Mechanical Properties Of Wire Research Articles

КОМП’ЮТЕРНЕ МОДЕЛЮВАННЯ НЕРІВНОМІРНОСТІ ДЕФОРМАЦІЇ ПРИ ВОЛОЧІННІ ДРОТУ

Low-carbon steel wire traditionally takes a large part in the production of wire products. The quality of the finished wire, and specifically the level of mechanical properties, is affected by non-uniform strain during the drawing process. The uniformity of strain depends on the configuration of the drawing die, specifically the length of the die bell and the length of the die bearing. In industry, the die bearing is bored to the required diameter size in worn out dies during previous drawing. Considering the constancy of the die length, this leads to a change in the ratio between the lengths of the die bell and die bearing and to a change in the level of non-uniform strain. The influence of the die geometric parameters on the wire mechanical properties is often determined using the results of experimental investigations, which leads to significant costs of material and energy. FEM simulation makes it possible to reduce the number of experiments and predict the quality of finished products.

Evaluation of strength and electrical conductivity of copper clad-AA6063 bimetallic composite wire after annealing treatment

This study investigates the manufacturing of copper-AA6063 aluminum alloy composite wire and the effect of microstructural changes and metal-metal interface after annealing at 300 °C at different times on the strength and electrical conductivity. For fabrication of the composite wire, first AA6063 aluminum alloy wire was inserted inside an OFHC copper tube with a diameter of 6 mm. Afterward, a composite wire was produced using a cold drawing process in thirteen steps to a diameter of 1.5 mm. The tensile and microhardness tests used for evaluation of the composite wire's mechanical properties. Also, the light and scanning electron microscopes (SEM) used for microstructural characterization. The results showed that forming a region with a strain gradient at interface has a determinative effect on the strength and ductility of composite wire. The composite wire without annealing showed the highest strength, 278 ± 7 MPa. The annealing treatment result in strength reduction and negligible change in the electrical conductivity. The composite wire after annealing treatment for 30 and 60 min showed the highest electrical conductivity, 83 ± 1%IACS, and the highest elongation, 45 ± 4%, respectively.

Microstructure and mechanical properties of wire and arc additive manufactured thin wall with low-temperature transformation

Microstructure and mechanical properties of wire and arc additive manufactured thin wall with low-temperature transformation

Tailoring the microstructure and mechanical properties of wire and arc additive manufactured Al–Mg alloy via interlayer friction stir processing

In this study, a hybrid additive manufacturing method was developed by combining the wire and arc additive manufacturing (WAAM) with a synchronously conducted interlayer friction stir processing (FSP). Straight walls were prepared using Er5356 wire, and interlayer FSP was conducted to modify the microstructure of the deposited layers. Special attention was paid to the effects of interlayer FSP on the microstructural evolution and mechanical properties of the manufactured Al–Mg alloy. Results show that the interlayer FSP can greatly decrease the size and density of pores in the additively manufactured Al–Mg alloy. The grains in the WAAM-FSP manufactured Al–Mg demonstrates layered distribution characteristics and grain refinement is achieved as compared to the WAAM sample. Both strengths and elongations in the vertical and horizontal directions of the manufactured Al–Mg alloy are enhanced by interlayer FSP. Grain refinement strengthening and porosity reduction mainly contribute to the improvement of the strength. The WAAM coupled with interlayer FSP is an efficient technique to refine grains and pores, and thus improve mechanical properties of additively manufactured Al–Mg alloys. These results can promote the development and application of additively manufactured Al–Mg alloys.

Microstructure and Solute Concentration Analysis of Epitaxial Growth during Wire and Arc Additive Manufacturing of Aluminum Alloy

Microstructure and solute distribution have a significant impact on the mechanical properties of wire and arc additive manufacturing (WAAM) deposits. In this study, a multiscale model, consisting of a macroscopic finite element (FE) model and a microscopic phase field (PF) model, was used to predict the 2319 Al alloy microstructure evolution with epitaxial growth. Temperature fields, and the corresponding temperature gradient under the selected process parameters, were calculated by the FE model. Based on the results of macroscopic thermal simulation on the WAAM process, a PF model with a misorientation angle was employed to simulate the microstructure and competitive behaviors under the effect of epitaxial growth of grains. The dendrites with high misorientation angles experienced competitive growth and tended to be eliminated in the solidification process. The inclined dendrites are commonly hindered by other grains in front of the dendrite tip. Moreover, the solute enrichment near the solid/liquid interface reduced the driving force of solidification. The inclined angle of dendrites increased with the misorientation angle, and the solute distributions near the interface had similar patterns, but various concentrations, with different misorientation angles. Finally, metallographic experiments were conducted on the WAAM specimen to validate the morphology and size of the dendrites, and electron backscattered diffraction was used to indicate the preferred orientation of grains near the fusion line, proving the existence of epitaxial growth.

