銅(tong)(tong)原(yuan)子序數為29，隸屬(shu)于過渡金屬(shu)，密度是(shi)8.92g/cm3，熔點(dian)1083.4℃，具有(you)良好的(de)導(dao)熱和導(dao)電(dian)性能，但(dan)在潮(chao)濕的(de)空氣中金屬(shu)銅(tong)(tong)表面(mian)與氧(yang)氣發生(sheng)化(hua)學(xue)反應，生(sheng)成Cu2(OH)2CO3，即銅(tong)(tong)綠，通常電(dian)纜(lan)生(sheng)產(chan)廠中銅(tong)(tong)氧(yang)化(hua)多顯示表面(mian)發黑，正是(shi)這種銅(tong)(tong)導(dao)體表面(mian)氧(yang)化(hua)現(xian)象的(de)存在，困擾(rao)著眾多電(dian)纜(lan)企(qi)業。我(wo)們在長期(qi)日常生(sheng)產(chan)中觀察(cha)發現(xian)，通過銅(tong)(tong)桿選擇、有(you)效(xiao)控制拉絲工(gong)藝及乳化(hua)液濃度和溫度、鈍化(hua)處理(li)銅(tong)(tong)導(dao)體絞合或束絞銅(tong)(tong)絲表面(mian)、后續工(gong)序優化(hua)處理(li)等手段，會有(you)效(xiao)控制電(dian)纜(lan)銅(tong)(tong)導(dao)體的(de)質量、防(fang)止其氧(yang)化(hua)，會提高(gao)工(gong)作效(xiao)率，減少返(fan)工(gong)頻次，從而達到(dao)降(jiang)低成本和提高(gao)內在產(chan)品(pin)質量的(de)有(you)益效(xiao)果(guo)。

下面我們以中(zhong)壓電力(li)電纜生(sheng)產(chan)(chan)為(wei)例，從銅桿抵達(da)生(sheng)產(chan)(chan)廠、儲存、拉(la)絲(si)、絞合、內芯存放到絕緣擠(ji)出，對每個步(bu)驟有效控制措施進行(xing)分析。

▎中壓(ya)電力電纜生產過(guo)程中的銅導體防氧化控制

電纜用金屬(shu)銅(tong)從原(yuan)理(li)(li)上(shang)講主要有(you)物理(li)(li)方(fang)法阻(zu)隔銅(tong)與潮濕空氣接觸、陰極(ji)保護(hu)氧化(hua)(hua)還原(yuan)法阻(zu)止(zhi)銅(tong)導體氧化(hua)(hua)、化(hua)(hua)學方(fang)法在銅(tong)導體表(biao)面生產鈍化(hua)(hua)膜(mo)阻(zu)止(zhi)氧化(hua)(hua)，抑或在導體表(biao)面噴涂特(te)殊(shu)液(ye)體予以(yi)(yi)保護(hu)。以(yi)(yi)中壓電力電纜生產為(wei)例，每(mei)道工序防氧化(hua)(hua)控(kong)制的主要方(fang)法。

? 銅桿進廠前(qian)運輸、檢測及儲存(cun)

