Introduction
Anode packaging (inside view)
Material Composition
Enhanced Surface Processing
Vickers Hardness
Manufacturing Processes
Suspension Rod Fabrication
The conductive rods are meticulously prepared to ensure optimal performance and durability. The rods are first cleaned of grease and oxides using a combination of detergent and acid. They are then coated with a specialized alloy layer designed to enhance adhesion between the lead alloy and copper rod. Finally, the rods are bonded to the lead material through advanced metallurgical processes, resulting in a robust, corrosion-resistant structure that withstands the demanding conditions of copper electrowinning.
Plate and Rod Welding
To ensure a firm and durable connection between the anode plates and conductive rods, a trapezoidal connection design is used. This configuration increases the contact area, facilitating a stronger bond. Argon-oxygen arc welding is employed, which not only secures the components but also maintains the integrity of the materials involved. This welding method ensures the anode plates can endure the mechanical stresses and chemical environments they are exposed to.
Alloy Casting and Rolling
The lead alloy is cast at precisely controlled temperatures of 180°C ± 20°C to achieve a uniform composition and fine-grained structure. The cast billets are then hot-rolled to reduce their thickness to 25 mm before undergoing repeated cold rolling to achieve a final thickness of 12 mm. These processes are carefully managed, with 24-hour cooling intervals between each stage, ensuring the plates meet stringent standards for uniformity and strength.
Dimensioning and Surface Finishing
Dimensional precision is paramount for anode plate performance. The length and width of each plate have a tolerance of less than 3 mm, while diagonal deviations are limited to under 10 mm. Each plate undergoes meticulous finishing to ensure a smooth, defect-free surface. Any scratches, pits, or inclusions are eliminated, and plates are carefully stacked and marked to facilitate traceability.
Inspection and Quality Assurance
Material Testing
All raw materials, including lead, tin, and copper, are subjected to comprehensive testing for chemical composition and physical properties. Random sampling from each batch ensures consistency and adherence to production standards. The results of these tests are meticulously documented for traceability and quality control.
Process Controls
Critical production parameters such as mold temperature, alloy composition, and rolling thickness are rigorously monitored. Advanced testing equipment, including atomic absorption spectrometers and metallurgical microscopes, supports precise analysis and ensures that each stage of production meets predefined quality benchmarks.
Product Testing
Mechanical properties of the finished anode plates are assessed using Brinell hardness testers and hydraulic universal testing machines. These evaluations confirm the plates’ ability to withstand operational stresses. Final inspections verify compliance with all dimensional and structural specifications before the plates are approved for shipment.
Packaging and Shipping
Packaging Design
To ensure safe transportation, the anode plates are suspended vertically on steel racks, which prevent physical damage and deformation. Plastic foam sheets are placed between each plate to protect their surfaces from scratches. Finally, the plates are wrapped in plastic to secure them during handling and shipping.
Marking and Traceability
Each pallet, weighing less than three tons and under 0.8 meters in height, is clearly marked to allow for easy identification and traceability. This organized system ensures the plates arrive at their destination in optimal condition and facilitates efficient handling and inventory management.
