopts the T6 aging process with precise temperature control through hot air circulation. The aging process uses real-time temperature monitoring and closed-loop control. The straightening adopts a combination of vibration aging and CNC roller straightening to simultaneously eliminate residual stress in the template and correct its shape and position accuracy.

[0012] Preferably, before the composite coating modification treatment, laser descaling and silane passivation pretreatment are performed. The coating adopts a room temperature nano-superhydrophobic composite coating system. The coating and curing are completed in one step. After curing, batch testing of coating adhesion and corrosion resistance is performed.

[0013] Preferably, a digital twin of the entire process is established, and equipment parameters, process parameters and quality data of each process are collected in real time. The process parameters are optimized in reverse through digital twin simulation to achieve adaptive closed-loop control of the entire process.

[0014] Preferably, a full lifecycle management system for templates is established, assigning each template a unique and traceable identity, tracking the turnover and wear of templates in real time, and performing non-destructive testing, reshaping, and performance repair and reconstruction on templates after turnover.

[0015] Preferably, the template structure design simultaneously reserves the robot construction positioning structure and visual recognition target, the integrated molding pre-embeds the RFID smart identification chip, and simultaneously reserves the prefabricated building pipeline trench and pre-embedded point slot, adapting to the construction needs of intelligent construction and prefabricated building in all scenarios.

[0016] Compared with the prior art, the present invention provides a lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings, which has the following beneficial effects:

[0017] The overall structural integrity has been significantly improved, completely resolving the core pain points of the welding process. Through integrated extrusion molding of panels, frames, reinforcing ribs, and even end plates, more than 80% of the welding processes in traditional processes have been eliminated, fundamentally eliminating industry-wide problems such as welding deformation, weld cracking, and stress concentration. The overall integrity of the template structure has been improved by more than 50%, while the processing steps have been significantly reduced, production efficiency has increased by more than 60%, and the yield rate has been stabilized at over 99%.

[0018] By improving the specific strength of the material through rare earth micro-alloying modification and combining it with AI topology and other strength optimization designs, the surface density of the template is reduced to 16-18 kg / ㎡ while ensuring the rated construction load capacity of 60kN / m². This is more than 20% lighter than traditional aluminum alloy templates. It does not require large hoisting equipment, and manual handling and installation are convenient. On-site construction efficiency is improved by more than 30%, while reducing the overall construction costs such as hoisting and labor.

[0019] By using online closed-loop shape control and one-time clamping for full-process CNC machining, the cumulative error of multi-process decentralized processing is eliminated. The template size accuracy deviation is ≤ ±0.3mm, the assembly gap is controlled within 0.5mm, and the concrete forming surface accuracy error is ≤2mm. This allows for direct plaster-free construction, completely eliminating wall hollowing and cracking problems, and significantly reducing the subsequent decoration procedures and costs of prefabricated buildings.

[0020] Through modification treatments such as room-temperature nano-superhydrophobic composite coating, the number of template turnovers has been increased from the traditional 300 times to more than 800 times, and the total life cycle cost has been reduced by more than 30%. At the same time, the high-value closed-loop application of recycled aluminum has been realized, reducing carbon emissions from raw materials by more than 90%. Scrap templates can be 100% recycled and remelted, and after turnover, the templates can be repaired and remanufactured for tiered utilization. The overall energy consumption and carbon emissions of the entire process have been greatly reduced, which meets the requirements of green and low-carbon development in the construction industry.

[0021] By building a digital twin for the entire process, real-time acquisition, simulation optimization, and adaptive closed-loop control of process parameters are achieved, solving the problem of large batch performance fluctuations in traditional processes. The consistency of product performance and precision is improved by more than 90%. At the same time, each template is given a unique traceable identity, realizing full life cycle traceability from raw materials to production, use, and recycling. It can be seamlessly integrated with BIM design and smart construction site management systems, adapting to the digital management needs of prefabricated buildings.

