Wire Drawing Research Articles

Tungsten fiber-reinforced tungsten composites and their thermal stability

Tungsten will be used as armor material for plasma-facing components in future fusion reactors, but its propensity to embrittlement by microstructural restoration at high temperatures poses a challenge for its use. Tungsten fiber-reinforced tungsten composites (Wf/W) with drawn tungsten wires embedded in a polycrystalline tungsten matrix remedy the inherent brittleness of tungsten and achieve pseudo-ductile behavior via extrinsic toughening mechanisms. As plasma-facing materials experience high heat fluxes during operation, their thermal stability is important. In Wf/W composites, the restoration processes at high temperatures differ significantly between wires and matrix: initially recrystallization dominates in the wires, as they were plastically deformed during wire drawing, whereas abnormal grain growth occurs in the matrix. Growing grains may obstruct the interface between wire and matrix and deteriorate the otherwise improved fracture properties of Wf/W. An yttria interlayer is introduced to separate wire from matrix, to hinder an interplay between the restoration processes and to impede grains from the wire from growing into the matrix and vice versa. Cylindrical model systems containing a single wire in a chemically vapor-deposited matrix are investigated without any interlayer and with an yttria interlayer of either 1 μm or 3 μm thickness. Isothermal annealing at 1450°C for different times up to 2 weeks, followed by microstructural characterization by means of EBSD are carried out to characterize the microstructural evolution. The role of the interlayer on the microstructural evolution is elucidated to establish if decoupling of the restoration processes is actually achieved.

Wire Drawing Behaviors with Die Angle and Strain Hardening Rate of a Metal

Wire Drawing Behaviors with Die Angle and Strain Hardening Rate of a Metal

High deformation and delamination mechanisms explained through mesoscale and nanoscale phenomena in pearlitic steel wires

Pearlitic steel wires subjected to severe cold drawing deformation exhibit a unique combination of high strength and excellent ductility, making them suitable for critical applications such as hanging bridge cables, crane cables and tire cord. Torsion tests up to rupture are commonly used in the industry for quality control purposes. A flat fracture surface is indicative of wire aptitude, while a delaminated surface suggests degradation of mechanical properties. This paper aims to expand the understanding of the structural evolution and deformation mechanisms that occur during wire drawing, as well as the origin of delamination problems. Different deformation and strengthening mechanisms are identified and discussed, applying different microscopy techniques (optical microscopy, scanning electron microscopy, electron backscatter diffraction), synchrotron diffraction and atom probe tomography. The information is correlated with the cementite stability on the structure studied at meso, nano, and atomic scale, reaching an understanding of the compositional evolution of cementite and ferrite even at the very lowest level. All the obtained information, including thermal analysis and thermodynamic simulation results, allow to identify the deformation mechanisms present during cold drawing and at the delamination process. In addition, the compositional evolution of cementite and ferrite is also clarified by atom probe tomography.

Divergence in physicochemical and microstructural properties of set-type yogurt derived from bean proteins and animal milks: An inquiry into substitution viability

To clarify the comprehensive disparities in quality between bean- and milk-based set-type yogurts, this investigation undertook a thorough evaluation of the physicochemical and structural attributes of yogurts derived from three bean beverages with 12 g/100 mL (pea, fava bean, and chickpea) and three animal milk sources (Holstein cow, Jersey cow, and goat). The outcomes indicated that bean-based yogurts exhibited a reddish and had high adhesiveness and low tan δ, as well, the proportion of β-sheet declined and gels characterized by a more compact and dense protein structure with a high water-holding capacity (90–100%). Conversely, milk-based yogurts exhibited higher acidity and lower pH under identical fermentation temperature and post-ripening time conditions. Additionally, the proportion of β-sheet increased and gels featured a porous network structure with reduced water-holding capacity. Notably, fava bean yogurt demonstrated the highest adhesiveness (5.90 ± 0.03 N*s), hardness (4.76 ± 0.01 N), and apparent viscosity, and goat yogurt showcased notable cohesiveness (0.83 ± 0.02) and lowest viscosity and distinct wire drawing characteristics among the tested samples. Fava bean yogurt and Jersey cow yogurt garnered greater acceptability through sensory analysis. These findings underscore the contrasting attributes of bean- and milk-based yogurts, thereby contributing to the development of set-type yoghurts with different bean proteins.

