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CN-116274366-B - Continuous casting-rolling forming equipment and method for foam metal plate with controllable shape

CN116274366BCN 116274366 BCN116274366 BCN 116274366BCN-116274366-B

Abstract

The invention belongs to the technical field of foam metal forming, and particularly relates to a continuous casting-rolling forming device and method for a foam metal plate with controllable shape, wherein the device comprises a melt chute, a melt processing device, an air supply device, a detection device, a casting-rolling device and an air blowing device, wherein the air blowing device is arranged at the bottom of a foaming cavity and is positioned right below the casting-rolling device, an internal air hole structure of the air blowing device is distributed in a gradient manner along the width direction and/or the length direction of a roll gap, and bubbles are continuously blown into a prefabricated metal melt in the foaming cavity.

Inventors

  • JI CE
  • WANG TAO
  • HUANG HUAGUI
  • HUANG QINGXUE

Assignees

  • 季策

Dates

Publication Date
20260505
Application Date
20230215

Claims (7)

  1. 1. A foam metal plate continuous casting-rolling forming device with controllable shape is characterized by comprising a melt chute (1), a melt processing device (2), an air supply device (3), a detection device (5), a casting-rolling device (6) and an air blowing device (7), The inner cavity of the melt chute (1) is sealed, the outer wall of the melt chute is embedded with a heating device and used for controlling the temperature, the melt chute (1) comprises a pouring cavity (101), a communicating cavity (102) and a foaming cavity (103), the melt processing device (2) and the detecting device (5) are arranged above the pouring cavity (101), the melt processing device (2) is used for preparing a prefabricated metal melt and pouring the prefabricated metal melt into the pouring cavity (101) through a sealing interface, and the detecting device (5) is used for detecting the liquid level height of the prefabricated metal melt in the pouring cavity (101) and feeding back the pouring flow of the melt processing device (2) to realize the constant liquid level height of the pouring cavity (101); The casting and rolling device (6) comprises a transmission system (601), a pressing system (602), a main frame (603), a casting roller system (604) and a profiling side seal (605), wherein the casting roller system (604) is arranged inside the main frame (603) and comprises two sets of hole type casting rollers (6041) and bearing seats (6042), circulating cooling water is led inside the hole type casting rollers (6041) and gradual change hole types are arranged on the surfaces of the hole type casting rollers, a thermal insulation coating with the same thickness distribution rule is coated on the surfaces of the hole type casting rollers (6041), the thermal insulation coating is used for controlling the cooling capacity uniformity of the hole type casting rollers (6041) along the axis direction of the hole type casting rollers with the solidifying point height as a target, the transmission system (601) is used for driving the hole type casting rollers (6041) to rotate, the pressing system (602) is used for controlling the relative positions between the hole type casting rollers (6041), so that the purpose of controlling the roll gaps is achieved, the two hole type casting rollers (6041) jointly form gradual change section roll gaps, and the blowing cavities (303) and the side seals (605) positioned at the two ends are jointly formed into a gradual change section roll gap with the blowing cavity (303) and the rolling cavity (605) with the size which can be regulated between the hole type casting rollers and the arc-shaped roll gap; The air supply device (3) provides compressed air for the air blowing device (7), the air blowing device (7) is arranged at the bottom of the foaming containing cavity (103) and is positioned under the casting device (6), the internal air hole structure of the air blowing device (7) is distributed in a gradient mode along the width direction and/or the length direction of the roll gap, the air bubble group is continuously blown into the prefabricated metal melt in the foaming containing cavity (103) to form the prefabricated metal melt containing the gradient distribution air bubble group, and the prefabricated metal melt containing the gradient distribution air bubble group is subjected to rapid solidification and rolling deformation of the casting roller simultaneously when passing through the casting region, so that the foam metal plate with the space gradient structure of the gradient fibrous holes is formed.
  2. 2. The continuous casting and rolling forming equipment for the foam metal plate with controllable shape according to claim 1, further comprising a pressurizing device (4), wherein compressed gas provided by the gas supply device (3) passes through the pressurizing device (4) and then enters the upper part of the casting cavity (101) through a sealing interface, downward extrusion pressure is applied to the prefabricated metal melt in the casting cavity (101), and the detecting device (5) can be used for detecting the extrusion pressure in the casting cavity (101), so that the output pressure of the pressurizing device (4) is fed back and adjusted, and the extrusion pressure of the casting cavity (101) is constant.
  3. 3. The continuous casting and rolling forming equipment for the foam metal plate with controllable shape according to claim 2, further comprising a rectifying device (8), wherein the rectifying device (8) is arranged at the bottom of the foaming cavity (103) and is positioned right below the casting and rolling device (6), the air blowing device (7) is positioned in the rectifying device (8), the rectifying device (8) is provided with two side runners (801) along the axis of the grooved casting roller (6041), the prefabricated metal melt enters the rectifying device (8) through the two side runners (801), the prefabricated metal melt containing gradient bubble groups is formed after the air blowing device (7) blows, a prefabricated metal melt circulation gap without the gradient bubble groups is reserved between the outer wall of the rectifying device (8) and the inner wall of the foaming cavity (103), the top of the rectifying device (8) is not lower than the top of the foaming cavity (103) and an arc-shaped gap is reserved between the top of the foaming cavity (103) and the grooved casting roller (6041), and the shape of the air blowing device (7) and the rectifying device (8) is the same as the shape of a gradual change roll gap.