[0022] Through pre-integration in the structural design stage, the integrated pre-formed structure is designed to accommodate robot construction, prefabricated pipeline trenches, and pre-embedded slots. Simultaneously, RFID smart chips can be pre-embedded, eliminating the need for subsequent on-site drilling and cutting. This not only adapts to automated construction equipment such as aluminum formwork installation robots but also achieves synergistic adaptation between the formwork structure function and prefabricated decoration and smart construction sites. The standardization rate of the formwork is increased to over 95%, which can fully adapt to the construction needs of prefabricated buildings in all scenarios, including residential, commercial, and municipal projects. Detailed Implementation

[0023] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0024] A lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings is proposed. This process employs AI-driven topology optimization and equal-strength design methods, using a 60kN / m² concrete lateral pressure as the rated load-bearing benchmark. Combined with the 100mm standard module for prefabricated buildings, the aluminum alloy formwork is structurally designed. The formwork is designed as an integrated irregular cross-section of panel, longitudinal frame, and reinforcing ribs. Genetic algorithms are used to optimize the cross-sectional dimensions, spacing, rib height, and rib thickness of the reinforcing ribs, eliminating redundant structural materials. Simultaneously, standardized parametric modeling of the formwork is completed, adapting to a full range of products including planar formwork, internal corner formwork, external corner formwork, beam formwork, and column formwork.

[0025] A digital twin of the template was established based on the BIM model. Using multiphysics finite element simulation software, the stress, strain, deformation and springback of the template under rated load were simulated to verify the structural bearing capacity and stiffness, and to optimize and lock the section parameters. At the same time, CAE mold flow simulation was performed on the extrusion die to optimize the dimensions of the flow divider, welding chamber and working zone, to ensure the uniformity of metal flow in the die cavity, and to complete the structural optimization and design of the one-piece molding flow divider.

[0026] To meet the needs of intelligent construction, the structural design includes provisions for robot construction positioning structures and visual recognition targets, as well as RFID chip pre-embedded slots. Pre-embedded slots for prefabricated building pipelines and decoration pre-embedded points are also included. All reserved structures are incorporated into the integrated molding section design, eliminating the need for subsequent secondary processing.

[0027] Recycled 6061 aluminum alloy is used as the main raw material, combined with primary aluminum ingots and master alloys. Before smelting, the composition of the recycled aluminum is tested by a spectrometer. According to the design composition requirements, alloying elements such as Mg, Si, and Cu are added in a targeted manner to complete the composition adjustment. The designed composition is a rare earth modified Al-Mg-Si system 6061 aluminum alloy. Based on the national standard 6061 composition, 0.15%-0.3% of La-Ce mixed rare earth elements are added. Alternatively, a Sc-Zr composite microalloying system can be used according to performance requirements.

[0028] The melting is carried out in a medium-frequency induction furnace, with the melting temperature controlled at 730-760℃. After the furnace charge is completely melted, it is held at the temperature for 15-30 minutes to complete the homogenization and diffusion of alloying elements.

[0029] A rotary jet refining process is adopted, using high-purity argon as a carrier gas. Sodium-free refining agent is added to the molten aluminum. The refining temperature is controlled at 720-740℃, and the refining time is 15-25 minutes. After refining, multi-stage slag removal and degassing treatment is carried out. After standing for 10-20 minutes, the surface slag is removed. The hydrogen content of the molten aluminum is controlled to be ≤0.12ml / 100g, and the inclusion content is ≤0.05%. Before casting, the composition and cleanliness of the melt are detected online using an online spectrometer and a melt cleanliness detector. Only after the test is qualified can the casting be carried out.

[0030] The semi-continuous casting process is used to prepare round ingots. The casting temperature is controlled at 710-730℃, the casting speed is controlled at 80-120mm / min, and the cooling water pressure is controlled at 0.08-0.12MPa. The ingot specifications are matched according to the tonnage of the extrusion press, with Φ120mm-Φ200mm round ingots preferred. The ingot length is controlled at 500-800mm to ensure that the internal structure of the ingot is dense and free from porosity, cracks, segregation defects.

[0031] Place the ingot into a hot air circulating homogenizing furnace and heat it to 550-570℃, then hold it for 8-12 hours. After holding, use water mist for rapid cooling at a rate of ≥100℃ / min to completely eliminate alloy composition segregation, homogenize the internal grain structure, and improve the material's extrusion formability.

[0032] The mold adopts an optimized one-piece molding process. The mold base material is H13 hot work die steel, which is vacuum quenched and tempered three times to control the hardness at HRC48-52. The surface of the mold working zone is polished to Ra≤0.4μm. The mold is preheated before assembly, and the preheating temperature is controlled at 450-480℃ and held for 2-4 hours.

