Final Wire Research Articles

The Analysis of the High Speed Wire Drawing Process of High Carbon Steel Wires Under Hydrodynamic Lubrication Conditions

Abstract In this work the analysis of the wire drawing process in hydrodynamic dies has been done. The drawing process of φ5.5 mm wire rod to the final wire of φ1.7 mm was conducted in 12 passes, in drawing speed range of 5-25 m/s. For final wires of φ1.7 mm the investigation of topography of wire surface, the amount of lubricant on the wire surface and the pressure of lubricant in hydrodynamic dies were determined. Additionally, in the work selected mechanical properties of the wires have been estimated. It has been shown that in the drawing process under hydrodynamic lubrication by drawing speed of 25 m/s the phenomena of uncontrolled formation of the surface and the diameter of the wire appears, and in the process the compressive stresses eliminating cracks on the wire surface occur, causing further smoothing. The wires drawn hydrodynamically in speed of 25 m/s, besides clearly worse properties compared to the wires drawn hydrodynamically at speeds in the range of 5 to 20 m/s, also exhibit large dimensional variations.

Fabrication and Cold Drawing of Copper Covetic Nanostructured Carbon Composites/ Otrzymywanie Oraz Ciągnienia Kompozytów Miedzianych Typu Covetic O Strukturze Nanometrycznej

Abstract This paper presents the research results of copper Covetic metallurgical synthesis along with the characterization of cast material and the processing of casts into wires. The Cu-C composite production method was based on patent applications of Third Millennium Metals. Obtained materials were tested for their chemical composition (including Secondary Ion Mass Spectrometry (SIMS) analysis for carbon presence), mechanical properties and electrical conductivity. Measurements were also performed for wires which were first cut from obtained casts and next cold drawn into final wire form. Produced wires were tested for their mechanical and electrical properties. Electrical conductivity of wires was measured with the use of high precision Thompson’s- Kelvin’s bridge type device. A key objective of the research was to determine if Covetic copper has higher electrical conductivity than pure oxygen free copper.

Preparation, microstructure and degradation performance of biomedical magnesium alloy fine wires

With the development of new biodegradable Mg alloy implant devices, the potential applications of biomedical Mg alloy fine wires are realized and explored gradually. In this study, we prepared three kinds of Mg alloy fine wires containing 4wt% RE(Gd/Y/Nd) and 0.4wt% Zn with the diameter less than 0.4μm through casting, hot extruding and multi-pass cold drawing combined with intermediated annealing process. Their microstructures, mechanical and degradation properties were investigated. In comparison with the corresponding as-extruded alloy, the final fine wire has significantly refined grain with an average size of 3–4μm, and meanwhile shows higher yield strength but lower ductility at room temperature. The degradation tests results and surface morphologies observations indicate that Mg–4Gd–0.4Zn and Mg–4Nd–0.4Zn fine wires have similar good corrosion resistance and the uniform corrosion behavior in SBF solution. By contrast, Mg–4Y–0.4Zn fine wire shows a poor corrosion resistance and the pitting corrosion behavior.

Development of ultrafine-grained microstructure in Al-Cu-Mg alloy through equal-channel angular pressing

Al-Cu-Mg alloys are extensively used for riveting applications in aerospace industries due to their relatively high shear strength coupled with high plasticity. The significant advantage of using V65 aluminum alloy ((Al-4Cu-0.2Mg) for rivet application also stems from its significantly slower natural aging kinetics, which gives operational flexibility to carryout riveting operation even after 4 days of solution heat treatment, in contrast to its equivalent alloy AA2024.Rivets are usually made by cold heading of wire rods. In order to form a defect free rivet head, grain size control in wire rods is essential at each and every stage of processing right from casting onwards upto the final wire drawing stage. Wire drawing is carried out at room temperature to reduce diameter as well as impart good surface finish. In the present study, different microstructures in V65 alloy bars were produced by rolling at different temperatures (room temperature to 523K) and subsequently deformed by equal channel angular pressing (ECAP) at 423K upto an equivalent strain of 7. ECAP was carried out to study the effect of initial microstructure on grain refinement and degree of deformation on the evolution of ultrafine grain structure. The refinement of V65 alloy by ECAP is significantly influenced by Initial microstructure but amount of deformation strongly affects the evolution processes as revealed by optical microscopy and transmission electron microscopy.

