WO2015182624A1 - アルミニウム合金導体線、アルミニウム合金撚線、被覆電線、ワイヤーハーネスおよびアルミニウム合金導体線の製造方法 - Google Patents
アルミニウム合金導体線、アルミニウム合金撚線、被覆電線、ワイヤーハーネスおよびアルミニウム合金導体線の製造方法 Download PDFInfo
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/023—Alloys based on aluminium
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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 OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
- B21C1/003—Drawing materials of special alloys so far as the composition of the alloy requires or permits special drawing methods or sequences
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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 OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
- B21C1/02—Drawing metal wire or like flexible metallic material by drawing machines or apparatus in which the drawing action is effected by drums
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
- B22D21/002—Castings of light metals
- B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
- B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
- B60R16/0207—Wire harnesses
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
- C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/047—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with magnesium as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/05—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/02—Single bars, rods, wires, or strips
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/08—Several wires or the like stranded in the form of a rope
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0045—Cable-harnesses
Definitions
- the present invention relates to an aluminum alloy conductor wire, an aluminum alloy twisted wire, a covered electric wire, a wire harness, and an aluminum alloy conductor wire manufacturing method used as a conductor of an electric wiring body.
- an electric wiring body of a moving body such as an automobile, a train, an aircraft, or an electric wiring body of an industrial robot
- a terminal made of copper or a copper alloy for example, brass
- a so-called wire harness member equipped with a connector has been used.
- the performance and functionality of automobiles have been rapidly advanced, and as a result, the number of various electric devices and control devices mounted on the vehicle has increased, and these devices are used in these devices.
- the means for achieving such weight reduction of the moving body for example, it is considered to replace the conductor of the electric wiring body with a lighter aluminum or aluminum alloy instead of the conventionally used copper or copper alloy. It is being advanced.
- the specific gravity of aluminum is about 1/3 of the specific gravity of copper
- the electrical conductivity of aluminum is about 2/3 of the electrical conductivity of copper (pure aluminum is about 66% IACS when pure copper is used as a standard of 100% IACS).
- the cross-sectional area of the aluminum conductor wire needs to be about 1.5 times the cross-sectional area of the copper conductor wire.
- the above% IACS represents the electrical conductivity when the resistivity 1.7241 ⁇ 10 ⁇ 8 ⁇ m of universal standard annealed copper (International Annealed Copper Standard) is 100% IACS.
- pure aluminum wires represented by aluminum alloy wires for power transmission lines are generally inferior in tensile durability, impact resistance, bending characteristics, and the like. For this reason, for example, a load that is unexpectedly applied by an operator or industrial equipment during installation to the vehicle body, a tension at a crimping portion at a connection portion between an electric wire and a terminal, or a load at a bending portion such as a door portion. It cannot withstand stress.
- materials alloyed by adding various additive elements can increase the tensile strength, it causes a decrease in conductivity due to the solid solution phenomenon of the additive elements in aluminum, and excessive metal in the aluminum.
- the intermetallic compound By forming the intermetallic compound, disconnection due to the intermetallic compound may occur during wire drawing. Therefore, by limiting or selecting the additive element, it is essential that the element has sufficient elongation characteristics so as not to be disconnected, and it is necessary to ensure the conventional level of electrical conductivity and tensile strength.
- a high-strength aluminum alloy wire for example, an aluminum alloy wire containing Mg and Si is known, and a typical example of the aluminum alloy wire is a 6000 series aluminum alloy (Al—Mg—Si alloy) wire. It is done.
- 6000 series aluminum alloy wire can be increased in strength by solution treatment and aging treatment. Therefore, when producing a thin wire having a wire diameter of 1.5 mm or less using 6000 series aluminum alloy wire.
- high strength can be achieved by applying a solution treatment and an aging treatment.
- Patent Document 1 Conventional 6000 series aluminum alloy wires used for electric wiring bodies of moving bodies and their manufacturing methods are disclosed in, for example, Patent Documents 1 to 4.
- Patent Document 1 in a method for producing a 6000 series aluminum alloy wire in which the steps of casting / rolling, wire drawing, intermediate heat treatment, wire drawing, and solution treatment (recrystallization) heat treatment are performed in this order, a cooling rate of 1 is applied during casting / rolling.
- a rod of 10 mm ⁇ was prepared at ⁇ 20 ° C./s, intermediate annealing was performed at 300 to 450 ° C. for 0.5 to 4 hours during the intermediate heat treatment, and 437 to 641 ° C. and 0.03 to 0 at the subsequent solution heat treatment. It is disclosed to perform finish annealing in 54 hours.
- Patent Document 2 in a method for producing a 6000 series aluminum alloy wire that performs the same process as described above, a 10 mm ⁇ bar is produced at a cooling rate of 1 to 20 ° C./s during casting and rolling, and 300 mm during intermediate heat treatment. It is disclosed that intermediate annealing is performed at ⁇ 450 ° C. for 0.17-4 hours, and finish annealing is performed at 415-633 ° C. for 0.03-0.54 hours during the subsequent solution heat treatment.
- Patent Document 3 in a method for producing a 6000 series aluminum alloy wire in which the steps of casting, wire drawing, intermediate heat treatment, wire drawing, and solution treatment (recrystallization) heat treatment are performed in this order, a cooling rate of 10 to 300 ° C. / It is disclosed that an ingot is produced with s, heat-treated at 300 to 450 ° C. for 1 to 4 hours during intermediate heat treatment, and further heat-treated at 300 to 450 ° C. for 1 to 4 hours during solution heat treatment. In Patent Document 4, an ingot is produced at a cooling rate of 10 to 300 ° C./s during casting in a method for producing a 6000 series aluminum alloy wire in which the steps of casting, wire drawing, intermediate heat treatment and wire drawing are performed in this order. Is disclosed.
- the crystal grains may locally grow abnormally during the heat treatment during the manufacturing process, resulting in variations in the amount of plastic deformation of the wire during crimping, and the like. There is a problem that the pressure bonding reliability at the time of pressure bonding with the adherend is insufficient.
- An object of the present invention is aluminum used as a conductor of an electric wiring body with improved crimping reliability while ensuring good strength even when used as a thin wire having a strand diameter of 1.5 mm ⁇ or less.
- An object of the present invention is to provide an alloy conductor wire, an aluminum alloy twisted wire, a covered electric wire, and a wire harness, and to provide a method for producing an aluminum alloy conductor wire.
- the present inventors Based on the premise of using an aluminum alloy containing Mg, Si, and Fe, the present inventors uniformly control the abnormal growth of crystal grains during recrystallization using the particle pinning effect by controlling the component composition and the manufacturing process. The present inventors have found a production method and a structure that suppresses and improves the pressure bonding reliability while ensuring good strength, and have completed the present invention.
