Patent Application
20240200167
The present disclosure relates to an aluminum matrix composite (AMC), and in particular to an AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, and a preparation method thereof.
With the development and application of the fifth-generation mobile communication technology (5G technology), the power consumption of an active antenna unit of a 5G base station is 3 times the power consumption of an active antenna unit of a 4G base station (the power consumption of an active antenna unit of a single 5G base station reaches 1.300 W), and the high power consumption leads to increasing requirements for the thermal conductivity, design, and manufacture of a heat-dissipation substrate material. The current blown aluminum heat-dissipation substrate is a novel phase-change efficient heat-dissipation structure, which is obtained through runner printing, ply-roll cold welding, blowing molding, or the like to manufacture a hollow aluminum plate shell, vacuum infusion of a phase-change working medium, and welding sealing. The blown aluminum heat-dissipation substrate has a thermal conductivity of 50,000 W/(m*K), which is 5 to 10 times of a thermal conductivity of the traditional copper/aluminum extruded heat-dissipation substrate. The blown aluminum heat-dissipation substrate is a brand-new application for 5G base stations. However, the common 3003 aluminum alloy has a relatively-low strength and thermal conductivity, and a phase-change working medium cavity after ply-roll cold welding has low gas tightness, which have become major problems faced by aluminum materials for the current blown heat-dissipation substrate.
The current main methods to improve the performance and yield rate of the blown aluminum heat-dissipation substrate include: improving a strength of an alloy through composition control; and improving the gas tightness through grain refinement and elevation of a temperature for ply-roll cold welding. Invention Patent Application No. CN201910691412.7 discloses a preparation method of a blown water-cooling plate and a composite plate used thereby. In the preparation method, a strength of an alloy is improved by adjusting contents of Mn, Fe, and Cu, alloy grains are refined by adjusting a content of Ti, and the basic ply-roll cold welding performance and yield rate are improved through strict temperature and time control. However, the introduction of a large amount of alloying elements will reduce the thermal conductivity, corrosion resistance, and plastic toughness of an alloy, the grain refinement through single Ti can only lead to a limited effect, and a high ply-roll welding temperature leads to the rapid growth of grains, which is not conducive to the thermal conductivity and formability of an alloy. Therefore, it is urgent to develop a novel aluminum material for a blown heat-dissipation substrate for a 5G base station, and a preparation method thereof.
An objective of the present disclosure is to provide an AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, and a preparation method thereof in view of the shortcomings of the prior art. A strip of the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station can be prepared by an electromagnetically and ultrasonically-controlled twin-roll continuous casting-rolling device developed and designed based on chemical composition designing, in-situ nanoparticle strengthening and refinement, and rare-earth metal (REM) microalloying.
A cast-rolled strip of the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station of the present disclosure can be prepared by an electromagnetically and ultrasonically-controlled twin-roll continuous casting-rolling device developed and designed based on chemical composition designing, in-situ nanoparticle strengthening and refinement, and REM microalloying. The cast-rolled strip of the AMC includes the following components in mass percentage: Si: 1.0 to 1.5, Fe: 0.6 to 1.0, Cu: 0.05 to 0.2, Mn: 1.0 to 2.0. Zr: 0.5 to 1.0. Ti: 0.5 to 1.0. B: 0.5 to 2.0. O: 0.2 to 1.0, Er: 0.05 to 0.3. Sc: 0.05 to 0.3. Y: 0.1 to 0.5. Zn: less than or equal to 0.5, Mg: less than or equal to 0.5. Cr: less than or equal to 0.5, and Al: the balance.
With respect to the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, the chemical composition designing includes: on a basis of a 3003 aluminum alloy for the traditional heat-dissipation substrate, increasing a content of Si to 1.0 wt. % to 1.5 wt. % to further reduce a melting point of the alloy, and adding Zr, Ti, B, O, Er, Sc, and Y to the alloy to achieve the in-situ nanoparticle strengthening and refinement, the REM microalloying, and matrix grain refinement, and improve strength, toughness, and ply-roll weldability of the alloy.
