A continuous manufacturing apparatus and method for high-performance aluminum alloy or magnesium alloy sheets and profiles

Abstract

The application belongs to the technical field of continuous manufacturing of metal materials, and discloses a kind of continuous manufacturing device and method of high-performance aluminum alloy or magnesium alloy sheet and profile.The device comprises a melt feeding module, an extrusion module and a forming die;The extrusion module comprises an extrusion wheel, a compaction wheel and a shoe block, the extrusion wheel and / or the compaction wheel adopt a split structure arranged along the axial direction, the split structure comprises at least two wheel body units, each wheel body unit is connected to an independent driving mechanism and a speed regulation mechanism, and the speed of each wheel body unit is adjusted to realize the regulation and control of the continuous billet conveying speed, material flow and extrusion pressure in different regions.The continuous billet is continuously formed into a sheet or a profile by the extrusion module and the forming die, and further combined with online heating, hot rolling, rapid cooling and finishing processes to obtain a continuously manufactured product.The application can improve the material supply capacity and forming stability during continuous manufacturing, and realize short-process and continuous manufacturing of aluminum alloy or magnesium alloy sheet and complex cross-section profile.

Description

Technical Field

[0001] This invention belongs to the field of high-performance aluminum alloy or magnesium alloy sheet and profile manufacturing technology, specifically relating to a continuous manufacturing apparatus and method for high-performance aluminum alloy or magnesium alloy sheet and profile. Background Technology

[0002] The statements herein are for the purpose of providing background information in relation to this invention and do not necessarily constitute prior art.

[0003] Aluminum and magnesium alloy sheets and profiles are essential basic materials for aerospace, rail transportation, shipbuilding, automobile and high-end equipment manufacturing and other fields. Their manufacturing process directly affects the dimensional accuracy, microstructure uniformity, mechanical properties, surface quality and subsequent processing adaptability of the products.

[0004] Continuous extrusion technology utilizes the friction between the extrusion roller and the material to achieve continuous material transport and continuous plastic deformation. Compared with the traditional intermittent extrusion process, it has advantages such as high production efficiency, high material utilization rate and reduced joint defects, and has good application prospects in the manufacturing of aluminum alloy and magnesium alloy plates and profiles.

[0005] However, existing continuous extrusion equipment typically employs a single-channel feeding system and an integral extrusion roller structure. Limited by feeding capacity, extrusion roller size, and equipment load-bearing capacity, it is difficult to achieve continuous and stable forming of large-format panel materials and complex cross-section profiles. Furthermore, integral extrusion rollers usually use a synchronous drive method, which cannot independently adjust the material conveying speed, flow distribution, and extrusion pressure in different areas of the die based on differences in material flow resistance. This easily leads to problems such as uneven material flow, uneven pressure distribution, product deviation, bending deformation, and decreased dimensional accuracy. Summary of the Invention

[0006] To address the problems of insufficient material supply capacity, limited forming dimensions, difficulty in controlling material flow state, and insufficient uniformity of microstructure and product quality stability in the existing continuous manufacturing process of aluminum alloy and magnesium alloy sheets and profiles, especially the problems that existing continuous extrusion equipment usually adopts a single-channel feeding and integral extrusion roller structure, which is difficult to meet the continuous and stable forming requirements of large sheet materials and complex cross-section profiles, and cannot independently adjust the material conveying speed, flow distribution and extrusion pressure according to the differences in material flow resistance in different areas inside the die, this invention provides a high-performance continuous manufacturing device and manufacturing method for aluminum alloy or magnesium alloy sheets and profiles.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a continuous manufacturing apparatus for high-performance aluminum alloy or magnesium alloy plates, comprising a melt feeding module, an extrusion module, a plate forming die, a straightening and guiding module, a first tension control module, an online heating module, a hot rolling module, a second tension control module, a rapid cooling module, a cold rolling finishing module, and a coiling and unloading module, which are arranged sequentially and interconnected along the material conveying direction.

[0008] The melt feeding module includes an independent pressurized liquid supply chamber, a heat-insulated liquid delivery channel, and a short-range crystallization zone that are connected sequentially along the direction of metal material conveying.

[0009] The independent pressurized liquid supply chamber is used to contain the molten metal and apply a conveying pressure to the molten metal, so that the molten metal enters the heat-insulating liquid conveying channel at a stable flow rate; the heat-insulating liquid conveying channel is used to heat-insulate and convey the molten metal; the short-range crystallization zone is used to cool and solidify the molten metal in a controlled manner, so that the molten metal forms a continuous billet with a preset solid fraction and residual heat state within a short conveying distance, and the continuous billet is conveyed to the extrusion module.

[0010] The extrusion module includes an extrusion roller, a compaction roller, a shoe block, and a drive transmission mechanism. The extrusion roller and the compaction roller cooperate to form a continuous billet conveying area, used for biting, clamping, compacting, and conveying the continuous billet; the shoe block and the extrusion roller together form an extrusion forming cavity, the outlet of which is connected to the inlet of the sheet metal forming die, so that the continuous billet undergoes plastic deformation under extrusion pressure and frictional shearing, and is continuously formed into a sheet metal with a preset cross-sectional shape through the sheet metal forming die.