- the gist configuration of the present invention is as follows. (1) 0.1 to 1.0% by mass of Mg, 0.1 to 1.20% by mass of Si, 0.01 to 1.40% by mass of Fe, 0 to 0.100% by mass of Ti, B 0 to 0.030 mass%, Cu 0 to 1.00 mass%, Ag 0 to 0.50 mass%, Au 0 to 0.50 mass%, Mn 0 to 1.00 mass%, Cr 0 to 1.00 mass%, Zr 0 to 0.50 mass%, Hf 0 to 0.50 mass%, V 0 to 0.50 mass%, Sc 0 to 0.50 mass%, Co Containing 0 to 0.50 mass% and Ni containing 0 to 0.50 mass%, with the balance being Al and inevitable impurities (provided that Ti, B, Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co, and Ni may be included in any one or more components, or any optional component that may not be included in any component There.) Has a particle size is 0.5
- the chemical composition is Cu: 0.01 to 1.00% by mass, Ag: 0.01 to 0.50% by mass, Au: 0.01 to 0.50% by mass, Mn: 0.01 to 1.00% by mass, Cr: 0.01-1.00% by mass, Zr: 0.01-0.50% by mass, Hf: 0.01-0.50% by mass, V: 0.01-0.
- the aluminum alloy conductor wire according to the above (1) or (2) which contains seeds or more.
- the total content of Fe, Ti, B, Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co, and Ni is 0.01 to 2.00% by mass (1)
- the aluminum alloy conductor wire according to any one of the above (1) to (5) which is an aluminum alloy wire having a strand diameter of 0.1 to 1.5 mm.
- the covered electric wire which has a coating layer in the outer periphery of the aluminum alloy wire as described in said (6) or the aluminum alloy twisted wire as described in said (7).
- a wire harness comprising the covered electric wire according to (8) and a terminal attached to an end of the covered electric wire from which the covering layer is removed.
- a method for producing an aluminum alloy conductor wire in which a rough drawn wire is formed through hot working after melting and casting, and thereafter at least each step of wire drawing, solution heat treatment, and aging heat treatment is performed.
- (11) A method for producing an aluminum alloy conductor wire in which a rough drawn wire is formed through hot working after melting and casting, and thereafter at least each step of wire drawing, solution heat treatment, and aging heat treatment is performed.
- the aluminum alloy conductor wire of the present invention is premised on the use of an aluminum alloy containing Mg, Si, and Fe, and controls at least the cooling rate during casting or the temperature rise temperature during solution heat treatment, so that grains within a predetermined range are used.
- an aluminum alloy containing Mg, Si, and Fe controls at least the cooling rate during casting or the temperature rise temperature during solution heat treatment, so that grains within a predetermined range are used.
- the aluminum alloy conductor wire, the aluminum alloy twisted wire, the covered electric wire, and the wire harness of the present invention are useful as a battery cable, a harness, a motor lead wire, or an industrial robot wiring body mounted on a moving body.
- the aluminum alloy conductor wire of the present invention has Mg of 0.1 to 1.0% by mass, Si of 0.1 to 1.20% by mass, Fe of 0.01 to 1.40% by mass, and Ti of 0 to 0%. 100% by mass, B 0-0.030% by mass, Cu 0-1.00% by mass, Ag 0-0.50% by mass, Au 0-0.50% by mass, Mn 0-1 0.000% by mass, Cr from 0 to 1.00% by mass, Zr from 0 to 0.50% by mass, Hf from 0 to 0.50% by mass, V from 0 to 0.50% by mass, Sc from 0 to 0 .50% by mass, Co 0 to 0.50% by mass and Ni 0 to 0.50% by mass, the balance being Al and inevitable impurities (provided that Ti, B, Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co, and Ni may be included in any one or more components, or included in any component Is a good optional additive ingredients even without.) Has a particle
- the aluminum alloy conductor wire of the present invention can be used as an aluminum alloy wire or an aluminum alloy twisted wire obtained by twisting a plurality of aluminum alloy wires, and further, an aluminum alloy wire or an aluminum alloy twisted wire. It can also be used as a covered electric wire having a covering layer on the outer periphery, and in addition, as a wire harness (assembled electric wire) comprising a covered electric wire and a terminal attached to the end of the covered electric wire from which the covering layer has been removed It is also possible to use it.
- a wire harness assembled electric wire
- Chemical composition ⁇ Mg: 0.10 to 1.00% by mass> Mg has the effect of strengthening by dissolving in an aluminum base material, and a part thereof forms precipitates or Mg-Si clusters together with Si to form tensile strength, bending fatigue resistance and It is an element that has the effect of improving heat resistance.
- Mg content is less than 0.10% by mass, the above-described effects are insufficient, and when the Mg content exceeds 1.00% by mass, an Mg-concentrated portion is formed at the crystal grain boundary.
- the Mg content is 0.10 to 1.00% by mass.
- the Mg content is preferably 0.50 to 1.00% by mass when high strength is important, and 0.10 to 0.50% by mass when conductivity is important. From such a viewpoint, the total content is preferably 0.30 to 0.70% by mass.
- Si is an element having an effect of improving tensile strength, bending fatigue resistance, and heat resistance by forming precipitates or Mg—Si clusters together with Mg.
- Si content is less than 0.10% by mass, the above-described effects are insufficient, and when the Si content exceeds 1.20% by mass, a Si-concentrated portion may be formed at the crystal grain boundary. The tensile strength, the elongation, and the bending fatigue resistance are lowered, and the electrical conductivity is lowered by increasing the amount of Si element dissolved. Therefore, the Si content is 0.10 to 1.20 mass%.
- the Si content is preferably 0.50 to 1.00% by mass when high strength is important, and 0.10 to 0.50% by mass when conductivity is important. From such a viewpoint, the total content is preferably 0.30 to 0.70% by mass.
- Fe is an element that contributes to refinement of crystal grains mainly by forming an Al—Fe-based intermetallic compound and improves tensile strength and bending fatigue resistance. Fe can only dissolve at 0.05% by mass in Al at 655 ° C. and is even less at room temperature. Therefore, the remaining Fe that cannot be dissolved in Al is Al—Fe, Al—Fe—Si, Al—Fe. -Crystallizes or precipitates as an intermetallic compound such as Si-Mg. This intermetallic compound contributes to refinement of crystal grains and improves tensile strength and bending fatigue resistance.
- Fe has the effect
- the Fe content is less than 0.01% by mass, these effects are insufficient, and when the Fe content exceeds 1.40% by mass, the crystallized product or precipitates are coarsened at the time of pressure bonding. The amount of plastic deformation does not fall within a predetermined range, and the conductor crimping property during crimping is reduced. Therefore, the Fe content is 0.01 to 1.40 mass%, preferably 0.15 to 0.90 mass%, and more preferably 0.15 to 0.45 mass%.
