Wire Manufacturing Research Articles

DEVELOPMENT OF A MATHEMATICAL MODEL OF THE "SHROEDER-TRANSPORTER" SYSTEM IN THE TECHNOLOGY OF PROCESSING CABLE WASTE

The article deals with the development of a mathematical model of the "Schroeder - Transporter" system, which is the main part of the technological process of processing waste cable and wire products. The task of increasing the efficiency of the cable waste recycling process is solved by optimizing the operation of all electromechanical systems: crushers, shredders, granulators and their connecting elements - conveyors. The very process of moving crushed cable production waste has an unstable nature of the load of the moving web, and the reduction of dynamic loads during the start-up of the electromechanical system of the conveyor, the transfer of cargo from one crushing equipment to another is very important. The solution is to control the operating modes of the conveyor by the speed parameters of the tape movement and the change in dynamic loads in case of uneven loading and movement of the flow of the crushed cable mass. The mathematical model of the electromechanical system "Conveyor - shredder" is based on the study of the movement of the tape, which will take into account the uneven traffic, as well as the presence of large and unstable dynamic effects. The choice of modeling parameters is also determined by the flow of processes in the conveyor belt with variable loads and will ensure that the elastic-viscous properties of the entire system are taken into account when the load is transferred along the conveyor in compliance with the speed parameters that are optimal for the operation of the entire waste processing line.

Microstructural evolution of AA7050 alloy wires during tandem hot rolling (THR) and cold-drawing process

A novel processing route, the combination of two-step tandem hot rolling (THR) and cold drawing, was recently developed to produce AA7050 wire products. The evolution of second phases, grain microstructures, and micropores during the whole process was thoroughly studied. The specific effect of second phases on continuous dynamic recrystallization (CDRX) and grain refinement was also systematically investigated, which was of great significance to optimize the processing parameters and further improve the mechanical properties of AA7050 wires. Firstly, both the strip-shaped microscale and tens-of-nanometer MgZn2 primary phases are observed in the as-received extruded sample. The strip-shaped primary MgZn2 phases break and gradually spheroidize throughout the THR process, with some of them redissolving into the Al matrix. However, the nanoscale MgZn2 phases are obviously coarsened and equiaxed only during the second-step THR process. After the first-step THR process, the coarse columnar grains are refined to thin fibrous grains due to the occurrence of CDRX, and a high number of dislocations are stored in the recrystallized structures. During the second-step THR process, only dynamic recovery occurs and no obvious CDRX is observable. This may be due to the coarsening of nanoscale MgZn2 phases, which reduces the driving force of recrystallization by attracting and combining with other solute atoms. The following two-step cold-drawing process has little influence on the primary MgZn2 phases, but promotes the formation of refined and equiaxed grains due to the recurrence of CDRX. This may be because the larger coarsened MgZn2 phases accelerate the recrystallization nucleation and increase the driving force of recrystallization.

Prediction and Control of Product Shape Quality for Wire and Arc Additive Manufacturing

Abstract Wire and arc additive manufacturing (WAAM) has become an economically viable option for fast fabrication of large near-net shape parts using high-value materials in the aerospace and petroleum industries. However, wide adoption of WAAM technologies has been limited by low shape accuracy, high surface roughness, and poor reproducibility. Since WAAM part quality is affected by a multitude of factors related to part geometries, materials, and process parameters, experimental characterization or physics-based simulation for WAAM process optimization can be cost prohibitive, particularly for new part designs. As an effective alternative, data-analytical approaches have been developed for prescriptive modeling and compensation of shape deviations in 3D printed parts. However, WAAM faces a unique challenge of large shape deviation and high surface roughness at the same time. Accurate prediction and control of WAAM part quality require process-meaningful error decomposition under geometric measurement uncertainties. We propose a generalized additive modeling approach to separate global geometric shape deformation from surface roughness. Under this statistical framework, tensor product basis expansion is adopted to learn both the low-order shape deformation and high-order roughness patterns. The established predictive model enables optimal geometric compensation for product redesign to reduce shape deformation from the target geometry without altering process parameters. Experimental validation on WAAM manufactured cylindrical walls of various radii shows the effectiveness of the proposed framework.

