US3631586A - Manufacture of copper-clad aluminum rod - Google Patents

Manufacture of copper-clad aluminum rod Download PDF

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Publication number
US3631586A
US3631586A US759138A US3631586DA US3631586A US 3631586 A US3631586 A US 3631586A US 759138 A US759138 A US 759138A US 3631586D A US3631586D A US 3631586DA US 3631586 A US3631586 A US 3631586A
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US
United States
Prior art keywords
copper
billet
aluminum
composite
composite billet
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.)
Expired - Lifetime
Application number
US759138A
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English (en)
Inventor
John Patrick Bearpark
Stanley Wilton Pigott
Rees Jenkin Llewellyn
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Balfour Beatty PLC
Original Assignee
BICC PLC
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by BICC PLC filed Critical BICC PLC
Application granted granted Critical
Publication of US3631586A publication Critical patent/US3631586A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/007—Hydrostatic extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/22—Making metal-coated products; Making products from two or more metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C33/00—Feeding extrusion presses with metal to be extruded ; Loading the dummy block
    • B21C33/004—Composite billet

Definitions

  • Copperclad aluminum rod can be produced by making a composite start body by inserting a billet of aluminum in a tube of copper and rolling and/or drawing down the composite body to form rod which can be drawn to form copper-clad aluminum wire.
  • Our invention resides in the discovery that copper-clad alu' minum rod in which the copper is soundly metallurgically bonded to the aluminum core can be produced by direct extrusion of a cold composite billet comprising a preformed core of aluminum surrounded by a close fitting sheath of copper, to effect a reduction in cross-sectional area of the composite billet providing the contiguous surfaces of the copper and aluminum components of the composite billet are clean and substantially free of surface oxides.
  • a cold composite billet we mean in this specification and in the claims which form part thereof a composite billet of which the temperature prior to and at the time of its insertion into the extrusion press is lower than the temperature at which copper and aluminum alloy when in contact.
  • Such a composite billet may be obtained by so machining or otherwise working the external surface of a billet of aluminum and/or the internal surface of a copper tube that the billet is a close fit in the tube, chemically and/or mechanically cleaning the whole of the mating surfaces of the aluminum billet and the copper tube to remove substantially all oxide and other contaminating films therefrom immediately before fitting the one in or on the other, fitting the one in or on the other and sealing the ends of the composite structure to prevent contact of the cleaned contiguous surfaces with the atmosphere.
  • the external surface of the aluminum billet and the internal surface of the copper tube may be purged with a nonoxidizing gas, for example nitrogen, during the cleaning and during the assembly of the two components to form the composite structure.
  • a nonoxidizing gas for example nitrogen
  • the cleaning operation may be carried out in an atmosphere of nitrogen or other nonoxidizing gas or under vacuum.
  • a composite billet is formed by electroplating a sheath of copper on to the surface of an aluminum billet. This may be effected after pretreating the surface of the aluminum billet either by the zincate process, by the socalled Alstan 70 process or by any other suitable pretreatment process.
  • the zincate process a layer of zinc is deposited on the circumferential surface of the aluminum billet before the sheath of copper is electroplated thereon.
  • the Alstan 7O process a layer of copperbased tin alloy is first deposited on the circumferential surface of an aluminum billet and thereafter a relatively thick layer of copper is deposited on the alloy layer. It will be appreciated that the electroplating method of building the composite billet permits of a reduction in the minimum proportion of copper present as compared with the copper tube method of building a composite billet.
  • Extrusion of a cold composite billet to effect a reduction in cross-sectional area and yield an extrudate in which the copper and aluminum components of the billet are soundly metallurgically bonded at the interface can be effected by the process known as hydrostatic extrusion.
  • the billet in the press container is surrounded by a liquid, usually oil, through which are transmitted the forces necessary to deform the billet and force it through the extrusion orifice.
  • hydrostatic extrusion is used to effect a reduction in cross-sectional area of a composite billet obtained by fitting an aluminum billet in a copper tube and sealing the ends of the composite structure so formed, the seals at the ends of the composite billet prevent ingress of the liquid between the mating surfaces of the composite billet.
  • FIG. 1 is a sectional side elevation of a composite billet formed from copper tube and an aluminum billet
  • FIG. 2 is a similar view of an electroplated composite billet
  • FIG. 3 is a sectional side elevation of an extrusion press for manufacturing copper-clad aluminum rod from a composite billet as shown in FIG. 1 or FIG. 2.
