Metal Carved Plate

I. Definition and Classification

Metal carved plates are decorative composite materials made from aluminum sheets (such as 6061, 6063 series) through precision mold carving, etching, or laser processing to create three-dimensional patterns. They are classified by process:

1. Mold Carving Plates: High-precision patterns formed by CNC or hydraulic molds, with depths of 0.5–3mm.

2. Chemical Etching Plates: Complex micro-porous patterns created using FeCl₃ solution.

3. Laser Carving Plates: Micron-level textures achieved via high-energy CO₂ lasers (minimum line width 0.1mm).

II. Material Properties

1. Base Material Performance

• 6061-T6: Tensile strength ≥310MPa, yield strength ≥270MPa (suitable for high-strength structural components).

• 6063-T5: Surface hardness HV ≥120, easy forming (primarily used for decorative parts).

• Alloy Systems:

• Density: 2.7g/cm³ (lightweight advantage, 1/3 of steel).

• Corrosion Resistance: Natural oxide film (10–15μm), salt spray resistance >2000h (ASTM B117).

• Surface Treatment Characteristics

• Weatherability ≥25 years (QUV aging test >2000h), self-cleaning function (contact angle >110°).

• Film thickness 10–25μm, color stability (ΔE <2, GB/T 12967-2008).

• Closed treatment ensures chloride ion penetration resistance >5000h (ASTM G154).

• Anodizing (Aluminum):

• Fluorocarbon Spraying:

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III. Production Process Flow

1. Base Material Pretreatment

• Cleaning: Alkaline degreasing (pH 12–14, 60–80°C) to remove surface contaminants.

• Acid Etching: HNO₃ solution (10–15%) for surface roughening to enhance adhesion.

• CO₂ laser (power 2–5kW, scanning speed 50–200mm/s), minimum pulse width 0.1μs.

• CNC/mold pressing with precision ±0.005mm, single pass depth 0.1–1mm.

• Residual stress control: Surface compressive stress 50–100MPa (crack suppression).

• Mold Carving:

• Laser Carving:

• Two-coat two-bake process, film thickness ≥35μm, pencil hardness ≥2H (GB/T 9278).

• Electrolyte composition (sulfuric acid 15–20%, temperature 18–22°C), voltage 12–18V, duration 30–60 minutes.

• Anodizing:

• Fluorocarbon Spraying:

• Bending: Bending radius ≥t²/(1.5δ) (t: plate thickness, δ: yield strength).

• Welding: TIG welding (current 80–120A), weld strength ≥90% of base material.

IV. Performance Indicators

1. Mechanical Properties

• Tensile Strength: ≥270MPa (6061-T6 state)

• Bending Stiffness: EI = E×I (E=70GPa, I: section moment of inertia)

• Impact Toughness: Charpy V-notch impact value ≥15J (-20℃ environment)

• Surface Roughness: Ra 0.8–3.2μm (dependent on pattern depth)

• Color Difference Control: ΔE ≤1.5 (CIE Lab standard)

• Glossiness: High-gloss surface ≥85GU, matte finish ≤20GU

• Weatherability: QUV aging test >2000h, Δb* ≤3% (GB/T 29743-2013)

• Corrosion Resistance: 10% NaOH solution immersion for 24h, mass loss <0.5%

V. Typical Applications

1. High-end Architectural Curtain Walls

• Lightweight alternative to stone/glass (weight reduction by 50%), superior wind load resistance (design value ≥4kPa/m²).

• Case Study: A landmark building in Dubai uses 6061-T6 aluminum carved plates with total curtain wall area of 12,000㎡, reducing construction time by 30%.

• Lightweight: Door trim panels (0.8mm thickness) reduce weight by 1.2kg/㎡, improving fuel economy by 0.5%.

• Functional Integration: Micro-porous structure for sound absorption (NRR ≥20dB).

• Anti-static: Surface resistance <1×10⁶Ω (ISO 18184), protecting electronic components.

• Thermal Management: Thermal conductivity 237W/m·K for high-power device cooling.

• High-end Gift Boxes: 5mm thick aluminum carved plates with UV ink printing, scratch resistance (pencil hardness ≥HB).

• Electronic Product Packaging: Shielding效能＞40dB (FCC Part 18 standard).

VI. Technical Development Trends

1. Functional Integration

• Photochromism: TiO₂ nanocoating (10nm thickness) for light transmittance adjustment (10%–80%).

• Electromagnetic Shielding: Copper-plated aluminum composite plates (copper layer ≥50μm), shielding效能＞60dB.

• Short-process Recycling: Aluminum recovery rate >98%, carbon emissions reduced by 45% compared to conventional processes.

• Chromium-free Pretreatment: Silane coupling agent replaces Cr⁶⁺, reducing wastewater toxicity by 90%.

VII. Selection Reference Standard

Metal carved plates have become a mainstream material in high-end architecture, automotive, and electronic fields due to their combination of high strength, lightweight, and decorative compatibility. Future advancements through material genomics and digital manufacturing will further expand their applications in flexible electronics and extreme environments.