- the aluminum alloy conductor wire of the present invention contains Mg, Si and Fe as essential components, but if necessary, one or two selected from the group consisting of Ti and B, Cu, Ag, One or more of Au, Mn, Cr, Zr, Hf, V, Sc, Co and Ni can be contained.
- Ti is an element having an effect of refining the structure of the ingot at the time of melt casting. If the structure of the ingot is coarse, the ingot cracking in the casting or disconnection occurs in the wire processing step, which is not industrially desirable. If the Ti content is less than 0.001% by mass, the above-mentioned effects cannot be fully exhibited, and if the Ti content exceeds 0.100% by mass, the conductivity tends to decrease. It is. Accordingly, the Ti content is set to 0.001 to 0.100 mass%, preferably 0.005 to 0.050 mass%, more preferably 0.005 to 0.030 mass%.
- B like Ti
- a coarse ingot structure is not industrially desirable because it tends to cause ingot cracking and disconnection in the wire processing step during casting.
- the B content is 0.001 to 0.030 mass%, preferably 0.001 to 0.020 mass%, more preferably 0.001 to 0.010 mass%.
- ⁇ Cu 0.01 to 1.00% by mass>, ⁇ Ag: 0.01 to 0.50% by mass>, ⁇ Au: 0.01 to 0.50% by mass>, ⁇ Mn: 0.01 to 1 .00 mass%, ⁇ Cr: 0.01 to 1.00 mass%> and ⁇ Zr: 0.01 to 0.50 mass%>, ⁇ Hf: 0.01 to 0.50 mass%>, ⁇ V : 0.01 to 0.50 mass%, ⁇ Sc: 0.01 to 0.50 mass%>, ⁇ Co: 0.01 to 0.50 mass%> ⁇ Ni: 0.01 to 0.50 mass% %> 1 type or 2 types or more Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co, and Ni all have the effect of refining crystal grains and abnormal coarse growth.
- Cu, Ag, and Au are elements that also have the effect of increasing the grain boundary strength by precipitating at the grain boundaries. If at least one of these elements is contained in an amount of 0.01% by mass or more, the above-described effects can be obtained, and the tensile strength, elongation, and bending fatigue resistance can be improved. On the other hand, if any of the contents of Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co and Ni exceeds the above upper limit values, the compound containing the element becomes coarse. In order to deteriorate wire drawing workability, disconnection is likely to occur, and the conductivity tends to decrease.
- the ranges of the contents of Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co, and Ni are set to the above ranges, respectively.
- Ni When Ni is contained, the crystal grain refining effect and the abnormal grain growth suppressing effect become remarkable, and the tensile strength and elongation are improved. Moreover, it becomes easy to suppress the fall of electrical conductivity and the disconnection in wire drawing. Since this effect becomes remarkable, the Ni content is more preferably 0.05 to 0.3% by mass.
- the total content of these elements is preferably 2.00% by mass or less. Since Fe is an essential element in the aluminum alloy conductor wire of the present invention, the total content of Fe, Ti, B, Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co and Ni is 0.01. To 2.00% by mass. The total content of these elements is more preferably 0.10 to 2.00% by mass. However, when these elements are added alone, the larger the content, the more the compound containing the elements tends to become coarser, which deteriorates the wire drawing workability and easily causes disconnection. In the element, the content range is as defined above.
- Fe, Ti, B, Cu, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co, and Ni are used.
- the total content is particularly preferably 0.01 to 0.80% by mass, and more preferably 0.05 to 0.60% by mass.
- the conductivity is slightly lowered, in order to further improve the tensile strength, elongation, and proof stress value, it is particularly preferably more than 0.80 to 2.00% by mass, and further 1.00 to 2.00% by mass. preferable.
- Al and inevitable impurities The balance other than the components described above is Al (aluminum) and inevitable impurities.
- the inevitable impurities referred to here mean impurities in a content level that can be unavoidably included in the manufacturing process. Depending on the content of the inevitable impurities, it may be a factor for reducing the electrical conductivity. Therefore, it is preferable to suppress the content of the inevitable impurities to some extent in consideration of the decrease in the electrical conductivity. Examples of components listed as inevitable impurities include Ga, Zn, Bi, Pb, and the like.
- Such an aluminum alloy conductor wire can be realized by combining and controlling the alloy composition and the manufacturing process.
- the suitable manufacturing method of the aluminum alloy conductor wire of this invention is demonstrated.
- the aluminum alloy conductor wire of the present invention has a particle size of 0.5 to 5.0 ⁇ m and a compound containing Fe at a density of 1 to 300 / 10,000 ⁇ m 2 . Exists.
- the particle size of this compound is preferably 1.0 to 5.0 ⁇ m.
- the density of this compound is preferably 10 to 100 / 10,000 ⁇ m 2 . That is, by uniformly dispersing the Fe-based compound having a grain size within a predetermined range, abnormal growth of crystal grains can be suppressed uniformly, and as a result, the amount of plastic deformation during compression bonding is stabilized.
- an aluminum alloy conductor wire for a wire harness that achieves good strength and can achieve crimping reliability when crimping to an adherend and has high mechanical and electrical connection reliability. Can do. If the density of the compound containing Fe and having a particle size of 0.5 to 5.0 ⁇ m is less than 1 piece / 10000 ⁇ m 2 , the pinning effect is small, so that coarse particles are likely to be generated and impact resistance is lowered. If the density of the compound containing Fe having a particle size of 0.5 to 5.0 ⁇ m exceeds 300 / 10,000 ⁇ m 2 , the strength tends to decrease.
- the compound contains Fe is determined using an EPMA (Electron Probe Micro Analyzer), and the particle size of the particle is the area of the particle observed in the cross section of the aluminum alloy conductor wire. , Measured using free software “ImageJJ” and evaluated by the diameter (equivalent circle diameter) when converted to the equivalent of a circle. The number density of the Fe-containing compound having a particle size of 0.5 to 5.0 ⁇ m (pieces / 10,000 ⁇ m 2 ) was processed by ion milling until the cross-sectional center of the aluminum alloy conductor wire could be observed.
- EPMA Electro Probe Micro Analyzer
- the cross-section was observed using a scanning electron microscope (SEM), and the number of Fe-based compounds having a particle size of 0.5 to 5.0 ⁇ m existing in the field size (1000 ⁇ m 2 ) was measured. the number of compounds were determined by converted per 10000 2 to 10 times. In addition, the numerical value of the number density of the compound is determined by arbitrarily determining three different cross-sectional positions, specifically, the first cross-sectional position, which are located at intervals along the longitudinal direction of the aluminum alloy conductor wire.
- the second cross-sectional position is a position that is separated from the first cross-sectional position by 1000 mm or more (for example, 1000 mm)
- the third cross-sectional position is a position that is separated from the first cross-sectional position by 2000 mm or more (for example, 2000 mm) and It means an average value of the number density of the compounds determined at the first to third cross-sectional positions, at a position distant from the second cross-sectional position by 1000 mm or more (for example, 1000 mm).
