DE60012369T2 - DRAWN METAL COMPOSITE WIRE - Google Patents

Abstract

A deformed metal composite wire (14) comprises a matrix (12) of a first metal having a first melting point. The composite wire also comprises two or more filaments (10) of a second or further metal embedded in the matrix (12) and surrounded by the matrix (12). The second or further metal has a melting point which is higher or equal to the first melting point. The wire (14) is in a deformed state so that the two or more filaments (10) have a non-circular filament cross-section. <IMAGE>

Description

Technical area

The The present invention relates to a deformed metal composite wire and a method for producing such a composite wire. The present invention also relates to the uses of such deformed metal composite wire.

General state of the art

According to general understanding are metal composite wires as metal wires to understand, which consist of elements, which consist of different ones Consist of metals.

such Metal composite wires are known in the art. For example, the Patent GB 325 248 (date of filing: 1928) discloses a composite wire, to be used as an electrical conductor. This conductor wire consists of at least three filaments. At least one filament, z. As a steel filament acts as a tension element and at least one Filament, e.g. As a copper filament acts as a conductive element.

The Japanese Patent Application JP-A-09-047810 discloses a metal composite wire which is manufactured as follows: individual steel filaments are first by means of an electrolytic plating technique coated with aluminum, the filaments coated in this way are bundled and pulled together, so that the aluminum coating material the gaps between the steel filaments crowded. The steel filaments are not deformed.

The JP-A-09-047810 discloses the features of the preamble of claim 1 and 17.

Metal composite structures where metal filaments are separated by another metal, were z. In US-A-3,394,213 and in Japanese JP-A-51-017163, JP-A-62260018 as a manufacturing method for the production of metal fibers described. In all these documents the only task was to combine different metals in it, the production very thin To allow fibers. The function of the metal around and between the filaments was in it, the filaments during to keep the deformation separate. After deformation, this becomes Metal removed to obtain fibers. This metal is with it not part of the final product.

The Separating metal is also a metal that can withstand the temperatures of hot rolling or the treatment described in this process does not melt (typically low carbon steel). The number The filaments are always pretty high as this is the only way in order to obtain small size fibers (typically more than 500).

The US-A-3,907,550 discloses composite billets as starting material for superconducting wires act. Rods of a metal that is capable of producing a superconductor To form, are in a molten bath of normal material dipped, d. h., which is unable to accept a superconductor form. After solidification, a coarse billet is formed, the strong Deformations can be subjected by interim heat treatments possible be made. The function of consolidating or amplifying is no problem.

According to other It is also well known in the art to be flexible to improve a long metal element by using thinner elements (Wires, Filaments, ...) makes a strand or a rope. The improvements of the flexibility thus obtained stands a diminution the strength (compared to a similar long element with solid Cross-section; because of a low degree of filling) and also a lower one Performance re z. B. the corrosion resistance and abrasion resistance. A further improvement of these cables involves the compactification of these strands or ropes (compacting, swaging, drawing): the filaments are compacted so that the degree of filling increases, whereby the strength per unit cross-section is improved and to a lesser extent also the abrasion resistance and corrosion resistance is improved. (See, for example, the patents US-A-3,131,469, US-A-3,364,289, US-A-3,130,536, US-A-3,083,817). In this process, the Starting strands or ropes pulled to a lesser extent (typically 30-50% elongation) be (lengthened with a necking).

The Patent application WO-A-99/23673 also describes the possibility in the middle of a filament to add a softer material that by compacting the open spaces between the filaments better fill. But here, too, the degree of deformation is limited.

Brief description of the invention

A The object of the invention is to overcome the disadvantages of the prior Fix technique.

A Another object of the invention is to provide a highly deformed To provide metal composite wire.

A The object of the invention is also to provide wires that either by a high tensile strength (i.e., substantially higher than 2000 MPa), high corrosion resistance, high flexibility, one high conductivity, .. (or any combination) compared to conventional ones wires Marked are.

