China's copper processing innovation is very active. It plays an important role in maintaining a stable development of the copper and butadiene industry in a complex and ever-changing external environment. The characteristics of China's copper processing innovation are: focusing on enterprises, focusing on technological innovation, and The close integration of industrialization not only results in significant results but also serves as guidance.
The change in production methods has a prominent position in copper processing. The traditional classical copper plus L method is three-stage, namely smelting ingots—thermal processing—cold processing. Among them, thermal processing includes hot extrusion, hot rolling, hot forging, etc. These processes result in high energy consumption, environmental pollution, reduced yield, increased production costs, and investment in equipment. Therefore, compression hot processing and shortening of the process flow become important for copper processing workers. Struggle direction.
Any change in the process cannot be achieved without the innovation of the equipment. It depends on the equipment and the production line. The change of the production method is based on the equipment. During the “10th Five-Year Plan†period, China’s copper processing has made significant progress in the innovation of production therapy. The development of three major technologies has provided strong technical support for the transformation of China’s copper processing methods. The three major technologies are:
The first is continuous casting technology. China's continuous casting technology mainly consists of upward and horizontal continuous casting, which can produce copper and alloys on the riser, rod, rod, type, line billet; horizontal continuous casting coil, rod, type, line billet, these billets roll major, length Long, direct cold processing can be performed.
The second is planetary rolling technology. This technology is a three-roller rotation that is arranged at a 120-degree angle to each other and revolves around the rolling line to form the composite billet rolling. Its characteristic is that when the pipe is cold-rolled, it depends on the deformation heat to heat itself, and the temperature in the deformation zone can reach 700 degrees to 850 degrees, which is equivalent to the hot processing state, thus realizing dynamic recrystallization, and the pipe quality and heat after rolling in Xinjiang. The extrusion is the same, and the rolled product has no oxidation on the surface, large length, and rolling, and can be directly cold-processed, laying the foundation for the production of tube-type cattle, and becoming a key technology for the direct cold processing of the cast tube blank. The appearance, maturity, and industrialization of this technology have led to major changes in the production methods of copper and alloy pipes.
The third is continuous extrusion technology. This technology is also known as the Kangdang method in foreign countries. This method is essentially the forced feeding of the wire blanks on the friction wheel. The metal flows out of the die hole plastically. The heat of deformation heats the metal itself. The deformation zone temperature Up to 600 degrees to 800 degrees, thus achieving the dynamic recrystallization of metals.
Important innovations
First, the establishment of a precision rolled copper tube industry was established. The use of horizontal continuous casting tube planetary rolling plate drawing tube, through the planetary ball mold spinning into a high precision internal thread coil, the product has a small diameter, thin wall thickness, complex tooth type, high cleanliness, high heat dissipation, material saving, adaptation Environmental protection refrigerants and other characteristics, product quality, production technology are in the world leading level. This technological innovation breaks through the technical point of view that cast pipe blanks cannot produce thin-walled internally-threaded pipes, so that the planetary rolling of cast blanks and the coiled-rolled planetary ball-die rolling crushing of internally threaded pipe technology quickly form a powerful industry in China. The world's precision copper pipe production technology occupies an important position, and quickly replaced the hot extrusion - cycle rolling - Pan pull production methods; currently air conditioning pipe is developing into a large disk, highly automated, continuous direction; China's casting - rolling precision Copper pipe production technology and equipment have achieved the export of the entire production line.
Second, submerged horizontal continuous casting is applied in the direct production of copper processing materials from alloy regeneration raw materials. The shortage of copper resources highlights the importance of copper and alloy regenerated raw materials for the direct production of copper processed materials. Among them, alloy remnants have always been a problem of recovery and regeneration due to the complex chemical composition. China Ningbo Jintian Copper Group has developed large tonnage, submerged flow, horizontal continuous casting lead brass rods, type, line, tube production technology, and built a continuous, automated environmental protection production line. This kind of production line can continuously cast 64 different specifications and shapes of copper processing materials at the same time, forming a technology with China's autonomous intellectual property: right, known as the "Golden Field Law."
“Jintian Law†consists of the following main processes: alloy induction melting, chemical composition monitoring, alloy composition adjustment, soot collection, bag dust collection, alloy liquid submergence discharge type transfer, multi-faceted multi-flow, first-class multi-level horizontal continuous casting, pulling System, automatic sawing, automatic product collection, etc. These processes form an automatic production line. Alloy smelting and horizontal continuous casting are all in sealed state. All process parameters are automatically regulated, thus realizing the automation, continuity, and environmental protection of alloy ingredients from machine train to finished product output. produce.
Third, production of oxygen-free copper strip. Oxygen-free copper is a key material in electric vacuum components, but the excessive oxygen content and uneven oxygen distribution have been plaguing the production of oxygen-free copper. Domestic and foreign companies have been using fine material sealed induction melting technology to obtain ingots with acceptable oxygen content. The production cost is high and the qualification rate is low. In the subsequent thermal processing, oxygen infiltration is again caused. China Wanbao Copper Industry Group has successfully developed high-precision cold-rolling technology for the horizontal continuous casting of wide-flow billets of oxygen-free copper with submerged flow, and built an automated, environmentally-friendly, and continuous production line. Produces 510 mm width and thickness o. 1mm oxygen-free copper strip, oxygen content is less than 10ppm, the finished product rate is as high as 85%, and the oxygen-free copper strip horizontal caster has been industrialized and produced in many home appliance furnaces in China.
