ã€China Aluminum Industry Network】 1 Foreword Photovoltaic energy is a new type of non-polluting green energy. It is one of the seven emerging industries that China has identified as its key development. The pillars and rods of its battery panel frame and its supporting structure are The support legs, etc., can be manufactured by extrusion using aluminum alloy materials that are currently more economical and durable. They are new markets for the application of aluminum alloy materials and have been applied globally. The following briefly introduces the production process technology and key nodes of the solar photovoltaic aluminum manufacturing process for reference.
2 Optimization of aluminum extrusion die design and manufacturing Extrusion die is an important tool to ensure the shape and dimensional accuracy of solar photovoltaic aluminum profiles. Extrusion die design and manufacturing quality is an important guarantee for high quality, high output, low consumption, high efficiency, and low cost for extrusion production. Therefore, to produce and manufacture high-precision photovoltaic aluminum alloy profiles, it is necessary to optimize the design and manufacture of extrusion dies.
2.1 The use of advanced extrusion die manufacturing equipment High-precision advanced extrusion die processing equipment is a prerequisite to ensure the qualification of metal extrusion die. Therefore, the production of photovoltaic aluminum alloy profiles should use advanced mold processing equipment, such as CNC, slow walking wire cutting, three-axis machining center, EDM machining center, etc. to improve the processing precision and performance of the mold.
2.2 Appropriate layout of die holes In order to ensure good symmetry of photovoltaic aluminum profiles and improve production efficiency and yield, the arrangement of die holes must abide by the principle of central symmetry and use multi-mode holes symmetrically arranged. Design the mould process and try to design the bridge position on the non-decorative surface of the profile to avoid exposure of defects.
2.3 Optimization of the extrusion die design Work zone is the part that stabilizes the dimensions of the product and guarantees the surface quality of the product. When designing the length of the mold working belt, it is necessary to reduce the drop as much as possible, to be gentle in length change, and to use the obstruction angle and the promoting flow angle to reduce the metal flow rate, and to achieve uniform metal flow and improve the surface quality of the profile.
3 The chemical composition is controlled by using 6063 aluminum alloy material. The chemical composition control is shown in Table 1.
Practice shows that the use of 6063 aluminum alloy has become an important choice for producing high-precision photovoltaic aluminum alloy profiles. 6063 aluminum alloy belongs to Al-Mg-Si series heat treatable aluminum alloy. The alloy reinforced phase is Mg2Si. It has good extrusion performance and low quenching sensitivity, good high temperature plasticity, wide quenching temperature range, and low critical quenching rate. In the 6063 aluminum alloy composition range specified in the national standard GB/T3190, different values ​​of the chemical composition will result in different material properties. When the chemical composition is in a large range, the performance difference will fluctuate within a wide range. As a result, the overall performance of the profile can be difficult to control. In order to ensure the precision of photovoltaic aluminum alloy profiles, the chemical composition of the alloy must be determined in strict accordance with the corporate control standards.
4 Smelting, casting and ingot homogenization process 4.1 melting, refining process Rotary heat storage smelting furnace, melting temperature of 720-760 °C. At a temperature above 720°C, high-purity nitrogen is used to inject the refining agent into the refining agent for 15 minutes. The amount of the refining agent is 0.08% of the melt weight. After refining, the mixture is electromagnetically stirred for 15 minutes, and the aluminum liquid is allowed to stand for 20-30 minutes. Sampling inspection strictly controls the chemical composition of the aluminum alloy solution so that the material achieves the required mechanical properties.
4.2 The casting process uses a semi-continuous direct water-cooled casting method. The direct water cooling method has a large cooling intensity and a fast cooling rate, which refines the casting structure and increases the density of the structure, thereby improving the mechanical properties and the heat treatment effect of the ingot. Control casting temperature 710-730°C, casting speed 50-70mm/min, cooling water pressure 0.1-0.3MPa. In order to reduce the tendency of hot cracks and improve the chemical composition of the alloy, online addition of aluminum-titanium-boron wire, the addition speed is 1700-2000mm/min.
4.3 Homogenization treatment of casting rods In order to reduce and eliminate intragranular segregation of ingots and to improve the chemical composition and non-uniformity of the microstructure, aluminum alloy casting rods are homogenized. The technical condition of the control is to heat the cast rod to 540-550° C., hold it for 8-10 h, and the strong wind cooling and water mist cooling. After the homogenization annealing, the cooling should be accelerated to ensure the uniformity of color after anodizing.
5 Extrusion and aging process technical conditions Control 6063 aluminum alloy extrusion, online quenching and aging process technology, to control the temperature of the cast rod heating: 440-480 °C; mold heating temperature: 450-480 °C, mold Heating time less than 5h; extrusion tube heating temperature 460-500 °C; extrusion speed: 12-18m/min; outlet temperature 510-550 °C; cooling method for online air cooling or water mist cooling; After the aging treatment: control temperature is 200 ± 5 °C, holding time: 3h. The combination of solution treatment and extrusion process of 6063 aluminum alloy can avoid grain growth and improve the physical and mechanical properties of profile products.
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