- the aluminum alloy conductor wire of the present invention includes [1] melting, [2] casting, [3] hot working (groove roll processing, etc.), [4] first Steps of wire drawing, [5] first heat treatment (intermediate heat treatment), [6] second wire drawing, [7] second heat treatment (solution heat treatment), and [8] third heat treatment (aging heat treatment) Can be manufactured by a manufacturing method including sequentially performing. Note that a step of forming a stranded wire or a step of coating a wire with a resin may be provided before or after the second heat treatment or after the aging heat treatment. The steps [1] to [8] will be described below.
- the rate of temperature increase during solution heat treatment (second heat treatment) described later is from 20 ° C./s between room temperature and 550 ° C. Is too high, the cooling rate during casting and the temperature rising rate during solution heat treatment are too fast, so the number of Fe-based compounds having a particle size of 0.5 to 5.0 ⁇ m existing in a predetermined area is reduced, and the crystal grains are reduced. As a result of coarsening and easy generation of abnormally grown grains, the impact durability and the wire crimping property of the crimping part are lowered.
- the temperature rising rate at the second heat treatment is limited to 20 ° C./s or less between room temperature and 550 ° C. It was decided to.
- This casting and hot rolling may be performed by billet casting or extrusion.
- the degree of work ⁇ is preferably in the range of 1-6.
- the degree of work ⁇ is less than 1, the recrystallized grains are coarsened during the heat treatment in the next step, the tensile strength and elongation are remarkably reduced, and there is a risk of disconnection.
- the processing degree ⁇ is larger than 6, the wire drawing process becomes difficult, and there is a risk of causing a problem in terms of quality such as disconnection during the wire drawing process.
- the surface is cleaned by performing surface peeling, it may not be performed.
- a first heat treatment is performed on the cold-drawn workpiece. Specifically, the first heat treatment is performed by heating to a predetermined temperature within a range of 300 to 480 ° C. and holding for a holding time of 0.05 to 6 hours.
- the first heat treatment of the present invention is performed in order to restore the flexibility of the workpiece and improve the wire drawing workability. If the wire drawing workability is sufficient and disconnection does not occur, the first heat treatment may not be performed.
- the working degree ⁇ is preferably in the range of 1 to 6.
- the degree of work ⁇ affects the formation and growth of recrystallized grains. If the degree of work ⁇ is less than 1, the recrystallized grains tend to be coarsened during the heat treatment in the next step, and the tensile strength and elongation tend to be significantly reduced. This is because it tends to cause problems in terms of quality, such as disconnection during wire drawing. In addition, when not performing 1st heat processing, you may perform 1st wire drawing and 2nd wire drawing continuously.
- Second heat treatment (solution heat treatment) A second heat treatment is applied to the drawn workpiece.
- the second heat treatment of the present invention is a solution heat treatment performed in order to dissolve a randomly contained Mg and Si compound in the aluminum matrix.
- the solution treatment can smoothen (homogenize) the concentrated portion of Mg or Si during processing, leading to suppression of grain boundary segregation of the compound of Mg and Si after the final aging heat treatment.
- the temperature rise rate is 20 ° C./s or less between room temperature and 550 ° C., and within the range of 480 to 620 ° C.
- the cooling rate during casting exceeds 5 ° C./s and the rate of temperature increase in the second heat treatment exceeds 20 ° C./s, the cooling rate during casting or the rate of temperature increase during solution heat treatment is too high, so the predetermined area
- the number of Fe-based compounds having a particle size of 0.5 to 5.0 ⁇ m present therein decreases, crystal grains become coarse and abnormally grown grains are generated, and impact durability is lowered.
- the predetermined temperature at the time of heating in the second heat treatment is in the range of 480 to 620 ° C., preferably in the range of 520 to 580 ° C.
- the range of the temperature rising rate at the time of the second heat treatment is not particularly limited, but is, for example, 5 to 80 ° C./s.
- the method of performing the second heat treatment may be, for example, high-frequency heating, continuous heat treatment such as energization heating or running heat.
- the wire temperature When high-frequency heating or current heating is used, the wire temperature usually rises with the passage of time because the current is usually kept flowing through the wire. For this reason, if the current is kept flowing, the wire may be melted. Therefore, it is necessary to perform heat treatment in an appropriate time range. Even when running heating is used, since the annealing is performed for a short time, the temperature of the running annealing furnace is usually set higher than the wire temperature. Since heat treatment for a long time may cause the wire to melt, it is necessary to perform the heat treatment in an appropriate time range. Hereinafter, heat treatment by each method will be described.
- the continuous heat treatment by high frequency heating is a heat treatment by Joule heat generated from the wire itself by an induced current as the wire continuously passes through a magnetic field by high frequency. It includes a rapid heating and rapid cooling process, and the wire can be heat-treated under control of the wire temperature and heat treatment time. Cooling is performed by passing the wire continuously in water or in a nitrogen gas atmosphere after rapid heating.
- This heat treatment time is 0.01 to 2 s, preferably 0.05 to 1 s, more preferably 0.05 to 0.5 s.
- the continuous energization heat treatment is a heat treatment by Joule heat generated from the wire itself by passing an electric current through the wire passing continuously through the two electrode wheels. It includes a rapid heating and rapid cooling process, and the wire can be heat-treated under control of the wire temperature and heat treatment time. Cooling is performed by passing the wire continuously through water, air, or a nitrogen gas atmosphere after rapid heating. This heat treatment time is 0.01 to 2 s, preferably 0.05 to 1 s, more preferably 0.05 to 0.5 s.
- the continuous running heat treatment is a heat treatment in which a wire continuously passes through a heat treatment furnace maintained at a high temperature.
- Heat treatment can be performed by controlling the temperature in the heat treatment furnace and the heat treatment time, including rapid heating and rapid cooling processes. Cooling is performed by passing the wire continuously through water, air, or a nitrogen gas atmosphere after rapid heating. This heat treatment time is preferably 0.5 to 30 s.
- a third heat treatment is performed. This third heat treatment is performed to precipitate acicular Mg 2 Si precipitates and improve the tensile strength.
- the heating temperature in the aging heat treatment is 100 to 250 ° C., and the heating time is 0.5 to 15 hours. When the heating temperature is less than 100 ° C., acicular Mg 2 Si precipitates cannot be sufficiently precipitated, and the strength, the bending fatigue resistance and the conductivity tend to be insufficient. On the other hand, if the heating temperature is higher than 250 ° C., the size of the Mg 2 Si precipitate increases, so that the electrical conductivity increases, but the strength and the bending fatigue resistance tend to be insufficient.