Wire and Arc Additive Manufacturing of a CoCrFeMoNiV Complex Concentrated Alloy Using Metal-Cored Wire—Process, Properties, and Wear Resistance

The field of complex concentrated alloys offers a very large number of variations in alloy composition. The achievable range of properties varies greatly within these variants. The experimental determination of the properties is in many cases laborious. In this work, the possibility of using metal-cored wires to produce sufficient large samples for the determination of the properties using arc-based additive manufacturing or in detail wire and arc additive manufacturing (WAAM) is to be demonstrated by giving an example. In the example, a cored wire is used for the production of a CoCrFeNiMo alloy. In addition to the process parameters used for the additive manufacturing, the mechanical properties of the alloy produced in this way are presented and related to the properties of a cast sample with a similar chemical composition. The characterization of the resulting microstructure and wear resistance will complete this work. It will be shown that it is possible to create additively manufactured structures for a microstructure and a property determination by using metal-cored filler wires in arc-based additive manufacturing. In this case, the additively manufactured structure shows an FCC two-phased microstructure, a yield strength of 534 MPa, and a decent wear resistance.

Determination of optimal parameters technological process of polling of copper wire with alloy POS-61

The development of the technique for the manufacture of round copper wire coated with "tin-lead" alloy is considered. The optimal parameters such as the temperature of the "tin-lead" alloy melt, the linear speed for tinning of the wire with a round copper alloy and the diameter of the diamond die were determined. The test results of the experimental wire samples are presented.

Thermal process monitoring and control for a near-net-shape Wire and Arc Additive Manufacturing

Wire and Arc Additive Manufacturing (WAAM) is a promising technology for the fabrication of large metal parts. During the process, the wire electrode is melted continuously or in a pulsating mode and deposited layer-by-layer onto a substrate. Due to the recurring energy input into the part during WAAM, adequate thermal management is crucial. The temperature distribution, especially the interlayer temperature in the part, is determined by the parameter settings as well as by the dwell times and can be monitored. This paper presents the cause-effect relationships between the interlayer temperature and the dwell times to enable a suitable temperature management. Thermal imaging was implemented during the manufacturing process, allowing the analysis of different interlayer dwell times and their effect on the interlayer temperatures. In addition, the influence of the temperature management on the geometric quality characteristics of the part was investigated. It was observed that a constant interlayer dwell time led to geometric irregularities in the part height and width. Monitoring the interlayer temperature is crucial in WAAM in order to maintain a constant temperature level along multiple layers for meeting the requirements for the geometry of the part and enabling near-net-shape manufacturing.

A Versatile Simulation-Assisted Layered Mesh Analysis for Generalized Litz Wire Performance

This article introduces a semi-analytical method of predicting ac loss in commercial Litz wires. Simple finite-element simulations are used to compute the resultant proximity fields in a coil system of arbitrary geometry. The approach addresses non-ideal Litz wire construction by applying a surrogate skin effect model to inform and distribute the current over the cross Section into segmented layers. This simplifies the finite-element problem into a 2-D, dc simulation with a low number of mesh elements. Analytical solutions are then used to compute frequency-dependent loss due to skin and proximity effect. The method is demonstrated using two 14 American Wire Gauge (AWG) equivalent Litz wires with very different constructions and is validated with experimental results from several coil configurations. Finally, an appeal is made to commercial Litz wire manufacturers to provide an empirical “fabrication factor” specification that would allow consumers to predict the performance of a conductor in their application.

Effect and mechanism of inter-layer ultrasonic impact strengthening on the anisotropy of low carbon steel components fabricated by wire and arc additive manufacturing

The problem of anisotropy in the microstructure and mechanical property of the fabrications limits the application and development of wire and arc additive manufacturing (WAAM). By introducing inter-layer ultrasonic impact (UI) strengthening in the low carbon steel WAAM process, the anisotropy can be effectively improved. After being treated by UI, the typical columnar microstructure with obvious direction is transformed into a uniform and fine equiaxed microstructure. Digital image correlation results show that the stress concentration in the tensile process is significantly improved. The anisotropy of tensile strength and yield strength is reduced from 4.2% to 1.6% and 10.1%–2.3%, respectively. Scanning electron microscope (SEM) and electron backscattering diffraction (EBSD) are applied to investigate this phenomenon. The results indicate that UI can break the constraint for dislocations to move, promoting dislocation merging and annihilating. And then, numerous substructures are formed, partially recrystallized by the subsequently deposited layers' thermal effect. The transformation can block the columnar microstructure growth and divide the columnar microstructure into the cellular or equiaxed microstructure. In addition, the results show that inter-layer ultrasonic impact strengthening can result in local misorientation reduction, grain refinement (average grain size reduction from 2.18 μm to 1.65 μm), and texture orientation strength weakening.