[0011] The extrusion wheel and / or compaction wheel are respectively connected to the drive mechanism and the speed regulation mechanism to realize the speed adjustment of the extrusion wheel and the compaction wheel.

[0012] In one embodiment, the short-range crystallization zone includes a crystallization sleeve, a molten metal flow channel disposed within the crystallization sleeve, a cooling medium circulation channel disposed around the crystallization sleeve, and a temperature detection component.

[0013] By adjusting the temperature and flow rate of the cooling medium, the cooling rate and solidification state of the molten metal are controlled, so that the formed continuous billet maintains a preset residual heat state.

[0014] In one embodiment, the extrusion wheel and the compaction wheel are of an integral structure.

[0015] In another embodiment, the extrusion wheel and / or compaction wheel adopts an axially split structure. The split structure includes at least two wheels arranged sequentially along the axial direction, each wheel being arranged along the same rotation axis and together forming a continuous extrusion working surface; each wheel is connected to an independent drive mechanism and a speed regulating mechanism, so that each wheel can rotate independently at a preset speed.

[0016] Each wheel is arranged along the width of the sheet or different deformation areas of the profile cross section. By adjusting the speed difference between different wheel units, different areas of the continuous billet can obtain differentiated conveying speed, friction shearing action and extrusion pressure. In this way, the material flow distribution and pressure state can be adjusted according to the material flow resistance in different areas inside the sheet forming die or profile forming die, thereby improving the material flow uniformity, dimensional stability and forming quality in the forming process of wide sheet and complex cross section profile.

[0017] At least two material channels are provided between the extrusion wheel and the compaction wheel, and multiple material channels are arranged at intervals along the axial direction to simultaneously transport multiple continuous billets, thereby improving the material supply capacity in the continuous manufacturing process.

[0018] The cross-sectional shape of the material channel is adapted to the cross-section of the continuous billet, including rectangular, circular, polygonal, rounded rectangle or other adapted cross-sections.

[0019] The straightening and guiding module is located downstream of the sheet forming die and is used to straighten, center and guide the sheet formed by continuous extrusion.

[0020] The first tension control module is located upstream of the online heating module and is used to adjust the conveying speed and tension of the sheet material before it enters the online heating module and the hot rolling module.

[0021] The online heating module is used to continuously heat the extruded sheet material to bring it to the preset rolling temperature.

[0022] The hot rolling module is located downstream of the online heating module and is used to perform online hot rolling on the heated sheet metal. The hot rolling module includes an upper roll and a lower roll arranged opposite each other. The upper roll and the lower roll are provided with a medium flow channel. By introducing a hot medium or a cold medium into the medium flow channel, the temperature of the roll is adjusted, thereby controlling the temperature state of the sheet metal during the hot rolling process.

[0023] The second tension control module is located downstream of the hot rolling module and is used to adjust the front tension and conveying speed of the hot-rolled sheet to keep the sheet in a stable conveying state.

[0024] The rapid cooling module is located downstream of the hot rolling module and is used to rapidly cool the hot-rolled sheet material to achieve online quenching or controlled cooling.

[0025] The cold rolling finishing module is located downstream of the rapid cooling module and is used to perform cold rolling, leveling, and surface finishing on the cooled sheet metal.

[0026] The coiling and unloading module is located downstream of the cold rolling finishing module. It is used to continuously coil the formed sheet material and cut and unload it according to the preset length, coil diameter or weight.

[0027] In some embodiments, the continuous manufacturing apparatus does not include a cold rolling finishing module; the sheet metal processed by the rapid cooling module directly enters the coiling and uncoiling module for winding and uncoiling.

[0028] In some implementations, when bars, rods, or pre-formed continuous billets are used as raw materials, the raw materials can be directly fed into the extrusion module for continuous extrusion forming without passing through the melt feeding module.

[0029] Secondly, the present invention provides a continuous manufacturing apparatus for high-performance aluminum alloy or magnesium alloy profiles, comprising a melt feeding module, an extrusion module, and a profile forming die arranged sequentially along the material conveying direction.

[0030] The melt feeding module and extrusion module have the same structure as the corresponding modules in the above-mentioned continuous sheet metal manufacturing device.

[0031] The extrusion module adopts an integral or split extrusion wheel and / or compaction wheel structure. By adjusting the rotation speed of the extrusion wheel, compaction wheel or each wheel unit, the material conveying speed, flow distribution and extrusion pressure in different areas of the profile are controlled, so that the continuous billet is continuously formed into a profile with a preset cross-sectional shape through the profile forming die.

[0032] The profile forming mold is used to form aluminum alloy or magnesium alloy profiles with asymmetrical cross-sections, non-uniform cross-sections, large differences in wall thickness, or other complex cross-sections.

