Roller made of seamless aluminum alloy tube, preparation method and application in gravure printing roller
阅读说明：本技术 一种无缝铝合金管制的辊筒及制备方法和在凹版印刷版辊中的应用 (Roller made of seamless aluminum alloy tube, preparation method and application in gravure printing roller ) 是由 曾常青 李舟 于 2021-09-01 设计创作，主要内容包括：本申请涉及凹版印刷版辊加工技术领域,具体公开了一种无缝铝合金管制的辊筒及制备方法和在凹版印刷版辊中的应用,无缝铝合金管制的辊筒为无缝铝合金管I、或为带有两层涂层的无缝铝合金管II；带有两层涂层的无缝铝合金管II中的两层涂层,其中的一层涂层为镍层I且紧邻无缝铝合金管I外周面设置,另一层涂层为镍-碳化硅-碳化钛复合层且设置在镍层I外周面上,无缝铝合金管I由以下组分制备而成：Si、Cu、Mn、Mg、Ti、Sb、Ni、Co、Cr、Zr、不可避免杂质元素、Al。无缝铝合金管制的辊筒,满足凹版印刷版辊作为基础的需求,以其为基础得到的凹版印刷版辊,单位体积的重量低,因此可增加一次空运凹版印刷版辊的运输量。(The application relates to the technical field of gravure printing roller processing, and particularly discloses a roller made of seamless aluminum alloy, a preparation method and application thereof in a gravure printing roller, wherein the roller made of seamless aluminum alloy is a seamless aluminum alloy pipe I or a seamless aluminum alloy pipe II with two layers of coatings; the seamless aluminum alloy pipe II with two coatings comprises two coatings, wherein one coating is a nickel layer I and is arranged close to the outer peripheral surface of the seamless aluminum alloy pipe I, the other coating is a nickel-silicon carbide-titanium carbide composite layer and is arranged on the outer peripheral surface of the nickel layer I, and the seamless aluminum alloy pipe I is prepared from the following components: si, Cu, Mn, Mg, Ti, Sb, Ni, Co, Cr, Zr, inevitable impurity elements and Al. The roller made of the seamless aluminum alloy meets the requirement that a gravure printing roller is taken as a base, and the weight of the gravure printing roller obtained on the basis of the roller is low in unit volume, so that the transportation amount of the gravure printing roller in one-time air transportation can be increased.)
1. The utility model provides a roller of seamless aluminum alloy pipe system which characterized in that: the roller made of the seamless aluminum alloy pipe is a seamless aluminum alloy pipe I or a seamless aluminum alloy pipe II with two layers of coatings;
the seamless aluminum alloy pipe II with two coatings comprises two coatings, wherein one coating is a nickel layer I and is arranged close to the outer peripheral surface of the seamless aluminum alloy pipe I, and the other coating is a nickel-silicon carbide-titanium carbide composite layer and is arranged on the outer peripheral surface of the nickel layer I;
the seamless aluminum alloy pipe I is prepared from the following components in percentage by weight: si: 4.5-5.0%, Cu: 3.0-3.4%, Mn: 2.6-3.0%, Mg: 9.0-10.0%, Ti: 2.2-2.6%, Sb: 0.4-0.6%, Ni: 0.3-0.5%, Co: 0.2-0.3%, Cr: 0.2 to 0.3%, Zr: 0.1-0.2%, unavoidable impurity elements less than or equal to 0.5%, and the balance of Al.
2. A roller of seamless aluminum alloy tube according to claim 1, wherein: the seamless aluminum alloy pipe I is prepared from the following components in percentage by weight: si: 4.8%, Cu: 3.2%, Mn: 2.8%, Mg: 9.5%, Ti: 2.4%, Sb: 0.5%, Ni: 0.4%, Co: 0.22%, Cr: 0.25%, Zr: 0.13 percent, less than or equal to 0.5 percent of unavoidable impurity elements and the balance of Al.
3. A roller of seamless aluminum alloy tube according to claim 1, wherein: the nickel-silicon carbide-titanium carbide composite layer is prepared from the following raw materials in parts by weight: 45-55 parts of nickel, 16-20 parts of silicon carbide and 9-10 parts of titanium carbide.
4. A method for manufacturing a roller based on the seamless aluminum alloy pipe of any one of claims 1 to 3, characterized in that: the method comprises the following specific steps:
when the roller made of the seamless aluminum alloy pipe is a seamless aluminum alloy pipe I, the roller is prepared by the following method:
preparing AlSi20, AlCu50, AlMn10, AlTi10, AlNi10, AlSb10, AlCo10, AlCr5, AlZr5, Mg ingot and Al ingot for later use;
A. heating the Al ingot under the condition of continuous stirring, and heating to 790-800 ℃ for melting to obtain aluminum liquid; adding AlCo10, AlCr5, AlZr5 and AlTi10 into the obtained aluminum liquid, carrying out heat preservation treatment for 60-70min, and slagging off to obtain a first aluminum alloy mixed liquid;
B. cooling the first aluminum alloy mixed solution obtained in the step A to 750-;
C. cooling the second aluminum alloy mixed solution obtained in the step B to 700-710 ℃, adding AlCu50, AlSb10, Sn ingots and Mg ingots, carrying out heat preservation treatment for 50-60min, standing for 10-20min, and slagging off to obtain a third aluminum alloy mixed solution;
D. c, refining and deslagging the third aluminum alloy mixed solution obtained in the step C, then standing for 10-20min, deslagging, and casting and forming to obtain an aluminum alloy rod;
E. cooling the aluminum alloy rod obtained in the step D to 610-plus-one temperature of 620 ℃, carrying out heat preservation treatment for 1-2h, then cooling to 580-plus-one temperature of 590 ℃, carrying out heat preservation treatment for 6-7h, then cooling to 570-plus-one temperature of 580 ℃, carrying out heat preservation treatment for 9-10h, continuously cooling to 550-plus-one temperature of 560 ℃, carrying out heat preservation treatment for 3-5h, then cooling to 450-plus-one temperature of 460 ℃, and extruding into a tubular shape to obtain a semi-finished product of the aluminum alloy pipe;
F. heating the semi-finished product of the aluminum alloy pipe to the temperature of 540-;
G. heating the semi-finished product of the aluminum alloy pipe to 410-;
H. heating the semi-finished product of the aluminum alloy pipe to 140-150 ℃, carrying out heat preservation treatment for 9-10h, cooling to 110-120 ℃, carrying out heat preservation treatment for 4-5h, and cooling to room temperature to obtain a seamless aluminum alloy pipe I;
when the roller of the seamless aluminum alloy pipe is a seamless aluminum alloy pipe II with two layers of coatings, the method is adopted for preparation:
(1) preparing a seamless aluminum alloy pipe I;
(2) carrying out ultrasonic water washing on the seamless aluminum alloy pipe I obtained in the step (1), then respectively installing plugs for protecting the inner peripheral surface of the seamless aluminum alloy pipe I at two ends of the seamless aluminum alloy pipe I, and then grinding the outer peripheral surface of the seamless aluminum alloy pipe I;
(3) and (3) carrying out ultrasonic water washing, acid washing and electrolytic degreasing on the outer peripheral surface of the seamless aluminum alloy pipe I treated in the step (2), then thermally spraying nickel on the outer peripheral surface of the seamless aluminum alloy pipe I to form a nickel layer I, then thermally spraying a compound mixture on the outer peripheral surface of the nickel layer I to form a nickel-silicon carbide-titanium carbide composite layer, and removing a plug to obtain a seamless aluminum alloy pipe II with two layers of coatings.
5. The method for preparing a roller made of seamless aluminum alloy tube according to claim 4, wherein the method comprises the following steps: in the step D, the following method is adopted for refining and deslagging: under the condition of continuous stirring, adding a deslagging agent on the surface of the third aluminum alloy mixed solution, simultaneously introducing inert gas into the third aluminum alloy mixed solution, and performing ventilation treatment for 20-30min, thereby finishing refining deslagging.
6. The method for preparing a roller made of seamless aluminum alloy tube according to claim 5, wherein the method comprises the following steps: the deslagging agent is RJ-J3, and the addition amount of the deslagging agent is 1-3% of the total weight of the third aluminum alloy mixed liquid.
