Wire Production Research Articles

Hardware industry of the Russian Federation: History of formation, current situation and forecast of development

Subject. The article discusses the economics of the hardware industry of the Russian Federation. Objectives. The study aims at the forecast assessment of production volumes of hardware products in Russia, based on the analysis of strategic planning documents for the development of the main related sectors of the economy, using steel and wire products in their operations (construction, transport, energy, industry, agriculture). Methods. The study draws on research methods, like monographic, statistical and economic, systems analysis, and forecasting. Results. We considered the main aspects of the hardware industry development in the era of the USSR and at the present time. Currently, the production of hardware has decreased fourfold, as compared to the Soviet period. The findings are important for planning the strategic development of the hardware industry and devising the industry support measures. Conclusions. According to the forecast analysis of the steel and wire production in the Russian Federation for 2030–2035 that rests on planned indicators of the branches of the national economy being the main consumers of hardware, the hardware industry should increase production volumes by 32% by 2030–2035 relative to 2023.

Development of structures and production technologies of reinforcing wire with a screw profile

Reinforcing wire is the main structural element in reinforced concrete structures, widely used in the construction of buildings and structures for various purposes. The type of profile is important factor which determines the consumer properties of fittings. This indicator directly affects the quality of reinforcement adhesion to concrete and the properties of the wire. Currently a periodic profile is the most common type, but a screw profile is the most promising form of the profile. Two methods are used in the production of cold-formed screw profiles: applying a screw profile and torsion process. The first is carried out by rotating the profiling element, and the second by torsion of the workpiece of the shaped section. The patent and literature review of methods for obtaining cold-formed screw profiles has shown that the most effective way to obtain reinforcing wire with a screw profile is torsion, which provides, in addition to profiling, an increase in the mechanical and operational properties of the wire. With the help of the Deform-3D software package we identified impact of the profile, namely the shape of the cross section on the tension. By choosing rational torsion parameters, it is possible to achieve a favorable stress-strain state and respectively the properties of the product. One of the promising areas of development is the combination of a periodic and a screw profile, and it is necessary to obtain a screw profile using torsion deformation as a method of intense plastic deformation in order to form a uniform structure in metal with a minimum stress state in addition to the profile. We justified the application of radial shear broaching, an analogue of the radial shear rolling process, which allows to obtain a screw profile reinforcing wire with high mechanical properties due to the production of a finely dispersed structure. This method is implemented on standard drawing equipment and provides an increase in the productivity of wire production by torsion compared to other methods

Models for the Design and Optimization of the Multi-Stage Wiredrawing Process of ZnAl15% Wires for Spray Metallization.

Metallization, a process for applying anti-corrosion coatings, has advantages over hot-dip galvanizing, such as reduced thermal stress and the ability to work "in situ". This process consists of the projection of a protective metal as coating from a wire as application material, and this wire is obtained by multi-stage wiredrawing. For the metallization process, a zinc-aluminum alloy wire obtained by this process is used. This industrial process requires multiple stages/dies of diameter reduction, and determining the optimal sequence is complex. Thus, this work focuses on developing models with the aim of designing and optimizing the wiredrawing process of zinc-aluminum (ZnAl) alloys, specifically ZnAl15%, used for anti-corrosion applications. Both analytical models and numerical models based on the finite element method (FEM) and implemented by computer-aided engineering (CAE) software Deform 2D/3D v.12, enabled the prediction of the drawing stress and drawing force in each drawing stage, producing values consistent with experimental measurements. Key findings include the modeling of the material behavior when ZnAl15% wires were subjected to the tensile test at different speeds, with strain rate sensitivity coefficient m = 0.0128, demonstrating that this type of alloy is especially sensitive to the strain rate. In addition, the optimal friction coefficient (µ) for the drawing process of this material was experimentally identified as µ = 0.28, the ideal drawing die angle was determined to be 2α = 10°, and the alloy's deformability limit has been established by a reduction ratio r ≤ 22.5%, which indicates good plastic deformation capacity. The experimental results confirmed that the development of the proposed models can be feasible to facilitate the design and optimization of industrial processes, improving the efficiency and quality of ZnAl15% alloy wire production.

