EP0149064A1 - Continuous molten copper cladding of ferrous alloys - Google Patents
Continuous molten copper cladding of ferrous alloys Download PDFInfo
- Publication number
- EP0149064A1 EP0149064A1 EP19840114169 EP84114169A EP0149064A1 EP 0149064 A1 EP0149064 A1 EP 0149064A1 EP 19840114169 EP19840114169 EP 19840114169 EP 84114169 A EP84114169 A EP 84114169A EP 0149064 A1 EP0149064 A1 EP 0149064A1
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- EP
- European Patent Office
- Prior art keywords
- core
- copper
- bath
- layer
- preheated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 47
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 47
- 239000010949 copper Substances 0.000 title claims abstract description 47
- 238000005253 cladding Methods 0.000 title claims abstract description 15
- 229910000640 Fe alloy Inorganic materials 0.000 title 1
- 238000000034 method Methods 0.000 claims abstract description 34
- 239000002131 composite material Substances 0.000 claims abstract description 18
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical group [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 claims abstract description 11
- 230000008018 melting Effects 0.000 claims abstract description 8
- 238000002844 melting Methods 0.000 claims abstract description 8
- 239000004020 conductor Substances 0.000 claims abstract description 7
- 239000001257 hydrogen Substances 0.000 claims abstract description 6
- 229910052739 hydrogen Inorganic materials 0.000 claims abstract description 6
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims abstract description 5
- 238000009736 wetting Methods 0.000 claims abstract description 5
- 238000001816 cooling Methods 0.000 claims abstract description 4
- 238000007711 solidification Methods 0.000 abstract description 5
- 230000008023 solidification Effects 0.000 abstract description 5
- 230000008569 process Effects 0.000 description 15
- 229910052751 metal Inorganic materials 0.000 description 9
- 239000002184 metal Substances 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 8
- 239000000155 melt Substances 0.000 description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- 229910002804 graphite Inorganic materials 0.000 description 5
- 239000010439 graphite Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 4
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 3
- 238000013459 approach Methods 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 239000004359 castor oil Substances 0.000 description 3
- 235000019438 castor oil Nutrition 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- ZEMPKEQAKRGZGQ-XOQCFJPHSA-N glycerol triricinoleate Natural products CCCCCC[C@@H](O)CC=CCCCCCCCC(=O)OC[C@@H](COC(=O)CCCCCCCC=CC[C@@H](O)CCCCCC)OC(=O)CCCCCCCC=CC[C@H](O)CCCCCC ZEMPKEQAKRGZGQ-XOQCFJPHSA-N 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000009749 continuous casting Methods 0.000 description 2
- 239000000498 cooling water Substances 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 230000001747 exhibiting effect Effects 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000000886 hydrostatic extrusion Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910052770 Uranium Inorganic materials 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000011437 continuous method Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004070 electrodeposition Methods 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 238000005098 hot rolling Methods 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
- C23C2/36—Elongated material
- C23C2/38—Wires; Tubes
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
Definitions
- the invention relates to the manufacture of copper-clad redraw rod and, more particularly, to the continuous casting of a molten copper coating to a hot, active, ferrous alloy base rod under controlled conditions.
- the disclosure suggests either a rod and solvent swabbing technique or a high pressure solvent system for pumping liquid solvent through the sheath. Thereafter both the core and surrounding sheath are drawn through a reducing die exhibiting a die angle of approximately 30 to 40 degrees. In this process, while the core diameter remains substantially unaltered, the cross-sectional area of the sheath can be expected to experience a reduction of approximately 20 to 50 percent, depending on, inter alia, the original thickness of the sheath and the die angle employed.
- the cold bonded sheath and rod process described above provides a high quality composite wire with only a modest capital requirement, it is-available to provide wire of only limited sizes, generally 2 millimeter diaemter or less. Furthermore, the cold bonding process is significantly dependent on existence of quality copper tubes.
- Copper-clad composite wire may also be produced by extrusion of the constituent rod and copper tube.
- a cold, hydrostatic, extrusion process for forming copper-clad aluminum is described in publication pamphlet AG 14-110 E (January 1972) of the ASEA corporation, Vasteras, Sweden.
