Increase the aluminization rate of van and special transport vehicles

According to the bulk non-ferrous net reprinted: special vehicles can be divided into general-purpose van (box vans), specialized transport vehicles, refrigerated trucks, civil construction vehicles, environmental protection vehicles and service vehicles for different purposes such as the six major categories. Different countries have different classification methods. The aluminization rate of cars is also different. The rate of aluminumization in Europe, North America, and Japan is high, the overall aluminum ratio of special vehicles in China is very low, and the aluminumization rate of vans in North America is very low. At more than 92%, the refrigerated truck's aluminumization rate has almost reached 100%. The aluminumization of China's special vehicles is still in its infancy, but it has great potential.

Universal car van's aluminization rate should reach 80%

General vans usually have 8 categories: wing-shaped, side-opening, with lifting equipment, lift-type rear door, with automatic loading device, self-dumping, body removable and flat type. The wing-type van is the representative of the van and dominates. It has wings on both sides of the door when it is opened. The wing-type vans open the doors in the following ways: manual, hydraulic and electric. Both doors can be opened simultaneously or separately. Some of the doors were opened and the doors on both sides of the doors were over the top of the car. Some of the doors were almost flush with the roof after opening. Forklifts can generally be opened directly into the van. Some vans are divided into two or more layers, and the partitions are lifted or detached. Alcoa and Johnstown's 27m-long, double-decker passenger car transporter is longer, lighter, safer, and more loaded because its skeleton structure is entirely made of high-strength aluminum. Extruded alloys are constructed using aluminum alloy die castings. China also has such a multi-storey car transporter, but it is a steel structure. Changyi is fully aluminized, and all the aluminum needed in China can be produced.

Some wing-type vans can not only open the doors upwards, but also open the doors on both sides downwards, allowing the forklifts to open up and work, and can also use cranes to lift goods. This type of vehicle is called the W wing-type van. . Although most wing-type vans are made of aluminum and plastic, there are also some aluminum alloy extrusions, pipe rods to support the external tarpaulin, but it can be as convenient as the ordinary van outside the van. The door, that is, the bracket and the tarpaulin, all open upwards together, and it is not necessary to remove the tarpaulin and the bracket, which does not affect the loading and unloading and does not affect the efficiency.

Side-opening vans are a fairly common type of vehicle. The doors on both sides are usually chute type. The whole side consists of two or three doors and can be slid left and right for loading and unloading goods in low warehouses and roadsides. The three doors have large openings and are suitable for handling large cargoes. In China, this type of side-door vans account for about 65% of the total number of vans. It is the main model of urban goods transport in urban areas, especially in large cities. It should be fully aluminized. However, it is not yet possible to see full-aluminization. car.

After two and a half years of intensive research and development, Chrysler Automotive used the A356 alloy to cast the front support beam of the mini-van, which reduced the quality of the steel by 42% and reduced the car's noise and vibration.

Urgent need to increase the rate of aluminum

Special transport vehicles are vehicles that specialize in transporting certain types of materials and can be roughly divided into seven categories: container transport vehicles, liquid transport vehicles, bulk powder material transport vehicles (dump trucks), passenger car transport vehicles, construction machinery transport vehicles, and Transporters and other special vehicles. The latter type of vehicle has a wide variety of different kinds of goods, such as furniture transporters, livestock transporters, soft material transporters, armored transport vehicles, fine art transporters, precision instrument transporters, and bullet-proof armored vehicles. Some carriages are made of heat-insulating materials and equipped with air conditioners, which are suitable for the transportation of expensive fine arts, precision instruments, and flowers. Some armored cars have the same appearance as regular tourers. Most of them are truck-modified, but they are different from the armored personnel carriers used by the military. The container carrier is actually a flat-panel large-sized transport vehicle. Its aluminumization is relatively simple, as long as the steel bottom plate that carries the container is replaced with an aluminum alloy, just like the aluminum alloy bottom plate of a high-speed railcar, the available thickness is 6mm~8mm. 5083 alloy extrusion profile welding.

