Three-dimensional (3D) profiled woven fabrics with varying cross-sections along the component parts are needed in a number of industrial applications. One of the main advantages of the ribbon loom weaving technique is the ability to produce highly diverse structures with open or closed edges. The realization of 3D profiled woven fabrics that satisfy the requirements is directly connected to the ability to process high-performance fibers in the weft direction. The processing of high-performance yarns in the weft direction with low fiber damage will open new application areas for shuttle weaving machines. By employing modified mechanical loom elements, the variety of producible structures can be increased significantly.

A technique for manufacturing wires with imposed modulation in radius with axial wavelengths as short as 1 mm is presented. Extruded aluminum 5056 with 15 μm diameter was masked and chemically etched to reduce the radius by ∼20% in selected regions. Characterized by scanning electron microscopy, the modulation in radius is a step function with a ∼10 μm wide conical transition between thick and thin segments, with some pitting in etched regions. Techniques for mounting and aligning these wires in arrays for fast z-pinch experiments will be discussed. Axially mass-modulated wire arrays of this type will allow the study of seeded Rayleigh-Taylor instabilities in z pinches, corona formation, wire initiation with varying current density in the wire core, and correlation of perturbations between adjacent wires. This tool will support magnetohydrodynamics code validation in complex three-dimensional geometries, and perhaps x-ray pulse shaping.

No abstract