Repair device, system and method for repairing microcracks in metal wire using electric pulses

Abstract

The present invention relates to the technical field of crack repair in metal materials. The present invention provides a device, system, and method for repairing microcracks in metal wires using electric pulses. A pulsed current is transmitted from one side of a microcrack on a metal wire to the other side of the microcrack. The pulsed current can generate localized heating in the high-resistance dislocation at the microcrack tip to repair the microcrack. The resistance near the microcrack is relatively greater than that of the metal wire matrix, generating higher heat near the microcrack. The high heat softens the area surrounding the microcrack, thereby healing the microcrack in the metal wire and inhibiting its expansion. Furthermore, the pulsed current has a localized effect, enhancing the material properties around the crack while avoiding damage or weakening other parts of the metal wire. Furthermore, the pulsed current can place the metal wire in a low-oxygen environment during the process, preventing oxidation of the metal wire. Microcracks in small-sized materials (metal wires) can be repaired, resulting in excellent application results.

Description

Technical Field

[0001] The present invention belongs to the technical field of metal material crack repair, and in particular relates to a repair device, system and method for repairing microcracks in metal wires using electric pulses. Background Art

[0002] Microcracks on the surface of metal materials are an important factor leading to the ultimate failure of metal parts. Therefore, repairing microcracks on the metal surface is an important method to increase the service life of metal parts.

[0003] One common method for repairing surface cracks in metal materials is to weld them together. Welding equipment applies extremely high energy near the crack, softening the area surrounding it and allowing the material on either side of the crack to fuse together again. Another common method for repairing surface cracks in metal materials is to drill holes at the ends of the crack. Drilling rounds the ends of the crack, thus preventing it from expanding further.

[0004] The above two conventional methods are mainly for large-sized materials, but it is difficult to use these two methods to repair micro cracks in small-sized materials (such as metal wires). Summary of the Invention

[0005] The purpose of the present invention is to overcome at least one of the above-mentioned deficiencies of the prior art and to provide a repair device, system and method for repairing microcracks in metal wire using electric pulses, which can repair microcracks in small-sized materials (such as metal wires) and has good use effect.

[0006] The technical solution of the present invention is: a method for repairing microcracks on the surface of a metal wire using electric pulses, the repair method comprising:

[0007] Installation steps: connecting the metal wire with micro-cracks to the wiring device of the junction box, and placing the metal wire in the repair cavity of the junction box;

[0008] Hypoxia adjustment step: adjusting the environment of the repair cavity to a hypoxic environment by an adjustment device;

[0009] The electric pulse applying step: an electric pulse generating device applies electric pulses to the metal wire through a wiring device to heal the micro cracks of the metal wire.

[0010] Specifically, the installation step includes:

[0011] Open the cover of the junction box;

[0012] Connecting the two ends of the metal wire to the positive electrode wiring component and the negative electrode wiring component of the wiring component respectively;

[0013] The cover is sealed in the junction box to form the repair cavity.

[0014] Specifically, the hypoxia adjustment step includes:

[0015] Inert gas is introduced into the junction box; or, the repair cavity of the junction box is evacuated to a set vacuum degree by a vacuum pumping device.

[0016] Specifically, the current intensity of the electric pulse is 1.5A-400A.

[0017] Specifically, the frequency of the electric pulse is 100 Hz-2000 Hz; the electric pulse is a unidirectional pulse wave; and the duty cycle of the electric pulse is 5%-20%.

[0018] Specifically, the diameter of the metal wire is 20um-1000um.

[0019] The present invention also provides a repair device for repairing microcracks on the surface of a metal wire using electric pulses, comprising a junction box for connecting to an electric pulse generating device, the junction box being provided with a wiring device for connecting to a metal wire with microcracks and to the electric pulse generating device, the junction box having a repair cavity therein; the repair device also comprising an adjustment device for adjusting the repair cavity to a low-oxygen environment.