  • the composite billet shown in FIG. 1 comprises a preformed billet l of commercially pure aluminum which, over a major part of its length, has an overall diameter of approximately 1.29 in. (3.28 cm.) and which has at one end an integral substantially conical nose portion 2 tapering to a short cylindrical end portion 3 and, surrounding a major portion of the length of the billet, a length 4 of copper tube of similar shape which is sealed to the billet at each of its ends. Over the greater part of its length the copper tube 4 has an overall diameter of approximately 1.375 in. (3.49 cm.) and the copper of the tube constitutes approximately 10 percent by volume of the composite billet.
  • the external surface of the aluminum billet l is so machined and the copper tube 4 is so worked that when the billet is fitted in the tube the billet will be a close fit with a radial clearance of approximately 0.0075 in. (0.19 mm.) and each end of the billet will tightly engage an end of the tube to form an effective seal.
  • the mating surfaces of the billet and tube are mechanically and/or chemically cleaned to remove substantially all oxide and other contaminating films from these surfaces and the billet is fitted in the tube until the ends of the billet tightly engage the ends of the tube to seal the composite billet against contact of the contiguous surfaces with the atmosphere and against ingress of the oil to be used in the hydrostatic extrusion process, the cleaning and assembling operations being carried out in an atmosphere of nitrogen.
  • the ends of the billet 1 may alternatively, or additionally, be sealed to the ends of the tube 4 by means of rings or sleeves of elastomeric material or by use of suitable plastics sealing compound (not shown).
  • the composite billet shown in FIG. 2 comprises a preformed billet ll of commercially pure aluminum of similar shape and dimensions to that described with reference to FIG. 1 on which is electroplated a sheath 14 of copper of a wall thickness of approximately 0.016 in. (0.41 mm.), the copper of the sheath constituting 5 percent by volume of the composite billet.
  • a thin layer of copper-based tin alloy of approximately 0.0003 in. (0.0076 mm.) thickness is first deposited on the circumferential surface of the aluminum billet 11 and the relatively thick layer 14 of copper is deposited on the alloy layer.
  • the press comprises a tubular container 25 in one end of the bore of which is sealed an extrusion die 26 and in the other end of which bore a pressurizing ram 27 is in oiltight slidable engagement.
  • a cold composite billet 21. from which copper-clad aluminum rod 29 is to be extruded, is placed in the container 25 with its nose portion 22 in the throat of the extrusion die 26 and is surrounded by oil 28 through which are transmitted the forces necessary to deform the billet and force it through the orifice ofthe extrusion die.
  • an extrusion ratio of :1 was used, by which we mean that the ratio of cross-sectional area of composite billet to cross-sectional area of extrudate was 20:1 l.
  • the product a copper-clad aluminum rod of about 0.3 in. (7.62 mm.) diameter was successfully drawn down by conventional copper wire drawing practice, to composite wire of a diameter of 0.0076 in. (0.193 mm.) without any intermediate heat treatment.
  • an extrusion ratio of 17:1 was employed and, in this case, a copper-clad aluminum rod of about 0.3 in. (7.62 mm.) diameter was produced.
  • This composite rod was successfully drawn down by conventional copper wire drawing practice to copper-clad aluminum wire of a diameter of 0.0076 in. (0.193 mm.) without any intermediate heat treatment.
  • the rod or the wire formed from both of the billets shown in FIGS. 1 and 2 could at any stage in the wire drawing process be bent around a mandrel of the same diameter as that of the rod or wire without peeling or fissure of the copper coating.
  • Provided conditions are such that the formation of a brittle alloy at the interface does not take place to any substantial extent the rod or wire can be so heated that its ductility as measured by elongation under tensile load and its electrical conductivity are increased.
  • Wire or rod so heat treated can be wrapped around a mandrel of the same diameter for six complete turns then completely unwrapped and again wrapped for six complete turns without its coating of copper fissuring or peeling off the aluminum core.
  • the method in accordance with the present invention has the important advantage that copper-clad aluminum rod can be produced in which the percentage by volume of copper is as low as 5 percent with the result that composite wire with a very thin coating of copper can be formed.
  • a method of manufacturing copper-clad aluminum rod in which the copper cladding is soundly metallurgically bonded to the aluminum core comprises forming a cold composite billet by so working the external surface of a preformed billet of aluminum and the internal surface of a copper tube that the billet is a close fit in the tube, cleaning the whole of the mating surfaces of the aluminum billet and the copper tube to remove substantially all oxide and other contaminating films therefrom and immediately fitting the aluminum billet in the copper tube and sealing the ends of the tube to the billet to prevent contact of the cleaned contiguous surfaces with the atmosphere, and directly extruding the cold composite billet so formed to effect a reduction in cross-sectional area ofthe composite billet of at least 70 percent.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Extrusion Of Metal (AREA)
  • Wire Processing (AREA)
  • Electroplating Methods And Accessories (AREA)
  • Metal Extraction Processes (AREA)
US759138A 1967-09-14 1968-09-11 Manufacture of copper-clad aluminum rod Expired - Lifetime US3631586A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB41927/67A GB1186419A (en) 1967-09-14 1967-09-14 Improvements in or relating to the manufacture of Copper Clad Aluminium Rod