Сравнительная оценка влияния технологий аддитивного синтеза на количество и размер пор в изделии

A comparative analysis of samples porosity, synthesized from powder and wire is given. A higher efficiency of wire additive technologies, the implementation of which results in a significantly smaller pore size with reduced volume occupied by them, is shown. It is concluded that the use of layer-wise compaction or periodic undular strainer-hardening allows for achieving, at least 2 times, size loss of pores and 3 times reduction in the number of them, compared to the synthesis of wire products using the same method in similar most rational modes.

Influence of heat input on microstructure and mechanical behaviour of austenitic stainless steel 316L processed in wire and arc additive manufacturing

Wire arc additive manufacturing (WAAM) has long been considered an efficient method for producing medium- and large-sized components, due to its minimal material consumption, high deposition, superior structural quality and environmental friendliness. The ER 316L wire was employed as the filler metal in the fabrication process with varying heat input by altering welding current (C), wire feed speed (WFS) and travel speed (TS). The first portion of the studies involved producing single-bead welds by adjusting the heat input condition, while the second part involved fabricating three single-bead walls using optimum parameters determined in the first part of the research. The mechanical properties of SS316L samples remained impressively constant when WFS and TS were varied. The macroscopic morphology and microstructure of a thick-walled component were studied using a metallurgical microscope and optical electron microscopy. The mechanical properties of tensile study and micro-hardness analysis were reported. From a microstructural study, it can be observed that the deposited weld beads consist of a columnar structure with primary dendrites. The cooling rate and heat dissipation during the weld deposition process affect the variance of microstructure in different areas. The average micro-hardness value of various linear heat input manufactured components demonstrated stability, with values of 313, 249 and 398 HV, respectively. The hardness results of as-deposited walls provide a higher value in bottom regions due to heat accumulation. Tensile properties were determined parallel and perpendicular to the deposition directions; decreased heat input resulted in superior mechanical properties in terms of tensile characteristics. From the tensile properties, the mean values of various heat input SS 316L ultimate tensile strength, yield strength and elongation were found to be 426 MPa, 304 MPa and 20%, respectively. Fractography showed typical dimple fracture characteristics in all the specimens. It is clear from the current research that parts made by WAAM exceed their 316L casting parts and wrought alloy.

Microstructural Evolution and Mechanical Properties of 2219 Aluminum Alloy Deposited by Wire and Arc Additive Manufacturing

Thin‐walled specimens of 2219 aluminum alloy are fabricated at different deposition speeds using the wire + arc additive manufacturing (WAAM) method. The effects of deposition speed on the microstructure, growth rate of columnar grains, and tensile strength of WAAM‐printed Al–Cu alloys are investigated. The fraction of columnar grains decreases from 86.7% to 12.2%, and the average grain size decreases from 147 to 65.3 μm as the deposition speed increased. Also, the fraction of θ phase gradually decreases as the deposition speed increased. Specifically, the growth rate of columnar grains varies from 1.02 × 10−3 to 2.05 × 10−3 m s−1, which possesses two orders of magnitude higher than the growth rate of equiaxed grains. With increasing the loading stress, the cracks first form on the dendritic θ phases located at the grain boundaries, reducing the effective loading area. With the deposition speed increased, the typical dimple‐like structures are presented at the fracture surfaces, attributing to a decrease in Cu content at the grain boundaries and the producing of the spot‐like θ phase inside the matrix. The specimen with a deposition speed of 250 mm min−1 possesses a tensile strength around 274 MPa, and the corresponding elongation reaches to 12.6%.

