Evaluation of strength and electrical conductivity of copper clad-AA6063 bimetallic composite wire after annealing treatment

Traditional rigid mandrels are somewhat effective in preventing cross-sectional collapse during the bending of small-radius bimetallic composite tubes, but they are prone to inducing defects such as cracks. This study introduced five plastic mandrels of PTFE, PE, PP, POM and PVC materials, and developed the constitutive model of elastic-plastic deformable bodies that can describe their pressure-sensitive characteristics. Focusing on the bimetallic composite tube with a relative bending radius of 1.76, this research investigated the bending defect characteristics associated with plastic mandrel filling, rigid mandrel filling and non-mandrel filling, from the perspectives of springback, surface cracks, wall thinning and cross-sectional collapse. This study also evaluated the enhancement in bending quality achieved through the use of the five plastic mandrels. Results show that the springback angle of the composite tube is proportional to that of the plastic mandrel, indicating that the utilization of plastic mandrels results in an augmentation of springback angles. But the springback angle can be controlled through overbending techniques. Transverse cracks appear on the surface of the covered tube, regardless of whether a mandrel is used or the type of mandrel employed. Among these mandrels, the PTFE, PE and PP mandrels demonstrate superior performance in reducing crack distribution and wall thinning, with the PP and PE mandrels showing the best results. In contrast, mandrels with higher hardness, such as rigid, PVC and POM mandrels, are effective in preserving the tube’s cross-sectional shape and minimizing cross-sectional collapse, with the POM mandrel being the most effective. Nonetheless, these harder mandrels are less effective in reducing tube damage and wall thinning.

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Evaluation of the Mechanical and Electrical Properties of Multistage Drawn Copper-Clad Aluminum Wire After Annealing Process

Song,

Hong,

et al. 2024

Metals

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This study evaluates the mechanical and electrical properties of copper-clad aluminum (CCA) wire prepared with a total cross-section reduction of 89% through a multistage cold drawing process and subjected to annealing at various temperatures. In addition to the CCA wire, individual samples of oxygen-free copper and aluminum, drawn with a cross-sectional reduction of 50%, were annealed under the same temperature conditions to enable a comparative analysis. Tensile tests for strength and elongation measurements were conducted, while electrical conductivity was assessed through resistivity tests. SEM and EDS analyses were performed to examine the diffusion thickness and the composition of intermetallic compounds generated at the Al/Cu interface of CCA wire. The tensile strength of the CCA wire decreased and its elongation increased up to 250 °C, after which were maintained. As the annealing temperature increased, intermetallic compound layers of Al2Cu, AlCu, and Al4Cu9 were formed at the Al/Cu interface of the CCA wire, and their thickness increased. Electrical conductivity reaches a maximum at 200 °C and then continuously decreases, showing a negative linear correlation with an increase in the diffusion layer thickness of intermetallic compounds. The study confirmed that cold-drawn CCA wire achieves stable mechanical properties and maximum electrical conductivity at the optimal annealing temperature.

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Evaluation of strength and electrical conductivity of copper clad-AA6063 bimetallic composite wire after annealing treatment

Cited by 3 publications

References 45 publications

Effect of thermo-mechanical age hardening on the strength and electrical conductivity of Copper-AA6063 bimetallic wire

Effect of thermo-mechanical age hardening on the strength and electrical conductivity of Copper-AA6063 bimetallic wire

Comprehensive study on the effects of plastic mandrels on springback, crack and collapse in small radius bending of composite tubes

Evaluation of the Mechanical and Electrical Properties of Multistage Drawn Copper-Clad Aluminum Wire After Annealing Process

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