[0020] Specifically, the wiring device includes a base that can clamp the metal wire and a pressure plate, and the pressure plate is connected to the base through a locking piece; or, the wiring device is provided with two groups, and the two groups of wiring devices are positive wiring devices and negative wiring devices, respectively. The positive wiring device is connected to the positive pole of the electric pulse generating device, and the negative wiring device is connected to the negative pole of the electric pulse generating device.

[0021] Specifically, the junction box is provided with an inert gas input hole and an inert gas output hole, and the inert gas input hole is connected to an inert gas input device;

[0022] Alternatively, the junction box is provided with a vacuum hole, and the vacuum hole is connected to a vacuum device.

[0023] The present invention also provides a repair system for repairing microcracks on the surface of metal wires using electric pulses, including the above-mentioned repair device for repairing microcracks on the surface of metal wires using electric pulses, and the repair system also includes an electric pulse generating device connected to the wiring device.

[0024] The present invention provides a device, system, and method for repairing microcracks in metal wires using electric pulses. When the electric pulse generator is in operation, a pulse current is transmitted from one side of a microcrack on the metal wire to the other side of the microcrack. The pulse current can generate local heating in the high-resistance dislocation at the microcrack tip to repair the microcrack. The resistance near the microcrack is relatively greater than that of the metal wire substrate, generating higher heat near the microcrack. The high heat softens the area around the microcrack, thereby healing the microcrack in the metal wire and inhibiting its expansion. Moreover, the effect of the pulse current is localized, strengthening the material properties around the crack while avoiding damage or weakening other parts of the material. During the process, the repair cavity can be placed in a low-oxygen environment, preventing oxidation of the metal wire. This method can repair microcracks in small-sized materials (metal wires) and has excellent application effects. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 This is a front view (with a partial cross-section) of a repair device for repairing microcracks on the surface of a metal wire using electric pulses, provided by an embodiment of the present invention;

[0027] Figure 2 1 is a cross-sectional schematic diagram (from the right side) of a repair device for repairing microcracks on the surface of a metal wire using electric pulses, provided by an embodiment of the present invention;

[0028] Figure 3 1 is a top view (with partial cross-section) of a repair device for repairing microcracks on the surface of a metal wire using electric pulses, provided by an embodiment of the present invention;

[0029] Figure 4 This is a schematic cross-sectional view (from the main view direction) of a wiring device and an insulating plate in a repair device for repairing microcracks on the surface of a metal wire using electric pulses provided by an embodiment of the present invention;

[0030] Figure 5 This is a right side view of a wiring device and an insulating plate in a repair device for repairing microcracks on the surface of a metal wire using electric pulses provided by an embodiment of the present invention;

[0031] Figure 6 The figure is a top view of a wiring device and an insulating plate in a repair device for repairing microcracks on the surface of a metal wire using electric pulses, provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0032] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0033] It should be noted that the terms "setting" and "connecting" should be understood in a broad sense. For example, it can be directly setting or connecting, or it can be indirectly setting or connecting through a central component or a central structure.

[0034] In addition, if there are terms such as "longitudinal", "transverse", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicating orientation or positional relationships in the embodiments of the present invention, they are based on the orientation or positional relationships shown in the drawings or the conventional placement state or usage state, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the structure, feature, device or element referred to must have a specific orientation or positional relationship, nor must it be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0035] The various specific technical features and embodiments described in the specific implementation methods can be combined in any suitable manner unless there is any contradiction. For example, different implementation methods can be formed by combining different specific technical features / embodiments. In order to avoid unnecessary repetition, the various possible combinations of the specific technical features / embodiments in the present invention will not be described separately.

