药用铝箔的生产工艺及存在的问题
铝箔缺陷及产生原因
2)保证管芯和导路的洁净
7
表面
气泡
箔材表面不规则的圆形或条状空腔凸起。凸起边缘圆滑、两面不对称，分布无规律
1)退火温度过高，加热时间过长2)金属含氢量偏高
1)严格控制坯料质量
2)采取合理的退火工艺
8
腐蚀
铝箔表面与周围介质接触，发生化学或电化学反应后，在铝箔表面产生的缺陷，被腐蚀的铝箔表面会失去金属光泽，严重时会产生灰色腐蚀产物
正确调整刀缝；及时换刀
20
串层
铝箔卷端面层与层之间不规则，造成端面不平整
1)坯料不平整2)卷取张力控制不当3)压平辊调整不当4)卷取时对中系统异常
1)提高来料板形质量
2)合理使用卷取张力和压平辊
21
塔形
铝箔卷端面层与层之间的串层造成塔状偏移。塔形是串层中的特例
1)来料板型不好2)卷取对中调节控制系统异常3)熨平辊调整不当4)卷取张力小
1)铝箔用润滑油粘度高2)退火工艺不当
1)控制工艺油理化性能指标
2)采用合适的退火工艺
10
裂边
铝箔表面纵向边部破裂，严重时呈锯齿状
1)辊型控制不当，使铝箔边部出现拉应力2)中间退火不充分，金属塑性差3)剪切时送料不正，一边未切掉4)压下量过大
1)采取合理的生产工艺
2)正确操作
11
波浪
由于不均匀变形而使箔材表面局部产生起伏不平的现象。在边部的称边部波浪，在中间的称中间波浪，二者兼而有之的称复合波浪，既不在中间又不在边部的称二肋波浪
1)采取合理的退火工艺
2)控制工艺油理化性能指标
30
燕窝
箔卷端面上产生的局部“V”型缺陷，在箔卷卷取过程结束，卸卷后产生，有些待放置一段时间后产生
铝箔加工缺陷及措施
铝箔轧制常见缺陷的一般特征、原因及措施在轧辊的表面与机体中形成高微裂纹的铬层。
这种高高微裂纹的网状结构有利于轧制油吸附在轧辊表面，以便润滑。
网状结构的铬层可以承受轧制力高达2000吨以上的的压力。
以下是其与传统镀铬的金相结构图的比较对照表：轧辊镀铬的铬层硬度是随着镀铬的技术条件变化而变化的。
科德工作辊服务集团的镀铬层硬度通过其技术的创新可以达到900-1100VICKERS PN。
这么高的硬度值就是所谓的“镀硬铬”技术。
通过这样的硬度值来增加轧辊的耐磨性能。
它的硬度要比通常的铸铁或者热处理的锻钢工作辊的硬度还要高。
镀铬层的摩擦系数更低，以下是一些金属表面的摩擦系数表：铝箔轧辊的镀铬对铝箔的生产带来了较好的效果。
工作辊—所有机架（粗轧→中轧）冷轧镀铬辊的所有绩效在铝箔轧辊上都能体现出来，此外，还具备以下优点：（1）、能够成倍减缓随通过量轧制速度下降的趋势从而获得稳定的轧制速度；（2）、能够从窄到宽的变规格轧制；（3）、大幅度改善润滑状态减少了不明断带；（4）、获得稳定一致的板型和表面质量。
在生产10—30um的箔材中，由于支撑辊的原因常常损坏工作辊。
而对支撑辊的镀铬可以改善工作辊的损伤，减少氧化物的产生和线条的产生。
在铝箔精轧中，使用镀铬工作辊可以获得更稳定均匀的表面质量，延缓线条产生。
抑制原料带来色差的倾向。
分切常见缺陷及调整措施工艺参数与铝箔质量产量的关系COMALCOFOIL DIVISIONDEFECT CATALOGUEDanyang Training VisitMay 1992Comalco Aluminium Ltd SMP 7479.00Yennora Words Page 1 of xxxFoil Division Date 9.9.91Standard Metallurgical Practices Prepared by: C. Cleary Foil Division Defect CatalogueScopeThis S.M.P. is for all foil personnel and covers the description and classification of various defects found in the Foil Division. It describes defects which occur during rolling, slitting and annealing.This catalogue describes the defect, why it occurs and when possible, tells you how to eliminate it.The numbering system follows the Comalco Claim System used site wide for categorizing claims from external customers (see page 2 and 3 for a full listing).This S.M.P. covers the following defects:0.1 Stickiness0.1.1 Orange Peel0.1.2 Exploded Areas0.2 Wettability1.6.1 Hot Spots1.9 Tension Cuts2.1 Water Stain2.2.1 Herringbone2.2.2 Line of Holes2.2.3 Roll Holes2.2.4 Chatter2.2.5 Mill Lines2.2.6 Bruised coil2.2.7 Indents2.2.8 Splits2.5.1 Dross2.5.2 Staining2.6.1 Chicken Tracks2.7 Broken Matte2.7.1 Streaky Matte6.3 Step Outs6.4 Telescoping6.5 Out of Round6.7.1 Edge Cracks6.7.2 Laminations6.10 BridgingFULL LISTING OF SITE WIDE DEFECTS0.0 Annealing 0.1 Stickiness 0.1.1 Orange Peel 0.1.2 Exploded Areas 0.2 Wettability1.0 Dimensional 1.1 Gauge1.2 Width1.3 Lateral Bow1.4 Length1.6 Flatness 1.6.1 Hot Spots1.6.2 Creasing1.7 Edge Burr1.8 Mass1.9 Tension Crease2.0 Surface 2.1 Water Stain2.2 Metal Surface 2.2.1 Herringbone2.2.2 Line of Holes2.2.3 Roll Holes2.2.4 Chatter2.2.5 Mill Lines2.2.6 Bruised Coil2.2.7 Indents2.2.8 Splits2.3 Surface Condition2.4 Applied Coating2.5 Surface Contamination 2.5.1 Dross2.5.2 Staining2.6 Blade Marks 2.6.1 Chicken Tracking 2.7 Broken Matte 2.7.1 Streaky Matt3.0 Metallurgy 3.1 Alloy3.2 Mechanical Properties3.3 Earing3.4 Inclusion3.5 Failure To Form Cans4.0 Document 4.1 Specification4.2 Planning4.3 Sales5.0 Packaging 5.15.2 Identification6.0 Coil Cond n 6.1 Loose Wraps6.2 Broken Welds6.3 Step Outs6.4 Telescope6.5 Out of Round6.6 Coil Size6.7 Broken Edge 6.7.1 Edge Cracks 6.7.2 Laminations 6.8 Edge Damage6.9 Handling Damage6.10 Bridging7.0 Transport 7.1 Seafreight7.2 Road/Rail8.0 Acc Reject9.0 No Defect 9.1 BU/CP Wrecks0.1 StickinessWhat is stickiness?Stickiness is a measure of how difficult it is to pull a single layer of foil from the coil. This defect can cause problems, especially when it occurs in light gauge foils such as insulation and flexible packaging metal.When does stickiness occur?When the annealing process is out of specification or the wrong annealing cycle has been used for a particular product if the metal is kept at the incorrect temperature.Why does stickiness occur?* incorrect conditions in the annealing furnace:-any residual rolling oil left from the rolling process can polymerise and form weak bonds with the meta.What can you do about it?