Strategic management of the enterprise: analysis of sectoral determinants

The article proposes a methodology for determining and analyzing the determinant of the development of the industry, which makes it possible to formulate a list of applied recommendations for the formation of a strategy for the development of enterprises in the cable industry. The study uses a number of methods, the use of which allows us to explore the strategic prospects for the development of the industry, identify the determinants of development, evaluate them, and establish the nature of the impact on the activities of enterprises in the industry; highlight the structural and logical relationships between the studied factor conditions and development determinants, substantiate practical recommendations on the formation of a development strategy for enterprises in the industry. These methods include: methods of analyzing time series, methods of expert evaluation, the rhombus of state advantages by Porter, graph-analytical methods.The article provides statistical data on the volume of the world market for cable and wire products, identifies the main manufacturers and exporters of cable products. Trends in changes in the volume of production and sales of cable products in the world and in Ukraine are studied, in particular, the prospects for the development of the industry are substantiated. The main determinants of the development of the cable industry are determined, which are systematized and studied by the rhombus method of national advantages by M. Porter. Based on the method of expert assessment, a linguistic assessment of the established determinants is carried out, and the nature of their influence on the activities of enterprises in the industry is determined; the structural relationships between the studied factor conditions and development determinants are studied. The article provides arguments for choosing this particular methodological approach to analysis, which, on the one hand, makes it possible to ensure the complexity of the study - taking into account the systematic identification of determinants, the ability to take into account dynamic changes, determine the nature of their influence and track the structural and logical relationships between the studied factor conditions and development determinants. industries. Based on the results obtained, the author makes practical proposals for the formation of a strategy for the development of Ukrainian enterprises for the production of cable and wire products in the global and domestic markets.

Microstructure and mechanical properties of twin wire and arc additive manufactured Ni3Al-based alloy

A Ni3Al-based alloy was prepared for the first time using a twin wire and arc additive manufacturing (T-WAAM) by adjusting the relative feeding speed of the Ni and Al wires, and the microstructure and mechanical properties of the deposited alloy were investigated. The results showed that the deposited Ni3Al-based alloy consisted of a dendritic γ + γ' dual-phase structure and an interdendritic γ' block. The interdendritic γ' block was partially transformed into a γ + γ' dual-phase structure owing to multiple thermal cycles during the deposition process. Thus, the proportion of the γ + γ' dual-phase structure gradually decreased with increasing building height. Meanwhile, the tensile strength and elongation of the deposited alloy exhibited a similar decline in the height direction. Fracture analysis revealed that the interdendritic γ' block hindered dislocation slip in the γ + γ' dual-phase structure, which caused dislocation stacking and stress concentration at the dendrite/interdendritic phase interface. The increase in the interdendritic γ' block was responsible for the decline in the tensile strength and elongation of the deposited alloy along the height direction. With the lowest proportion of interdendritic γ' block, the bottom deposited alloy had an optimal combination with a tensile strength of 817.3 MPa and elongation of 20.9%. Evaluation of the mechanical properties showed that the tensile strength and elongation of the T-WAAMed Ni3Al-based alloy were equivalent to those of commercial cast IC218 and IC221M Ni3Al-based alloys.

Directly Printed Interconnection Wires between Layers for 3D Integrated Stretchable Electronics

AbstractMultilayer circuits, especially in stretchable electronic devices, are considered to be an effective way to integrate various components and modules for complex functions. However, the existing manufacturing methods for multilayer flexible and stretchable electronics have problems such as complex technology, expensive equipment, and low production efficiency. Here, a direct ink writing 3D printing method is proposed to fabricate multilayer stretchable electronic devices by using high‐viscosity stretchable silver paste as the material for interconnecting wires, and stretchable polydimethylsiloxane as the dielectric layer. The optimal range of printing parameters is explored to realize the stable and repeatable manufacturing of wires. A protective layer is printed on the interconnection wires and rigid components to connect the soft substrate and the rigid electronic components. The results show that stress concentration is reduced and stable electrical response of the device is achieved under more than 49% tensile deformation. Vertical interconnect accesses and arc‐shaped wires are applied to a multilayer flexible thermal imaging display device and a NE555 timer device, and the outcomes prove that the direct ink writing 3D printing method provides an efficient, simple, and low‐cost manufacturing method for fabricating multilayer stretchable electronics.