- the pressure chamber requires hydraulic fluid, normally castor oil, in order to provide an enveloping pressure so as to force the billet through the die.
- Pressure in the chamber is developed by a ram driven into the chamber, thereby compressing the oil.
- the billet begins to extrude through the die. Extrusion continues as long as the ram moves in the chamber in the direction of the die.
- the process desribed above is alleged to extrude material at a high rate of reduction and into desired geometrical shapes. Because the castor oil also serves as a lubricant, the billet and die also need be configured so that the castor oil cannot escape between the billet and the die.
- a primary disadvantage of the hydrostatic extrusion process presently described is that there are no known refinements allowing the process to be used for the formation of copper-clad ferrous composites.
- a "dip-forming" method of manufacturing copper-clad dumet (a nickel-iron alloy) is described in THE IRON AGE, December 22, 1966, pp. 46,47.
- the conceptual basis of that process is that, under appropriate circumstances, molten metal will form a sheath around a metal rod passing through the melt at a proper speed.
- a properly cleaned nickel-iron rod is caused to pass through a refractory metal bushing where it enters a graphite crucible holding a molten copper bath.
- molten copper freezes around the rod.
- the thickness of the copper sheath is determined by the temperature and depth of the bath as well as the speed with which the rod passes through the bath.
- U.S. Patent No. 3,714,701 entitled “Manufacture of Clad Metals" by Dion et al. represents yet another approach to the production of cladding a metal core rod with a sheath of dissimilar metal.
- two thin, flat strips of cladding material are preformed into confronting semicylindrical shapes and positioned into convergence around a core rod.
- the strips and rods, which must remain substantially contaminant-free, are maintained at equal temperatures as the assembly is solid-phase roll bonded.
- the result is asserted to be a clad rod suitable for subsequent drawing into wire, requiring neither subsequent sintering, metal removal, or similar finishing operations.
- a method of forming a composite conductor the conductor characterized by a ferrous core and a copper cladding.
- the method comprises the steps of preheating the core in a hydrogen atmosphere to a temperature approximately 50 to 100 degrees Farenheit below the melting point of copper, drawing the preheated core in an upwardly vertical direction through a dry orifice and a molten copper bath at a rate that permits wetting of the core and adhesion of a copper layer to the core, and cooling the composite ferrous core and copper cladding so that solidification of the cladding occurs at a point below the surface of the molten copper bath.
- an apparatus for forming the composite conductor in another aspect of the invention, includes an annular dry orifice through which a ferrous rod is drawn up and through a molten bath into a core positioned by a nozzle threaded into an interior surface of a chill mold.
- the chill mold is provided a fireproof lining so that it may be inserted a requisite depth into molten copper bath.
- the drawing is an apparatus, including a chill mold, nozzle, annular core and fireproof lining, according to which the subject invention is to be practiced.
- Patent 3,746,077 includes a water cooled jacket, or chill mold, comprising an inner pipe, and intermediate pipe and an outer pipe through which cooling water is caused to flow.
- a nozzle is threaded into an interior of surface of the inner pipe and provides a guide surface at its lower end for a substantially annular core.
- the nozzle, the core and an accuminated mandrel, positioned within the nozzle, define a passageway through which molten metal is caused to flow in an upward direction.
- the chill mold itself is surrounded with a fireproof lining attached at the lower end of the nozzle so that chill may be immersed so deeply into the melt that the solidifying front is formed below the surface of the melt.
- the extension of the inner pipe above the surface of the melt serves as an after-cooler of the pipe. Because the dimensions of the pipe are largely determined by the inner diameter of the core at the solidification front, it is possible to control relevant. pipe dimensions, principally pipe thickness, by appropriately controlling the point at which the solidification front occurs.
- the apparatus includes a chill mold 1 including an inner pipe 11, an outer pipe 12 and an intermediate pipe 13. Cooling water is caused to run into the chill mold through pipe A and out pipe B. A nozzle 2 is threaded into an interior surfaces of pipe 11 in order to promote efficient heat transfer between the chill mold and the nozzle. It is anticipated that the nozzle may be fabricative from solid graphite or from a sintered alloy of metal and metal oxide. An annular core 3 is attached to nozzle and is positioned with the assistance a guiding surface 21 defined by the nozzle. The lower end of the chill mold is protected by a fireproof lining 5 contacted tightly to the nozzle at exterior surface 22 largely through the operation of a nut 6 or similar fastening means.