The Analysis of the Mechanical Properties of High Carbon Steel Wires after Multipass High Speed Drawning Process in Conventional and Hydrodynamic Dies

Abstract In this work the influence of the drawing speed on lubrication conditions and mechanical properties of high carbon steel wires drawn in conventional and hydrodynamic dies has been assessed. The drawing process of ϕ5.5 mm wires to the final wire of ϕ1.7 mm was conducted in 12 passes, in industrial conditions, by means of a modern Koch multi-die drawing machine. The drawing speeds in the last passes were: 5, 10, 15, 20 and 25 m/s. For final wires ϕ1.7 mm the investigation of mechanical properties has been carried out, in which yield strength, tensile strength, uniform and total elongation and also number of twists were determined. It has been shown that the increase of drawing speed from 5 m/s up to 25 m/s caused the increase by 6% strength properties and decrease of plasticity properties by 10%. Higher values of tensile strength and yield strength of the wires drawn conventionally with high speeds are associated with worse conditions, while in case of wires drawn hydrodynamically the main factor which caused the increase of strength properties was high lubricant pressure in hydrodynamic die, which caused the increase of total draft.

Bi-2212 Round Wire Development for High Field Applications

Oxford Superconducting Technology continuously improves Bi-2212 round wire performance because this product has a unique property for ultra high-field magnet ( 25 T) applications. Our recent results on improving the engineering current density by filament densification and reducing trace carbon and hydrogen contamination are presented. The swaging, isostatic pressing, and over-pressure heat treatment processes have been demonstrated to effectively increase the Bi-2212 filament mass density in the final wire and results in high performance over long wire length. Engineering current density values exceeding 550 A/mm <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup> at 4.2 K, 15 T have been achieved on 1-m-long barrel samples. Several configurations have been developed to meet different operating current requirements with optimum filament size ( ~ 15 micron) on critical current density, Jc. The round wire has also been twisted down to 12 mm in twist pitch length without performance degradation.

Bi-2212 round wire development for high field applications

Oxford Superconducting Technology (OST) has been continuously improving Bi-2212 round wire performance because of its potential for application in high-field magnets (> 25 T). We focused on Bi-2212 wire configuration design, filament densification and reducing carbon and hydrogen contamination to improve the engineering critical current density (JE). Several wire configurations have been developed to meet different wire diameter and operating current requirements. The swaging, cold isostatic pressing (CIP) and over-pressure heat treatment processes have been demonstrated to effectively increase Bi-2212 filament mass density in the final wire and result in high performance over long length. The JE values exceeding 550 A/mm2 at 4.2 K, 15 T have been achieved on the CIPed 1 m long sample using a 10 bar over-pressure (OP) heat treatment. The twisted Bi-2212 wire significantly reduced ac loss without the critical current degradation.

Effect of Severe Plastic Deformation on Microstructure and Properties of Polycrystalline Aluminium Al99.5

Abstract Polycrystalline aluminium Al99.5 was deformed through the combination of equal-channel angular pressing (ECAP) by B route (4, 8 and 16 passes) and then by the hydrostatic extrusion (HE) using the cumulative way of deformation, just to the achieving the final wire diameter d = 3 mm. The microstructure of samples was investigated by means light microscopy (LM). Additionally the microhardness measurement and the tensile test were performed to determine the level of aluminium hardening. The texture was determined by using the Brucker Advance D8 equipment. The aim of the research was to determine the influence of severe plastic deformation exerted in the process of equal-channel angular pressing (ECAP) and hydrostatic extrusion (HE) on the microstructure and properties of polycrystalline aluminium Al99.5. The microstructure observations both after the HE process and the combination of ECAP + HE revealed the elongated to the extrusion direction grains and numerous bands and shear bands. The bands and shear bands most clearly revealed at the perpendicular section. The performed investigations showed that with the increase of the deformation the aluminium level hardening increase. The highest properties of tensile strength - UTS = 218 MPa and microhardness level HV0.1 = 46 were obtained after 8 ECAP + HE.