[0036] like Figures 1 to 6As shown, an embodiment of the present invention further provides a repair device for repairing microcracks on the surface of a metal wire using electric pulses, comprising a junction box 10, which is used to connect to an electric pulse generating device (not shown in the figure). The junction box 10 is provided with a wiring device 20, which is used to connect to a metal wire with microcracks. The electric pulse generating device can be connected to the wiring device 20; the junction box 10 has a repair cavity 101 for accommodating the metal wire, and the repair device also includes a regulating device (not shown in the figure) for regulating the repair cavity 101 to a low-oxygen environment, which can keep the repair cavity 101 in a low-oxygen environment to prevent oxidation of the metal wire. In a specific application, the positive and negative electrodes of the electric pulse generator are connected to the two ends of a metal wire (with microcracks on its surface) via two wiring devices 20. When the electric pulse generator is operating, a pulse current is transmitted from one side of the microcrack on the metal wire to the other side of the microcrack. The pulse current can generate local heating in the high-resistance dislocation at the microcrack tip to repair the microcrack. The resistance near the microcrack is relatively greater than that of the metal wire matrix, and higher heat can be generated near the microcrack. The high heat softens the area around the microcrack, thereby healing the microcrack in the metal wire and inhibiting its expansion. Moreover, the effect of the pulse current remains localized. While strengthening the material properties around the crack, the pulse current avoids damaging or weakening other parts of the metal wire, resulting in a good application effect.

[0037] Specifically, the wiring device 20 includes a base 21 capable of clamping a metal wire and a pressure plate 22. At least one of the base 21 and the pressure plate 22 is a metal component. In this embodiment, both the base 21 and the pressure plate 22 are metal components and can be made of steel, copper, aluminum, or other materials. The pressure plate 22 can be connected to the base 21 via a locking member 23 to clamp the end of the metal wire.

[0038] Specifically, two groups of wiring components 20 are provided, namely a positive wiring component 20a and a negative wiring component 20b. The positive wiring component 20a and the negative wiring component 20b can be spaced apart along the length of the junction box 10. The positive wiring component 20a is connected to the positive electrode of the electric pulse generator, and the negative wiring component 20b is connected to the negative electrode of the electric pulse generator.

[0039] Specifically, the positive terminal connection member 20a and the negative terminal connection member 20b can be fixed within the junction box 10, resulting in a simple structure. Alternatively, to accommodate the repair of metal wires of varying lengths, the positive terminal connection member 20a and / or the negative terminal connection member 20b can be disposed within the junction box 10 via a sliding connection structure. This allows the distance between the positive terminal connection member 20a and the negative terminal connection member 20b to be adjusted to accommodate metal wires of varying lengths.

[0040] Specifically, the positive and negative electrode wiring members 20a and 20b can be removed from the junction box 10, and a metal wire can be connected to the positive and negative electrode wiring members 20a and 20b outside the junction box 10. The metal wire can then be placed inside the junction box 10. Alternatively, the positive and negative electrode wiring members 20a and 20b can be pre-fixed inside the junction box 10, and the metal wire can be connected to the positive and negative electrode wiring members 20a and 20b inside the junction box 10.

[0041] Specifically, the sliding connection structure may include a linear guide rail, to which the base 21 of the positive electrode wiring component 20a or the base 21 of the negative electrode wiring component 20b is slidably connected. The linear guide rail may be an insulated guide rail. In specific applications, the linear guide rail may also be a metal guide rail. The metal guide rails may be provided in two sets, separated by an insulating sheet, and used to connect the base 21 of the positive electrode wiring component 20a and the base 21 of the negative electrode wiring component 20b, respectively.

[0042] Specifically, the junction box 10 is provided with a positive electrode threading hole 102 and a negative electrode threading hole (not shown in the figure). The positive electrode of the electric pulse generating device is connected to the positive electrode wiring component 20a via a positive electrode cable, and the positive electrode cable passes through the positive electrode threading hole 102; the negative electrode of the electric pulse generating device is connected to the negative electrode wiring component 20b via a negative electrode cable, and the negative electrode cable passes through the negative electrode threading hole. Sealing structures (such as rubber plugs, rubber sleeves, etc.) can be provided at the positive electrode threading hole 102 and the negative electrode threading hole to prevent air leakage at the positive electrode threading hole 102 and the negative electrode threading hole.