我國大多(duo)數電(dian)(dian)纜(lan)(lan)(lan)企(qi)業(ye)(ye)用(yong)銅(tong)(tong)(tong)(tong)基本外購，而多(duo)數企(qi)業(ye)(ye)往(wang)往(wang)忽視了(le)銅(tong)(tong)(tong)(tong)桿(gan)(gan)進(jin)廠前運輸過程的(de)(de)(de)控制，在江南及(ji)沿海地帶（江浙、閩(min)粵(yue)）夏(xia)季較(jiao)長且(qie)多(duo)雨(yu)，銅(tong)(tong)(tong)(tong)桿(gan)(gan)基本通過重型卡車運輸至公司，通過筆者了(le)解，很多(duo)電(dian)(dian)纜(lan)(lan)(lan)企(qi)業(ye)(ye)沒有(you)制定(ding)(ding)相應的(de)(de)(de)銅(tong)(tong)(tong)(tong)桿(gan)(gan)供應商(shang)運輸規范、夏(xia)季雨(yu)天包裝規范等制度，這使得往(wang)往(wang)出現銅(tong)(tong)(tong)(tong)桿(gan)(gan)供應商(shang)發貨時銅(tong)(tong)(tong)(tong)桿(gan)(gan)表(biao)面完好無氧化發黑，而到達(da)電(dian)(dian)纜(lan)(lan)(lan)企(qi)業(ye)(ye)用(yong)戶面前時則(ze)出現銅(tong)(tong)(tong)(tong)桿(gan)(gan)表(biao)面發黑現象(xiang)，帶來了(le)不必要的(de)(de)(de)麻煩。銅(tong)(tong)(tong)(tong)桿(gan)(gan)進(jin)廠檢驗基本依(yi)照(zhao)GB/T 3048.2或(huo)電(dian)(dian)纜(lan)(lan)(lan)企(qi)業(ye)(ye)企(qi)標，有(you)嚴(yan)格(ge)的(de)(de)(de)程序。銅(tong)(tong)(tong)(tong)桿(gan)(gan)的(de)(de)(de)儲(chu)存一(yi)(yi)般電(dian)(dian)纜(lan)(lan)(lan)企(qi)業(ye)(ye)均(jun)放(fang)在倉庫里，一(yi)(yi)般企(qi)業(ye)(ye)有(you)較(jiao)為嚴(yan)格(ge)的(de)(de)(de)儲(chu)存管理(li)辦(ban)法，在銅(tong)(tong)(tong)(tong)桿(gan)(gan)儲(chu)存時，尤其是(shi)夏(xia)季雨(yu)天，一(yi)(yi)定(ding)(ding)要用(yong)塑料(liao)布(bu)或(huo)塑料(liao)薄膜覆蓋銅(tong)(tong)(tong)(tong)桿(gan)(gan)，用(yong)簡單的(de)(de)(de)物理(li)阻(zu)隔法阻(zu)止銅(tong)(tong)(tong)(tong)桿(gan)(gan)與(yu)潮濕(shi)空氣的(de)(de)(de)接觸制，而這一(yi)(yi)點往(wang)往(wang)受到電(dian)(dian)纜(lan)(lan)(lan)企(qi)業(ye)(ye)的(de)(de)(de)忽視。在車間(jian)領用(yong)銅(tong)(tong)(tong)(tong)桿(gan)(gan)時一(yi)(yi)定(ding)(ding)要逐個銅(tong)(tong)(tong)(tong)桿(gan)(gan)卷進(jin)行肉眼檢查是(shi)否有(you)發黑現象(xiang)，從生(sheng)產源頭加以控制。

? 銅桿拉絲(si)工(gong)序(xu)的控制(zhi)

本階段以電(dian)力(li)電(dian)纜(lan)常用的8mm銅(tong)(tong)(tong)桿為(wei)例，如今拉(la)(la)絲時一(yi)般使用連續退(tui)(tui)火(huo)的銅(tong)(tong)(tong)大拉(la)(la)，需經過(guo)(guo)放(fang)線(xian)、拉(la)(la)絲與(yu)退(tui)(tui)火(huo)、冷卻、烘(hong)干、收線(xian)等過(guo)(guo)程，選取對應規格(ge)的模具(ju)，切不可(ke)過(guo)(guo)小(xiao)，如過(guo)(guo)小(xiao)會強(qiang)制(zhi)使金屬(shu)銅(tong)(tong)(tong)的晶格(ge)變異(yi)，加劇金屬(shu)溫度(du)的急劇上升(sheng)。在(zai)(zai)開(kai)機(ji)前檢查乳化(hua)(hua)(hua)液的濃度(du)，確保濃度(du)合(he)格(ge)，在(zai)(zai)放(fang)線(xian)過(guo)(guo)程中(zhong)，應保持放(fang)線(xian)張力(li)穩定、均勻(yun)，不可(ke)過(guo)(guo)度(du)顫動（顫動不可(ke)避(bi)免），拉(la)(la)絲過(guo)(guo)程中(zhong)操作者應密切關(guan)注(zhu)退(tui)(tui)火(huo)溫度(du)的變化(hua)(hua)(hua)，拉(la)(la)絲后導(dao)體硬化(hua)(hua)(hua)，延伸率變小(xiao)，導(dao)體直流電(dian)阻率上升(sheng)，拉(la)(la)絲候成(cheng)圈時銅(tong)(tong)(tong)導(dao)體表面不應有(you)殘余(yu)乳化(hua)(hua)(hua)液，此處(chu)需要操作者肉眼(yan)識別，在(zai)(zai)拉(la)(la)絲下盤(pan)后用透(tou)明塑(su)料薄(bo)膜(mo)(mo)密封(feng)，存放(fang)于干燥環境之中(zhong)，待流轉，但多數電(dian)纜(lan)企業(ye)因為(wei)嫌銅(tong)(tong)(tong)絲包薄(bo)膜(mo)(mo)麻煩而省略包薄(bo)膜(mo)(mo)工序。剛拉(la)(la)絲成(cheng)圈的導(dao)體表面溫度(du)高于室溫，如遇(yu)雨季會潛在(zai)(zai)氧化(hua)(hua)(hua)的風險(xian)。

