Wire Size Research Articles

How to use eddy current technology to test ferrous and non-ferrous wire

Eddy Current inspection is a technique used for detecting surface seams, cracks, pits, slivers and internal discontinuities in ferrous and non-ferrous wire. Different test sensor configurations including encircling coil and rotary probes can be used. When using encircling coil eddy current testing, the wire passes through the coil excited by an alternating current with one or more Drive signals. Rotary probe inspection can reliably detect surface seams and cracks using eddy currents which are induced by one or more probes traversing the surface of the material under test. Wire sizes can range from ultra-fine below .002” (.051mm), fine wire .002” (.051mm) to .005” (.127mm), standard wire .006” (.152mm) to .725” (18.42mm). Encircling coil testing can be used for the whole range whereas Rotary probe inspection can only be used above .200” (5.08mm).

Analysis and Optimization of Laser Beam Welding Parameters for Aluminium Composite (Al-Zn-Cu Alloy) by Grey Relational Optimization

Aluminium and its composites are widely used in production to enhance the strength of lightweight objects. In this study, an AA7075/SiC composite was fabricated using a stir casting route. Multi-objective optimization and finite element analysis were performed with various process parameters on a manufactured aluminium composite (AA7075 + SiC) undergoing a laser beam welding process. Four welding parameters, i.e., pulse frequency, power, welding speed (transverse), and wire size were taken for laser welding as per the L-9 orthogonal array for experimental study. Tensile strength, deflection, temperature distribution, Rockwell hardness (fusion zone), and Rockwell hardness (heat affected zone) were taken as output parameters after welding. The standard deviation objective weighting–grey relational optimization method optimized the process parameter. ANSYS APDL 23 software was utilized to simulate the entire laser welding method with a cylindrical heat source to predict the temperature distribution in the butt-welded plates. This software uses finite element analysis and gives a deviation of only 5.85% for temperature distribution with experimental results. This study helps to understand the effect of various parameters on the welding strength of the aluminium composite.

Beam tests of SNSPDs with 120 GeV protons

We report the test results for a 120GeV proton beam incident on superconducting nanowire particle detectors of various wire sizes. NbN devices with the same sensitive area were fabricated with different wire widths and tested at a temperature of 2.82K. The relative detection efficiency was extracted from bias current scans for each device. The results show that the wire width is a critical factor in determining the detection efficiency and larger wire widths than 400nm leads to inefficiencies at low bias currents. These results are particularly relevant for novel applications at accelerator facilities, such as the Electron-Ion Collider, where cryogenic cooling is readily available.

Pengaruh Ukuran Kawat dan Jarak Alur Stator Terhadap Nilai Arus Starting Motor Induksi 3 Fasa

<p><strong>The use of electric motors in industry often experiences damage caused by several things, including high <em>starting</em> current surges, overload or full load, loss of one phase in the electric motor, and other causes of damage to the 3-phase motor. The main problem that occurred in this research was damage caused by high <em>starting</em> currents, where in the case study many 3-phase motors were used to drive factory machines. The use of 3-phase motors to drive factory machines is often damaged by unstable currents in the machines. This is because the time and workers for monitoring are very minimal and the materials for repairing machines are inadequate. In this way, the solution for repairing a 3-phase motor is to replace and rewind the damaged motor so that it can be used again. This research aims to find a solution on how to reduce high <em>starting</em> currents in 3-phase motors by utilizing the influence of replacing damaged induction motor components as well as repair methods used in <em>starting</em> when <em>rewinding</em> 3-phase motors. The research results from the groove distance with a wire size of 0.90 mm showed that the groove distance of 9, 9, 8 was 29.3, and at a distance of 10, 10, 10 it had a current of 31 A with no-load testing and recommended groove distances of 10, 10, 10. Next, testing wire sizes of 0.75 mm and 0.90 mm with distances of 10, 10, 10, and 9, 9, 8 without load obtained 26.1 A and 27.4 A while 0.90 mm was 30, 7 A and 28, 1 A. The load was 43.5 A and 43.9 A, while 0.90 mm was 51.3 A and 49.3 A. From the test results, the largest current decrease was at a distance of 10, 10, 10 with a wire size of 0.75 mm. </strong></p><p><strong>Keyword - <em>3 Phase Induction Motor, Groove Spacing, Starting, Wire Size.</em></strong></p>