7. The utility model provides a gravure printing version roller, includes both ends opening and cavity columniform roller, sets firmly at both ends opening and cavity columniform roller outer peripheral face, from inside to outside, is nickel layer II, copper layer and protective layer, its characterized in that in proper order: wherein the hollow cylindrical roller with two open ends is the roller made of seamless aluminum alloy tube as claimed in any one of claims 1-3.
8. A gravure printing cylinder according to claim 7, characterized in that: the protective layer is a chromium layer.
9. A process based on a gravure printing plate roll according to any of claims 7 to 8, characterized in that: the method comprises the following steps:
s1, ultrasonically washing the seamless aluminum alloy-made roller, respectively installing plugs for protecting the inner peripheral surface of the seamless aluminum alloy-made roller at two ends of the seamless aluminum alloy-made roller, and then grinding the outer peripheral surface of the seamless aluminum alloy-made roller;
s2, performing ultrasonic water washing, acid washing and electrolytic degreasing on the outer peripheral surface of the roller made of the seamless aluminum alloy pipe processed in the step S1, and then thermally spraying nickel on the outer peripheral surface of the roller made of the seamless aluminum alloy pipe to form a nickel layer II;
s3, thermally spraying copper on the outer peripheral surface of the nickel layer II processed in the step S2 to form a copper layer;
s4, grinding the copper layer processed in the step S3, then coating laser photosensitive glue solution on the outer peripheral surface of the copper layer, drying to form a glue layer, developing the pattern on the glue layer by adopting laser according to the pattern, and utilizing a mask plate to expose the copper layer at the pattern position, and reserving the glue layer at the non-pattern position;
s5, after the treatment of the step S4, spraying and corroding the copper layer at the position where the pattern is exposed, then carrying out ultrasonic water washing, and then removing the glue layer at the position where the pattern is not exposed to form the pattern at the position where the copper layer is exposed;
and S6, after the protective layer is thermally sprayed on the outer peripheral surface of the copper layer processed in the step S5, removing the plug to obtain the gravure printing roller.
10. The process according to claim 9, characterized in that: the specific method of step S6 is: and (4) carrying out ultrasonic water washing and electrolytic degreasing on the outer peripheral surface of the copper layer treated in the step (S5), then thermally spraying chromium on the outer peripheral surface of the copper layer to form a protective layer, and then polishing the protective layer.
Technical Field
The application relates to the technical field of gravure printing roller processing, in particular to a roller made of seamless aluminum alloy tubes, a preparation method and application of the roller in a gravure printing roller.
Background
With the progress of science and technology and the improvement of the living standard of people, the printing industry is rapidly developed. The printing is mainly divided into relief printing, intaglio printing, flat printing and orifice printing, wherein the image-text part in the intaglio printing is lower than the blank part of the surface of the printing plate, and the intaglio printing has the characteristics of bright color, rich layers, high printing speed, wide adaptive medium, high printing durability and stable quality of printed products, is widely applied and occupies an important position in the field of packaging and printing.
Gravure printing can not leave gravure printing roller, and gravure printing roller includes steel roller, and steel roller is both ends opening and hollow cylindrical, and steel roller is gravure printing roller's basis, has higher hardness, can effectual increase gravure printing roller's intensity, and the outer peripheral face of steel roller has set firmly the nickel layer, and the nickel layer adopts hot spraying's mode to spray nickel on the outer peripheral face of steel roller. The copper layer is fixedly arranged on the peripheral surface of the nickel layer, the copper layer is sprayed on the peripheral surface of the nickel layer in a thermal spraying mode, and then pattern patterns are engraved on the peripheral surface of the copper layer, so that a gravure printing roller can be used for printing to form patterns conveniently. The chromium layer is fixedly arranged on the peripheral surface of the copper layer, and the chromium layer is sprayed on the peripheral surface of the copper layer in a thermal spraying mode, so that the hardness of the copper layer is increased, and the printing resistance of the gravure printing roller is improved. The applicant finds that in the actual processing and transportation, the gravure plateWhen the printing plate roller is in large-scale air transportation, the steel roller is used as the base and the carrier of the gravure printing plate roller, and the density of the steel roller is 7.8g/cm3On the left and right sides, the steel roller bears the main weight of the gravure printing roller, and the total load of the primary airborne transportation of the gravure printing roller is certain and limited, so that the transportation volume of the primary airborne transportation of the gravure printing roller is reduced.
Disclosure of Invention
In order to reduce the weight of a gravure printing roller and increase the transportation volume of the gravure printing roller in one-time air transportation, the application provides a roller made of seamless aluminum alloy and a preparation method thereof, the gravure printing roller based on the roller made of seamless aluminum alloy and a processing technology of the gravure printing roller.
In a first aspect, the application provides a roller made of seamless aluminum alloy, which adopts the following technical scheme:
the roller made of the seamless aluminum alloy pipe is a seamless aluminum alloy pipe I or a seamless aluminum alloy pipe II with two layers of coatings;
the seamless aluminum alloy pipe II with two coatings comprises two coatings, wherein one coating is a nickel layer I and is arranged close to the outer peripheral surface of the seamless aluminum alloy pipe I, and the other coating is a nickel-silicon carbide-titanium carbide composite layer and is arranged on the outer peripheral surface of the nickel layer I;
the seamless aluminum alloy pipe I is prepared from the following components in percentage by weight: si: 4.5-5.0%, Cu: 3.0-3.4%, Mn: 2.6-3.0%, Mg: 9.0-10.0%, Ti: 2.2-2.6%, Sb: 0.4-0.6%, Ni: 0.3-0.5%, Co: 0.2-0.3%, Cr: 0.2 to 0.3%, Zr: 0.1-0.2%, unavoidable impurity elements less than or equal to 0.5%, and the balance of Al.
By adopting the technical scheme, the applicant finds that the roller of the traditional gravure printing roller is a steel roller, the steel roller is the basis of the gravure printing roller, and the density of the steel roller is 8.0g/cm3On the left and right sides, the steel roller bears the main weight of the gravure printing roller and increases the unit volume weight of the gravure printing roller. In the application, the roller adopts a seamless aluminum alloy pipe I or a seamless aluminum alloy pipe II with two layers of coatingsThe density of the alloy pipe I and the seamless aluminum alloy pipe II with two layers of coatings are both 3.0g/cm3Compared with a roller made of steel, the weight of the roller in unit volume is reduced, the weight of the gravure printing roller is further reduced, and the transportation amount of the gravure printing roller in one-time air transportation is increased.
Simultaneously the roller of seamless aluminum alloy pipe in this application, seamless aluminum alloy pipe I or have the seamless aluminum alloy pipe II of two-layer coating, compare the aluminum alloy pipe that adopts aluminum alloy plate to roll up the board welding and form, the seamless aluminum alloy pipe I of this application or have the seamless aluminum alloy pipe II of two-layer coating can avoid the aluminum alloy plate welding and appear the condition of oxidation in the welding department, improves the oxidation resistance and the life of the roller of seamless aluminum alloy pipe.
The application discloses roller of seamless aluminum alloy pipe system: the seamless aluminum alloy pipe I has higher tensile strength through the synergistic effect of raw materials under the condition that the seamless aluminum alloy pipe I has good low density, the tensile strength is greater than 880MPa and is greater than a steel roller, the seamless aluminum alloy pipe I also has good hardness, the Vickers hardness is greater than 260HV and is almost the same as the Vickers hardness of the steel roller, the requirement of applying the seamless aluminum alloy pipe I to a gravure printing roller is met, and meanwhile, under the condition that the seamless aluminum alloy pipe I meets the strength and hardness of the gravure printing roller, the weight of the unit volume of the roller is reduced, so that the transportation capacity of one-time air transportation of the gravure printing roller is increased, and the market demand is met.
The application discloses roller of seamless aluminum alloy pipe system: a seamless aluminum alloy pipe II with two coatings, having a high hardness, a Vickers hardness of more than 390HV, the peripheral surface of the seamless aluminum alloy pipe I is provided with a nickel-silicon carbide-titanium carbide composite layer, silicon carbide and titanium carbide in the nickel-silicon carbide-titanium carbide composite layer can play a role in dispersing and distributing nickel, the structure of the nickel-silicon carbide-titanium carbide composite layer is refined, the mechanical strength, hardness, wear resistance and corrosion resistance of the seamless aluminum alloy pipe II are improved through the synergistic effect among the nickel, the silicon carbide and the titanium carbide, the service life of the seamless aluminum alloy pipe II is prolonged, and the nickel layer I between the nickel-silicon carbide-titanium carbide composite layer and the seamless aluminum alloy pipe I is utilized to increase the bonding strength of the nickel-silicon carbide-titanium carbide composite layer and the seamless aluminum alloy pipe I.
