CN112117023A - Copper-aluminum composite wire and preparation method thereof - Google Patents
Copper-aluminum composite wire and preparation method thereof Download PDFInfo
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- 239000002131 composite material Substances 0.000 title claims abstract description 172
- JRBRVDCKNXZZGH-UHFFFAOYSA-N alumane;copper Chemical compound [AlH3].[Cu] JRBRVDCKNXZZGH-UHFFFAOYSA-N 0.000 title claims abstract description 122
- 238000002360 preparation method Methods 0.000 title claims abstract description 17
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 143
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 143
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 106
- 229910052802 copper Inorganic materials 0.000 claims abstract description 104
- 239000010949 copper Substances 0.000 claims abstract description 104
- 238000005096 rolling process Methods 0.000 claims abstract description 88
- 238000000137 annealing Methods 0.000 claims abstract description 33
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims abstract description 27
- 238000005253 cladding Methods 0.000 claims abstract description 23
- 230000006698 induction Effects 0.000 claims abstract description 12
- 239000011261 inert gas Substances 0.000 claims abstract description 8
- 238000001514 detection method Methods 0.000 claims description 32
- 230000009467 reduction Effects 0.000 claims description 32
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 claims description 20
- 238000000034 method Methods 0.000 claims description 19
- 238000010438 heat treatment Methods 0.000 claims description 16
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 12
- 239000003513 alkali Substances 0.000 claims description 12
- 235000019270 ammonium chloride Nutrition 0.000 claims description 10
- 238000010330 laser marking Methods 0.000 claims description 9
- 238000012806 monitoring device Methods 0.000 claims description 7
- 238000004381 surface treatment Methods 0.000 claims description 7
- 244000137852 Petrea volubilis Species 0.000 claims description 6
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 6
- 229910052757 nitrogen Inorganic materials 0.000 claims description 6
- 238000010926 purge Methods 0.000 claims description 6
- 238000005406 washing Methods 0.000 claims description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 238000005491 wire drawing Methods 0.000 abstract description 15
- 238000004519 manufacturing process Methods 0.000 abstract description 12
- 238000009792 diffusion process Methods 0.000 abstract description 6
- 239000006185 dispersion Substances 0.000 abstract description 3
- 238000012544 monitoring process Methods 0.000 abstract description 3
- 230000007547 defect Effects 0.000 description 10
- 239000000047 product Substances 0.000 description 9
- 239000012466 permeate Substances 0.000 description 6
- 230000008569 process Effects 0.000 description 6
- 230000008859 change Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000010301 surface-oxidation reaction Methods 0.000 description 4
- 230000005540 biological transmission Effects 0.000 description 3
- 239000004020 conductor Substances 0.000 description 3
- 230000008595 infiltration Effects 0.000 description 3
- 238000001764 infiltration Methods 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- 239000013543 active substance Substances 0.000 description 2
- WPPDFTBPZNZZRP-UHFFFAOYSA-N aluminum copper Chemical compound [Al].[Cu] WPPDFTBPZNZZRP-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- IXCSERBJSXMMFS-UHFFFAOYSA-N hydrogen chloride Substances Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 description 2
- 229910000041 hydrogen chloride Inorganic materials 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 230000009466 transformation Effects 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 229910018565 CuAl Inorganic materials 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000010310 metallurgical process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/023—Alloys based on aluminium
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/026—Alloys based on copper
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0006—Apparatus or processes specially adapted for manufacturing conductors or cables for reducing the size of conductors or cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/02—Single bars, rods, wires, or strips
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- Manufacturing & Machinery (AREA)
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- Pressure Welding/Diffusion-Bonding (AREA)
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Abstract
The invention relates to a copper-aluminum composite wire and a preparation method thereof. The copper-aluminum composite wire comprises a copper cladding layer, a composite layer and an aluminum core, wherein the area of the cross section of the copper cladding layer is 16-58% of the area of the cross section of the copper-aluminum composite wire, the area of the cross section of the composite layer is 0.5-3% of the area of the cross section of the copper-aluminum composite wire, and the area of the cross section of the aluminum core is 40-80% of the area of the cross section of the copper-aluminum composite wire; the preparation method comprises the following steps: under the protection of inert gas, the copper strip is welded after being coated with the aluminum rod to form a copper-coated aluminum profile with an outer layer being a closed copper-coated layer and an inner layer being the aluminum rod; continuously drawing the welded copper-clad aluminum section by a wire drawing machine to form a copper-clad aluminum wire, wherein the temperature of a wire drawing die is 300-450 ℃ during wire drawing; and (3) carrying out multi-pass rolling on the continuously drawn copper-clad aluminum wire, monitoring the rolling pressure by a pressure sensor during rolling to be 10-100 MPa, and carrying out online induction annealing. The prepared copper-aluminum composite wire diffusion layer is uniform in dispersion, firm in combination and stable and reliable in performance; the preparation process is simple and easy to operate, and the production cost is low.