One-step electrochemical fabrication of nanoporous gold wire arrays from ionic liquid

Nanoporous gold wire arrays were fabricated by a simple and straightforward template-free method from ionic liquid. The electrodeposition of AuZn nanowires was coupled with the galvanic metal displacement of the zinc in the wires by gold, creating the final nanoporous gold wire arrays.

Recent Advances in Bi-2212 Round Wire Performance for High Field Applications

There has been sustained interest in the development of Bi-2212/Ag round wire because of its unique potential for application in ultra-high-field magnets (>; 25 T). Our development activity with this material has been focused on improving the engineering current density. Filament densification by swaging and isostatic pressing processes have been evaluated, as has further optimization of the melt heat treatment conditions. These improvements lead to an increased mass density of the filament in the final wire, and are essential to reduce filament porosity and obtain high performance over long wire length. Engineering current density values exceeding 480 A/mm <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup> at 4.2 K, 15 T have been achieved on 1-m-long barrel samples.

Numerical and Experimental Analysis of Wire Drawing for Hardly Deformable Biocompatible Magnesium Alloys / Numeryczna I Doswiadczalna Analiza Ciagnienia Drutu Z Trudno Odkształcalnych Biozgodnych Stopów Magnezu

In the present paper the drawing processes of thin wire of biocompatible magnesium alloys in heated die was investigated. Due to the hexagonal close packet structure magnesium alloys have low plasticity. In order to design the technological parameters the FEM model of wire drawing process in heated die and models of yield stress and ductility were developed. The relationship between technological parameters of drawing and fracture parameters was obtained based on developed models. The maps of possible elongation for MgCa0.8 and Ax30 magnesium alloys were developed using simulations. The draft schedule for final wire diameter 0.1 mm was design assisted with FEM model in experimental part of work. Based on this draft plan the drawing process from initial diameter 1.0 mm to final diameter 0.1 mm in heated die was performed in designed by author’s device.

The Theoretical and Experimental Analyses of the Influence of Single Draft on Properties of Rope Wires / Analiza Teoretyczo-Doświadczalna Wplywu Wielkości Gniotu Pojedynczego Na Własności Drutów Liniarskich

In the paper the influence of the value of a single draft on the properties of rope wires has been assessed. The drawing process of φ5.5 mm wire rod to the final wire of φ2.18 mm was conducted in 6, 11 and 17 drafts, by means of a block drawing machine with the drawing speed of 1.6 m/s. For the wires drawn with the medium single draft: 10.4%, 15.5% and 26.5% the investigation of mechanical-technological properties has been done, in which yield strength, tensile strength, elongation, contraction, number of twists and number of bands were determined. In order to explain the effect of value of a single draft on properties of rope wires, the fatigue strength, roughness and residual stresses of drawn wires have been also determined. In addition, the numerical analysis of the drawing process on the base of Drawing 2D in which distribution of redundant strain, effective strain, longitudinal residual stresses and temperature of drawn wires has been shown. The theoretical-experimental analysis of drawing of rope wires have enabled the evaluation of optimal value of single drafts by which relatively the most advantageous and useful properties of wires can be used. The investigation has shown, that in manufacturing of rope wires small single draft in 10% range should be applied. It allowed to obtain products of good plasticity properties, low deformation inhomogeneity and residual stresses, high bending and fatigue strength. The obtained data investigation can be applied while designing the production process of high carbon steel wires.

Characterization of Fine Metallic Wires for Wire-Array $Z$-Pinch Experiments

The Z Facility at Sandia National Laboratories can produce >;2 MJ of X-ray energy with peak powers >;280 TW. Achieving optimal load performance requires the control of the implosion time of the Z-pinch with respect to the current pulse shape from the pulsed-power driver. Additionally, accurate estimates of the implosion time are required for the precise timing of diagnostics used to study the implosion. A key aspect for assessing this load-driver match, both computationally and experimentally, is the mass of the wire array. In this paper, we present new methods to characterize wire arrays. Accurate mass measurements were made of individual wires. Individual wire diameters were measured from a sampling of wire sections, and a statistical analysis was performed. Finally, the wire arrays were imaged to ensure and document the quality of the final wire array. Data provide an estimate of the load mass that can be used to track experimental trends, provide accurate implosion time predictions for diagnostic timing, and provide input for computational models.