[0043] Specifically, the junction box 10 is provided with an inert gas input hole 121 and an inert gas output hole 122. The inert gas input hole 121 can be connected to an inert gas input device through a connecting pipe. The inert gas input device can be a compressed gas tank, etc., and the inert gas can be argon, etc.; an inert gas output pipe can be provided at the inert gas output hole 122, and a one-way valve can be provided at the inert gas output hole 122 or the inert gas output pipe, so that the gas in the junction box 10 can only be discharged in one direction from the inert gas output hole 122. In specific applications, even if there is a leak at the positive electrode threading hole 102 and the negative electrode threading hole, etc., the repair cavity 101 can maintain a low oxygen environment because the inert gas fills the repair cavity 101 to form a positive pressure.

[0044] Specifically, the junction box 10 may be optionally provided with a vacuum hole, and the vacuum hole may be connected to a vacuum device. By vacuuming, the repair cavity 101 in the junction box 10 may also maintain a low oxygen environment.

[0045] Specifically, the junction box 10 includes a box body 110 and a cover body 120. An opening is provided on one side of the box body 110. The cover body 120 is connected to the box body 110 through fasteners (screws or snaps, etc.) and closes the opening. A seal 130 is provided between the box body 110 and the cover body 120. The seal 130 can be a rubber ring, etc.

[0046] Specifically, the inert gas input hole 121 is arranged at one end of the junction box 10 and close to a corner of the bottom of the junction box 10, and the inert gas output hole 122 is arranged at the other end of the junction box 10 and close to the top of the junction box 10 away from the inert gas input hole 121. In this embodiment, the junction box 10 has a rectangular shape, and the inert gas input hole 121 and the inert gas output hole 122 are arranged relative to the diagonal line of the junction box 10 to facilitate the exhaust of air in the junction box 10 as much as possible and quickly form a low-oxygen environment.

[0047] Specifically, the locking member 23 is a bolt that passes through the pressure plate 22 and is threadedly connected to the base 21. A gasket 24 is provided around the bolt. The positive cable of the electric pulse generator is connected to the locking member 23 of the positive terminal component 20a, and the negative cable of the electric pulse generator is connected to the locking member 23 of the negative terminal component 20b. The locking member 23 can be a hexagon socket head bolt, etc. The positive and negative cables can be sandwiched between the gasket 24 and the pressure plate 22 and compressed by the locking member 23.

[0048] In specific applications, a positive terminal block can be provided at one end of the junction box 10, and a negative terminal block can be provided at the other end. The positive cable of the electric pulse generator is connected to the positive terminal block, and the negative cable of the electric pulse generator is connected to the negative terminal block, employing an external wiring structure. The positive terminal block passes through the junction box 10 and is connected to the positive terminal block 20a via a wire. The negative terminal block passes through the junction box 10 and is connected to the negative terminal block 20b via another wire.

[0049] Specifically, an insulating pad 25 may be provided in the junction box 10, and the positive electrode wiring component 20a and the negative electrode wiring component 20b are provided on the insulating pad 25 to form a clamping device. The clamping device can be removed from the junction box 10 to facilitate wiring, or the clamping device can be fixed in the junction box 10.

[0050] In specific applications, the junction box 10 may also be secured with multiple winding posts, allowing metal wire to be wound around different winding posts, enabling reliable installation of longer wires. The multiple winding posts may be arranged in a matrix. Alternatively, the multiple winding posts may be arranged in multiple staggered rows to accommodate installation of wires of varying lengths. The winding posts may be ceramic or plastic and secured to the insulating backing plate 25.

[0051] Specifically, the junction box 10 may be made of a metal body, which has a high structural strength. The inner side of the junction box 10 may be provided with an insulating coating. The outer side of the junction box 10 may also be provided with an insulating coating, which has a good reliability.

[0052] In specific applications, one, two, or more metal wires can be clamped between the base 21 and the pressing plate 22, and one, two, or more metal wires can be repaired simultaneously. When two or more metal wires are clamped between the base 21 and the pressing plate 22, the metal wires do not contact each other.

[0053] In a specific application, the edges of the facing surfaces of the base 21 and the pressing plate 22 may be provided with arc chamfers to prevent the metal wire from being pinched off.