In the composition of the seamless aluminum alloy pipe I, Si has good castability and corrosion resistance, and is in a short rod shape in the seamless aluminum alloy pipe I, so that the strength and hardness of the seamless aluminum alloy pipe I can be improved. Mg has good corrosion resistance, can effectively increase the strength of the seamless aluminum alloy pipe I, and can be combined with Si, Si and Mg to form MgSi compounds in the seamless aluminum alloy pipe I, so that the strength of the seamless aluminum alloy pipe I can be improved. Cu has a solid solution strengthening effect, a CuAl2 compound is formed in the seamless aluminum alloy pipe I, the aging strengthening effect can be obvious, and the strength of the seamless aluminum alloy pipe I is effectively improved by combining Si and Mg and utilizing the compound synergistic effect among Cu, Si and Mg.
Ni has good plasticity and corrosion resistance, is not easily oxidized in air, and can improve the hardness, ductility and corrosion resistance of the seamless aluminum alloy pipe I. Cr forms a (CrMn) Al12 compound in the seamless aluminum alloy pipe I, can hinder the nucleation and growth process of crystals, refine crystal grains, improve the toughness and cracking sensitivity of the seamless aluminum alloy pipe I and improve the strength of the seamless aluminum alloy pipe I, and meanwhile, as the Cu corrosion resistance is low, Gr is added at the moment, and the Gr can also reduce the influence of the Cu corrosion resistance on the seamless aluminum alloy pipe I.
Mn forms MnAl6 compound in the seamless aluminum alloy pipe I, MnAl6 compound dispersoids play a role in inhibiting the growth of recrystallized grains, namely, the recrystallization process is inhibited, the recrystallized grains are effectively refined, and the MnAl6 compound can also dissolve Fe to form (Mn, Fe) Al6 compound. The strength of the seamless aluminum alloy pipe I can be effectively improved through the synergistic effect between Mn and Mg. Co forms a Co2Al9 compound in the seamless aluminum alloy pipe I, the Co2Al9 compound is distributed in the seamless aluminum alloy pipe I in a dispersed mode, the effects of dispersion strengthening and wear resistance are achieved, meanwhile, Mn and Mg are combined, and the strength of the seamless aluminum alloy pipe I is effectively improved through the synergistic effect among Co, Mn and Mg.
Ti has good mechanical property, TiAl2 compound is formed in the seamless aluminum alloy pipe I, and TiAl2 compound is a non-spontaneous core, so that the structure of the seamless aluminum alloy pipe I is refined. Zr forms a ZrAl3 compound in the seamless aluminum alloy pipe I, and the ZrAl3 compound can hinder the recrystallization process and refine recrystallized grains, so that the structure of the seamless aluminum alloy pipe I is refined. By combining Mn, Zr and Ti and through the synergistic interaction among Mn, Zr and Ti, the structure of the seamless aluminum alloy pipe I is effectively refined, and the strength of the seamless aluminum alloy pipe I is improved.
In the case where Na exists as free sodium in the seamless aluminum alloy pipe I, brittle cracking of the seamless aluminum alloy pipe I is likely to occur, and in the case where Si exists, Na can be bonded to form NaAlSi compound, and Na is in a compound state at this time, and brittle cracking due to Na precipitation can be avoided, but in the case where Mg exists, Mg and Na are in a competitive relationship, and in the present application, Mg is contained in a large amount, and in this case, Sb is added, Sb can be bonded to Na to form Na3Sb compound, and brittle cracking due to Na precipitation can be avoided, and the strength and service life of the seamless aluminum alloy pipe I can be improved.
Optionally, the seamless aluminum alloy pipe I is prepared from the following components in percentage by weight: si: 4.8%, Cu: 3.2%, Mn: 2.8%, Mg: 9.5%, Ti: 2.4%, Sb: 0.5%, Ni: 0.4%, Co: 0.22%, Cr: 0.25%, Zr: 0.13 percent, less than or equal to 0.5 percent of unavoidable impurity elements and the balance of Al.
By adopting the technical scheme, the components of the seamless aluminum alloy pipe I are optimized, and the performance of the seamless aluminum alloy pipe I is improved.
Optionally, the nickel-silicon carbide-titanium carbide composite layer is prepared from the following raw materials in parts by weight: 45-55 parts of nickel, 16-20 parts of silicon carbide and 9-10 parts of titanium carbide.
By adopting the technical scheme, the raw materials of the nickel-silicon carbide-titanium carbide composite layer are optimized, the structure of the nickel-silicon carbide-titanium carbide composite layer is strengthened, the bonding strength of the nickel layer I and the nickel-silicon carbide-titanium carbide composite layer is increased, and the hardness of the seamless aluminum alloy pipe II with two coatings is improved.
In a second aspect, the present application provides a method for preparing the roller made of the seamless aluminum alloy tube, which adopts the following technical scheme:
the preparation method of the roller made of the seamless aluminum alloy pipe comprises the following specific steps:
when the roller made of the seamless aluminum alloy pipe is a seamless aluminum alloy pipe I, the roller is prepared by the following method:
preparing AlSi20, AlCu50, AlMn10, AlTi10, AlNi10, AlSb10, AlCo10, AlCr5, AlZr5, Mg ingot and Al ingot for later use;
A. heating the Al ingot under the condition of continuous stirring, and heating to 790-800 ℃ for melting to obtain aluminum liquid; adding AlCo10, AlCr5, AlZr5 and AlTi10 into the obtained aluminum liquid, carrying out heat preservation treatment for 60-70min, and slagging off to obtain a first aluminum alloy mixed liquid;
B. cooling the first aluminum alloy mixed solution obtained in the step A to 750-;
C. cooling the second aluminum alloy mixed solution obtained in the step B to 700-710 ℃, adding AlCu50, AlSb10, Sn ingots and Mg ingots, carrying out heat preservation treatment for 50-60min, standing for 10-20min, and slagging off to obtain a third aluminum alloy mixed solution;
D. c, refining and deslagging the third aluminum alloy mixed solution obtained in the step C, then standing for 10-20min, deslagging, and casting and forming to obtain an aluminum alloy rod;
E. cooling the aluminum alloy rod obtained in the step D to 610-plus-one temperature of 620 ℃, carrying out heat preservation treatment for 1-2h, then cooling to 580-plus-one temperature of 590 ℃, carrying out heat preservation treatment for 6-7h, then cooling to 570-plus-one temperature of 580 ℃, carrying out heat preservation treatment for 9-10h, continuously cooling to 550-plus-one temperature of 560 ℃, carrying out heat preservation treatment for 3-5h, then cooling to 450-plus-one temperature of 460 ℃, and extruding into a tubular shape to obtain a semi-finished product of the aluminum alloy pipe;
F. heating the semi-finished product of the aluminum alloy pipe to the temperature of 540-;
G. heating the semi-finished product of the aluminum alloy pipe to 410-;
H. heating the semi-finished product of the aluminum alloy pipe to 140-150 ℃, carrying out heat preservation treatment for 9-10h, cooling to 110-120 ℃, carrying out heat preservation treatment for 4-5h, and cooling to room temperature to obtain a seamless aluminum alloy pipe I;
when the roller of the seamless aluminum alloy pipe is a seamless aluminum alloy pipe II with two layers of coatings, the method is adopted for preparation:
(1) preparing a seamless aluminum alloy pipe I;
(2) carrying out ultrasonic water washing on the seamless aluminum alloy pipe I obtained in the step (1), then respectively installing plugs for protecting the inner peripheral surface of the seamless aluminum alloy pipe I at two ends of the seamless aluminum alloy pipe I, and then grinding the outer peripheral surface of the seamless aluminum alloy pipe I;
(3) and (3) carrying out ultrasonic water washing, acid washing and electrolytic degreasing on the outer peripheral surface of the seamless aluminum alloy pipe I treated in the step (2), then thermally spraying nickel on the outer peripheral surface of the seamless aluminum alloy pipe I to form a nickel layer I, then thermally spraying a compound mixture on the outer peripheral surface of the nickel layer I to form a nickel-silicon carbide-titanium carbide composite layer, and removing a plug to obtain a seamless aluminum alloy pipe II with two layers of coatings.