Influence of assisted longitudinal magnetic field on the microstructure and mechanical properties of ER2319 aluminium alloy parts fabricated by wire and arc additive manufacturing

The deposit morphology, microstructure, and mechanical properties of wire and arc additive manufacturing (WAAM) of ER2319 aluminium alloy with and without assisted longitudinal magnetic field (ALMF) were investigated comprehensively and comparatively in this study. The results showed that the ALMF improved the surface forming accuracy slightly, and effectively promoted the equiaxed transformation of grains. Simultaneously, the introduction of ALMF is beneficial to improving the morphology and distribution of the strengthening phase and reducing the tendency of intergranular corrosion caused by the segregation of Cu elements along the grain boundaries. Moreover, ALMF can remarkably reduce the generation rate of large pores, thereby effectively improving the tensile strength of the deposits and reducing the anisotropy of mechanical properties.

Effect of welding parameters on bead characteristics and mechanical properties of wire and arc additive manufactured inconel 718

In this study, a bi-directional, low-cost, gas metal arc welding (GMAW) based wire arc additive manufacturing (WAAM) setup is used to deposit aerospace-grade super-alloy IN718. The orthogonally designed experiments are carried out to optimize process parameters for bead geometry characteristics. Study result shows that with an increase in heat input, the bead parameters like bead width, reinforcement, dilution, penetration, and weld form factor are increasing, while it has a detrimental effect on weld shape factor and wetting angle. Microstructural examination reveals that at high heat input, coarser grain structure having average grain size of 72.29 µm is obtained while at low heat input, a finer grain structure with average grain size of 32.12 µm along with smaller amount of Laves phases are present. The XRD reveals NbC and TiC phases present in case of low heat input sample which enhances the mechanical properties of deposited material. The multilayer wall structures fabricated at high heat input showed more uniformity in shape with lesser waviness than that fabricated with low heat input. The tensile result of low heat input sample (775.82 MPa) shows higher strength than high heat input sample (741.07 MPa) which is because of smaller grain structure and higher hardness (278.11 HV) as obtained in low heat input sample as compared to high heat input sample (257.26 HV). The EBSD analysis also confirms highly textured surface, more grain boundary lengths and larger grain boundary orientation in low heat input sample imparted better mechanical properties.

The electrothermal fracture mechanism between aluminum and copper wires

This study investigates the energization and high-temperature damage characteristics of pure aluminum and copper wires of 20 mil (500 μm) wire diameter. Due to the wire drawing annealing process, the base of aluminum wire has an equiaxed grain structure, while the base of copper wire has an equiaxed grain structure containing a twin crystal structure.Normally, in terms of mechanical characteristics, copper wire is inherently stronger than aluminum wire, and both are ductile materials. Electrical experiments found that the voltage of the copper wire showed a stable upward trend with the increase in current; it is worth noting that the resistance of aluminum wire increases abnormally when the current increases continuously, resulting in an overload resistance zone, and the resistance overload zone will cause the wire to appear incandescent.This study discusses the characteristics of the overload resistance zone with various wire lengths. Changing the length of copper wire has no obvious effect on the electrical properties, but decreasing the length of aluminum wire decreases the width of the overload resistance zone. When comparing the energized tensile test and the simulated environmental heat treatment experiment, it can be inferred that the surface temperature of the copper wire is about 900 °C when energized, whereas the surface temperature of aluminum wire is about 600 °C when energized.The tensile mechanical properties of the aluminum wire at different energization stages show that the incandescent phenomenon in the overload resistance zone will deteriorate the wire's mechanical properties. It is confirmed that the incandescent phenomenon is dominated by the micro-AlNi eutectic cladding structure in the aluminum wire, and the eutectic phase is formed in overload resistance zone. These eutectic liquid spherical areas will reduce the ductility (embrittlement) of the wire when energized and stretched, and the eutectic liquid spherical phase will then produce holes after solidification, which will affect the aluminum wire's reliability. Incorporating a trace amount of nickel can improve the strength and corrosion resistance in aluminum wire, but the voltage and current need to be controlled during application to avoid the occurrence of incandescence or affecting the electrical and thermal stability.