Description
Technical Field
The invention belongs to the technical field of metal calendering processing, and particularly relates to a copper-aluminum composite wire and a preparation method thereof.
Background
The copper-aluminum composite wire, in particular to a copper-aluminum composite wire, is a bimetal composite special-shaped wire, is used for replacing a pure copper wire, can be widely applied to the fields of medium and low voltage power generation, power transmission and distribution, motors, large and medium wind power generation and the like, and has the advantages of substantially same mechanical property and electrical property, greatly reduced cost, low density, light weight and the like compared with the pure copper wire.
Chinese patent CN101131892A discloses a method for manufacturing copper-clad aluminum flat wire, which needs to be annealed after drawing and before rolling to meet the rolling requirement, but the annealing can generate CuAl at the copper-aluminum bonding interface2And a brittle phase is formed, and the metallurgical bonding layer is separated in the subsequent metallurgical process, so that the conductivity and the service life of the copper-aluminum composite wire are influenced.
However, in the actual production process, the copper-aluminum composite wires produced by the prior art including the above patents cannot completely replace pure copper wires due to the conductivity, heat conductivity, stability and the like, and particularly relate to the application of large-scale power transmission and transformation devices and large-scale generators such as wind generating sets.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: aiming at the defects, the invention provides the copper-aluminum composite wire and the preparation method thereof, the diffusion layer of the copper-aluminum composite wire is dispersed uniformly, the combination is firm, and the performance is stable and reliable; the preparation process is simple and easy to operate, and the production cost is low.
The technical scheme adopted by the invention for solving the technical problems is as follows: a copper-aluminum composite wire comprises a copper cladding layer, a composite layer and an aluminum core, wherein the area of the cross section of the copper cladding layer is 16% -58% of the area of the cross section of the copper-aluminum composite wire, the area of the cross section of the composite layer is 0.5% -3% of the area of the cross section of the copper-aluminum composite wire, and the area of the cross section of the aluminum core is 40% -80% of the area of the cross section of the copper-aluminum composite wire;
the copper mass percent in the composite layer of the copper-aluminum composite wire is 50-85%, and the aluminum mass percent in the composite layer is 15-50%.
The area of each layer of section of the copper-aluminum composite wire is limited, the mass ratio of copper to aluminum is controlled, the problem that the metallurgical composite layer is broken due to the fact that the section of the composite layer is too thin is solved, waste of raw materials due to the fact that the composite layer is too thick is avoided, and the interface bonding strength is high; the area of the copper layer section is controlled, so that the heating phenomenon caused by overlarge current-carrying capacity is avoided, the service life of the copper-aluminum composite wire is influenced, the production cost is reduced on the premise of meeting the conductivity and mechanical properties of the copper-aluminum composite wire as far as possible, and the copper-aluminum composite wire is high in economy; the copper-aluminum composite wire has the advantages of large cross section area of the composite layer, thick composite layer, uniform dispersion of copper-aluminum components, firm combination and stable and reliable performance.
Furthermore, two sides of the cross section of the copper-aluminum composite wire are fillet sides, round sides or full round sides.
A preparation method of a copper-aluminum composite wire comprises the following steps:
step A1, copper-aluminum cladding: under the protection of inert gas, the copper strip is welded after being coated with the aluminum rod to form a copper-coated aluminum profile with an outer layer being a closed copper-coated layer and an inner layer being the aluminum rod;
step a2, continuous draw: continuously drawing the welded copper-clad aluminum section bar by a drawing machine to form a copper-clad aluminum wire, wherein the temperature of a drawing die is 300-450 ℃ during drawing;
step A3, rolling and extending the copper-clad aluminum wire: carrying out multi-pass rolling on the continuously drawn copper-clad aluminum wire, wherein the rolling speed is 5-30 m/min during rolling, the relative rolling reduction of a single pass is 10% -30%, the rolling is monitored by a pressure sensor, and the rolling pressure is 10-100 MPa; the total deformation after multi-pass rolling and extension is 80% -95%;
step A4, in-line induction annealing: the annealing temperature is 200-400 ℃ and the annealing time is 0.5-2 h by the temperature detection of an on-line monitoring device.
The copper-aluminum composite wire produced by the preparation method is continuously drawn by a wire drawing machine, and is preheated during drawing, the drawn round rod is directly flattened to obtain a corresponding size, the obtained finished product is directly annealed, and the annealing of flattening money is cancelled, so that the brittle phase is avoided, the stability of a copper-aluminum section composite layer is ensured, the energy is saved, the monitoring by a pressure sensor is realized during flattening, the stability during detection is good, and the process is controllable; and the online induction annealing is adopted, so that the temperature can be monitored in time, the product quality during annealing is ensured, and the production efficiency is high.