Improvement of technology for the production of jewelry wire from platinum alloys

Improvement of technology for the production of jewelry wire from platinum alloys

Production of AZ80 magnesium alloy wires: influence of heat treatment on microstructure and properties after twin-roll casting

AbstractTwin-roll casting (TRC) of magnesium sheets has already been analysed in numerous ways. The installation of a pilot plant for the twin-roll casting of magnesium wire at the Institute of Metal Forming, TU Bergakademie Freiberg, has opened up a further area for research. The principle of twin-roll casting of wire is comparable, although the microstructure development is different because of the resulting process-specific solidification and forming conditions. In this work, wire was produced for the first time from the magnesium alloy AZ80 using the TRC process. The microstructure consists of dendritic areas, twins, deformed areas and recrystallised grains. A non-basal texture with low intensity is developed, which is retained even after heat treatment. A temperature of 450 °C and a holding time of 1 h have been shown to be favourable for heat treatment to achieve a uniform grain structure. On the basis of the microstructure and texture analysis, the responsible recrystallisation mechanisms were discussed. Finally, mechanical properties at room temperature were presented and compared with extruded and cast material from the literature.

Influence of high-carbon wire drawing method on its production efficiency

The issue of improving the production efficiency and competitiveness of high-carbon steel wire, determined by a rational ratio of quality and costs of its production, is an urgent task. The main way to solve it is the development and implementation of an effective technical process, the main elements of which are the technological process and equipment for its realization. Since the middle of the last century, domestic steel wire production has been operating on imported equipment, which significantly hampers the use of modern technological processes. This unfavorable situation has been aggravated at present by the imposition of severe economic sanctions by “unfriendly states”. The way out of this situation in the current production is the improvement of existing and introduction of new methods of wire drawing. According to the original methodology the analysis of the existing at one of the domestic enterprises route of drawing of high-carbon wire rope wire with a diameter of 1.70 mm from wire rod of 5.50 mm with the use of standard single monolithic fibers, twin monolithic fibers, roller fibers, as well as modules including roller and monolithic fibers (combined drawing) was carried out. The obtained results have shown that when using standard fibers, the drawing route should be designed with the minimum possible multiplicity, which will provide on the existing equipment to improve the quality of wire and reduce the cost of its production. The greatest efficiency is provided by the application of combined drawing: twofold reduction of drawing multiplicity, energy saving up to 30%, improvement of wire quality by creating a favorable stress-strain state when deforming the wire first in roller and then in monolithic drawing. In addition, in comparison with the roller fibers, the equipment is simplified and the costs of its purchase and operation are reduced. Recommendations on the directions of increasing the efficiency of production in the conditions of existing production, purchase of new imported and designing of domestic drawing equipment are given

Unveiling the mechanisms behind texture formation and its impact on the torsional performance of cold-drawn pearlitic steel wires

High carbon pearlitic steel wires are widely used in the industry, such as for producing tyre cords and steel cables due to its excellent mechanical properties. Cold drawing is a crucial step in steel wire production. Due to the loading state during the cold drawing process, pearlitic wires tend to exhibit a <110> fiber texture. The non-uniform texture distribution on the cross-section of steel wires has been observed experimentally. The mechanisms yielding this non-uniformly distributed texture are carefully investigated in this study using a multi-scale computational approach. Firstly, a macroscale finite element model is established to simulate the deformation behaviour of pearlitic steel wires during cold drawing, with the aim of thoroughly investigating the inhomogeneous elastic-plastic deformation behaviours. Secondly, the macro mechanical responses are incorporated into the mesoscale representative volume element model as boundary conditions to comprehensively study the effect of inhomogeneous deformation characteristics on texture formation. The results present a significant advancement by revealing that the non-uniform texture distribution in a steel wire can primarily be attributed to the multiaxial stress state on the cross-section. Notably, at the center of the steel wire, the maximum principal stress aligns with the drawing axis, resulting in a dominant <110> fiber texture. Conversely, at the subsurface, the maximum principal stress progressively shifts towards the circumferential direction, yielding an evolving texture characterized by a {110}<110> circumferential texture. Furthermore, the research uncovers a crucial finding that it is the {110}<110> circumferential texture that significantly weakens the torsion ability of the wires. This is due to the limited activation of slip systems, marking a key advancement in understanding the mechanical properties of steel wires.

Numerical Simulation and Optimization Design of Particle Transport in 3D Printers Spiral Extrusion 3D Printers

Abstract In response to the challenges of feed delay and inconsistent wire production in existing 3D printers, a novel 3D simulation model for spiral extrusion 3D printers was developed. This model incorporates the particle filling rate within the spiral groove as a critical evaluation criterion, establishing a correlation between the transport section parameters and the filling rate. The simulation software STAR-CCM+ was utilized for in-depth analysis, leading to structural optimizations based on various feeding mechanisms. The effects of different hopper models on feeding efficiency were investigated using the principles of the discrete element method. The findings indicate that the enhanced feed structure effectively addresses particle transportation issues within the printer. An increase in rotational speed is shown to improve the filling efficiency of the spiral groove, while simultaneously reducing the residence time of the particle material in the extruder, which in turn affects particle melting quality. By integrating the simulation data with experimental validation, an optimized printing structure was designed to fulfill the requirements of spiral extrusion printers.