[0033] Thirdly, the present invention provides a continuous manufacturing method for high-performance aluminum alloy or magnesium alloy sheets, employing the aforementioned continuous manufacturing apparatus, comprising the following steps: S1. Melt feeding: The aluminum alloy or magnesium alloy raw material is melted to form a molten metal. The molten metal is conveyed by an independent pressurized liquid supply chamber, so that the molten metal enters the short-range crystallization zone through the heat-insulated liquid supply channel. In the short-range crystallization zone, it is cooled and solidified in a controlled manner to form a continuous billet with residual heat.

[0034] S2. Continuous extrusion forming: The continuous billet is conveyed to the extrusion module. The extrusion roller and the compaction roller bite, clamp, compact and convey the continuous billet, so that the continuous billet enters the extrusion forming cavity and is continuously formed into extruded sheet through the sheet forming die.

[0035] S3. Online heating and hot rolling: The extruded sheet is heated online to reach the preset rolling temperature, and then continuously hot rolled through the hot rolling module.

[0036] S4. Rapid cooling: Rapidly cool the hot-rolled sheet material to achieve online quenching or controlled cooling.

[0037] S5. Cold Rolling Finishing and Coiling: According to performance requirements, the cooled sheet metal is cold rolled, leveled and surface finished, and continuously coiled or unloaded through the coiling and unloading module.

[0038] When using split extrusion rollers and / or compaction rollers, the rotational speed of each roller unit is adjusted according to the material flow resistance in different areas inside the sheet forming die, so as to achieve regional control of material conveying speed, material flow rate and extrusion pressure in different areas.

[0039] Fourthly, the present invention provides a method for continuous manufacturing of high-performance aluminum alloy or magnesium alloy profiles, using the aforementioned continuous profile manufacturing apparatus, comprising the following steps: S1. A continuous billet with residual heat is formed through the melt feeding module; S2. The continuous billet is conveyed to the extrusion module, where it is continuously conveyed and plastically deformed by the extrusion rollers and compaction rollers; S3. Adjust the rotation speed of the extrusion wheel, compaction wheel, or each wheel unit according to the profile cross-sectional shape and the material flow requirements in different areas; S4. Aluminum alloy or magnesium alloy profiles with a preset cross-sectional shape are continuously formed by profile forming mold.

[0040] The beneficial effects of this invention include: Eliminating transverse welds: This enables continuous production from molten metal to finished sheet metal, eliminating transverse welds and interface defects in traditional extrusion processes, resulting in high product integrity and yield.

[0041] Superior performance: Through large plastic deformation and online quenching, the material grains are significantly refined, and the comprehensive mechanical properties of the sheet are superior to those of traditional extruded and rolled products.

[0042] High efficiency and energy saving: It uses the residual heat from melting and casting to directly extrude and form, eliminating the need for secondary heating, resulting in low energy consumption and meeting the requirements of green manufacturing.

[0043] High controllability: The extrusion rollers can be independently speed adjusted, dynamically balancing the pressure inside the mold, optimizing material flow, and improving forming stability and efficiency.

[0044] This device, by setting up a multi-channel continuous extrusion module, can not only continuously extrude conventional solid bar stock, but also directly introduce molten metal into the extrusion rollers to achieve continuous rheological extrusion. It can also work in conjunction with subsequent hot rolling, cooling, cold rolling finishing and online detection units to achieve short-process, continuous and stable manufacturing of high-performance sheet metal. Attached Figure Description

[0045] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0046] Figure 1 A three-dimensional diagram of a continuous manufacturing apparatus for high-performance aluminum alloy or magnesium alloy plates according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the mating structure of the split extrusion wheel and the compaction wheel according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the split extrusion wheel and compaction wheel according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the internal structure of the split extrusion wheel and compaction wheel according to an embodiment of the present invention; Figure 5 This is a side view of a continuous manufacturing apparatus for high-performance aluminum alloy or magnesium alloy sheets according to an embodiment of the present invention. Figure 6 This is a schematic diagram of the material flow and deformation path of a continuous billet during the extrusion process in an embodiment of the present invention; Figure 7 This is a side view of a high-performance aluminum or magnesium alloy sheet continuous manufacturing apparatus that omits the cold rolling finishing module in another embodiment of the present invention. Figure 8 This is a side view of a high-performance aluminum alloy or magnesium alloy sheet continuous manufacturing apparatus using solid raw materials in another embodiment of the present invention. Figure 9 The following are schematic diagrams of raw materials with different cross-sectional shapes in embodiments of the present invention, wherein (a) is a rectangular cross-section, (b) is a rounded rectangle, (c) is a second type of rounded rectangle, and (d) is a circle; Figure 10 A three-dimensional diagram of a continuous manufacturing apparatus for high-performance aluminum alloy or magnesium alloy profiles according to an embodiment of the present invention; Figure 11 This is a cross-sectional view of a non-uniform profile prepared using a continuous manufacturing apparatus for high-performance aluminum alloy or magnesium alloy profiles in an embodiment of the present invention.

