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1、 The Mechanics of theAluminum Sheet Rolling Process铝板带轧制工艺机理 The Mechanics of the Aluminum Sheet Rolling Process 铝板带轧制工艺机理 Index索引1. Preamble导言2. Casting2.铸造 (i) Description(i) 描述 (ii) Metal Filter (ii) 金属过滤器 (iii) Casting Machines (iii) 铸造机 (iv) Continuous Casters(iv) 连续铸造机3. Scalping3.铣削 (i) Surfa
2、ce (i) 表面 (ii) Edge (ii) 边 (iii) Head and Tails (iii) 头和尾 4. Preheating and Homogenizing4.加热和均热5. Hot lines5. 热轧线 (i) Hot line table Geometry (i) 热轧线辊道几何学 (ii) Configuration (ii) 配置 (iii) Hot mill roll roughness(iii) 热轧机轧制粗糙度 (iv) Roll grinding (iv)磨辊 (v) Scratch brushes (v) 钢丝刷6. Hot rolling6.热轧7.
3、Cold rolling7.冷轧 (i) Reductions (i) 压下量 (ii) Shape (ii) 形状 (iii) Surface finish (iii) 表面光洁度 Fourth Annual Hiarc MeetingOctober 16-18, 1996Toronto, Canada 第四届Hiarc年会 1996年10月16日到18日 多伦多，加拿大The mechanism of the aluminum sheet rolling process 铝板带轧制工艺机理1. Preamble1. 导言During the rolling of aluminum shee
4、t, particularly hot rolling many problems may arise. There is frequently an initial tendency to ascribe many of these to the coolant. Some of the issues in the circumstances are not coolant related. This paper describes the treatment of aluminum from casting to cold rolling in an attempt to give som
5、e insight into the many problems that can arise in the rolling process.铝板带轧制过程中，尤其是热轧，会出现很多问题。经常性的最初倾向是，把这些问题的多数归因于冷却液。一些问题所处的环境与冷却液无关此文件描述了从铸造到冷轧的铝处理方法，试图就轧制过程中可能会出现的许多问题给出一些深刻的见解。 2. Casting2.铸造(i)Description(i)描述For the purposes of rolling sheet or plate as opposed to extruding, aluminum is mainl
6、y cast by the V.D.C. or vertical direct chill process which produce large block of up to 30 inches thick suitable for rolling, or to a lesser extent may be produced by continuous casting which makes coil with a metal thickness of between a l/4”to 3/4”.轧制铝带材或铝板的目的，不允许有挤压，铝主要是由立式直冷铸造机铸造的，立式直冷铸造机可生产适用于
7、轧制厚度达30英寸的大铝块，或在较小程度上也可通过连续铸造生产厚度在l/4到3/4英寸之间的卷材。The molten metal which is used for casting may be any one of series of alloy from 1xxx through 2, 3, 4, 5, 6 to 7xxx. The most common are 1xxxs which are largely pure with minor alloying and are used for foil stock, to 3xxxs used extensively as 3004 f
8、or body stock to 5xxxs as 5182 for can end stock and 5086 as a high tensile sheet. Series 2xxx and 6xxx are heat treatable and besides magnesium have higher concentrations of copper. The 7xxx series alloys with significant zinc are used in some places for armour plate.用于铸造的熔化金属可以是从1XXX到7XXX的任何一系列合金。
9、最普通的是1XXX系列，它的纯度很高、合金很少，被用作铝箔原料；3xxx系列如3004大量用于罐体坯料 ；5xxx系列如5182用于罐盖料以及5086用于高强度拉伸板。2xxx和6xxx系列可进行热处理，除了镁之外，还含较高浓度的铜。7xxx系列含有大量的锌，用于需要装甲板的地方。The melting point for most alloys falls within the range 1125 to 1215oF 8or 610 to 660oC)大多数合金的熔点在1125到 1215oF 或 610 660oC范围内。During the melting and casting op
10、eration due attention must be paid to two parameters.在熔铸操作过程中必须关注两个参数。l Hydrogenl 氢 Firstly hydrogen which is absorbed by the metal with increased solubility the molten metal temperature increase. As the molten metal cools any dissolved hydrogen will come out of solution and forms small bubbles in t
