A method for accurately dividing an aluminum alloy ingot in combination with an ultrasonic flaw detection technique

Abstract

The present application relates to a kind of methods for accurately segmenting aluminum alloy ingot in combination with ultrasonic flaw detection technology, comprising: (1) ultrasonic flaw detection treatment is carried out to aluminum alloy ingot, and defect information is obtained;(2) according to the defect information, defect severity determination is carried out;If defect equivalent size or area proportion exceeds preset threshold, it is judged as unqualified;Otherwise, it is judged as qualified;(3) according to the defect information, defect treatment determination is carried out to qualified aluminum alloy ingot;If there is no defect, step (4) is carried out;If there is defect, the defect area is removed, and then step (4) is carried out;(4) according to the defect treatment determination result of step (3), automatic cutting is carried out, and aluminum alloy ingot finished product is obtained.The method of the present application adopts automatic ingot flaw detection and automatic sawing scheme, improves overall work efficiency through information integration.

Description

Technical Field

[0001] This invention relates to the field of high-purity aluminum technology, and in particular to a method for accurately dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology. Background Technology

[0002] Ultra-high purity aluminum alloys are characterized by easy deposition, good etching and processing performance, high electrical conductivity, good thermal conductivity, good adhesion and bonding performance with substrates, and low cost, making them the main material for metal interconnects in integrated circuit manufacturing.

[0003] The high-purity aluminum used in high-purity aluminum sputtering targets needs to meet a purity of 5N or higher (99.999wt%). Defects such as cracks, inclusions, and shrinkage cavities in aluminum alloy ingots can cause abnormalities in the sputtering process.

[0004] The common technical approach involves first manually performing ultrasonic testing on high-purity aluminum ingots to record defective product information. The ingots are then cut using a saw. This process is cumbersome, labor-intensive, and prone to error accumulation.

[0005] For example, CN104391041A discloses a non-destructive testing method for aluminum alloy rods using ultrasonic technology, including the following steps: Step 1: Grind an inner arc at the bottom of the longitudinal wave dual-crystal probe, the inner arc matching the outer arc of the aluminum alloy rod to be tested; Step 2: Use a flat-bottomed hole test block to plot a Φ1.2mm flat-bottomed hole distance-amplitude DAC curve and a Φ0.8mm flat-bottomed hole distance-amplitude DAC curve; and adjust the testing sensitivity, which includes a reference sensitivity, a detection sensitivity, and a scanning sensitivity; Step 3: Place the longitudinal wave dual-crystal probe on the outer circular surface of the aluminum alloy rod to be tested and scan along the longitudinal direction of the rod; mark a rotation mark on the end of the rod; rotate three times, each rotation angle being 90°±2°, to scan the entire circumference area of ​​the aluminum alloy rod to be tested.

[0006] CN107102063A discloses an ultrasonic flaw detection method for 7xxx series aluminum alloy square ingots, including: 1. Probe selection; 2. Fabrication of comparison test blocks; 3. Probe testing and AVG curve fabrication; 4. Flaw detection test of comparison test blocks; 5. Calculation of large flat-bottom gain values ​​of probes at different frequencies; 6. Determination of the optimal probe; 7. Testing the ingot under test using the optimal probe. This method mainly addresses the problem of low detection rates of metallurgical defects such as irregularly distributed inclusions and compound agglomerations in existing flaw detection methods, leading to the scrapping of plates after multiple processing steps.

[0007] CN107843643A discloses an automatic eddy current flaw detection device and method for aluminum and aluminum alloy thin-walled tubes, including a cylinder, an eddy current flaw detector, a conveying device, a loading and unloading device, an eddy current probe, a photoelectric switch, a PLC, and an eddy current flaw detector. The conveying device horizontally conveys the aluminum and aluminum alloy thin-walled tubes to be tested. The loading device loads the aluminum and aluminum alloy thin-walled tubes to be tested onto the conveying device, and the unloading device unloads the inspected aluminum and aluminum alloy thin-walled tubes from the conveying device. The cylinder is located below the conveying device. The CPU processes the data based on the processed information, and the cylinder loads the aluminum and aluminum alloy thin-walled tubes to be tested and marks and sorts the inspected aluminum and aluminum alloy thin-walled tubes according to the loading control signal, the marking control signal, and the sorting control signal to complete the automatic flaw detection of the aluminum and aluminum alloy thin-walled tubes.