STUDY OF THE POSSIBILITY OF INCREASING THE PLASTICITY OF TUNGSTEN WIRE AT NORMAL TEMPERATURES BY OPTIMIZING THE DRAWING TECHNOLOGY

Purpose. The development of a mathematical model for the process of drawing a tungsten-thorium wire for the analysis of the influence of technological factors of the specified process on the plasticity of the material and the recommendations on how to choose their optimal values, from the point of view reaching the plasticity of the wire at the maximum productivity of the wire drawing process.
 Research methods. The problem of creating a mathematical model for investigating the influnce of technological parameters into the process of drawing on the plasticity of a tungsten-thorium rod was considered to be based on the theory of experiment, in particular the method of experiment planning. Various material samples were prepared using methods of powder metallurgy and pressure treatment, in particular wire drawing. Experiments were carried out in real production conditions using industrial equipment. The plasticity of the tungsten-thorium rod was determined by torsion testing using the K-5 machine.
 Results. A mathematical model has been created that adequately describes the impact of technological factors on the plasticity of tungsten wire, which allows thoroughly analyze the physical processes that occur during wire drawing, and, if necessary, correct regimes without conducting a large number of physical experiments.
 Scientific novelty. The mathematical model has been proposed as it allows to analyze the impact of technological factors of drawing process on plasticity of tungsten-thorium wire produced at real manufacturing.
 Practical value. It can be useful for the technologists for higher productive application of industrial equipment and decrease of expenses for production of experiment consignment.

CONTRIBUTIONS REGARDING THE IMPLEMENTATION OF LEAN MANUFACTURING AND SIX SIGMA TECHNIQUES IN THE METALLURGICAL INDUSTRY

Lean Manufacturing is a production philosophy that determines the reduction of the time from the customer's order to the shipment of the product, by eliminating losses. 6s is a method to organize and manage a workspace or a workflow and aims to improve efficiency and quality by eliminating waste, improving workflow and eliminating useless processes/activities. Predictable, organized and safe workplace. The method is based on the 5S methodology and has been empowered by including "Safety" as one of the pillars. The presented research referred to the improvements brought by the implementation of the 6 sigma concept in a processing section by wire drawing of different sizes. the article presents the six steps followed in order to implement the concept: 1s: sorting; 2s: ordering; 3s: cleaning; 4s: standardization. In the last part of the article, the audits that take place in the wire drawing section and their results are presented and the ways in which non-conformities are treated.

CONTRIBUTIONS REGARDING NON-CONFORMITY MANAGEMENT OF TECHNOLOGICAL PROCESSES IN A WIRE DRAWING FACTORY

In order to demonstrate the way of meeting the quality requirements by electric cable manufacturers, different quality tools can be used to achieve the quality objectives imposed in the Quality Manual such as: SWOT Analysis, PEST Analysis, 8D methodology in handling complaints and methodologies Fishbone and 5Why in dealing with Critical Nonconformances. According to these, the article includes several types of analyzes that are carried out in a wire drawing factory, namely: the Swot analysis, which is a very good way of evaluating the general state of an organization so that a development plan in which to take into account its strong points, to eliminate the weak points, to efficiently exploit the opportunities that have arisen and to allow countering possible threats; Pest analysis that takes into account political factors, economic factors, social factors and technological factors. Within the Quality Management System, the guidelines and responsibilities for the correct management of non-conformities were officially defined by identifying their causes and implementing all the necessary actions for their final solution in all manufacturing processes.