Stearate from Steel Wire Drawing Processes as a Resource

STAR (Stearato dai processi di Trafilatura del filo di Acciaio come Risorsa) project, funded by the Italian Ministry of the Environment, has the ambition of redesigning the use and life cycle of waste stearates from the steel wire drawing industry, promoting the circular life of such materials. Waste stearate is having a strong impact on the economic and environmental sustainability of the steel wire production processes, adding up to the increasing pressure that industry has been facing in the last years: the pandemic crisis, the raw material price increase, the commercial restrictions related to the Ukraine and other regional conflicts.The short-term goal of the project is to develop a technology to be applied on a local scale and the long-term one is expanding it internationally. The benefits are both environmental, due to the reduction of waste and related impact on the environment, and economic, due to stearate valorization.First, stearate waste from wire drawing process were characterized in order to valorize them in the production of new materials or as an energy source.Samples of stearate waste were provided by wire drawing industries and the analyses showed that the humidity content was always low (0.1 – 5 %), while the volatile solids (VS) content varied from 2 to 70%, covering a very wide range and thus indicating a variable organic matter content. The mean higher heating value was 26 MJ/kg and the Chemical Oxygen Demand (COD) 500 mg O2/g and correlated well with VS. pH was strongly basic (&gt;11).Anaerobic digestion can surely have an important role in valorization, as it allows to recover energy and to produce a stabilized digestate for which a further use can be studied, according to its properties. Preliminary BMP tests (BMP = Biomethane Potential) determined a biomethane production in the range 500-900 L/kgVS, much higher than the production from animal waste (around 400 L/kgVS). The toxicity of the digestate was assessed by Microtox® assay and was negligible. This finding supports the hypothesis that recalcitrant compounds, which do not undergo degradation in anaerobic conditions, are not toxic.

Efficient production of kilometer-scale ultrafine aluminum wire with superior strength and electrical conductivity

The rapid development of new energy vehicles has generated considerable interest in the efficient production of ultrafine aluminum electronic wiring harnesses with superior strength and electrical conductivity (EC). However, achieving a balance between strength and EC/ductility remains a challenge. To overcome the trade-off relation, we precisely controlled the grain size and grain boundary structure by using ultrafine aluminum powders (∼1 μm) as the starting material, and introduced dislocations into the as-sintered sample to enhance the strain rate sensitivity via cold deformation. In the cold-deformed sample, a unique mechanical response was observed: the elongation increased with deformation. Meanwhile, the strength and EC maintained to be a high level. Based on the unique properties, we successfully fabricated kilometer-scale ultrafine aluminum wire (0.2 mm in diameter) by cold deformation without any intermediate annealing, realizing high strength (206 MPa) and high EC (59.1%IACS, International Annealed Copper Standard) simultaneously. Our work provides a new concept and a new processing route to efficiently produce ultrafine aluminum electronic wiring harness with excellent properties.

Climate true‐cost analysis of industrial goods and its regulatory implications on value chains and global competition

AbstractClimate change and its damaging consequences for ecology and humanity is advancing. Industry and its metals sector are responsible for most greenhouse gas emissions. Current costs of industrial goods do not reflect the true costs caused by the externalized climate damages of its production and thus offer no competitive incentive to decarbonize. Additionally, regional climate regulation can lead to competitive distortion. We therefore aim to investigate the impact of climate cost internalization on the metals industry. Using true‐cost analysis for an exemplary and widely used metal product, the effects of climate true costs depending on production region, technology, and energy mix, CO2e taxation and value chain are examined. Based hereon, the impact of internalizing climate true costs together with the introduction of a carbon‐border tax on the carbon leakage problem, climate protection, and the cost situation for companies in global competition are investigated. The results of the study show that steel and wire production is responsible for most CO2e emissions showing significant decarbonization effects by steel recycling whereas production location and logistics play a minor role. On a competitive level, cost internalization has hardly any effect on the product costs because of the currently low CO2e‐taxation rates. Thus, almost no incentive to produce or consume in a climate‐protective way is generated, incentivizing production in pollution havens versus highly climate regulated regions. Instead, to realize emission efficiency gains and innovations leading to a competitive advantage of decarbonized products and value chains, a significant increase of CO2e‐taxation rates together with a carbon‐border tax is necessary.