Further, before the copper-aluminum coating in the step A1, the surface treatment of an aluminum rod and a copper strip in the step A0 is carried out, the aluminum rod is immersed in alkali liquor, an oxide film on the surface is removed by alkali washing, and nitrogen purging is carried out for standby application; the copper strip is subjected to oil removal, sand paper rust removal and ammonium chloride coating, is washed by clean water after being dried, and is dried for later use. The surfaces of the aluminum rod and the copper strip are polished, so that the contact area between the copper strip and the aluminum rod can be increased, the mutual permeation area between copper and aluminum is large, and the defects of gaps and the like of a composite layer are reduced; the aluminum-copper composite wire has the advantages that the ammonium chloride is used as an infiltration-assisting active agent, the aluminum infiltration effect of the aluminum rod to the copper strip is promoted in the stretching and pressing process, the ammonium chloride is decomposed at the temperature of more than 340 ℃ along with the temperature change during drawing and annealing, the generated ammonia gas and hydrogen chloride cannot remain in the composite layer, the mechanical property and the conductivity of the copper-aluminum composite wire cannot be influenced, the aluminum layer permeates to the copper layer while the copper layer permeates to the aluminum layer, the copper and the aluminum are dispersed uniformly, and the solid-solid interface is combined firmly.
Further, in the step A3 copper-clad aluminum wire rolling and extending operation, the temperature during rolling is 620-675 ℃. The surface of the aluminum core is gradually heated to form a molten state and the aluminum core is softened, the molten aluminum is easier to permeate into the copper strip when the aluminum core is rolled, the mutual diffusion effect between the contact surfaces corresponding to the copper is good when the aluminum core is rolled, the formed composite layer is connected and fastened, the rolling speed is controlled, the inside of the aluminum core is ensured not to be melted, and therefore the dislocation between the aluminum rod and the copper strip can not occur when the aluminum core is rolled, and the uniformity of the copper-aluminum composite conductor product is affected.
Further, the step A3 is to heat the copper-clad aluminum wire by a high-frequency wire heater during rolling in the rolling and extending operation. Adopt high-frequency heating, rate of heating is fast, can realize instantaneous heating, and the heating homogeneity is good, and the wire can instantaneously soften, and production efficiency is high.
Further, after the online induction annealing in the step A4, the method further comprises the step A5 of online accurate flaw detection, wherein the copper-aluminum composite lead is fixed on a tension pulley for ultrasonic online flaw detection, and the position with the flaw is marked by a laser marking method. The online ultrasonic flaw detection is adopted, the detection is convenient, the defects of impurities, cracks, layering and the like which possibly occur in the copper-aluminum composite wire, particularly in the process of flattening the composite layer can be monitored, the detection is accurate, and the ultrasonic flaw detection is free of radiation and safe; and unqualified products can be discharged in time through laser marking, and the production efficiency is improved.
The invention has the beneficial effects that:
1. the area of each layer of section of the copper-aluminum composite wire is limited, the mass ratio of copper to aluminum is controlled, the problem that the metallurgical composite layer is broken due to the fact that the section of the composite layer is too thin is solved, waste of raw materials due to the fact that the composite layer is too thick is avoided, and the interface bonding strength is high; the area of the copper layer section is controlled, so that the heating phenomenon caused by overlarge current-carrying capacity is avoided, the service life of the copper-aluminum composite wire is influenced, the production cost is reduced on the premise of meeting the conductivity and mechanical properties of the copper-aluminum composite wire as far as possible, and the copper-aluminum composite wire is high in economy; the copper-aluminum composite wire has the advantages of large cross section area of the composite layer, thick composite layer, uniform dispersion of copper-aluminum components, firm combination and stable and reliable performance.
2. The copper-aluminum composite wire produced by the preparation method is continuously drawn by a wire drawing machine, and is preheated during drawing, the drawn round rod is directly flattened to obtain a corresponding size, the obtained finished product is directly annealed, and the annealing of flattening money is cancelled, so that the brittle phase is avoided, the stability of a copper-aluminum section composite layer is ensured, the energy is saved, the monitoring by a pressure sensor is realized during flattening, the stability during detection is good, and the process is controllable; and the online induction annealing is adopted, so that the temperature can be monitored in time, the product quality during annealing is ensured, and the production efficiency is high.
3. The surfaces of the aluminum rod and the copper strip are polished, so that the contact area between the copper strip and the aluminum rod can be increased, the mutual permeation area between copper and aluminum is large, and the defects of gaps and the like of a composite layer are reduced; the aluminum-copper composite wire has the advantages that the ammonium chloride is used as an infiltration-assisting active agent, the aluminum infiltration effect of the aluminum rod to the copper strip is promoted in the stretching and pressing process, the ammonium chloride is decomposed at the temperature of more than 340 ℃ along with the temperature change during drawing and annealing, the generated ammonia gas and hydrogen chloride cannot remain in the composite layer, the mechanical property and the conductivity of the copper-aluminum composite wire cannot be influenced, the aluminum layer permeates to the copper layer while the copper layer permeates to the aluminum layer, the copper and the aluminum are dispersed uniformly, and the solid-solid interface is combined firmly.