* monitor the annealing cycle closely and watch the:-heat up rate-soak time-temperature-cool down rate;* report any furnace problems-e.g. burner failure;* keep excess coolant carryover to a minimum.STICKY COILIT REQUIRES FORCE TO PULL THESINGLE SHEET FROM THE COIL FREE UNWIND COILTHE METAL SHEET EASILY FALLS AWAYFROM THE COIL UNDER ITS OWN WEIGHT0.1.1 Orange Peel EffectWhat is orange peel effect?Orange peel effect is a change in the surface of the metal. It becomes mottled, like the surface of an orange peel. This defect is always associated with high stickiness levels (see 0.1).When does orange peel effect occur?This defect mainly occurs on medium gauge coils (30 to 70 microns) and of a soft alloy and O Temper.Why does orange peel effect occur?* too much coolant left on the coil:-during annealing, the excess coolant between the foil layers forms a vapour.-the pressure from the vapour deforms the foil in localized pockets.What can you do about it?Minimize the amount of coolant left on the coil:* always use the splash guard when rolling the final. pass on No. 1 foil mill; * make sure the air wiper system is working properly;* check the amount of residual coolant on the metal when it is on the slitter -if the level is high, make a note of this on the lot ticket.0.1.2 Exploded AreasWhat are exploded areas?Exploded areas are small blister-like bubbles that occur between layers of light gauge foil after it has been annealed. You will find this defect mainly on annealed household foil coil.When do exploded areas occur?When light gauge foil is annealed.Why do exploded areas occur?* too much coolant left on the coil:-as the foil is annealed, the excess coolant between the foil layers forms a vapour-the foil is deformed by pressure from the vapour in localized pockets, this causes an exploded blistered effect.* incorrect anneal practice-too high an annealing temperature will also cause exploded areas.What can you do about them?* keep the amount of the coolant left on the coil to a minimum: -make sure the mill air wiper system is working properly,-check the amount of residual coolant on the metal when it is on the slitter.Make a note on the lot ticket if the level is high.* make sure the metal is annealed correctly and check:-heat up rate-soak time-temperature-cool down rate0.2 WettabilityWhat is wettability?Wettability is a measure of the amount of rolling lubricant left on the foil strip after annealing. If there is too much, it can interfere when plastics and inks are applied to the metal at the customers plant.When does wettability occur?When there is too much rolling lubricant left on the metal after it has been anneal.Why does wettability occur?* excess coolant carryover on the mill;* incorrect conditions in the annealing furnace.Why can you do about it?* monitor the annealing cycle closely and watch the:-heat up rate-soak time-temperature-cool down rate;* report any furnace problems-e.g. burner failure;* keep excess coolant carryover to a minimum.A GRADE WETTABILITYWHEN WATER IS APPLIED TO A SHEET OF FOILIT STAYS ON THE FOIL e.g. IT WETS THE SURFACEB BRADE WETTABILITYWHEN WATER IS APPLIED TO A SHEET OF FOILIT DOES NOT STAY ON THE FOIL SURFACE1.6.1 Hot SpotsWhat are hot spots?Hot spots are a continuous buckle (or belly) anywhere on the width of the exit strip. Provided the exit tension is not too high, hot spots are very easy to see when you are rolling. The buckled area is a lower gauge and longer than the rest of the strip. As a result it ‘puckers’.When do hot spots occur?When excess heat builds up in a section of a work roll or backup roll, the roll expands more in this area. The metal which comes into contact with this area is rolled to a lower gauge than the rest of the strip.Why do hot spots occur?Excess heat in a localized section of a work roll or backup roll is caused by: * foreign objects rubbing against the roll;* too mach wiper pressure in one area of the roll;* a blocked coolant spray;* coolant sprays which are not correctly aligned;* too much thermal crown;* local hard or soft spots on the roll;* disturbed oxide layer in the area of the buckle.What can you do about them?* check for foreign objects and remove any you find;* check the pressure on the wiper and alter it if uneven or too high;* unblocked any blocked coolant sprays;* make sure the coolant sprays are correctly aligned;* check the coolant pressure and increase it if necessary;* change the work rolls.Hot Spot \ Shape Defect Description1.9 Tension CutsWhat are tension cuts?Tension cuts are stretched bands of broken metal on the edges of the strip. They point towards the centre of the strip and spread out as they reach the edges. This defect is very easy to identify during rolling.When do tension cuts occur?When the strip wrinkles or folds over as it enters the mill bite.Why do tension cuts occur?