With respect to the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, the in-situ nanoparticle strengthening and refinement includes: producing nano-ZrB2. Al2O3, and TiB2 ceramic particles with high hardness, high thermal conductivity, and low expansibility through a reaction of an in-situ reactive powder with an Al melt. The nano-ceramic particles serve as heterogeneous nucleation cores of α-Al to significantly refine matrix grains, and are finally distributed in grains or at grain boundaries to improve strength and toughness of the composite through an interaction with dislocations; and the nano-ceramic particles synthesized in-situ efficiently refine the matrix grains, significantly increase a grain boundary content, and reduce a ply-roll cold welding temperature. The nanoparticles have a particle size of 10 nm to 100 nm, and a content of the nanoparticles is 1% to 15% of a volume of the composite. The in-situ reactive powder is two to more selected from the group consisting of Co3O4, K2ZrF6, K2TiF6, KBF4, Na2B4O7, ZrO2, B203, and Al2(SO4)3.
With respect to the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, the REM microalloying includes: composite addition of REMs Sc. Er, and Y to the composite, such that the REMs react with Al and Zr to produce nano-Al3Er, Al3Sc. Al3(Er+Zr). Al3(Sc+Zr), and Al3Y REM precipitated phases dispersed in matrix grains, to significantly improve a strength and a work hardening capacity of the composite and enable an excellent ductility; and the addition of the REMs also purifies a melt, eliminate inclusions in pores, improve wettability of in-situ nano-ceramic particles, promote spheroidization of the in-situ nano-ceramic particles, and achieve strengthening and toughening of the in-situ nano-ceramic particles and the REMs in a synergetic and coupled manner.
With respect to the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, the cast-rolled strip of the AMC has a grain size of less than or equal to 60 μm, a tensile strength of more than or equal to 250 MPa, a yield strength of more than or equal to 120 MPa, and an elongation rate of more than or equal to 20%.
With respect to the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, the cast-rolled strip of the AMC has a thermal conductivity of higher than or equal to 250 W/(m*K), which is 30% or more higher than a thermal conductivity (190 W/(m*K)) of a 3003 aluminum alloy.
With respect to the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, a ply-roll welding temperature of the cast-rolled strip of the AMC is lower than or equal to 500° C., and a presence of the in-situ nano-ceramic particles and REM nano-dispersed phases effectively inhibits a growth of grains during ply-roll welding to achieve the high strength, high toughness, high thermal conductivity, and good weldability of the strip of the composite.
A preparation method of the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station described above is provided, where the AMC is prepared by the electromagnetically and ultrasonically-controlled twin-roll continuous casting-rolling device designed, and the preparation method includes the following specific steps:
The electromagnetically and ultrasonically-controlled twin-roll continuous casting-rolling device includes the helical magnetic field, the degassing system, a filtration system, a liquid level control launder, a high-energy ultrasonic generator, a casting nozzle, a casting-rolling machine, and a strip winder, as shown in
Further, a ceramic filter screen is provided in the filtration system.
Further, a shearing machine is provided at a rear end of the casting-rolling machine, and a spraying system is provided at a side of the casting-rolling machine.
In the preparation method of the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, in the step (2), an in-situ reaction is conducted at 850° ° C. to 900° C. for 20 min to 30 min; and in the step (1), an Ar gas with a purity of 99.99% is adopted for degassing, and the hollow blowing rotor has a rotational speed of 300 r/min to 400 r/min.
In the preparation method of the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, in the step (2), the helical magnetic field has a frequency of 15 Hz to 30 Hz and an intensity of 0.3 T to 0.5 T.
In the preparation method of the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, in the step (3), the REM intermediate alloys are added in forms of Al-20Er. Al-5Sc, and Al-10Y.
In the preparation method of the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, in the step (3), the high-energy ultrasonic treatment is conducted with an ultrasonic power of 5 kW to 10 KW and in an ultrasonic mode of continuous ultrasound.
In the preparation method of the AMC with high strength, high toughness, high thermal conductivity, and good weldability for a 5G base station, in the step (4), a temperature of the composite melt in the casting nozzle is maintained at 700° ° C. to 720° ° C.