Study on deformation characteristics of multi-pass continuous drawing of micro copper wire based on crystal plasticity finite element method

Abstract Copper-based wire has excellent comprehensive performance and is widely used in integrated circuit packaging, electronic communication, connectors, audio and video transmission, and other fields. Based on the crystal plasticity finite element method, the crystal plasticity finite element model of multi-pass continuous drawing deformation of pure copper micro wires was established, and the reliability of the model was proved. The continuous drawing deformation behavior of micro wires under high-speed deformation and micro wire diameter scale effect was studied. The research shows that there is a fracture risk zone under the alternating action of positive and negative stress values in the deformation zone of the drawn wire. The changing drawing force and contact stress during the continuous drawing process of the wire will also reduce the stability and surface quality of the wire during the drawing process. The shear deformation and slip degree of the surface grain of the drawn wire are greater than those of the core grain, and the drawing die has a greater impact on the slip system state of the surface of the wire. With the increase in drawing passes, the mechanical characteristics inside the wire increase accordingly, and the deformation uniformity inside the grains is improved. The established model can demonstrate the deformation history characteristics and structure inheritance of the continuous wire drawing process.

A microstructure-based constitutive model for eutectoid steels

This work presents a constitutive model for eutectoid steels based on their two-phase lamellar microstructure. The model accounts for the individual behaviour of both ferrite and cementite, with perfect interphase adhesion assumed. It considers anisotropic hardening mechanisms in ferrite derived from the lamellar structure of pearlite while ignoring the crystal structure of either phase. The model also accounts for the evolution of orientation and spacing of lamellae under directional deformation, along with the evolution of internal stress distribution in both phases. Due to its simplicity, the model has very few calibration parameters but is still able to reproduce complex strain paths and loading conditions with excellent accuracy. The model was compared with tensile, compression and torsion tests from a 13-pass wire drawing series (up to drawing strains of 2.7) and reproduced accurately the mechanical response under any loading condition. The robustness of the model lies in the fact that it is able to recreate the evolution of internal stresses built in cementite and ferrite. Such internal stress evolution was confirmed to reproduce accurately the stress partitioning observed in neutron and X-ray diffraction tests reported in literature. Moreover, the model contributes to the understanding of the rapid broadening of cementite diffraction peaks observed during in-situ tensile tests of patented wires.

Influence of bimodal copper grain size distribution on electrical resistivity and tensile strength of silver - copper composite wires

In order to obtain the best compromise between high strength and low resistivity it was decided to introduce a controlled content of copper (Cu) large grains in copper-silver (Ag-Cu) composite wires. Composite powders are prepared by mixing of 1 vol% Ag nanowires and bimodal Cu powder. The so-obtained composites powders are consolidated into cylinders (8 mm in diameter and 30 mm long) by Spark Plasma Sintering (SPS) at only 450 °C. The cylinders served as starting materials for room temperature wire-drawing (WD) for the preparation of fine wires (1–0.2 mm diameter). The microstructure of the cylinders and the wires was investigated by scanning electron microscopy imaging and electron backscattered diffraction analysis. The electrical resistivity and the tensile strength were measured at 293 K and 77 K. The electrical resistivity of the wires is the lowest when the large Cu grain content is the highest. Cu large grains greatly limit the electronic scattering, forming areas with few grain boundaries and no Ag/Cu interfaces and therefore can be considered as fast conduction channels. Conversely, the addition of Cu large grains leads to a moderate decrease in mechanical strength. By presenting a 12 % lower electrical resistivity and an equivalent ultimate tensile strength (UTS) wires with bimodal Cu matrix show a better compromise between low electrical resistivity and high UTS (0.45 μΩ cm, 1082 MPa at 77 K) compared to wires with a fine-grained Cu matrix (0.51 μΩ cm, 1138 MPa at 77 K).

Sai Coating: Detonation Spray Gun

Sai Coating, a small entrepreneurial firm, was one of the three firms that had received the license from ARCI for marketing the Detonation Spray Coating (DSC). Sai Coating made and sold the detonation gun (D-Gun) to three sectors, namely: Wire Drawing, Textiles and Aero components. The coating enhanced the life of the coated wire or surface and its functionality in some ways. The firm had a turnover of INR 4,500,000 and was looking to generate scale and maximize its revenues. The case revolves around the pricing strategy to be adopted by Sai coating to extract value from different set of customers. What should be the price levels given the nature of the product?