By adopting the technical scheme, the raw materials of the seamless aluminum alloy pipe I are from intermediate alloy and metal simple substances, the raw materials are wide in source and low in cost, the raw materials are cooled for multiple times and added in batches in steps, the raw materials can be fully reacted, the uniformity of raw material mixing is improved, then an aluminum alloy rod is obtained by casting and forming, then the aluminum alloy rod is annealed and heated, extruded into a tubular shape to obtain a semi-finished product of the aluminum alloy pipe, then the semi-finished product of the aluminum alloy pipe is subjected to solid solution, annealing, quenching and heat treatment to obtain the seamless aluminum alloy pipe I, the influence of internal stress generated in the crystallization and solidification process of the aluminum alloy rod is reduced through synergistic effect among the steps, the mechanical strength of the aluminum alloy rod can be improved, segregation is reduced, the texture of the aluminum alloy rod is homogenized, and the mechanical property and corrosion resistance of the seamless aluminum alloy pipe I are effectively improved, is convenient for the stable processing of the seamless aluminum alloy pipe I.
Meanwhile, the seamless aluminum alloy pipe II with the two coatings effectively increases the mechanical property and hardness of the seamless aluminum alloy pipe II with the two coatings by utilizing the synergistic interaction between the first nickel layer I and the nickel-silicon carbide-titanium carbide composite layer.
Optionally, in the step D, the following method is adopted for refining and deslagging: under the condition of continuous stirring, adding a deslagging agent on the surface of the third aluminum alloy mixed solution, simultaneously introducing inert gas into the third aluminum alloy mixed solution, and performing ventilation treatment for 20-30min, thereby finishing refining deslagging.
By adopting the technical scheme, after the deslagging agent is added into the third aluminum alloy mixed liquid, the deslagging agent floats on the surface of the third aluminum alloy mixed liquid, under the condition of stirring, the third aluminum alloy mixed liquid forms an eddy current and brings the deslagging agent to the bottom of the third aluminum alloy mixed liquid, the contact area of the deslagging agent and the third aluminum alloy mixed liquid is increased, meanwhile, when the deslagging agent is added, the inert gas is introduced into the third aluminum alloy mixed liquid, the disturbance of the third aluminum alloy mixed liquid is further increased, the contact area of the deslagging agent and the third aluminum alloy mixed liquid is further increased, the deslagging agent and the third aluminum alloy are in full contact by utilizing the synergistic effect between stirring and the inert gas, the hydrogen and the floating oxidation slag inclusion in the third aluminum alloy mixed liquid are effectively removed, and the performance of the seamless aluminum alloy pipe I is improved.
Optionally, the slag remover is RJ-J3, and the addition amount of the slag remover is 1-3% of the total weight of the third aluminum alloy mixed solution.
By adopting the technical scheme, the slag remover is RJ-J3, the slag remover RJ-J3 does not contain sodium salt, sodium is reduced, so that the seamless aluminum alloy pipe I generates brittle cracking, the using effect of the slag remover is improved, and the performance of the seamless aluminum alloy pipe I is improved.
In a third aspect, the present application provides a gravure printing plate roller, which adopts the following technical scheme:
the utility model provides a gravure printing roller, includes both ends opening and hollow circular cylinder shape roller II, sets firmly at both ends opening and hollow circular cylinder shape roller outer peripheral face, from inside to outside, is nickel layer, copper layer and protective layer in proper order, and wherein both ends opening and hollow circular cylinder shape roller are the roller of foretell seamless aluminum alloy control.
By adopting the technical scheme, the weight of the gravure printing roller per unit volume is about 62% lower than that of a steel roller on the basis that the gravure printing roller is made of seamless aluminum alloy, so that the weight of the gravure printing roller per unit volume can be reduced, and the transportation amount of the gravure printing roller in one-time air transportation can be increased.
Furthermore, the roller made of the seamless aluminum alloy tube is taken as the basis, particularly the gravure printing roller obtained on the basis of the seamless aluminum alloy tube II with two layers of coatings, and the mechanical property and the hardness of the seamless aluminum alloy tube II are effectively improved due to the synergistic interaction between the nickel layer I and the nickel-silicon carbide-titanium carbide composite layer.
Optionally, the protective layer is a chromium layer.
By adopting the technical scheme, the chromium layer can effectively improve the strength, the wear resistance and the corrosion resistance of the copper layer, and improve the practicability and the service life of the gravure printing roller.
In a fourth aspect, the present application provides a processing technology of the gravure printing roller, which adopts the following technical scheme: the processing technology of the gravure printing plate roller comprises the following steps:
s1, ultrasonically washing the roller made of the seamless aluminum alloy tube, respectively installing plugs for protecting the inner circumferential surface of the roller made of the seamless aluminum alloy tube at two ends of the roller made of the seamless aluminum alloy tube, and then grinding the outer circumferential surface of the roller made of the seamless aluminum alloy tube;
s2, performing ultrasonic water washing, acid washing and electrolytic degreasing on the outer peripheral surface of the roller made of the seamless aluminum alloy pipe processed in the step S1, and then thermally spraying nickel on the outer peripheral surface of the roller made of the seamless aluminum alloy pipe to form a nickel layer II;
s3, thermally spraying copper on the outer peripheral surface of the nickel layer II processed in the step S2 to form a copper layer;
s4, grinding the copper layer processed in the step S3, then coating laser photosensitive glue solution on the outer peripheral surface of the copper layer, drying to form a glue layer, developing the pattern on the glue layer by adopting laser according to the pattern, and utilizing a mask plate to expose the copper layer at the pattern position, and reserving the glue layer at the non-pattern position;
s5, after the treatment of the step S4, spraying and corroding the copper layer at the position where the pattern is exposed, then carrying out ultrasonic water washing, and then removing the glue layer at the position where the pattern is not exposed to form the pattern at the position where the copper layer is exposed;
and S6, after the protective layer is thermally sprayed on the outer peripheral surface of the copper layer processed in the step S5, removing the plug to obtain the gravure printing roller.
By adopting the technical scheme, the processing of the gravure printing roller is realized, and the advantages of simplicity and stability in processing are also realized.
Optionally, the specific method of step S6 is: and (4) carrying out ultrasonic water washing and electrolytic degreasing on the outer peripheral surface of the copper layer treated in the step (S5), then thermally spraying chromium on the outer peripheral surface of the copper layer to form a protective layer, and then polishing the protective layer.
By adopting the technical scheme, the protective layer is arranged as the chromium layer, so that the protective layer can be conveniently processed, the chromium layer can effectively improve the strength, the wear resistance and the corrosion resistance of the copper layer, and the practicability and the service life of the gravure printing roller are improved.
In summary, the present application has the following beneficial effects:
1. the application discloses roller of seamless aluminum alloy pipe system: the seamless aluminum alloy pipe I or the seamless aluminum alloy pipe II with two coatings is used for a gravure printing roller, the unit volume weight of the gravure printing roller is reduced, and therefore the transportation capacity of the gravure printing roller in one-time air transportation can be increased.
2. The preparation method of the roller made of the seamless aluminum alloy pipe has the advantage of stable preparation, reduces the influence of internal stress generated by the aluminum alloy rod in the crystallization and solidification process through the synergy among all the steps, reduces segregation, enables the structure of the aluminum alloy rod to be uniform, and effectively improves the mechanical property and the corrosion resistance of the seamless aluminum alloy pipe.
3. The processing technology of the gravure printing roller has the advantages of simplicity and convenience in processing and stability.
Drawings
Fig. 1 is a schematic cross-sectional view of a gravure roll of application example 1;
fig. 2 is a schematic cross-sectional view of a gravure roll of application example 2.
Description of reference numerals: 1. a roller; 11. a seamless aluminum alloy pipe I; 12. a nickel layer I; 13. a nickel-silicon carbide-titanium carbide composite layer; 2. a nickel layer II; 3. a copper layer; 4. and a protective layer.
Detailed Description
The present application will be described in further detail with reference to examples.