- the process for a manufacturing a composite conductor comprising a ferrous core and copper cladding proceeds as follows.
- the core is preheated in a reducing atmsophere, e.g. five percent hydrogen, ninety-five percent nitrogen, to a temperature slightly below the melting point of copper.
- core may be heated to a temperature of approximately 1900° Farenheit.
- a reducing atmosphere is utilized in order to activate, i.e., flux, the preheated core.
- the core is drawn up through a dry orifice 7, annular in configuration, supported by the bottom of the melt furnace 8 and through the molten copper bath 9. It should be noted that prevention of copper spillage through orifice 7 depends on the maintenance of the rod temperature to just below the melting point of copper.
- the subject invention comprises is a process and enabling apparatus for forming a composite conductor (read: wire) having a ferrous core, be it steel or iron- nickel alloy, and a copper cladding. It is to be understood that specific details of the process and apparatus are to be tailored according to the particular end product desired.
- the subject invention is useful in the effective and efficient manufacture of copper-clad composite wire.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating With Molten Metal (AREA)
- Continuous Casting (AREA)
Abstract
A method of forming a composite conductor characterized by a ferrous core and a copper cladding comprises the steps of preheating the core in a hydrogen atmosphere to a temperature approximately 50 to 100 degrees F below the melting point of copper, drawing the preheated core in an upwardly vertical direction through a dry orifice and through a molten copper bath at a rate that permits wetting of the core and adhesion of a copper layer to the core, and cooling the composite ferrous core and copper cladding so that solidification of the cladding occurs at a point about the surface of the molten copper bath.
Description
- The invention relates to the manufacture of copper-clad redraw rod and, more particularly, to the continuous casting of a molten copper coating to a hot, active, ferrous alloy base rod under controlled conditions.
- Heretofore a variety of approaches have emerged in an attempt to effectively and efficiently produce a composite wire comrising an inner core of, for example, steel or a nickel-iron alloy, and an outer layer of copper. In particular, U.S. Patent 3,820,232 by the present inventor and entitled "Method for Forming Composite Wire" is directed to the cold bonding of a copper sheath to a metallic core rod of dissimilar material. According to the invention embodied therein the external surface of the core is cleaned, coated with a relatively thin coating of copper and inserted into the copper sheath. Prior to core insertion, the sheath itself must be internally cleaned. The disclosure suggests either a rod and solvent swabbing technique or a high pressure solvent system for pumping liquid solvent through the sheath. Thereafter both the core and surrounding sheath are drawn through a reducing die exhibiting a die angle of approximately 30 to 40 degrees. In this process, while the core diameter remains substantially unaltered, the cross-sectional area of the sheath can be expected to experience a reduction of approximately 20 to 50 percent, depending on, inter alia, the original thickness of the sheath and the die angle employed.
- Although the cold bonded sheath and rod process described above provides a high quality composite wire with only a modest capital requirement, it is-available to provide wire of only limited sizes, generally 2 millimeter diaemter or less. Furthermore, the cold bonding process is significantly dependent on existence of quality copper tubes.
- Copper-clad composite wire may also be produced by extrusion of the constituent rod and copper tube. A cold, hydrostatic, extrusion process for forming copper-clad aluminum is described in publication pamphlet AG 14-110 E (January 1972) of the ASEA corporation, Vasteras, Sweden. According to the hydrostatic extrusion process, a composite billet consisting of a round aluminum bar and a surrounding copper tube is fed into a pressure chamber toward the direction of a reducing die. The pressure chamber requires hydraulic fluid, normally castor oil, in order to provide an enveloping pressure so as to force the billet through the die. Pressure in the chamber is developed by a ram driven into the chamber, thereby compressing the oil. When the fluid has become sufficiently compressed, in the direction of the die, the billet begins to extrude through the die. Extrusion continues as long as the ram moves in the chamber in the direction of the die.