Effect of Cold Metal Transfer Mix Synchro-Pulse Process on the Overall Morphology, Microstructure and Mechanical Properties of Wire+ Arc Additively Manufactured AA2219 Alloy

Effect of Cold Metal Transfer Mix Synchro-Pulse Process on the Overall Morphology, Microstructure and Mechanical Properties of Wire+ Arc Additively Manufactured AA2219 Alloy

Effect of interlayer surface preparation on microstructures and mechanical properties of wire and arc additive manufactured low carbon steel objects

The workpiece fabricated by wire and arc additive manufacturing is usually made up of hundreds of welds. If the slag is not cleaned up and adherent to the weld surface, it will be stuck in welds and becomes inclusions and other defects within the structures. This is not only the case when using flux cored wire as the consumable material, but also with solid wire. Different weld morphologies were studied by controlling the slag treatment after each layer deposition, in terms of non-destructive test (X-ray radiographic testing). Further investigation of the microstructures and composition of slag inclusions were developed by SEM and EDS analysis. Charpy V-notch impact test has been conducted on the specimens both in vertical and horizontal direction to the deposition direction and tested at 0°C, −20°C and −60°C. The fracture surfaces of the specimen made without any slag treatment after deposition exhibit large number of welding defects, which is highly responsible for lowering the impact toughness. On the other hand, completely clear away of the slag by extensively inter-pass grinding gives rise to a fine grain structure and relative high impact toughness, however, a huge sacrifice of the production efficiency and high material waste is unavoidable.

Effect of Microalloying Ti on Microstructure and Mechanical Properties of Wire and Arc Additively Manufactured Reduced-Activation Ferritic/Martensitic Steel

Effect of Microalloying Ti on Microstructure and Mechanical Properties of Wire and Arc Additively Manufactured Reduced-Activation Ferritic/Martensitic Steel

Mechanical properties of wire and arc additively manufactured high-strength steel structures

Additive manufacturing with steel opens up new possibilities for the construction sector. Especially direct energy deposition processes like DED-arc, also known as wire arc additive manufacturing (WAAM), is capable of manufacturing large structures with a high degree of geometric freedom, which makes the process suitable for the manufacturing of force flow-optimized steel nodes and spaceframes. By the use of high strength steel, the manufacturing times can be reduced since less material needs to be deposited. To keep the advantages of the high strength steel, the effect of thermal cycling during WAAM needs to be understood, since it influences the phase transformation, the resulting microstructure, and hence the mechanical properties of the material. In this study, the influences of energy input, interpass temperature, and cooling rate were investigated by welding thin walled samples. From each sample, microsections were analyzed, and tensile test and Charpy-V specimens were extracted and tested. The specimens with an interpass temperature of 200 °C, low energy input and applied active cooling showed a tensile strength of ~ 860–900 MPa, a yield strength of 700–780 MPa, and an elongation at fracture between 17 and 22%. The results showed the formation of martensite for specimens with high interpass temperatures which led to low yield and high tensile strengths (Rp0.2 = 520–590 MPa, Rm = 780–940 MPa) for the specimens without active cooling. At low interpass temperatures, the increase of the energy input led to a decrease of the tensile and the yield strength while the elongation at fracture as well as the Charpy impact energy increased. The formation of upper bainite due to the higher energy input can be avoided by accelerated cooling while martensite caused by high interpass temperatures need to be counteracted by heat treatment.