* if the unwind tension is too low to hold the strip flat as it enters the work roll bite, the strip edges can wavy and wrinkle;* if the bridle is uneven or out of alignment, it may not hold the strip flat.What can you do about them?* increase the unwind tension until you can’t see any more fractures;* make sure the bridle is correctly aligned and the strip is flat as it enters the mill bite.2.1 Water stainsWhat are water stains?Water stains are a white or grey discolouration on the surface of the metal. Water reacts with the metal, causing surface oxidation and the formation of a metal oxide. This oxide stain is harder than the rest of the strip. When it passes through the mill bite, it can cause the strip to break.When do water stains occur?When the metal comes into contact with water.Why do water stains occur?* direct exposure to water;* condensation caused by rapid temperature changes in the metal:* when water is trapped between two closely packed metal surfaces there is no air circulating and the metal surface reacts with the water, this is known as surface oxidation.What can you do about them?* keep water away from the aluminium at all time- store away from roof leaks or keep the metal covered- keep the metal off the floor;* make the wooden boxes have low moisture content when you pack coils in them; * make sure the coils are cool before you pack them;* cover coils when transporting them from No. 1 to No. 2 mill on an overcast day.How to determine where the water staining occurredUsing a Scanning Electron Microscope, a good understanding of where the staining occurred can be achieved. With this type of microscope the stain can be studied, and other elements other than Aluminium can be detected. These will give you a rough estimate of the nature of the stain.* If Sodium or Chlorine are detected, then the stain is probably from sea water. * If Sulphur is detected, then the stain could be caused by acid rain.* If Calcium or Iron is detected, then the water source could possibly be unclean tap water.These generalizations can only be used as a rough guide when determining where the water staining has occurred..01 5.12 KeV Typical SEM Trace for a salt water caused “Waterstain”.2.2.1 HerringboneWhat is Herringbone?Herringbone is a surface marking along the strip which resembles a string of corpo ral’s stripes or the backbone of a fish.When does herringbone occur?There are a number of possible reasons:* the coolant may not be lubricating the strip well enough under the extreme pressure of the mill bite;* the strip may have a poor shape either from a previous pass or the present one; * the gauge reduction may be too great;* an earlier annealing treatment may have been missed* work roll finish may be incorrectly ground.What can you do about it?Herringbone is probably not the fault of your rolling technique, so you should follow or report on these matters:* check the composition of the coolant to ensure it has the correct levels of additives to give lubrication. The Rolling Superintendent or Foil Metallurgist keeps records of coolant additive levels;* check the previous rolling and annealing history of the coil from the Lot Ticket - report any ways in which this differs from the process schedule;* check the Roll Grind Requisition form, ensuring that the rolls have had the correct grinding performed on them.2.2.2 Lines of HolesWhat is lines of holes?Lines of holes are a continuous line of little holes in the metal. It varies in severity and can sometimes occur consistently throughout a coil. Lines of holes often cause strip break during the last single and the final doubling passes.When does lines of holes occur?This defect occurs when the metal has been scratched at any stage of processing or when a source of pick-up is introduced to the roll bite.Why do lines of holes occur?When the surface of the strip has been broken, by:* mechanical failure, for example- pulling the strip over a seized roll- a scratch on the work roll surface;* careless handling of the