11、he solidified metal called occlusions. 0n the rolling surface defects result.首先，氢被金属吸收增加，其溶解性随熔铸金属温度升高而升高。熔铸金属冷却时，氢会从溶液中挥发出来，在凝固的金属上形成小气泡被称作吸留物，这种吸留物会影响轧制表面质量，成为表面缺陷。l Aluminum Oxidel 氧化铝Secondly the presence of aluminum oxide which forms readily in oxygen and of course in air.第二，氧化铝的存在，氧化铝在氧气中形成，当然
12、在空气中也形成。Aluminum oxide can exist in any size particles called inclusions. Considering that the thinnest foil rolled is about 0.2 thousandth of an inch (5.5 microns)and that the thickness of a drawn and ironed aluminum can wall is about this thickness then inclusion over about half this size are unac
13、ceptable.氧化铝能够以任何尺寸的颗粒存在，称之为夹杂物。考虑到最薄的轧制铝箔的厚度大约是千分之0.2英寸（5.5微米）并且拉深铝罐壁的厚度大约也是这个厚度，那么，如果夹杂物的厚度超过此尺寸的一半将不能被接受。(ii) Metal Filters金属过滤器Figure 1 shows the outline of the two most common aluminum filters used to remove hydrogen and assist in the extraction of aluminum oxide from the molten metal.图1显示了两种最普
14、通的用于除去氢和帮助从金属熔化物中除去氧化铝的铝过滤器的外形图。l Gas Filtersl 气体过滤器One is called a SNIF previously made by Union Carbide and the other an Alpur made by Pechiney (Alcoa has a similar unit called a 622). These filter all operate on the same basis, that is passing sheared bubbles of Argon Gas with 2% to 3% of chlorin
15、e through the molten metal. This should extract any hydrogen to less than 0.2 milliliters (ccs) per 100 grams of metal (in fact to much less than this is standard) and lifts a high percentage of all aluminum oxide to the surface of the filters where it can be skimmed off.一个被称之为SNIF，先前由Union Carbide制
16、造，另一个叫Alpur,由Pechiney生产（Alcoa拥有类似装置，叫做622）。所有这些过滤器操作基理相同： 将氩气及浓度为2到3的氯的混合气泡通过金属熔化物。这将取出金属中的氢，使之少于每100克0.2毫升（ccs）的氢（实际上甚至可以比这标准更少），及提升所有氧化铝到过滤器的表层位置，然后可以撇去。l Ceramic Foam FiltersIn addition to the above type of filter most plants use a CFF (ceramic foam filter) or a TKR (aluminum oxide or silicon car
17、bide) filter as a final filter. The first is a probability filter in the sense that it is self blinding while the second is a positive screen.陶瓷泡沫过滤器除了以上类型的过滤器，大多数工厂使用CFF(陶瓷泡沫过滤器)或TKR（氧化铝或碳化硅）型过滤器作为最终选择。CFF(陶瓷泡沫过滤器)是一种几率性过滤器（因为它本身是一些盲管），而TKR（氧化铝或碳化硅）是一种绝对的过滤器。The most common CFFs are made by Selee a
18、nd Foseco while TKR filters which were first developed by Keiser Aluminum are widely used and marketed under that name in Japan.最常见的CFF过滤器由Selee 和 Foseco生产制造，而TKR过滤器最先由Keiser铝业公司研制，并在日本被广泛使用和以此冠名销售。The effectiveness of the above type of arrangement is that in the worlds biggest product which is can
19、body stock the occurrence of what is called split flanges during the body making process, has gone from 1 in 10,000 in 1980 to about ! in 1,000,000 as we speak.上述类型配置的效果是，对于世界上最大用量的罐体料产品中出现的问题，被称为罐体制造过程的开裂问题，像我们说的那样，已经从1980年的1/10,000降到目前的1/1,000,000。A note of caution however is appropriate, and that
20、 is, that not all rolling plants have these facilities. In the absence of the above, surface quality can be adversely affected.但是，有一条注意事项：这就是，并不是所有的轧机工厂都有这些设备。没有上述设备，表面质量将受到不利影响。(iii) Casting Machines铸造机V.D.C Casters V.D.C铸机Figure No.2 depicts the type of machinery which is used for casting. The V.D
21、.C has had several developments over a period of years. The basic principle is to contain and cool the molten aluminum in a vertical drop (horizontal can be done but it is generally not favored). Initially the molds were copper, then aluminum with rear water jackets and bottom mounted water sprays.