- the wire diameter is not particularly limited and can be appropriately determined according to the application.
- a thin wire 0.1 to 0.5 mm ⁇ , and in the case of a medium thin wire 0.8 to 1.5 mm ⁇ is preferable.
- the aluminum alloy conductor wire of the present invention is one of the advantages that it can be used as an aluminum alloy wire by thinning it with a single wire, but it can also be used as an aluminum alloy twisted wire obtained by bundling a plurality of wires, Among the steps [1] to [8] constituting the production method of the present invention, after the aluminum alloy wires obtained by sequentially performing the steps [1] to [6] are bundled and twisted, 7] Steps of second heat treatment and [8] aging heat treatment may be performed.
- the present invention it is possible to perform a homogenization heat treatment as performed by a conventional method after continuous casting and rolling.
- the homogenization heat treatment precipitates of the additive elements (mainly Mg—Si compounds) can be uniformly dispersed, so that a uniform crystal structure can be easily obtained in the subsequent first heat treatment. Elongation and yield strength can be improved more stably.
- the homogenization heat treatment is preferably performed at a heating temperature of 450 ° C. to 600 ° C. and a heating time of 1 to 10 hours, more preferably 500 to 600 ° C.
- the cooling in the homogenization heat treatment is preferably slow cooling at an average cooling rate of 0.1 to 10 ° C./min from the viewpoint of easily obtaining a uniform compound.
- the second heat treatment was performed at the temperature rising temperature and the maximum temperature 480 to 620 ° C. shown in Table 2, respectively.
- the wire temperature was measured by winding a thermocouple around the wire.
- the wire temperature in the vicinity of the heat treatment section exit was measured.
- an aging heat treatment was performed at 100 to 250 ° C. for 0.05 to 12 hours to produce an aluminum alloy wire having a finished diameter of 0.1 to 1.5 mm ⁇ .
- the aluminum alloy wires of Invention Examples 1 to 25 all had good strength and excellent wire crimping properties.
- the aluminum alloy wires of Comparative Examples 1 to 4, 6 to 9, 13 to 16, 18 and 20 to 23 are all out of the scope of the present invention because the cooling rate during casting is less than 0.1 ° C./s.
- the density of the Fe-based compound having a particle size of 0.5 to 5.0 ⁇ m was outside the range of the present invention, and the strength was poor.
- the aluminum alloy wires of Comparative Examples 5, 10-12, 17 and 19 all had a cooling rate during casting of 15 ° C./s or higher and a temperature increase temperature during solution heat treatment of 50 ° C./s or higher.
- the density of the Fe-based compound was outside the range of the present invention, and the wire crimping property of the crimped part was inferior.
- the aluminum alloy conductor wire of the present invention provides an aluminum alloy conductor wire, an aluminum alloy twisted wire, a covered electric wire, and a wire harness that are used as a conductor of an electric wiring body, while ensuring good strength and improving electric wire crimpability. And a method for producing an aluminum alloy conductor wire, and is useful as a battery cable, a harness or a conductor for a motor mounted on a moving body, and a wiring body for an industrial robot. Furthermore, since the aluminum alloy conductor wire of the present invention has high strength, it is possible to make the wire diameter thinner than a conventional wire.