4. Under a proper temperature, the surface of the aluminum core is gradually heated to form a molten state at the temperature, the aluminum is softened, the molten aluminum is easy to permeate into the copper strip during rolling, the mutual diffusion effect between contact surfaces corresponding to the copper is good during rolling, the formed composite layer is connected and fastened, the rolling speed is controlled, and the inside of the aluminum core is ensured not to be melted, so that the aluminum rod and the copper strip are ensured not to be dislocated during rolling, and the uniformity of the manufactured copper-aluminum composite conductor product is influenced; adopt high-frequency heating, rate of heating is fast, can realize instantaneous heating, and the heating homogeneity is good, and the wire can instantaneously soften, and production efficiency is high.
5. The online ultrasonic flaw detection is adopted, the detection is convenient, the defects of impurities, cracks, layering and the like which possibly occur in the copper-aluminum composite wire, particularly in the process of flattening the composite layer can be monitored, the detection is accurate, and the ultrasonic flaw detection is free of radiation and safe; and unqualified products can be discharged in time through laser marking, and the production efficiency is improved.
Based on the beneficial effects, the copper-aluminum composite wire prepared by the invention has wide application, and is particularly suitable for application in the fields of large-scale power transmission and transformation devices, large-scale generator sets such as wind generating sets and the like.
Drawings
The foregoing and other objects, features, and advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings.
FIG. 1 is a schematic view of a copper-aluminum composite wire with rounded edges on two sides of the cross section;
FIG. 2 is a schematic view of a copper-aluminum composite wire with rounded edges on two sides of the cross section;
FIG. 3 is a schematic view of a copper-aluminum composite wire with a full-circle structure on two sides of the cross section.
Wherein, 1 is the cross section of the copper cladding layer, 2 is the cross section of the composite layer, 3 is the cross section of the aluminum core, 4 is the cross section of the copper-aluminum composite conductor, R1 is the radius of the fillet edge, R2 is the radius of the full-circle edge, and b is the short half shaft of the circle edge.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to examples and the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1: preparation of copper-aluminum composite wire with size of 3.4mm by 10.7mm
Step A1, copper-aluminum cladding: under the protection of inert gas, the copper strip is welded after being coated with the aluminum rod to form a copper-coated aluminum profile with an outer layer of a closed copper-coated layer and an inner layer of aluminum, the mass ratio of the copper strip coated with the aluminum rod to the aluminum rod is 52:48, the thickness of a copper layer of the formed copper-coated aluminum profile is 6.1mm, the radius of the aluminum rod is 40mm, and the diameter of the formed copper-coated aluminum profile is 46.1 mm;
step a2, continuous draw: continuously and circularly drawing the welded copper-clad aluminum profile by a wire drawing machine, sequentially drawing and deforming by 5 passes with the average single-pass end face reduction rate of 15%, and then drawing and deforming by 3 passes with the single-pass end face reduction rate of 10%; drawing to obtain a copper-clad aluminum wire, wherein the copper-clad aluminum wire is a copper-clad aluminum composite round wire, the diameter of the copper-clad aluminum composite round wire is 15mm, and the temperature of a wire drawing die during drawing is 350 ℃;
step A3, rolling and extending the copper-clad aluminum wire: carrying out multi-pass rolling on the continuously drawn copper-clad aluminum composite round wire at the rolling speed of 5m/min and the single-pass relative reduction range of 10% -30%, flattening and extending by 12 passes to form a 3.4mm by 10.7mm copper-aluminum composite wire, wherein the thickness of the flat wire is 3.4 mm; when the thickness of the wire blank is 10-15mm, the relative reduction of a single pass is 30%, the total number of the passes is 5, and the rolling pressure is 100 MPa; when the thickness of the wire billet is 5-10mm, the relative reduction of a single pass is 20 percent, the total number of the passes is 4, and the rolling pressure is 60 MPa; when the thickness of the wire billet is 3.4-5mm, the relative reduction of a single pass is 9%, the rolling pressure is 20MPa for 3 passes in total, the pressure during rolling is monitored by a pressure sensor, and the total deformation after multi-pass rolling and elongation is 95%; the temperature during rolling is 620-650 ℃, and a high-frequency online heater is adopted for heating during rolling; two sides of the section of the rolled copper-aluminum composite wire are full-circle sides, and the radius R2 of the full-circle sides is 1/2 of the thickness of the section of the copper-aluminum composite wire;
step A4, in-line induction annealing: the temperature detection of an online monitoring device is carried out, the annealing temperature is 350 ℃, the annealing time is 0.5h, the manufactured copper-aluminum composite wire comprises a copper cladding layer, a composite layer and an aluminum core, the area of the cross section 1 of the copper cladding layer is 24.5% of the area of the cross section 4 of the copper-aluminum composite wire, the area of the cross section 2 of the composite layer is 0.6% of the area of the cross section 4 of the copper-aluminum composite wire, and the area of the cross section 3 of the aluminum core is 74.9% of the area of the cross section 4 of the copper-aluminum composite wire;
step A5, online accurate flaw detection: fixing the copper-aluminum composite wire on a tension wheel, carrying out ultrasonic online flaw detection, and marking the position with the defects by adopting a laser marking method.