[0047] The components include: 1. Melt feeding module; 2. Insulated liquid delivery channel; 3. Short-range crystallization zone; 4. Extrusion wheel drive gear assembly; 4-1. First extrusion wheel drive gear; 4-2. Second extrusion wheel drive gear; 4-3. Third extrusion wheel drive gear. 5. Compactor drive gear assembly; 5-1. First compactor drive gear; 5-2. Second compactor drive gear; 5-3. Third compactor drive gear; 6. Extrusion rollers; 6-1. First extrusion roller unit; 6-2. Second extrusion roller unit; 6-3. Third extrusion roller unit; 7. Compactor wheel; 7-1. First compactor wheel unit; 7-2. Second compactor wheel unit; 7-3. Third compactor wheel unit; 8. Sheet metal forming die; 9. Straightening and guiding module; 10. First tension control module; 11. Online heating module; 12. Hot rolling module; 13. Rapid cooling module; 14. Second tension control module; 15. Cold rolling finishing module; 15-1. First cold rolling finishing module; 15-2. Second cold rolling finishing module; 15-3. Third cold rolling finishing module; 16. Cold-rolled sheet metal; 17. Coiling and unloading module; 18. Raw materials; 18-1. First raw material; 18-2. Second raw material; 18-3. Third raw material; 19. Deformable material; 20. Material inside the die; 21. Extruded sheet; 22. Hot-rolled sheet; 23. Sheet coil; 24. Profile forming die; 25. Non-uniform cross-section profile. Detailed Implementation

[0048] It should be noted that the following detailed descriptions are exemplary and intended to further illustrate the present invention, and should not be construed as limiting the scope of protection of the present invention. Unless otherwise stated, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0049] Where there is no conflict, the various embodiments and technical features of the present invention can be combined with each other.

[0050] In view of the problems existing in the manufacturing process of aluminum alloy and magnesium alloy sheets and profiles, such as the separation of processes, long production process, low material heat utilization rate, insufficient large-size forming capacity, and difficulty in controlling material flow state, the present invention provides a continuous manufacturing apparatus and manufacturing method for high-performance aluminum alloy or magnesium alloy sheets and profiles.

[0051] like Figure 1 and Figure 5 As shown, this embodiment provides a continuous manufacturing apparatus for high-performance aluminum alloy or magnesium alloy sheets, including a melt feeding module 1, an extrusion module, a sheet forming die 8, a straightening and guiding module 9, a first tension control module 10, an online heating module 11, a hot rolling module 12, a second tension control module 14, a rapid cooling module 13, a cold rolling finishing module 15, and a coiling and unloading module 17, which are arranged sequentially and connected to each other along the material conveying direction.

[0052] The melt feeding module 1 is connected to the extrusion module and is used to continuously supply molten metal and form a continuous billet suitable for continuous extrusion. The melt feeding module 1 includes an independent pressurized liquid supply chamber, a heat-insulated liquid delivery channel 2, and a short-range crystallization zone 3, which are connected sequentially along the material conveying direction.

[0053] The independent pressurized liquid supply chamber is used to contain the molten metal and apply a delivery pressure to the molten metal, allowing it to enter the heat-insulated delivery channel 2 at a stable flow rate. The independent pressurized liquid supply chamber can be equipped with a heating device and a temperature detection device to maintain and detect the temperature of the molten metal, ensuring it remains at a suitable temperature for delivery and solidification control.

[0054] The conveying pressure can be achieved through gas pressure, mechanical pressurization mechanism or other structures that can apply pressure to the molten metal to ensure continuous and stable conveying of the molten metal.

[0055] The insulated infusion channel 2 is located between the independent pressurized infusion chamber and the short-range crystallization zone 3, and is used to transport molten metal and reduce heat loss during the transport process. An insulation structure and / or heating element may be installed on the outside of the insulated infusion channel 2 to maintain a preset temperature before the molten metal enters the short-range crystallization zone 3.

[0056] The short-path crystallization zone 3 is used to control the cooling and solidification of molten metal within a shorter transport path. The short-path crystallization zone 3 includes a crystallization sleeve, a molten metal flow channel disposed inside the crystallization sleeve, a cooling medium circulation channel disposed around the crystallization sleeve, and a temperature detection component.

[0057] The molten metal flow channel is connected to the heat-insulating infusion channel 2. After the molten metal enters the short-range crystallization zone 3, it moves along the molten metal flow channel and is cooled and solidified through the heat exchange between the crystallization sleeve and the cooling medium circulation channel.

[0058] The extrusion module includes an extrusion roller 6, a compaction roller 7, a shoe block, and a drive transmission mechanism. The extrusion roller 6 and the compaction roller 7 are arranged opposite to each other, and their opposite surfaces are respectively provided with mutually cooperating material channels. The inlet of the material channel is correspondingly arranged with the outlet of the short-path crystallization zone 3.

