The world's first to achieve mass production Copper-aluminum composite material is a new type of layered composite material developed in the electric power and industrial electrical appliances industry in recent years, and is a kind of high-performance composite conductor. The copper-aluminum composite material is mainly composed of an aluminum core and a copper coating layer, and has the advantages of excellent electrical conductivity of copper, good corrosion resistance, low cost and light weight of aluminum. When used as a high-frequency wire, a high-current conductive row, etc., its electrical conductivity is almost the same as that of a pure copper conductor. Although the material advantages are obvious, there is no international mass production method. In order to overcome the technical difficulties of copper-aluminum composite materials, in 2008, the State Key Laboratory of New Metal Materials of Beijing University of Science and Technology and Yantai Fuxinda Bimetal Co., Ltd. signed a patent license agreement for copper-clad aluminum composite billet continuous casting composite forming technology. And began the research and development of the process technology and equipment for the production of copper-aluminum composite conductor materials by horizontal continuous casting. "From the laboratory research results of Beijing University of Science and Technology, to the company's subsequent pilot and industrialization research, the six-year innovation and research and development, and finally achieve today's industrial scale production." Wang Lianzhong, general manager of Fuxinda Bimetal Co., Ltd. According to the introduction, at present, the company has formed a complete set of copper and aluminum horizontal continuous casting production and processing technology and a full set of high-end composite metal material production and processing equipment, which is unique in the whole industry. By the end of 2016, the company had invested more than 122 million yuan in research and development, and the number of experiments reached thousands of times. In 2013, it was the most crucial year for the industrialization of copper-aluminum composite casting technology. On the one hand, a large amount of capital investment is required. On the other hand, the precise control of the cooling of the bimetal composite casting process becomes an important bottleneck problem for product quality uniformity and consistency control. "At this time, we can only face difficulties. After repeated demonstrations with experts from Beijing University of Science and Technology, after repeated experiments and research, we finally broke through the core cooling control problem of bimetal composite casting. At the end of 2013, it was high. The performance copper and aluminum composite power flat row product development and application project passed the national appraisal and became the first technology at home and abroad." Wang Lianzhong told reporters. “Our technology has enabled large-scale application of copper-aluminum composite power flat slabs, which has solved the shortcomings of long production process, low yield, high production cost and high volume production.†Academician of Chinese Academy of Engineering and Professor of Beijing University of Science and Technology Xie Jianxin Tell the reporter that in the past, in the production of copper-aluminum composite row, only the hydrostatic extrusion method in Europe can produce products with good quality and satisfying the requirements of use, while the quality of other technical products can not meet the requirements of large-scale industrial application, and the products are qualified. The rate is very low. In the interview, the reporter learned that the hydrostatic extrusion method of British BRUKER can only realize the small-scale production of copper-aluminum composite materials, which cannot be industrialized on a large scale, and the technical process is complicated, the finished product rate is low, and the cost is high. Used in the high-end market, it cannot meet the huge demand of the civilian conventional market. Academician Xie Jianxin revealed that the process cost of China's first copper-aluminum composite continuous casting technology is only half of that of hydrostatic extrusion. Although the quality of the two methods is comparable, this technology can simplify the process and greatly reduce costs. Achieve mass production. Break through the bottleneck of industrial transformation and upgrading Considering resource security and cost, replacing a part of copper with low-priced and low-density aluminum to form copper-aluminum composite materials for power transmission and industrial electrical conductor materials is a hot spot for research and development at home and abroad. For example, the Eurostar train electrical system uses copper-aluminum composite products to reduce the weight of trains; in the 1990s, copper-aluminum flats were used in the world's largest high-speed ferry; in recent years, low-voltage switchgear Copper and aluminum composite flat bars are also used to reduce costs. “Copper resources are the largest in the power industry. Therefore, the development of copper-aluminum composite conductor materials and the realization of aluminum-copper copper is an important way to save copper resources. It is also the research and development direction of new material technologies that support the development of national medium- and long-term development planning. 1." The documentary director of the China Nonferrous Metals Industry Association said. In recent years, due to strong demand, the development and application of domestic copper-aluminum composite flat slabs have gradually received attention. The products produced by casing drawing and copper tube aluminum casting have also obtained a small amount of applications in some electric power fields. However, due to the low joint strength of products produced by casing drawing and other methods, separation and bulging are easy to occur during processing. The quality of the products is uneven and cannot meet the requirements of transformation and upgrading of related industries. Nowadays, after years of research and development and innovation, the application of China's copper-aluminum composite technology in the power industry has achieved initial success. "High-performance copper-aluminum composite continuous casting direct forming technology is an international advanced copper-aluminum composite preparation process with short process, high degree of automation and high production efficiency." Academician Xie Jianxin said that compared with the existing copper row The