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Abstract
Description
(1)Mgを0.1~1.0質量%、Siを0.1~1.20質量%およびFeを0.01~1.40質量%、Tiを0~0.100質量%、Bを0~0.030質量%、Cuを0~1.00質量%、Agを0~0.50質量%、Auを0~0.50質量%、Mnを0~1.00質量%、Crを0~1.00質量%、Zrを0~0.50質量%、Hfを0~0.50質量%、Vを0~0.50質量%、Scを0~0.50質量%、Coを0~0.50質量%およびNiを0~0.50質量%含有し、残部がAlおよび不可避不純物である組成(ただし、上記Ti、B、Cu、Ag、Au、Mn、Cr、Zr、Hf、V、Sc、CoおよびNiは、いずれか1成分以上含有させてもよいし、いずれの成分とも含有させなくてもよい任意添加成分である。)を有し、粒径が0.5~5.0μmであり、且つFeを含有する化合物の密度が、1~300個/10000μm2であることを特徴とするアルミニウム合金導体線。
(2)前記化学組成が、Ti:0.001~0.100質量%およびB:0.001~0.030質量%からなる群から選択された1種または2種を含有する上記(1)に記載のアルミニウム合金導体線。
(3)前記化学組成が、Cu:0.01~1.00質量%、Ag:0.01~0.50質量%、Au:0.01~0.50質量%、Mn:0.01~1.00質量%、Cr:0.01~1.00質量%、Zr:0.01~0.50質量%、Hf:0.01~0.50質量%、V:0.01~0.50質量%、Sc:0.01~0.50質量%、Co:0.01~0.50質量%およびNi:0.01~0.50質量%からなる群から選択された1種または2種以上を含有する上記(1)または(2)に記載のアルミニウム合金導体線。
(4)前記化学組成が、Ni:0.01~0.50質量%を含有する上記(1)~(3)のいずれかに記載のアルミニウム合金導体線。
(5)Fe、Ti、B、Cu、Ag、Au、Mn、Cr、Zr、Hf、V、Sc、Co、Niの含有量の合計が0.01~2.00質量%である(1)~(4)のいずれか1項に記載のアルミニウム合金導体線。
(6)素線径が0.1~1.5mmであるアルミニウム合金線である上記(1)~(5)のいずれか1項に記載のアルミニウム合金導体線。
(7)上記(6)に記載のアルミニウム合金線を複数本撚り合わせて得られるアルミニウム合金撚線。
(8)上記(6)に記載のアルミニウム合金線または上記(7)に記載のアルミニウム合金撚線の外周に被覆層を有する被覆電線。
(9)上記(8)に記載の被覆電線と、該被覆電線の、前記被覆層を除去した端部に装着された端子とを具えるワイヤーハーネス。
(10)溶解、鋳造後に、熱間加工を経て荒引線を形成し、その後、少なくとも伸線加工、溶体化熱処理および時効熱処理の各工程を行うアルミニウム合金導体線の製造方法であって、前記鋳造時の冷却速度を0.1~5℃/sとすることを特徴とする、上記(1)~(6)のいずれかに記載のアルミニウム合金導体線の製造方法。
(11)溶解、鋳造後に、熱間加工を経て荒引線を形成し、その後、少なくとも伸線加工、溶体化熱処理および時効熱処理の各工程を行うアルミニウム合金導体線の製造方法であって、前記鋳造時の冷却速度を5℃/sを超える値とし、且つ前記溶体化熱処理時の昇温温度を、室温~550℃の間で20℃/s以下とすることを特徴とする、上記(1)~(6)のいずれかに記載のアルミニウム合金導体線の製造方法。
(1)化学組成
<Mg:0.10~1.00質量%>
Mg(マグネシウム)は、アルミニウム母材中に固溶して強化する作用を有するとともに、その一部はSiと一緒に析出物ないしは、Mg-Siクラスタを形成して引張強度、耐屈曲疲労特性および耐熱性を向上させる作用を有する元素である。しかしながら、Mg含有量が0.10質量%未満だと、上記作用効果が不十分であり、また、Mg含有量が1.00質量%を超えると、結晶粒界にMg濃化部分を形成する可能性が高まり、引張強度、伸び、耐屈曲疲労特性が低下するとともに、Mg元素の固溶量が多くなることによって導電率も低下する。したがって、Mg含有量は0.10~1.00質量%とする。なお、Mg含有量は、高強度を重視する場合には0.50~1.00質量%にすることが好ましく、また、導電率を重視する場合には0.10~0.50質量%とすることが好ましく、このような観点から総合的に0.30~0.70質量%が好ましい。
Si(ケイ素)は、Mgと一緒に析出物ないしは、Mg-Siクラスタを形成して引張強度、耐屈曲疲労特性、及び耐熱性を向上させる作用を有する元素である。Si含有量が0.10質量%未満だと、上記作用効果が不十分であり、また、Si含有量が1.20質量%を超えると、結晶粒界にSi濃化部分を形成する可能性が高まり、引張強度、伸び、耐屈曲疲労特性が低下するとともに、Si元素の固溶量が多くなることによって導電率も低下する。したがって、Si含有量は0.10~1.20質量%とする。なお、Si含有量は、高強度を重視する場合には0.50~1.00質量%にすることが好ましく、また、導電率を重視する場合には0.10~0.50質量%とすることが好ましく、このような観点から総合的に0.30~0.70質量%が好ましい。
Fe(鉄)は、主にAl-Fe系の金属間化合物を形成することによって結晶粒の微細化に寄与するとともに、引張強度および耐屈曲疲労特性を向上させる元素である。Feは、Al中に655℃で0.05質量%しか固溶できず、室温では更に少ないため、Al中に固溶できない残りのFeは、Al-Fe、Al-Fe-Si、Al-Fe-Si-Mgなどの金属間化合物として晶出又は析出する。この金属間化合物は、結晶粒の微細化に寄与するとともに、引張強度および耐屈曲疲労特性を向上させる。また、Feは、Al中に固溶したFeによっても引張強度を向上させる作用を有する。Fe含有量が0.01質量%未満だと、これらの作用効果が不十分であり、また、Fe含有量が1.40質量%超えだと、晶出物または析出物の粗大化により圧着時の塑性変形量が所定範囲の値とならず、圧着時の導体圧着性が低下する。したがって、Fe含有量は0.01~1.40質量%とし、好ましくは0.15~0.90質量%、更に好ましくは0.15~0.45質量%とする。
Tiは、溶解鋳造時の鋳塊の組織を微細化する作用を有する元素である。鋳塊の組織が粗大であると、鋳造において鋳塊割れや線材加工工程において断線が発生して工業的に望ましくない。Ti含有量が0.001質量%未満であると、上記作用効果を十分に発揮することができず、また、Ti含有量が0.100質量%超えだと導電率が低下する傾向があるからである。したがって、Ti含有量は0.001~0.100質量%とし、好ましくは0.005~0.050質量%、より好ましくは0.005~0.030質量%とする。
Bは、Tiと同様、溶解鋳造時の鋳塊の組織を微細化する作用を有する元素である。鋳塊の組織が粗大であると、鋳造において鋳塊割れや線材加工工程において断線が発生しやすくなるため工業的に望ましくない。B含有量が0.001質量%未満であると、上記作用効果を十分に発揮することができず、また、B含有量が0.030質量%超えだと導電率が低下する傾向がある。したがって、B含有量は0.001~0.030質量%とし、好ましくは0.001~0.020質量%、より好ましくは0.001~0.010質量%とする。