In the present disclosure, on the basis of a 3003 alloy, a content of Si is increased to reduce a melting point of a grain boundary and a ply-roll cold welding temperature; a nano-ceramic strengthening substance with high strength, high modulus, and high thermal conductivity is in-situ synthesized in the alloy, and the nano-ceramic strengthening substance serves as a heterogeneous nucleation core of Al to refine alloy grains and increase a grain boundary content of the alloy, and is finally distributed in grains and at grain boundaries of a solidified structure in large quantities to reduce a ply-roll cold welding temperature for the alloy, improve the gas tightness, inhibit the growth of recrystallized grains, and improve the strength and toughness of the alloy; and the composite addition of REMs to the alloy can purify a melt, eliminate inclusions in pores, improve the wettability of in-situ nano-ceramic particles, promote the spheroidization of in-situ nano-ceramic particles, efficiently refine the grains, improve the corrosion resistance of the alloy, and produce a large number of nano-dispersed phases in grains, thereby significantly improving the comprehensive performance of the alloy.
The present disclosure may be implemented according to the following examples, but is not limited to the following examples. Unless otherwise specified, the terms used in the present disclosure generally have the meanings commonly understood by those of ordinary skill in the art. It should be understood that these examples are intended only to illustrate the present disclosure and do not limit the scope of the present disclosure in any way. In the following examples, various processes and methods not described in detail are conventional methods known in the art.
A composite was provided, including the following components in mass percentage: Si: 1.2, Fe: 0.8. Cu: 0.1. Mn: 1.5, Zr: 0.8, Ti: 0.8, B: 1.0, O: 0.8, Er: 0.2, Sc: 0.2, Y: 0.2, Zn: 0.2. Mg: 0.2. Cr: 0.2, and Al: the balance.
An industrial pure aluminum ingot 5T was added to an industrial natural gas smelting furnace, heated to 870° C., and maintained at this temperature, then Al-20Si, Al-20Cr, a Fe agent (content: 70%), a Mn agent (content: 70%), pure Cu, pure Zn, and pure Mg were weighed and added, and contents of the alloy components were adjusted to design values; a resulting melt was poured into a holding furnace (850° C.) of an electromagnetically and ultrasonically-controlled twin-roll continuous casting-rolling device, a degassing system and an electromagnetic stirring system were started, and with the help of an Ar gas with a purity of 99.99%, a mixed powder of K2ZrF6. K2TiF6, KBF4, and Na2B4O7 weighed and dried was blown through a degassing pipeline into the holding furnace, such that nano-ZrB2, Al2O3, and TiB2 ceramic particles were produced in-situ in the Al melt, where a total time of blowing the mixed powder into the melt was 30 min. the blowing rotor had a rotational speed of 350 r/min, and electromagnetic stirring was conducted at a frequency of 30 Hz and an intensity of 0.5 T; after an in-situ reaction was completed. Al-10Zr. Al-5Sc. Al-20Er, and Al-10Y intermediate alloys were added, contents of the alloying components were adjusted to design values, and a resulting mixture was allowed to stand at a specified temperature for 15 min; a resulting melt was filtered through a ceramic filter screen, then introduced into a liquid level control launder, and incubated at 710° C., and a high-energy ultrasonic generator was started with an ultrasonic power of 5 kW to allow continuous ultrasound to improve the uniformity of the in-situ nano-ceramic strengthening substance in the melt; and then a 2 cm-thick strip of the composite was produced by a casting-rolling machine. A structure of the cast-rolled strip of the composite was shown in
A composite was provided, including the following components in mass percentage: Si: 1.0. Fe: 0.6, Cu: 0.05, Mn: 1.0, Zr: 0.5, Ti: 0.5. B: 0.5, O: 0.5, Er: 0.05, Sc: 0.05, Y: 0.05, Zn: 0.5. Mg: 0.5. Cr: 0.5, and Al: the balance.