use of copper-aluminum composite power flat row can save about 65% to 80% of copper, and has the advantages of light weight, convenient transportation and installation, saving copper resources, low cost and high electrical conductivity. In the production workshop of Fuxinda, the reporter saw that the two copper and aluminum production lines are running fast. In order to adapt to the rapidly growing market demand, the other two production lines in the factory are also under construction. Lan Zhanjun, deputy chief engineer of the company, said that in many application scenarios, the design of pure copper row leaves a considerable design margin, so the current carrying capacity of copper-aluminum row products does not need to reach 100% of pure copper row, even if The cross-sectional area replacement of copper and aluminum row products can also fully meet the requirements for use. Taking the circuit breaker as an example, if the equipment is required to meet the performance requirements, if the cross-sectional area is replaced, the copper can be saved by 55% by weight. In addition to copper, copper-aluminum composites have two major advantages in power applications: lightweight and low cost. In the case that the ratio of electricity to traditional energy is not dominant, for new energy companies, cost reduction is the first. Copper-aluminum composite materials with higher cost performance and better performance will undoubtedly bring good news to new energy companies and enhance their competitiveness. “In 2012, when some specifications of copper-aluminum composite materials were successfully produced, the wind power equipment leader Jinfeng Technology became the “first person to eat crabs.†Wang Lianzhong said that at present, Fuxinda produces copper-aluminum composite Materials have been widely used in the field of new energy. Another major application of copper-aluminum composites is in the traditional power transmission and distribution field. "This is related to the direction in which the future conductor technology will go." Wang Lianzhong said frankly that power grid construction is a key investment area of ​​the country. Our technology can significantly reduce the materials of transmission and distribution conductors while taking into account the guarantee performance and operational safety. Cost can reduce the dependence on copper resources and solve the big problems facing the power industry. "Because of the obvious comprehensive advantages, the promotion and application of copper-aluminum composite materials will definitely improve the international competitiveness of China's manufacturing enterprises and help the industry improve quality and efficiency, including power equipment, industrial electrical appliances and other industries." Academician Xie Jianxin said. Domestic market promotion is difficult In the power industry, “aluminum copper†must have two prerequisites: one is technically feasible and the other is safe and reliable. "Although the development of copper-aluminum composite materials is of great significance, if the normal operation of power products is not guaranteed, then everything is empty talk." "In 2012, the technology of 'horizontal continuous casting production of copper-aluminum composite materials' is in the stage of industrialization research, and the key technologies have just been broken, forming a small batch of qualified products, but the quality of the products of the 'casing method' for many years in China is not enough. The bad market impression caused by it has indirectly led to the hindrance of domestic market promotion.†Wang Lianzhong said that in view of the current situation in the domestic market and the excellent performance quality of the products, the company decided to seek breakthrough points from overseas markets. Fortunately, at an international power show, Fuxinda's products received the attention of international electric giants such as Schneider and ABB, and launched a three-year demonstration on the feasibility of the product. Severe conditions simulation test research, small-scale installation test verification, technical verification to factory inspection, and finally in 2015, 2016, respectively passed Schneider, ABB's global supplier qualification certification, become its exclusive supply of copper and aluminum composite materials Business. “In order to open the market, we cooperate with international companies to do experimental certification and small-volume applications.†Liang Yuncheng, deputy general manager of the company, said that in the second half of 2015, the company obtained the global supplier qualification of Schneider and supplied the products in volume for Schneider and other companies. "The entire complete experiment of ABB's low-voltage products has also been completed. They plan to use our products on the new switchgear. Now the world's top power transmission and distribution companies have established business contacts with us." Popular in the international market, the promotion of products in the domestic market is not ideal. Wang Lianzhong told reporters that the company's products occupy more than 50% of the market share of new energy mainframes, but in the transmission and distribution field, which accounts for more than 80% of the domestic power industry's market share, copper-aluminum composite conductive products have been difficult to get involved. "In the national network system, safe operation is the top priority, and there may be certain risks in the entry of new materials. This also causes new products to be blocked in the promotion of the national network system. It is urgent for the government and related industries to provide support." Wang Lianzhong said that In the future development, we must strive to use copper-aluminum composite materials as the third new type of conductor materials other than pure copper and pure aluminum, to meet the special needs of different customers, and to provide more for the market. Choose to accommodate a more diverse product distribution.
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China's copper-aluminum composite conductive flat row standard has become an international standard
In the application of “aluminum-copper copper†in the power industry, the technological innovation of copper-aluminum composite materials in China has made major breakthroughs, not only won the second prize of national technology invention, but also the “copper-aluminum composite conductive flat row standard†was also recently obtained. Approved by international organizations to become the only international standard in the field of non-ferrous metal materials.