  4. 4. A continuous casting and rolling forming device for foam metal plates with controllable shape according to claim 3, further comprising two uncoiling devices (9), wherein the two uncoiling devices (9) are arranged above the casting and rolling device (6) and symmetrically arranged on two sides of a roll gap with a gradual change section, the constant tension uncoiling is respectively used for different strips, the strips are respectively clung to adjacent hole-type casting rolls (6041) to wind a half circle after being uncoiled by the uncoiling devices (9), then pass through an arc gap between the hole-type casting rolls (6041) and a blowing containing cavity (303), enter a casting and rolling area, and then leave through the roll gap with the gradual change section to finish rolling compounding with a prefabricated metal melt.
  5. 5. A method for continuously casting and rolling a foam metal sheet with controllable shape by using the forming apparatus as claimed in claim 1, comprising the steps of: S1, prefabricating a metal melt, namely adding pure metal or alloy raw materials into a melt processing device (2), heating to a temperature T1 for melting and preserving heat, adding particles or powder to carry out tackifying treatment on the liquid metal melt, and then cooling to a temperature T2 along with a furnace and preserving heat to prepare the prefabricating metal melt meeting the requirement of foaming stability; S2, adjusting the installation size, namely adjusting the position of a casting roller system (604), setting the size H 0 of a roller gap with a gradual change section, adjusting the arc gap between a hole type casting roller (6041) and a foaming cavity (103) to be 0mm, and enclosing the casting roller system (604), a profiling side seal (605) and the foaming cavity (103) together to form a casting-rolling area; S3, stable and uniform pouring, namely, starting an air supply device (3) to generate compressed air, preheating a melt chute (1) to a temperature T3, pouring a prefabricated metal melt into a pouring cavity (101) through a melt processing device (2), flowing through a communication cavity (102) and then entering a foaming cavity (103), detecting the liquid level height in the pouring cavity (101) by using a detection device (5), and feeding back and adjusting the pouring flow of the melt processing device (2) to realize constant liquid level height; s4, continuously and dynamically pouring, namely starting a casting and rolling device (6), enabling compressed gas to enter a prefabricated metal melt to form a gradient bubble group after passing through a micron or nanometer internal pore of a blowing device (7), and then gradually rising to enter a casting and rolling area surrounded by a casting and rolling roller system (604), a profiling side seal (605) and a foaming cavity (103); And S5, continuous casting, namely, carrying out rapid solidification and rolling deformation on the prefabricated metal melt containing the gradient bubble groups in a casting and rolling zone by a hole type casting roller (6041), wherein the highest part of the boundary between the solidification zone and the rolling zone in the casting and rolling zone is called a solidification point, the distance between the solidification point and the plane of the axis of the hole type casting roller (6041) is the height L KP , the deformation degree of the foam holes is determined, the gradient bubble groups are solidified and then extend along the rolling direction, the gradient bubble groups are changed into fiber shapes from spherical shapes, and the foam metal plate with the gradient cross section and the characteristic of gradient fiber-shaped holes is formed, so that continuous forming is realized after the foam metal plate reaches a stable state.
  6. 6. A method for continuously casting and rolling a foam metal sheet of controllable shape by using the forming apparatus of claim 3, comprising the steps of: Adding pure metal or alloy raw materials into a melt processing device (2), heating to a temperature T1 for melting and preserving heat, adding particles or powder for tackifying the liquid metal melt, and then cooling to a temperature T2 along with a furnace and preserving heat to prepare the prefabricated metal melt meeting the requirement of foaming stability; a2, adjusting the installation size, namely adjusting the position of a casting roller system (604), setting the size H 0 of a roller gap with a gradual change section, adjusting the arc gap between a hole-type casting roller (6041) and a foaming cavity (103) to be 0mm, enclosing the casting roller system (604), a profiling side seal (605) and the foaming cavity (103) together to form a casting area, installing a rectifying device (8), and setting the width of the prefabricated metal melt without the gradient bubble group and the width of the prefabricated metal melt with the gradient bubble group before entering the casting area; A3, stable backward extrusion, namely starting an air supply device (3) to generate compressed air, preheating a melt chute (1) to a temperature T3, pouring a prefabricated metal melt into a pouring cavity (101) through a melt processing device (2), entering a foaming cavity (103) after flowing through a communication cavity (102), detecting the internal air pressure and the liquid level height of the pouring cavity (101) by using a detection device (5), and feeding back to adjust the output pressure of a pressurizing device (4) and the pouring flow of the melt processing device (2) to realize constant extrusion pressure and liquid level height; A4, dynamic foaming confluence, namely starting a casting and rolling device (6), enabling compressed gas to enter a