[0008] The aforementioned existing technologies all suffer from cumbersome processes, high labor costs, and the tendency to accumulate errors. Therefore, there is an urgent need for a new method for cutting aluminum alloy ingots that can achieve automated cutting, reduce labor costs, and improve work efficiency. Summary of the Invention

[0009] To address the aforementioned technical problems, this invention provides a method for precisely dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology. This invention deeply integrates ultrasonic flaw detection with the dividing process, enabling precise detection and location of internal defects in the ingot before dividing. Compared to traditional methods, this avoids the scrapping of entire sections due to defects located within the finished product segment. This invention employs an automated ingot flaw detection and automated sawing scheme, improving overall work efficiency through information integration.

[0010] To achieve this objective, the present invention adopts the following technical solution:

[0011] This invention provides a method for accurately dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology, the method comprising:

[0012] (1) Perform ultrasonic testing on aluminum alloy ingots to obtain defect information;

[0013] (2) Determine the severity of the defect based on the defect information; if the equivalent size or area ratio of the defect exceeds the preset threshold, it is determined to be unqualified; otherwise, it is determined to be qualified.

[0014] (3) Based on the defect information, the qualified aluminum alloy ingot is judged for defect treatment; if there is no defect, proceed to step (4); if there is a defect, the defect area is cut off and then step (4) is performed.

[0015] (4) Based on the defect handling judgment result of step (3), perform automated cutting to obtain the finished aluminum alloy ingot.

[0016] This invention combines ultrasonic flaw detection with the cutting process, enabling precise detection and location of internal defects in ingots before cutting. This reduces manual intervention time and improves overall production line efficiency. Compared to traditional methods, it avoids scrapping entire sections due to defects located within the finished product segment. This invention employs automated ingot flaw detection and automated sawing solutions, improving overall work efficiency through information integration.

[0017] As a preferred technical solution of the present invention, the ultrasonic flaw detection process in step (1) is performed using an ultrasonic flaw detector; the ultrasonic flaw detector includes any one of an analog ultrasonic flaw detector, a digital ultrasonic flaw detector, or a phased array ultrasonic flaw detector.

[0018] As a preferred technical solution of the present invention, the ultrasonic flaw detection process in step (1) specifically includes: applying an automated coupling agent to the aluminum alloy ingot.

[0019] Preferably, the coupling agent includes any one of engine oil, glycerin, or water glass.

[0020] As a preferred technical solution of the present invention, the step (1) of obtaining defect information includes: performing ultrasonic scanning detection on aluminum alloy ingots, determining the defect type, location and size through the control system; then marking the defect area and generating a defect distribution map.

[0021] As a preferred technical solution of the present invention, the preset threshold in step (2) includes: defect equivalent size ≥ 2 mm, or defect area ratio ≥ 0.02%.

[0022] As a preferred technical solution of the present invention, the defect handling judgment in step (3) further includes: for qualified aluminum alloy ingots with defects, if the defects cannot be removed or cannot be used after removal, they shall be scrapped.

[0023] If the defect can be removed, mark the aluminum alloy ingot information and upload it to the control system.

[0024] As a preferred technical solution of the present invention, before performing the automated cutting in step (4), the method further includes: distinguishing between normal aluminum alloy ingots and defective aluminum alloy ingots based on the aluminum alloy ingot marking information in the control system.

[0025] As a preferred technical solution of the present invention, the automated cutting in step (4) includes: the normal aluminum alloy ingot is automatically cut using a general program;

[0026] Defective aluminum alloy ingots are automatically cut by editing the cutting path based on the defect distribution map.

[0027] In this invention, the cutting path of the defective aluminum alloy ingot is edited according to the defect distribution map and manually verified to ensure the safety and effectiveness of the cutting.

[0028] As a preferred technical solution of the present invention, the method further includes: uploading the automated cutting data and aluminum alloy ingot finished product data in step (4) to the control system; and classifying and storing the aluminum alloy ingot finished product or sending the aluminum alloy ingot finished product to the next process.

[0029] As a preferred technical solution of the present invention, the method includes:

[0030] (1) Perform ultrasonic testing on aluminum alloy ingots to obtain defect information;

[0031] The ultrasonic flaw detection process is performed using an ultrasonic flaw detector; the ultrasonic flaw detector includes any one of an analog ultrasonic flaw detector, a digital ultrasonic flaw detector, or a phased array ultrasonic flaw detector.