[0033] The homogenized ingot is heated to 480-520℃ in a gradient heating furnace, and the extrusion cylinder is preheated to 450-480℃. Isothermal extrusion is performed using a horizontal extrusion press, or a multi-directional composite extrusion method combining horizontal and vertical processes can be used. The extrusion ratio is controlled at 30-40:1, and the extrusion speed is stably controlled at 2-5m / min. The extrusion process adopts zoned temperature control of the extrusion cylinder and adaptive closed-loop control of the extrusion speed to maintain constant extrusion temperature and speed throughout the process. The template panel, frame, longitudinal / transverse reinforcing ribs, and end plate are integrally formed in one step, completely eliminating the welding process.

[0034] The extruded profiles are rapidly cooled online using a combination of air cooling and water mist quenching, with a cooling rate ≥150℃ / s, ensuring the complete precipitation of the supersaturated solid solution in the alloy. The uniformity of cooling is ensured through graded controlled cooling, keeping the quenching deformation within 0.3mm / m. After extrusion molding, the cross-sectional dimensional accuracy of the profiles is monitored in real time using an online laser diameter gauge and a vision inspection system. Once the inspection is passed, the profiles proceed to the next process.

[0035] The extrusion line adopts an online linkage processing system. After online quenching and cooling, the extruded profiles directly enter the CNC machining unit without secondary transfer and clamping. The processing system completes the entire process of fixed-length sawing, hole milling, and edge deburring in sequence, realizing the completion of the entire process in one clamping.

[0036] Fixed-length sawing is performed using a CNC servo saw, which uses servo positioning for sawing based on BIM design dimensions. The length deviation is controlled within ≤±0.3mm, and the end face perpendicularity is ≤0.1mm / m. After sawing, the end face is deburred simultaneously.

[0037] The hole and slot processing adopts a multi-axis linkage CNC punching and milling machine, with special tooling fixtures, to complete the punching and milling processing of template connection holes, positioning holes, locking slots, end plate bayonet, and assembly notches in one go; the processing process adopts servo CNC positioning and machine vision closed-loop calibration, and the hole position accuracy after processing is ≤±0.2mm, and the cumulative deviation of hole distance is ≤±0.5mm / m.

[0038] After processing, the template hole positions and dimensional accuracy are 100% inspected online through an online machine vision inspection system. Unqualified products are automatically rejected, and qualified products proceed to the next process.

[0039] T6 artificial aging treatment is carried out in a hot air circulating aging furnace. The qualified template is placed in the aging furnace and heated to 170-180℃ and held for 6-8 hours. The aging process adopts multi-point temperature real-time monitoring and closed-loop control, and the temperature deviation in the furnace is controlled within ±5℃ to ensure uniform precipitation of alloy strengthening phase.

[0040] After aging, the template is first subjected to vibration treatment using a vibration aging device to eliminate residual stress generated during extrusion, quenching, and processing. Then, it is continuously straightened using a CNC roller straightener to eliminate overall bending and twisting deformation of the template. For local flatness and perpendicularity deviations, a multi-point CNC press is used for precise straightening to ultimately ensure that the template flatness is ≤0.3mm / m, the side straightness is ≤0.5mm / m, and the end face perpendicularity is ≤0.2mm / m.

[0041] The process employs a chromium-free and environmentally friendly pretreatment technique involving laser descaling and silane passivation. First, the oxide scale and processing residue on the template surface are removed using a fiber laser device. Then, the template is passivated at room temperature using a silane passivation solution for 5-10 minutes. After passivation, the template is washed with pure water and dried with hot air to ensure surface cleanliness and improve coating adhesion.

[0042] A room-temperature nano-superhydrophobic composite coating system is adopted, and the coating is completed in one step by high-voltage electrostatic spraying. After coating, room-temperature hot air curing is used, with the curing temperature controlled at 60-80℃ and the curing time at 20-30min. The total coating thickness is controlled at 50-80μm. Alternatively, micro-arc oxidation and nano-ceramic coating composite treatment processes can be adopted according to the application requirements.

[0043] After curing, batch testing of coating adhesion, hardness, and corrosion resistance is conducted on each batch of products to ensure that the coating adhesion reaches level 1 and the pencil hardness is ≥3H, meeting the design and usage requirements.