The Influence of Die Approach and Bearing Part of Die on Mechanical-Technological Properties of High Carbon Steel Wires / Wpływ Części Roboczej I Kalibrującej Ciągadła Na Własności Mechaniczno-Technologiczne Drutów Ze Stali Wysokowęglowej

In this work the influence of the die approach and bearing part of die on mechanical-technological properties of high carbon steel wires has been assessed. The drawing process of φ5.5 mm wires to the final wire of φ2.9 mm was conducted in 6 passes, by means of a multi-die drawing machine Koch type. The drawing speeds in the last passes were: 7 m/s. For wires drawn according to four variants the investigation of mechanical-technological properties has been carried out, in which yield strength, tensile strength, uniform and total elongation, reduction of area, the number of twists and the number of bends were determined. On the basis of numerical analyses wire drawing process, the influence of geometry of die on redundant strain and effective strain has been determined. The investigations have shown the essential influence of geometry of die on mechanical-technological properties of high carbon steel wires. It has been shown that the increase of strength properties in wires drawn with high die angle is related to the occurrence in their bigger effective strain.

The Influence of the High Speed Multipass Drawing Process on the Fatigue Strength of High Carbon Steel Wires / Wpływ Wielostopniowego Procesu Ciągnienia Z Dużymi Prędkościami Na Wytrzymałość Zmęczeniową Drutów Ze Stali Wysokowęglowej

In this work the influence of the drawing speed on fatigue strength of high carbon steel wires has been assessed. The drawing process of φ5.5 mm wires to the final wire of φ1.6 mm was conducted in 11 passes, in industrial conditions, by means of a modern Koch multi-die drawing machine. The drawing speeds in the last passes were: 5, 10, 15 and 20 m/s. For φ1.6 mm wires the investigation of fatigue strength has been carried out. In order to explain the effect of drawing speed on fatigue strength of rope wires, the roughness of drawn wires have been also determined. In addition, the numerical analysis of the drawing process on the base of Drawing 2D in which distribution of redundant strain, has been shown. The data of investigations prove the favourable effect of high drawing speed on fatigue strength of drawn wires. It was found that the better fatigue strength of wires drawn at the speed of 20 m/s compared to the wires drawn at the speeds of 5-15 m/s is associated with a better geometric structure of the surface of those wires. In addition to the high fatigue strength of the wires drawn with high speed is related to theirs higher redundant strain. The obtained data investigation can be applied in wire industry while implementing the new technologies of high speed drawing process of high carbon steel wires.

A Study of the Influence of Strain Hardening and Precipitation Hardening Sequence on Development of Mechanical Properties of AlMgSi Conductor Alloys

The paper focuses on 6xxx series AlMgSi conductor alloys. Such alloys are used for manufacturing of conductors for power transmission. Since the most current standards define as many as seven types of wires with various mechanical and electrical specifications, the existing philosophy of AlMgSi wires manufacturing technology for electrical applications has to be revised. Strength specifications of precipitation hardened AlMgSi alloys may be enhanced by strain and by precipitation hardening. Therefore from the scientific point of view identification seems to be relevant of the impact of the sequence of these mechanisms on development of final wire properties. In particular, this paper tries to answer the following question: Does the sequence of hardening mechanisms affect the development of mechanical properties of AlMgSi alloy wires? The paper presents results of a study of the impact of artificial ageing parameters of 6201 grade AlMgSi alloy wires on their final properties. The study results are presented and discussed in two parts. The first part addresses the impact of artificial aging temperature and duration on the strength properties of AlMgSi (grade 6201) alloy wire rod. The second part is focused on hardening development in the process of drawing of a AlMgSi wire made of the same alloy grade, subjected to different thermal treatments, the parameters of which have been selected based on analysis of the results of the first, wire-rod related, part of the study.

