Copper Wire Research Articles

Missed intralenticular foreign body – A cause of ocular inflammation

A 36-year-old male presented with a complaint of glare since 2 months. He had a history of trauma to the left eye with copper wire 2 years back. At presentation, the visual acuity was 20/20 in both eyes. Anterior-segment evaluation of the left eye revealed peripheral corneal scar, anterior uveitis, and iris hole. Dilated evaluation revealed sunflower cataract, focal cortical cataract, and an intralenticular foreign body (ILFB). The posterior segment was normal. Inflammation was controlled with topical steroids, followed by ILFB removal, phacoaspiration, and intraocular lens implantation. A thorough dilated ocular examination is essential to rule out an intraocular foreign body in all the cases of penetrating ocular trauma.

Effect of trace silver on the conductivity and softening temperature of high conductivity and high heat resistance pure copper

As a conductor material for high-power electronic devices, pure copper requires both conductivity and softening temperature. The effects of 0% (7NCu), 0.015% (Ag150), 0.030% (Ag300), 0.045% (Ag450) and 0.059% (Ag590) Ag on the microstructure, conductivity and softening temperature of pure copper were studied. The results show that trace Ag can refine the microstructure of pure copper and improve the mechanical properties at room temperature and high temperature. The hardness values of 7NCu, Ag 150, Ag 300, Ag 450 and Ag 590 were 112, 119.06, 122.14, 123.54 and 125.68HV, respectively, and the softening temperatures were 195, 310, 336, 344 and 345 °C, respectively. At the same time, the conductivity of the samples with different Ag content was more than 100.5 %IACS. The similar structure of Ag and Cu has little effect on the conductivity. On the one hand, the trace Ag element soluble in the matrix causes lattice distortion, inhibits recrystallization nucleation and grain boundary migration. On the other hand, the Ag element is polarized at the grain boundary, which reduces the grain boundary energy, decreases the atomic diffusion and increases the recrystallization temperature.

Active compliance control of grinding process for stripping enameled copper wire

The hairpin motor is among the motors used in eco-friendly automobiles. Unlike the random-winding method, this method features a square cross-sectional enamel coil formed into several hundred hairpins inserted into the stator. This offers an increased space factor, which leads to enhanced motor power. With the growing use of hairpin motors, there is an increasing demand for automated equipment in their production. With an aim to improve the manufacturing quality of hairpin motors, many countries are conducting research and development. The process of enamel removal is one of the key steps in hairpin-forming equipment and can significantly affect the performance of the motor. A precise machining process technology is required to improve the enamel removal process, achieve higher enamel removal rates, and reduce wire loss rates. Grinding is a technique used for enamel removal. In this study, an adaptive control algorithm was applied to the grinding process to enhance the enamel removal machining performance. During the machining process, the vertical position of the spindle was controlled to maintain a consistent machining depth for tracking the target grinding force. An experimental setup, which included a system for measuring the spindle torque to calculate the grinding force in real time, was created. To validate the performance of the adaptive control technology, experiments were conducted using this setup. Furthermore, experiments were conducted to observe the changes in the grinding force ratio based on the conditions of the grinding wheel. The correlation between the grinding force ratio and tool condition was analyzed, and based on this, the feasibility of assessing tool condition and determining the timing for tool replacement through real-time monitoring of the grinding force ratio was confirmed.

Crimp Height influence over Resistivity in Wiring Crimping Process

Abstract The main purpose of this paper is to present the influence between the crimp height and the resistivity for a crimp joint between a copper contact and a wire copper stranded cable using statistical relevant analysis. The experiment followed the analysis of 45 crimped assemblies grouped in 3 main categories to simulate a potential validation procedure according to the international validation process requirements from: DIN (“Deutsches Institut fu r Normung”) with the corresponding Romanian standard SR EN 60352-2:2006 and SAE/USCAR-21 REVISION 3. The baseline used was the behaviour of the resistivity versus the pre-set crimp height of the crimped joints before and after thermal shock test to enable us to conclude if we have a significant relation between the crimp height of the assembly joint and the resistivity.