? 銅(tong)絲絞合（束絞）與化學(xue)交聯擠出(chu)工序

以銅(tong)(tong)絲(si)(si)絞(jiao)(jiao)合(he)(he)(he)(he)(he)為(wei)例(li)，在(zai)(zai)(zai)(zai)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)絞(jiao)(jiao)合(he)(he)(he)(he)(he)過(guo)(guo)程中(zhong)，各(ge)單絲(si)(si)以規(gui)則(ze)絞(jiao)(jiao)合(he)(he)(he)(he)(he)或(huo)不規(gui)則(ze)絞(jiao)(jiao)合(he)(he)(he)(he)(he)等方(fang)式(shi)絞(jiao)(jiao)合(he)(he)(he)(he)(he)，經過(guo)(guo)各(ge)道壓(ya)模(mo)后金(jin)屬銅(tong)(tong)晶(jing)格改變結構，在(zai)(zai)(zai)(zai)強外力作(zuo)(zuo)用(yong)下，過(guo)(guo)模(mo)后銅(tong)(tong)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)溫(wen)度較過(guo)(guo)模(mo)前(qian)(qian)有較大提高，尤其(qi)是(shi)(shi)(shi)緊(jin)壓(ya)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)、扇(shan)形(xing)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)等，且框(kuang)(kuang)絞(jiao)(jiao)機(ji)目前(qian)(qian)無(wu)在(zai)(zai)(zai)(zai)線(xian)退火或(huo)降溫(wen)裝置，因此銅(tong)(tong)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)外層易(yi)氧(yang)(yang)化(hua)，在(zai)(zai)(zai)(zai)絞(jiao)(jiao)合(he)(he)(he)(he)(he)前(qian)(qian)，選擇合(he)(he)(he)(he)(he)適的(de)絞(jiao)(jiao)合(he)(he)(he)(he)(he)模(mo)具、緊(jin)壓(ya)輪(lun)、排線(xian)器(qi)，調(diao)(diao)(diao)整(zheng)(zheng)收線(xian)與(yu)(yu)放線(xian)張(zhang)力，設(she)備調(diao)(diao)(diao)整(zheng)(zheng)完畢后，操作(zuo)(zuo)者肉眼觀察上(shang)盤銅(tong)(tong)絲(si)(si)與(yu)(yu)放線(xian)架中(zhong)心銅(tong)(tong)絲(si)(si)的(de)表面光潔度，確(que)保(bao)(bao)無(wu)明顯黑(hei)點，再啟動機(ji)器(qi)。一般(ban)電(dian)(dian)纜企業(ye)會在(zai)(zai)(zai)(zai)絞(jiao)(jiao)合(he)(he)(he)(he)(he)工(gong)序(xu)（框(kuang)(kuang)絞(jiao)(jiao)機(ji)、籠絞(jiao)(jiao)機(ji)）中(zhong)施加抗(kang)氧(yang)(yang)劑(ji)(ji)(ji)，抗(kang)氧(yang)(yang)劑(ji)(ji)(ji)的(de)配方(fang)是(shi)(shi)(shi)0.3%左右的(de)苯并三氮唑酒精溶(rong)液(ye)，操作(zuo)(zuo)方(fang)法是(shi)(shi)(shi)將抗(kang)氧(yang)(yang)劑(ji)(ji)(ji)融(rong)入工(gong)業(ye)酒精之中(zhong)，用(yong)輸液(ye)軟(ruan)管滴(di)入銅(tong)(tong)絲(si)(si)中(zhong)，滴(di)入標準以剛好浸(jin)潤銅(tong)(tong)絲(si)(si)為(wei)準，避免過(guo)(guo)少局部潛在(zai)(zai)(zai)(zai)氧(yang)(yang)化(hua)或(huo)過(guo)(guo)多浪費的(de)現象發生，在(zai)(zai)(zai)(zai)所(suo)有防氧(yang)(yang)化(hua)工(gong)作(zuo)(zuo)準備穩妥后，再開(kai)機(ji)運轉。收線(xian)處(chu)應保(bao)(bao)證收線(xian)盤干燥，收線(xian)盤裝滿后，用(yong)透明塑料(liao)薄膜密封，與(yu)(yu)銅(tong)(tong)絲(si)(si)拉(la)制(zhi)同理，很(hen)多電(dian)(dian)纜企業(ye)也省略(lve)了此步(bu)驟(zou)，若(ruo)此步(bu)驟(zou)造成銅(tong)(tong)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)氧(yang)(yang)化(hua)，對(dui)低(di)壓(ya)電(dian)(dian)纜影響尚(shang)低(di)，對(dui)超高壓(ya)電(dian)(dian)纜而言，影響則(ze)不堪(kan)設(she)想。銅(tong)(tong)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)在(zai)(zai)(zai)(zai)經過(guo)(guo)拉(la)絲(si)(si)、絞(jiao)(jiao)合(he)(he)(he)(he)(he)、儲存后，金(jin)屬銅(tong)(tong)晶(jing)格形(xing)態已基(ji)本穩定。化(hua)學交聯即在(zai)(zai)(zai)(zai)交聯劑(ji)(ji)(ji)、抗(kang)氧(yang)(yang)劑(ji)(ji)(ji)、耦合(he)(he)(he)(he)(he)劑(ji)(ji)(ji)等條件下，將XLPE均勻(yun)的(de)擠包(bao)在(zai)(zai)(zai)(zai)銅(tong)(tong)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)上(shang)。在(zai)(zai)(zai)(zai)將裝滿銅(tong)(tong)導(dao)(dao)(dao)(dao)體(ti)(ti)(ti)的(de)放線(xian)盤啟動前(qian)(qian)，調(diao)(diao)(diao)整(zheng)(zheng)收放線(xian)張(zhang)力，保(bao)(bao)證設(she)備運行(xing)平穩。 