[0059] The extrusion roller 6 and compaction roller 7 are used to bite, clamp and compact the continuous billet, and rely on the friction between the extrusion roller 6, compaction roller 7 and the continuous billet to drive the continuous billet to move forward along the material channel.

[0060] The shoe block is disposed on one side of the extrusion roller 6, and the side of the shoe block facing the extrusion roller 6 has an arc-shaped working surface adapted to the outer peripheral surface of the extrusion roller 6. The shoe block and the extrusion roller 6 together form an extrusion forming cavity, the inlet of which is connected to the material channel, and the outlet is connected to the inlet of the sheet forming mold 8.

[0061] After the continuous billet enters the extrusion module, it is bitten, compacted, and conveyed forward under the combined action of the extrusion roller 6 and the compaction roller 7, forming deformable material 19 within the extrusion module. After entering the extrusion forming cavity, the deformable material 19 is further compacted and undergoes plastic deformation under the action of extrusion pressure and frictional shear force.

[0062] Subsequently, the material enters the sheet metal forming die 8 under extrusion pressure, forming material 20 inside the die. The material 20 inside the die is continuously extruded from the die opening under the constraint of the die, forming extruded sheet metal 21.

[0063] At least one material channel is provided between the extrusion roller 6 and the compaction roller 7. Multiple material channels are spaced apart along the axial direction of the extrusion roller 6 and the compaction roller 7 to simultaneously convey and extrude multiple continuous billets, thereby improving the material supply capacity in the continuous manufacturing process.

[0064] The cross-sectional shape of the material channel is adapted to the cross-section of the continuous billet, including rectangular, rounded rectangle, circular, polygonal or other adapted cross-sections.

[0065] like Figure 9 As shown, the raw material 18 or continuous billet can adopt different cross-sectional shapes to meet the requirements of different product specifications.

[0066] like Figure 2 As shown, in one embodiment, the extrusion wheel 6 and the compaction wheel 7 are integrated. The extrusion wheel 6 is connected to the drive mechanism via an extrusion wheel drive gear 4, and the compaction wheel 7 is connected to the drive mechanism via a compaction wheel drive gear 5.

[0067] like Figure 3 and Figure 4 As shown, in another embodiment, the extrusion wheel 6 and / or compaction wheel 7 adopt an axially split structure.

[0068] The split extrusion wheel includes a first extrusion wheel split unit 6-1, a second extrusion wheel split unit 6-2, and a third extrusion wheel split unit 6-3 arranged sequentially along the axial direction.

[0069] The first extrusion wheel split unit 6-1, the second extrusion wheel split unit 6-2, and the third extrusion wheel split unit 6-3 are arranged sequentially along the same rotation axis and are mounted on the extrusion wheel support shaft through an axial positioning structure.

[0070] The extrusion wheel split unit includes a wheel body and a power connection part. Each extrusion wheel split unit is installed sequentially on the same support shaft along the axial direction. Adjacent extrusion wheel split units are coaxially connected through an end face positioning structure and an axial locking structure, so that multiple extrusion wheel split units together form a continuous extrusion working surface.

[0071] The first extrusion wheel split unit 6-1, the second extrusion wheel split unit 6-2, and the third extrusion wheel split unit 6-3 are respectively connected to an independent drive mechanism and a speed regulation mechanism. Each drive mechanism is connected to the corresponding extrusion wheel split unit through a corresponding transmission component, so that each extrusion wheel split unit can rotate independently around a common rotation axis.

[0072] Each extrusion wheel unit can correspond to different regions in the width direction of the continuous billet. By adjusting the rotation speed of each wheel unit, the material conveying speed, friction shearing action, and extrusion pressure in different regions can be independently adjusted.

[0073] The compaction wheel 7 can also adopt an axially split structure, including a first compaction wheel split unit 7-1, a second compaction wheel split unit 7-2, and a third compaction wheel split unit 7-3. Each compaction wheel split unit is respectively arranged on the same rotation axis and is respectively connected to the corresponding drive mechanism and speed regulation mechanism to realize independent adjustment of the compaction force and friction in different axial areas.

[0074] During operation, based on the material flow resistance in different areas inside the sheet forming die 8, the rotation speeds of different extrusion wheel units and / or compaction wheel units are adjusted to allow different areas of the continuous billet to obtain differentiated conveying speeds, frictional shearing effects, and extrusion pressures. This improves the material flow state inside the die and enhances the uniformity of material flow and dimensional stability during the wide sheet forming process.

[0075] The straightening and guiding module 9 is located downstream of the sheet forming die 8 and is used to straighten, center and guide the extruded sheet 21 so that the extruded sheet 21 is kept in a stable conveying state.

[0076] The straightening and guiding module 9 includes guiding components disposed on both sides of the extruded sheet 21 in the width direction. The spacing between the guiding components is adjustable to accommodate extruded sheets 21 of different widths.

[0077] The first tension control module 10 is located downstream of the straightening and guiding module 9 and upstream of the online heating module 11. It is used to apply traction to the extruded sheet 21 and adjust the sheet conveying speed and tension before entering the online heating module 11 and the hot rolling module 12.