Fourth, many large diameter copper pipes were cast on the wire. The large-diameter copper pipe is an important waterway pipe used in many aspects such as building waterway pipes and seawater pipelines. The traditional method is extrusion-stretching and hot-rolling piercing-drawing method, which has high product cost and long production process. In recent years, China has developed a new method for casting large-diameter copper pipes on the line. It can directly cast copper pipes with a diameter greater than Φ120 mm, and can cast 6 lines at a time. The length of copper pipes is not limited. After cold stretching, it can produce large-caliber, thin-walled copper tubes required by the engineering and technical community. Industrial production practices show that this productivity method has the obvious advantages of short production process, high yield, low product cost, and low investment in production line construction.
Fifth, horizontal continuous casting and electromagnetic stirring technology. Tin phosphor bronze strip is an important elastic component and electrical connector material. All countries in the world generally make horizontal high-precision cold-rolling method of horizontal continuous casting and strip casting. However, the development of strip columnar crystals, declination of metal tin, and reverse deflection are serious, resulting in various defects in the production of strips. During the "10th Five-Year Plan" period, China first achieved electromagnetism stirring in the crystallizing process of 16-mm x 450-mm tin-phosphor bronze billets, which resulted in grain refinement of tin-phosphorus copper billets, increased plasticity, longer service life of the graphite molds, and improved strip yield. This technology has taken the lead in the world. In 2006, the technology was well applied to tin-phosphor bronze and zinc from copper 650 mm strips.
Sixth, production of copper and alloy profiles. The traditional production method of pure copper flat wire for transformers and motor manufacturing is that the pure copper round wire is repeatedly stretched into flat wires through a series of transitions. The process flow is long, the yield is low, and the production cost is high. At present, China has basically adopted a copper wire rod—continuous extrusion. Pressure-cold stretching method of cattle production, to achieve continuous production and automation of cattle. The product quality and finished product ratio are greatly improved, and energy consumption and metal consumption are significantly reduced. The brass flat wire is an important connector component material. The traditional production method is that the brass round wire is repeatedly stretched and flattened, and several times are needed therebetween. Intermediate annealing, long process, high energy consumption, is now using brass wire 8mm diameter, after continuous extrusion can produce a flat brass wire, profile, this production technology has a wide range of applications to empty space.
Seventh, the industrialization of copper coil production method. Shaoxing Libo Group built an automated and continuous production line, using a 22 mm diameter copper rod coil, extruded through a 400 mm continuous extrusion machine developed by Dalian Jiaotong University to form a 10 mm x 1.250 mm conductive copper bar. 4 tons to 6 tons. After 50 tons of hydraulic stretching machine, it will automatically stretch, straighten and cut into copper strips of the length required by customers. The product quality fully meets the standard requirements, the finished product rate is as high as 90%, the unit power consumption is 500 degrees/ton, and the production line is underinvested. 4 million yuan, with an annual output of 7,500 tons of copper. This production method and technology has the outstanding features of automation, continuous, energy saving, environmental protection, material saving, low cost, etc. It is a revolutionary change in the production methods of hot-rolled and hot-extruded billet-cold processing commonly used at home and abroad. Formed a new technology with independent intellectual property rights; Libo Group achieved innovation and innovation on this basis. In 2007, it also realized the production of electronic belts on this basis.
Eighth, aluminum-clad copper composite technology. The technical innovation was completed by Changzhou Xingrong Hi-Tech Co., Ltd. The core of its technology is to realize the metallurgical compounding of the outer aluminum inner copper sleeve through the planetary rolling method, and then adopting the pan-pull method to produce various copper-aluminum composite pipes and internal thread copper. tube. The development of copper for air-conditioning and building pipes has opened up new ways. The planetary rolling method realizes the metallurgical combination of copper and aluminum in conformity with the interface. This method fills a gap in the composite technology and the technology is at the leading level in the world. An automated production line has been built to promote industrial production.
Ninth, copper anode balls cold spin-rolling technology. Copper anode ball is a key material in the production of printed circuits. The traditional production methods at home and abroad include cold forging and hot rolling. The research and development of cold spin rolling technology at the Beijing University of Science and Technology was successful. The equipment has the advantages of short process flow, energy saving, environmental protection, and high efficiency. It has been widely used at home and abroad.
Prospect of China Copper Processing Technology Innovation
First, the important role of China's copper processing technology innovation in industrial production. The core of China's copper processing technology innovation is to shorten the process flow, cancel and compress the thermal processing procedures, directly lead to energy saving, environmental protection, reduce production costs, increase production efficiency, and reduce metal consumption. In many technical and economic indicators, the yield is a core Indicators, the various innovation processes are listed in the table below compared to traditional processes.
Second, technological innovation prospects. Through various technological innovations, China’s technology in the field of copper processing has entered an important historical stage of independent innovation and vigorous development. As a result, the output of China’s copper processing industry ranks first in the world, product varieties increase, technical and economic indicators improve, and production technology Enter the international advanced ranks. On the basis of major advances in technological innovation during the “10th Five-Year Planâ€, the development trends of China's copper processing technology innovation are as follows: First, the technological innovation system of copper processing companies has been continuously improved and strengthened, and the investment in technological innovation has been continuously increasing. The enterprise technology center and engineering research and development The Center is being established universally, and innovation is being given high priority. The innovative power of universities has been promoted to the goal of independent development. Secondly, the key direction of technological innovation is the continuous and automated processing process, and the traditional pressure processing mode and process are being broken. The process is continuously shortened, and the copper processing production process is further developed towards energy saving, material saving, and environmental protection. Finally, the copper processing technology innovation work will further develop to the depth and breadth of production, and the topics of technological innovation will further center on market competition. By increasing the variety of products, improving quality, and reducing costs, major issues and issues that urgently need to be solved in the production process will be highly valued, and technological innovation activities with new products, new processes, and new technologies will be fully implemented. Changing the mode of business operations and relying on technological innovation to develop companies will become the consensus of all successful companies.
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