阅读说明：本技术 一种高性能光伏铝合金边框及其生产工艺 (High-performance photovoltaic aluminum alloy frame and production process thereof ) 是由 张乐涛 牛腾超 于淼 于 2021-08-22 设计创作，主要内容包括：本发明公开了一种高性能光伏铝合金边框的加工工艺,它属于铝合金材料的制备技术领域,按元素的质量百分比为Si：0.60～0.65％、Fe：≤0.15％、Cu：≤0.05％、Mn：≤0.05％、Mg：0.50～0.55％、Cr：≤0.05％、Zn：≤0.1％、Ti：≤0.1％和余量为Al的配方进行配料,然后经过熔铸、挤压、喷砂及氧化工序,实现铝合金边框的加工成型,韦氏硬度15Hw以上,力学性能高,与6063铝合金相比,在相同的强度要求下,光伏太阳能边框壁厚能减少50%以上,光伏边框用铝成本降低50%,大大降低了光伏行业产电成本。(The invention discloses a processing technology of a high-performance photovoltaic aluminum alloy frame, which belongs to the technical field of preparation of aluminum alloy materials, and comprises the following components in percentage by mass: 0.60-0.65%, Fe: less than or equal to 0.15 percent, Cu: less than or equal to 0.05 percent, Mn: less than or equal to 0.05 percent, Mg: 0.50-0.55%, Cr: less than or equal to 0.05 percent, Zn: less than or equal to 0.1 percent, Ti: the aluminum alloy frame is processed by the processes of fusion casting, extrusion, sand blasting and oxidation, the processing and forming of the aluminum alloy frame are realized, the Vickers hardness is more than 15Hw, the mechanical property is high, compared with 6063 aluminum alloy, under the same strength requirement, the wall thickness of the photovoltaic solar frame can be reduced by more than 50%, the cost of aluminum for the photovoltaic frame is reduced by 50%, and the power generation cost of the photovoltaic industry is greatly reduced.)

1. A processing technology of a high-performance photovoltaic aluminum alloy frame is characterized by comprising the following steps:

s1: ingredients

According to the mass percentage of elements, Si: 0.60-0.65%, Fe: less than or equal to 0.15 percent, Cu: less than or equal to 0.05 percent, Mn: less than or equal to 0.05 percent, Mg: 0.50-0.55%, Cr: less than or equal to 0.05 percent, Zn: less than or equal to 0.1 percent, Ti: compounding with a formula of less than or equal to 0.1 percent and the balance of Al;

s2: casting

The method sequentially comprises the following steps: charging, heating, stirring, measuring temperature, slagging-off for the 1 st time, sampling for the 1 st time, supplementing materials, refining for the 1 st time, refining for the 2 nd time, sampling for the 2 nd time, slagging-off for the 2 nd time, discharging and casting to form a cylindrical ingot semi-finished product;

s3: extrusion

Putting the aluminum bar into an extruder, extruding and molding through a die, and immediately cooling by air cooling and quenching;

s4: sand blasting

The spray gun sprays carborundum with large grain diameter of 0.15-0.25mm, the technological parameters of sand spraying are fixed, a small amount of carborundum is added for many times, the grain diameter of the carborundum is analyzed periodically, the consistency of the sand surface effect is ensured, the slight lines and grains on the surface of the section can be removed, and the excellent surface effect is ensured;

s5; oxidation by oxygen

The method sequentially comprises the following steps: and (3) upward discharging, oil removing, alkaline etching, neutralizing, oxidizing, hole sealing, downward discharging, inspecting, packaging and warehousing.

2. The process for processing the high-performance photovoltaic aluminum alloy frame as claimed in claim 1, wherein the ratio of the slag striking agent to the refining agent is controlled during the casting process, the refining agent is 2.5kg/T, the slag striking agent is 1.3kg/T, nitrogen is refined and refined in 10 bottles in one furnace, the refining time is about 25-30min, and the standing and heat preservation time is controlled within 25-30 min.

3. The process as claimed in claim 1, wherein the melting temperature is 730-740 ℃ and the refining temperature is 740-750 ℃ in the step S2.

4. The process for manufacturing a high-performance photovoltaic aluminum alloy frame according to claim 1, wherein the casting is performed with homogenization at 560 ± 5 ℃ for 8 hours, and the frame is cooled to 300 ℃ after air cooling for one hour and then cooled to room temperature.