metal;* the work rolls have been ground with no relief on the ends. This results in small pieces of work roll surface breaking off and being forced through the bite.What can you do about it?Try to protect the metal throughout the process:* check and maintain a high level of cleanliness on the mill regularly;* when you detect lines of holes, the coil should be isolated and put on hold. The coil should not be processed any further;* check the work rolls for signs of spoiling.2.2.3 Roll HolesWhat are roll holes?Roll holes are small marks or holes that repeat at a regular interval along the metal strip. This defect is very difficult to see during rolling.When do roll holes occur?When a roll work become damaged and the damaged portion imprints a mark onto the metal surface.Why do roll holes occur?The work rolls can be damaged by a number of things:* grit;* dirt;* dust;* an inclusion in the strip.What can you do about them?* make sure the mill is cleaned thoroughly- after a PM- after a strip break;* make sure the metal stays off the ground;* wear clean gloves when you handle the metal;* remove one wrap from the feed coil if it has been standing for a long time; * if the holes are repeating at an interval of about 1 metre when you measure them along the length of the strip, then the mark is caused by your work rolls - change the rolls;* if the holes are about 2 metres apart, they were caused before you received the coil- there is nothing you can do about them.2.2.4 ChatterWhat is chatter?Chatter is evenly spaced, two tone lines which run across the width of the strip. If you could see the edge of the strip magnified, it would look similar to the edge of a piece of corrugated iron. You will hear chatter occurring before see it.When does chatter occur?Chatter often occurs during mill acceleration and deceleration, for short periods only. Only when this occurs at longer periods of times does the defect become a problem.Why does it occur?Chatter is caused by machine resonance. Machine resonance can occur under the following condition:* the coolant is out of specification;* the feed strip is a hard alloy;* the pass line is incorrect;* the drive transfer box is worn;* the drive couplings are worn.What can you do about it?* if you want to finish the coil, try altering the mill speed and unwind tension,then stop rolling and look for the problem;* make sure the coolant is within specification at all times - if it is not, stop the mill until you can correct it;* change the product or program until someone alters the mill; * if the pass line is wrong, check the mill shims;* change the work rolls.THE LINES ON THE STRIP IF MAGNIFIEDWOULD SHOW VARIATIONS OF GAUGE WHICH WOULD GIVETHE CROSS SECTION A CORRUGATED EFFECT AS SHOWN ABOVE 2.2.5 Mill LinesWhat are mill lines?Mill lines are very narrow stripes which run along the strip in the rolling direction. To see them clearly, you need to straight down onto the strip.When do mill lines occur?When the work rolls or backup rolls are damaged.Why do mill lines occur?There are a number of reasons:* there is a scratch on the work roll;* the oxide layer on the work roll is uneven;* there are lines on the work roll caused by the damaged backup roll - the backup roll can be damaged by a worn wiper.What can you do about them?* if the defect is present in the following products, you must do a roll change - R No. 62715 Leigh Mardon .040mm x 592mm- R No. 62780 Leigh Mardon .040mm x 674mm- R No. 62576 Leigh Mardon .050mm x 675mm- R No. 62303 Leigh Mardon .040mm x 643mm* if there are lines on the backup roll, there is no point in changing the work rolls because the damaged backup roll will mark the new rolls- remove the mark from the backup roll with emery paper or a fine grinding wheel - if you can not remove the lines, change the backup roll;* if only the work roll is damaged, change the work rolls.2.2.6 Bruised CoilWhat is a bruised coil?A bruised coil is an area of discolouration which repeats along the metal strip at regular interval.When does a bruised coil occur?When a work roll has an impact placed upon it. The bruise can occur at any upstream process and can manifest itself upon further reductions as a discolouration on the metal or shape problems with the coil.Why does a bruised coil occur?