Influence of drawing speed on thin wire mechanical properties and microhardness

A general idea of the steel cord and the process of drawing a thin steel wire is given. It has been determined that the properties of a thin wire influences the properties of a steel cord. At the stage of fine drawing and twisting into a steel cord, the wire receives the final set of mechanical properties. It has been determined that the properties of a thin wire are influenced by the degree of deformation, the rate of deformation at the stage of drawing, and the uniform of deformation. The necessity of increasing the uniformity of the distribution of deformations in the process of drawing a thin wire is determined. Increasing the uniformity of the microhardness distribution shows an increasing the uniformity of the deformation’s distribution. High uniformity of deformation distribution increases the technological properties of the wire, increases its quality. The influence of the drawing a thin wire speed on the mechanical properties is investigated. The influence of the drawing speed on the uniformity of the deformation’s distribution in the cross-section of a thin wire was investigated by the method of measuring the microhardness. Diagrams of distribution of values of microhardness on wire cross-section for the studied drawing speeds are presented. Microhardness values can be used to determine the mechanical properties of the wire samples. This makes it possible, by measuring the microhardness of the wire cross section, to assess the nature of the metal mechanical properties distribution in the wire cross section. The optimal drawing speed is shown at which the most uniform distribution of deformations is observed. The dependence of the microhardness over the wire cross section average value on the drawing speed is proposed. With an increase the drawing speed, the microhardness of the wire increases. 

Mechanical properties of wire and arc additive manufactured component deposited by a CNC controlled GMAW

Wire and arc Additive Manufacturing (WAAM) is gaining a lot of popularity in industries due to its ability to produce metallic components with a high deposition rate compared to other Additive Manufacturing (AM) processes. Moreover, there is no material wastage in the form of scrap as in the conventional subtractive manufacturing process. In this study, deposition of layers is done using a Computer numerical controlled Gas Metal Arc Welding (CNC GMAW) based WAAM setup. ER70S-6 low carbon-alloy mild steel wire is chosen as filler wire. A single square bead and a square-shaped component of 9 layers are fabricated on a substrate A36 steel. Deposition on the preheated and normal substrate is considered for analyzing the control of dimensional stability of bead height and bead humping phenomenon. Coordinate Measuring Machine (CMM) results shown that bead deposited on a preheated substrate has more dimensional stability and reduced humping. The hardness and wear test of the fabricated components were also carried out. The result revealed that hardness increases to some extent from149 to 159 BHN in the built direction (vertical). The average hardness is somewhat greater than that produced by conventional methods. The wear test was carried out at two different loading conditions of 1 kg and 2 kg, the wear rate calculated shows that the wear is lower in the case of the WAAM fabricated component compared to other traditional manufacturing methods. Results also revealed that the rate of wear gets lowered when the load is increased.

Microstructure and Mechanical Properties of Wire + Arc Additively Manufactured Mild Steel by Welding with Trailing Hammer Peening

Aiming at solving the problem of coarse grains and poor mechanical properties in weld by Wire Arc Additive Manufacture (WAAM), the welding with trailing hammer peening (WTHP) process is used. The stress state of weld after being processed by WTHP and the temperature distribution at different time are obtained by finite element simulation (FEM). The effects of different peening parameters on microstructure and mechanical properties of the weld are studied by using the light microscopy and Electron Back Scatter Diffraction (EBSD) for microcharacterization. The results show that the hardness of the near‐surface layer of weld is improved by 21.6% using WTHP. Ultimately, the yield strength of weld layer increases from 447 to 493.5 MPa, tensile strength from 560.8 to 661.9 MPa, while the ductility decreases from 32.9% to 21.1%. Three aspects of strengthening mechanisms for the near‐surface layer of the weld by WTHP are as follows: first, multiple high‐speed and high‐energy peening refines the grains of the near‐surface of the weld; second, the plastic deformation produced by hammer peening results in high‐density dislocation and deformation strengthening; and finally, the stress state of the weld is changed from the residual tensile stress to the residual compressive stress under the plastic deformation.

Regularities of the formation of the phase composition, structure and properties of the БрНХК 2.5-0.7-0.6 alloy during thermal and aerothermoacoustic treatments

The influence of thermal and aerothermoacoustic treatments on the structure and mechanical properties of БрНХК bronze is considered. An increase in the strength and elasticity of the alloy is established by optimizing the thermal and aerothermoacoustic modes. The influence of the pre-aging treatment, the aging and aerothermoacoustic modes on the structure, the possibility of an additional increase in the mechanical properties of wire from БрНХК after aerothermoacoustic treatment are shown. Keywords: bronze, heat treatment, aerothermoacoustic treatment, microstructure, mechanical properties. remshev_eiu@voenmeh.ru

Evaluation of the Biomechanical Properties of Austenitic Stainless Steel Fixed Retainers