A numerical study on MHD Maxwell fluid with nanoparticles over a stretching surface: Impacts of thermal radiation, convective boundary condition and induced magnetic field

The current study investigates the influence of induced magnetic field and convective boundary condition on the behavior of a magnetohydrodynamic (MHD) Maxwell fluid including nanoparticles flowing through a stretching sheet. Furthermore, the analysis considers the existence of radiation. Numerical solutions to the basic governing equations are achieved using the Runge–Kutta–Fehlberg technique. The impact of various physical parameters on concentration, velocity, and temperature profiles is deployed through graphs. The primary conclusions of this study are that increasing the Magnetic parameter decreases the Induced Magnetic field while increasing the Deborah parameter improves the velocity profile. Temperature distribution is growing due to increased estimates of the Radiation, Biot number, and Deborah number values. When the Lewis number values are raised, the concentration profiles get smaller but there is an opposite scenario deployed as the Thermophoresis parameter upsurges. The findings of this study are consistent with those that have been previously reported. The phenomenon of flow induced by a stretched surface finds several applications in various industrial and technological domains, including copper wire production, polymer extrusion, article manufacturing, and fiber synthesis. Induced magnetic fields are extremely prominent in many areas of science and technology, including electromagnetism, magnetic materials, and magnetic resonance imaging (MRI).

Kolomenskij mashinostroitel'nyj zavod v gody Pervoj mirovoj vojny: proizvodstvo voennoj i grazhdanskoj produkcii

The article presents the peculiarities of the Kolomna Machine-Building Plant during the First World War. The process of expanding production is shown by increasing the production of steam locomotives for military field railways, medium-speed piston engines for navy ships and submarines, as well as new products for the enterprise - artillery shells, machines for the production of barbed wire, machine-gun carriages, marching infantry and artillery kitchens.

High critical current density in low-cost iron-based superconducting round wires annealed at ambient pressure

Superconducting round wires with isotropic architecture are preferred in fabrications of cables and magnets. To diminish the obstacles to supercurrent, e.g., voids, cracks and bubbles, over-pressure heat treatment or hot isostatic pressing is indispensable in the final annealing process. Here, we fabricated a stainless steel/Cu/Ag sheathed Ba0.6K0.4Fe2As2 superconducting round wire without the aid of high-pressure sintering. It was found that high-strength outer sheaths and groove rolling synergistically enhance the core density to ∼100%. Combined with the fiber and concentric texture of the superconducting core, the J c reaches 4.45 × 104 A cm−2 at 4.2 K and 10 T. Furthermore, the specially designed conductor architecture not only reduces material costs by lowering the proportion of Ag to ∼3.1%, but also provides high mechanical and thermal stability. This straightforward and cost-effective process can be scaled up for the massive production of long wires for high-field applications.

Development and research of technology for obtaining and properties of welding wire from Al–Mg–Sc alloys using combined methods of thermal deformation treatment

The results of studies technological processes for obtaining welding wire from alloys of the Al–Mg system with a scandium content of 0.12 (alloy 1580) and 0.25 wt % (alloy 01570) presented. A feature of the technology is the production of a billet for further cold deformation by an energy-efficient method of ingotless rolling-extrusion (IRE). It was found that hot-extruded rods from the investigated alloys obtained by the IRE method have the required level of plastic and strength properties necessary for further cold deformation up to 80%. Thermomechanical processing of hot-extruded rods manufactured by IRE have been developed and experimentally tested, which made it possible to obtain a billet with a square side of 5 × 5 mm by sectional rolling and wire with a diameter of 3 mm by drawing. Studies of the structure and mechanical properties of deformed semi-finished products have shown that the developed modes make it possible to obtain a welding wire from the investigated alloys that meets the requirements of current standards. Studies of the operational properties of the obtained welding wire were carried out. It was found that alloy 1580 with a minimum content of scandium (0.12 wt %) is not inferior to alloy 01570 in terms of corrosion resistance and weld quality. Developed technology for the production of welding wire from alloys of the Al–Mg system with different scandium content can be recommended for industrial use. It is advisable to implement alloy 1580, which has a lower cost compared to alloy 01570.

