Abstract
The success of composite extrusion is influenced by multiple process parameters. In order to investigate the significance of specific parameters during indirect extrusion of copper-clad aluminum (CCA) rods, statistical methods were applied and a central composite experimental design was implemented. The runs of the experimental design were modeled with the finite element method based software DEFORM 2D and evaluated with respect to product quality, described by four response variables. Using variance and regression analyses, as well significant linear and quadratic effects of the five investigated process parameters as interactions between them were identified. Based on a statistical model, an overall optimum setting for the process parameters was predicted utilizing the response surface methodology with a desirability approach. By applying the output of the statistical analysis to an extrusion trial, the extrusion of a high quality CCA rod was achieved. Moreover, the results of the statistical analysis could be verified by comparing predicted and experimentally determined values of the investigated quality characteristics.
Highlights
Copper and aluminum are the most used materials for electrical conductors
Copper clad aluminum (CCA) composites are usually fabricated with a copper volume fraction of 10–30%
The presented FE-model was altered according to the corresponding process parameters of each run and run separately
Summary
Copper and aluminum are the most used materials for electrical conductors. Their high electrical conductivity predestinates them for this application. The high density and instable price of copper as well as the high contact resistance of the superficial aluminum oxide layer are downsides which must be coped with. Clad composites made of a copper sleeve and aluminum core synergize the benefits of both materials while neutralizing the disadvantages. Copper clad aluminum (CCA) composites are usually fabricated with a copper volume fraction of 10–30%. Due to the lower price and density of aluminum the material cost and weight of busbars can be reduced by up to 40 and 60%, respectively
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