A 6th-8th c. wire-drawing iron plate with silver residue from a Vendel Period workshop in Old Uppsala, Sweden

Metal wire is in modern society manufactured by drawing metal rods through dies with conical holes of decreasing diameters, until the desired thickness is obtained. The history and origin of this technique remains unclear, although it was likely developed from earlier wire-making techniques such as strip-drawing and roll-drawing. Proper wire-drawing was an established technology in Europe during the High Middle Ages, and numerous draw-plates have been found at Scandinavian Viking Age trading centers. Here, we report the technical examination of an iron draw-plate found in Uppsala in central Sweden. The draw-plate was excavated in a Vendel Period fine metals workshop, located immediately next to the royal hall in Old Uppsala, the central building of the royal estate in the 6th −8th c. X-ray and scanning electron microscopy (SEM) analysis of the draw-plate revealed silver particles in the plate’s holes, indicating drawing of silver wire. The plate is dated to the 6th – 8th c., which makes it one of the oldest confirmed tools for wire-drawing so far encountered. The presence of this tool in the workshop indicates that some high-quality jewelry in this region was locally produced. Thus, the finding of this draw-plate increases our understanding of Vendel Period jewelry production, and of the social organization of this craft.

Technology of calibrated wire production for bearing rolling elements manufacturing

The article considers technological schemes of cold‑formed wire production for bearing rolling elements production. Several technological schemes of wire production are considered. The paper presents a step‑by‑step development of drawing technology of alloyed (chromium) bearing steel grade. Problems arising at drawing of bearing steels are described. The reason of formation of “flaking” on the surface of rod is revealed. Ways of solving the problem of unsatisfactory drawing of wire from bearing steel grades are stated.Relevance and novelty of technical and technological solutions of the present work are caused by the absence of production of calibrated wire for manufacturing of rolling elements of bearings on the territory of the Republic of Belarus. The development of this type of production will allow to increase the production of high‑tech products with a deep degree of processing (calibrated wire) for the growth of profitability and efficiency indicators. Creation of production of calibrated wire for manufacturing of rolling elements of bearings will allow to reach new consumers of metal products with increase of added value of finished products.

Sintering window and sintering mechanism for diamond

High performance sintered diamond tools, such as those applied to wire drawing and rock drilling, represent a considerable advance in hard materials technology. A dense diamond-metal composite is produced using liquid phase sintering. With a cemented carbide substrate, a cobalt-rich liquid infiltrates between the diamond grains at temperatures near 1400 °C. For small diamond particles (nominally below 20 μm), a combination of high pressure (5 GPa or more) and high temperature (1400 °C or more) gives full density in minutes. A sintering window is defined by the pressure and temperature combination that avoids graphitization while ensuring cobalt melt infiltration. The sintering mechanism is carbon transport by dissolution of graphite from low pressure regions away from grain contacts with precipitation of diamond at grain contacts under high pressure. Sinter bonds preferentially nucleate at surface defects, such as screw dislocation spirals. Bonding rates depend on particle size, carbon solubility, temperature, pressure, and hold time. Calculations are shown for interface reaction site limited growth kinetics.

Dislocation behavior and strengthening mechanisms of Cu–Te alloy drawn at room and cryogenic temperatures

In the work, the cryogenic and room temperature drawing behaviors of Cu–Te alloy with a wide range of accumulative drawing true strain up to 1.1 are systematically investigated. For the first time, the storage of geometrically necessary dislocations (GND) and statically stored dislocations (SSD), occurrence of deformation twinning, as well as their respective roles in strain hardening in the drawn Cu–Te alloy at cryogenic and room temperature have been studied. The results show that the liquid nitrogen temperature drawn (LNT-D) Cu–Te alloy presents higher yield strength (YS), ultimate tensile strength than the room temperature drawn (RT-D) Cu–Te alloy. Microstructural investigation reveals that cryogenic wire drawing of Cu–Te alloy promotes the formation of simultaneous twinning and shear bands, accompanied by the fragmentation of Cu2Te phase. The LNT-D Cu–Te alloy exhibits planar slip characteristics, while RT-D Cu–Te alloy presents wave slip characteristics. Compared with RT-D Cu–Te alloy, the higher YS of LNT-D Cu–Te alloy can be mainly attributed to dislocation strengthening and twinning strengthening, which account for 76.25–80.45% and 4.79–4.91% of the total YS respectively. During room temperature drawing, both GND and SSD play an important role in the hardening of Cu–Te alloy. During cryogenic temperature drawing, work hardening is predominantly through rapid multiplication of SSDs.