Example 2: preparation of copper-aluminum composite wire with size of 3.4mm by 10.7mm
Step A0, surface treatment of the aluminum rod and the copper strip, immersing the aluminum rod in alkali liquor, removing a surface oxidation film by alkali washing, and purging with nitrogen for standby; the copper strip is subjected to oil removal, rust removal by using sand paper, then is coated with ammonium chloride, is washed by using clean water after being dried, and is dried for later use;
step A1, copper-aluminum cladding: under the protection of inert gas, the copper strip is welded after being coated with the aluminum rod to form a copper-coated aluminum profile with an outer layer of a closed copper-coated layer and an inner layer of aluminum, the mass ratio of the copper strip coated with the aluminum rod to the aluminum rod is 52:48, the thickness of a copper layer of the formed copper-coated aluminum profile is 6.1mm, the radius of the aluminum rod is 40mm, and the diameter of the formed copper-coated aluminum profile is 46.1 mm;
step a2, continuous draw: continuously and circularly drawing the welded copper-clad aluminum profile by a wire drawing machine, sequentially drawing and deforming by 5 passes with the average single-pass end face reduction rate of 15%, and then drawing and deforming by 3 passes with the single-pass end face reduction rate of 10%; drawing to obtain a copper-clad aluminum wire, wherein the copper-clad aluminum wire is a copper-clad aluminum composite round wire, the diameter of the copper-clad aluminum composite round wire is 15mm, and the temperature of a wire drawing die during drawing is 350 ℃;
step A3, rolling and extending the copper-clad aluminum wire: carrying out multi-pass rolling on the continuously drawn copper-clad aluminum composite round wire at the rolling speed of 5m/min and the single-pass relative reduction range of 10% -30%, flattening and extending by 12 passes to form a 3.4mm by 10.7mm copper-aluminum composite wire, wherein the thickness of the flat wire is 3.4 mm; when the thickness of the wire blank is 10-15mm, the relative reduction of a single pass is 30%, the total number of the passes is 5, and the rolling pressure is 100 MPa; when the thickness of the wire billet is 5-10mm, the relative reduction of a single pass is 20 percent, the total number of the passes is 4, and the rolling pressure is 60 MPa; when the thickness of the wire billet is 3.4-5mm, the relative reduction of a single pass is 9%, the rolling pressure is 20MPa for 3 passes in total, the pressure during rolling is monitored by a pressure sensor, and the total deformation after multi-pass rolling and elongation is 95%; the temperature during rolling is 620-650 ℃, and a high-frequency online heater is adopted for heating during rolling; two sides of the section of the rolled copper-aluminum composite wire are full round sides, and the radius R2 of the full round sides is 1/2 of the thickness of the section of the copper-aluminum composite wire;
step A4, in-line induction annealing: the temperature detection of an online monitoring device is carried out, the annealing temperature is 350 ℃, the annealing time is 0.5h, the manufactured copper-aluminum composite wire comprises a copper cladding layer, a composite layer and an aluminum core, the area of the cross section 1 of the copper cladding layer is 24.0% of the area of the cross section 4 of the copper-aluminum composite wire, the area of the cross section 2 of the composite layer is 1.6% of the area of the cross section 4 of the copper-aluminum composite wire, and the area of the cross section 3 of the aluminum core is 74.4% of the area of the cross section 4 of the copper-aluminum composite wire;
step A5, online accurate flaw detection: fixing the copper-aluminum composite wire on a tension wheel, carrying out ultrasonic online flaw detection, and marking the position with the defects by adopting a laser marking method.