- The process desribed above is alleged to extrude material at a high rate of reduction and into desired geometrical shapes. Because the castor oil also serves as a lubricant, the billet and die also need be configured so that the castor oil cannot escape between the billet and the die. A primary disadvantage of the hydrostatic extrusion process presently described is that there are no known refinements allowing the process to be used for the formation of copper-clad ferrous composites.
- A "dip-forming" method of manufacturing copper-clad dumet (a nickel-iron alloy) is described in THE IRON AGE, December 22, 1966, pp. 46,47. The conceptual basis of that process is that, under appropriate circumstances, molten metal will form a sheath around a metal rod passing through the melt at a proper speed. According to this process, a properly cleaned nickel-iron rod is caused to pass through a refractory metal bushing where it enters a graphite crucible holding a molten copper bath. As the small diameter rod passes through the bath, molten copper freezes around the rod. The thickness of the copper sheath is determined by the temperature and depth of the bath as well as the speed with which the rod passes through the bath. After the rod is coated, it is cooled by a water-spray in an inert atmosphere.
- U.S. Patent No. 3,714,701, entitled "Manufacture of Clad Metals" by Dion et al. represents yet another approach to the production of cladding a metal core rod with a sheath of dissimilar metal. As described therein, two thin, flat strips of cladding material are preformed into confronting semicylindrical shapes and positioned into convergence around a core rod. The strips and rods, which must remain substantially contaminant-free, are maintained at equal temperatures as the assembly is solid-phase roll bonded. The result is asserted to be a clad rod suitable for subsequent drawing into wire, requiring neither subsequent sintering, metal removal, or similar finishing operations.
- Other approaches to the production of copper-clad composite wire, in addition to those alluded. to above, comprise, inter alia, brazed tube and rod assemblies, hot rolling of cast composite ingots, and electro deposition, both single rod and continuous process.
- In spite of the above, what continued to be sought, prior to the subject invention, was a process for producing copper-clad redraw rod of superior quality, the process to be characterized by modest capital investment and material cost requirements, to allow the use of large core rod coil weight, and to provide, at elevated levels of productivity a quality product exhibiting, especially, a formidable bond between core and sheath.
- The above and other objects advantages and capabilities are achieved in one aspect of the invention by a method of forming a composite conductor, the conductor characterized by a ferrous core and a copper cladding. The method comprises the steps of preheating the core in a hydrogen atmosphere to a temperature approximately 50 to 100 degrees Farenheit below the melting point of copper, drawing the preheated core in an upwardly vertical direction through a dry orifice and a molten copper bath at a rate that permits wetting of the core and adhesion of a copper layer to the core, and cooling the composite ferrous core and copper cladding so that solidification of the cladding occurs at a point below the surface of the molten copper bath.
- In another aspect of the invention, an apparatus for forming the composite conductor includes an annular dry orifice through which a ferrous rod is drawn up and through a molten bath into a core positioned by a nozzle threaded into an interior surface of a chill mold. The chill mold is provided a fireproof lining so that it may be inserted a requisite depth into molten copper bath.
- The drawing is an apparatus, including a chill mold, nozzle, annular core and fireproof lining, according to which the subject invention is to be practiced.
- For a better understanding of the subject invention, together with the objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in conjunction with the above-described drawing.
