Cast Slab Temperature Control for High-Flux Aluminum Rolling
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Solution Overview
Problem
The existing high-flux continuous casting and direct rolling processes for aluminum alloy sheets face challenges in accurately controlling the hot continuous rolling temperature, which affects the mechanical properties and surface quality of the sheets, failing to meet the comprehensive performance requirements of different aluminum alloy series.
Innovation Solution
A continuous rolling temperature control process utilizing a spraying system with through-beam laser temperature measurement and control, infrared temperature measurement, and a lubricating metal-cooling liquid to adjust the rolling temperature dynamically, ensuring optimal temperature control for different aluminum alloy series.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the hot continuous rolling temperature is increased to facilitate rolling, then the alloy is easier to roll, but the final mechanical properties fail to meet factory standards
Solution Approach 1:
The patent implements dynamic temperature control during the rolling process by adjusting the spraying system parameters (water flow rate, spraying pressure) in real-time based on the rolling stage. The temperature is maintained higher during initial rolling passes to facilitate deformation, then gradually reduced in subsequent passes to improve mechanical properties, creating a dynamic temperature profile that adapts to process requirements
Solution Approach 2:
The patent changes the temperature parameter throughout the rolling process by controlling the water spraying system. Different temperature levels are applied at different stages: higher temperatures during early passes for plastic deformation, and controlled cooling in later passes to achieve desired mechanical properties. The spraying intensity and water flow rate are adjusted as controllable parameters to achieve the required temperature profile
2Strength
If the hot continuous rolling temperature is decreased to improve mechanical properties, then the alloy strength increases, but rolling causes cracking of the rolled sheet
Solution Approach 1:
The patent applies preliminary heating or temperature maintenance during early rolling passes to ensure the alloy has sufficient plasticity before deformation. By controlling the temperature to remain above the recrystallization temperature during initial passes, the material maintains ductility and avoids cracking, while subsequent controlled cooling achieves the desired mechanical properties without compromising sheet integrity
3Productivity
If traditional hot-rolling and cold-rolling process equipment is used for DC casting slabs, then the production capability is achieved, but the investment cost increases and production procedures become complicated
Solution Approach 1:
The patent merges the continuous casting process with hot rolling operations into an integrated high-flux continuous casting and direct rolling line. The casting machine and rolling mill are coupled such that the cast slab is directly fed into the rolling mill without intermediate handling or storage. This integration eliminates separate production procedures, reduces equipment complexity, and maintains productivity by combining two previously separate processes into one continuous operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process effectively achieves the comprehensive performance standards for various aluminum alloy sheets by precisely controlling the rolling temperature, reducing internal inclusions and defects, and enhancing the mechanical properties and surface quality of the sheets.
Implementation Method 1
The cooling liquid used in the spraying system is a lubricating metal-cooling liquid
Implementation Method 2
a spraying system comprises a manual valve DO, a first electromagnetic valve D1, a second electromagnetic valve D2 and a spraying head
Implementation Method 3
a through-beam laser transmitter K, a through-beam laser receiver G, a controller
Implementation Method 4
a first infrared temperature measuring system and a second infrared temperature measuring system
Data Source
AI summary
The present invention provides a continuous rolling temperature control process for high-flux continuous casting and direct rolling of a continuous aluminum alloy cast slab, comprising a continuous casting machine, a through-beam laser transmitter K, a controller, a spraying head, and a spraying system. A liquid-state aluminum alloy metal melt passes through the continuous casting machine and then is cooled and solidified to form a continuous cast slab; the movement direction of the continuous cast slab is controlled by a lifting table so that the continuous cast slab passes through an interior of a traction machine and extends into a continuous rolling machine; and the through-beam laser transmitter K is arranged between the continuous casting machine and the traction machine. According to the present invention, comprehensive performance indicators required by different series of aluminum alloys under high-flux continuous casting and direct rolling conditions are distinguished, and the continuous rolling temperatures of continuous cast slabs of different series of high-flux continuous cast and rolled aluminum alloy sheets are correspondingly designed and controlled. A preset continuous rolling temperature enables the comprehensive performance of different series of aluminum alloys to reach a product quality standard, reduces interior defects and alleviates the problems of segregation and the like. The flow velocity (or flow rate) of the spraying system can be controlled to reduce the loss of a cooling liquid (an emulsion), thereby reducing the cost, and achieving the purpose of energy conservation and emission reduction.