[0054] In specific applications, the wiring device 20 may also be a spring metal clip, a screw-type terminal connector, or the like.

[0055] In specific applications, the junction box 10 serves as a sealed housing, and the cover 120 can be a metal cover or a plastic cover. In specific applications, the cover 120 can also be a transparent cover, through which an operator can observe the shape of the metal wire inside. The transparent cover can be provided with a convex lens structure, which acts like a magnifying glass, so that the operator can better observe the metal wire.

[0056] In specific applications, a temperature detection device can be optionally provided in the junction box 10 to detect the surface temperature of the metal wire. The temperature detection device can be a non-contact temperature sensor. The temperature sensor can be connected to the electric pulse generator in a wired or wireless manner. When the temperature of the metal wire is too high, the electric pulse generator can be powered off or reduce the current intensity, frequency, etc. By providing a temperature sensor to detect the temperature of the metal wire, it can also be ensured that the input of the inert gas is turned off after the temperature of the metal wire drops to a set range. In specific applications, the temperature detection device can also be omitted. The electric pulse generator (power supply) applies electric pulses to the metal wire through the junction device 20. After the microcracks in the metal wire are healed, the electric pulse generator (power supply) can be turned off first, and then the input of the inert gas can be turned off after a set period of time.

[0057] In specific applications, the use process of the repair device can be referred to as follows: the ends of the metal wire are clamped between the base 21 and the pressure plate 22 corresponding to the positive wiring component 20a and the negative wiring component 20b respectively, and the base 21 and the pressure plate 22 are connected using the hexagon socket bolt (locking part 23) and the gasket 24. The two ends of the metal wire can be fixed to the positive wiring component 20a and the negative wiring component 20b respectively. After the cover 120 of the junction box 10 is opened, the clamping device can be placed into the box body 110 from the opening of the box body 110, and the positive and negative poles of the electric pulse generating device (power supply) are respectively connected to the positive wiring component 20a and the negative wiring component 20b, that is, the positive and negative cables of the electric pulse generating device (power supply) are respectively passed through the positive wiring hole 102 and the negative wiring hole, and the positive and negative poles of the electric pulse generating device (power supply) are respectively connected to the hexagon socket bolts of the positive wiring component 20a and the negative wiring component 20b. The opening of the box body 110 is sealed by using a seal 130 and a cover 120. The inert gas input hole 121 at the bottom of one end of the junction box 10 is connected to the pipeline for the incoming argon gas, and the inert gas output hole 122 at the upper part of the other end of the junction box 10 is connected to the pipeline for the exhaust of the argon gas. The oxygen content in the junction box 10 is ensured to be at a low level by continuously introducing argon gas. Before the electric pulse generating device (power supply) is powered on, the pipeline for inputting argon gas is first opened for a period of time; then the electric pulse generating device (power supply) with the parameters set in advance is turned on, and the electric pulse generating device applies electric pulses to the metal wire material to heal the microcracks of the metal wire material. After the treatment is completed, the electric pulse generating device (power supply) is first turned off, and then the pipeline for inputting argon gas is closed.

[0058] An embodiment of the present invention also provides a repair system for repairing microcracks on the surface of a metal wire using electric pulses, comprising the aforementioned repair device and an electric pulse generator connected to the wiring device. When the electric pulse generator is in operation, a pulse current is transmitted from one side of a microcrack on the metal wire to the other side of the microcrack. The pulse current can generate localized heating in the high-resistance dislocation at the microcrack tip to repair the microcrack. The resistance near the microcrack is relatively greater than that of the metal wire matrix, generating higher heat near the microcrack. The high heat softens the area surrounding the microcrack, thereby healing the microcrack in the metal wire and inhibiting its expansion. Furthermore, the effect of the pulse current remains localized, enhancing the material properties around the crack while avoiding damage or weakening other parts of the material, resulting in excellent application results.