Effects of wire size on electrical and shock-wave characteristics in underwater electrical explosions of aluminum wires

Initial wire resistance is an important parameter in an underwater electrical wire explosion because it directly affects the discharge characteristics of the circuit and indirectly affects the explosion and shock-wave generation. This paper presents a study on how the initial resistance affects electrical and shock-wave characteristics of underwater electrical explosions of aluminum wires with an initial energy storage of ∼53.5 kJ under the optimal mode. Load voltage, circuit current, and shock-wave pressure were recorded and analyzed. The experimental results show that the average of the discharge channel resistance and the total energy deposition all increase with the initial resistance. In addition, there is no simple functional relationship between the energy deposition during the phase transition process and the initial resistance, while the energy deposition during the plasma growth process increases with the initial resistance. As for shock waves at ∼33 cm, it is observed that when the initial resistance increases from 674.82 to 1581.60 μΩ, the peak pressure, energy density, and impulse increase from 12.65 MPa, 2.67 kJ/m2, and 964.51 Pa s to 42.37 MPa, 18.21 kJ/m2, and 1940.42 Pa s, respectively. In other words, for the optimal mode, an underwater electrical explosion with thinner and longer wire is more conducive to generating strong shock waves in the far-field regime. These results should help select loads for underwater electrical wire explosions in engineering applications.

How alloying and processing effects can influence the microstructure and mechanical properties of directly extruded thin zinc wires

Zinc (Zn) in particular has gained attention as biodegradable metal due to its advantageous corrosion rates compared to magnesium (Mg) or iron (Fe). Still, strength and ductility of zinc are found to be unfavorable for many medical applications. Strategies to overcome such issues base on a distinct grain refinement of the respective product. One important condition of the metal is assumed to be in the form of wires, which in the present work stem from a direct extrusion setup and high degrees of deformation, therefore a hot forming procedure as the underlying thermomechanical treatment. A basic binary alloying approach with Mg, manganese (Mn) and copper (Cu) is applied, limiting the content to a solid solution range of the alloys. The processability and the processing ranges are examined as well as their impact on the microstructure development and the resulting mechanical behavior. Higher extrusion speed leads to inhomogeneous material flow during extrusion. Alloying Zn can reduce the influence of process parameters and decrease the average grain sizes of wires which experienced lower temperature impact. The forming ability of pure Zn and ZnMg-alloy remain limited whereas they appear more beneficial for the alloys with Mn and especially Cu.

Experimental investigation on the effects of stainless-steel mesh reinforcing layers on low-velocity impact response of hybrid thermoplastic glass fiber composites

This study aims to assess the hybridization effect on the perforation threshold of Low-Velocity Impact (LVI) in thermoplastic glass composite laminates, incorporating layers of resin-impregnated stainless-steel mesh. Reinforcing methodologies such as hybridization are recently being adopted as a practical approach to increasing the energy-absorbing capacity of polymer composites. In the current paper, a multi-step hot press lamination method has been employed to fabricate the hybrid composite laminates strengthened with stainless-steel mesh layers. Several stacking sequences, metal mesh wire sizes, orientation and position relative to the impactor have been examined under various LVI energies. It was revealed that the LVI penetration energy was increased for the thermoplastic-based composite laminates reinforced with stainless-steel mesh layers. Furthermore, the LVI penetration energy threshold was significantly influenced by the metal mesh wire size, orientation and stacking sequence. Finally, the backlight method capability was assessed to detect the after-impact interlaminar damages.