* when the tail of a coil passes through the roll bite and damages the work rolls. This mark is then transferred onto the strip.- this occurs most often on heavier gauges and when you roll hard alloys (e.g.3003 and 3004 alloys).What can you do about it?* when you are rolling a breakdown pass, stop the mill before the tail of the strip passes through the mill bite;* cut the tail in an arc, reduce the load and pull the tail through;* when programming semi-rigid container metal on No. 1 Mill, always programme 8001 and other soft alloys before 3003 and 3004 alloys. The 3003 and 3004 alloys are harder than the 8001 alloy and are therefore less susceptible to the effect of bruising the work rolls.2.2.7 IndentsWhat are indents?Indents are small depressions that appear on the surface of the metal as the coil unwinds.When do indents occur?This defect mainly occurs on medium gauge coils (30 to 70 microns). It is most obvious on O-Temper metal.Why do indents occur?* small particles of dust, dirt and grit get trapped between the metal layers as the coil is slit- the problem gets worse when the metal is annealed because the metal is softer and more prone to mark.What can you do about them?* clean the slitter thoroughly before you use it- this is especially important if the slitter has not been used for a while; * keep the metal off the floor;* handle the metal with clean gloves;* when slitting metal on the 755 slitter always use rotary blades, as razer blades tend to produce a larger amount of swarf which then deposits on the metal strip.2.2.8 SplitsWhat are splits?Splits are very thin creases which have been rolled into the metal. These creases weaken the metal and will easily break apart during rolling. When you are rolling, a split looks like a continuous black line, usually on the centre of the rewinding coil, but sometimes on other side. Take care you don’t confuse this defect with mill lines which look very similar.When do splits occur?When you roll a fold or crease into the strip.Why do splits occur?There are a number of reasons:* incorrect pass line- if the pass line is wrong, the strip will not be level when it enters the mill bite;* the unwind tension is too high, cause a crease in the unwinding strip - this occurs mainly in light gauge strips;* the entry bridle is not correctly aligned.* the backup roll has recently been changed and the work roll camber has not been change to accommodate this change.* the work roll finish may be incorrectly ground.What can you do about them?* carry out a pass line check whenever you change the top backup roll;* make sure the pass line is correct;* make sure the unwind tension is correct;* make sure the correct shims are inserted at every work roll change;* check that the entry bridle is correctly aligned.* ensure that the correct work roll camber is used after the backup rolls have been change.2.5.1 DrossWhat is dross?Dross is a mark or hole in the strip. In very severe cases, it ban lead to web break.When does dross occur?True dross is very rare. It occurs when the metal has not been sufficiently drossed off during casting. Many other defects are mistakenly reported as dross.Why does dross occur?* oxidational impurities form in the metal during casting and hard oxide particlesbecome embedded in the aluminium;* during rolling the oxide particles do not deform as readily as the aluminium and can damage the work rolls;* this leads to marks and holes in the strip and finer gauge strips may disintegrate.What can you do about it?* there is nothing you can do about true dross because the defect is already in the metal before you receive it;* by keeping the metal clean, you can avoid defects which show similar characteristics, but are not in reality dross.2.5.2 StainingWhat is staining?Staining is a black or brown mark which appears or the coil after annealing.When does staining occur?When there are organic compounds left on the strip during annealing, they burn on and cause staining.Why does staining occur?Staining can occur on different parts of the coil:* on the side- if the staining compound was deposited during rolling;* on the side, but only near a join- if the compound was left when the coil was being joined or welded;* on the outside wraps- if the compound came into contact with the metal inside the furnace;* if there is ‘wet lube’ on the furna ce tree when it enters the furnace, the lube evaporates, concentrates and burns on the coil- this could come from a side arm tree that has had container coils on it.What can you do about it?