[0059] The present invention also provides a method for repairing microcracks on the surface of a metal wire using electric pulses. The method can use the above-mentioned repair device or the above-mentioned repair system, and includes the following steps:

[0060] Installation step: connecting the metal wire with micro-cracks to the wiring device 20 of the junction box 10 , and placing the metal wire in the repair cavity 101 of the junction box 10 .

[0061] Low oxygen adjustment step: The environment of the repair chamber 101 is adjusted to a low oxygen environment through an adjustment device to overcome the problem that the metal wire is easily oxidized. Placing the metal wire in an isolated repair chamber 101 can also prevent hidden dangers such as accidental electric shock, leakage, and short circuit, and has good safety and reliability.

[0062] Electric pulse application step: The electric pulse generating device (power source) applies electric pulses to the metal wire through the wiring device 20 to heal the microcracks in the metal wire. In a specific application, the positive and negative poles of the electric pulse generating device are respectively connected to the two ends of the metal wire (with microcracks on the surface) through two wiring devices 20. When the electric pulse generating device is working, the pulse current is transmitted from one side of the microcrack on the metal wire to the other side of the microcrack. The pulse current can generate local heating in the high-resistance dislocation at the tip of the microcrack to repair the microcrack. The resistance near the microcrack is relatively larger than the resistance of the metal wire matrix, and higher heat can be generated near the microcrack. The high heat softens the area around the microcrack, thereby healing the microcracks in the metal wire and inhibiting the expansion of the microcrack. Moreover, the effect of the pulse current is still local. While strengthening the material properties around the crack, the pulse current avoids damaging or weakening other parts of the material, resulting in a good application effect.

[0063] Specifically, the installation step includes the following steps:

[0064] Open the cover 120 of the junction box 10;

[0065] The two ends of the metal wire are connected to the positive wiring component 20a and the negative wiring component 20b of the wiring component 20 respectively; the positive wiring component 20a and the negative wiring component 20b are connected to the positive and negative electrodes of the electric pulse generating device respectively, so that the electric pulse generated by the electric pulse generating device can flow through the metal wire;

[0066] The cover 120 is encapsulated in the junction box 10 to form the repair cavity 101 . The repair cavity 101 can be a closed inner cavity, and during the electric pulse applying step, external oxygen can be isolated from entering the repair cavity 101 .

[0067] Specifically, the hypoxia adjustment step includes: introducing an inert gas into the junction box 10 , or evacuating the repair cavity 101 of the junction box 10 to a set vacuum level by a vacuum pumping device.

[0068] In a specific application, before the electric pulse generating device is turned on, an inert gas is first introduced into the junction box 10. After the inert gas is introduced for a set period of time, the electric pulse generating device is started to perform the electric pulse applying step. After the electric pulse applying step, after a set period of time, when the temperature of the metal wire drops, the introduction of the inert gas into the junction box 10 is stopped. The inert gas may be argon, etc. The junction box 10 may be connected to an inert gas input device (which may be an argon compression tank, etc.). The inert gas may fill the interior of the junction box 10 with inert gas and maintain a positive pressure. The junction box 10 may be provided with an inert gas output pipe. The inert gas output pipe may be provided with a one-way valve to prevent external air from entering the repair cavity 101 from the inert gas output pipe.

[0069] Specifically, the electric pulse is a unidirectional pulse wave. Pulsed electricity can provide high-intensity current in a very short time, resulting in localized heating within the material while keeping the substrate temperature relatively low. In contrast, direct current provides a relatively low current density throughout the entire process, thus failing to produce sufficient localized heating. The waveform, frequency, amplitude, and width of the unidirectional pulse wave can be adjusted and controlled by controlling the current pulse parameters, thereby enabling more precise control of processing parameters to meet specific processing requirements.

[0070] Specifically, the current intensity of the electric pulse is 1.5A-400A, and the appropriate current intensity can be set according to the diameter of the metal wire and the degree of microcracks. For example, the current intensity of the electric pulse can be 10A, 20A, 50A, 80A, 100A, 120A, 150A, 180A, 200A, 220A, 250A, 280A, 300A, 320A, 350A, 380A, and can also be set to a current of 400A or more as needed, such as 420A, 450A, 480A, 500A, etc.