The insertion of the fixed retention is an important stage of the orthodontic treatment after fixed appliances. The fixed retainers used in orthodontic treatments must be passive towards teeth, without developing any stress. This characteristic is challenging to achieve due to the mechanical properties (bending properties, stiffness) of the materials the retainers are manufactured from. Residual stress might be generated because of their flexibility and because the chemical composition of the stainless steel wires.This study aims to determine the mechanical properties of different austenitic stainlees steel wires used in retention. Also, we have compared the mechanical properties of wires with different sizes, as well as wires with the same size, new and intra-orally used. The results confirm that the mechanical parameters of the two types of wires used in fixed retention (3 braided round wires and 6 braided Flat wires) present statistically insignificant differences. The study also reflects that the mechanical properties of the intra-orally used wires showed decreased values of the parameters.

Phase stability and mechanical properties of wire + arc additively manufactured H13 tool steel at elevated temperatures

Wire + arc additive manufacturing (WAAM) is considered an innovative technology that can change the manufacturing landscape in the near future. WAAM offers the benefits of inexpensive initial system setup and a high deposition rate for fabricating medium- and large-sized parts such as die-casting tools. In this study, AISI H13 tool steel, a popular die-casting tool metal, is manufactured by cold metal transfer (CMT)-based WAAM and is then comprehensively analyzed for its microstructural and mechanical properties. Location-dependent phase combinations are observed, which could be explained by nonequilibrium thermal cycles that resulted from the layer-by-layer stacking mechanism used in WAAM. In addition, remelting and reheating of the layers reduces welding anomalies (e.g., pores and voids). The metallurgical characteristics of the H13 strongly correlate with the mechanical properties. The combinations of phases at different locations of the additively manufactured part exhibit a periodic microhardness profile. Martensite, Retained Austenite, Ferrite, and Carbide phases are found in combination at different locations of the part based on the part’s temperature distribution during additive deposition. Moreover, the tensile properties at elevated temperatures (23 °C, 300 °C, and 600 °C) are comparable to those from other WAAM and additive manufacturing (AM) processes. The X-ray diffraction results verify that the microstructural stability of the fabricated parts at high temperatures would allow them to be used in high temperatures.

Computer Simulation of Micro-Mechanic in Pearlitic Steel Wire Drawing

Cold-drawn high-carbon steel wire with pearlite microstructure is one of the most popular raw materials for modern reinforcing ropes. Lamellae thinning, changes in interlamellar interface and metallographic texture, strain localization is the main property-forming phenomena in the wire drawing process. However, the experimental study of these phenomena dynamics is difficult and time-consuming. Drawing process of pearlitic steel wire was investigated. Behavior of pearlite colonies on the surface and the central layer of the wire were researched, based on the multiscale computer simulation. Cementite lamellae orientation in relation to the drawing axis, interlamellar spacing and shape of cementite inclusions were key factors. Regularities of the pearlite colonies reorientation, changing the shape and size of cementite lamellae and strain localization in the ferrite were established on the basis of FEM. It was established that the cementite lamellae, that are parallel to the drawing axis, had the maximum thinning. Interlamellar distance in pearlite colonies with such lamellae changed most intensively. Cementite lamellae, that are perpendicular to the drawing axis, are the most susceptible to fracture. It was found out that for certain values interlamellar distance this effect can be reduced. Intensive reorientation of pearlite colonies in relation to the drawing axis was observed in the case of their location at an angle to the drawing direction. At the same time, there was a significant bending of cementite lamellae and their susceptibility to fragmentation. Estimated values of the wire mechanical properties were compared with a real experiment. The simulation results were verified by metallographic analysis.

Ultrasound influence on the physical and mechanical properties of wire at equal-channel angular broaching

The structure of ultrafine-grained materials obtained by deformation methods under the influence of ultrasonic vibrations is investigated; new methods of intense plastic deformation have been developed with the imposition of ultrasonic vibrations, allowing the formation of an ultrafine-grained structure in extended materials; optimal modes of plastic deformation and heat treatment were determined, allowing one to achieve the highest thermal stability and ductility in combination with high strength of materials. The designs of ultrasonic oscillatory systems for obtaining extended bulk nanostructured materials were developed, and a technological scheme of producing an ultrafine-grained wire using ultrasonic processing with equal-channel angular broaching was tested. It is shown that this process of deformation processing is industrially applicable, and can be combined into a single technological cycle with wire drawing. The results can be used in engineering, instrument making and cable industry.