5. The process for processing a high-performance photovoltaic aluminum alloy frame as claimed in claim 1, wherein in the upper row process of step S5, each end of the horizontal wire tying trace is within 2.5cm, and the vertical wire is controlled within 5 cm.

6. The processing technology of the high-performance photovoltaic aluminum alloy frame as claimed in claim 1, wherein in the step S5, the section bar is placed in a sulfuric acid solution with a concentration of 160-210g/l for 1-3min to remove oil stains and natural oxide films on the surface, and the section bar is washed after oil removal, wherein the pH value of the washing water is not less than 4.

7. The processing technology of the high-performance photovoltaic aluminum alloy frame according to claim 1, wherein in the alkaline etching process of step S5, the section is placed in a sodium hydroxide solution with a concentration of 40-60g/l to remove an oxide film on the surface of the section and to level the surface, the concentration of aluminum ions is 15-40g/l, the alkaline cleaning temperature is 40-50 ℃, the alkaline cleaning time is 1-4min, and the section is washed with water after alkaline etching, wherein the pH of the washing water is not less than 4.

8. The processing technology of the high-performance photovoltaic aluminum alloy frame as claimed in claim 1, wherein in the neutralization process of step S5, the section bar is placed in a mixed solution of sulfuric acid and nitric acid with a concentration of 160-200g/l for 2-4min to remove black ash after alkaline washing, and then the section bar is washed with water after neutralization, wherein the pH value of the washing water is not less than 4.

9. The processing technology of the high-performance photovoltaic aluminum alloy frame as claimed in claim 1, wherein in the oxidation process of step S5, the section bar is placed in an electrolytic cell for electrolysis, and the electrolyte is sulfuric acid with concentration of 150-; the electrolytic voltage is 16-18V, the current density is 140A/m2, the aluminum ion concentration is 5-15g/l, the temperature is 20 +/-2 ℃, and the oxidation time is set according to the film thickness; the oxidation water is washed by water and spraying water, and the pH value of the water is not less than 6.

10. The process for processing a high-performance photovoltaic aluminum alloy frame according to claim 1, wherein in the intermediate temperature hole sealing process of step S5, the section is placed in a solution with a Ni2+ concentration of 1.2-1.8g/L, pH of 5.2-6.5 at a temperature of 60 ± 5 ℃ to be sealed, the hole sealing time is set according to the thickness of an oxide film, generally according to 1-1.2un/min, and the maximum time is not more than 22 min.

Technical Field

The invention relates to the technical field of preparation of aluminum alloy materials, in particular to a high-performance photovoltaic aluminum alloy frame and a production process thereof.

Background

The worldwide energy crisis is promoting the rapid development of new energy industries, and solar energy is the most important cost-saving energy source among various renewable energy sources, so that the photovoltaic industry, which is a solar power generation technology for converting solar radiation energy into electric energy, is developing rapidly. The photovoltaic solar bracket is a special bracket designed for placing, installing and fixing a solar panel in a solar photovoltaic power generation system, and is characterized by no welding, no drilling, 100 percent adjustability and 100 percent reutilization.

The photovoltaic solar energy frame uses the 6063 material as the main thing today, and this material surface quality is good but intensity is low relatively, and general wall thickness is big, and the aluminum alloy ex-trusions cost is on the high side when causing photovoltaic power generation, has hindered the development of photovoltaic power generation trade to a certain extent. According to market demands, a photovoltaic solar frame with high strength, high surface quality and thin wall thickness is urgently needed.

Disclosure of Invention

For the problems in the prior art, the high-performance photovoltaic aluminum alloy frame and the production process thereof provided by the invention have the advantages that the wall thickness of the aluminum alloy plate processed by the scheme can be reduced by more than 50% under the same strength requirement, the cost of aluminum for the photovoltaic frame is reduced by 50%, and the electricity production cost in the photovoltaic industry is greatly reduced.

In order to achieve the purpose, the technical scheme adopted by the invention is as follows:

a high-performance photovoltaic aluminum alloy frame is composed of the following components in parts by weight: si: 0.60-0.65%, Fe: less than or equal to 0.15 percent, Cu: less than or equal to 0.05 percent, Mn: less than or equal to 0.05 percent, Mg: 0.50-0.55%, Cr: less than or equal to 0.05 percent, Zn: less than or equal to 0.1 percent, Ti: less than or equal to 0.1 percent, Al: and (4) the balance.

