Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
  • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
  • B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
  • B21C37/042—Manufacture of coated wire or bars
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
  • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
  • B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
  • B21C37/045—Manufacture of wire or bars with particular section or properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
  • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
  • B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
  • B21C37/047—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire of fine wires
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B1/00—Constructional features of ropes or cables
  • D07B1/14—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable
  • D07B1/147—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable comprising electric conductors or elements for information transfer
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B5/00—Making ropes or cables from special materials or of particular form
  • D07B5/007—Making ropes or cables from special materials or of particular form comprising postformed and thereby radially plastically deformed elements
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2001—Wires or filaments
  • D07B2201/2014—Compound wires or compound filaments
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2019—Strands pressed to shape
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2042—Strands characterised by a coating
  • D07B2201/2043—Strands characterised by a coating comprising metals
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2046—Strands comprising fillers
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2047—Cores
  • D07B2201/2052—Cores characterised by their structure
  • D07B2201/2059—Cores characterised by their structure comprising wires
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2047—Cores
  • D07B2201/2052—Cores characterised by their structure
  • D07B2201/2065—Cores characterised by their structure comprising a coating
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2047—Cores
  • D07B2201/2066—Cores characterised by the materials used
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
  • D07B2205/3025—Steel
  • D07B2205/3046—Steel characterised by the carbon content
  • D07B2205/305—Steel characterised by the carbon content having a low carbon content, e.g. below 0,5 percent respectively NT wires
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
  • D07B2205/3025—Steel
  • D07B2205/3046—Steel characterised by the carbon content
  • D07B2205/3053—Steel characterised by the carbon content having a medium carbon content, e.g. greater than 0,5 percent and lower than 0.8 percent respectively HT wires
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
  • D07B2205/306—Aluminium (Al)
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
  • D07B2205/3067—Copper (Cu)
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
  • D07B2205/3071—Zinc (Zn)
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/12—All metal or with adjacent metals
  • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/12—All metal or with adjacent metals
  • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
  • Y10T428/12736—Al-base component
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/12—All metal or with adjacent metals
  • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
  • Y10T428/12771—Transition metal-base component
  • Y10T428/12785—Group IIB metal-base component
  • Y10T428/12792—Zn-base component

Definitions

• the present invention relates to a deformed metal composite wire and to a method of manufacturing such a composite wire.
• the present invention also relates to the uses of such a deformed metal composite wire.
• metal composite wires are to be understood as metal wires being composed of elements being made of different metals.
• Such metal composite wires are known in the art.
• GB 325 248 discloses a composite wire to be used as an electricity conductor.
• This conductor wire is composed of at least three filaments. At least one filament, e.g. a steel filament, functions as a tensile member and at least one filament, e.g. a copper filament, functions as a conducting member.
• Japanese patent application JP-A-09-047810 discloses a metal composite wire which is made as follows : individual steel filaments are first coated by aluminium by means of an electrolytic plating technique, the thus coated filaments are bundled and are integrally drawn so that the aluminium coating material fills up the gaps between the steel filaments. The steel filaments are not deformed.
• Metal composite structures where metal filaments are separated by another metal have been described in e.g. patent specification US-A- 3,394,213 and in Japanese documents JP-A-51-017163, JP-A-62- 260018, as a manufacturing process to make metal fibers.
• the only objective of the combination of various metals was to allow the manufacturing of very fine fibers.
• the function of the metal around and in between the filaments was to keep the filaments separated during the deformation. After deformation this metal is removed to obtain fibers. This metal thus is not part of the final product.
• the separating metal is a metal which does not melt at the temperatures of hot rolling or heat treatmentdesc bed in this process (typically low carbon steel).
• the number of filaments is always very high, as this is the only way to obtain small sized fibers with this process (typically more than 500).
• US-A-3, 907, 550 discloses composite billets which function as starting stock for superconducting wire. Rods of a metal capable of forming a superconductor are immersed in a molten bath of 'normal' material, i.e. not capable of forming a superconductor. After solidification a rough billet is formed which may be subjected to high deformations which are enabled may intermediate heating treatments. The function of strengthening or reinforcing is not an issue.
• a further improvement to these cables involves the compacting of these strands or ropes (compacting, swaging, drawing) : the filaments are compacted so that the filling degree increases, thus improving strength per unit of section, and to a lesser degree also improving abrasion resistance and corrosion resistance.
• Patent application WO-A-99/23673 also describes the possibility to add in the center a filament in a softer material, which by compacting fills more easily the open spaces in between the filaments. But here again, the deformation degree is limited.
• a deformed metal composite wire comprising a matrix of a first metal with a first melting point and two or more filaments of a second or further metal which are embedded in and surround by the matrix without leaving interstices.
• Either the second or the further metal or both are carbon steel or stainless steel.
• the second or further metals have a melting point which is higher than or equal to the first melting point.
• the composite wire is in a deformed state so that the two or more filaments have a non-circular cross-section.
• the function of the matrix of the first metal can be multiple :
• the quantity of matrix material and its volume ratio with respect to the volume of the filaments have an influence on the drawability. A volume ratio of 1 to 1 already allows a high deformation degree.