A particular object of the present invention is to wire with to provide a high corrosion resistance.

According to one First aspect of the present invention is a deformed metal composite wire provided. This composite wire comprises a matrix of one first metal having a first melting point and two or more filaments from a second or third metal embedded in the matrix and are surrounded by the matrix. Either the second or further Metal or both are a carbon steel or a stainless one Stole. The second or further metal has a melting point, the higher or equal to the first melting point. The composite wire is in a deformed state, so that two or more filaments one not circular Have filament cross section.

• – Sie hält die Filamente während der Verformung zusammen;
• – Sie fungiert als Gleitmittel während des Verformungsprozesses;
• – Sie fügt eine zusätzliche Eigenschaft zu dem endgültigen verformten Metallverbunddraht hinzu, wie beispielsweise eine Antireibungseigenschaft, elektrische Leitfähigkeit, Korrosionsfestigkeit,...
• – Sie sorgt für eine höhere Verformung und Spannungshärtung der Filamente. Die Menge des Matrixmaterials und sein Volumenverhältnis in Bezug zum Volumen der Filamente haben Einfluss auf die Ziehfähigkeit. Ein Volumenverhältnis von 1 zu 1 erlaubt bereits einen hohen Verformungsgrad.

The function of the matrix of the first metal can be multiple:

• - It holds the filaments together during the deformation;
• - It acts as a lubricant during the deformation process;
• It adds an additional property to the final deformed metal composite wire, such as anti-friction property, electrical conductivity, corrosion resistance, ...
• - It ensures a higher deformation and stress hardening of the filaments. The amount of matrix material and its volume ratio relative to the volume of the filaments have an influence on the drawability. A volume ratio of 1 to 1 already allows a high degree of deformation.

The Filaments in the deformed composite wire are typically obtained a cross section similar to a polygon. Due to the degree of deformation, which can be very high some "sides" of the polygon have a rough appearance.

Of the Composite wire preferably has due to its pulling through Peel a round cross section.

For the first, softer metal can be zinc, a zinc alloy, aluminum, brass, Tin, a tin alloy, etc ... are used.

The Metal filaments can in any number, starting with the minimum number of two filaments present be. Typical values are between three and twenty. In most make the number of filaments is less than twenty-seven.

The Metal filaments are made of a second or third metal with a Melting point made, the higher is equal to or equal to the melting point of the matrix material.

As already mentioned is either the second metal filament or the third Metal filament or both filaments of carbon steel or stainless Steel, to the desired Strengthening or strengthening effect to obtain.

The metal filaments can be of any size. Typical values for the cross-sectional area vary between 0.01 mm ² and 10 mm ² .

The Metal filaments have the same longitudinal orientation of the wire on; you can either parallel or twisted, twisted, bundled or stranded ... The individual metal filaments can also have any metal coating of any thickness (eg Zn-coated steel, ...) and this coating can by any method (electrolytic, hot dipping, Dress, ..). Also single metal filaments without coating are also possible.

According to the invention a final deformation reduction of at least 50%, z. B. more than 90% or even more than 99% possible. The term 'final deformation' refers to deformation of the composite wire without intermediate heat treatments. The term "reduction" is defined as a cross-sectional reduction and can be calculated as: (S i -S f ) X 100 / S i

Where S _{i is} the value of the starting cross-sectional area of the composite wire;
and where S _{f is} the value of the final cross-sectional area of the composite wire.

Of the Wire can be filaments in any combination of the above Hold cases (eg a carbon steel filament surrounded by six smaller ones Copper or aluminum filaments or low filament steel filaments Carbon content or a copper filament surrounded by six steel filaments with high carbon content).

The Filaments can can be placed anywhere in the cross section of the wire and can in Subgroups are grouped (eg 3 × 3 or 7 × 3). Some filaments may be in the center of a wire cross section ("Kernfilamente") and one or be surrounded by several layers of other filaments ("Schichtfilamente"). In other embodiments There are no core filaments and all filaments are more or less at the same distance from the center of a wire cross-section positioned.

