Copper Alloy Billet Processing Without Solid Solution Heat Treatment
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Solution Overview
Problem
Current methods for producing high-strength and high-conductivity copper alloys are energy-intensive, costly, and involve multiple processes, leading to low yield and high equipment investment, while also requiring high-temperature solid solution treatments that consume energy and lose pre-cold rolling hardening effects.
Innovation Solution
A method involving horizontal continuous casting to achieve a supersaturated solid solution state in copper alloy billets, followed by continuous extrusion, cold working, and aging annealing, which maintains the supersaturated state to ensure high strength and conductivity without the need for high-temperature solid solution treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional three-stage processing method (smelting and casting-hot working-cold working) is used, then copper alloy can be produced, but the process is complex, energy consumption is high, and production cost is high
Solution Approach 1:
The patent combines smelting, casting, and hot working into a one-step continuous casting process. The copper alloy ingot is directly cast into the desired shape without separate heating and deformation steps, eliminating multiple process stages and reducing equipment requirements while maintaining product quality
Solution Approach 2:
The patent performs alloying element addition and distribution uniformization during the casting process itself rather than requiring subsequent heat treatment. The continuous casting process is designed to achieve supersaturated solid solution state directly, eliminating the need for separate solid solution treatment steps
2Stability of the object's composition
If high-temperature solid solution treatment is conducted before aging, then alloying elements can be in supersaturated solid solution state, but energy consumption increases and pre-cold rolling hardening effect is lost
Solution Approach 1:
The patent changes the temperature parameters during the continuous casting process to achieve supersaturated solid solution state directly. By controlling the cooling rate and temperature gradient in the mold, the alloying elements remain in solid solution without requiring subsequent high-temperature heat treatment
Solution Approach 2:
The patent maintains the supersaturated solid solution state continuously from the casting process through to the aging treatment. The one-step continuous casting ensures uniform distribution of alloying elements that remains stable throughout subsequent processing without needing intermediate heating
3Productivity
If conventional casting and extrusion methods are used, then copper alloy products can be produced, but the process requires multiple steps including milling, hot-rolling cogging, and blooming, leading to low yield and high equipment investment
Solution Approach 1:
The patent merges multiple conventional steps (milling, hot-rolling cogging, blooming, extrusion) into a single continuous casting and extrusion process. The copper alloy is cast directly into the final profile shape without intermediate processing steps, significantly reducing equipment requirements and improving yield
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate processing steps from the conventional manufacturing flow. By using continuous casting with direct extrusion, steps such as milling, blooming, and re-heating are completely removed from the process
4Reliability
If traditional processing methods are used, then copper alloy can be produced, but equipment investment and energy consumption are high
Solution Approach 1:
The patent changes the energy input parameters by eliminating high-temperature holding steps and multiple heating cycles. The continuous casting process uses controlled cooling rates and temperature gradients that achieve the desired microstructure with lower total energy input compared to traditional batch processing
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
This approach significantly reduces energy consumption, shortens the production process, increases yield, and maintains high strength and conductivity by ensuring uniform deformation and controlled precipitation, resulting in consistent performance and reduced production costs.
Implementation Method 1
horizontal continuous casting to achieve a supersaturated solid solution state in copper alloy billets
Implementation Method 2
horizontal continuous casting to achieve a supersaturated solid solution state
Implementation Method 3
aging annealing, which maintains the supersaturated state to ensure high strength and conductivity
Implementation Method 4
controlled precipitation, resulting in consistent performance
Data Source
AI summary
A high-efficiency and short-process method for preparing a high-strength and high-conductivity copper alloy is disclosed, comprising the following steps: performing horizontal continuous casting to obtain an as-cast primary billet of copper alloy, wherein the alloying elements in the obtained as-cast primary billet being in a supersaturated solid solution state; after peeling the obtained as-cast primary billet, directly performing continuous extrusion, cold working and aging annealing treatment to obtain a copper alloy, and keeping the alloying elements of the billet in a supersaturated solid solution state during the process of continuous extrusion. The method shortens the flow, reduces energy consumption and improves the product forming rate.