Improving the Industrial Efficiency of Recycling Aluminum Alloy Chips Using Friction Stir Extrusion: Thin Wires Production Process

Friction stir extrusion is one of the most promising solid-state chip recycling techniques because of its relative simplicity and high efficiency. One of the most straightforward applications for the process is the production of recycled wires to be utilized as filler material in welding or welding-based additive manufacturing processes, in order to create an industrial symbiosis link, fostering a circular economy and enhancing the technology readiness level of the process. The scalability of the process to the thin wires needed for such applications has not been investigated so far. In this paper, an experimental and numerical analysis was developed. A dedicated numerical model was first validated and then used to design the tool geometry. The effect of tool rotation and tool force on both “standard” mechanical properties, as Ultimate Tensile Strength and microhardness, and specific properties for the envisaged application, as the wrapping around reels with different radii, was investigated. The numerical model results were used to explain the influence of the process parameters on the material flow as well as on the distribution of the primary field variables, namely temperature, strain, and strain rate. Finally, the energy demand was measured, and the specific energy consumption (SEC) was evaluated. It was found that a conical shoulder surface favors the conditions for effective solid bonding. Low values of the extrusion force have detrimental effects on the wires properties as they result either in insufficient strain, or hot cracking defects. High values of extrusion force results in lower SEC, unlocking the potential of the process as symbiotic link enabler.

Numerical Analysis of Process Parameters and Tool Geometry in Friction Stir Back Extrusion of Pure Aluminum

Friction Stir Back Extrusion (FSBE) is an innovative process that offers efficient aluminum waste recycling and wire production. This process boasts economic and environmental advantages, as it requires minimal energy compared to traditional recycling casting methods. The objective of this study is to analyze the impact of process parameters using a Finite Element Method (FEM) model based on thermo-mechanical 3D Lagrangian. The study focuses on an AA1080 aluminum alloy and employs different geometric tools, including hole extrusion diameters of 4 mm and 8 mm, as well as a shoulder with two distinct angles of 10° and 15°. Furthermore, variations in several process parameters, such as a constant axial feed rate of 0.5 and 1 mm/min and a constant rotational speed of the die set at 100, 300, and 500 rpm, are considered. The simulation plan encompasses a total of 24 combinations of these parameters to identify the optimal conditions for chips extrusion. Subsequently, the obtained results were analyzed using Design of Experiments (DoE) analysis to assess the influence of each parameter on peak force, torque, and temperature during the process.

Analýza vlastností medených drôtov vyrobených pretlačovaním

The article focuses on the production of copper wires by extrusion and the evaluation of their mechanical properties. The article presents the results obtained on the basis of tensile tests and on the basis of hardness measurement. The tests were carried out on a semi-finished product with a circular cross-section and on manufactured wires with a rectangular cross-section. The wires produced were 9.5x4.5 mm, 10.5x1.65 mm and 5.75x1.35 mm. The impact of the transformation on the microstructure of the produced wire was also monitored.

Sustainable Recovery of Titanium Alloy: From Waste to Feedstock for Additive Manufacturing

Titanium and its alloys are widely employed in the aerospace industry, and their use will increase in the future. At present, titanium is mainly produced by the Kroll method, but this is expensive and energy-intensive. Therefore, the research of efficient and sustainable methods for its production has become relevant. The present review provides a description of the titanium recycling methods used to produce mostly aeronautical components by additive manufacturing, offering an overview of the actual state of the art in the field. More specifically, this paper illustrates that ilmenite is the main source of titanium and details different metallurgic processes for producing titanium and titanium alloys. The energy consumption required for each production step is also illustrated. An overview of additive manufacturing techniques is provided, along with an analysis of their relative challenges. The main focus of the review is on the current technologies employed for the recycling of swarf. Literature suggests that the most promising ways are the technologies based on severe plastic deformation, such as equal-channel angular pressing, solid-state field-assisted sintering technology-forge, and the Conform process. The latter is becoming established in the field and can replace the actual production of conventional titanium wire. Titanium-recycled powder for additive manufacturing is mainly produced using gas atomization techniques.

Investigation of Hybrid Wires Combining Superconductive MgB2 and Ultra-conductive Graphene/Cu sheath

In our study, hybrid wires with ultra-conductive Graphene/Copper(GCu) sheath and superconducting MgB2 core were produced and experimentally examined. Cu tubes with outer/inner diameters of 15/12 mm were first coated with multi-layered graphene by chemical vapour deposition (CVD) method. Then, the ultra-conductive G/Cu tubes were filled with Mg+2B powder and they were gradually drawn into wires with a diameter of 1.94 mm. According the analysis results, the graphene coating process was successfully completed and the hybrid wires were produced by achieving MgB2 superconducting phase formation after annealing at 650∘C for 1 h. In this study, a graphene-coated copper tube with a CVD process was used for the first time to manufacture a superconducting wire. The ampacity value of industrial G/Cu sample has been improved in hybrid wires about 75% despite Cu exposed to mechanical deformations throughout the wire production process after graphene coating.