* make sure the coils do not have excess coolant left on them- use the splash guards during the final pass on No. 1 foil mill;* make sure the side arm trees do not have any wet lube on them before you place a coil on them for annealing;* make sure the mill air wiper system is working properly;* check that there is no tape or other foreign matter on the coil before you anneal it.* always ensure that furnace exhaust vents are working properly.2.6.1 Chicken trackingWhat is chicken tracking?Chicken tracking is a slit defect that looks like lines on the edge of a slit coil which radiate from the centre to the outside.When does chicken tracking occur?This defect is a result of slitter blade flutter.Why does chicken tracking occur?Slitter blade flutter can be caused by following:* a damaged female knife roll:* a loose knife;* badly shaped feed metal.What can you do about it?* make sure the knives are firm;* make sure the female knife roll is in good condition.2.7 Broken MatteWhat is broken matte?Broken matte are shiny spots scattered over the dull, matte side of the metal.When does broken matte occur?Broken matte occurs when you are doubling strips and the two strips weld together in spots. As the strips are separated, the welded areas break leaving shiny spots.Why does broken matte occur?There are a number of possible reasons:* not enough inter lap solvent used;* too much speed when rolling;* uneven roll grind;* the two entry strips have different surface textures;* in some alloys, broken matte can occur if the inter lap solvent has a higher lubrication capability than the coolant (e.g. alloy 1145).What can you about it?* make sure you use enough inter lap solvent;* make sure the mill speed is correct;* change the work rolls if you suspect the roll grind is mismatched.2.7.1 Streaky MatteWhat is streaky matte?Streaky matte is also known as no matte and is exactly as the name suggests, a section of the metal strip on the matte surface where there is no matte.When does streaky matte occur?When you are doubling two strips and the solvent application is not consistent you get varied lubrication characteristics in different areas of the strip.Why does streaky matte occur?* there is not adequate inter lap solvent being deposited across the whole strip of foil.What can you do about it?* use plenty of inter lap solvent;* ensure that none of the inter lap sprays have become blocked;* if you increase the mill speed during doubling, then ensure that the inter lap sprays are accordingly adjusted to a greater outflow.6.3 Step OutsWhat are step outs?Step outs are uneven wraps in the coil that have deviated from the normally smooth end face of the coil.When do step outs occur?When you alter variables such as steering or tension during rolling or slitting.Why do step outs occur?* when you alter variables such as steering or tension during rolling or slitting. What can you do about them?* if you need to change any variables when the metal is either being slit or rolled, then do so gradually and smoothly. Any quick changes could result in step outs.6.4 TelescopingWhat is telescoping?The wraps of the coil slip out sideways and result in a telescoped effect.When does telescoping occur?Telescoping generally occurs when there are steerage problems on the slitter or mill.Why does telescoping occur?* incorrect steerage on the slitter- because of badly shaped feed metal;* insufficient tension during rolling/slitting can result in a loose coil, that may slip to one side during coil handling.What can you do about it?* increase the ironing roll pressure on the side of the coil that the telescoping is steering away from;* increase the unwind tension on the side of the coil that the telescoping is steering towards.LATERAL MOVEMENT OF FOIL LAYERS RELATIVE TOEACH OTHER HAS CAUSED THE COIL TO GELESCOPE6.5 Out of RoundWhat is out of round?This term describes a coil which is not perfectly round. To measure the extent of the defect, find the maximum distance between the core and the outside diameter (shown by the bottom arrow in the diagram) and from this, take the minimum distance (shown by the top arrow in the diagram).maximum distance – minimum distance = extent of defectNote: this diagram has been exaggeratedNORMAL SLIT COILTELESCOPING OF SLIT COILWhen does out of round occur?Out of round generally occurs on insulation coils and wide flexible packaging coils.Why does out of round occur?