• the filaments in the deformed composite wire obtain a cross- section which is similar to a polygon. Due to the deformation degree, which can be very high, some "sides" of the polygon may show a very coarse aspect.
• the composite wire has a round cross-section due to its drawing through a die.
• the first - softer - metal may be selected from a group consisting of zinc zinc alloy, aluminium, brass, tin, tin alloy, etc...
• the metal filaments can be present in any number, starting with a minimum number of two filaments. Typical values are between three and twenty. For most cases, the number of filaments is smaller than twenty-seven.
• the metal filaments are made out of a second or further metal with a melting point higher than or equal to the melting point of the matrix material.
• the second metal filament or the further metal filament, or both filaments are made of carbon steel or stainless steel in order to obtain the required strenghtening or reinforcinc effect.
• the metal fiiaments can have any size. Typical values of surface sectior vary between 0.01 mm 2 to 10mm 2 .
• the metal filaments have the same longitudinal orientation of the wire; they can either be parallel or twisted, stranded, bunched, or cabled...
• the individual metal filaments may also have any metallic coating, of any thickness (e.g. Zn-coated steel, ...) and this coating can be applied by any process (electrolytic, hot dip, cladding,..). Individual metal filaments without coating are possible as well.
• a final deformation reduction of at least 50%, e.g. more than 90% or even more than 99% is possible.
• the terms 'final deformation' refer to a deformation of the composite wire without intermediate thermal treatments.
• the term 'reduction' is defined as the cross-sectional reduction and can be calculated as : ( S, - S f ) x 100 / S, where S, is the value of the initial cross-sectional surface of the composite wire ; and where S f is the value of the final cross-sectional surface of the composite wire.
• the wire can hold filaments in any combination of the cases mentioned above (e.g. one carbon steel filaments surrounded by six smaller copper or aluminium filaments or one low carbon steel filament or copper filament surrounded by six high carbon steel filaments).
• the filaments can be positioned anywhere in the section of the wire, and can be grouped in sub-groups (e.g. 3 x 3 or 7 x 3). Some filaments can be positioned in the center of a wire cross-section ("core filaments") and be surrounded by one or more layers of other filaments ("layer filaments"). In other embodiments, no core filaments are present and all filaments are positioned more or less at the same distance from the center point of a wire cross-section.
• the metal of the filaments can have any metallurgical structure e.g. due to thermal treatments or mechanical deformation. The metal filaments may or may not have undulations, torsions, crimp, etc...
• a method of manufacturing a composite wire comprises the following steps :
• the step of providing a matrix around the filaments may be done by means of an electrolytical plating step or hot dip operation, or a combination of both, whereby the electrolytical plating step precedes the hot dip operation.
• the step of deforming is done by cold drawing, preferably without intermediate heat treatments.
• the two or more filaments may or may not be twisted prior to providing the matrix around these two or more filaments.
• FIGURE 1 (a), FIGURE 1 (b), FIGURE 1 (c), FIGURE 1 (d),
• FIGURE 1(e) illustrate with cross-sections the subsequent steps of manufacturing a deformed metal composite wire
• FIGURE 2 shows a cross-section of a deformed metal composite wire with two different types of filaments
• FIGURE 3 shows a cross-section of a deformed metal composite wire where the filaments have a separate metal coating.
• FIGURES 1 (a) through 1 (e) illustrate the subsequent steps of manufacturing a deformed metal composite wire according to the present invention.
• FIGURE 1 (a) shows a cross-section of the starting material : three separate parallel filaments 10 with an initial diameter of 0.68 mm.
• the filaments are made of a 0.70 % carbon steel.
• the processing of three filaments has been experienced as being easier than similar processing of four or five filaments. A higher deformation degree could be obtained for three filaments than for four or five filaments. This is probably due to the more stable construction of a 3x1 configuration in comparison with a 4x1 or 5x1 configuration and due to the smaller central "hole" of a 3x1 configuration in comparison with a 4x1 or 5x1 configuration.
• FIGURE 1 (b) illustrates the three filaments 10 after a twisting operation, e.g.
• FIGURE 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 covered with a zinc matrix 12. The diameter of the galvanized 1x3 is about 1.5 mm. The zinc coated twisted structure is then cold drawn through a series of dies.
• FIGURE 1 (d) shows an intermediate cross-section half way the series of drawing steps. The intermediate diameter of this cross-section is 0.20 mm. The intermediate tensile strength is 2850 MPa.
• FIGURE 1(e) shows the final cross-section of the deformed metal composite wire 14.
• the individual filaments 10 show within the composite wire 14 more or less polygonal cross-sections.
• the sides 13 of these cross-sections, which are faced with sides of other filaments, show a rough pattern due to the high deformation degree and due to an alloy layer formed between the zinc and the steel.
• zinc matrix material 12 is present around each deformed filament, which means that the zinc has performed its lubricating function until the very last drawing step.
• the final diameter is 0.10 mm.
• the final tensile strength is 3840 MPa for the total cross-section.
• a final diameter of 0.10 mm means that a degree of reduction of 99.55 % has been reached without any intermediate heat treatment.