Some techniques for producing copper wire in late Classical and Hellenistic Macedonia

This paper discusses different techniques for making copper wire in the fourth and third centuries BCE in ancient Macedonia (Northern Greece). Wire was used to form stems on gilded wreaths, and to support berries, leaves and rosettes. Stems were made in one piece with the leaves, and are likely to have been formed in at least two ways: one involved cutting them out of sheet copper about 0.5 mm thick, which was creased and then hammered into shape; the other involves using copper rods 1mm square. Some of the square copper rods can be seen on the wreaths, and their regularity suggests they may have been formed on a swaging block. Berries were joined to the wreath circlets by round wires, formed in some cases, it is suggested, by hammering sheet metal around a central core; in other cases, these stems may have been formed by rolling a rod between stone slabs. No evidence, such as longitudinal striations, was found of drawing. Some examples of strip-twisted wire were found, but there are fewer cases of this than of wire formed by hammering. The most expensive gilded wreaths at Derveni, cist grave A, Phoinikas cist grave 5 and Sedes, sometimes had special features, such as gilded copper tubes (‘branches’) with smaller stems on either side, or square wires formed into spirals.

A comparative study of flow boiling performance in smooth and multi-stage enhanced open microchannels

Flow boiling in open microchannels is currently one of the research focuses in the field of phase-change heat transfer. The present paper described a comparative and experimental research on flow boiling heat transfer of SF-33, an environmentally friendly working fluid, in smooth surfaces open microchannels (SOM) and multi-stage enhanced open microchannels (MSEOM). The study investigated the flow boiling performance of SF-33 in two open microchannels with different mass fluxes, heat fluxes and inlet subcooling. The different boiling flow patterns in two open microchannels were analyzed with high-speed visualization. The results indicated that under different inlet cooling conditions, the MSEOM improved the flow boiling heat transfer performance significantly and improved the wall temperature uniformity. The visualization images indicated that the flow pattern transition was different due to the different surface structures of two open microchannels. The SOM experienced plug-stratified flow at high heat flux, while MSEOM transformed into churn flow due to its sintered copper powder and wire mesh micro-nanocomposite structures. The multi-stage enhanced structures exhibited excellent hydrophilicity and wicking capability, leading to a less pressure drop in the MSEOM compared with that in SOM. The pressure drops for both open microchannels decreased as inlet subcooling increased.

Microstrip Patch Antenna Design for 5G and Beyond Wireless Communication Systems

This paper gives a theoretical evaluation on how feeder lengths are appropriate for distinct conductor materials using rectangular microstrip patch antenna shape with the help of finite integration techniques (FIT). In this study, the ground surface width is 5.6mm and the ground surface length is 4.65 mm for the rectangular microstrip patch antenna. The length of the patch is 3.44 mm while the patch width is 4.40 mm. The substrate thickness is at 0.20 mm, the patch thickness is 0.035 mm the additional inner feed length is 1.05 mm and the microstrip line feed width is 0.6 mm. Antenna of rectangular microstrip patch type has been designed to work in the 20 – 36 frequency band and working frequency of the proposed antenna is 28 GHz. Compared to the use of a single conductor on the surface of the designed patch antenna, three different conductor materials-copper, gold, and aluminum-were applied to the patch surface of the antenna. The return loss (S11), voltage standing wave ratio (VSWR), bandwidth (BW), directivity and gain of the microstrip antenna parameters are studied using finite integration method Computer Simulation Technology (CST) based on nine different feed lengths in microstrip antenna design. When analyzing the feature of the simulation, the optimal S11 can be observed at the 28 resonant frequencies in the copper conductor. According to the analysis results, for copper conductor the best S11 was obtained at a resonant frequency of 28.03 GHz. The value of S11 is -31.19 dB and the BW value is 968 MHz. For the gold conductor the high return loss is achieved using the at the resonated frequency of 28.01 GHz. S11 value is -32 dB and the BW value is 972 MHz Aluminum conductor has the highest value of S11 with a resonant frequency of 28.01 GHz as shown in -33.29 dB and BW value is 976 MHz. Unsurprisingly, the characterization of the conductor deposition on each structure shows that aluminum conductor yielded the best S11 among all the conductor types. The VSWR is equal to 1.05 for copper conductor at resonant frequency of 28.03 GHz, 1.05 at gold conductor at a resonant frequency of 28.01 and 1.04 for aluminum conductor at a resonant frequency of 28.01 GHz. The maximum directivity values that have been attained in the three-dimensional (3D) representation of the copper conductor, gold and aluminum conductor antennas are nearly 6.99 dBi, respectively. The maximum values of the gain are obtained for the 3D representation of copper, gold and aluminum conductor antennas are 6.61, 6.60 and 6.58 dBi, respectively.