Examples
Example 1
The roller is a seamless aluminum alloy pipe I, and the seamless aluminum alloy pipe I is prepared from the following components in percentage by weight: si: 4.5%, Cu: 3.0%, Mn: 3.0%, Mg: 10.0%, Ti: 2.2%, Sb: 0.4%, Ni: 0.5%, Co: 0.2%, Cr: 0.2%, Zr: 0.2 percent, less than or equal to 0.5 percent of unavoidable impurity elements and the balance of Al.
The seamless aluminum alloy pipe I is prepared by the following method:
preparing AlSi20, AlCu50, AlMn10, AlTi10, AlNi10, AlSb10, AlCo10, AlCr5, AlZr5, Mg ingot and Al ingot for later use;
A. heating the Al ingot under the condition of continuously stirring, heating to 790 ℃ for melting to obtain aluminum liquid, then adding AlCo10, AlCr5, AlZr5 and AlTi10, carrying out heat preservation treatment for 70min, and slagging off to obtain a first aluminum alloy mixed liquid.
B. And C, cooling the first aluminum alloy mixed solution obtained in the step A to 750 ℃, adding AlSi20, AlMn10 and AlNi10, preserving heat for 70min, and removing slag to obtain a second aluminum alloy mixed solution.
C. And C, cooling the second aluminum alloy mixed solution obtained in the step B to 700 ℃, adding AlCu50, AlSb10, Sn ingots and Mg ingots, carrying out heat preservation treatment for 60min, and slagging off to obtain a third aluminum alloy mixed solution.
D. And C, adding a deslagging agent into the surface of the third aluminum alloy mixed solution obtained in the step C under the condition of continuous stirring, wherein the deslagging agent is RJ-J3 and is selected from Siheyuan metallurgy materials Co., Ltd, the addition amount of the deslagging agent is 1% of the total weight of the third aluminum alloy mixed solution, introducing argon into the third aluminum alloy mixed solution when the deslagging agent is added, and performing ventilation treatment for 30min to refine and descale the third aluminum alloy mixed solution. And then standing for 10-20min, slagging off, and casting to form to obtain the aluminum alloy rod.
E. And D, cooling the aluminum alloy rod obtained in the step D to 610 ℃, performing heat preservation treatment for 2 hours, then cooling to 580 ℃, performing heat preservation treatment for 7 hours, then cooling to 570 ℃, performing heat preservation treatment for 10 hours, continuously cooling to 550 ℃, performing heat preservation treatment for 5 hours, then cooling to 450 ℃, and extruding into a tubular shape to obtain a semi-finished product of the aluminum alloy pipe.
F. Heating the semi-finished product of the aluminum alloy pipe to 540 ℃, carrying out heat preservation treatment for 80min, then rapidly placing the semi-finished product of the aluminum alloy pipe in cold water of 10 ℃ within 20s, carrying out heat preservation treatment for 30min, then heating to 170 ℃, carrying out heat preservation treatment for 11h, and cooling to room temperature.
G. Heating the semi-finished product of the aluminum alloy pipe to 410 ℃, carrying out heat preservation treatment for 80min, then rapidly placing the semi-finished product in 10 ℃ cold water within 20s, carrying out heat preservation treatment for 30min, then heating to 220 ℃, carrying out heat preservation treatment for 100min, then rapidly placing the semi-finished product in 10 ℃ cold water within 20s, and carrying out heat preservation treatment for 30 min.
H. Heating the semi-finished product of the aluminum alloy pipe to 140 ℃, carrying out heat preservation treatment for 10 hours, cooling to 110 ℃, carrying out heat preservation treatment for 5 hours, and cooling to room temperature to obtain a seamless aluminum alloy pipe;
and the seamless aluminum alloy pipe I has an inner diameter of 300mm, an outer diameter of 360mm and a length of 1200 mm.
Example 2
A roller for seamless aluminum alloy pipe is different from that of example 1 in the composition of a seamless aluminum alloy pipe I and the rest is the same as that of example 1.
The seamless aluminum alloy pipe I is prepared from the following components in percentage by weight: si: 4.8%, Cu: 3.2%, Mn: 2.8%, Mg: 9.5%, Ti: 2.4%, Sb: 0.5%, Ni: 0.4%, Co: 0.22%, Cr: 0.25%, Zr: 0.13 percent, less than or equal to 0.5 percent of unavoidable impurity elements and the balance of Al.
Example 3
A roller for seamless aluminum alloy pipe is different from that of example 1 in the composition of a seamless aluminum alloy pipe I and the rest is the same as that of example 1.
The seamless aluminum alloy pipe I is prepared from the following components in percentage by weight: si: 4.6%, Cu: 3.1%, Mn: 2.8%, Mg: 9.7%, Ti: 2.5%, Sb: 0.5%, Ni: 0.4%, Co: 0.25%, Cr: 0.2%, Zr: 0.15 percent, less than or equal to 0.5 percent of unavoidable impurity elements and the balance of Al.
Example 4
A roller for seamless aluminum alloy pipe is different from that of example 1 in the composition of a seamless aluminum alloy pipe I and the rest is the same as that of example 1.
The seamless aluminum alloy pipe I is prepared from the following components in percentage by weight: si: 5.0%, Cu: 3.4%, Mn: 2.6%, Mg: 9.0%, Ti: 2.6%, Sb: 0.6%, Ni: 0.3%, Co: 0.3%, Cr: 0.3%, Zr: 0.1 percent, inevitable impurity elements less than or equal to 0.5 percent and the balance of Al.
Example 5
A roller for seamless aluminum alloy pipe is different from that of the roller in the embodiment 2 in that the preparation method of the seamless aluminum alloy pipe I is different, and the rest is the same as that of the roller in the embodiment 2.
The seamless aluminum alloy pipe I is prepared by the following method:
preparing AlSi20, AlCu50, AlMn10, AlTi10, AlNi10, AlSb10, AlCo10, AlCr5, AlZr5, Mg ingot and Al ingot for later use;
A. heating the Al ingot under the condition of continuous stirring, heating to 795 ℃ for melting to obtain molten aluminum, then adding AlCo10, AlCr5, AlZr5 and AlTi10, carrying out heat preservation treatment for 65min, and slagging off to obtain a first aluminum alloy mixed solution.
B. And C, cooling the first aluminum alloy mixed solution obtained in the step A to 755 ℃, adding AlSi20, AlMn10 and AlNi10, carrying out heat preservation treatment for 65min, and removing slag to obtain a second aluminum alloy mixed solution.
C. And C, cooling the second aluminum alloy mixed solution obtained in the step B to 705 ℃, adding AlCu50, AlSb10, Sn ingots and Mg ingots, carrying out heat preservation treatment for 55min, and slagging off to obtain a third aluminum alloy mixed solution.
D. And C, adding a deslagging agent into the surface of the third aluminum alloy mixed solution obtained in the step C under the condition of continuous stirring, wherein the deslagging agent is RJ-J3 and is selected from Siheyuan metallurgy materials Co., Ltd, the addition amount of the deslagging agent is 2% of the total weight of the third aluminum alloy mixed solution, introducing argon into the third aluminum alloy mixed solution when the deslagging agent is added, and performing ventilation treatment for 25min to refine and descale the third aluminum alloy mixed solution. And then standing for 10-20min, slagging off, and casting to form to obtain the aluminum alloy rod.
E. And D, cooling the aluminum alloy rod obtained in the step D to 615 ℃, carrying out heat preservation treatment for 1.5h, then cooling to 585 ℃, carrying out heat preservation treatment for 6.5h, then cooling to 575 ℃, carrying out heat preservation treatment for 9.5h, continuously cooling to 555 ℃, carrying out heat preservation treatment for 4h, then cooling to 455 ℃, and extruding into a tubular shape to obtain a semi-finished product of the aluminum alloy tube.
F. Heating the semi-finished product of the aluminum alloy pipe to 545 ℃, carrying out heat preservation treatment for 75min, then rapidly placing the semi-finished product of the aluminum alloy pipe in cold water at the temperature of 8 ℃ within 20s, carrying out heat preservation treatment for 35min, then heating to 175 ℃, carrying out heat preservation treatment for 10.5h, and cooling to room temperature.
G. Heating the semi-finished product of the aluminum alloy pipe to 415 ℃, carrying out heat preservation treatment for 75min, then rapidly placing the semi-finished product of the aluminum alloy pipe in cold water at 8 ℃ within 20s, carrying out heat preservation treatment for 35min, then heating to 225 ℃, carrying out heat preservation treatment for 95min, then rapidly placing the semi-finished product of the aluminum alloy pipe in cold water at 8 ℃ within 20s, and carrying out heat preservation treatment for 35 min.