Cu、Ag、Au、Mn、Cr、Zr、Hf、V、Sc、CoおよびNiは、いずれも結晶粒を微細化する作用と異常な粗大成長粒の生成を抑制する元素であり、さらに、Cu、AgおよびAuは、粒界に析出することで粒界強度を高める作用も有する元素であって、これらの元素の少なくとも1種を0.01質量%以上含有していれば、上述した作用効果が得られ、引張強度、伸び、耐屈曲疲労特性を向上させることができる。一方、Cu、Ag、Au、Mn、Cr、Zr、Hf、V、Sc、CoおよびNiの含有量のいずれかが、それぞれ上記の上限値を超えると、該元素を含有する化合物が粗大になり、伸線加工性を劣化させるため、断線が生じやすく、また、導電率が低下する傾向がある。したがって、Cu、Ag、Au、Mn、Cr、Zr、Hf、V、Sc、CoおよびNiの含有量の範囲は、それぞれ上記の範囲とした。なお、この元素群の中で、特にNiを含有するのが好ましい。Niを含有すると、結晶粒微細化効果と異常粒成長抑制効果が顕著になり引張強度と伸びが向上する。また、導電率の低下と伸線加工中の断線をより抑制しやすくなる。この効果が顕著になるので、Niの含有量は0.05~0.3質量%であるのが更に好ましい。
上述した成分以外の残部はAl(アルミニウム)および不可避不純物である。ここでいう不可避不純物は、製造工程上、不可避的に含まれうる含有レベルの不純物を意味する。不可避不純物は、含有量によっては導電率を低下させる要因にもなりうるため、導電率の低下を加味して不可避不純物の含有量をある程度抑制することが好ましい。不可避不純物として挙げられる成分としては、例えば、Ga、Zn、Bi、Pbなどが挙げられる。
本発明のアルミニウム合金導体線には、粒径が0.5~5.0μmであり、かつFeを含有する化合物が、1~300個/10000μm2の密度で存在する。この化合物の粒径は、好ましくは、1.0~5.0μmである。この化合物の密度は、好ましくは、10~100個/10000μm2である。すなわち所定範囲内の粒径を有するFe系化合物を均一に分散させることで、結晶粒の異常成長を均一に抑制することができ、この結果圧着時の塑性変形量が安定化する。したがって、良好な強度を実現するとともに被着体と圧着する際の圧着信頼性を達成することができ、機械的、電気的な接続信頼性の高いワイヤーハーネス用のアルミニウム合金導体線を提供することができる。Feを含有する粒径0.5~5.0μmである化合物の密度が1個/10000μm2未満であると、ピンニング効果が小さいことから粗大粒が発生しやすくなり、耐衝撃性が低下する。また、粒径0.5~5.0μmであるFeを含有する化合物の密度が300個/10000μm2を超えると、強度が低下しやすくなる。なお、化合物がFeを含有するか否かの判定は、EPMA(Electron Probe Micro Analyzer)を用いて行ない、また、粒子の粒径は、アルミニウム合金導体線の断面にて観察された粒子の面積を、フリーソフト「ImageJJ」を用いて測定し、円等価に換算した際の直径(円相当径)で評価した値である。また、粒径0.5~5.0μmであるFeを含有する化合物の個数密度(個/10000μm2)は、イオンミリング法によって、アルミニウム合金導体線の断面中心が観察できるまで加工し、加工した断面を、走査型電子顕微鏡(SEM)を用いて観察し、視野サイズ(1000μm2)内に存在する、粒径0.5~5.0μmのFe系化合物の個数を測定し、測定したFe系化合物の個数を10倍して10000μm2当たりに換算することにより求めた。なお、前記化合物の個数密度の数値は、アルミニウム合金導体線の長手方向に沿って間隔をおいて位置する、異なる3つの断面位置、具体的には、第1の断面位置を任意に決めた位置とし、第2の断面位置を、第1の断面位置から1000mm以上(例えば1000mm)離れた位置とし、第3の断面位置を、第1の断面位置から2000mm以上(例えば2000mm)離れた位置でかつ第2の断面位置から1000mm以上(例えば1000mm)離れた位置とし、これら第1~第3の断面位置で求めた前記化合物の個数密度の平均値を意味する。
本発明のアルミニウム合金導体線は、[1]溶解、[2]鋳造、[3]熱間加工(溝ロール加工など)、[4]第1伸線加工、[5]第1熱処理(中間熱処理)、[6]第2伸線加工、[7]第2熱処理(溶体化熱処理)、および[8]第3熱処理(時効熱処理)の各工程を順次行うことを含む製造方法によって製造することができる。なお、第2熱処理前後、または時効熱処理の後に、撚り線とする工程や電線に樹脂被覆を行う工程を設けてもよい。以下、[1]~[8]の工程について説明する。
溶解は、上述したアルミニウム合金組成になるように各成分の分量を調整して溶製する。
次いで、鋳造輪とベルトを組み合わせたプロペルチ式の連続鋳造圧延機を用いて、溶湯を水冷した鋳型で鋳造し、連続して圧延を行い、例えば直径5~13mmφの適宜の太さの棒材とする。このときの鋳造時の冷却速度は、0.1~5.0℃/sであり、好ましくは0.1~1.0℃/である。鋳造時の冷却速度が0.1℃/s未満であると、鋳造時冷却速度が遅すぎるため、所定面積中に存在する粒径0.5~5.0μmのFe系化合物数(個/10000μm2)が多くなり過ぎて、強度が低下する。一方、鋳造時の冷却速度が5.0℃/sを超える場合には、後述する溶体化熱処理(第2熱処理)時の昇温速度が、室温~550℃までの間で20℃/sよりも大きいと、鋳造時の冷却速度および溶体化熱処理時の昇温速度が速すぎるため、所定面積中に存在する粒径0.5~5.0μmのFe系化合物数が少なくなり、結晶粒が粗大化して異常成長粒が生成しやすくなる結果、衝撃耐久性や、圧着部の電線圧着性が低下する。このため、本発明では、鋳造時の冷却速度が5.0℃/sを超える場合には、第2熱処理時の昇温速度を、室温~550℃までの間で20℃/s以下に制限することとした。この鋳造及び熱間圧延は、ビレット鋳造及び押出法などにより行ってもよい。
次いで、表面の皮むきを実施して、例えば直径5mm~12.5mmφの適宜の太さの棒材とし、これを冷間で伸線加工する。加工度ηは、1~6の範囲であることが好ましい。ここで加工度ηは、伸線加工前の線材断面積をA0、伸線加工後の線材断面積をA1とすると、η=ln(A0/A1)で表される。加工度ηが1未満だと、次工程の熱処理時、再結晶粒が粗大化し、引張強度及び伸びが著しく低下し、断線の原因になるおそれがある。また、加工度ηが6よりも大きいと、伸線加工が困難となり、伸線加工中に断線するなど品質の面で問題を生ずるおそれがあるからである。表面の皮むきは、行うことによって表面の清浄化がなされるが、行わなくてもよい。
次に、冷間伸線した被加工材に第1熱処理を施す。この第1熱処理は、具体的には、300~480℃の範囲内で所定温度まで加熱し、保持時間0.05~6時間で保持する。本発明の第1熱処理は、被加工材の柔軟性を取り戻し、伸線加工性を高めるために行うものである。伸線加工性が十分であり、断線が生じなければ第1熱処理は行わなくてもよい。
上記第1熱処理の後、さらに冷間で伸線加工を施す。この際の加工度ηは1~6の範囲が好ましい。加工度ηは、再結晶粒の形成及び成長に影響を及ぼす。加工度ηが1よりも小さいと、次工程の熱処理時、再結晶粒が粗大化し、引張強度及び伸びが著しく低下する傾向があり、また、加工度ηが6よりも大きいと、伸線加工が困難となり、伸線加工中に断線するなど品質の面で問題を生ずる傾向があるからである。なお、第1熱処理を行わない場合、第1伸線加工と第2伸線加工は連続で行ってもよい。