Investigation into the Impact of Groove Shape on the Tensile Strength of Commercial Steel

In the industrial landscape, welding holds a prominent position, with a significant demand for both effective and high-quality welding processes. Manufacturers, striving to maintain competitiveness, rely on their manufacturing engineers and production personnel to swiftly and efficiently establish manufacturing processes for new products. Among the various welding methods employed, Gas Metal Arc Welding (GMAW) stands out as one of the most widely utilized processes. Several input factors, including welding current, welding voltage, gas flow rate, wire feed speed (WFS), wire size, and welding speed, play a crucial role in determining the quality of welding outcomes. Taguchi's design, recognized for its effectiveness, serves as a powerful optimization tool for enhancing the quality and performance output of manufacturing processes. In this particular study, GMAW was employed to weld commercial steel under predetermined factors of welding voltage, WFS, and groove shape. The X-groove welding exhibited lower tensile strength and hardness compared to V-groove weldments. Utilizing Taguchi's design, the objective was to identify the optimal process factors that would result in higher tensile strength and hardness. The analysis revealed that welding groove shape had the most significant impact on both tensile strength and hardness, followed by voltage. In contrast, WFS exerted the least influence on tensile strength and hardness. The optimized combination of welding factors identified was a V-groove shape, 20 V welding voltage, and a 5.9 m/min WFS.

Using Simplified Distflow-Based Mixed-Integer Quadratically Constrained Programming Formulation for Optimum Selection of Conductor Size in Electrical Distribution Networks

Determining conductor size is a subproblem that plays a vital role in the planning process of distribution systems. The problem of selecting the conductor cross-sectional area is usually made a model of mixed-integer non-linear programming (MINLP). It is important to note, however, that the MINLP model is not always capable of ensuring convergence to a solution that is globally optimum. In this research, a mixed-integer quadratically constrained programming (MIQCP) formulation is developed as a method for determining the conductor cross-sectional area in power distribution networks in an optimal manner. The goal function aims at minimizing the lifetime cost of lines, including initial capital cost together with operational expenses. The suggested optimization model’s constraints consist of power balance equations, thermal loading capacity of branches, nodal voltage restrictions, budget limitations for investment, and the need to have the same wire size in the main feeder. By using the simplified DistFlow approach for electrical distribution networks and precisely linearizing the product of a binary variable and a continuous variable, the MIQCP formulation is derived from the MINLP model. It is likely possible to solve the MIQCP formulation efficiently in the GAMS environment by using available commercial solvers like CPLEX. The developed MIQCP model is validated using three medium voltage distribution grids of IEEE 33 buses, IEEE 85 nodes, and the Vietnamese real 102 buses. The calculation results revealed the accuracy along with the efficacy of the proposed optimization procedure.

Optimal design of stator slot with semi-closed type to maximize magnetic flux connection and reduce iron leakage in high-speed spindle drives

A novel approach was devised to optimize the stator slot semi-closed type in order improve the magnetic flux connection and minimize iron leakage in high-speed spindle drives. The concept was executed through a combination of response surface approach including the technique of finite element analysis. The primary objective of this investigation would be to provide an engineering approach which improves the functionality of stator criteria, including the stator slot geometry, coil turn per slot, and wire size. The purpose is to achieve higher flux connection and minimize iron leakage. This study presents an enhanced analytical approach that incorporates the analysis of stator flux connection, finite element calculation of flux connection, and iron leakage analysis of stator variables. The results are analyzed through the utilization of finite element computation, and their accuracy is verified through experimental measurements. The findings suggest the ideal design yields increased magnetic flux connection and reduced iron leakage in comparison to the industrial layout. The precision provided by the suggested model is confirmed through the comparison of the simulation and experimental information. In general, the percentage of errors is estimated to be around 7%.