Thermal calculation and experimental study of a double-disk magnetic coupler

Aiming to tackle the difficulties and inaccuracies in calculating the temperature field of double-disk magnetic coupler, a novel thermal calculation method is proposed, integrating the equivalent thermal network method and CFD method. This approach deviates from traditional methods that substitute empirical formulas with rotational speed. An equivalent thermal network model is established to ascertain the temperature rise at each network node. Additionally, a fluid-solid coupling model is constructed, and the impact of uneven air temperature distribution on air density, specific heat capacity, dynamic viscosity, and thermal conductivity is analyzed using the least squares method. The results reveal that after incorporating variable temperature air physical properties, the high-temperature area of the copper conductor decreases, the calculated temperature rise aligns closer to actual values, and air friction loss on the copper surface is reduced by 6.5 %. Experimental verification, conducted on a 55 kW double-disk magnetic coupler, demonstrates maximum errors of 8.86 % and 6.53 % when comparing experimental values to those calculated by the equivalent thermal network method and CFD method, respectively, thereby validating the proposed method. This research provides a theoretical reference for thermal calculations in double-disk magnetic coupler.

500 μm heavy micro-alloyed Cu wire for IGBT application: The study on microstructure characteristics, electrical fatigue fracture mechanism and bonding reliability

In this study, we introduced trace amounts of silver and nickel into 500 μm diameter copper wires to form micro-alloyed copper wires used in insulated gate bipolar transistors (IGBT). The addition of silver and nickel enhanced the mechanical properties of the conductors and suppressed the work hardening effect, significantly improving the power cyclic lifetime. Additionally, this study conducted chlorination and high-temperature oxidation test to compare the application characteristics of the heavy micro-alloyed copper wires with pure copper wires, through tensile and bending test, as well as electrical property comparisons. Finally, Cu50Ni (50 ppm Ni) wires were selected and nickel ceramic substrates for wire bonding to evaluate module electrical properties and bonding reliability.In the chloride test, there was no significant pitting corrosion observed in copper wire, and the micro-alloyed copper wire outperformed the pure copper wires in terms of bending lifetime and power cycling performance. In the high-temperature oxidation test, an oxide layer of cuprous oxide formed on the surface of all wires. The pure copper wire exhibited a significant increase in resistance. Notably, the micro-alloyed copper wires had better resistance to oxidation. Regarding wire bonding, the use of Cu50Ni wires and nickel ceramic substrates reduced the diffusion rate of nickel atoms from the substrate to the copper wire, forming a thinner alloy diffusion layer. This prevented electrical degradation and achieved high bonding reliability, especially under higher bonding forces. These findings confirm that micro-alloyed copper wires are suitable for high-power applications.

Experimental detection of mechanical deformations exploiting electromechanical effects

The present paper discusses experimental results concerning the deformation-induced generation of electric potential difference in steel specimens. According to our observations, voltages in the order of 10 microVolts can be measured between points on the surfaces of steel bodies during mechanical deformation. Three different experimental set-ups were used to determine the properties of the phenomenon, carefully excluding the influence of possible external electromagnetic fields. In order to exclude thermoelectric effects, a special steel specimen was fabricated. Further experimental campaigns were conducted with long, thin metallic rods in two different set-ups: the generation of voltage was measured during the traveling of longitudinal shock waves and during bending vibrations of the specimens. The results indicate that the variation of the magnetization of the material – the magnetoelastic effect – plays an important role in the phenomenon, but thermoelectricity also contributes to the measurable voltage signals. The electromechanical effect identified in the present paper may have several applications in measurement technology. The most relevant advantage of the applied measurement methods is that these are essentially sensor-free, since the mechanical vibrations can be detected by simply soldering, welding, or pressing copper wires to the examined steel specimen.