A processing technology of a high-performance photovoltaic aluminum alloy frame comprises the following steps:

s1: ingredients

The 6005 alloy is adopted, and the mass percentage of the elements is Si: 0.60-0.65%, Fe: less than or equal to 0.15 percent, Cu: less than or equal to 0.05 percent, Mn: less than or equal to 0.05 percent, Mg: 0.50-0.55%, Cr: less than or equal to 0.05 percent, Zn: less than or equal to 0.1 percent, Ti: compounding with a formula of less than or equal to 0.1 percent and the balance of Al;

s2: casting

The method sequentially comprises the following steps: charging, heating, stirring, measuring temperature, slagging-off for the 1 st time, sampling for the 1 st time, supplementing materials, refining for the 1 st time, refining for the 2 nd time, sampling for the 2 nd time, slagging-off for the 2 nd time, discharging and casting to form a cylindrical ingot semi-finished product;

s3: extrusion

Putting the aluminum bar into an extruder, extruding and molding through a die, and immediately cooling by air cooling and quenching;

s4: sand blasting

The spray gun sprays the large-grain-size carborundum with the grain diameter of 0.15-0.25mm, the technological parameters of sand spraying are fixed, a small amount of carborundum is added for many times, the grain diameter of the carborundum is analyzed periodically, the consistency of the sand surface effect is ensured, the slight lines and grains on the surface of the section can be removed, and the excellent surface effect is ensured.

S5; oxidation by oxygen

The method sequentially comprises the following steps: and (3) upward discharging, oil removing, alkaline etching, neutralizing, oxidizing, hole sealing, downward discharging, inspecting, packaging and warehousing.

Preferably, the proportion of the slag-removing agent and the refining agent is well controlled in the casting process, the refining agent is generally refined and refined according to 2.5kg/T, the slag-removing agent is refined and refined according to 1.3kg/T and 10 bottles of nitrogen in one furnace, the refining time is about 25-30min, and the standing and heat preservation time is controlled to be 25-30 min.

Preferably, the smelting temperature is between 730 ℃ and 740 ℃ and the refining temperature is between 740 ℃ and 750 ℃ in the fusion casting process.

Preferably, after the casting is finished, homogenizing treatment is carried out, the homogenizing temperature is 560 +/-5 ℃, the heat preservation is carried out for 8 hours, air cooling is carried out for one hour after the heat preservation is finished, the temperature is reduced to 300 ℃, and then water cooling is carried out to the room temperature.

Preferably, in the upper row process, each end of the horizontal wire binding trace is within 2.5cm, and the vertical wire is controlled within 5 cm.

Preferably, in the oil removing process, the section is placed in a sulfuric acid solution with the concentration of 160-210g/l for 1-3min, surface oil stains and a natural oxidation film are removed, and the section is washed after oil removal, wherein the pH value of the washing water is not less than 4.

Preferably, in the alkaline etching process, the section is placed in a sodium hydroxide solution with the concentration of 40-60g/l to remove an oxide film on the surface of the section and level the surface, the concentration of aluminum ions is 15-40g/l, the alkaline washing temperature is 40-50 ℃, the alkaline washing time is 1-4min, and the section is washed with water after alkaline etching, wherein the pH value of the washing water is not less than 4.

Preferably, in the neutralization process, the section bar is placed in a mixed solution of sulfuric acid and nitric acid with the concentration of 160-200g/l for 2-4min, black ash after alkali washing is removed, and water washing is carried out after neutralization, wherein the pH value of the water washing is not less than 4.

Preferably, in the oxidation process, the section bar is placed in an electrolytic cell for electrolysis, and the electrolyte is sulfuric acid with the concentration of 150-180 g/l. The electrolytic voltage is 16-18V, the current density is 140A/m2, the aluminum ion concentration is 5-15g/l, the temperature is 20 +/-2 ℃, the oxidation time is set according to the film thickness, the oxidized water is washed by water and spray water, and the pH value of the water washing water is not less than 6.

Preferably, in the process of medium-temperature hole sealing, the section is placed in a solution with the concentration of 1.2-1.8g/L, pH of 5.2-6.5 of Ni2+ and the temperature is 60 +/-5 ℃ for hole sealing, the hole sealing time is set according to the thickness of an oxide film, generally according to 1-1.2un/min, and the longest time is not more than 22 min.