[0032] The ultrasonic flaw detection process specifically includes: applying an automated coupling agent to the aluminum alloy ingot; the coupling agent includes any one of machine oil, glycerin, or water glass.

[0033] The acquisition of defect information includes: performing ultrasonic scanning detection on aluminum alloy ingots, determining the defect type, location, and size through a control system; subsequently marking the defect area and generating a defect distribution map;

[0034] (2) Determine the severity of the defect based on the defect information; if the equivalent size or area ratio of the defect exceeds the preset threshold, it is determined to be unqualified; otherwise, it is determined to be qualified.

[0035] The preset thresholds include: defect equivalent size ≥ 2mm, or defect area percentage ≥ 0.02%;

[0036] (3) Based on the defect information, the qualified aluminum alloy ingot is judged for defect treatment; if there is no defect, proceed to step (4); if there is a defect, the defect area is cut off and then step (4) is performed.

[0037] For qualified aluminum alloy ingots with defects, if the defects cannot be removed or the ingots cannot be used after removal, they shall be scrapped; if the defects can be removed, the aluminum alloy ingot information shall be marked and uploaded to the control system.

[0038] (4) Based on the defect handling judgment result of step (3), perform automated cutting to obtain the finished aluminum alloy ingot;

[0039] Before performing the automated cutting in step (4), the process further includes: distinguishing between normal aluminum alloy ingots and defective aluminum alloy ingots based on the aluminum alloy ingot marking information in the control system; the automated cutting includes: normal aluminum alloy ingots are automatically cut using a general program; defective aluminum alloy ingots are automatically cut by editing the cutting path according to the defect distribution map.

[0040] Upload the automated cutting data and aluminum alloy ingot finished product data described in step (4) to the control system; and classify and store the aluminum alloy ingot finished products or send them to the next process.

[0041] Compared with the prior art, the present invention has at least the following beneficial effects:

[0042] This invention combines ultrasonic flaw detection with the cutting process, enabling precise detection and location of internal defects in ingots before cutting. This reduces manual intervention time and improves overall production line efficiency. Compared to traditional methods, it avoids scrapping entire sections due to defects located within the finished product segment. This invention employs automated ingot flaw detection and automated sawing solutions, improving overall work efficiency through information integration. Attached Figure Description

[0043] Figure 1 This is a judgment logic diagram of a method for accurately dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology provided by the present invention.

[0044] Figure 2 This is a logic diagram for determining the severity of defects in a method for accurately dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology provided by the present invention.

[0045] Figure 3 This is an automated cutting and determination logic diagram in a method for accurately dividing aluminum alloy ingots using combined ultrasonic flaw detection technology provided by the present invention. Detailed Implementation

[0046] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments. However, the following examples are merely simplified examples of the present invention and do not represent or limit the scope of protection of the present invention. The scope of protection of the present invention is determined by the claims.

[0047] Example 1

[0048] This embodiment provides a method for accurately dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology, the method comprising:

[0049] (1) Apply an automated coupling agent to the aluminum alloy ingot, the coupling agent being machine oil; use a simulated ultrasonic flaw detector to perform ultrasonic scanning on the aluminum alloy ingot, and determine the defect type, location, and size through the control system; then mark the defect area and generate a defect distribution map;

[0050] (2) Determine the severity of the defect based on the defect information; if the equivalent size of the defect is ≥2mm, or the defect area accounts for ≥0.02%, it is determined to be unqualified; otherwise, it is determined to be qualified.

[0051] (3) Based on the defect information, the qualified aluminum alloy ingot is judged for defect treatment; if there is no defect, proceed to step (4); if there is a defect, the defect area is cut off and then step (4) is performed.

[0052] For qualified aluminum alloy ingots with defects, if the defects cannot be removed or the ingots cannot be used after removal, they shall be scrapped; if the defects can be removed, the aluminum alloy ingot information shall be marked and uploaded to the control system.

[0053] (4) Based on the aluminum alloy ingot marking information in the control system, distinguish between normal aluminum alloy ingots and defective aluminum alloy ingots; normal aluminum alloy ingots are automatically cut using a general program;

[0054] Defective aluminum alloy ingots are automatically cut by editing the cutting path based on the defect distribution map;

[0055] The automated cutting data and aluminum alloy ingot finished product data are uploaded to the control system; and the aluminum alloy ingot finished products are classified and stored or moved to the next process.