Publications (1)

Publication Number Publication Date
US3631586A true US3631586A (en) 1972-01-04

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Application Number Title Priority Date Filing Date
US759138A Expired - Lifetime US3631586A (en) 1967-09-14 1968-09-11 Manufacture of copper-clad aluminum rod

Country Status (5)

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US (1) US3631586A (enrdf_load_stackoverflow)
BE (1) BE763312Q (enrdf_load_stackoverflow)
DE (1) DE1777158A1 (enrdf_load_stackoverflow)
FR (1) FR1582699A (enrdf_load_stackoverflow)
GB (1) GB1186419A (enrdf_load_stackoverflow)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3750264A (en) * 1971-02-10 1973-08-07 Asea Ab Method of manufacturing rod, wire or tube shaped products of compound material by means of hydrostatic extrusion
US3777362A (en) * 1971-03-04 1973-12-11 Asea Ab Method of manufacturing rods or wire of compound material
US3777361A (en) * 1972-08-04 1973-12-11 Western Electric Co Method of producing clad wire
US3807032A (en) * 1971-03-15 1974-04-30 Asea Ab Method of manufacturing tubes of compound material
US3833987A (en) * 1971-02-10 1974-09-10 Hudson Products Corp Finned tubes for use in heat exchangers
US4015765A (en) * 1976-05-10 1977-04-05 Western Electric Company, Inc. Formation and utilization of compound billet
FR2325445A1 (fr) * 1975-09-24 1977-04-22 Asea Ab Procede pour le filage par voie hydrostatique
GB2260095A (en) * 1991-10-02 1993-04-07 Ass Elect Ind Manufacture of cables
US6202303B1 (en) * 1999-04-08 2001-03-20 Intel Corporation Method for producing high efficiency heat sinks
US6428858B1 (en) 2001-01-25 2002-08-06 Jimmie Brooks Bolton Wire for thermal spraying system
US20160344269A1 (en) * 2014-03-31 2016-11-24 Mitsubishi Electric Corporation Motor, blower, and compressor
CN106298080A (zh) * 2016-10-14 2017-01-04 国网辽宁省电力有限公司阜新供电公司 一种铜包铝母线排的生产方法
CN112466562A (zh) * 2020-11-18 2021-03-09 安徽聚虹电子有限公司 一种镀锡铜包铝线的生产方法
CN113352019A (zh) * 2021-04-22 2021-09-07 东方日升新能源股份有限公司 铜铝复合焊带的制作方法及铜铝复合焊带和太阳能组件
CN116329313A (zh) * 2023-05-29 2023-06-27 西安峰见智能电子有限公司 一种铝型材冲压成型设备

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2891309A (en) * 1956-12-17 1959-06-23 American Leonic Mfg Company Electroplating on aluminum wire
US3160951A (en) * 1957-10-29 1964-12-15 Babcock & Wilcox Co Method of making fuel pins by extrusion
US3296660A (en) * 1964-07-31 1967-01-10 Atomic Energy Authority Uk Extrusion apparatus
US3328998A (en) * 1964-12-17 1967-07-04 Battelle Development Corp High-reduction drawing
US3344636A (en) * 1963-04-04 1967-10-03 Council Scient Ind Res Extrusion of metals
US3417589A (en) * 1965-10-18 1968-12-24 Pressure Technology Corp Of Am Process and apparatus for working metals under high fluid pressure
US3434320A (en) * 1966-02-04 1969-03-25 Atomic Energy Authority Uk Hydrostatic extrusion apparatus
US3457760A (en) * 1966-12-16 1969-07-29 Reynolds Metals Co Extrusion of composite metal articles