Influence of doping additive on thermophysical and rheological properties of halogen-free polymer composition for cable insulation and sheaths

Introduction. The demand for halogen-free fire-resistant compositions for the manufacture of fire-retardant wires and cables is constantly growing. Problem. Therefore, the creation and further processing of these materials is an urgent problem. Goal. The aim of the article is to study the effect of the doping additive on the thermophysical and rheological properties of halogen-free compositions for power cables with voltage 1 kV with the determination of both the temperatures of phase and structural transformations of polymer compositions. Methodology. Experiments investigating the phase transformations were carried out with the help device of thermogravimetric analysis and differential scanning calorimetry TGA/DSC 1/1100 SF of METTLER TOLEDO company. Rheological studies of polymeric materials were conducted by using the method of capillary viscosimetry in the device IIRT–AM. Results. The influence of the doping additive on the formation of the supramolecular structure of the filled polymer compositions for cable products was determined, that resulted in the temperature increase of the decomposition beginning by 11 °С and the end of decomposition by 7 °С. Originality. The effect of a doping additive on reducing the effective melt viscosity of a polymer composition from 6·104 to 1·104 Pa·s with increasing shear rate has been shown for the first time. The shear rate of the polymer composition containing the doping additive increases from 0.5 to 20 s–1 with increasing shear stress. Practical value. The research results provide an opportunity to reasonably approach the development of effective technological processes for the manufacture of the insulation and sheaths of power cables from halogen-free polymer compositions.

Region-based path planning method with all horizontal welding position for robotic curved layer wire and arc additive manufacturing

For the curved layer deposition with wire and arc additive manufacturing on complex surface, the molten pool behavior and bead geometry are variant at different welding positions for the dragging effect of gravity, which lead to inconsistent layer appearance. A region-based path planning method for robotic curved layer wire and arc additive manufacturing (CL-WAAM) is developed, with which all horizontal welding position can be maintained at arbitrary region of the complex surface. The adverse effect of gravity is minimized and uniform bead appearance can be guaranteed. Firstly, with a two-stage clustering method , the complex surface was divided into a certain number of simple subregions . Then, the contour line across cluster centroid of each subregion was employed as initial path, and an adaptive bead overlapping model changed with local inclined angle was used to generate the offset curved path covering the subregion. Therefore, the overall welding paths were approximate to the contour line on the surface, and the horizontal welding position and consistent forming appearance can be achieved. Finally, three surface parts were designed to validate feasibility of the method, and the forming appearance was compared with traditional iso-parametric method and flat layer WAAM (FL-WAAM). The results suggested that the surface waviness and thickness were relatively consistent at arbitrary region of complex surface with the region-based method, and the stair-step effect appeared in FL-WAAM was significantly alleviated with the CL-WAAM. The proposed method helps achieve the uniform layer appearance deposited on complex surface, which could be widely used in the manufacturing or repairing of wear-resistant surface parts, such as the hot forging die and hydraulic turbine blade. • A framework of robotic curved layer wire and arc additive manufacturing (CL-WAAM) was proposed. • A region-based path planning method with all horizontal welding position for the CL-WAAM was implemented. • The complex surface was subdivided into simple patches with a two-stage clustering method. • The contour line across the cluster centroid was employed as the initial path, with which the all horizontal welding position could be ensured. • The uniform forming appearance was achieved through the proposed region-based path planning method.

Micro wire and arc additive manufacturing (µ-WAAM)

• A novel variant of WAAM is developed. • Increased accuracy, while maintaining high depositions rates. • µ-WAAM can overcome some limitations of powder-bed fusion additive manufacturing processes. In this work we explore the wire and arc additive manufacturing (WAAM) process scale limits by using a wire diameter of 250 µm and about 2 mm stickout. This WAAM variant, named µ-WAAM, aims at competing with laser powder bed fusion technology, by enabling the fabrication of smaller parts with significantly higher deposition rates. The main issues of descaling the WAAM process are discussed and an acceptable parameter window to fabricate thin walls is presented. Several depositions were successfully performed with ASTMA 228 steel using a wire feed speed ranging from 75 to 90 mm/s, travel speed from 7 to 10 mm/s, a current intensity of 16 A RMS and power of ≈ 35 W RMS.