[0078] The first tension control module 10 includes tension roller assemblies disposed on the upper and lower sides or front and rear of the sheet material. By adjusting the speed, spacing and clamping force of the tension rollers, the sheet material conveying status and tension level can be controlled.

[0079] The online heating module 11 is located between the first tension control module 10 and the hot rolling module 12, and is used to continuously heat the extruded sheet 21 so that the sheet reaches the preset rolling temperature.

[0080] The online heating module 11 adopts a transverse magnetic induction heating method. The online heating module 11 includes an induction coil and a power supply control device connected to the induction coil. The induction coil generates a transverse alternating magnetic field, which induces a current inside the extruded sheet 21 and generates heat, thereby achieving rapid and uniform heating of the sheet.

[0081] By adjusting the frequency, power, and heating time of the induced current, the heating temperature of the extruded sheet 21 can be controlled so that the sheet meets the requirements of subsequent hot rolling processes.

[0082] The hot rolling module 12 is located downstream of the online heating module 11 and is used to perform online hot rolling on the heated extruded sheet 21.

[0083] The hot rolling module 12 includes an upper and lower roll arranged opposite to each other, a roll drive mechanism, and a roll gap adjustment mechanism. A rolling zone is formed between the upper and lower rolls, and the roll gap adjustment mechanism is used to adjust the distance between the upper and lower rolls to control the thickness of the hot-rolled sheet 22.

[0084] The upper and lower rolls are internally equipped with media flow channels, each including a media inlet and multiple media outlets. Hot or cold media enter the rolls through the media inlets and exit through the media outlets to regulate the roll temperature.

[0085] When a hot medium is introduced into the medium flow channel, the temperature of the rolls can be increased and the temperature stability during the hot rolling process can be maintained; when a cold medium is introduced into the medium flow channel, the temperature of the rolls can be reduced and the temperature state of the sheet during the rolling process can be adjusted through the heat exchange between the rolls and the sheet.

[0086] The extruded sheet 21 can be rolled online by the hot rolling module 12, which can further adjust the sheet thickness, microstructure and mechanical properties.

[0087] The second tension control module 14 is located downstream of the hot rolling module 12 and is used to apply front tension to the hot-rolled sheet 22 and adjust the conveying speed of the hot-rolled sheet 22.

[0088] The second tension control module 14 includes a tension roller assembly, which can achieve stable conveying of the hot-rolled sheet 22 by adjusting the speed, spacing and clamping force of the tension roller.

[0089] The first tension control module 10 and the second tension control module 14 work together to maintain a stable tension state in the sheet material during continuous manufacturing, and to avoid wrinkling, bending or dimensional fluctuations in the sheet material due to differences in conveying speed.

[0090] The rapid cooling module 13 is located downstream of the second tension control module 14 and is used to rapidly cool the hot-rolled sheet 22.

[0091] The rapid cooling module 13 includes cooling components disposed on the upper and lower sides of the sheet metal. The cooling components include multiple cooling nozzles, which exchange heat with the sheet metal surface through a cooling medium to achieve rapid cooling of both sides of the sheet metal.

[0092] The rapid cooling module 13 can be water-cooled, air-cooled, or other cooling methods that can achieve rapid cooling.

[0093] Through the combined action of the roll temperature control in the hot rolling module 12 and the rapid cooling module 13, online quenching or controlled cooling of the sheet metal can be achieved to adjust the sheet metal microstructure and mechanical properties.

[0094] The cold rolling finishing module 15 is located downstream of the rapid cooling module 13 and is used to perform cold rolling, leveling and surface finishing on the rapidly cooled sheet material. It includes a first cold rolling finishing module 15-1, a second cold rolling finishing module 15-2 and a third cold rolling finishing module 15-3.

[0095] Each cold rolling finishing module includes an upper cold rolling roll and a lower cold rolling roll arranged opposite each other. Through cold rolling, the thickness, flatness and surface quality of the sheet are further adjusted to obtain cold rolled sheet 16.

[0096] The coiling and unloading module 17 is located downstream of the cold rolling finishing module 15. It is used to continuously coil the cold rolled sheet material 16 and cut and unload the formed sheet material coil 23 according to the preset coil diameter, coil weight or length.

[0097] like Figure 6 As shown, the deformation path of the metal material in the continuous manufacturing process includes raw material 18, deformed material 19 in the extrusion module, material in the mold 20, extruded sheet 21, hot-rolled sheet 22, cold-rolled sheet 16, and sheet coil 23 in sequence.

[0098] In the aforementioned continuous manufacturing process, the metal material is continuously supplied by the melt feeding module 1, and forms a continuous billet with residual heat in the short-range crystallization zone 3. It then enters the extrusion module for continuous plastic deformation, and successively undergoes online heating, hot rolling, rapid cooling and cold rolling finishing to realize continuous manufacturing from molten metal to high-performance sheet metal.