The beneficial effects of the invention are as follows:

1. the high-performance aluminum alloy formed by processing replaces the traditional 6063 alloy, the Vickers hardness is more than 15Hw, the mechanical property is high, the wall thickness can be reduced by more than 50 percent under the same strength requirement, the cost of aluminum for the photovoltaic frame is reduced by 50 percent, and the electricity production cost in the photovoltaic industry is greatly reduced;

2. according to the invention, by optimizing the alloy components and adding a small amount of Mg and Si auxiliary materials during production, the aluminum alloy has smaller quenching sensitivity, the control difficulty of section deformation of the section in a production field is reduced, the quality of the section is improved, and the comprehensive performance requirement of the aluminum template for the building is met;

3. in the invention, online air cooling quenching is adopted to replace direct water cooling during extrusion, thereby greatly reducing the control difficulty of section deformation of the section bar in the production field and improving the quality of the section bar.

Detailed Description

The present invention is further described below to facilitate understanding by those skilled in the art.

A high-performance photovoltaic aluminum alloy frame is composed of the following components in parts by weight: si: 0.60-0.65%, Fe: less than or equal to 0.25%, Cu: less than or equal to 0.05 percent, Mn: less than or equal to 0.05 percent, Mg: 0.50-0.55%, Cr: less than or equal to 0.05 percent, Zn: less than or equal to 0.05 percent, Ti: less than or equal to 0.05 percent, Al: and (4) the balance.

A processing technology of a high-performance photovoltaic aluminum alloy frame comprises the following steps:

s1: ingredients

The 6005 alloy is adopted, and the mass percentage of the elements is Si: 0.60-0.65%, Fe: less than or equal to 0.25%, Cu: less than or equal to 0.05 percent, Mn: less than or equal to 0.05 percent, Mg: 0.50-0.55%, Cr: less than or equal to 0.05 percent, Zn: less than or equal to 0.05 percent, Ti: compounding with a formula of less than or equal to 0.05 percent and the balance of Al;

wherein, the raw materials must be ensured to be clean, oil stain and non-aluminum impurities are not doped in the furnace burden as much as possible, the waste material is only allowed to be added into the extrusion head tailing and the discard, and the oxidation waste material is not allowed to be added.

S2: casting

The method sequentially comprises the following steps: charging, heating, stirring, measuring temperature, slagging-off for the 1 st time, sampling for the 1 st time, supplementing materials, refining for the 1 st time, refining for the 2 nd time, sampling for the 2 nd time, slagging-off for the 2 nd time, discharging and casting to form a cylindrical ingot semi-finished product;

wherein, the smelting and refining temperature is strictly carried out according to the process requirements, the smelting temperature is between 730-740 ℃, and the refining temperature is 750-740 ℃; the requirement of exhaust refining is stable, the height of the spray cannot exceed 15cm, excessive oxide skin is prevented from being involved in the melt, the oxide skin is gathered from four corners to the middle in the exhaust and refining processes, the slag is completely removed as shallow as possible, the slag is removed to a furnace mouth and is stopped properly, and the separation of liquid materials and slag materials in the slag can be realized; the proportion of the slag removing agent and the refining agent is well controlled, the general refining agent is 2.5kg/T, the slag removing agent is 1.3kg/T, nitrogen is refined and refined in 10 bottles in one furnace, the refining time is about 25-30min, and the standing and heat preservation time is controlled to be 25-30 min; when water is drained, a ceramic filter plate is selected, the mesh number is preferably 60, the casting speed is 60-70mm/min, the water temperature is controlled at 30-45 ℃, the sawing length of the rod head and the rod tail is strictly controlled, the sawing length of the rod head and the rod tail is generally 200mm, the sawing length of the rod tail is 100mm, after water is drained every time, the chute and the aluminum skin of the splitter plate are cleaned, and then the next furnace can be carried out after the chute and the splitter plate are brushed clean by talcum powder; and (3) homogenizing after the casting is finished, wherein the homogenizing temperature is 560 +/-5 ℃, preserving the heat for 8 hours, cooling the mixture by air for one hour after the heat preservation is finished, reducing the temperature to 300 ℃, and then cooling the mixture to the room temperature by water.

