万丰镁业：“双碳”驱动下，“小巨人”轮毂转得飞快-我的钢铁网

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href='https://m.mysteel.com/market/p-967-----0201-0--------1.html' target='_blank' style='color:#3861ab'>铜</a>合金新材料经过配制、浇注、加工、测试后，源源不断地产出副车架，它们将被运往哈雷、宝马、杜卡迪等主机厂，安装到大排量机车上，成为前后车桥的“骨架”，阻挡振动和噪音，提升驾驶舒适性。</p> <p><img id="3464045" style="border-width: medium; border-image-width: 1; max-width: 100%; width: 600px; height: 399.375px;" src="//img01.mysteelcdn.com/wz/uploaded/steel/2023/05/31/1435371.jpg" /></p> <p>在基地车间里，工人正在喷涂副车架产品。</p> <p>“骨架”自然要有足够的强度，而万丰镁业的这款副车架最薄处仅有3毫米，减重效果是传统产品的50%以上，却依然拥有着与航空航天产品一样的500MPa抗拉强度，直径5毫米高强镁铝合金试棒最重可吊起1000公斤的重量。</p> <p>“传统副车架是用铸铁做的，非常重，而且部件需要焊接在一起，工序成本较高。”公司高级工程师刘旦说，2018年，哈雷提出了部件轻量化的需求，这加速了公司新材料和新工艺的研发。</p> <p>强度要高还要轻，铝铜合金成了最佳选择，而这款材料一直应用于航空航天领域，并没有在民用领域大规模应用，怎么打破“次元壁”？“之前的铝铜合金中有贵金属‘钒’，价格昂贵，每吨高达150万元，要想用在民用领域，必须找到‘性价比’更高的元素。”刘旦说。研发人员大量查阅国内外文献，发现在铝铜合金中加入<a href='https://m.mysteel.com/market/p-967-----0220-0--------1.html' target='_blank' style='color:#3861ab'>稀土</a>元素可以起到很好的强化效果。而10多种稀土元素哪个才是最合适的？只有一个笨办法，“一个一个试”。</p> <p>查找文献、交叉试验、对比优化……每一种稀土元素都被“掰碎了”，研发人员穷尽每一种可能，推动试验结果上的微小改变，寻找“最优解”。最终，经过一次次在夏天守着780℃的熔炉做试验后，他们找到了一种价格低廉但性能优异的稀土元素来替代贵金属“钒”，材料强度一致，材料成本每吨最高下降了1万元。</p> <p>合适的材料找到了，接下来要攻下的就是成型工艺。“铝合金凝固过程中会产生大量的晶粒，晶粒就像石头一样，石头越小，流动得越快，要想制造结构复杂的副车架，必须保证材料有较高的流动性。”刘旦说，为此，他们研发出了含有微米级陶瓷颗粒的晶种合金，从而确保流动性，并通过模流分析，对充型及凝固过程进行分析，获得最佳产品及模具结构，形成高强中空薄壁大尺寸铸造技术。</p> <p>一切的研发，都指向了一个目标——轻量化。为何对轻量化孜孜以求？据测算，传统燃油车整备质量每减少100千克，每百公里油耗可降低0.3—0.6升，二氧化碳排放可减少约6—14克/千米。在环保节能和激烈的市场竞争环境下，轻量化对于节能减排意义非凡，这也是万丰镁业追寻轻量化的重要原因。目前，公司在材料、成型工艺、产品设计上加速轻量化技术发展步伐，已研制成功强度更高、轻便节能的碳纤维轮毂，在减重的同时，保证产品安全、提高性能。</p> <p>眼下，数字轻量化高强镁铝合金机车部件生产基地已正式投产，建设2.7万平方米生产厂房及附属设施，购置生产检测设备100台（套），可年产250万件数字轻量化高强镁铝合金机车部件。</p> <p>在公司轻量化技术创新中心，工作人员正在进行着高强铝硅合金的研发，成本将比铝铜合金更低，成型性更好。可以预见，这将进一步助力万丰镁业突破竞争重围，掌握轻量化市场主导权。</p> <p><img style="width: 600px; height: 183.529px;" src="//img07.mysteelcdn.com/wz/uploaded/steel/2023/05/31/b692928ac3b64f519d095a8f7392ccf8.jpg" width="600" height="183" /></p>  <br /> </div> </div> </article> <article class="content-block m-copyRight"> 资讯编辑：张博 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