Example 3: preparation of copper-aluminum composite wire with size of 3.4mm by 10.7mm
Step A0, surface treatment of the aluminum rod and the copper strip, immersing the aluminum rod in alkali liquor, removing a surface oxidation film by alkali washing, and purging with nitrogen for standby; the copper strip is subjected to oil removal, rust removal by using sand paper, then is coated with ammonium chloride, is washed by using clean water after being dried, and is dried for later use;
step A1, copper-aluminum cladding: under the protection of inert gas, the copper strip is welded after being coated with the aluminum rod to form a copper-coated aluminum profile with an outer layer of a closed copper-coated layer and an inner layer of aluminum, the mass ratio of the copper strip coated with the aluminum rod to the aluminum rod is 65:35, the thickness of a copper layer of the formed copper-coated aluminum profile is 10mm, the radius of the aluminum rod is 40mm, and the diameter of the formed copper-coated aluminum profile is 50 mm;
step a2, continuous draw: continuously and circularly drawing the welded copper-clad aluminum profile by a wire drawing machine, sequentially performing drawing deformation with the average single-pass end face reduction rate of 20% for 4 passes, and sequentially performing single-pass end face reduction rate of 10% for 3 passes; drawing to obtain a copper-clad aluminum wire, wherein the copper-clad aluminum wire is a copper-clad aluminum composite round wire, the diameter of the copper-clad aluminum composite round wire is 15mm, and the temperature of a wire drawing die during drawing is 400 ℃;
step A3, rolling and extending the copper-clad aluminum wire: carrying out multi-pass rolling on the continuously drawn copper-clad aluminum composite round wire at the rolling speed of 10m/min and the single-pass relative reduction range of 10% -30%, flattening and extending by 12 passes to form a 3.4mm by 10.7mm copper-aluminum composite wire, wherein the thickness of the flat wire is 3.4 mm; when the thickness of the wire blank is 10-15mm, the relative reduction of a single pass is 30%, the total number of the passes is 5, and the rolling pressure is 100 MPa; when the thickness of the wire billet is 5-10mm, the relative reduction of a single pass is 20 percent, the total number of the passes is 4, and the rolling pressure is 60 MPa; when the thickness of the wire billet is 3.4-5mm, the relative reduction of a single pass is 9%, the rolling pressure is 20MPa for 3 passes in total, the pressure during rolling is monitored by a pressure sensor, and the total deformation after multi-pass rolling and elongation is 95%; the temperature during rolling is 650-670 ℃, and a high-frequency online heater is adopted for heating during rolling; the two sides of the section of the rolled copper-aluminum composite wire are fillet sides, and the radius R1 of the fillet sides is 0.8 mm;
step A4, in-line induction annealing: the temperature detection of an online monitoring device is carried out, the annealing temperature is 300 ℃, the annealing time is 1h, the manufactured copper-aluminum composite wire comprises a copper cladding layer, a composite layer and an aluminum core, the area of the cross section 1 of the copper cladding layer is 33.7% of the area of the cross section 4 of the copper-aluminum composite wire, the area of the cross section 2 of the composite layer is 2.6% of the area of the cross section 4 of the copper-aluminum composite wire, and the area of the cross section 3 of the aluminum core is 62.7% of the area of the cross section 4 of the copper-aluminum composite wire;
step A5, online accurate flaw detection: fixing the copper-aluminum composite wire on a tension wheel, carrying out ultrasonic online flaw detection, and marking the position with the defects by adopting a laser marking method.
Example 4: preparation of copper-aluminum composite wire with size of 3.4mm by 10.7mm
Step A0, surface treatment of the aluminum rod and the copper strip, immersing the aluminum rod in alkali liquor, removing a surface oxidation film by alkali washing, and purging with nitrogen for standby; the copper strip is subjected to oil removal, rust removal by using sand paper, then is coated with ammonium chloride, is washed by using clean water after being dried, and is dried for later use;
step A1, under the protection of inert gas, welding the copper strip coated with the aluminum rod to form a copper-coated aluminum profile with an outer layer of a closed copper-coated layer and an inner layer of aluminum, wherein the mass ratio of the copper strip coated with the aluminum rod to the aluminum rod is 75:25, the thickness of a copper layer of the formed copper-coated aluminum profile is 15.3mm, the radius of the aluminum rod is 40mm, and the diameter of the formed copper-coated aluminum profile is 55.3 mm;
step a2, continuous draw: continuously and circularly drawing the welded copper-clad aluminum profile by a wire drawing machine, sequentially performing 4-pass drawing deformation with the average single-pass end face reduction rate of 20%, and performing 4-pass single-pass end face reduction rate of 10%; drawing to obtain a copper-clad aluminum wire, wherein the copper-clad aluminum wire is a copper-clad aluminum composite round wire, the diameter of the copper-clad aluminum composite round wire is 14.9mm, and the temperature of a wire drawing die is 420 ℃ during drawing;
step A3, rolling and extending the copper-clad aluminum wire: rolling and extending the copper-clad aluminum wire: carrying out multi-pass rolling on the continuously drawn copper-clad aluminum composite round wire at the rolling speed of 20m/min and the single-pass relative reduction range of 10% -30%, flattening and extending by 12 passes to form a 3.4mm by 10.7mm copper-aluminum composite wire, wherein the thickness of the flat wire is 3.4 mm; when the thickness of the wire blank is 10-15mm, the relative reduction of a single pass is 30%, the total number of the passes is 5, and the rolling pressure is 100 MPa; when the thickness of the wire billet is 5-10mm, the relative reduction of a single pass is 20 percent, the total number of the passes is 4, and the rolling pressure is 60 MPa; when the thickness of the wire billet is 3.4-5mm, the relative reduction of a single pass is 9%, the rolling pressure is 20MPa for 3 passes in total, the pressure during rolling is monitored by a pressure sensor, and the total deformation after multi-pass rolling and elongation is 95%; the temperature is 620-650 ℃ during rolling, and a high-frequency online heater is adopted for heating during rolling; the two sides of the section of the rolled copper-aluminum composite wire are fillet sides, and the radius R1 of the fillet sides is 0.8 mm;
step A4, in-line induction annealing: the temperature detection of an online monitoring device is carried out, the annealing temperature is 350 ℃, the annealing time is 1.5h, the manufactured copper-aluminum composite wire comprises a copper cladding layer, a composite layer and an aluminum core, the area of the cross section 1 of the copper cladding layer is 46.9% of the area of the cross section 4 of the copper-aluminum composite wire, the area of the cross section 2 of the composite layer is 1.6% of the area of the cross section 4 of the copper-aluminum composite wire, and the area of the cross section 3 of the aluminum core is 51.5% of the area of the cross section 4 of the copper-aluminum composite wire;
step A5, online accurate flaw detection: fixing the copper-aluminum composite wire on a tension wheel, carrying out ultrasonic online flaw detection, and marking the position with the defects by adopting a laser marking method.