22、Lubrication was and is done by pre-greasing the molds or injecting rape seed or castor oil over the contact surface.图2描述了用于铸造的机器类型。V.D.C铸机在几年中已经经历了多次发展。基本原理是一个坩埚盛放和冷却熔化铝，垂直落下并凝固（水平方向能够实现但是一般不被采用）。最初结晶器为铜质，然后是带水套及底部装有喷水器的铝质材料。由提前对结晶器加好油脂或对接触表面注入油菜仔或蓖麻油来实现润滑。The object is to freeze the peripheral alum
23、inum before it leaves the mold and to complete the solidification with the water sprays. To produce a good block surface the following parameters need attention:-目的是在脱离结晶器前将外围铝冷冻，使其在水喷射下完整凝固。形成良好铸锭表面，需要注意以下参数：l Quick solidification.快速凝固This of course is inhibited by the aluminum mold.这当然是在铝质结晶器/模具内完
24、成。l Non binding of the contact surface接触表面无粘滞Lubrication, mold material and drop speed are factors.润滑，模型材料和下落速度是其影响因素。l Safety water flow可靠的流动水Unsteady flow affects the rate of cooling and solidification. Pressurization of the water head is usually done by a gravity tower for constancy and safety.不稳
25、定的水流会影响冷却及凝固速率。水位差增压的持续性和可靠性通常由重力塔完成。l Constant drop speed恒定的下落速度Usually a hydraulic ram, single (better) or double acting is use. Motor drives with wire hoist are used occasionally.通常液压缸，使用单向（最好）或双向执行机构。偶尔使用带电缆提升的电机驱动。Failure to observe the above results in what is called blebs and cold shuts or ev
26、en a bleed out which means molten aluminum into the pit and the risk of an explosion. It is generally accepted that fast casting means a better surface finish and of course higher production. A good casting speed is just over 2 inches per minutes.如果不能遵守以上内容，将导致叫做“水泡”现象和冷隔或甚至是漏铝，这意味着熔化铝流入铸井，有爆炸的危险。通常
27、认为：快速铸造会形成较好的表面光滑度（表面抛光），当然也有较高的产量。好的铸造速度恰恰超过每分钟2英寸。l Chill Zone激冷区More importantly metal cast in this manner produces two zones near the surface of the cast block called a chill zone (on the outside) and a liquation zone ( inwards of this).最重要的是在这种方式下金属铸锭在接近铸锭块的表面形成两个区域，一个为激冷区（外层），一个叫做熔析区（内层）。The m
28、etal in these zones, particularly the very outside, where elements like magnesium，silicon and iron have come out of solution, due to slow cooing, is very hard and brittle and is particularly unsuitable for rolling, and if not removed by scalping will produce a quite unsatisfactory surface finish on
29、rolling. 这两个区域的金属，特别是区域最外层，在此区域，由于缓慢冷却，如镁，硅和铁元素从溶液中析出，非常硬和脆，特别不适合进行轧制，如果不铣削将其除去，在轧制时将会产生令人不满意的表面光滑度。 Two subsequent developments have seen the quality of cast block improve considerably. They are: -以下两种发展极大的改善了铸块的质量。这两种发展是：l EMC or Electro Magnetic CastingEMC或电磁铸造This is where the molten is held sus
30、pended in a high frequency (1,000 kilo hertz) electro magnetic field and cooled by direct water sprays. There is of course no metal contact and cooling is as swift as can be achieved by direct spraying. This was invented by Russian, Getselev in about 1969 and while expensive is used widely in the US
31、A and Europe but not in Japan. 使熔化物悬浮在高频率（1000千赫兹）的电磁场内，由喷射水直接冷却，当然没有金属接触，冷却是由尽量快的直接喷射完成。这项技术由俄国人Getselev大约在1969年发明，并在美国和欧洲被广泛使用，不包括日本。l LHC or Low head CarbonLHC或低液面石墨复合材料结晶器In this method the metal is contained by a porous carbon band through which oil and nitrogen are passed. There is little or n
32、o metal contact and cooling is done by direct water sprays. This development was carried out by Wagstaff and has been available for about 2 years. In both the above methods the combined chill and liquation zones are very small. With EMC the zone depth is negligible and with LHC perhaps a few thousan
33、dths of an inch.在这种方法中，金属被包含在油和氮可通过的多孔可渗透碳夹层中。有很少或没有金属接触，由喷射水直接冷却。这种技术由Wagstaff研发，已经应用了两年。在以上两种方法中，激冷和偏析区非常狭小。在EMC中两种区域深度可以忽略，在LHC中或许有千分之几英寸的区域。(4) Continuous Casters连续铸造机There a three recognized form of continuous caster. They are the roll caster, the Hazelett steel belt caster and the Alluisse/ La
34、uener block caster. 有三种公认的连续铸造机形式，分别是辊式连铸机，Hazelett钢带连铸机和Alluisse/ Lauene块式连铸机Figure No.3 shows these casters.图3给出了这些连铸机。Roll Caster辊式连铸机The roll caster normally has 2 cast iron water cooled work rolls reducing hot metal to a strip about a 1/4 inch thick. Two common manufacturers are Hunter and Pech