* the bulk of the metal sags to the bottom of the coil during annealing - the cool down rate is particularly important, if the cooldown rate is too high it creates a thermal gradient in the coil. This defect is minised by using 152mm cores.What can you do about it?* make sure the cool down rate is within specification.6.7.1 Edge CracksWhat are edge cracks?Edge cracks are cracks or small splits along the edge of the strip. They are generally 0.2 to 0.3 mm long. Edge cracks are particularly a problem in hard alloys and can make it difficult, Sometimes impossible to roll the final pass.When do edge cracks occur?When the coolant composition, the pass schedule or the condition of the strip are out of specification.Why do edge cracks occur?There are a number of reasons:* too much friction during rolling;* the gauge reduction may be too great;* the edges of the strip may be shorter than the body of the strip, putting more tension on the edges.What can you do about them?* bend the edges of the coil, to do this:- turn positive bending off- increase negative bending to -2- increase the load;。
药用铝箔生产工艺的注意事项
在日常生活中，药用铝箔的应用非常广泛和成熟，药箔的主要用途有药品胶囊、片剂等的泡罩包装以及粉剂颗粒、水剂的袋状包装。
由于其直接接触食用药品，因此国家对药箔的外观和性能要求非常严格。
市场上常见的药箔有两种，为8011铝箔和8021铝箔，其中8011合金一般厚度都是在0.05mm以下，8021合金则厚度都在0.05mm以上。
大体上来讲，主要生产工艺流程是：坯料检验-开坯轧-开中分轧-合卷轧-轧成品-分切-装炉退火-成品包装。
药用铝箔表面要求无油污、无亮晶、无黑线、无针孔、无黄斑、无荷叶边等，在生产过程中，对于表面和性能的控制，主要为几下几点：
一、首先要从源头上控制质量，严格检验坯料;
二、然后在轧制过程中，通过对轧辊的清洗及粗糙度的控制、轧制油的选择、降低轧制油的黏度以及控制机器的运转速度等方面来控制表面质量;
三、再次，在分切过程中，要确保分切时铝卷边缘部分齐整，不能出现荷叶边等质量问题;
四、最后在退火工艺上，根据对药箔的性能要求来控制退火时间及退火温度，保证除油干净。
随着制药业的发展，药用铝箔凭着其具有优良的防潮性，阻隔性，耐药品性，化学稳性，卫生性，应用比例不断攀升，外观及质量要求也越来越高，市场前景非常广阔。
药品包装铝箔印刷涂布
会出现轻微 的色差 ，多数是因为原料或基材差异造成 的。
过程要严格把关。
颜 色过淡或过 浓 （ 同－ ￣ 次印刷颜色浓度不够 ：造成的原因：１ １） － Ｌ Ｌ ）
必要时可 由需 方在供 方现场进行确认 ，而作 为生产 印刷 箔针孔是 因为穿透性缺陷 ，影响铝箔 的阻隔性 （ 阻气性、
● 技术与工艺
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、
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三、铝箔 印刷 的常见质量 问题
各种文字或 图案。 当制成 泡罩 时 ，使用时稍加便可将其
压破 ，患者取药便利 ，携 带方便。
（ 方面应建立巡回检查制度 ，定期给运 转加油。 １）
磨 损的部 件要定期更换 ，并建 立更换 日期记 录 ，以便查
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（ 无毒、无味 ； １） （ 优 良的导 电性和遮光性 ； ２） （ 极高 的性 、阻气性和保 味性 ，能最 有效地被 ３）
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版辊左右两端 不均 、印刷辊松动等 因素造成 套 印不； 隹， 字体错位 ； （ 工艺技术 方面 的问题 ，原 料的开卷、 ３）
在 药品应用的金属箔均 为铝箔 ，称 为药品用铝 箔 （ 俗称Ｐ Ｐ Ｔ 铝箔 ），Ｐ Ｐ Ｔ 铝箔行业 中比较正 规的叫法为药 品用铝箔 ，也有叫泡罩用铝箔。我 国对 Ｐ Ｐ ￣ Ｔ ￥ 箔在 药品
药用包装铝箔工艺
药用包装铝箔工艺药用包装铝箔是一种具有高阻隔性能、防潮、防菌、防氧化的材料，常用于药品、食品等包装领域。
以下是药用包装铝箔的工艺流程：1.铝箔选材药用包装铝箔应选用符合国家相关标准的优质铝箔材料，如12μm或15μm的铝箔。
铝箔应表面平整、无划痕、无折痕，并具有足够的强度和韧性。
2.铝箔清洗在铝箔裁剪和成形前，需要进行清洗处理。
清洗的目的是去除铝箔表面的油污、尘埃和手指印等杂质，以确保药品的卫生安全。
清洗后的铝箔应立即进行干燥处理。
3.铝箔热处理热处理是提高铝箔强度和韧性的重要步骤。
热处理过程中，铝箔经过加热和冷却的循环处理，可以改变其内部结构，提高机械性能。
热处理后的铝箔应平整无皱褶，无变形。
4.铝箔成形根据药品包装的要求，将清洗并热处理后的铝箔裁剪成所需形状和尺寸。
在成形过程中，应注意保持铝箔的平整度和清洁度。
5.铝箔封合将成形的铝箔与其它包装材料进行封合，以形成一个封闭的包装体系。
封合过程应确保封口处平整、无凸起或凹陷，同时也要确保封合强度符合要求。
6.包装质量检测在封合完成后，应对药用包装铝箔进行质量检测。
检测项目包括外观检测（如封口处是否有气泡、皱褶等）、密封性能检测（如是否漏气）、阻隔性能检测（如透氧率、透湿率等）等。
只有符合质量标准的包装才能进入下一道工序。
7.包装标识打印根据药品包装的标识要求，利用数字印刷机或激光打印机等设备将标识打印在药用包装铝箔上。
标识内容应清晰、易读，包括药品名称、生产日期、有效期等重要信息。
同时也要确保标识颜色鲜艳、持久不褪色。
8.包装入库最后一道工序是将打印好标识的药用包装铝箔进行整理、入库。
在入库前，应确保药用包装铝箔的数量、规格等信息准确无误。
药用铝箔的生产工艺及存在的问题
药用铝箔的生产工艺及存在的问题目前，各种片剂、丸剂、胶囊剂、颗粒剂等药品均采用铝塑泡罩的方式包装,这种包装除了能较好地保护药品的质量性能外,还具有包装生产速度快,成本低,质量轻,储存空间小,运输和使用方便等特点。
随着用户对药品的质量和外观的要求越来越高,表面印刷套色可达6～8 种文字和图案,药用箔的质量要求越来越高。
1、药用铝箔的生产工艺现在药用铝箔的包装大都采用8011 合金箔,厚度为0. 02 mm ,状态为H18 。
其工艺流程为:坯料检验→轧制→合卷→轧制→分切→检查、包装、入库。
轧制道次分配为0. 3 mm(H14) →0. 145 mm→01072mm→0. 032 mm→2 ×0. 02 mm(H18) 。
其中1、2 道次放在粗轧机(轧辊的凸度为0. 09 mm, Ra 值为0. 3μm) 上轧制;3、4 道次放在中轧(轧辊的凸度为0. 10 mm, Ra 值为0. 15μm)上轧制。
轧制速度1、2、3 道次在800 mPmin～1200 mPmin ,第4 道次速度在400 mPmin～450 mPmin。
在生产和研制阶段主要遇到以下技术难点：1. 1 箔面除油由于铝箔产品是硬状态交货,并且铝箔的轧制是在油润滑的环境下进行的,铝箔的表面不可避免地会粘上轧制油,这样对轧机除油效果的要求更高了。
对轧机的清辊器进行了改造,使清辊器作用在支撑辊上的压力增大,并在上清辊器与两牌坊之间的连接梁上加上一幅整块的聚氨酯挡板,使入口的轧制油不会从支撑辊上面溅到出口的箔面上。
在出口活动的机后装置靠近支撑辊处加上一幅挡油帘,使下面的轧制油不会甩到箔面上,并且对防溅板,吹扫风嘴进行了改造,以及风嘴的角度和风压进行了调整,使轧机本身除油达到最佳状况。
控制轧制成品的速度和轧制力,从而降低油效应,使轧辊于铝箔表面产生一个较小的强制压应力,使进入变形区的油膜的厚度减薄。
降低轧制油的油压和提高轧制油的温度,降低成品道次的道次加工率。
药用铝箔(国家药包材标准YBB00152002—2015)
YBB00152002—2015药用铝箔YaoyongLüboAluminium Foils for Medicine本标准适用于与聚氯乙烯（PVC）、聚偏二氯乙烯（PVCD）等硬片黏合，用于固体药品（片剂、胶囊剂等）包装用的铝箔。
本品涂有保护层和黏合层。