伸線加工した加工材に第2熱処理を施す。本発明の第2熱処理は、ランダムに含有されているMgとSiの化合物をアルミニウム母相中に溶け込ませるために行う溶体化熱処理である。溶体化処理は、加工中にMgやSiの濃化部分をならす(均質化する)ことができ、最終的な時効熱処理後でのMgとSiの化合物の粒界偏析の抑制につながる。第2熱処理は、具体的には、上記鋳造時の冷却速度が5℃/sを超える場合、室温~550℃までの間では昇温速度20℃/s以下で、480~620℃の範囲内の所定温度まで加熱し、保持し、その後、急冷する熱処理である。鋳造時の冷却速度が5℃/sを超え、且つ第2熱処理における昇温速度が20℃/sを超える場合、鋳造時冷却速度あるいは溶体化熱処理時の昇温速度が速すぎるため、所定面積中に存在する粒径0.5~5.0μmのFe系化合物数が少なくなり、結晶粒が粗大化して異常成長粒が生成し、衝撃耐久性が低下する。また、第2熱処理の加熱時の所定温度が620℃よりも高いと、結晶粒が粗大化し、同所定温度が480℃よりも低いと、Fe系化合物を分散して析出させることができない。なお、本発明における異常成長粒とは、線径に対して1~2個程度の粗大化した結晶粒であり、直径が50μm以上であるものを指す。したがって、第2熱処理における加熱時の所定温度は480~620℃の範囲とし、好ましくは520~580℃の範囲とする。一方、上記鋳造時の冷却速度が0.1~5℃/sである場合、第2熱処理時における昇温速度の範囲は特に制限されないが、例えば5~80℃/sである。
次いで、第3熱処理を施す。この第3熱処理は、針状のMg2Si析出物を析出させ、引張強度を向上させるために行う。時効熱処理における加熱温度は、100~250℃、加熱時間は、0.5~15時間である。前記加熱温度が100℃未満であると、針状のMg2Si析出物を十分に析出させることができず、強度、耐屈曲疲労特性および導電率が不足しがちである。また、前記加熱温度が250℃よりも高いと、Mg2Si析出物のサイズが大きくなるため、導電率は上昇するが、強度および耐屈曲疲労特性が不足しがちである。
Mg、Si、Fe及びAlと、選択的に添加するTi、B、Mn、Cr、Cu、Co、NiおよびZrを、表1に示す含有量(質量%)になるようにプロペルチ式の連続鋳造圧延機を用いて、溶湯を水冷した鋳型で連続的に鋳造しながら圧延を行い、約9.5mmφの棒材とした。このときの鋳造時の冷却速度はそれぞれ表2に示す値とした。これを所定の伸線度が得られるように第1伸線加工を施した。次に、この第1伸線加工を施した加工材に、300~480℃、0.05~6時間で第1熱処理を施し、さらに0.31mmφの線径まで第2伸線加工を行った。次に、それぞれ表2に示す昇温温度、最高到達温度480~620℃で第2熱処理を施した。第1熱処理における、バッチ式熱処理では、線材に熱電対を巻きつけて線材温度を測定した。第1、第2熱処理における連続走間熱処理では、熱処理区間出口付近の線材温度を測定した。第2熱処理後に、100~250℃、0.05~12時間で時効熱処理を施し、仕上げ径0.1~1.5mmφのアルミニウム合金線を製造した。
実施例及び比較例のアルミニウム合金導体線をFIB法にて薄膜にし、走査型電子顕微鏡(SEM)を用いて、観察倍率500~5000倍で、10000μm2の範囲を観察した。この観察範囲において、粒径が0.5~5.0μmであり、かつFeを含有する化合物の個数を数えて密度(個/μm2)とした。なお、粒子の粒径は、観察された粒子の面積を円等価に換算した際の直径(円相当径)で評価した。
アルミニウム合金線の端部に端子を圧着し、圧着前に対する圧着後のアルミニウム合金導体線の塑性変形量を測定し、塑性変形量が55~65%である場合を合格レベルとし、55%未満、あるいは65%を超えた場合を不合格レベルとした。
JIS Z 2241に準じて各3本ずつの供試材(アルミニウム合金線)について引張試験を行い、その後、0.2%耐力を算出し、その平均値を求めた。強度は、電線と端子の接続部における圧着部の強度を保つため、80MPa以上を合格レベルとし、80MPa未満を不合格レベルとした。
Claims (11)
- Mgを0.1~1.0質量%、Siを0.1~1.20質量%およびFeを0.01~1.40質量%、Tiを0~0.100質量%、Bを0~0.030質量%、Cuを0~1.00質量%、Agを0~0.50質量%、Auを0~0.50質量%、Mnを0~1.00質量%、Crを0~1.00質量%、Zrを0~0.50質量%、Hfを0~0.50質量%、Vを0~0.50質量%、Scを0~0.50質量%、Coを0~0.50質量%およびNiを0~0.50質量%含有し、残部がAlおよび不可避不純物である組成(ただし、上記Ti、B、Cu、Ag、Au、Mn、Cr、Zr、Hf、V、Sc、CoおよびNiは、いずれか1成分以上含有させてもよいし、いずれの成分とも含有させなくてもよい任意添加成分である。)を有し、
粒径が0.5~5.0μmであり、且つFeを含有する化合物の密度が、1~300個/10000μm2であることを特徴とするアルミニウム合金導体線。 - 前記化学組成が、Ti:0.001~0.100質量%およびB:0.001~0.030質量%からなる群から選択された1種または2種を含有する請求項1に記載のアルミニウム合金導体線。
- 前記化学組成が、Cu:0.01~1.00質量%、Ag:0.01~0.50質量%、Au:0.01~0.50質量%、Mn:0.01~1.00質量%、Cr:0.01~1.00質量%、Zr:0.01~0.50質量%、Hf:0.01~0.50質量%、V:0.01~0.50質量%、Sc:0.01~0.50質量%、Co:0.01~0.50質量%、およびNi:0.01~0.50質量%からなる群から選択された1種または2種以上を含有する請求項1または2に記載のアルミニウム合金導体線。
- 前記化学組成が、Ni:0.01~0.50質量%を含有する請求項1~3のいずれか1項に記載のアルミニウム合金導体線。
- Fe、Ti、B、Cu、Ag、Au、Mn、Cr、Zr、Hf、V、Sc、CoおよびNiの含有量の合計が0.01~2.00質量%である、請求項1~4のいずれか1項に記載のアルミニウム合金導体線。
- 素線の直径が0.1~1.5mmであるアルミニウム合金線である請求項1~5のいずれか1項に記載のアルミニウム合金導体線。
- 請求項6に記載のアルミニウム合金線を複数本撚り合わせて得られるアルミニウム合金撚線。
- 請求項6に記載のアルミニウム合金線または請求項7に記載のアルミニウム合金撚線の外周に被覆層を有する被覆電線。
- 請求項8に記載の被覆電線と、該被覆電線の、前記被覆層を除去した端部に装着された端子とを具えるワイヤーハーネス。
- 溶解、鋳造後に、熱間加工を経て荒引線を形成し、その後、少なくとも伸線加工、溶体化熱処理および時効熱処理の各工程を行うアルミニウム合金導体線の製造方法であって、
前記鋳造時の冷却速度を0.1~5℃/sとすること
を特徴とする、請求項1~6のいずれか1項に記載のアルミニウム合金導体線の製造方法。 - 溶解、鋳造後に、熱間加工を経て荒引線を形成し、その後、少なくとも伸線加工、溶体化熱処理および時効熱処理の各工程を行うアルミニウム合金導体線の製造方法であって、
前記鋳造時の冷却速度を5℃/sを超える値とし、且つ前記溶体化熱処理時の昇温温度を、室温~550℃の間で20℃/s以下とすることを特徴とする、請求項1~6のいずれか1項に記載のアルミニウム合金導体線の製造方法。
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JPWO2015182624A1 (ja) | 2017-04-20 |
EP3150732B1 (en) | 2021-08-18 |
KR101982913B1 (ko) | 2019-05-27 |
JP6678579B2 (ja) | 2020-04-08 |
EP3150732A1 (en) | 2017-04-05 |
CN106574329A (zh) | 2017-04-19 |
US20170069403A1 (en) | 2017-03-09 |
US9875822B2 (en) | 2018-01-23 |
KR20170009842A (ko) | 2017-01-25 |
EP3150732A4 (en) | 2018-01-03 |
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