Development Method of Fully Automatic Wire Winding Device Based on Dual Motion Control System

In the construction of overhead contact wire for electrified railways, the entire process of wire drawing is manually made, especially for the winding and fixing of the back tie wire. With the length of construction lines often reaching hundreds or even thousands of kilometers, the task of wrapping and fixing the back tie line becomes very heavy and cumbersome. In addition, whether the entanglement is firm, tightly attached, and smooth greatly tests the wrist strength and craftsmanship of construction workers. The comparison between teachers and beginners in construction is obvious, and it is difficult to ensure the consistency of construction standards. In response to the above issues, the fully automatic winding machine adopts a mechanical dual transmission design, a mechanical moving slide mechanism, a reduction motor, and a stepper motor control system to achieve winding process standards such as tight adhesion, reliability, and smoothness, and improve manual operation efficiency by 3-5 times.

Finite element analysis of multi-pass dry wire drawing process of steel cord for tire reinforcement considering Al2O3 inclusion

Finite element analysis of multi-pass dry wire drawing process of steel cord for tire reinforcement considering Al2O3 inclusion

Thermofluid of Maxwellian type past a porous stretching cylinder with heat generation and chemical reaction

This article evaluated the effects of heat generation and the chemical reaction of Maxwell fluid over a porous stretching cylinder. Partial differential equations are framed using the mentioned parameters. The partial differential equations for momentum, heat, and mass are changed using similarity transformations into highly nonlinear ordinary differential equations. These equations are answered numerically via the Runge-Kutta with the shotting scheme of the 4th order in MATLAB with the help of inbuilt software bvp4c. Results are offered graphically and in tabular format for essential parameters over a velocity, temperature, concentration, skin friction coefficient, Sherwood number, and Nusselt number. We checked our coding against an existing article and obtained a good match. The essential findings of this research are that velocity decreases as the permeability parameter rises. It has been observed that a viscoelastic fluid parameter induces a decreasing velocity profile. Due to the Maxwell fluid, porosity, heat generation, and chemical reaction parameters, the thermal profile has been improved. These results have several manufacturing applications, including metal turning, the fabrication of glass filaments, the formation of elastic sheets, wire drawing, the ejection of polymer sheets by oil companies, and the synthesis of polymers.

Fabrication of wire drawing machine

Wire drawing is a metal working process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing dies. There are many applications for wire drawing, including electrical wiring, cables, tension loaded structural components, springs, paper clips, spokes for wheels, and stringed musical instruments. Although similar in process, drawing is different from extrusion, because in drawing the wire is pulled, rather than pushed, through the die. Drawing is usually performed at room temperature, thus classified as a cold working process, but it may be performed at elevated temperatures for large wires to reduce forces. The main objective of this project is to Fabrication of Wire Drawing Machine for reducing the silver and gold wire diameter.

Influence of Strain Hardening Rate of Material on Temperature and Strain Distributions during Wire Drawing.

Temperature rise of a specimen is a significant issue in drawing industries for wire, rod, and bar products, because an excessive increase in temperature during the drawing process can deteriorate the product quality and die life. The influence of the strain hardening exponent (n) of a wire on the temperature and strain distributions during wire drawing is investigated to understand its effect and to improve the quality of drawn wire. Finite element analysis and experiments are conducted to analyze the temperature and strain distributions of wires with n values of 0.0, 0.1, 0.5, and 1.0. The temperature increase of the wire augments as the n of the wire increases, despite the same amount of ideal plastic deformation, which is associated closely with the redundant work. The shear strain increases with the n of the specimen, which generates redundant work, leading to a high temperature rise. Similarly, drawing force increases with the n of the specimen, owing to the increase in redundant work with the n of the wire. In addition, the drawing force presents a linear relationship with the temperature rise of the wire. The drawing speed should be reduced and/or the cooling of wire and die should be strengthened during wire drawing, with increasing n value of the wire, because product quality and die wear are highly associated with the temperature rise of the wire in the deformation zone.