Application of Control Algorithm in the Design of Automatic Crimping Device for Connecting Pipe and Ground Wire

Due to the low effectiveness and poor quality of manual crimping of grounding wires, the author proposes the design of an automatic crimping device for connecting tube grounding wires based on intelligent fully automatic technology. The device consists of a microcontroller, an upper computer control interface, an electric push rod, an infrared sensor, a pressure transmitter, and other devices. The staff used the upper computer monitoring interface to set the relevant parameters for grounding wire crimping, and used X-ray digital imaging technology to measure the crimping size of the grounding wire. The size met the set parameter conditions. Through the PID control algorithm in the microcontroller, the stepper motor was controlled to push the clamp to move, completing the automatic crimping of the grounding wire. The X-ray detection method was introduced to detect the quality of the grounding wire after the crimping was completed. The experimental results show that the average deviation between the measured crimping size of the grounding wire and the actual measurement size by the automatic crimping device is only 0.06 mm, indicating that its measurement results are accurate; The success rate of crimping exceeds 95%. The above experimental results verify that the designed crimping device has high stability and reliability, and good quality detection effect.

Effect of wire size on the functional and structural fatigue behavior of superelastic nitinol

Despite the widespread use of the superelastic nitinol wires in various industries, there exists a critical understanding gap regarding the relationship between wire diameter and fatigue behavior. This study aims at bridging this gap through a systematic, experimental investigation. During the wire drawing process, which is commonly employed to produce smaller wires, microstructural damage is introduced to the material. Microstructural inhomogeneities affect the phase transformations and also serve as fatigue crack initiation sites. Through microstructural analysis and low-cycle fatigue tests on nitinol wires of varying sizes, we confirmed that wire size significantly influences superelastic properties and fatigue response. Smaller wires exhibit better functional performance but are more vulnerable to surface defects, while larger wires experience greater microstructural damage. These findings highlight the need for careful control of wire size and microstructure in designing nitinol-based devices.

Initial arch wires used in orthodontic treatment with fixed appliances.

Initial arch wires used in orthodontic treatment with fixed appliances.

Forces achieved by different material and type of intrusion arches applied in different horizontal levels

Background: Intrusion is one of the most needed movements in orthodontics. It is possible to achieve this with arch wires, miniscrews, and bite-blocks. Purpose: This in vitro study aimed to evaluate forces achieved by different types of intrusion arches made of different materials and anchored in two different horizontal levels by either miniscrews or molar teeth. Methods: An upper jaw typodont was applied different types of intrusion arches: intrusion and utility arches, made of different materials (nitinol, beta III titanium, stainless steel) and different wire sizes (0.016” x 0.022” and 0.017” x 0.025”) to the incisors, both anchoring from molars and miniscrews respectively. Each application was measured by a Correx gauge. Each wire was applied to both the auxiliary slot of the triple tube and the slot in the head of the miniscrew. One-way analysis of variance (ANOVA), Tukey’s HSD test, and a paired two-sample t-test were used to analyze the data. Results: In the intrusion arches, the main effect of the material was found to be statistically significant on force values (p = 0.034) while the main effect of the size was not found statistically significant on force values (p = 0.083). In the utility arches, both the main effect of the material (p = 0.067) and the size (p = 0.140) were not found to be statistically significant on force values. Conclusion: Regardless of the anchorage unit level and size, nitinol was the material that applied the lowest forces among all materials. The material is the most effective factor in the force generated, while the anchorage unit level is the least.

Finite Element Analysis of Protective Measures against Lateral Hinge Fractures in High-Tibial Osteotomy.