Quantification of Corrosion on Cu Wire Bonding on Ag-Plated Lead Frame in HCl for Automotive Electronic Application

Copper (Cu) wire bonding has been widely used in automotive electronics as an interconnection technology. However, Cu wire bonding faces long-term reliability challenges due to corrosion, particularly when exposed to harsh environments. While the corrosion behavior and mechanisms of bulk-sized Cu metal are well studied, the corrosion behavior of submicron-sized Cu wire bonding in miniaturized components remains unclear. This study investigates the corrosion susceptibility of Cu wire with a 1 mil diameter, bonded to an Ag-plated leadframe in a small-outline transistor (SOT-23) package, commonly used in automotive electronics. The Cu wire bonds were subjected to varying concentrations of hydrochloric acid (HCl), specifically 3 M, 5 M, and 7 M, for exposure durations of 6, 12, and 18 hours. The samples were characterized using a field emission scanning electron microscope to observe the microstructure, and ImageJ software was used to quantify the corrosion of the Cu wire bonds. The findings show that the Cu wire bonding is susceptible to corrosion when exposed to high concentrations of HCl. The corrosion of the microstructure became more severe with increasing HCl concentration and exposure time. The affected area of the Cu wire bonding was 21% after 6 hours of exposure to 3 M HCl, increasing to 100% after 18 hours of exposure to 7 M HCl. This study reveals that the corrosion behavior of Cu wire bonding is a combination of selective and pitting-like corrosion, resulting in localized surface degradation rather than uniform corrosion. These findings provide valuable insights into the corrosion behavior of 1 mil Cu wire bonding in SOT-23 packages under highly corrosive environments.

Analysis of the Development of Downstream Copper Industry in Indonesia to Obtain Maximum Added Value Using Dynamic Systems

This research aims to design a dynamic system model for the downstream copper processing industry. The secondary data obtained is data provided by the BKPM Strategic Investment Downstreaming Expert Team. Vensim software is used to simulate downstream development in the form of CLD and SFD from 2024 to 2045. The results of the value-added simulation resulted in an increase in the added value of copper cathode by 2.15 times, the added value of cathode slab by 1.62 times, the added value of copper billet by 1.65 times, the added value of copper bar &rods by 1.08 times, the added value of copper tube by 1.02 times, the added value of copper strip by 1.39 times, and the added value of copper wire by 1.58 times. After a sensitivity analysis of the selling price at CAGR and an increase in energy costs by 20%, there was a change in the average value-added margin, so that the increase in added value changed which resulted in an added value of copper cathode of 1.9 times, added value of cathode slab of 1.47 times, added value of copper billet of 1.49 times, added value of copper bar &rods of 1.26 times, added value of copper tube of 0.93 times, added value of copper strip of 0.98 times, and added value of copper wire of 1.44 times.

Recycling of e-waste power cables using microwave-induced pyrolysis - process characteristics and facile recovery of copper metal.

This article reports on recycling e-wastes using a VVF power cable as a model through a rapid pyrolytic process following exposure to microwave radiation. This occurred via three possible pathways: (i) discharges at the copper wire on exposure to microwaves, with heat produced causing the thermal decomposition of the covering material - a relationship exists between the length of the copper wire and the wavelength of the microwaves; (ii) microwave heating softened the wire's covering material and ultimately led to its decomposition - in addition, the coating material carbonized by the discharge is rapidly heated by microwaves; (iii) the carbonaceous component present in the covering material absorbed the microwaves, causing the thermal decomposition. On the other hand, for VVF cables longer than 12 cm canceled the wavelength-dependent process, and the longer the VVF cable was, the more efficient was the microwave-induced pyrolysis, therefore eliminating the need to pre-cut the waste VVF cable into smaller pieces. The microwave-induced pyrolysis showed that chlorine could be recycled as HCl and the carbon and activated carbon produced could be recovered as carbon black. While conventional pyrolysis might produce tar substances and polycyclic aromatic compounds, microwave pyrolysis has been shown to enable extremely rapid resource recovery, with only C6 to C12 linear alcohols produced as intermediates; no formation of tar-like substances, polycyclic aromatic compounds, or dioxins were detected. Clearly, microwave-induced pyrolysis has proven suitable for recycling/recovery of e-waste containing metals and requires no pre-treatment to separate the plastics from the metals.