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2891309A (en) * 1956-12-17 1959-06-23 American Leonic Mfg Company Electroplating on aluminum wire
US3160951A (en) * 1957-10-29 1964-12-15 Babcock & Wilcox Co Method of making fuel pins by extrusion
US3344636A (en) * 1963-04-04 1967-10-03 Council Scient Ind Res Extrusion of metals
US3296660A (en) * 1964-07-31 1967-01-10 Atomic Energy Authority Uk Extrusion apparatus
US3328998A (en) * 1964-12-17 1967-07-04 Battelle Development Corp High-reduction drawing
US3417589A (en) * 1965-10-18 1968-12-24 Pressure Technology Corp Of Am Process and apparatus for working metals under high fluid pressure
US3434320A (en) * 1966-02-04 1969-03-25 Atomic Energy Authority Uk Hydrostatic extrusion apparatus
US3457760A (en) * 1966-12-16 1969-07-29 Reynolds Metals Co Extrusion of composite metal articles

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3750264A (en) * 1971-02-10 1973-08-07 Asea Ab Method of manufacturing rod, wire or tube shaped products of compound material by means of hydrostatic extrusion
US3833987A (en) * 1971-02-10 1974-09-10 Hudson Products Corp Finned tubes for use in heat exchangers
US3777362A (en) * 1971-03-04 1973-12-11 Asea Ab Method of manufacturing rods or wire of compound material
US3807032A (en) * 1971-03-15 1974-04-30 Asea Ab Method of manufacturing tubes of compound material
US3777361A (en) * 1972-08-04 1973-12-11 Western Electric Co Method of producing clad wire
FR2325445A1 (fr) * 1975-09-24 1977-04-22 Asea Ab Procede pour le filage par voie hydrostatique
US4037305A (en) * 1975-09-24 1977-07-26 Allmanna Svenska Elektriska Aktiebolaget Method for hydrostatic extrusion
US4015765A (en) * 1976-05-10 1977-04-05 Western Electric Company, Inc. Formation and utilization of compound billet
GB2260095A (en) * 1991-10-02 1993-04-07 Ass Elect Ind Manufacture of cables
US6374491B1 (en) 1999-04-08 2002-04-23 Intel Corporation Method and apparatus for producing high efficiency heat sinks
US6202303B1 (en) * 1999-04-08 2001-03-20 Intel Corporation Method for producing high efficiency heat sinks
US6539614B2 (en) 1999-04-08 2003-04-01 Intel Corporation Apparatus for producing high efficiency heat sinks
US6428858B1 (en) 2001-01-25 2002-08-06 Jimmie Brooks Bolton Wire for thermal spraying system
US6861612B2 (en) 2001-01-25 2005-03-01 Jimmie Brooks Bolton Methods for using a laser beam to apply wear-reducing material to tool joints
US20160344269A1 (en) * 2014-03-31 2016-11-24 Mitsubishi Electric Corporation Motor, blower, and compressor
US10389215B2 (en) * 2014-03-31 2019-08-20 Mitsubishi Electric Corporation Motor, blower, and compressor
CN106298080A (zh) * 2016-10-14 2017-01-04 国网辽宁省电力有限公司阜新供电公司 一种铜包铝母线排的生产方法
CN112466562A (zh) * 2020-11-18 2021-03-09 安徽聚虹电子有限公司 一种镀锡铜包铝线的生产方法
CN113352019A (zh) * 2021-04-22 2021-09-07 东方日升新能源股份有限公司 铜铝复合焊带的制作方法及铜铝复合焊带和太阳能组件
CN116329313A (zh) * 2023-05-29 2023-06-27 西安峰见智能电子有限公司 一种铝型材冲压成型设备
CN116329313B (zh) * 2023-05-29 2023-10-27 西安峰见智能电子有限公司 一种铝型材冲压成型设备

Also Published As

Publication number Publication date
FR1582699A (enrdf_load_stackoverflow) 1969-10-03
DE1777158A1 (de) 1971-09-09
BE763312Q (fr) 1971-07-16
GB1186419A (en) 1970-04-02

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