Opening wedge high-tibial osteotomy (OWHTO) is widely used for correcting mechanical axis deviations and offloading the medial compartment in unicompartmental osteoarthritis. However, lateral hinge fractures (LHFs) pose a significant complication. This study investigates protective measures to mitigate these fractures, guided by prior observations of mechanical stress impact on LHFs. The study aims to assess the effectiveness of different protective measures, specifically the use of varying sizes of Kirchner wires and drill holes, in reducing the incidence of LHFs during OWHTO. Study Design. The study employs a quantitative, comparative analysis using a finite element method (FEM) based on computed tomography (CT) scans. Using CT-based FEM, the study compares the impact of different sizes of K-wires (1.6 mm, 2.0 mm, and 2.5 mm) and drill holes (3.2 mm and 4.5 mm) on the mechanical stresses around the hinge area in OWHTO. The models were created from a CT scan of a healthy 33-year-old male, focusing on the force required to open the osteotomy gap and the incidence of cracked shell elements. The study found that thicker K-wires increased the force required to open the osteotomy gap, whereas larger apical holes decreased it. The 4.5 mm apical hole model demonstrated significantly fewer cracks compared to the 2.0 mm K-wire model, with no significant difference observed compared to the 2.5 mm K-wire model. Models using a 1.6 mm K-wire or a 3.2 mm drill hole did not significantly reduce cracks compared to the base model. The findings suggest that a 4.5 mm drill hole may be more effective in reducing the risk of LHFs compared to thinner diameter K-wires or smaller apical holes. Both a 2.5 mm K-wire and a 4.5 mm drill hole reduce the number of cracked elements, but the 4.5 mm drill hole also significantly decreases the average and maximum principal stresses as well as the average tensile strength ratio at the hinge area. These findings may be important for surgical planning, particularly in cases requiring increased osteotomy distraction.

Developing adjustable stiffness for smart material of magnetorheological elastomer to diminish vibration

Many vibration isolators, such as passive vehicle mounting devices, have an inflexible stiffness. This article presents the development of a smart material vibration isolator based on magnetorheological elastomer (MRE), which has adjustable stiffness to minimize unwanted vibrations. The objective of this research is to first create a design for the vibration isolator, and then simulate a magnetic circuit. The Finite Element Method Magnetics (FEMM) software was employed to simulate the effectiveness of the electromagnetic circuit in generating a magnetic field through the vibration isolator by employing MRE samples. Pure iron was chosen as the material for the housing of the vibration isolator test rig. To attain an optimal magnetic field, an inventive design of the magnetic circuit, including examination of the wire type, size, and coil turn number, along with the housing material of the test rig, was performed. The study analyzed the performance of the MRE vibration isolator concerning different current inputs in the coil. The results indicate that the stiffness value of the MRE-based isolator system can be more effectively modified by increasing the current inputs. Therefore, a larger current input leads to a greater change in stiffness.

Effect of grain size and wire size on mechanical properties of polycrystalline Ta nanowire: Molecular Dynamics simulation

The effects of grain size and length-to-diameter ratio (LDR) on the mechanical properties of Polycrystalline Tantalum (Ta) nanowire were investigated by Molecular Dynamics (MD) simulation as a result of uniaxial tension deformation applied at 300 K temperature. The Embedded Atom Method (EAM) was used to determine the forces acting on the nanowire atoms. Young's modulus (E), yield strength and fracture stress values were determined from the stress-strain relationship determined as a result of the deformation process. Microstructural changes that occur as a result of plastic deformation from atomic positions determined using the common neighbor analysis method (CNA) were examined. It was determined that the grain size and LDR had a significant effect on the deformation behavior of the Ta nanowire, and the plastic deformation and fracture were caused by the rearrangement of atomic positions by the surface effect. It was found that nanowires with small grain size and LDR exhibited superplastic behavior. In the modeled polycrystalline nanowire system, it was determined that the grain size affects the movement mechanisms of the grains, grain boundaries and the relationship between grain size and yield strength. From this relationship, Hall-Petch effect and after a certain critical grain size inverse Hall-Petch effect were observed.