The Metal filaments can be any metallurgical structure z. B. due to heat treatments or have mechanical deformations.

The Metal filaments can Waves, torsions, waveforms, etc. or not.

• (a) Bereitstellen von zwei oder mehr Filamenten aus einem zweiten oder dritten Metall,
• (b) Bereitstellen einer Matrix aus einem ersten Metall mit einem ersten Schmelzpunkt um die zwei oder mehr Filamente, um eine Verbundstruktur zu erhalten, wobei die Filamente in der Matrix eingebettet und von der Matrix umgeben sind; das zweite oder dritte Metall besitzen einen Schmelzpunkt, der höher oder gleich dem ersten Schmelzpunkt ist;
• (c) Verformen der Verbundstruktur zu einem Verbunddraht, so dass die Filamente einen nicht kreisförmigen Querschnitt aufweisen.

According to a second aspect of the present invention there is provided a method of making a composite wire, the method comprising the following steps

• (a) providing two or more filaments of a second or third metal,
• (b) providing a matrix of a first metal having a first melting point about the two or more filaments to obtain a composite structure, wherein the filaments are embedded in the matrix and surrounded by the matrix; the second or third metal has a melting point higher than or equal to the first melting point;
• (c) deforming the composite structure into a composite wire such that the filaments have a non-circular cross-section.

Of the Step of providing a matrix around the filaments can by means of an electrolytic coating step or a hot dip process or a combination of both, the electrolytic Coating step the hot dipping process precedes.

Of the Deformation process is carried out by cold drawing, preferably without a Intermediate heat treatment.

The two or more filaments can before providing the matrix around these two or more filaments twisted or not.

Brief description of the drawings

The Invention will now be more detailed with reference to the following attached drawings become:

1 (a) . 1 (b) . 1 (c) . 1 (d) . 1 (e) illustrate in cross-sections the sequential steps of manufacturing a deformed metal composite wire;

2 shows a cross section of a deformed metal composite wire with two different types of filaments;

3 shows a cross section of a deformed metal composite wire, wherein the filaments have a separate metal coating.

description of the preferred embodiments the invention

1 (a) to 1 (e) illustrate the sequential steps of making a deformed metal composite wire according to the present invention.

1 (a) shows a cross section of the starting material: three separate, parallel filaments 10 with a starting diameter of 0.68 mm. The filaments consist of a 0.70% carbon steel. Processing three filaments has proven to be easier than processing four or five filaments. For three filaments a higher degree of deformation could be obtained than for four or five filaments. This is probably due to the more stable construction of a 3 × 1 configuration compared to a 4 × 1 or 5 × 1 configuration, and to smaller "center holes" of a 3 × 1 configuration compared to a 4 × 1 or 5 × 1 configuration.

1 (b) illustrates the three filaments 10 after the twisting process, for. Example by means of a conventional double seed drill (Bundler) or by means of a conventional tubular rotary machine. The filaments may or may not be deformed beforehand, so that a more or less open cross-section is obtained.

1 (c) shows the cross section after the twisted structure of three filaments 10 has left a hot dip galvanizing bath. The twisted structure is with a zinc matrix 12 covered. The diameter of the galvanized 1 × 3 structure is about 1.5 mm.

The zinc coated, twisted structure is then cold drawn through a series of drawing dies. 1 (d) shows an intermediate cross-section halfway the drawing step. The intermediate diameter of this cross section is 0.20 mm. The intermediate tensile strength is 2850 MPa.

1 (e) shows the end cross-section of the deformed metal composite wire 14 , The individual filaments 10 show inside the composite wire 14 more or less polygonal cross sections. The pages 13 These cross sections, which are opposite sides of other filaments, show a rough pattern due to the high degree of deformation and due to an alloy layer formed between the zinc and the steel. Preferably, zinc matrix material 12 present around each deformed filament; this means that the zinc has fulfilled its lubricating function until the very last drawing step. The final diameter is 0.10 mm. The final tensile strength for the total cross section is 3840 MPa.