One‐Step Laser Synthesis of Copper Nanoparticles and Laser‐Induced Graphene in a Paper Substrate for Non‐Enzymatic Glucose Sensing

AbstractThe synergy resulting from the high conductivity of graphene and catalytic properties of metal nanoparticle has been a resource to improve the activity and functionality of electrochemical sensors. This work focuses on the simultaneous synthesis of copper nanoparticles (CuNPs) and laser‐induced graphene (LIG) derived from paper, through a one‐step laser processing approach. A chromatography paper substrate with drop‐casted copper sulfate is used for the fabrication of this hybrid material, characterized in terms of its morphological, chemical, and conductive properties. Appealing conductive properties are achieved, with sheet resistance of 170 Ω sq−1 being reached, while chemical characterization confirms the simultaneous synthesis of the conductive carbon electrode material and metallic copper nanostructures. Using optimized laser synthesis and patterning conditions, LIG/CuNPs‐based working electrodes are fabricated within a three‐electrode planar cell, and their electrochemical performance is assessed against pristine LIG electrodes, demonstrating good electron transfer kinetics appropriate for electrochemical sensing. The sensor's ability to detect glucose through a non‐enzymatic route is optimized, to assure good sensing performance in standard samples and in artificial sweat complex matrix.

Yttrium cuprates modification in linear generator application for power generation

Abstract Yttrium barium copper oxide (YBCO) is used for special applications in linear generators because of its excitation loss, lower weight, and higher efficiency. These qualities enable the compound to operate better than the conventional copper wire coil in the stator unit of the linear generator. However, the continuous use of YBCO in linear generators has a fundamental challenge that affects industrial production and material stability after prolonged use. This paper seeks to sustain the adoption of YBCO by improving its quality for linear generator applications. The yttrium cuprates modification (YBYbCO) was synthesized using the solid-state reaction technique by doping YBCO with ytterbium. The crystalline structure, microstructural pattern, and stability of the new sample were adequately measured and found to be structurally stable to ensure durability. It was reported that applying YBYbCO in the linear generator would lead to a 200% increase in energy generation. The higher number of particles and lower individual particulate resistance enable it to withstand chemical pressure, thereby prolonging the lifespan of the linear generator.

DC current sensor based upon a fused fiber optic Fabry-Perot interferometer (FPI) and copper wire

In order to meet the demand for direct current (DC) current measurements in industrial production, a new type of fiber optic DC current sensor, combining thin copper wire and fiber optic Fabry-Perot interferometer (FPI), is reported. FPI is a sandwich structure formed by splicing a single-mode fiber (SMF) and a quartz capillary, with a cavity length of approximately 200 μm. The copper wire, with a length of 3.2 cm and a diameter of 1 mm, is attached to the FPI to form the sensor. Due to the excellent thermal conductivity of copper, the results showed that the sensor increased the sensitivity from 4.1 pm/°C to 11 pm/°C. After applying direct current to the sensor, a large quantity of heat generated by the copper wire was absorbed by the FPI, resulting in a significant shift in the resonant wavelength of FPI, which can indirectly measure the current. Three current experiments were performed, and parabolic curves have been used in fitting of the Dip wavelength and the square of the current. The results provide high correlation coefficients with values exceeding 0.99. Therefore, this curve may be used to measure the square of the current, further obtaining the current. In summary, the sensor is compact and durable, easy to manufacture, and provides high correlation coefficients, providing an alternative for measuring DC current.

Efficient and emission-reduced recovery of high-purity copper from waste enameled copper wires

The escalating demand for refined copper intensifies research into the recycling of copper-based solid waste, exemplified by recovery of copper from waste enameled copper wires (WECWs). Despite its potential, the pyrolysis process for WECWs is hindered by embrittlement, diminishing both recycling yield and quality. Our study pioneers the elucidation of the embrittlement mechanism during WECWs pyrolysis through atom probe tomography and first-principles calculations, revealing that hydrogen, a byproduct of paint film pyrolysis, accumulates at copper grain boundaries, inducing embrittlement by reducing adhesion energy. We introduce two innovative strategies to mitigate hydrogen-induced embrittlement: vacuum pyrolysis and enhanced N2 flow. These approaches significantly reduced hydrogen content from 11.1 % to about 5 % and increased elongation from 2.65 % to 15 %. Moreover, pyrolysis efficiencies of 92.79 % and 91.4 % were achieved, respectively, at temperatures 50 °C lower than conventional methods. Our findings provide crucial theoretical insights into embrittlement and offer effective recovery strategies for copper from solid waste.