prefabricated metal melt to form a gradient bubble group after passing through a micron or nanometer internal pore of a blowing device (7), then entering a casting and rolling area after passing through the inside of a rectifying device (8), and enabling the prefabricated metal melt without the gradient bubble group between the rectifying device (8) and a foaming cavity (103) to enter the casting and rolling area under the action of backward extrusion pressure of a casting cavity (101) to be converged with the prefabricated metal melt with the gradient bubble group in the casting and rolling area; And A5, continuous casting and rolling, namely, through the rapid solidification and rolling combination of the inner hole type casting roller (6041) in the casting and rolling area, solidifying and deforming the prefabricated metal melt without the gradient bubble group into a solid coating with the thickness of H 1 , solidifying and deforming the prefabricated metal melt with the gradient bubble group into a foam core layer with the thickness of H 2 , realizing the metallurgical combination of a composite interface between the solid coating and the foam core layer, wherein the highest part of the boundary between the solidification area and the rolling area in the casting and rolling area is called a solidification point, the distance between the solidification point and the plane of the axis of the hole type casting roller (6041) is the height L KP of the solidification point, determining the deformation degree of cells, solidifying the gradient bubble group, extending along the rolling direction, changing the spherical shape into the fibrous shape, and forming the foam metal sandwich board with the gradient fibrous hole characteristic and gradually changing the cross section after reaching a stable state.
  7. 7. A method for continuously casting and rolling a foam metal sheet with controllable shape by using the forming apparatus according to claim 4, comprising the steps of: Adding pure metal or alloy raw materials into a melt processing device (2), heating to a temperature T1 for melting and preserving heat, adding particles or powder for tackifying the liquid metal melt, and then cooling to a temperature T2 along with a furnace and preserving heat to prepare the prefabricated metal melt meeting the requirement of foaming stability; Adjusting the installation size, namely adjusting the position of a casting roller system (604), setting the size H 0 of a roller gap with a gradual change section, adjusting the arc gap between a hole-type casting roller (6041) and a foaming cavity (103) to be the thickness H S1 of a strip A and the thickness H S2 of a strip B respectively, enclosing a casting rolling area by the casting roller system (604), a profiling side seal (605) and the foaming cavity (103), installing a rectifying device (8), and setting the width of the prefabricated metal melt without gradient bubble groups and the width of the prefabricated metal melt with gradient bubble groups before entering the casting rolling area; Uncoiling the strip A with the thickness of H S1 and the strip B with the thickness of H S2 by two uncoiling devices (9) with constant tension respectively, enabling the strip A and the strip B to pass through an arc-shaped gap between a hole-type casting roller (6041) and a foaming cavity (103) to enter a casting-rolling area after tightly adhering adjacent hole-type casting rollers (6041) around half a circle, and leaving a gap H 3 between the strip A and the strip B when leaving a roller gap with a gradual change section; B4, stable backward extrusion, namely starting an air supply device (3) to generate compressed air, preheating a melt chute (1) to a temperature T3, pouring a prefabricated metal melt into a pouring cavity (101) through a melt processing device (2), entering a foaming cavity (103) after flowing through a communication cavity (102), detecting the air pressure and the liquid level height in the pouring cavity (101) by using a detection device (5), and feeding back to adjust the output pressure of a pressurizing device (4) and the pouring flow of the melt processing device (2) to realize constant extrusion pressure and liquid level height; Starting a casting and rolling device (6), enabling compressed gas to enter a prefabricated metal melt to form gradient bubble groups after passing through micro-scale or nano-scale internal pores of a blowing device (7), then entering a casting and rolling area after passing through the inside of a rectifying device (8), and enabling the prefabricated metal melt without the gradient bubble groups between the rectifying device (8) and a foaming cavity (103) to enter the casting and rolling area under the action of backward extrusion pressure of the casting cavity (101), and converging the prefabricated metal melt with the gradient bubble groups, a strip A and a strip B with a prepreg coating in the casting and rolling area; And B6, continuous casting, namely, carrying out composite interface metallurgical bonding on the strip A and the strip B which contain the prepreg coating, the prefabricated metal melt without gradient bubble groups and the prefabricated metal melt with gradient bubble groups in a casting rolling zone by rapid solidification and rolling compounding of a hole type casting roller (6041), solidifying and deforming the prefabricated metal melt without gradient bubble groups into a solid coating with the thickness of H 1 , solidifying and deforming the prefabricated metal melt with gradient bubble groups into a foam core layer with the thickness of H 2 , wherein the highest part of the boundary between the solidification zone and the rolling zone in the casting rolling zone is called a solidification point, the distance between the solidification point and the plane of the axis of the hole type casting roller (6041) is the height L KP , determining the deformation degree of a cell, solidifying the gradient bubble groups, and then extending from a spherical shape to a fibrous shape to form a foam metal sandwich plate with a gradient fibrous hole characteristic, and realizing continuous forming after the foam metal sandwich plate reaches a stable state.