One Final diameter of 0.10 mm means that a reduction of 99.55% without an intermediate heat treatment was achieved.

The result of the hot dip galvanizing bath is that a small iron-zinc alloy layer on the surface of the 3 × 1 steel filaments 10 is produced. This has the advantage of having a good adhesion between the zinc matrix 12 and the steel filaments 12 is achieved.

This iron-zinc alloy layer may become too brittle, e.g. B. if the immersion time in the zinc bath is too long. This brittleness can be avoided by reducing the immersion time by using the 3 × 1 steel filaments 10 be electroplated prior to hot dipping or by electroplating the 3x1 steel filaments to their final thickness without the hot dipping step.

A deformed metal composite wire, as in relation to the 1 (a) to 1 (e) (3 × 1 steel + zinc) can be used in many applications where high tensile strength, flexibility and corrosion resistance are required properties.

One An example of such an application is the use as a wire for electric discharge machining.

Another example of such an application is the final twisting of the wire into a 3 × [3 × 1 steel + zinc] rope and its use in window lifting applications.

• 1) Bereitstellen von Stahlfilamenten mit einem Kohlenstoffgehalt von 0,80% mit einem Zwischenfilamentdurchmesser von 0,68 mm;
• 2) Beschichten der bereitgestellten Stahlfilamente mit einer dünnen Messingbeschichtung mittels eines Thermodiffusionsvorgangs;
• 3) Verdrillen von drei (oder mehr) mit Messing beschichteten Stahlfilamenten mittels einer rohrförmigen Drillmaschine;
• 4) Durchleiten der verdrillten 3×1 Filamente durch ein ZnCl₂(NH₄Cl) Bad;
• 5) Entfernen von Badresten von der verdrillten Struktur und Trocknen der verdrillten Struktur;
• 6) Kurzes (i. e. weniger als 1,0 Sekunde, z. B. weniger als 0,50 Sekunden) Eintauchen der verdrillten Struktur in ein Heißtauchmessingbad, mit einer Temperatur über 930°C, und der folgenden Zusammensetzung: 62% bis 70% Kupfer (z. B. 64% Cu), 30% bis 38% Zn (z. B. 36% Zn). Der Grund für die kurze Eintauchzeit besteht darin, dass die Temperatur der Stahlfilamente so niedrig wie möglich gehalten werden muss, um Änderungen der Metallstruktur zu vermeiden und eine mögliche Reaktion des Stahls mit dem Messing zu begrenzen;
• 7) Entfernen der überschüssigen Messingmengen von der mit Messing beschichteten Struktur und Kühlen der mit Messing beschichteten Struktur;
• 8) Nassziehen der mit Messing beschichteten Struktur von einem Durchmesser von etwa 1,50 mm auf einen Enddurchmesser von 0,10 mm oder sogar geringer. Während dieses Ziehvorgangs fungiert die Messingmatrix als exzellentes Schmiermittel, das hohe Verformungsgrade ermöglicht.

As an alternative to the embodiment described above, brass may be used as the matrix material 12 be used. A method of making such a deformed metal composite with brass comprises the following steps:

• 1) providing steel filaments having a carbon content of 0.80% with an intermediate filament diameter of 0.68 mm;
• 2) coating the provided steel filaments with a thin brass coating by means of a thermal diffusion process;
• 3) Twisting three (or more) brass-coated steel filaments by means of a tubular drill;
• 4) passing the twisted 3 x 1 filaments through a ZnCl ₂ (NH ₄ Cl) bath;
• 5) removing bath residue from the twisted structure and drying the twisted structure;
• 6) Short (ie, less than 1.0 second, eg, less than 0.50 seconds) immersion of the twisted structure in a hot dip brass bath, having a temperature above 930 ° C, and the following composition: 62% to 70% copper (eg 64% Cu), 30% to 38% Zn (eg 36% Zn). The reason for the short immersion time is that the temperature of the steel filaments must be kept as low as possible in order to avoid changes in the metal structure and to limit a possible reaction of the steel with the brass;
• 7) remove the excess brass from the brass coated structure and cool the brass coated structure;
• 8) Wet drawing the brass coated structure from a diameter of about 1.50 mm to a final diameter of 0.10 mm or even less. During this drawing process, the brass matrix acts as an excellent lubricant, allowing high degrees of deformation.