[0044] Establish a digital twin of the entire process flow, and collect equipment parameters, process parameters, and quality inspection data of each process, including smelting, casting, extrusion, processing, aging, and surface treatment, in real time through the Industrial Internet; optimize the process parameters of each process through digital twin simulation, realize adaptive closed-loop control of the entire process, and ensure the consistency of performance and precision of batch products.

[0045] Each template is assigned a unique QR code / RFID identification, which is linked to record raw material batches, production process parameters, full-item test data, and project usage information. A full life cycle management system for templates is established to track the number of times templates are used and their wear and tear in real time. For templates that have reached the repair threshold after use, non-destructive testing, reshaping, and surface coating repair and reconstruction are carried out to realize the tiered utilization and closed-loop circulation of templates.

[0046] The template digital twin outputs IFC format files, which can be seamlessly integrated with the construction party's BIM platform and smart construction site management system to meet the needs of digital construction management for prefabricated buildings.

[0047] Example 1

[0048] For the standard planar template (600mm×2400mm), AI topology optimization and equal strength design are adopted. The panel wall thickness is 2.5mm, the longitudinal frame is integrally formed, and the embedded T-shaped reinforcing ribs are evenly arranged with a rib height of 15mm and a rib thickness of 2mm. Through finite element simulation verification, the deformation under the rated load of 60kN / m² is ≤1 / 1000. Simultaneously, the mold flow simulation and structural design of the integrally formed diversion mold are completed. The design reserves the robot construction positioning structure, visual recognition target and pipeline slot.

[0049] The aluminum alloy used is 6061 according to national standards, with 0.2% La-Ce mixed rare earth elements added. It is smelted in a medium-frequency induction furnace at a melting temperature of 745℃, and held at that temperature for 20 minutes after complete melting. Rotary jet refining is used at a refining temperature of 730℃ for 20 minutes. After refining, it is allowed to stand for 15 minutes to remove slag. The hydrogen content of the molten aluminum is controlled to be ≤0.1ml / 100g. The composition and cleanliness are tested online before casting, and the test results are qualified.

[0050] Φ178mm round ingots were prepared by semi-continuous casting at a casting temperature of 720℃, a casting speed of 100mm / min, and a cooling water pressure of 0.1MPa. The ingots were placed in a homogenizing furnace, heated to 560℃, held for 10h, and then rapidly cooled with water mist.

[0051] A 3600T horizontal extrusion press is used. The ingot is heated to 500℃, the extrusion cylinder is preheated to 460℃, and the die is preheated to 470℃. The extrusion ratio is 35:1 and the extrusion speed is 3m / min. The panel, frame and reinforcing ribs are formed in one step. After extrusion, the panel is cooled by air and water mist in stages. The cooling rate is 180℃ / s. The dimensional accuracy is checked online. After passing the test, the panel enters the next process.

[0052] The online linkage machining system completes all processes, including fixed-length sawing, connecting hole milling, locking groove machining, and deburring, in one clamping. The sawing length deviation is ±0.2mm, the hole position accuracy is ±0.15mm, and the machined parts pass online inspection.

[0053] The T6 aging process is adopted, which involves heating to 175℃ and holding for 7 hours. After aging, vibration aging is performed to eliminate residual stress, followed by CNC roller straightening and local pressure straightening. The final template has a flatness of 0.2mm / m and a side straightness of 0.3mm / m.

[0054] Laser descaling and silane passivation pretreatment were used. A nano-superhydrophobic composite coating was then sprayed at room temperature with a thickness of 60 μm. The coating was cured with hot air at 80℃ for 25 min. The coating adhesion was tested to be grade 1, and the pencil hardness was 4H.

[0055] Each template is assigned a unique QR code identifier, which is linked to the entire production and testing data to create a digital twin and complete the closed-loop management of the entire process.

[0056] Example 2

[0057] The difference from Example 1 is as follows:

[0058] The batching process uses 85% recycled 6061 aluminum alloy as the main raw material. Before smelting, the composition is tested by spectral analysis, and alloying elements are added in a targeted manner to ensure that the composition meets the national standard requirements for 6061. 0.25% of La-Ce mixed rare earth elements are added.

[0059] The extrusion process employs a multi-directional composite extrusion method that combines horizontal and vertical movements, completing the entire structure of the template panel, longitudinal / transverse reinforcing ribs, end plates, and frame in one step without any welding procedures.

[0060] The remaining process steps and parameters are the same as in Example 1.