Example 5: preparation of copper-aluminum composite wire with size of 3.4mm by 10.7mm
Step A0, surface treatment of the aluminum rod and the copper strip, immersing the aluminum rod in alkali liquor, removing a surface oxidation film by alkali washing, and purging with nitrogen for standby; the copper strip is subjected to oil removal, rust removal by using sand paper, then is coated with ammonium chloride, is washed by using clean water after being dried, and is dried for later use;
step A1, copper-aluminum cladding: under the protection of inert gas, the copper strip is welded after being coated with the aluminum rod to form a copper-coated aluminum profile with an outer layer being a closed copper-coated layer and an inner layer being aluminum, the mass ratio of the copper strip coated with the aluminum rod to the aluminum rod is 82:18, the thickness of a copper layer of the formed copper-coated aluminum profile is 13.6mm, the radius of the aluminum rod is 25mm, and the diameter of the formed copper-coated aluminum profile is 38.6 mm;
step a2, continuous draw: continuously and circularly drawing the welded copper-clad aluminum profile by a wire drawing machine, sequentially performing drawing deformation with the average single-pass end face reduction rate of 15% for 3 passes, and performing single-pass end face reduction rate of 10% for 4 passes; drawing to obtain a copper-clad aluminum wire, wherein the copper-clad aluminum wire is a copper-clad aluminum composite round wire, the diameter of the copper-clad aluminum composite round wire is 15.5mm, and the temperature of a wire drawing die is 450 ℃ during drawing;
step A3, rolling and extending the copper-clad aluminum wire: rolling and extending the copper-clad aluminum wire: rolling and extending the copper-clad aluminum wire: carrying out multi-pass rolling on the continuously drawn copper-clad aluminum composite round wire at the rolling speed of 20m/min and the single-pass relative reduction range of 10% -30%, flattening and extending by 12 passes to form a 3.4mm by 10.7mm copper-aluminum composite wire, wherein the thickness of the flat wire is 3.4 mm; when the thickness of the wire blank is 10-15mm, the relative reduction of a single pass is 30%, the total number of the passes is 5, and the rolling pressure is 100 MPa; when the thickness of the wire billet is 5-10mm, the relative reduction of a single pass is 20 percent, the total number of the passes is 4, and the rolling pressure is 80 MPa; when the thickness of the wire billet is 3.4-5mm, the relative reduction of a single pass is 9%, the rolling pressure is 30MPa for 3 passes in total, the pressure during rolling is monitored by a pressure sensor, and the total deformation after multi-pass rolling and elongation is 95%; the temperature is 660-675 ℃ during rolling, and a high-frequency online heater is adopted for heating during rolling; two sides of the cross section of the rolled copper-aluminum composite wire are round sides, and the short half shaft b of each round side is 1/4 of the thickness of the cross section of the copper-aluminum composite wire;
step A4, in-line induction annealing: the annealing temperature is 380 ℃ and the annealing time is 2 hours through the temperature detection of an online monitoring device, the manufactured copper-aluminum composite wire comprises a copper cladding layer, a composite layer and an aluminum core, the area of the cross section 1 of the copper cladding layer is 57% of the area of the cross section 4 of the copper-aluminum composite wire, the area of the cross section 2 of the composite layer is 2% of the area of the cross section 4 of the copper-aluminum composite wire, and the area of the cross section 3 of the aluminum core is 41% of the area of the cross section 4 of the copper-aluminum composite wire;
step A5, online accurate flaw detection: fixing the copper-aluminum composite wire on a tension wheel, carrying out ultrasonic online flaw detection, and marking the position with the defects by adopting a laser marking method.