One deformed metal composite wire with a brass matrix can be used as a reinforcement used by rubber articles such as tires, conveyor belts, toothed belts become.

Of the Molded metal composite wire coated with brass may be used in this Reinforcement can be used as such or it can be bundled or together with other wires or filaments, which may or may not be composite material before being embedded in the rubber article.

2 shows the cross section of another deformed metal composite wire 14 , This deformed metal composite wire 14 includes a core filament 16 made of steel and a layer of filaments 18 which are made of a conductive metal, such as copper or aluminum. The matrix material 12 may again be zinc or aluminum.

Such a metal composite wire can be used as a cable for heavy current applications. The steel filament 16 acts as the tension member while the copper or aluminum filaments act as electrical conduction members. The matrix material 12 provides additional corrosion protection. Such a metal composite wire may have high tensile strength due to the steel core filament and the high degree of deformation and high flexibility due to its composite structure.

For this 1 + 6 configuration, other embodiments are possible.

It can be a core filament 16 which is softer than the six layer filaments 18 ,

If the six layer filaments made of a high-carbon steel consist (carbon content over 0.6%), the core filament can be made of a low carbon steel (% C less than 0.5%), made of copper or aluminum.

in the In the case of a 1 + 6 configuration, it has been shown to be beneficial is, as initial configuration, a core filament with a diameter a bit bigger than to have the diameter of the six layer filaments. This improves the penetration of the metal matrix material into the strand and improves the drawability.

3 shows yet another cross section of a deformed metal composite wire 14 , The difference to the metal composite wire of 1 (e) is that the steel filaments 10 now with a metal coating 20 are coated.

Examples and results

1. Stainless steel in 3 × 1 configuration

stainless steel wires with the composition 316L will be from 1.50 mm to 0.50 mm Filament pulled. Three filaments are added to 3 x 0.50 mm (outside diameter of the Composite wire equal to 1.08 mm) twisted, hot dip in zinc and subsequently drawn. The composite wire was without problems on an outer diameter drawn from 0.15 mm, d. H. far beyond the normal drawability of stainless steel wire. The initial metal cross section of the stainless steel wire (diameter 1.50 mm) was placed on a metal cross-section with a diameter of approximately 0.07 mm within the cross-section of the deformed composite wire reduced. This is equivalent to a reduction of 99.8% without intermediate heat treatment.

2. Carbon steel in 3 × 1 configuration tensile strength

The tensile strength R _{m of} a single filament (reference) was compared with the tensile strength of a deformed composite wire (invention). Both the single filament and the filaments of the composite wire are made of a 0.70% C carbon steel. The three filaments in the composite wire were plated. In the case of the invention, there is a significant gain in tensile strength due to the increased deformation. Table 1 summarizes the results.

Table 1

3. Carbon steel in 3 × 1 configuration - corrosion resistance

The Corrosion resistance of a single galvanized wire was with the corrosion resistance of a deformed composite wire according to the invention compared. Table 2 indicates the amount of time it takes before The first spots of dark brown rust (DBR) occur and up to 5% of the surface covered with dark brown rust.

Table 2

4. Properties of off the deformed composite wires manufactured ropes or ropes

One inventive, deformed Composite wire of 0.15 mm (consisting of three filaments) was used around a rope of 3 × 3 × 0, 15 mm to manufacture. This rope was made with a slightly galvanized 3 × 3 × 0.15 mm Rope and a heavily galvanized 3 × 3 × 0.15 mm rope compared. Table 3 gives the results.