[0056] Example 2

[0057] This embodiment provides a method for accurately dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology, the method comprising:

[0058] (1) Apply an automated coupling agent to the aluminum alloy ingot, wherein the coupling agent is glycerin; use a digital ultrasonic flaw detector to perform ultrasonic scanning detection on the aluminum alloy ingot, and determine the defect type, location and size through the control system; then mark the defect area and generate a defect distribution map;

[0059] (2) Determine the severity of the defect based on the defect information; if the equivalent size of the defect is ≥2mm, or the defect area accounts for ≥0.02%, it is determined to be unqualified; otherwise, it is determined to be qualified.

[0060] (3) Based on the defect information, the qualified aluminum alloy ingot is judged for defect treatment; if there is no defect, proceed to step (4); if there is a defect, the defect area is cut off and then step (4) is performed.

[0061] For qualified aluminum alloy ingots with defects, if the defects cannot be removed or the ingots cannot be used after removal, they shall be scrapped; if the defects can be removed, the aluminum alloy ingot information shall be marked and uploaded to the control system.

[0062] (4) Based on the aluminum alloy ingot marking information in the control system, distinguish between normal aluminum alloy ingots and defective aluminum alloy ingots; normal aluminum alloy ingots are automatically cut using a general program;

[0063] Defective aluminum alloy ingots are automatically cut by editing the cutting path based on the defect distribution map;

[0064] The automated cutting data and aluminum alloy ingot finished product data are uploaded to the control system; and the aluminum alloy ingot finished products are classified and stored or moved to the next process.

[0065] Example 3

[0066] This embodiment provides a method for accurately dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology, the method comprising:

[0067] (1) Apply an automated coupling agent to the aluminum alloy ingot, wherein the coupling agent is water glass; use a phased array ultrasonic flaw detector to perform ultrasonic scanning detection on the aluminum alloy ingot, and determine the defect type, location and size through the control system; then mark the defect area and generate a defect distribution map;

[0068] (2) Determine the severity of the defect based on the defect information; if the equivalent size of the defect is ≥2mm, or the defect area accounts for ≥0.02%, it is determined to be unqualified; otherwise, it is determined to be qualified.

[0069] (3) Based on the defect information, the qualified aluminum alloy ingot is judged for defect treatment; if there is no defect, proceed to step (4); if there is a defect, the defect area is cut off and then step (4) is performed.

[0070] For qualified aluminum alloy ingots with defects, if the defects cannot be removed or the ingots cannot be used after removal, they shall be scrapped; if the defects can be removed, the aluminum alloy ingot information shall be marked and uploaded to the control system.

[0071] (4) Based on the aluminum alloy ingot marking information in the control system, distinguish between normal aluminum alloy ingots and defective aluminum alloy ingots; normal aluminum alloy ingots are automatically cut using a general program;

[0072] Defective aluminum alloy ingots are automatically cut by editing the cutting path based on the defect distribution map;

[0073] The automated cutting data and aluminum alloy ingot finished product data are uploaded to the control system; and the aluminum alloy ingot finished products are classified and stored or moved to the next process.

[0074] In summary, this invention provides a method for precisely dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology. By deeply integrating ultrasonic flaw detection with the dividing process, accurate detection and location of internal defects in the ingot can be completed before dividing, reducing manual intervention time and improving the overall processing efficiency of the production line. Compared with traditional technical routes, it avoids the scrapping of the entire section due to defects located within the finished product section. This invention employs an automated ingot flaw detection and automated sawing scheme, improving overall work efficiency through information integration.

[0075] The applicant declares that the above description is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Those skilled in the art should understand that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention fall within the protection and disclosure scope of the present invention.

Claims

1. A method for precisely dividing aluminum alloy ingots using a combination of ultrasonic flaw detection technology, characterized in that, The method includes: (1) Perform ultrasonic testing on aluminum alloy ingots to obtain defect information; (2) Determine the severity of the defect based on the defect information; if the equivalent size or area ratio of the defect exceeds the preset threshold, it is determined to be unqualified; otherwise, it is determined to be qualified. (3) Based on the defect information, the qualified aluminum alloy ingot is judged for defect treatment; if there is no defect, proceed to step (4); if there is a defect, the defect area is cut off and then step (4) is performed. (4) Based on the defect handling judgment result of step (3), perform automated cutting to obtain the finished aluminum alloy ingot.