[0099] like Figure 7 As shown, in another embodiment, the continuous manufacturing apparatus may omit the cold rolling finishing module 15, and the sheet material processed by the rapid cooling module 13 may directly enter the coiling and unloading module 17.

[0100] This implementation method is applicable to sheet metal manufacturing processes where dimensional accuracy requirements are low or where performance requirements have been met after hot rolling and cooling.

[0101] like Figure 8 As shown, in another embodiment, the continuous manufacturing apparatus uses bars, rods, or pre-formed continuous billets as raw materials 18.

[0102] The raw material 18 bypasses the melt feeding module 1, the heat preservation and liquid delivery channel 2, and the short-range crystallization zone 3, and directly enters the material channel between the extrusion wheel 6 and the compaction wheel 7.

[0103] The raw material 18 is continuously extruded to form extruded sheets or profiles, and further processed through online rolling, cooling and finishing processes according to product requirements to obtain the final product.

[0104] Based on the above-mentioned apparatus, the present invention also provides a continuous manufacturing method for high-performance aluminum alloy or magnesium alloy plates, comprising the following steps: First, prepare the metal raw materials according to the preset composition, and add the metal raw materials to the melt feeding module 1 for heating and melting to obtain the metal melt.

[0105] Subsequently, the molten metal is supplied with conveying pressure through an independent pressurized liquid supply chamber, causing the molten metal to flow sequentially through the heat-insulating liquid supply channel 2 and the short-path crystallization zone 3. Controlled cooling and solidification are carried out in the short-path crystallization zone 3 to form a continuous billet with residual heat.

[0106] The continuous billet is conveyed to the extrusion module, where the extrusion roller 6 and compaction roller 7 bite, clamp, compact and convey the continuous billet, so that the continuous billet enters the extrusion forming cavity and is continuously formed into extruded sheet 21 by sheet forming die 8.

[0107] When using split extrusion rollers 6 and / or compaction rollers 7, the rotation speed of each split extrusion roller unit and / or compaction roller unit is adjusted according to the material flow resistance in different areas inside the sheet forming die 8, so as to control the material conveying speed, material flow rate and extrusion pressure in different areas.

[0108] The straightening and guiding module 9 is used to straighten, center and guide the extruded sheet 21, and the first tension control module 10 is used to adjust the sheet conveying speed and back tension.

[0109] The extruded sheet 21 is continuously heated using the online heating module 11 to bring it to the preset rolling temperature.

[0110] The heated extruded sheet 21 is hot rolled online using the hot rolling module 12, and the temperature of the rolls is adjusted by the medium flow channel inside the hot rolling rolls. At the same time, the front tension of the hot rolled sheet 22 is adjusted by the second tension control module 14.

[0111] The hot-rolled sheet 22 is rapidly cooled using the rapid cooling module 13 to achieve online quenching or controlled cooling.

[0112] According to the product performance requirements, the cooled sheet material is transported to the cold rolling finishing module 15 for cold rolling, leveling and surface finishing to obtain cold rolled sheet material 16.

[0113] Finally, the sheet material is continuously wound up by the winding and unwinding module 17, and then cut and unwound according to the preset length, roll diameter or weight.

[0114] Furthermore, the present invention also provides a continuous manufacturing method for high-performance aluminum alloy or magnesium alloy profiles.

[0115] The method employs the aforementioned continuous manufacturing apparatus, but replaces the sheet metal forming mold 8 with the profile forming mold 24.

[0116] First, the metal raw materials are melted to form a molten metal, and then a continuous billet with residual heat is formed through the molten metal feeding module 1.

[0117] Subsequently, the continuous billet is conveyed to the extrusion module, where it is bitten, clamped, compacted, and conveyed by the extrusion roller 6 and the compaction roller 7, so that the continuous billet enters the profile forming die 24.

[0118] When there are differences in material flow resistance in different areas inside the profile forming die 24, the material flow rate and extrusion pressure in different areas are compensated by adjusting the rotation speed of each extrusion roller unit and / or compaction roller unit.

[0119] Finally, the continuous billet is continuously formed into an extruded profile with a preset cross-sectional shape by the profile forming die 24.

[0120] The extruded profile can be an asymmetric cross-section profile, a non-uniform cross-section profile 25, a profile with a large difference in wall thickness, or other complex cross-section profiles.

[0121] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, any equivalent substitutions, simple modifications, or improvements made to the present invention without departing from its concept should fall within the protection scope of the present invention.

Claims

1. A continuous manufacturing apparatus for high-performance aluminum alloy or magnesium alloy sheets and profiles, characterized in that, It includes a melt feeding module, an extrusion module, and a forming mold that are arranged sequentially and interconnected along the material conveying direction; The extrusion module includes an extrusion roller, a compaction roller, and a shoe block. The extrusion roller and the compaction roller are arranged opposite to each other, forming a material channel between them. The inlet of the material channel is corresponding to the outlet of the short-path crystallization zone. The shoe block and the extrusion roller together form an extrusion forming cavity, and the outlet of the extrusion forming cavity is connected to the forming mold. At least one of the extrusion wheel and the compaction wheel adopts a split structure. The split structure includes at least two wheel bodies arranged sequentially along the axial direction. Each wheel body is connected to an independent drive mechanism and a speed regulation mechanism, so that each wheel body can independently adjust its rotation speed, thereby adjusting the conveying speed, material flow rate and extrusion pressure of the continuous billet in different regions.