Structural Integrity Analysis of Marine Dynamic Cables: Water Trees and Fatigue

Abstract Offshore power cables are typically designed to have a service life of around 25 years. A pattern is emerging where these cables only last 10 years or even as little as two. The main consensus as to why the service life is so short is due to a combination of fatigue and fretting/wear damages of the copper conductors and water treeing in the insulation material. This study presents a method that can be used to analyze the structural integrity of dynamic subsea power cables and estimate their service life determined by the factors above. The numerical simulation models developed and used to carry out global and local fatigue analyses of dynamic subsea power cables are presented, together with methods and models for assessing fretting, wear, and growth of water tree defects. A methodology for structural integrity assessment that includes all these factors is proposed. A dynamic subsea power cable connected to a wave energy converter is used as the case study for comparison of the service life when these factors are considered compared to when, e.g., the growth of water trees is excluded. A numerical sensitivity analysis demonstrates that the value of the seawater's electrical conductivity and the insulation material's threshold stress-intensity factor greatly influence the cable's service life.

High-Performance Pomegranate-Like CuF2 Cathode Derived from Spent Lithium-Ion Batteries.

With the large-scale application of lithium-ion batteries (LIBs), a huge amount of spent LIBs will be generated each year and how to realize their recycling and reuse in a clean and effective way poses a challenge to the society. In this work, using the electrolyte of spent LIBs as solvent, we in situ fluorinate the conductive three-dimensional porous copper foam by a facile solvent-thermal method and then coating it with a cross-linked sodium alginate (SA) layer. Benefiting from the solid-electrolyte interphase (SEI) that accommodating the volume change of internal CuF2 core and SA layer that inhibiting the dissolution of CuF2, the synthesized CuF2@void@SEI@SA cathode with a pomegranate-like structure (yolk-shell) exhibits a large reversible capacity of ~535 mAh g-1 at 0.05 A g-1 and superb cycling stability. This work conforms to the development concept of green environmental protection and comprehensively realizes the unity of environmental, social and economic benefits.

A novel method for investigating the underwater explosion loads and bubble evolution

This paper presents an innovative experimental method for studying the evolution and energy output characteristics of underwater explosion bubbles. We independently constructed an experimental testing system for underwater electrical wire explosions (UEWE), in which electrodes connected to a metal wire serve as the load, and underwater explosions are initiated through instantaneous high-voltage discharge. By varying the diameter of the metal wire and configuring parallel wire arrays, we analyzed and discussed the explosion characteristic parameters and the current–voltage (I–V) signals under different conditions. The maximum bubble radius of the underwater metal wire explosion was compared with the corresponding equivalent explosive simulation results, and a numerical model for underwater metal wire explosion equivalent to explosive detonation was established. Subsequently, we discussed the characteristics of bubble generation and evolution under various conditions, clarifying the similarities and differences between wire explosions and explosive detonations. On this basis, we explored the propagation laws of shock waves and secondary pulsation waves (SPW) under different conditions. We also calculated and analyzed energy output characteristic parameters, such as shock wave energy and bubble energy. The results indicate that there are significant differences between copper wire and aluminum wire loads in UEWE. For copper wires with a diameter greater than 0.4 mm, the shock wave overpressure peak value significantly decreases, while for aluminum wires with a diameter greater than 0.5 mm, it slightly decreases. Both metals exhibit similar trends in parallel wire arrays, with the shock wave overpressure peak value initially increasing and then decreasing as the number of wires increases. Unlike underwater explosive detonations, the SPW peak value in UEWE may exceed that of the shock wave. For single wires, the SPW peak value of copper wires is generally higher than that of aluminum wires, but in wire arrays, the trend is reversed. The multi-wire parallel connection can improve the energy conversion efficiency of the shock waves. However, for bubble energy, under all conditions, a single aluminum wire with a diameter of 0.5 mm produced the maximum bubble energy, reaching 1023.1 J. These findings provide new insights into the energy features of UEWE.