Dependence of microstructure evolution of novel CoreFlow™ aluminium alloy wire on wire diameter

The wire diameter Dr is one of the key parameters used to tailor the microstructure of alloy wires prepared using a novel room-temperature (RT), one-step CoreFlow™ process. However, the microstructural evolution of CoreFlowed wires at varying Dr remains unclear. The dependence of microstructure characteristics on the Dr should be considered in the future design of CoreFlowed wires. In this study, the microstructure evolution of CoreFlowed 6082 aluminium (Al) wires with four diameters (Dr = 1, 2, 3, and 4 mm) was systematically investigated. After the CoreFlow™, the average grain sizes of all CoreFlowed wires were less than 12 μm compared with the original Al sheet with a coarse grain of 2000 μm. As the Dr increases, the refinement degree of the grain decreases. Particularly, a gradient structure, characterised by grain size increasing from the edge to its centre along the radial diameter, is introduced into CoreFlowed wires. The difference in interaction between strain and heat during CoreFlow™ is responsible for the gradient in grain size. As the Dr increases, the grain size at the edge and its centre increases simultaneously, but the difference in average grain size between them decreases, which is related to the nonlinear change of heat and strain with the Dr. Moreover, the gradient distribution of grain size causes the gradient distribution of specific micro-texture components. The texture components in CoreFlowed wires show a great change with Dr, but their variations show a trend from recrystallization texture to deformation texture with an increase in Dr.

Simulation of radon detection efficiency with small pulse ionization chamber based on Geant4

Radon measurement is crucial in assessing the damage to the human body caused by natural radiation. Pulsed ionization chambers are effective for real-time radon measurement and have widespread applications in other radiation techniques. However, due to practical constraints such as limited space and portability concerns, it becomes imperative to consider not only the detection efficiency but also their ease of transportation. This work utilizes the Geant4 Monte Carlo simulation toolkit to characterize the detection models of small cylindrical and flat plate-type pulsed ionization chambers, and carry out a simulation study to analyze the three crucial factors that influence detection efficiency, including the geometry of the chamber, electrode size, and operating temperature. The results indicate that the cylindrical pulse ionization chamber, with a length of 8 cm and radius of 2 cm, has the best detection efficiency and portability in terms of geometric dimensions, achieving a detection efficiency of (58 ± 4)%. Meanwhile, the flat plate pulse ionization chamber, with dimensions of 7 cm in length and 3 cm in width, achieves the best detection efficiency and portability, with a detection efficiency of (54 ± 3)%. In terms of electrode wire size, the cylindrical ionization chamber electrode wire with a length of 7 cm and a radius of 2.5 mm was optimal with a detection efficiency of (59 ± 4)%. In terms of operating temperature, the detection efficiency of the flat-plate pulsed ionization chamber was the highest at 30 °C, which was (58 ± 4)%, and that of the cylindrical pulsed ionization chamber was the highest at 20 °C, which was (63 ± 4)%. By analyzing the influencing factors of the detection efficiency of the pulsed ionization chamber, it has a certain reference value and guiding significance for the research and design of small pulsed ionization chamber detectors for radon measuring instruments.

ОБРАТИМЫЙ ПРЕОБРАЗОВАТЕЛЬ ЭНЕРГИИ С МАХОВИЧНЫМ НАКОПИТЕЛЕМ В СИСТЕМАХ ЭЛЕКТРОСНАБЖЕНИЯ

The problem of voltage unbalance and the need to power factor correction remain a relevant objective for electric power engineering. A variable load profile reduces the operating efficiency of electric power plants and leads to an overestimation of the power of transformer substations and the wire size of supply lines. Thus residential buildings power equipment remains underloaded for a significant part of the time. The decrease of power-frequency characteristic is becoming increasingly noticeable. This situation is not a problem yet, but in the future it may complicate the task of frequency stabilization. Finding solutions to existing and predicted problems is an important topic of research. To solve the problems posed, the work proposes the concept of a reversible energy converter, that is an electrotechnical complex with a flywheel energy storage and a two-section frequency converter based on two reversible voltage converters (active front end). The planning area of application of a reversible energy converter is transformer substations of residential and public buildings of urban power supply systems. The reversible energy converter is designed to solve such problems as load leveling, reactive power compensation (power factor correction), balancing voltages and power-frequency characteristic control. The work presents a connection scheme a reversible energy converter to the supply system and provides an expression for the phase load voltage.