▎總結(jie)

我(wo)國幾乎所有的(de)電(dian)纜(lan)廠都面臨銅(tong)導體氧化的(de)困擾，從金(jin)屬銅(tong)化學特性(xing)講，就是要保持金(jin)屬銅(tong)的(de)還原性(xing)。在日常生產中，采(cai)(cai)用(yong)如下措施(shi)可減少銅(tong)導體氧化的(de)幾率： 1） 選擇質(zhi)優金(jin)屬銅(tong)桿，規范(fan)供(gong)應商運輸、交貨流程與制(zhi)度，銅(tong)桿到(dao)公司后，采(cai)(cai)取(qu)透明(ming)塑料薄膜密封措施(shi)，銅(tong)導體拉制(zhi)、絞合后都應采(cai)(cai)取(qu)透明(ming)塑料薄膜密封措施(shi)； 2） 采(cai)(cai)用(yong)合適的(de)銅(tong)絲(si)(si)(si)拉制(zhi)工(gong)(gong)藝，定(ding)(ding)期(qi)檢查拉絲(si)(si)(si)機(ji)的(de)退火部件(jian)，優先選擇含抗氧劑的(de)拉絲(si)(si)(si)油，定(ding)(ding)期(qi)檢查乳化液濃度，保質(zhi)期(qi)到(dao)期(qi)前一(yi)定(ding)(ding)提(ti)前更換； 3） 銅(tong)絲(si)(si)(si)絞合、擠包絕緣工(gong)(gong)序采(cai)(cai)用(yong)鈍(dun)化處(chu)理(li)技術； 4） 樹立質(zhi)量意(yi)識，加強業務培訓讓以上工(gong)(gong)序操作者清(qing)楚銅(tong)絲(si)(si)(si)氧化帶來的(de)不良(liang)后果。

                                                                                                                                                  生產部