2. The continuous manufacturing apparatus according to claim 1, characterized in that, The melt feeding module includes an independent pressurized liquid supply chamber, a heat-insulating liquid conveying channel, and a short-range crystallization zone connected in sequence. The independent pressurized liquid supply chamber is used to contain and pressurize the molten metal. The heat-insulating liquid conveying channel is used to heat-insulate and convey the molten metal. The short-range crystallization zone is used to controllably cool and solidify the molten metal to form a continuous billet with residual heat. Preferably, the short-range crystallization zone includes a crystallization sleeve, a molten metal flow channel disposed within the crystallization sleeve, a cooling medium circulation channel disposed around the crystallization sleeve, and a temperature detection component.

3. The continuous manufacturing apparatus according to claim 1, characterized in that, At least two material channels are provided between the extrusion wheel and the compaction wheel, and multiple material channels are spaced apart along the axial direction of the extrusion wheel and the compaction wheel for simultaneously conveying multiple continuous billets; Alternatively, the cross-sectional shape of the material channel may be adapted to the cross-sectional shape of the continuous billet, including rectangular, rounded rectangle, circular or polygonal shapes.

4. The continuous manufacturing apparatus according to claim 1, characterized in that, Both the extrusion wheel and the compaction wheel adopt a split structure; Preferably, the extrusion wheel includes a plurality of extrusion wheel units arranged sequentially along the axial direction, and the compaction wheel includes a plurality of compaction wheel units arranged sequentially along the axial direction; Each of the extrusion wheel units and each of the compaction wheel units is connected to an independent drive mechanism through a corresponding transmission mechanism.

5. The continuous manufacturing apparatus according to claim 1 or 4, characterized in that, The forming mold is a profile forming mold; The profile forming mold is used to form profiles with asymmetrical cross-sections, non-uniform cross-sections, or large differences in wall thickness. Adjust the rotational speed of the corresponding wheel unit according to the material flow resistance in different areas of the profile to improve the uniformity of material flow during the profile forming process.

6. The continuous manufacturing apparatus according to claim 1, characterized in that, The forming mold is a sheet metal forming mold; Downstream of the sheet metal forming die, along the material conveying direction, a straightening and guiding module, a first tension control module, an online heating module, a hot rolling module, a second tension control module, a rapid cooling module, and a coiling and unloading module are sequentially arranged. The first tension control module is used to adjust the post-tension of the sheet material before entering the hot rolling module, and the second tension control module is used to adjust the pre-tension of the sheet material after hot rolling.

7. The continuous manufacturing apparatus according to claim 6, characterized in that, The online heating module adopts a transverse magnetic induction heating method; Preferably, the hot rolling module includes an upper roll and a lower roll arranged opposite to each other, and both the upper roll and the lower roll are provided with a medium flow channel for adjusting the roll temperature by means of a hot medium or a cold medium.

8. The continuous manufacturing apparatus according to claim 6, characterized in that, The rapid cooling module includes cooling components disposed on the upper and lower sides of the sheet metal; A cold rolling finishing module is provided between the rapid cooling module and the coiling and unloading module for cold rolling, leveling and surface finishing of the rapidly cooled sheet material.

9. A continuous manufacturing method for high-performance aluminum alloy or magnesium alloy sheets and profiles, characterized in that, Includes the following steps: Aluminum alloy or magnesium alloy raw materials are heated and melted to form a molten metal. The molten metal is then transported through an independent pressurized liquid supply chamber, allowing it to pass sequentially through a heat-insulating liquid supply channel and a short-range crystallization zone. In the short-range crystallization zone, the molten metal is cooled and solidified in a controlled manner to form a continuous billet with residual heat. The continuous billet is conveyed to the extrusion module, where the extrusion rollers and compaction rollers bite, clamp, compact, and convey the continuous billet into the extrusion forming cavity, and then continuously form sheet or profile through the forming die. When using split extrusion rollers and / or compaction rollers, the rotational speed of each roller unit is adjusted according to the material flow state in different areas of the forming die to control the material conveying speed, material flow rate and extrusion pressure.

10. The continuous manufacturing method according to claim 9, characterized in that, When the forming die is a sheet metal forming die, the continuously formed sheet metal is further subjected to at least one of the following processes: straightening and guiding, online heating, hot rolling, rapid cooling, and cold rolling finishing. Preferably, the online heating adopts a transverse magnetic induction heating method, and the rolling temperature of the sheet is controlled by adjusting the temperature of the medium inside the rolls during the hot rolling process.

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