H. Heating the semi-finished product of the aluminum alloy pipe to 145 ℃, carrying out heat preservation treatment for 9.5h, cooling to 115 ℃, carrying out heat preservation treatment for 4.5h, and cooling to room temperature to obtain a seamless aluminum alloy pipe;
and the seamless aluminum alloy pipe I has an inner diameter of 300mm, an outer diameter of 360mm and a length of 1200 mm.
Example 6
A roller for seamless aluminum alloy pipe is different from that of the roller in the embodiment 2 in that the preparation method of the seamless aluminum alloy pipe I is different, and the rest is the same as that of the roller in the embodiment 2.
The seamless aluminum alloy pipe I is prepared by the following method:
preparing AlSi20, AlCu50, AlMn10, AlTi10, AlNi10, AlSb10, AlCo10, AlCr5, AlZr5, Mg ingot and Al ingot for later use;
A. heating the Al ingot under the condition of continuous stirring, heating to 800 ℃ for melting to obtain aluminum liquid, then adding AlCo10, AlCr5, AlZr5 and AlTi10, carrying out heat preservation treatment for 60min, and slagging off to obtain a first aluminum alloy mixed liquid.
B. And C, cooling the first aluminum alloy mixed solution obtained in the step A to 760 ℃, adding AlSi20, AlMn10 and AlNi10, preserving heat for 60min, and removing slag to obtain a second aluminum alloy mixed solution.
C. And C, cooling the second aluminum alloy mixed solution obtained in the step B to 710 ℃, adding AlCu50, AlSb10, Sn ingots and Mg ingots, carrying out heat preservation treatment for 50min, and slagging off to obtain a third aluminum alloy mixed solution.
D. And C, adding a deslagging agent into the surface of the third aluminum alloy mixed solution obtained in the step C under the condition of continuous stirring, wherein the deslagging agent is RJ-J3 and is selected from Siheyuan metallurgy materials Co., Ltd, the addition amount of the deslagging agent is 3% of the total weight of the third aluminum alloy mixed solution, introducing argon into the third aluminum alloy mixed solution when the deslagging agent is added, and performing ventilation treatment for 20min to refine and descale the third aluminum alloy mixed solution. And then standing for 10-20min, slagging off, and casting to form to obtain the aluminum alloy rod.
E. And D, cooling the aluminum alloy rod obtained in the step D to 620 ℃, carrying out heat preservation treatment for 1 hour, then cooling to 590 ℃, carrying out heat preservation treatment for 6 hours, then cooling to 580 ℃, carrying out heat preservation treatment for 9 hours, continuously cooling to 560 ℃, carrying out heat preservation treatment for 3 hours, then cooling to 460 ℃, and extruding into a tubular shape to obtain a semi-finished product of the aluminum alloy tube.
F. Heating the semi-finished product of the aluminum alloy pipe to 550 ℃, carrying out heat preservation treatment for 70min, then rapidly placing the semi-finished product of the aluminum alloy pipe in cold water at 5 ℃ within 20s, carrying out heat preservation treatment for 40min, then heating to 180 ℃, carrying out heat preservation treatment for 10h, and cooling to room temperature.
G. Heating the semi-finished product of the aluminum alloy pipe to 420 ℃, carrying out heat preservation treatment for 70min, then rapidly placing the semi-finished product in cold water at 5 ℃ within 20s, carrying out heat preservation treatment for 40min, then heating to 230 ℃, carrying out heat preservation treatment for 90min, then rapidly placing the semi-finished product in cold water at 5 ℃ within 20s, and carrying out heat preservation treatment for 40 min.
H. Heating the semi-finished product of the aluminum alloy pipe to 150 ℃, carrying out heat preservation treatment for 9 hours, cooling to 120 ℃, carrying out heat preservation treatment for 4 hours, and cooling to room temperature to obtain a seamless aluminum alloy pipe;
and the seamless aluminum alloy pipe I has an inner diameter of 300mm, an outer diameter of 360mm and a length of 1200 mm.
Example 7
The roller is a seamless aluminum alloy pipe II with two layers of coatings, wherein one layer of the coating is a nickel layer I and is arranged close to the outer peripheral surface of the seamless aluminum alloy pipe, and the other layer of the coating is a nickel-silicon carbide-titanium carbide composite layer and is arranged on the outer peripheral surface of the nickel layer I.
The seamless aluminum alloy pipe II with the two layers of coatings is prepared by the following method:
(1) preparing a seamless aluminum alloy pipe I;
a seamless aluminum alloy tube I was produced as in example 2, and the seamless aluminum alloy tube I had an inner diameter of 300mm, an outer diameter of 360mm and a length of 1200 mm.
(2) And (2) ultrasonically washing the seamless aluminum alloy pipe I obtained in the step (1), then respectively installing plugs for protecting the inner peripheral surface of the seamless aluminum alloy pipe I at two ends of the seamless aluminum alloy pipe I, and then grinding the outer peripheral surface of the seamless aluminum alloy pipe I.
(3) And (3) carrying out ultrasonic water washing, acid washing and electrolytic degreasing on the outer peripheral surface of the seamless aluminum alloy pipe I treated in the step (2), then thermally spraying nickel on the outer peripheral surface of the seamless aluminum alloy pipe I to form a nickel layer I, wherein the thickness of the nickel layer is 5 microns, then thermally spraying a compound mixture on the outer peripheral surface of the nickel layer I to form a nickel-silicon carbide-titanium carbide composite layer, wherein the thickness of the nickel-silicon carbide-titanium carbide composite layer is 5 microns, and removing a plug to obtain a seamless aluminum alloy pipe II with two layers of coatings.
The thermal nickel spraying adopts oxyacetylene flame spraying, the spraying angle is vertical spraying, the spraying distance is 230mm, the temperature is raised to 410 ℃ after the nickel spraying, and the heat preservation treatment is carried out for 2h, so as to form a nickel layer I.
The thermal spraying of the compound mixture adopts oxyacetylene flame spraying, the spraying angle is vertical spraying, the spraying distance is 230mm, the temperature is raised to 410 ℃ after the compound mixture is sprayed, and the heat preservation treatment is carried out for 2 hours, so as to form the nickel-silicon carbide-titanium carbide compound layer.
The compound mixture is prepared from the following raw materials: 45kg of nickel, 20kg of silicon carbide and 9kg of titanium carbide, wherein the nickel is nickel powder, the silicon carbide is silicon carbide powder and the titanium carbide is titanium carbide powder, and the nickel powder, the silicon carbide powder and the titanium carbide powder are uniformly mixed to obtain a compound mixture.
Example 8
The roller made of the seamless aluminum alloy pipe is different from the roller made of the seamless aluminum alloy pipe in the embodiment 7 in the raw material ratio of the compound mixture, and the rest is the same as the roller made of the embodiment 7.
The compound mixture is prepared from the following raw materials: 50kg of nickel, 18kg of silicon carbide and 9.5kg of titanium carbide.
Example 9
The roller made of the seamless aluminum alloy pipe is different from the roller made of the seamless aluminum alloy pipe in the embodiment 7 in the raw material ratio of the compound mixture, and the rest is the same as the roller made of the embodiment 7.
The compound mixture is prepared from the following raw materials: 55kg of nickel, 16kg of silicon carbide and 10kg of titanium carbide.
Example 10
A seamless aluminum alloy tube roller is distinguished from example 7 in that no silicon carbide is added to the raw materials of the compounded mixture, and the remainder is the same as in example 7.
Example 11
A seamless aluminum alloy tube roller is distinguished from example 7 in that titanium carbide is not added to the raw materials of the compounded mixture, and the remainder is the same as in example 7.
Example 12
A roller made of seamless aluminum alloy tubes is different from the roller made of the seamless aluminum alloy tubes in the embodiment 7 in that silicon carbide and titanium carbide are not added in raw materials of a compound mixture, and the rest parts are the same as the roller made of the embodiment 7.
Example 13
The roller is characterized in that the peripheral surface of the seamless aluminum alloy pipe I is not provided with a nickel layer I, namely a nickel-silicon carbide-titanium carbide composite layer is directly and fixedly arranged on the peripheral surface of the seamless aluminum alloy pipe I, and the rest parts are the same as those in the embodiment 7.
