Breakthrough in Gradient Temperature Control Technology! Patent Solves Decades-Long Aluminum Ingot Heating Uniformity Challenge

Technical Revolution
A leading aluminum enterprise in Jiangxi Province has announced that its self-developed gradient temperature control extrusion system for aluminum profiles has obtained certification from China’s National Intellectual Property Administration, resolving a 30-year global challenge of uneven aluminum ingot heating. Leveraging multi-field coupling intelligent control technology, the system achieves precise coordination of temperature fields, stress fields, and flow velocity fields in aluminum profile production:

Dynamic Gradient Thermal Field Design: Seven independent temperature control units are arranged along the extrusion cylinder’s axis, with temperatures increasing linearly from 380°C at the feed end to 520°C at the discharge end. This design precisely matches the temperature gradient caused by frictional heating during extrusion. Simulations show that traditional processes resulted in a 15°C temperature difference between the head and tail of profiles, whereas the new system reduces this to ±1.2°C.

Full-Process Intelligent Closed-Loop Control: Thirty-two high-precision temperature sensors (accuracy ±0.5°C) and laser displacement monitors are integrated to collect 12 key parameters—such as extrusion speed and die temperature—in real time. AI algorithms drive solenoid valves to adjust cold air flow, achieving ±1°C temperature control with a response time of less than 500 milliseconds.

Industrial Application Results: Scaled implementation in a new energy vehicle battery tray production line has reduced surface roughness from Ra3.2μm to Ra1.6μm. The pass rate in 5,000-hour salt spray tests (ISO 9227) has increased from 78% to 95%. Additionally, unit energy consumption has dropped from 1,350kWh/ton to 1,188kWh/ton, saving over 20 million kWh of electricity annually and cutting costs by 15 million yuan.

Industry Reconstruction Impact
This breakthrough fills a technical void in high-precision industrial aluminum production, particularly meeting the strict requirements for material homogeneity in aerospace, semiconductor equipment, and other cutting-edge fields. For example, in aviation structural components, traditional processes caused a 40% deviation in internal grain size within profiles, while the gradient temperature control technology enhances grain uniformity to 92% and increases fatigue strength by 22%, directly replacing imported American-standard 7050-T7451 alloys. According to the International Aluminum Institute (IAI), the global high-end aluminum profile market is expected to exceed 700 billion yuan by 2025. Chinese enterprises may leverage this technology to increase their import substitution rate in aerospace from the current 12% to over 30%.

Expert Commentary
"This technology achieves homogenization of material microstructure through precise regulation of physical fields, marking a milestone in aluminum processing from 'experience-based manufacturing' to 'science-based manufacturing,'" said Wang Haitao, Vice President of the China Nonferrous Metals Industry Association. He noted that gradient temperature control technology is not limited to 6xxx and 7xxx series aluminum alloys but can also be extended to difficult-to-process metals like magnesium and titanium alloys, potentially driving technological upgrades across the entire light alloy processing industry.