Liquid vehicle

In fact, the liquid transport vehicle is a tank car. Usually, the shape, composition and material of the tank are determined according to the different materials to be transported. However, the most critical point is that the material does not react chemically with the contained liquid and does not corrode aluminum. Usually stainless steel, pure aluminum or aluminum alloys are used, and some tank surfaces need to be treated with titanium plating, fluorinated resin, etc.

Tank trucks come in a wide variety of shapes. Some tanks are very large, such as transporting liquefied natural gas (LNG) vessels with a tank volume of 28,000 L, and some tanks are vacuumed. Under certain conditions, the quality of the bottom is determined, and the quality of the tank becomes the decisive factor influencing the quality of the tanker. For this reason, as long as aluminum and aluminum alloys do not affect the quality of the materials being transported, they must be welded with aluminum or aluminum alloy plates in order to reduce the quality of vehicles and achieve energy conservation, emission reduction, and environmental protection.

Tanker

Oil tanks for transportation of aviation gasoline and jet kerosene must be welded with aluminum alloys, because even with stainless steel tanks, there will be a very small amount of iron entering the oil, which is not allowed. The cross-section of the cylinder is a circular-arc rectangle, which is based on the consideration of reducing the center of gravity of the vehicle and increasing the cross-sectional area within the vehicle's external dimensions. According to GB 18564, 5083 alloy welding is used, and the thickness is 5 mm to 6 mm. The 16t tank truck developed by Mitsubishi Motors Corporation of Japan, except that the tank is welded with aluminum alloy plates, its frame (11210mm×940mm×300mm) is made of aluminum alloy profiles, 320kg lighter than the steel frame, and the entire vehicle Reduce 1.5t. Finite element analysis and experimental tests show that the full aluminum alloy tanker has sufficient rigidity and strength.

The anti-wave plate and head material are the same as those of the tank body, and are also 5083 alloy. The wall thickness of the head is equal to or greater than that of the tank plate. The thickness of the wave plate and the reinforcement plate is 1 mm thinner than that of the tank body, and the thickness of the left and right support plates of the tank body is 6 mm to 8 mm, and the material is 5A06.

The top of the tank has a guardrail and a walking platform. The walking platform adopts a pattern of aluminum plates or stencils. The guardrail is made of aluminum tubes, and its height is not less than the maximum height of the tank top functional device. In order to reduce the external side of the tank body and improve the integrity of the appearance, the top oil gas recovery pipe, control air pipe, wire, and water leakage pipe all pass through the pipes that pass through the upper and lower walls of the tank body. There is an aluminum tube on the lower part of both sides of the tank body. In the past, low-carbon steel tubes were used. Because of the easy detachment and rust of the inner wall paint layer, the maintenance workload was heavy and inconvenient. After the steel tubes were used, these deficiencies were eliminated. At the same time, there are also some weight loss effects, and can not use PV plastic pipe, because the inner wall is easy to scratch, not wear-resistant, low rigidity. The aluminum tube can be equipped with a seam welded tube, which can be welded to the aluminum alloy saddle in the tank body. All aluminum materials needed for tanker trucks can be produced in batches.

China is the world leader in the field of aluminum alloy tanker cars. In August 2009, CIMC Vehicles (Shandong) Co., Ltd. and Alcoa Corporation (hereinafter referred to as Alcoa) signed an agreement to establish a strategic partnership for the Asian commercial transportation market. Design and manufacture of a new energy-saving and environmentally friendly aluminum alloy tanker. This car's own quality is 30% lighter than traditional stainless steel cars, which can significantly increase the effective load, improve fuel economy and reduce emissions. It can emit 90 tons of CO2 in its life cycle. The investment in the energy-saving aluminum oil tanker project can be improved. Recycling within one year.

