Microstructure and mechanical properties characterization of architectured copper aluminum composites manufactured by cold-drawing

Keller, Clément; Moisy, F.; Nguyen, Nga; Eve, S.; Dashti, Alireza; Vieille, B.; Guillet, Alain; Sauvage, Xavier; Hug, Éric

doi:10.1016/j.matchar.2020.110824

Cited by 24 publications

(10 citation statements)

References 42 publications

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“…For the CCA wires, the aluminum volume fraction is about 50% whereas values of 25% and 32% are associated to the ACCA 61 and ACCA 22 , respectively. Details about the manufacturing process can be found in the two previous articles [ 15 , 17 ]. The corresponding cross-sections of the three microstructures, imaged via optical microscopy, are illustrated in Figure 1 .…”

Section: Materials and Experimental Proceduresmentioning

confidence: 99%

“…Indeed, the exact development of residual stresses in the architectured composite wires is not straightforward. The simulations were applied towards identifying the potential source of the strengthening effect observed in the architectured Cu-Al wires (reported by [ 17 ]).…”

Section: Numerical Proceduresmentioning

confidence: 99%

“…The elastic-plastic behavior of the aforementioned ACCA sample (≈25% Al) of a gauge length of 25 mm was also studied by straining it up to one percent. The use of CCA input for simulating the tensile testing of ACCA is acceptable to a fairly good approximation due to stress saturation in both Al and Cu at high strains (see [ 17 ]). Chinh et al [ 26 ] also report stress saturation in highly strained Al.…”

Section: Numerical Proceduresmentioning

confidence: 99%

“…Architectured copper-clad aluminum wire (ACCA or multi-Al-fiber Al-Cu composite wire), however, has proved to be superior in a variety of areas offering improved thermal diffusivity [ 16 ] and proper electrical conductivity at both low and high frequencies. Moreover, in a previous article, the authors have reported that ACCA samples exhibit rather complex mechanical behavior in both as-drawn and heat-treated states (see [ 17 ] for more details).…”

Section: Introductionmentioning

confidence: 99%

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Experimental and Finite Element Analysis of the Tensile Behavior of Architectured Cu-Al Composite Wires

et al. 2021

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The present study investigates, experimentally and numerically, the tensile behavior of copper-clad aluminum composite wires. Two fiber-matrix configurations, the conventional Al-core/Cu-case and a so-called architectured wire with a continuous copper network across the cross-section, were considered. Two different fiber arrangements with 61 or 22 aluminum fibers were employed for the architectured samples. Experimentally, tensile tests on the two types of composites show that the flow stress of architectured configurations is markedly higher than that of the linear rule of mixtures’ prediction. Transverse stress components and processing-induced residual stresses are then studied via numerical simulations to assess their potential effect on this enhanced strength. A set of elastic-domain and elastoplastic simulations were performed to account for the influence of Young’s modulus and volume fraction of each phase on the magnitude of transverse stresses and how theses stresses contribute to the axial stress-strain behavior. Besides, residual stress fields of different magnitude with literature-based distributions expected for cold-drawn wires were defined. The findings suggest that the improved yield strength of architectured Cu-Al wires cannot be attributed to the weak transverse stresses developed during tensile testing, while there are compelling implications regarding the strengthening effect originating from the residual stress profile. Finally, the results are discussed and concluded with a focus on the role of architecture and residual stresses.

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Section: Materials and Experimental Proceduresmentioning

confidence: 99%

Section: Numerical Proceduresmentioning

confidence: 99%

Section: Numerical Proceduresmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Experimental and Finite Element Analysis of the Tensile Behavior of Architectured Cu-Al Composite Wires

et al. 2021

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“…% leads to the formation of first stable −CuAl2, and then at a copper concentration of 50 аt. % -CuAl and -Cu11Al9, at 60 at.% the existence of -Cu3Al2, at 70 аt.% --Cu9Al4 is possible [6][7][8].…”

Section: Introductionmentioning

confidence: 99%

Comprehensive study of changes in the phase composition of copper-aluminum conductors during heating

Pariyskaya

Mokryak

Pyankova³

2022

J. Phys.: Conf. Ser.

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Changes in the microstructural characteristics and phase composition of copper plated conductors CCA-20 in the temperature range of 100-600 °C were studied by XRD and SEM methods. Fiducial markers for determining the temperature of exposure to conductors are the appearance of the Al2Cu phase at the phase boundary of the conductor at temperatures above 300 °C and the existence of the Al4Cu9 phase in the temperature range of 300-400 °C.

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Impact of hardening law on the FEM prediction of residual stresses in copper-clad aluminum wires

Dashti

Keller

Vieille

et al. 2023

Int J Adv Manuf Technol

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Near-surface axial tensile residual stresses (from manufacturing) are reportedly detrimental to the yield strength of cold-drawn wires. Therefore, a reliable evaluation of their magnitude is necessary. The size and geometry of electrical wires can pose challenges for experimental measurement of those residual stresses. For that reason, the nite element analysis can prove useful. However, great care must be taken with the right choice of strain hardening law for a sound assessment of residual stresses. Given the complex loading condition during cold drawing, cyclic loading arises through the wire cross section even in single-pass drawing. As a result, it is of crucial importance to account for associated backstresses. The current study makes a comparison between two different hardening laws' prediction of axial residual stress pro les in numerically cold-drawn Cu-Al composite wires of various Al volume fractions. The impact of die geometry on this prediction was also examined for a 25%Al-wire. To that end, a combined isotropic-kinematic law and a pure isotropic constitutive equation were considered. The results imply a possible overestimation of residual stresses by the pure isotropic model at relatively low Al volume fractions. The difference between the maximum magnitudes of tensile or compressive residual stresses (predicted by the two models) could be as large as about 100 MPa (larger than the yield strength of the starting materials). Furthermore, the tooling geometry minimally affects the prediction of the hardening models. In conclusion, backstresses are not to be overlooked for accurate estimations of drawing residual stresses at low Al volume fractions.

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Microstructure and mechanical properties characterization of architectured copper aluminum composites manufactured by cold-drawing

Cited by 24 publications

References 42 publications

Experimental and Finite Element Analysis of the Tensile Behavior of Architectured Cu-Al Composite Wires

Experimental and Finite Element Analysis of the Tensile Behavior of Architectured Cu-Al Composite Wires

Comprehensive study of changes in the phase composition of copper-aluminum conductors during heating

Impact of hardening law on the FEM prediction of residual stresses in copper-clad aluminum wires

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