35、ineyo. The cast strip passes through a 2 or 4 high hot reduction mill which can reduce the strip to about 1/8” or 2 meters with an annual output of 50 million pounds. Usual alloy are 1xxx, 3xxx, and 5005. No 3004 or 5182 is rolled and very little 5052.辊式连铸机通常有2个水冷铸铁工作辊，将热金属轧制为1/4英寸厚的板材。两个常见制造商为Hunte
36、r公司Pechineyo公司。板材铸件通过2或4辊热板材轧机， 使板材轧成1/8”或两米，年产量50000万磅重。通常合金种类为1XXX系列，3XXX系列和5005。没有3004或5182被轧制，有很少的5052采用这种方式。The only application for hot mill coolant is in the hot reduction mill. Quaker has been active in this field. 热轧冷却液只用于热板材轧机，Quaker在这一领域非常活跃。l Hazelett CasterThe Hazelett Caster uses steel
37、 belt to form a 3/4” thick sheet which then passes through a 4 high hot reduction mill reducing the sheet to about a 1/4” thick for coiling or cold reduction. Sheet profile is a problem. Can sheet is not viable product. Again there is an application for hot mill coolant. Hazelett连轧机使用钢带来冷却铸造3/4”厚的板材
38、，然后通过4连轧轧机轧制成成卷或冷轧1/4”厚的材。卷材凸度是一个问题，罐料板材产品不能采用这种方式，热轧冷却液再一次被应用。l Aluisse/Lauener CasterThe Aluisse/Lauener caster uses nickel plated copper blocks to form a sheet about 3/4”thick. A 4 high hot reduction mill follows reducing the sheet to about 1/4”. Surface quality may be a problem and maintenance i
39、s high. Again there is an application for hot mill coolant.Aluisse/Lauene连铸机使用镀镍的铜块来冷却铸造3/4”厚的板材，之后经过4辊热连轧将板材轧制1/4”厚。表面质量可能是一个问题并且维护费用高，热轧冷却液再一次被应用。There are only 2 such caster in existence. A 32” wide caster at Golden and a 64” at San Antonio where an attempt was made to make can body stock from 50
40、17. Can end stock was tried on both casters but only small width 5182 seems to have succeeded at Golden.只有两种类型的连轧机存在，一个是Golden的32”宽的连轧机，另一个是San Antonio的64”宽的连轧机。试图使其能够使5017变成罐体材料，两种类型连铸机都尝试过生产罐盖材料，但是只有小宽度的5182带材在Golden试轧取得成功。Both the above types of casters seemingly have large capacities up to 200 m
41、illion pounds per annum and of course could produce some aluminum feed at very low cost. 以上两种类型的连铸造具有每年高达200000万磅的产能，当然也可以在非常的低成本下生产某些铝料。l Thin-Strip Castersl 薄带铸机These casters producing strip at about 1/10 thick at five times the normal speed have been recently developed. A Davy model at Granges Sw
42、eden produces foil stock. It remains to be seen whether there will be a challenge to can stock. 这种能够以一般速度的5倍生产约1/10厚的卷材薄带铸机已经被研发出来。在瑞典Granges，一种为Davy型的连铸机能够生产铝箔坯料，是否能够生产罐坯料将会是一个挑战。l Metallurgyl 冶金A peculiar attribute of continuous cast aluminum is its ability to work harden at about twice the rate o
43、f V.D.C. cast metal. While not a problem with soft alloys or those with a high aluminum content，it is however disadvantageous with alloys causing a need for additional annealing during rolling. 连续铸铝的一个特性是能够在V.D.C.铸造机铸造金属两倍率速度下变硬，对软合金或铝含量高的合金不成问题，但弱点是合金在轧制过程中需要退火处理。l Foil Stockl 铝箔坯料In USA nearly all
44、 foil stock is made with roll caster. The alloy is chiefly 1xxx. The surface course is not scalped and some oxide may persist. Minimum finished foil gauge rarely falls below 6.5 microns whereas Japanese and European foil mills roll block for foil down to 5.5 microns. This situation is probably more
45、forgiving for the USA product and of course there is a significant cost saving.在美国几乎所有的铝箔坯料都由辊式连铸机制造，合金主要是1XXX系列。表面未经铣削,可能存在许多氧化物。最小的成品铝箔厚度很少在6.5微米以下，但日本和欧洲的铝箔轧机生产的铝箔达到5.5微米，这种情况对美国产品可能更加宽松，节省了大量成本。3. Scalping铣削(i) Surface表面Not only is the depth of the chill and liquidation zones affected by the nat
46、ure of the casting process, but there is also a variation caused by alloy content. With normal V.C.D. casting （i.e. not EMC or LHC）there is a need to remove 3/8” of the surface of lxxx series alloys and l/2” or more for all others. Figure No 4 shows a diagrammatic representation of double sided hori
47、zontal and vertical surface scalping.不仅是激冷和偏析区域的深度受铸造过程/工艺的影响，也有合金成分引起的变化。正常V.C.D.铸造（也就是非EMC或LHC）铸锭，需要除去1XXX系列合金3/8”的表面，其他系列合金出去l/2”或更多的表面。图4说明了水平和垂直双侧的铣削。The only other concern arising with VDC casting is the question of geometric linearity or block squareness. If this is not within reasonable limits then additional scalping may be called for.唯一与其他VDC铸造所引起的关注问题是几何线性或铸块垂直度，如果没有控制在合