- Referring now-to the drawing, what is shown there is an apparatus according to the subject invention for the continuous molten copper cladding of a ferrous-rod. The apparatus depicted herein bears substantial similarily to ones disclosed and described in U.S. Patent 3,746,077, "Apparatus for Upwards Casting" to Lohikoski et al and U.S. Patent 3,872,913 "Continuous Method and Apparatus for Upwards Casting" to Lohikoski. (See also, "Upward Continuous Casting Technique in the Production of Nonferrous Wires", WIRE JOURNAL, March 1980, pp 102-104)
- Involved therein are a technique and an enabling apparatus for the continuous upwards casting of variously profiled metal products. The products are formed by partially submerging a graphite die in a molten metal. The upper part of the die is provided with a water-cooled jacket so that as the melt cools and solidifies, it is pulled upward through the die. In U.S. Patent 3,746,077 the nozzle of the graphite die is submerged in the melt to a depth sufficient to effect solidification of the melt below the surface of the molten bath. The solidified melt is then further cooled as it is pulled upwardsthrough the apparatus. With particularity, the apparatus disclosed in U.S. Patent 3,746,077 includes a water cooled jacket, or chill mold, comprising an inner pipe, and intermediate pipe and an outer pipe through which cooling water is caused to flow. A nozzle is threaded into an interior of surface of the inner pipe and provides a guide surface at its lower end for a substantially annular core. The nozzle, the core and an accuminated mandrel, positioned within the nozzle, define a passageway through which molten metal is caused to flow in an upward direction. The chill mold itself is surrounded with a fireproof lining attached at the lower end of the nozzle so that chill may be immersed so deeply into the melt that the solidifying front is formed below the surface of the melt.
- As the solidified pipe is drawn upward by a drawing apparatus, the extension of the inner pipe above the surface of the melt serves as an after-cooler of the pipe. Because the dimensions of the pipe are largely determined by the inner diameter of the core at the solidification front, it is possible to control relevant. pipe dimensions, principally pipe thickness, by appropriately controlling the point at which the solidification front occurs.
- Redirecting attention to the drawing included herein, there is depicted an apparatus similar in form to the apparatus described in U.S. Patent 3,746,077. The apparatus includes a chill mold 1 including an
inner pipe 11, anouter pipe 12 and anintermediate pipe 13. Cooling water is caused to run into the chill mold through pipe A and out pipeB. A nozzle 2 is threaded into an interior surfaces ofpipe 11 in order to promote efficient heat transfer between the chill mold and the nozzle. It is anticipated that the nozzle may be fabricative from solid graphite or from a sintered alloy of metal and metal oxide. Anannular core 3 is attached to nozzle and is positioned with the assistance a guidingsurface 21 defined by the nozzle. The lower end of the chill mold is protected by afireproof lining 5 contacted tightly to the nozzle atexterior surface 22 largely through the operation of a nut 6 or similar fastening means. - The process for a manufacturing a composite conductor comprising a ferrous core and copper cladding proceeds as follows. The core is preheated in a reducing atmsophere, e.g. five percent hydrogen, ninety-five percent nitrogen, to a temperature slightly below the melting point of copper. In practice core may be heated to a temperature of approximately 1900° Farenheit. A reducing atmosphere is utilized in order to activate, i.e., flux, the preheated core.
- The core is drawn up through a
dry orifice 7, annular in configuration, supported by the bottom of themelt furnace 8 and through the molten copper bath 9. It should be noted that prevention of copper spillage throughorifice 7 depends on the maintenance of the rod temperature to just below the melting point of copper. - The rod is drawn up through the molten bath at rates chosen to optimize the "wet" expose time of the rod, also dependent on the extent of immersion of the rod in the bath. The rod is then drawn up into the
annular entry guide 3 and through the nozzle and chill mold so that a copper cladding forms around the rod. The weight of the cladding is primarily determined by the core rod size and the graphite die size. In summary, what the subject invention, as disclosed herein, comprises is a process and enabling apparatus for forming a composite conductor (read: wire) having a ferrous core, be it steel or iron- nickel alloy, and a copper cladding. It is to be understood that specific details of the process and apparatus are to be tailored according to the particular end product desired. - Accordingly, while there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims.
- The subject invention is useful in the effective and efficient manufacture of copper-clad composite wire.
Claims (10)
1. A method of cladding a ferrous core with a copper layer, this method comprising the steps of:
preheating the core in a reducing atmosphere to a temperature slightly below the melting point of copper, drawing the preheated core in a vertical, upward direction through a bath of molten copper and through dry orifice so that a layer of copper adheres to the core, and
cooling the composite core and copper layer so that the copper layer solidifies to the core.
2. A method as defined in Claim 1 wherein the core is preheated to a temperture approximately 50 to 100 degrees below the melting point of copper.
3. A method as defined in Claim 2 wherein the core is preheated in a hydrogen atmosphere.
4. A method as defined in Claim 3 wherein the core is drawn through the bath at a rate that permits wetting of. the core.