Analysis of temperature-dependent viscosity effect on wire coating using MHD flow of incompressible third-grade nanofluid filled in cylindrical coating die

The convective heat and mass propagation inside dies are used to determine the characteristics of coated wire products. As a result, comprehending the properties of polymerization mobility, heat mass transport, and wall stress concentration is crucial. The wire coating procedure necessitates an increase in thermal performance. As a result, this research aims to find out how floating nanoparticles affect the mass and heat transport mechanisms of third-grade fluid in the posttreatment for cable coating processes in presence of a magnetic field with time-dependent viscosity. For nanofluids, the Buongiorno model is used. The model equations are developed using continuity, momentum, and energy in the presence of nanoparticle and time-dependent variable viscosity. We propose a few nondimensional transformations that are relevant. The numerical technique Runge-Kutta fourth method is used to generate numerical solutions for nonlinear systems. Pictorial depictions are used to examine the effects of various factors in the nondimensional flow. Furthermore, the numerical results are also verified analytically using Homotopy Analysis Method (HAM). The analytical findings of this investigation reveal that within the Reynolds modeling, the stress on the whole wire surface combined shear forces at the surface predominate the Vogel model. The contribution of nanomaterials on force on the entire surface of wire and shear forces at the surface appears positive. A non-Newtonian feature can increase the capping substance’s velocity. This research could aid in the advancement of wire coating technologies. For the very first instance, the significance of nanotechnology during wire coating evaluation is explored utilizing time-dependent variable viscosity regarding the magnetic field. For time-dependent viscosity, two alternative models are useful. The Lorentzian strength (a resistive form of force) increases in magnetic strength increases. As a result of the increased magnetic field, the motion of the polymerization in a die decreases. It is clear that increasing the intensity of Nb increases the heat transfer. The innovative fragment of the present study is to scrutinize the magnetized third-grade nanofluid for wire coating with variable viscosity inside the pressurized coating die, which still not has been elaborated in the available works to date. Consequently, in the restrictive sense, the existing work is associated with available work and originated in exceptional agreement.

Microstructure and Mechanical Properties of TiB2/AlSi7Mg0.6 Composites Fabricated by Wire and Arc Additive Manufacturing Based on Cold Metal Transfer (WAAM-CMT).

Wire and arc additive manufacturing based on cold metal transfer (WAAM-CMT), as a kind of clean and advanced technology, has been widely researched recently. It was analyzed in detail for the microstructure and mechanical properties of WAAM-CMT printed TiB2/AlSi7Mg0.6 samples fore-and-aft heat treatment in this study. Compared with the grain size of casted AlSi7Mg0.6 samples (252 μm), the grain size of WAAM-CMT printed AlSi7Mg0.6 samples (53.4 μm) was refined, showing that WAAM-CMT process could result in significant grain refinement. Besides, the grain size of WAAM-CMT printed TiB2/AlSi7Mg0.6 samples was about 35 μm, revealing that the addition of TiB2 particles played a role in grain refinement. Nevertheless, the grain size distribution was not uniform, showing a mixture of fine grain and coarse grain, and the mechanical properties were anisotropic of the as-printed samples. This study shows that T6 heat treatment is an efficient way to improve the nonuniform microstructure and eliminate the anisotropy in mechanical properties.

Study on the Effects of Different Cutting Angles on the End-Milling of Wire and Arc Additive Manufacturing Inconel 718 Workpieces.

This research presents an analysis of the effects of different cutting angles on the side milling of Inconel 718 products manufactured with the Wire and Arc Additive Manufacturing (WAAM) technique. Considering that this manufacturing technology can build near-net shape products, its surface quality is deemed unqualified as a final product, requiring a post-processing step. In this paper, three different angles—0°, 35°, and 90—are compared, looking for possible differences regarding its machinability. As the alloy in question is a material known for being difficult to machine, and the samples were produced with the additive manufacturing technique that created peculiar characteristics, it was deemed necessary to analyze different aspects of the machining process: the surface quality, tool wear, and cutting forces for all three cases, and to rank the angles regarding these results. With analog experiments with the same alloy but cold-rolled, it was possible to infer that not only is the 0-degree angle is the best option for milling, but the anisotropy of the WAAM samples could be the major source of the differences in the milling results.