S3: extrusion

Putting the aluminum bar into an extruder, extruding and molding through a die, and immediately cooling by air cooling and quenching;

wherein, the temperature of the aluminum bar is 470-510 ℃, the temperature of the die is 460-490 ℃, and the temperature of the extrusion cylinder is 390-420 ℃; the discharging speed of the section bar is 15-20m/min, cleaning the cylinder by using a special cylinder cleaning pad for every 20 bars, shaking the section bar at the discharging port for every 2 bars, and bringing out impurities at the connecting bar as much as possible; the freshly extruded section is soft and can bend and deform, straightening is required to be carried out, the straightening temperature is below 50 ℃, the stretching rate is controlled to be 0.6-1.0%, the residual stress of the section is completely released on the premise that the geometric dimension of the section meets the requirement, the interval between the sections is 10cm before and after straightening, and the section is prevented from being scratched; the section bar is compressed tightly by hand during sawing, so that the saw blade is prevented from being damaged and the section bars are different in length, oil stains on the section bar are wiped clean by using a cleaning cloth after the sawing, aluminum scraps are cleaned by using compressed air, after the conveying platform is subjected to bending, twisting and checking, qualified section bars are loaded into the material frame in an automatic framing mode, and layers are separated by using special high-temperature padding strips and padding pipes, so that scratching and crushing are avoided.

S4: sand blasting

The spray gun sprays the large-grain-size carborundum with the grain diameter of 0.15-0.25mm, the technological parameters of sand spraying are fixed, a small amount of carborundum is added for many times, the grain diameter of the carborundum is analyzed periodically, the consistency of the sand surface effect is ensured, the slight lines and grains on the surface of the section can be removed, and the excellent surface effect is ensured.

S5; oxidation by oxygen

Adopts anodic oxidation and sequentially comprises the following procedures: upward discharging, oil removing, alkaline etching, neutralization, oxidation, hole sealing, downward discharging, inspection, packaging and warehousing;

wherein, the upper row: each end of the horizontal wire binding trace is within 2.5cm, and the vertical wire is controlled within 5 cm.

Oil removal: and placing the mixture in sulfuric acid solution with the concentration of 160-210g/l for 1-3min to remove oil stains and natural oxidation films on the surface. And (4) washing after oil removal, wherein the pH value of the washing water is not less than 4.

Alkaline etching: and (3) placing the section bar in a sodium hydroxide solution with the concentration of 40-60g/l to remove an oxide film on the surface of the section bar and level the surface, wherein the concentration of aluminum ions is 15-40g/l, the alkali washing temperature is 40-50 ℃, and the alkali washing time is 1-4 min. Washing with water after alkaline etching, wherein the pH value of the washing water is not less than 4.

Neutralizing: placing the mixture in a mixed solution of sulfuric acid and nitric acid with the concentration of 160-200g/l for 2-4min, and removing black ash after alkaline cleaning. And (4) washing after neutralization, wherein the pH value of the washing water is not less than 4.

And (3) oxidation: the solution is placed in an electrolytic bath for electrolysis, and the electrolyte is sulfuric acid with the concentration of 150-. The electrolytic voltage is 16-18V, the current density is 140A/m2, the aluminum ion concentration is 5-15g/l, and the temperature is 20 +/-2 ℃. The oxidation time is set according to the film thickness. The oxidation water is washed by water and spraying water, and the pH value of the water is not less than 6.

Hole sealing at medium temperature: placing the membrane in a solution of Ni2+ with the concentration of 1.2-1.8g/L, pH of 5.2-6.5 at the temperature of 60 +/-5 ℃ for hole sealing, wherein the hole sealing time is set according to the thickness of an oxide film, generally according to 1-1.2un/min, and the longest time is not more than 22 min.

And (3) lower row: the water storage condition of the pipe cavity is checked before the lower row, and the lower row is blown clean by compressed air after water exists and the section bar protection is noticed.

And (4) checking: because the surface quality requirement of the solar frame is very high, the surface quality is inspected one by one after being discharged downwards, and the size of the notch is detected by a special inspection tool.

Packaging: in the process of inspecting qualified section bar film pasting, the in-place pasting of the decorative surface is ensured, no air bubbles exist, and the phenomenon of deviation pasting is not allowed. The width of the protective film is consistent with that of the section bar or is 1-2mm narrow on one side. The protective film is selected to have proper viscosity, and the phenomena of film flying and glue falling are not allowed to occur. According to the section bar and weather, the section bar is in butt joint with suppliers in time, and the viscosity of the protective film and the suitability of the section bar are ensured.

Warehousing: and each link of loading and warehousing, delivery and loading and the like needs to be lightly taken and lightly put, so that the qualified surface quality of the section bar is ensured.

The foregoing is merely exemplary and illustrative of the present invention and various modifications, additions and substitutions may be made by those skilled in the art to the specific embodiments described without departing from the scope of the present invention as defined in the accompanying claims.