[0071] Specifically, the frequency of the electric pulse is 100Hz-2000Hz, and the appropriate frequency can be set as needed, such as 200Hz, 500Hz, 800Hz, 1000Hz, 1200Hz, 1400Hz, 1600Hz, 1800Hz, etc. When the diameter of the metal wire and other parameters are fixed, the local temperature at the microcrack can be increased by increasing the frequency of the electric pulse. Lower frequency pulse electricity may result in a longer current interruption time, giving the temperature more time to conduct into the metal wire matrix. Higher electric pulses can help to concentrate heat faster and more intensively near the crack area, producing a more localized heating effect. For small-diameter wires with small crack sizes, parameters with a relatively low frequency range can be selected; for large-diameter wires with large crack sizes, parameters with a relatively high frequency range can be selected.

[0072] Specifically, the duty cycle of the electric pulse is 5%-20%. A high duty cycle means the high level lasts longer, providing more time to heat the cracked area, which helps heal microcracks. For large-diameter wires with large cracks, a relatively high duty cycle parameter can be selected.

[0073] Specifically, the diameter of the metal wire may be 20 μm-1000 μm, and the length of the microcracks of the metal wire may be less than 1500 nm.

[0074] The controllable parameters of the electric pulse generating device may include voltage parameters, current parameters, frequency parameters, pulse duty cycle parameters, power-on time parameters, etc.

[0075] The energy output of the pulse current of the electric pulse generating device to the metal wire can be expressed by the following formula:

[0076]

[0077] in:

[0078] Q: Energy output per unit time (J);

[0079] I p : Peak current of unidirectional pulse wave (A);

[0080] R: resistance of metal wire (Ω);

[0081] f: pulse frequency (Hz);

[0082] t: width of a single pulse (s).

[0083] The repair of microcracks on the surface of the metal wire is achieved through local Joule heating, which is related to the energy input. According to the above formula, when other parameters are constant, increasing the current, increasing the frequency, and increasing the power-on time can make the heat output of the power supply higher. Without damaging the metal wire matrix, the local heat is increased, which is more conducive to the repair of cracks. In this embodiment, by inputting inert gas into the junction box 10 to form a low-oxygen environment, the metal wire can withstand higher temperatures without being oxidized, that is, the metal wire can withstand larger currents, higher electric pulse frequencies, and longer power-on times, and the repair effect of microcracks on the surface of the metal wire is better.

[0084] In a specific application, as the first experimental example, a metal wire with a diameter of 50 μm was repaired. The electric pulse generator used the following current parameters: peak current of 1.75A, frequency of 300 Hz, duty cycle of 10%, and power-on time of 5 minutes. After the repair was completed, the metal wire was removed and observed under an electron microscope. Microcracks less than 1 μm in size on the wire surface disappeared.

[0085] In a second experimental example, a metal wire with a diameter of 500 μm was repaired. The electric pulse generator used the following current parameters: peak current of 200A, frequency of 300 Hz, duty cycle of 10%, and power-on time of 5 minutes. After the repair was completed, the wire was removed and observed under an electron microscope. Microcracks smaller than 1.5 μm on the wire surface disappeared.

[0086] As a third experimental example, a metal wire with a diameter of 250 μm was repaired. The current parameters used by the electric pulse generator were: peak current 100A, frequency 1000 Hz, duty cycle 10%, and power-on time 5 minutes. After the repair was completed, the metal wire was removed and observed under an electron microscope. Microcracks smaller than 1 μm on the wire surface were found to have disappeared.

[0087] As a fourth experimental example, a metal wire with a diameter of 250 μm was used. The current parameters used by the electric pulse generator were: peak current of 100A, frequency of 2000 Hz, duty cycle of 10%, and power-on time of 5 minutes. After the repair was completed, the metal wire was removed and observed under an electron microscope. Microcracks smaller than 1.5 μm on the surface of the wire were found to have disappeared.