Comparative example
Comparative example 1
A roller for seamless aluminum alloy pipe is different from that of the roller in the embodiment 2 in that Mn is not added to the composition of a seamless aluminum alloy pipe I, and the rest is the same as that of the roller in the embodiment 2.
Comparative example 2
A roller for seamless aluminum alloy pipe is different from that of the roller in the embodiment 2 in that Ti is not added in the composition of the seamless aluminum alloy pipe I, and the rest is the same as that of the roller in the embodiment 2.
Comparative example 3
A roller for seamless aluminum alloy pipe is different from that of example 2 in that Zr is not added to the composition of seamless aluminum alloy pipe I, and the rest is the same as that of example 2.
Comparative example 4
A roller for seamless aluminum alloy pipe is different from that of the roller in the embodiment 2 in that Mn, Ti and Zr are not added in the composition of a seamless aluminum alloy pipe I, and the rest is the same as that of the roller in the embodiment 2.
Comparative example 5
A roller for seamless aluminum alloy pipe is different from that of example 2 in that the Si content in the composition of seamless aluminum alloy pipe I is 3%, and the rest is the same as that of example 2.
Comparative example 6
A roller for seamless aluminum alloy pipe is different from that of example 2 in that the Si content in the composition of seamless aluminum alloy pipe I is 6%, and the rest is the same as that of example 2.
Comparative example 7
A roller for seamless aluminum alloy pipe is different from that of example 2 in that the Mg content of the composition of seamless aluminum alloy pipe I is 8%, and the rest is the same as that of example 2.
Comparative example 8
A roller for seamless aluminum alloy pipe is different from that of example 2 in that the Mg content of the composition of seamless aluminum alloy pipe I is 12%, and the rest is the same as that of example 2.
Comparative example 9
A steel roller for a gravure printing plate roller is a commercially available low-carbon steel roller, wherein the inner diameter of the low-carbon steel roller is 300mm, the outer diameter of the low-carbon steel roller is 360mm, and the length of the low-carbon steel roller is 1200 mm.
Roller performance testing
The following performance tests were carried out on the seamless aluminum alloy tube-made rolls obtained in examples 1 to 6 and comparative examples 1 to 8 and the steel roll of comparative example 9, and the test results are shown in table 1.
The method comprises the following steps of processing a seamless aluminum alloy tube or steel roller into a test bar, detecting the density of the test bar, and detecting the tensile strength of the test bar by adopting a WDW-30D microcomputer control electronic universal tester of Shandong mountain test instruments ltd, wherein the diameter of the test bar is 10mm and the length of the test bar is 100 mm;
a roller made of seamless aluminum alloy tube or steel is processed into a test block, the size of the test block is 50mm multiplied by 25mm multiplied by 5mm, and the Vickers hardness of the test block is detected by adopting an HV-50A Vickers hardness tester of Shandong mountain test instruments Co.
TABLE 1 test results of the rollers
Detecting items
Density/(g/cm)3)
Tensile strength/(MPa)
Vickers hardness/(HV)
Example 1
2.92
886.4
260.3
Example 2
2.93
915.2
275.2
Example 3
2.94
906.5
270.5
Example 4
2.95
894.1
265.7
Example 5
2.94
922.1
278.6
Example 6
2.95
901.3
267.8
Comparative example 1
2.81
793.5
206.3
Comparative example 2
2.88
806.8
211.5
Comparative example 3
2.92
838.3
238.9
Comparative example 4
2.75
714.3
188.4
Comparative example 5
2.95
840.2
240.4
Comparative example 6
2.92
831.4
235.6
Comparative example 7
2.95
848.5
251.8
Comparative example 8
2.91
864.3
250.3
Comparative example 9
7.85
872.4
271.4
From the comparison of examples 1 to 6 with comparative example 9 in Table 1 above, it can be seen that the seamless aluminum alloy pipe I of the present application not only has a low density of 2.92 to 2.95g/cm3The density was reduced by about 62% compared to the steel roll of comparative example 9. The seamless aluminum alloy pipe I also has good tensile strength, the tensile strength is 886.4-922.1MPa, compared with the steel roller of the comparative example 9, the tensile strength is improved by 1.6-5.7%, and simultaneously, the seamless aluminum alloy pipe I also has higher Vickers hardness, the Vickers hardness is 260.3-278.6HV, compared with the steel roller of the comparative example 9, the Vickers hardness of the seamless aluminum alloy pipe I is almost the same as that of the steel roller. It is thus shown that the seamless aluminum alloy pipe I of the present application can be applied to the requirements for basic use in a gravure printing roll.
In particular example 2, from Si: 4.8%, Cu: 3.2%, Mn: 2.8%, Mg: 9.5%, Ti: 2.4%, Sb: 0.5%, Ni: 0.4%, Co: 0.22%, Cr: 0.25%, Zr: the seamless aluminum alloy pipe I prepared from the components with the weight percentage of 0.13 percent, the unavoidable impurity elements less than or equal to 0.5 percent and the balance of Al has better tensile strength and Vickers hardness, so the seamless aluminum alloy pipe I is more suitable for serving as the basis of a gravure printing roller.
Further, by comparing the example 2 with the comparative examples 1 to 4, it can be seen that the tensile strength and the vickers hardness of the seamless aluminum alloy pipe I are obviously improved by adding Mn, Ti and Zr into the seamless aluminum alloy pipe I and by the synergistic interaction among Mn, Ti and Zr, so that the service life of the obtained gravure printing roller is prolonged when the seamless aluminum alloy pipe I is used as a basis of the gravure printing roller.
Comparing example 2 with examples 5 to 8, it can be seen that the seamless aluminum alloy tube has 9.0 to 10.0% of Mg and 4.5 to 5.0% of Si, and the performance of the seamless aluminum alloy tube can be remarkably improved, thereby increasing the service life of the gravure printing plate roll.
The roller manufacturing methods of seamless aluminum alloy pipes in examples 7 to 13 were respectively adopted to fixedly arrange a nickel layer I and a nickel-silicon carbide-titanium carbide composite layer on the surface of an aluminum alloy test block with the size of 50mm × 25mm × 5mm, the aluminum alloy test block was formed by processing the seamless aluminum alloy pipe I in example 2, and the vickers hardness of the nickel-silicon carbide-titanium carbide composite layer and the bonding strength between the aluminum alloy test block and the nickel-silicon carbide-titanium carbide composite layer, the nickel layer I and the composite layer were measured, and the measurement results are shown in table 2.
Wherein, a Vickers hardness tester HV-50A type of a Shandong mountain test instrument Co., Ltd is adopted to detect the Vickers hardness; the bonding strength was tested according to GB/T8642-2002 "determination of thermal spray bonding strength".
TABLE 2 detection results of nickel-silicon carbide-titanium carbide composite layer
As can be seen from the above Table 2, in the preparation method of examples 7-9, the nickel layer I and the nickel-silicon carbide-titanium carbide composite layer are sequentially and fixedly arranged on the surface of the aluminum alloy test block, the Vickers hardness is 398.5-412.3HV, in the preparation method of examples 10-12, the nickel layer I, the composite layer or the nickel layer are sequentially and fixedly arranged on the surface of the aluminum alloy test block, the Vickers hardness of the alloy is 331.2-347.4HV, so that the Vickers hardness of the surface of the aluminum alloy test block can be improved by fixedly arranging the nickel layer I and the nickel-silicon carbide-titanium carbide composite layer on the surface of the aluminum alloy test block in sequence, further, a nickel layer I and a nickel-silicon carbide-titanium carbide composite layer are sequentially and fixedly arranged on the surface of the seamless aluminum alloy pipe I, so that the Vickers hardness of the seamless aluminum alloy pipe I can be improved, it is probably due to the synergistic effect among nickel, silicon carbide and titanium carbide in the composite layer.
Further, by adopting the preparation method of the embodiment 7, the nickel layer I and the nickel-silicon carbide-titanium carbide composite layer are sequentially and fixedly arranged on the surface of the aluminum alloy test block, the Vickers hardness is 401.2HV, and compared with the method that the nickel layer I and the nickel-silicon carbide-titanium carbide composite layer are not fixedly arranged in the embodiment 2, the Vickers hardness is improved by 45.6%.