【外观】取本品适量（每卷取2m，在自然光线明亮处，正视目测。
表面应洁净、平整、涂层均匀；文字、图案印刷应正确、清晰、牢固。
【针孔度】取长400mm，宽250mm（当宽小于250mm时，取卷幅宽）试样十片，逐张置于针孔检查台（800mm×600mm×300mm或适当体积的木箱，木箱内安装30W日光灯，木箱上面放一块玻璃板，玻璃板衬黑纸并留有400mm×250mm空间以检查试样的针孔）上，在暗处检查其针孔。
不应有密集的、连续性的、周期性的针孔：每一平方米中，直径大于0.3mm的针孔不允许有；直径为0.1.～0.3mm的针孔数不得过1个。
【阻隔性能】水蒸气过量照水蒸气透过量测定法（YBB00092003-2015）第一法试验条件B或第二法试验条件B或第四法试验条件2测定，试验时热封面向低湿度侧，不得过0.5g/（㎡·24h）。
【黏合层热合强度】取100mm×100mm的本品二片，另取100mm×100mm 的聚氯乙烯固体药用硬片（符合YBB00212005-2015）或聚氯乙烯/聚偏二氯乙烯固体药用复合硬片（符合YBB00222005-2015）2片。
将试样的黏合层面向PVC面（或PVC/PVDC复合的硬片的PVDC面）进行叠合。
置于热封仪进行热合，热合条件为：温度155℃±5℃，压力0.2Mpa，时间1秒，热合后取出放冷，裁取成15mm宽的试样，取中间3条试样，照热合强度测定法（YBB00122003-2015）测定，试验速度为200mm/min±200mm/min，将PVC（或PVDC）片夹在试验机的上夹，铝箔夹在试验机的下夹。
药用铝箔行业报告
药用铝箔行业报告一、行业概况。
药用铝箔是一种专门用于包装药品的材料，具有防潮、防氧化、防紫外线等优良性能。
随着人们对药品包装要求的不断提高，药用铝箔的市场需求也在不断增加。
目前，全球药用铝箔市场规模已达到数十亿美元，预计未来几年将保持稳定增长。
二、市场需求。
1. 国际市场需求。
随着全球人口的增长和老龄化趋势的加剧，医药行业的市场需求不断增加。
而药用铝箔作为药品包装的重要材料，其市场需求也随之增加。
尤其是在发达国家和地区，对药品包装质量的要求更加严格，对药用铝箔的需求量更大。
2. 国内市场需求。
中国作为全球最大的医药市场之一，对药用铝箔的需求也非常巨大。
随着我国医药行业的不断发展和医疗水平的提高，对药品包装的要求也在不断提高，这为药用铝箔市场的发展提供了良好的机遇。
三、产业链分析。
1. 上游原材料。
药用铝箔的主要原材料是铝，而铝的生产主要依赖于铝土矿资源。
目前，全球铝土矿资源的储量丰富，保证了药用铝箔的原材料供应。
2. 中游加工。
药用铝箔的加工主要包括轧制、拉伸、涂层等工艺。
这些加工工艺的发展水平直接影响着药用铝箔的质量和性能。
3. 下游应用。
药用铝箔的主要应用领域是医药包装。
随着医药行业的快速发展，对药用铝箔的需求也在不断增加。
四、市场竞争格局。
目前，全球药用铝箔市场竞争格局较为分散，主要的生产企业包括美国的Reynolds、德国的Constantia Flexibles、中国的中铝公司等。
这些企业在技术研发、生产规模、市场占有率等方面都具有一定的竞争优势。
五、发展趋势。
1. 技术创新。
随着医药行业的不断发展，对药用铝箔的性能和质量要求也在不断提高。
因此，药用铝箔企业需要不断进行技术创新，提高产品的质量和性能，以满足市场需求。
2. 绿色环保。
随着全球环保意识的增强，绿色环保已成为行业发展的主要趋势。
药用铝箔企业需要加大绿色环保技术的研发和应用，减少对环境的影响。
3. 国际化发展。
随着全球医药行业的一体化发展，药用铝箔企业也需要加大国际化发展的步伐，积极拓展国际市场，提高国际竞争力。
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药用铝箔的生产工艺及存在的问题
目前，各种片剂、丸剂、胶囊剂、颗粒剂等药品均采用铝塑泡罩的方式包装,这种包装除了能较好地保护药品的质量性能外,还具有包装生产速度快,成本低,质量轻,储存空间小,运输和使用方便等特点。
随着用户对药品的质量和外观的要求越来越高,表面印刷套色可达6～8 种文字和图案,药用箔的质量要求越来越高。
1、药用铝箔的生产工艺
现在药用铝箔的包装大都采用8011 合金箔,厚度为0. 02 mm ,状态为H18 。
其工艺流程为:坯料检验→轧制→合卷→轧制→分切→检查、包装、入库。
轧制道次分配为0. 3 mm(H14) →0. 145 mm→01072mm→0. 032 mm→2 ×0. 02 mm(H18) 。
其中1、2 道次放在粗轧机(轧辊的凸度为0. 09 mm, Ra 值为0. 3μm) 上轧制;3、4 道次放在中轧(轧辊的凸度为0. 10 mm, Ra 值为0. 15μm)上轧制。
轧制速度1、2、3 道次在800 mPmin～1200 mPmin ,第4 道次速度在400 mPmin～450 mPmin。
在生产和研制阶段主要遇到以下技术难点：
1. 1 箔面除油
由于铝箔产品是硬状态交货,并且铝箔的轧制是在油润滑的环境下进行的,铝箔的表面不可避免地会粘上轧制油,这样对轧机除油效果的要求更高了。
对轧机的清辊器进行了改造,使清辊器作用在支撑辊上的压力增大,并在上清辊器与两牌坊之间的连接梁上加上一幅整块的聚氨酯挡板,使入口的轧制油不会从支撑辊上面溅到出口的箔面上。
在出口活动的机后装置靠近支撑辊处加上一幅挡油帘,使下面的轧制油不会甩到箔面上,并且对防溅板,吹扫风嘴进行了改造,以及风嘴的角度和风压进行了调整,使轧机本身除油达到最佳状况。
控制轧制成品的速度和轧制力,从而降低油效应,使轧辊于铝箔表面产生一个较小的强制压应力,使进入变形区的油膜的厚度减薄。
降低轧制油的油压和提高轧制油的温度,降低成品道次的道次加工率。
降低油压和提高油温主要是为了降低油膜厚度和轧制油量,降低成品的道次加工率是为了降低轧制速度,从而降低轧制区的温度和降低油膜的厚度,同时也使加工硬化更为明显,提高了铝箔的强度。
降低轧制油中油性添加剂含量。
油黏度大意味轧制油的馏程终结点高,减缩能力大,污染的可能性也大。
降低轧制油的黏度,从而降低油膜的厚度。
1. 2 亮晶( 亮点)
亮晶是双合轧制时出现在铝箔暗面上不均匀的发光点。
它不但影响美观,而且会导致铝箔的力学性能下降。
亮晶分布在铝箔的暗面,一般呈椭圆形,个别呈长方形弥散分布,有时在整个铝箔表面上或局部分布,双合的上下两张箔是呈一一对应关系的,亮晶的颜色比铝的基本颜色要深且发亮,特别严重时则会形成针孔。
亮晶产生的基本原因:在正常轧制的过程中,轧辊表面与铝箔的表面是不直接接触的,轧制力是通过轧制油膜进行传递的。
从金属的成形摩擦学的角度来说,轧辊和铝箔两个接触面之间完全由液体润滑剂隔开,铝箔成形过程中所产生的摩擦即为流体摩擦,如果在轧制过程中这一层液体润滑剂所组成的油膜一旦局部被破坏,就形成了混合摩擦(由流体摩擦、干摩擦、边界摩擦组成) 。
干摩擦和边界摩擦常常会导致轧制工件的成形异常,也就是成形压力不通过油膜,而是通过局部的点直接接触传递到轧制工件上,形成现在所谓的“亮晶”。
而流体摩擦部分属于正常成形表面,不会影响亮晶,这就是亮晶产生和弥散分布的原因。
根据亮晶产生的原因从以下几个方面进行改进:
(1) 合卷机的涂油。
由于合卷的涂油太少或涂油不均,使两层铝箔在轧制过程中油膜的厚薄不均,或部分地方没有油膜,致使两层铝箔之间形成干摩擦或边界摩擦,所以我们在合卷的过程中,加大涂油量,降低速度,并要求涂油均匀。
(2) 采用低闪点的双合油。
最先采用的是闪点为82 ℃的轧制基础油,后来改为闪点为70 ℃的双合油。
闪点为70 ℃的油与82 ℃的油相比,其黏度更低,挥发性更强,其形成的油膜更薄,铝箔暗面形成的油膜分布均匀,此时的润滑性能偏低,使两张铝箔之间
的摩擦力增大,使两层铝箔之间不存在相对滑动。
(3) 轧辊粗糙度的不均一或配对径差太大,也是产生亮晶的非常重要的原因,当轧
辊的上下辊粗糙度不均一时,致使上下层铝箔与上下工作辊的摩擦因数不一样,由于轧
辊的转速是同步的,致使两层铝箔之间产生相对错动。
同样由于上下工作辊的角速度是相同的,辊径的差别使其线速度不一样,在双合轧制时使两层铝箔之间也随着工作辊的
转动而产生相对滑动。
(4) 严格控制双合前的铝箔厚度,使双合时两张的厚度差达到要求,否则不允许双
合在一起。
当两张铝箔的厚度差较大时,由于金属的流动,上下两张铝箔的加工率不一致,使金属的流动不同步,两张铝箔容易产生错动,产生亮晶。
2、目前药用铝箔存在的主要问题
(1) PVC 板与铝箔的热压粘合力刚达到国标。
根据具体情况,产生粘合力较低的原因,可能是除油不好,经过试验铝箔表面已达到无油标准,其润湿表面张力已达到34
×10 - 3 NPm。
另外的原因可能是铝箔表面太亮,即轧辊的粗糙度值太小,我们把工作辊的粗糙度由原来的0. 1μm ,提高到现在的0. 15μm ,使粘合力大大提高。
(2) 抗拉强度偏低,仅达到168 NPmm2 。
分析其性能偏低可能的几个原因,其一,轧制速度高,因为轧制速度高(800 mPmin～1 200 mPmin) ,使轧制区的温度提高,就相当于轧件在轧辊之间进行了一次回复退火,使加工硬化不明显,由于是要提高轧机的工作效率, 我们只能在成品道次把速度控制在400mPmin～500 mPmin 之间,但效果不是太明显。
其二,对8011 合金中的化学成分相应的调整,要求w (Fe) :w (Si) ≥2. 0 ,w (Fe) = 0. 8 %～1. 0 % ,w (Si) ≤0. 6 % ,w (Mn) = 0. 02 %～ 0. 05 % , 其他杂质含量不大于0. 05 % ,通过调整使最终成品的抗拉强度大于193NPmm2 ,达到了用户的要求。
(3) 边部或局部微松。
边部松,我们根据实际情况对轧制过程中板形曲线的幅值由原来的25 I 降至现在的18 I。
局部松的原因是喷淋失控,要做到定期检查,及时维修。
3、结束语
对我公司在药箔的试生产过程中,从工艺到成品进入市场存在的问题作了简要的论述,要稳定产品质量提高市场竞争力,还要求每道工序的操作人员有很强的责任心,在实践中总结经验,提高自己的操作水平,把问题消除在本工序内。