5. A method as defined in Claim 1 wherein the core is drawn through the bath at a rate that permits wetting of the core.
6. A method as defined in Claim 5 wherein the core is preheated in a hydrogen atmosphere.
7. A method as defined in Claim 6 wherein the core is preheated to a temperature approximately 50 to 100 degrees Farenheit below the melting point of copper.
8. A method producing a composite conductor having a copper-clad ferrous core, the method comprising the steps:
preheating the core in a hydrogen atmosphere to a temperature approximately 50 to 100 degrees Farenheit below the melting point of copper, drawing the preheated core in a vertical, upward direction through a dry orifice and through a bath of molten copper at a rate that permits wetting of the core so that a layer of copper adheres to the core, and cooling the composite core and copper layer so that the layer solidfies to the core.
9. A method as defined in Claim 8 wherein the layer is caused to solidify to the core at a point below the surface of the molten copper bath.
10. A method as defined in Claim 8 wherein the layer is caused to solidify to the core at a point above the surface of the molten copper bath.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US56744183A | 1983-12-30 | 1983-12-30 | |
US567441 | 2006-12-06 |
Publications (1)
Publication Number | Publication Date |
---|---|
EP0149064A1 true EP0149064A1 (en) | 1985-07-24 |
Family
ID=24267166
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19840114169 Withdrawn EP0149064A1 (en) | 1983-12-30 | 1984-11-23 | Continuous molten copper cladding of ferrous alloys |
Country Status (2)
Country | Link |
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EP (1) | EP0149064A1 (en) |
DE (1) | DE149064T1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2002055753A1 (en) * | 2000-12-20 | 2002-07-18 | Outokumpu Oyj | A method for the manufacture of layered metal product slabs and layered metal product slabs |
EP2360286A1 (en) | 2010-02-15 | 2011-08-24 | Bogumil Miklasz | The method of production a coated wire |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AT239043B (en) * | 1960-09-12 | 1965-03-10 | Gen Electric | Process for depositing molten copper on a continuously moving core rod |
GB1527746A (en) * | 1974-12-20 | 1978-10-11 | Gen Electric | Metal casting |
WO1981003136A1 (en) * | 1980-05-08 | 1981-11-12 | S Ekerot | Method of manufacturing metallic wire products by direct casting of molten metal,and apparatus for carrying out the method |
-
1984
- 1984-11-23 EP EP19840114169 patent/EP0149064A1/en not_active Withdrawn
- 1984-11-23 DE DE1984114169 patent/DE149064T1/en active Pending
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AT239043B (en) * | 1960-09-12 | 1965-03-10 | Gen Electric | Process for depositing molten copper on a continuously moving core rod |
GB1527746A (en) * | 1974-12-20 | 1978-10-11 | Gen Electric | Metal casting |
WO1981003136A1 (en) * | 1980-05-08 | 1981-11-12 | S Ekerot | Method of manufacturing metallic wire products by direct casting of molten metal,and apparatus for carrying out the method |
Non-Patent Citations (1)
Title |
---|
PATENT ABSTRACTS OF JAPAN, unexamined applications, C field, vol. 4, no. 50, April 16, 1980 THE PATENT OFFICE JAPANESE GOVERNMENT page 43 C 7 * JP - A -55-21 537 ( YAZAKI SOUGIYOU K.K. ) * * |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2002055753A1 (en) * | 2000-12-20 | 2002-07-18 | Outokumpu Oyj | A method for the manufacture of layered metal product slabs and layered metal product slabs |
US7024750B2 (en) | 2000-12-20 | 2006-04-11 | Outokumpu Oyj | Method for the manufacture of layered metal product slabs and layered metal product slabs |
AU2002217180B2 (en) * | 2000-12-20 | 2006-05-25 | Outokumpu Oyj | A method for the manufacture of layered metal product slabs and layered metal product slabs |
EP2360286A1 (en) | 2010-02-15 | 2011-08-24 | Bogumil Miklasz | The method of production a coated wire |
Also Published As
Publication number | Publication date |
---|---|
DE149064T1 (en) | 1985-10-24 |
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