Numerical and Experimental Investigation of Process Parameters Effect of Low Carbon Steel Wire Produced with Roll Drawing Process

The effect of roll drawing process parameters on geometrical characteristics of flat roll draw wires is analyzed. Low carbon steel wires AISI 1010 are used in the experimental tests to assess the final geometry, mainly characterized by the width of flat wires, varying among several experimental levels the main process parameters i.e., initial wire dimensions, height reduction and lubrication conditions. Design of experiment technique was used to define the experimental plan and statistical techniques, such as analysis of mean (ANOM) and variance (AVOVA), were used to evaluate the effective influence of previous cited process parameters on final geometry of wire. A finite element model is developed to investigate a further process parameter i.e. the working rolls dimensions. In order to validate the finite element model, a campaign of experimental tests was conducted and the geometrical predictions of FE model were compared with experimental mea-surements with particular attention to final wire width, width of contact area and wire elongation. A linear regression analysis was performed and an empirical formulation to forecast the lateral spread of wire according to the main process parameters was developed.

A Degree-Based Clustering Technique for VLSI Placement

In this paper, clustering for the circuit placement problem is examined from the perspective of wire length contribution from groups of nets. First, the final wire length data of groups of nets with different degrees are extracted and studied. It is illustrated that nets with high-degree contribute a high percentage to the total wire length. To remedy this problem, a clustering algorithm for placement is proposed that focuses on clustering nets with high-degree. This new clustering algorithm is implemented as a preprocessing step in the placement stage. ICCAD04 benchmark circuits abstracted from IBM are used to validate the placement quality by using four academic placers with and without the proposed preprocessing step. Experiments show that the overall placement results can be improved by up to 5%.

Optimization of a range of 2D and 3D bulk forming processes by a meta-model assisted evolution strategy

After decades of developing efficient software, FORGE, for bulk metal forming simulation, its coupling with an optimization algorithm is considered in order to solve the actual engineering problem, the design problem, using the meta-model assisted evolution strategy proposed by Emmerich et al. The first application regards the shape optimization of a cylindrical preform to produce a crankshaft by closed die forging. It aims at minimizing the volume of the material while satisfying the filling of the dies. In the second application, the open die forging of an axisymmetric thick plate is considered. The objective is to optimize the initial geometry in order to minimize the material weight while overlapping a prescribed geometry at the end of forging. The third example regards a four-stepped wire drawing sequence. In order to prevent the formation of cracks, it is desired to minimize a damage criterion while keeping the targeted diameter of the final wire. The geometries of the four dies are optimized: reduction ratio, die angle and die length. The necessary calculations are run in parallel, by using both the parallel version of the software and by evaluating several designs at the same time.

Comparison of Alternate and Simultaneous Tensioning of Wires in a Single‐Ring Fixator Construct

To measure and compare the strain of wires tensioned with alternate (ALT) and simultaneous (SIM) tensioning in a single-ring fixator construct and compare the stiffness of these constructs under axial loading. Experimental mechanical study. Twenty-four, 84 mm diameter, single-ring constructs. Twenty-four, 84 mm diameter, single-ring constructs were assembled using 2 1.6 mm wires placed at a 60 degrees angle tensioned with either ALT or SIM technique to 90 kg tension. Voltage data from a strain gauge were recorded during the wire-tensioning process, cyclic axial loading, and load-to-failure testing. Wire strains were calculated for each wire and compared within constructs and between ALT and SIM groups. Construct stiffness was compared between groups. There was no difference between the tensioning methods in final wire strains after initial tensioning for both the wire below the ring (W1; P=.698) and the wire above the ring (W2; P=.233). There was also no difference in final wire strains within each tensioning method group (ALT, P=.289; SIM, P=.583). Loss of wire strain (3.5-5%) occurred after cyclic loading for both wires in both groups. There was no difference in construct stiffness between the ALT and SIM groups (P=.126). Mode of failure was by wire breakage in all constructs and occurred most frequently in W1. ALT tensioning of wires produced similar wire strains within a single-ring construct after initial tensioning to SIM tensioned wires. There was no difference in construct stiffness under axial loading between AIM and SIM tensioned constructs. ALT tensioning of wires in a single-ring fixator construct can be used as an alternative to SIM tensioning, as similar initial wire tensions are achieved.