[0061] Example 3

[0062] The difference from Example 1 is as follows:

[0063] The structural design incorporates a pre-embedded slot for an RFID chip. After the template is formed, an RFID smart identification chip is embedded, enabling intelligent inventory, positioning, and health monitoring on the construction site.

[0064] The extrusion process adopts a high-speed isothermal extrusion process, with the extrusion speed increased to 10m / min. The extrusion process uses zoned temperature control and speed adaptive closed-loop control to ensure molding accuracy.

[0065] The surface treatment employs a composite treatment of micro-arc oxidation and nano-ceramic coating. The micro-arc oxidation film has a thickness of 25μm, the nano-ceramic coating has a thickness of 35μm, and the composite coating has a hardness of HV350.

[0066] A digital twin closed-loop control system is established throughout the entire process to collect process parameters in real time and optimize them in reverse, thereby achieving adaptive control of the entire process.

[0067] The remaining process steps and parameters are the same as in Example 1.

[0068] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings, comprising conventional basic processes such as alloy batching and smelting, semi-continuous ingot casting, homogenization treatment, profile extrusion, CNC machining, aging treatment, and surface treatment, characterized in that, The process involves lightweight structural design and digital simulation verification of the pre-built template, rare earth micro-alloying modification in the smelting stage, and an integrated molding die in the extrusion stage to complete the integrated isothermal extrusion molding of the panel, frame, and reinforcing ribs. After extrusion, the process is completed online with graded quenching. In the CNC machining stage, the entire process of punching and milling is completed in one clamping. After aging, CNC precision straightening and residual stress elimination are completed simultaneously. In the surface treatment stage, an integrated composite coating modification treatment is used. The entire process is completed with digital quality inspection and traceability.

2. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, The batching process uses recycled aluminum alloy as the main raw material. Before smelting, the composition of the recycled aluminum is tested and directionally adjusted. During the smelting process, rotary jet refining and multi-stage slag and gas removal treatment are adopted. Before casting, the composition and cleanliness of the melt are tested online.

3. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, The lightweight structural design employs AI-driven topology optimization and equal strength design to complete the parametric modeling of the irregular cross-section of the template. The structural parameters are verified through multiphysics finite element simulation, and the mold flow simulation and structural optimization of the extrusion die are completed simultaneously.

4. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, Isothermal extrusion employs a multi-directional composite extrusion method that combines horizontal and vertical processes, simultaneously completing the integrated molding of the longitudinal and transverse reinforcing ribs and end plates of the template. The extrusion process utilizes zoned temperature control and adaptive closed-loop control of extrusion speed, and real-time online detection of dimensional accuracy is performed after extrusion molding.

5. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, The CNC machining adopts an online linkage machining system for the extrusion line, which sequentially completes the entire process of fixed-length sawing, hole milling, and edge deburring. The machining process uses servo CNC positioning and machine vision closed-loop calibration. After the machining is completed, the hole position and dimensional accuracy are simultaneously inspected online.

6. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, The aging process adopts the T6 aging process with precise temperature control through hot air circulation. The aging process uses real-time temperature monitoring and closed-loop control. The straightening process combines vibration aging with CNC roller straightening to simultaneously eliminate residual stress in the template and correct its shape and position accuracy.

7. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, Before the composite coating modification treatment, laser descaling and silane passivation pretreatment were carried out. The coating adopted a room temperature nano-superhydrophobic composite coating system. The coating and curing were completed in one step. After curing, the coating adhesion and corrosion resistance were tested in batches.

8. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, A digital twin of the entire process is established, and equipment parameters, process parameters and quality data of each process are collected in real time. The process parameters are optimized in reverse through digital twin simulation, so as to achieve adaptive closed-loop control of the entire process.

9. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, Establish a full lifecycle management system for templates, assign a unique traceable identity to each template, track the turnover and wear of templates in real time, and perform non-destructive testing, reshaping, and performance repair and reconstruction on templates after turnover.

10. The lightweight integrated molding process for aluminum alloy formwork in prefabricated buildings according to claim 1, characterized in that, The template structure design simultaneously reserves the robot construction positioning structure and visual recognition target, the integrated molding pre-embedded RFID smart identification chip, and simultaneously reserves the prefabricated building pipeline trench and pre-embedded point slot, adapting to the construction needs of intelligent construction and prefabricated building in all scenarios.