An industrial pure aluminum ingot 5T was added to an industrial natural gas smelting furnace, heated to 900° C., and maintained at this temperature, then Al-20Si. Al-20Cr, a Fe agent (content: 70%), a Mn agent (content: 70%), pure Cu, pure Zn, and pure Mg were weighed and added, and contents of the alloy components were adjusted to design values; a resulting melt was poured into a holding furnace (870° C.) of an electromagnetically and ultrasonically-controlled twin-roll continuous casting-rolling device, a degassing system and an electromagnetic stirring system were started, and with the help of an Ar gas with a purity of 99.99%, a mixed powder of K2ZrF6, K2TiF6, KBF4, and Na2B4O7 weighed and dried was blown through a degassing pipeline into the holding furnace, such that nano-ZrB2, Al2O3, and TiB2 ceramic particles were produced in-situ in the Al melt, where a total time of blowing the mixed powder into the melt was 20 min. the blowing rotor had a rotational speed of 400 r/min, and electromagnetic stirring was conducted at a frequency of 20 Hz and an intensity of 0.3 T; after an in-situ reaction was completed, Al-10Zr. Al-5Sc. Al-20Er, and Al-10Y intermediate alloys were added, contents of the alloying components were adjusted to design values, and a resulting mixture was allowed to stand at a specified temperature for 15 min; a resulting melt was filtered through a ceramic filter screen, then introduced into a liquid level control launder, and incubated at 700° ° C., and a high-energy ultrasonic generator was started with an ultrasonic power of 5 kW to allow continuous ultrasound to improve the uniformity of the in-situ nano-ceramic strengthening substance in the melt; and then a 2 cm-thick strip of the composite was produced by a casting-rolling machine. Test results showed that the cast-rolled strip of the AMC had a grain size of 58 μm, a tensile strength of 250 MPa, a yield strength of 123 MPa, an elongation rate of 26%, and a thermal conductivity of 251 W/(m*K) that was 30% or more higher than a thermal conductivity (190 W/(m*K)) of a 3003 aluminum alloy; and the cast-rolled strip required a ply-roll cold welding temperature of 410° C., and after ply-roll cold welding, the cast-rolled strip had a grain size of 50 μm, a tensile strength of 267 MPa, a yield strength of 134 MPa, and excellent gas tightness after being blown.
A composite was provided, including the following components in mass percentage: Si: 1.5, Fe: 1.0. Cu: 0.2, Mn: 2.0, Zr: 1.0, Ti: 1.0, B: 2.0, O: 1.0, Er: 0.3. Sc: 0.3. Y: 0.5, Zn: 0.1. Mg: 0.1, Cr: 0.1, and Al: the balance.
An industrial pure aluminum ingot 5T was added to an industrial natural gas smelting furnace, heated to 900° C., and maintained at this temperature, then Al-20Si, Al-20Cr, a Fe agent (content: 70%), a Mn agent (content: 70%), pure Cu, pure Zn, and pure Mg were weighed and added, and contents of the alloy components were adjusted to design values; a resulting melt was poured into a holding furnace (890° C.) of an electromagnetically and ultrasonically-controlled twin-roll continuous casting-rolling device, a degassing system and an electromagnetic stirring system were started, and with the help of an Ar gas with a purity of 99.99%, a mixed powder of K2ZrF6, K2TiF6, KBF4, and Na2B4O7 weighed and dried was blown through a degassing pipeline into the holding furnace, such that nano-ZrB2, Al2O3, and TiB2 ceramic particles were produced in-situ in the Al melt, where a total time of blowing the mixed powder into the melt was 25 min. the blowing rotor had a rotational speed of 350 r/min, and electromagnetic stirring was conducted at a frequency of 30 Hz and an intensity of 0.5 T; after an in-situ reaction was completed. Al-10Zr. Al-5Sc. Al-20Er, and Al-10Y intermediate alloys were added, contents of the alloying components were adjusted to design values, and a resulting mixture was allowed to stand at a specified temperature for 15 min; a resulting melt was filtered through a ceramic filter screen, then introduced into a liquid level control launder, and incubated at 730° C., and a high-energy ultrasonic generator was started with an ultrasonic power of 10 kW to allow continuous ultrasound to improve the uniformity of the in-situ nano-ceramic strengthening substance in the melt; and then a 2 cm-thick strip of the composite was produced by a casting-rolling machine. Test results showed that the cast-rolled strip of the AMC had a grain size of 45 μm, a tensile strength of 320 MPa, a yield strength of 183 MPa, an elongation rate of 20%, and a thermal conductivity of 250 W/(m*K) that was 30% or more higher than a thermal conductivity (190 W/(m*K)) of a 3003 aluminum alloy; and the cast-rolled strip required a ply-roll cold welding temperature of 350° C., and after ply-roll cold welding, the cast-rolled strip had a grain size of 40 μm, a tensile strength of 345 MPa, a yield strength of 197 MPa, and excellent gas tightness after being blown.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202110590679.4 | May 2021 | CN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CN2021/098104 | 6/3/2021 | WO |