2. The method according to claim 1, characterized in that, The ultrasonic flaw detection process described in step (1) is performed using an ultrasonic flaw detector; the ultrasonic flaw detector includes any one of an analog ultrasonic flaw detector, a digital ultrasonic flaw detector, or a phased array ultrasonic flaw detector.

3. The method according to claim 1 or 2, characterized in that, The ultrasonic flaw detection process in step (1) specifically includes: applying an automated coupling agent to the aluminum alloy ingot; Preferably, the coupling agent includes any one of engine oil, glycerin, or water glass.

4. The method according to any one of claims 1-3, characterized in that, Step (1) involves obtaining defect information by performing ultrasonic scanning on the aluminum alloy ingot, determining the defect type, location, and size through a control system, and then marking the defect area and generating a defect distribution map.

5. The method according to any one of claims 1-4, characterized in that, The preset threshold in step (2) includes: defect equivalent size ≥ 2 mm, or defect area ratio ≥ 0.02%.

6. The method according to any one of claims 1-5, characterized in that, The defect handling judgment in step (3) also includes: for qualified aluminum alloy ingots with defects, if the defects cannot be removed or cannot be used after removal, they shall be scrapped. If the defect can be removed, mark the aluminum alloy ingot information and upload it to the control system.

7. The method according to any one of claims 1-6, characterized in that, Before performing the automated cutting in step (4), the method further includes: distinguishing between normal aluminum alloy ingots and defective aluminum alloy ingots based on the aluminum alloy ingot marking information in the control system.

8. The method according to any one of claims 1-7, characterized in that, The automated cutting in step (4) includes: automated cutting of normal aluminum alloy ingots using a general program; Defective aluminum alloy ingots are automatically cut by editing the cutting path based on the defect distribution map.

9. The method according to any one of claims 1-8, characterized in that, The method further includes: uploading the automated cutting data and aluminum alloy ingot finished product data from step (4) to the control system; and classifying and storing the aluminum alloy ingot finished products or sending them to the next process.

10. The method according to any one of claims 1-9, characterized in that, The method includes: (1) Perform ultrasonic testing on aluminum alloy ingots to obtain defect information; The ultrasonic flaw detection process is performed using an ultrasonic flaw detector; the ultrasonic flaw detector includes any one of an analog ultrasonic flaw detector, a digital ultrasonic flaw detector, or a phased array ultrasonic flaw detector. The ultrasonic flaw detection process specifically includes: applying an automated coupling agent to the aluminum alloy ingot; the coupling agent includes any one of machine oil, glycerin, or water glass. The acquisition of defect information includes: performing ultrasonic scanning detection on aluminum alloy ingots, determining the defect type, location, and size through a control system; subsequently marking the defect area and generating a defect distribution map; (2) Determine the severity of the defect based on the defect information; if the equivalent size or area ratio of the defect exceeds the preset threshold, it is determined to be unqualified; otherwise, it is determined to be qualified. The preset thresholds include: defect equivalent size ≥ 2mm, or defect area ratio ≥ 0.02%; (3) Based on the defect information, the qualified aluminum alloy ingot is judged for defect treatment; if there is no defect, proceed to step (4); if there is a defect, the defect area is cut off and then step (4) is performed. For qualified aluminum alloy ingots with defects, if the defects cannot be removed or the ingots cannot be used after removal, they shall be scrapped. If the defect can be removed, mark the aluminum alloy ingot information and upload it to the control system; (4) Based on the defect handling judgment result of step (3), perform automated cutting to obtain the finished aluminum alloy ingot; Before performing the automated cutting in step (4), the process further includes: distinguishing between normal aluminum alloy ingots and defective aluminum alloy ingots based on the aluminum alloy ingot marking information in the control system; the automated cutting includes: normal aluminum alloy ingots are automatically cut using a general program; defective aluminum alloy ingots are automatically cut by editing the cutting path according to the defect distribution map. Upload the automated cutting data and aluminum alloy ingot finished product data described in step (4) to the control system; and classify and store the aluminum alloy ingot finished products or send the aluminum alloy ingot finished products to the next process.

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