The plate used to produce this kind of aluminum tanker is supplied by Alcoa Bohai Aluminum Co., Ltd. The fasteners of Hack brand are produced by Alcoa Fastening Systems (Suzhou) Co., Ltd., while the forged aluminum wheels are DuraBright. Alcoa's Kfem forging plant in Hungary. This is actually an all-aluminum tanker. In October 2009, the first prototype car was tested on the road surface in Beijing and Beijing, achieving a satisfactory result and achieving the design goal. This lightweight, environment-friendly high-end tanker has considerable market potential not only in China but also in Asia.

It must also be pointed out that oil products, LNG, and other flammable and explosive liquid chemicals are prone to combustion and explosion during storage and transportation, which has a great impact and a wide range of hazards, and has a great impact on people's lives and corporate production.

Since the 1980s, foreign countries have made great achievements in the research and development of metal suppression materials, adding a certain amount of honeycombs made of 3003 aluminum alloy foil to the storage and transportation tanks of oil products and liquid chemical products. Mesh or spherical blast suppression materials prevent their burning and explosion. This detonation net or ball is made of 3003-18 (or 24) alloy foil 0.05mm thick and 250mm wide. Although the 3003 aluminum foil net and ball can effectively prevent the combustion and explosion of oil and liquefied gas in tanks, during the Gulf War, the helicopters and tanks of the United States were filled with explosion-proof aluminum foil nets. Even if they were hit by bullets, they did not catch fire. The United States pulled After the explosion-proof material was filled in the 462L fuel tank of the light attack patrol ship produced by the Mo company, no explosion took place in the firing experiments of 300-powered light bombs and armor-piercing fire bombs. However, its major deficiency was in oil products. Corrosion occurs when it is immersed for 1 or more days. Not only does the corrosion product have an effect on the quality of the oil, but the elongation of the foil decreases sharply and the external force such as vibration breaks down and suppresses the explosion suppression performance. Explosion-proof aluminum has become a top priority. Fortunately, Professor Li Jianguo of the Department of Materials of Tsinghua University has done a lot of work in this area and has made gratifying achievements. He has developed excellent performance 6xxx alloy foil anti-explosive materials. Unfortunately, it has not yet formed mass production capacity. It is incredible.

Chemical Products

According to the corrosion of petrochemical products and other commonly used materials for 1xxx series and 5xxx series alloys, they can be divided into three categories: The first type is a substance that does not have a chemical effect with aluminum, that is, it does not corrode when it comes into contact with aluminum. Two-line alloys are used to make storage containers; the second category is those substances that are slightly corrosive to aluminum. If effective protective measures are taken against aluminum, it is safe for them to contact with them. The third type is when aluminum contacts them seriously. corrosion.

The medium concentration, temperature, pressure and movement state have a great influence on the corrosion of aluminum. The effect of concentration is not accurate. Generally, the corrosion rate increases with increasing concentration. However, there are many exceptions. Therefore, the relationship between corrosion of aluminum and the medium should be discussed in light of specific conditions. Corrosion rates always increase with temperature and pressure.

Most anhydrous inorganic salts, petroleum and petroleum products, and organic compounds do not corrode aluminum, but corrode aluminum in aqueous solutions or in small amounts. There are also substances such as ethoxylated monoalkyl ethers that corrode aluminum when not water, but do not corrode aluminum when there is a small amount of water.

Aluminum has good chemical stability in concentrated nitric acid and acetic acid, but 100% acetic acid and boiling 0.25% to 95% acetic acid corrode aluminum. Aluminum is stable in dilute sulfuric acid and fuming sulfuric acid, unstable in moderate and high concentrations of sulfuric acid, and aluminum is stable in sulfuric acid solution.

When aluminum is subjected to force or after bending, stamping and welding, it will generate a certain internal stress in the workpiece, which will accelerate the corrosion of aluminum. Therefore, measures should be taken to eliminate residual stress, and the surface state of aluminum also affects its corrosion. If there are scratches, cracks, holes and other defects on the surface, it is easy to form a concentrated battery, and accelerate corrosion.