• a hot dip galvanizing bath has as result that a small iron-zinc alloy layer is created at the surface of the 3x1 steel filaments 10. This has the advantage of achieving a good adherence between the zinc matrix 12 and the steel filaments 12.
• This iron-zinc alloy layer may become too brittle, e.g. if the immersion time in the zinc bath is too long. This b ttleness can be avoided by decreasing the immersion times, by electroplating the 3x1 steel filaments
• a deformed metal composite wire as described in relation to FIGURES 1(a) through 1(e) (3x1 steel + zinc) can be used in a lot of applications where high tensile strength, flexibility and corrosion resistance are the required properties.
• a method to manufacture such a deformed metal composite wire with brass comprises the following steps :
• the reason for the short dip time is that the temperature of the steel filaments must be kept so low as possible in order to avoid changes in metal structure and to limit a possible reaction of the steel with the brass ; 7) Removing the excesss amounts of brass of the brass coated structure and cooling the brass coated structure ; 8) Wet drawing the brass coated structure from a diameter of about
• a deformed metal composite wire with a brass matrix can be applied as reinforcements of rubber articles such as tires, conveyor belts, timing belts.
• the brass coated deformed metal composite wire can be used as such in this reinforcement or it can be bundled, or twisted together with other wires or filaments, which may be composite or not, before it is embedded in the rubber article.
• FIGURE 2 shows the cross-section of another deformed metal composite wire 14.
• This deformed metal composite wire 14 comprises a steel core filament 16 and a layer of filaments 18 made of a conducting metal such as copper or aluminium.
• the matrix material 12 can be zinc again or can be aluminium.
• Such a metal composite wire can be used as a cable in power applications.
• the steel filament 16 functions as the tensile member while the copper or aluminium filaments function as the electrical conducting elements.
• the matrix material 12 provides an additional corrosion protection.
• Such a metal composite wire can have a high tensile strength due to the steel core filament and the high degree of deformation and a high flexibility due to its composite nature.
• a core filament 16 softer than the six layer filaments 18 can be chosen.
• the six layer filaments are of a high carbon steel (carbon content above
• the core filament may of a low carbon steel (%C lower than
• FIGURE 3 shows yet another cross-section of a deformed metal composite wire 14.
• the difference with the metal composite wire of FIGURE 1 (e) is that the steel filaments 10 are now coated with a metallic coating 20.
• Stainless steel wires with composition 316L are drawn from 1.50 mm to a 0.50 mm filament. Three filaments are twisted into a 3x0.50 mm (external diameter of composite wire equal to 1.08 mm), hot dipped in zinc and subsequently drawn. The composite wire has been drawn without any problem to an external diameter of 0.15 mm, i.e. far beyond the normal drawability of stainless steel wire. The initial metal section of the stainless wire (diameter 1.50 mm) has been reduced to a metal section with a diameter of approximately 0.07 mm within the cross- section of the deformed composite wire. This is equivalent to an effective reduction of 99.8% without intermediate heat treatment.
• the tensile strength R m of a single filament has been compared with the tensile strength of a deformed composite wire (invention). Both the single filament and the filaments of the composite wire are of a 0.70%C carbon steel. The three filaments in the composite wire have been galvanized. In case of the invention there is clearly a considerable gain in tensile strength due to the increased deformation. Table 1 summarizes the results.
• the corrosion resistance of a single galvanized wire has been compared with the corrosion resistance of a deformed composite wire according to the invention.
• Table 2 mentions the time span it takes until the first spots of dark brown rust (DBR) and until 5% of the surface is covered with dark brown rust.
• a 0.15 mm deformed composite wire (comprised three filaments) according to the invention has been used to make a 3 x 3 x 0.15 mm cord. This cord has been compared with a lightly galvanized 3 x 3 x0.15 mm cord and with a heavily galvanized 3 x 3 x 0.15 mm cord. Table 3 mentions the results.
• the cord made of the invention wire performs best with respect to tensile strength and corrosion resistance. With respect to fatigue resistance it performs better than heavily galvanized cord and worse than lightly galvanized cord.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Ropes Or Cables (AREA)
• Coating With Molten Metal (AREA)
• Metal Extraction Processes (AREA)
• Superconductors And Manufacturing Methods Therefor (AREA)
• Manufacture Of Alloys Or Alloy Compounds (AREA)

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• 2000
  • 2000-01-19 EP EP00200186A patent/EP1118397A1/de not_active Withdrawn
  • 2000-12-22 EP EP00987445A patent/EP1250198B1/de not_active Expired - Lifetime
  • 2000-12-22 WO PCT/EP2000/013208 patent/WO2001053014A1/en active IP Right Grant
  • 2000-12-22 DE DE60012369T patent/DE60012369T2/de not_active Expired - Fee Related
  • 2000-12-22 AT AT00987445T patent/ATE271428T1/de not_active IP Right Cessation
  • 2000-12-22 US US10/181,290 patent/US20030131913A1/en not_active Abandoned
  • 2000-12-22 AU AU2001223689A patent/AU2001223689A1/en not_active Abandoned

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