Description

Continuous casting-rolling forming equipment and method for foam metal plate with controllable shape Technical Field The invention belongs to the technical field of foam metal forming, and particularly relates to a continuous casting-rolling forming device and method for a foam metal plate with controllable shape. Background The foam metal sandwich material realizes the interface combination between the solid coating and the foam core layer through a special forming technology, and typical products have the characteristics of low density, high specific stiffness, high specific strength and the like of the foam metal sandwich board and the foam metal sandwich pipe, can fully exert the excellent functional characteristics of the foam metal, can improve the defects of low strength, difficult connection and the like, are novel composite materials with integrated typical structure and function, can meet the performance requirements of extreme service environments, and have extremely high research value and wide application prospect. At present, the preparation process of the foam metal sandwich panel can be divided into a physical connection principle and a metallurgical connection principle according to the combination type of a composite interface. The physical connection principle is to realize the physical combination between the solid coating and the foam core layer by using the technologies of an adhesive combination method, a bolt connection method and the like, and has simple process but is severely restricted in practical application. In the adhesive compounding method, the adhesive is mostly organic matters, and the adhesive layer is easy to melt and deteriorate when in service under high temperature and corrosion conditions, so that the thermal processing treatment cannot be adopted, and meanwhile, the service aging problem is also faced. The through holes in the threaded connection method not only can influence the mechanical property, but also can generate stress concentration and corrosion in the service process. The metallurgical connection principle is to realize metallurgical combination between the foam core layer and the entity coating layer through the technologies of powder metallurgy, welding method, melt foaming method and the like. The powder metallurgy method is to uniformly mix metal powder and foaming agent powder, prepare a composite preform by molding techniques such as a die pressing method, a sheath-composite rolling method, a powder hot-pressing composite method and the like, and finally heat and foam to obtain a foam metal sandwich material, so that a complex component can be prepared, but the flow is complex and the yield is low. Welding methods are classified into brazing, friction stir welding, laser welding, etc., and can produce large-sized products, but are limited to only the interfacial joining process of semi-finished products. The melt foaming method adopts mechanical stirring to introduce a tackifier and a foaming agent into a melt, then injects the melt into a solid coating, utilizes in-situ decomposition of the foaming agent to generate gas to prepare a foam core layer and realize interface bonding, and is most hopeful to realize an integrated forming method at present, but the bubble floating phenomenon in the casting process causes great difficulty in controlling the size uniformity and the distribution uniformity of cells, and has great challenges in continuous forming. With the continuous expansion of the application fields of the foam metal sandwich plate, severe requirements on component metal performance, interface bonding performance and circumferential uniformity of the component metal performance, interface bonding performance and the interface bonding performance are provided by extreme service environments such as bending, impact, fatigue, high temperature and the like, and good interface bonding effect is a prerequisite for interaction. At present, the continuous forming process of the broad-width product faces the outstanding problems of low interface bonding strength, uncontrollable cell structure, poor performance uniformity and the like. The forming technologies such as an adhesive compounding method, a bolt connection method, a powder metallurgy method, a welding method, a melt foaming method and the like promote the development and the application of the foam metal sandwich panel, but the technology faces serious challenges in the aspects of further improving the production efficiency, the product quality and the like. Aiming at the service performance requirements of miniaturization of cell structures, customization of cell distribution, metallurgical bonding of interfaces, uniform tissue performance and the like faced by the wide foam metal sandwich plate, the development of a high-efficiency continuous near-end forming technology with controllable formability becomes an industrial difficulty and an international research hotspot. Disclosure of I