The samples collected are 3.4mm 10.7mm copper-aluminum composite wires, 3.4mm 10.7mm pure copper wires are used as comparative examples, the resistance change and the quality change of the product are shown in the following table 1, wherein the cross-sectional area of the composite layer is the area of the effective composite layer cross section formed by copper-aluminum mutual infiltration diffusion:
table 1:
from the above table, after the surface treatment is performed on the copper strip and the aluminum rod, under the same processing conditions, the area of the cross section of the composite layer formed by the treated copper strip and the treated aluminum rod accounts for a higher area of the cross section of the copper-aluminum composite wire, and the more the resistance is increased, the more the performance of the copper-aluminum composite wire is affected; when the temperature is closer to the melting point of the aluminum core during rolling, the surface of the aluminum core is close to softening and melting, mutual permeation among composite layers is easier, and the copper-aluminum composite wire has high connection strength and good stability; with the increasing aluminum consumption in the copper-aluminum composite wire, the wire quality is reduced, and the cost is reduced; however, with the increase of the resistance, the heat dissipation performance of the copper-aluminum composite wire is weakened, and the total thickness of the copper layer is selected according to the actual application condition. Through scanning detection of an electron microscope, the diffusion layer of the copper-aluminum composite wire is dispersed uniformly, is firmly combined and has stable and reliable performance.
In light of the foregoing description of the preferred embodiment of the present invention, many modifications and variations will be apparent to those skilled in the art without departing from the spirit and scope of the invention. The technical scope of the present invention is not limited to the content of the specification, and must be determined according to the scope of the claims.
Claims (7)
1. A copper-aluminum composite wire is characterized by comprising a copper cladding layer, a composite layer and an aluminum core, wherein the area of the cross section of the copper cladding layer is 16% -58% of the area of the cross section of the copper-aluminum composite wire, the area of the cross section of the composite layer is 0.5% -3% of the area of the cross section of the copper-aluminum composite wire, and the area of the cross section of the aluminum core is 40% -80% of the area of the cross section of the copper-aluminum composite wire;
the copper mass percent in the composite layer of the copper-aluminum composite wire is 50-85%, and the aluminum mass percent in the composite layer is 15-50%.
2. The copper-aluminum composite wire according to claim 1, characterized in that: the two sides of the section of the copper-aluminum composite wire are fillet sides, round sides or full round sides.
3. The preparation method of the copper-aluminum composite wire according to claim 1, characterized by comprising the following steps:
step A1, copper-aluminum cladding: under the protection of inert gas, the copper strip is welded after being coated with the aluminum rod to form a copper-coated aluminum profile with an outer layer being a closed copper-coated layer and an inner layer being the aluminum rod;
step a2, continuous draw: continuously drawing the welded copper-clad aluminum section bar by a drawing machine to form a copper-clad aluminum wire, wherein the temperature of a drawing die is 300-450 ℃ during drawing;
step A3, rolling and extending the copper-clad aluminum wire: carrying out multi-pass rolling on the continuously drawn copper-clad aluminum wire, wherein the rolling speed is 5-30 m/min during rolling, the relative rolling reduction of a single pass is 10% -30%, the rolling is monitored by a pressure sensor, and the rolling pressure is 10-100 MPa; the total deformation after multi-pass rolling and extension is 80% -95%;
step A4, in-line induction annealing: the annealing temperature is 200-400 ℃ and the annealing time is 0.5-2 h by the temperature detection of an on-line monitoring device.
4. The method for preparing the copper-aluminum composite wire according to claim 3, characterized in that: before the copper-aluminum coating in the step A1, the surface treatment of an aluminum rod and a copper strip in the step A0 is carried out, the aluminum rod is immersed in alkali liquor, an oxide film on the surface is removed by alkali washing, and nitrogen purging is carried out for standby application; the copper strip is subjected to oil removal, sand paper rust removal and ammonium chloride coating, is washed by clean water after being dried, and is dried for later use.
5. The method for preparing the copper-aluminum composite wire according to claim 3, characterized in that: in the step A3 copper-clad aluminum wire rolling and extending operation, the temperature is 620-675 ℃ during rolling.
6. The method for preparing the copper-aluminum composite wire according to claim 3 or 5, characterized in that: and in the step A3, a high-frequency online heater is adopted for heating during rolling in the copper-clad aluminum wire rolling and flattening extension operation.
7. The method for preparing the copper-aluminum composite wire according to claim 3, characterized in that: and the step A4 further comprises the step A5 of online accurate flaw detection after the online induction annealing, wherein the copper-aluminum composite lead is fixed on a tension pulley for ultrasonic online flaw detection, and the position with the flaw is marked by adopting a laser marking method.
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