Table 3

The rope made from the wire according to the invention is best in terms of tensile strength and corrosion resistance. In terms of fatigue strength, it behaves better than a strong gal vanished rope and worse than a slightly galvanized rope.

Claims (22)

Deformed metal composite wire ( 14 ) with a matrix ( 12 ) of a first metal having a first melting point, two or more filaments ( 10 ) of a second or third metal embedded in the matrix and separated from the matrix ( 12 ), wherein the second or further metal has a melting point higher than or equal to the first melting point, either the second or third metal or both being a carbon steel or a stainless steel, characterized in that the wire is in a deformed state is such that two or more filaments ( 10 ) have a non-circular filament cross-section. Composite wire ( 14 ) according to claim 1, wherein the wire ( 14 ) has a round wire cross-section. Composite wire ( 14 ) according to one of the preceding claims, wherein zinc, a zinc alloy, aluminum, brass, tin or a tin alloy is selected for the first metal. Composite wire ( 14 ) according to one of the preceding claims, wherein an alloy layer is formed between the first metal on one side and the second or further metal on the other side. Composite wire ( 14 ) according to one of the preceding claims, wherein the wire ( 14 ) has undergone a final deformation reduction of at least 50%. Composite wire ( 14 ) according to one of the preceding claims, wherein the wire ( 14 ) up to 27 filaments ( 10 ). Composite wire ( 14 ) according to one of the preceding claims, wherein the filaments ( 10 ) have a twisting step around each other, wherein the twisting step is greater than 50 mm. Composite wire ( 14 ) according to one of claims 1 to 6, wherein the filaments ( 10 ) are parallel to each other. Composite wire ( 14 ) according to one of the preceding claims, wherein the second metal is different from the third metal. Composite wire ( 14 ) according to one of the preceding claims, wherein the wire ( 14 ) has a cross-section comprising a core of one or more filaments ( 10 ) and one or more layers of filaments around the core. Composite wire ( 14 ) according to one of claims 1 to 9, wherein the wire ( 14 ) a cross section without middle core filaments ( 10 ) having. Composite wire ( 14 ) according to any one of the preceding claims, wherein the composite wire ( 14 ) has a tensile strength greater than 2000 MPa. Composite wire ( 14 ) according to any one of the preceding claims, wherein the first metal of each filament ( 10 ) surrounds. Composite wire ( 14 ) according to any one of the preceding claims, wherein one or all filaments ( 10 ) are individually provided with a metal coating. Composite wire ( 14 ) according to one of the preceding claims, wherein the filaments ( 10 ) are wavy or wavy. Use of a composite wire ( 14 ) according to one of the preceding claims as a wire for electric discharge machining. Method for producing a composite wire ( 14 ), the method comprising the following steps: (a) providing two or more filaments ( 10 ) of a second or third metal, (b) providing a matrix ( 12 ) of a first metal around the two or more filaments ( 10 ) to obtain a composite structure, the filaments ( 10 ) in the matrix ( 12 ) and from the matrix ( 12 wherein the first metal has a first melting point and the second or third metal has a melting point higher than or equal to the first melting point; characterized in that the method further comprises the step of: (c) deforming the composite structure into a composite wire ( 14 ), so that the filaments ( 10 ) have a non-circular cross-section. The method of claim 17, wherein the step of providing a matrix ( 12 ) around the filaments ( 10 ) by means of a hot dipping process. The method of claim 17 or 18, wherein the step the deformation is carried out by cold drawing. The method of claim 19, wherein the cold drawing without intermediate heating steps he follows. A method according to any one of claims 17 to 20, wherein the two or more filaments ( 10 ) are twisted around the two or more filaments prior to providing the matrix. Metal cord with one or more composite wires ( 14 ) according to one of claims 1 to 15.