Abstract
The present study investigates, experimentally and numerically, the tensile behavior of copper-clad aluminum composite wires. Two fiber-matrix configurations, the conventional Al-core/Cu-case and a so-called architectured wire with a continuous copper network across the cross-section, were considered. Two different fiber arrangements with 61 or 22 aluminum fibers were employed for the architectured samples. Experimentally, tensile tests on the two types of composites show that the flow stress of architectured configurations is markedly higher than that of the linear rule of mixtures’ prediction. Transverse stress components and processing-induced residual stresses are then studied via numerical simulations to assess their potential effect on this enhanced strength. A set of elastic-domain and elastoplastic simulations were performed to account for the influence of Young’s modulus and volume fraction of each phase on the magnitude of transverse stresses and how theses stresses contribute to the axial stress-strain behavior. Besides, residual stress fields of different magnitude with literature-based distributions expected for cold-drawn wires were defined. The findings suggest that the improved yield strength of architectured Cu-Al wires cannot be attributed to the weak transverse stresses developed during tensile testing, while there are compelling implications regarding the strengthening effect originating from the residual stress profile. Finally, the results are discussed and concluded with a focus on the role of architecture and residual stresses.
Highlights
Abundant copper demand for electrical applications from various sectors has prompted manufacturers to reduce material costs by replacing this rather expensive and high-density metal partly or entirely
The findings suggest that the improved yield strength of architectured Cu-Al wires cannot be attributed to the weak transverse stresses developed during tensile testing, while there are compelling implications regarding the strengthening effect originating from the residual stress profile
The rule of mixture is clearly not fulfilled revealing a complex mechanical behavior that can be attributed to the aforementioned transverse interactions or residual stresses
Summary
Abundant copper demand for electrical applications from various sectors has prompted manufacturers to reduce material costs by replacing this rather expensive and high-density metal partly or entirely. Lower-density and more affordable aluminum-copper (Al-Cu) composite wire is an example of such efforts. The following paragraphs provide a summary of the different features of Al-Cu wires and several other similar composite systems (developed by various techniques) already investigated. The missing aspects and the property of interest to be researched in the current work are presented at the end of this section. Among those already-studied features are the investigations covering the mechanical behavior and finite element modelling of the manufacture processes of severely cold worked composite systems akin to the one under study in this work. Feng et al [2] examined the compressive mechanical behavior of Al/Mg composite rods with different types of Al sleeve
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