High-purity aluminum can be used to manufacture concentrated nitric acid (98%), acetic acid, formalin storage and tanker, industrial pure aluminum to produce concentrated nitric acid, glacial acetic acid, acetic acid, urine tanks and tankers, 552 alloy can be used to manufacture glycol tanks With tanker.

2. Refrigerated vehicles and liquefied gas carriers

The biggest difference between aluminum and steel in terms of performance and temperature is that steel has low-temperature brittleness, but aluminum and aluminum alloys do not. When the temperature decreases, aluminum and aluminum alloys increase in strength properties, while plasticity and toughness also follow the temperature. As the reduction of the aluminum alloy increases, the aluminum alloy becomes a good material for manufacturing cryogenic equipment and facilities. Liquefied natural gas tankers and liquefied natural gas tankers can be welded to aluminum alloy 5083-0 plates.

After the use of aluminum alloys in the semi-refrigerated car produced by the Kagels company, the quality of the car itself has dropped by 480 kg. Another advantage of making refrigerated trucks with aluminum alloy panels, profiles and other materials is that aluminum is a clean, harmless, environmentally friendly metal that is easy to clean and does not absorb and emit gases. The four walls of the refrigerated truck are three-layer composite materials. The upper and lower layers are aluminum alloy sheets and the middle is an insulating material, which has a strong thermal insulation performance.

Cast aluminum alloy

There is no doubt that the use of aluminum in automobiles will increase year by year over the foreseeable period. To reduce the quality of the car itself, of course, one of the main purposes of aluminum application is to be improved. In order to greatly reduce the quality of the car, people are eager to study the body (about 30%) and the engine (about 18%) that have a large proportion of the body mass. Steel parts such as rotary systems (about 15%), walking systems (about 16%), and wheels (about 5%) are replaced with aluminum alloy materials. The aluminization of the wheels has basically been completed, and the aluminization of the engine is almost the same.

In automotive aluminum alloys, the final shaft and other cast alloys account for about 80%, and the processed aluminum materials only account for more than 20%. With the increase in the use of aluminum sheet metal, the proportion of aluminum will increase year by year, but it will increase. Not great. In the alloys used in automotive aluminum casting products, the output of die castings accounts for about 70%, so die-cast aluminum alloys account for 55% of automotive aluminum. Of course, this ratio is not the same in aluminum used in various countries, but all are 54%~70%.

About 80% of the regenerative aluminum alloys currently consumed in the world are used for the production of various die castings and castings. They are mainly used for the production of automobile and motorcycle parts. They require good casting properties of the alloy. Therefore, recycled aluminum and aluminum alloys are used in many cases. Production of YL1XX and ZLXXX alloys (Ai-Si alloys).

Die casting aluminum alloy is the most used YL101, YL102, YL104, YL112, YL113, YL117 and YL302 alloys; in the casting of aluminum alloys, the automotive industry used mostly: ZL101, ZL101A, ZL104, ZL105, ZL105A, ZL106, ZL107, ZL108, ZL109, ZL110, ZL111, ZL114A, ZL115, ZL116 alloy and so on.

Basic research is the key

To promote aluminum vehicles and increase aluminum in automotive applications, aluminum processing companies and automobile manufacturers should increase cooperation and work together to do a good job of this task. In addition, they must increase scientific and technological input and strengthen basic research. We have all seen that multinational car companies have more products, higher technological content, and a more complete product lineage. In fact, this is only their dominant feature as a multinational giant, and their continued large-scale investment in basic research is the foundation to support their dominant characteristics. Basic research is often the most basic, most core, and also the most costly, and can not see the effectiveness of the short-term behavior. But this is the basis for the formation of core competitiveness. We must do this. This step must be taken.