Further, by adopting the methods of examples 7, 10, 11, 12 and 13, in which the nickel layer I and the composite layer were fixed in this order on the surface of the aluminum alloy test piece, and the raw material of the composite layer contained silicon carbide and titanium carbide, the bonding strength between the composite layer and the nickel layer I was reduced, but the nickel layer I provided between the aluminum alloy test piece and the composite layer could compensate for the influence of the composite layer containing silicon carbide and titanium carbide on the bonding strength.
Application example
Application example 1
A gravure printing roller is shown in a schematic structural diagram of fig. 1, and comprises a hollow cylindrical roller 1 with openings at two ends, a nickel layer II2, a copper layer 3 and a protective layer 4 which are fixedly arranged on the peripheral surface of the hollow cylindrical roller with openings at two ends in sequence from inside to outside. The protective layer 4 is a chromium layer, the roller 1 which is hollow cylindrical and has two open ends is the seamless aluminum alloy pipe I11 obtained in the embodiment 2, and the roller 1 which is made of the seamless aluminum alloy pipe has the inner diameter of 300mm, the outer diameter of 360mm and the length of 1200 mm.
The gravure printing roller adopts the roller 1 as the basis of the gravure printing roller, the roller 1 adopts a seamless aluminum alloy pipe I11, and the density of the seamless aluminum alloy pipe I11 is 3.0g/cm3Compared with a steel roller adopted by the roller 1, the seamless aluminum alloy pipe I11 adopted by the roller obviously reduces the unit volume weight of the roller 1, so that the transportation amount of the gravure printing roller in one-time air transportation can be increased. Meanwhile, a nickel layer II2 is arranged between the seamless aluminum alloy pipe I11 and the copper layer 3, so that the overall use strength of the gravure printing roller is ensured, and the service life of the gravure printing roller is prolonged.
A processing technology of a gravure printing plate roller comprises the following steps:
s1, ultrasonically washing the roller 1 made of the seamless aluminum alloy pipe, then respectively installing plugs for protecting the inner peripheral surface of the roller 1 made of the seamless aluminum alloy pipe at two ends of the roller 1 made of the seamless aluminum alloy pipe, and then grinding the outer peripheral surface of the roller 1 made of the seamless aluminum alloy pipe.
S2, performing ultrasonic water washing, acid washing and electrolytic degreasing on the outer peripheral surface of the roller 1 made of the seamless aluminum alloy pipe processed in the step S1, and then thermally spraying nickel on the outer peripheral surface of the roller 1 made of the seamless aluminum alloy pipe to form a nickel layer II2, wherein the thickness of the nickel layer II2 is 5 microns; the thermal spraying nickel adopts oxyacetylene flame spraying, the spraying angle is vertical spraying, the spraying distance is 230mm, the temperature is raised to 410 ℃ after the nickel is sprayed, and the heat preservation treatment is carried out for 2h, so that a nickel layer II2 is formed.
S3, thermally spraying copper on the outer peripheral surface of the nickel layer II2 processed in the step S2 to form a copper layer 3, wherein the thickness of the copper layer 3 is 130 mu m;
the thermal spraying copper is sprayed by oxyacetylene flame, the spraying angle is vertical spraying, the spraying distance is 230mm, the temperature is raised to 410 ℃ after the copper is sprayed, and the thermal insulation treatment is carried out for 3 hours, so that the copper layer 3 is formed.
S4, grinding the copper layer 3 processed in the step S3, then coating laser sensitive glue on the outer peripheral surface of the copper layer 3, wherein the laser sensitive glue is RD-PFR/PFS and is selected from Shenzhen Shanghan photosensitive science and technology GmbH, drying to form a glue layer, the thickness of the glue layer is 0.15mm, and according to the pattern, a mask plate is utilized to develop the pattern on the glue layer by adopting laser, the copper layer 3 at the pattern is exposed, and the glue layer at the non-pattern is reserved.
S5, after the treatment in the step S4, spraying and corroding the copper layer 3 at the position where the pattern is exposed, then carrying out ultrasonic water washing, and then removing the glue layer at the position where the pattern is not exposed to form the pattern at the position where the copper layer 3 is exposed;
the spray corrosion adopts corrosive liquid, the corrosive liquid is ferric trichloride solution with Baume degree of 36, the corrosion time is 10s, and the corrosion temperature is 30 ℃.
S6, carrying out ultrasonic water washing and electrolytic degreasing on the outer peripheral surface of the copper layer 3 processed in the step S5, then thermally spraying chromium on the outer peripheral surface of the copper layer 3 to form a chromium layer, wherein the thickness of the chromium layer is 5 microns, and then polishing the chromium layer and removing plugs to obtain a gravure printing plate roller;
the thermal chromium spraying adopts oxyacetylene flame spraying, the spraying angle is vertical spraying, the spraying distance is 230mm, the temperature is raised to 410 ℃ after the chromium spraying, and the thermal insulation treatment is carried out for 1h to form the chromium layer.
Application example 2
A gravure printing roller is shown in a schematic structural diagram of fig. 2 and comprises a hollow cylindrical roller 1 with openings at two ends, a nickel layer II2, a copper layer 3 and a protective layer 4 which are fixedly arranged on the peripheral surface of the hollow cylindrical roller with openings at two ends in sequence from inside to outside, wherein the protective layer 4 is a chromium layer. The hollow cylindrical roller 1 with two open ends is the seamless aluminum alloy pipe II with two coatings obtained in example 7.
The roller 1 is a seamless aluminum alloy pipe II with two layers of coatings, and sequentially comprises a seamless aluminum alloy pipe I11, a nickel layer I12 closely adjacent to the outer peripheral surface of a seamless aluminum alloy pipe I11 and a nickel-silicon carbide-titanium carbide composite layer 13 closely attached to the outer peripheral surface of a nickel layer I12 from inside to outside.
Performance testing of coatings
The seamless aluminum alloy tube-made rollers obtained in example 2 and comparative examples 1 to 4 and the steel roller obtained in comparative example 9 were processed into test blocks of 50mm × 25mm × 5mm, and in the gravure roll processing process of application example 1, the nickel layer II was fixedly provided on the surface of the test block by the method of step S1 and step S2, and the bonding strength between the test block and the nickel layer II was measured, and the measurement results are shown in table 3.
Wherein, the bonding strength is detected according to GB/T8642-2002 'determination of thermal spraying bonding strength'.
TABLE 3 results of measurement of bonding strength
Detecting items
Bonding strength/(MPa) between the test piece and the nickel layer II
Example 2
45.5
Comparative example 1
42.8
Comparative example 2
43.1
Comparative example 3
43.6
Comparative example 4
41.1
Comparative example 9
22.8
As can be seen from table 3 above, the test block obtained by processing in example 2 is adopted, and the nickel layer II is fixedly arranged on the surface of the test block, and the bonding strength between the test block and the nickel layer II is greater than 45MPa, specifically 45.2MPa, so that the test block and the nickel layer II have good bonding strength, and thus the roller made of seamless aluminum alloy can be used as a base of a gravure printing roller, and the gravure printing roller is finally obtained.
By adopting the test block processed in the comparative examples 1 to 4, and the nickel layer II is fixedly arranged on the surface of the test block, the bonding strength between the test block and the nickel layer II is 41.1 to 43.6MPa, therefore, the bonding strength between the test block and the nickel layer II can be increased by the synergistic interaction among Mn, Ti and Zr in the test block processed in the example 2, Mn, Ti and Zr are added into the raw material, and the bonding strength between the test block and the nickel layer II is improved by 5.6 to 9.9 percent, so that the bonding strength between the test block and the nickel layer II can be improved by adding Mn, Ti and Zr into the raw material of the seamless aluminum alloy pipe I.
Furthermore, the reason that the roller made of the seamless aluminum alloy has higher hardness is that the bonding strength between the roller made of the seamless aluminum alloy and the nickel layer II is reduced due to the plasticity of the roller made of the seamless aluminum alloy, so that the bonding strength between the roller made of the seamless aluminum alloy and the copper layer II is improved, and the service life and the practicability of the gravure printing roller can be improved.
The present embodiment is only for explaining the present application, and it is not limited to the present application, and those skilled in the art can make modifications of the present embodiment without inventive contribution as needed after reading the present specification, but all of them are protected by patent law within the scope of the claims of the present application.
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