[0088] As a fifth experimental example, a metal wire with a diameter of 500 μm was used. The current parameters used by the electric pulse generator were: peak current 200A, frequency 300 Hz, duty cycle 10%, and power-on time 5 minutes. After the repair was completed, the metal wire was removed and observed under an electron microscope. Microcracks smaller than 1 μm on the wire surface were found to have disappeared.

[0089] As a sixth experimental example, a metal wire with a diameter of 500 μm was used. The current parameters used by the electric pulse generator were: peak current 200A, frequency 300 Hz, duty cycle 20%, and power-on time 5 minutes. After the repair was completed, the metal wire was removed and observed under an electron microscope. Microcracks below 1.5 μm on the surface of the wire were found to have disappeared.

[0090] Embodiments of the present invention provide a device, system, and method for repairing microcracks in metal wire using electric pulses. The positive and negative electrodes of the electric pulse generator are connected to the ends of a metal wire (having microcracks on its surface). When the pulse current of the electric pulse generator is transmitted from one side of the crack in the metal wire to the other, the pulse current can generate local heating in the high-resistance dislocation at the microcrack tip to repair the microcrack. The resistance near the microcrack is relatively greater than that of the metal wire matrix, generating more heat near the microcrack. The high heat softens the area around the microcrack, achieving the effect of healing the microcrack, thereby healing the microcrack in the metal wire and inhibiting its expansion. Furthermore, the effect of the pulse current remains localized, strengthening the material properties around the crack while avoiding damage or weakening other parts of the material, resulting in excellent application results.

[0091] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for repairing microcracks on the surface of a metal wire using electric pulses, characterized in that: The repair method comprises: an installation step of connecting a metal wire with microcracks to a wiring device of a junction box, and positioning the metal wire in a repair cavity of the junction box; a hypoxia adjustment step of adjusting the environment of the repair cavity to a hypoxic environment by means of an adjustment device; an electric pulse application step of applying an electric pulse to the metal wire via the wiring device, wherein the pulse current generates local heating in a high-resistance dislocation at the tip of the microcrack, wherein the resistance near the microcrack is relatively greater than the resistance of the metal wire matrix, and thus higher heat can be generated near the microcrack, and the high heat softens the area around the microcrack, thereby healing the microcrack of the metal wire; the current intensity of the electric pulse is 1.75A-400A; the frequency of the electric pulse is 100Hz-2000Hz; the electric pulse is a unidirectional pulse wave; and the duty cycle of the electric pulse is 5%-20%. The installation steps include: opening the cover of the junction box; connecting the two ends of the metal wire to the positive and negative wiring components of the wiring components, respectively; enclosing the cover in the junction box to form the repair cavity; fixing the positive and negative wiring components in the junction box, or placing the positive and / or negative wiring components in the junction box via a sliding connection structure, with the distance between the positive and negative wiring components being adjustable; The junction box is provided with an inert gas input hole and an inert gas output hole; the hypoxia adjustment step includes: introducing inert gas into the junction box; before the electric pulse generating device is powered on, the pipeline for inputting argon gas is first opened for a period of time, an inert gas output pipe is provided at the inert gas output hole, and a one-way valve is provided at the inert gas output hole or the inert gas output pipe. The gas in the junction box can only be discharged in one direction from the inert gas output hole, and the inert gas fills the repair cavity to form a positive pressure, so that the repair cavity maintains a hypoxic environment; then the electric pulse generating device with parameters set in advance is turned on, and the electric pulse generating device applies electric pulses to the metal wire to heal the microcracks of the metal wire. After the treatment is completed, the electric pulse generating device is first closed, and then the pipeline for inputting argon gas is closed.

2. The method for repairing microcracks on the surface of a metal wire using electric pulses according to claim 1, wherein: The diameter of the metal wire is 20um-1000um.

3. A repair device for repairing micro cracks on the surface of a metal wire using electric pulses, characterized in that: The device comprises a junction box for connecting to an electric pulse generator, the junction box being provided with a wiring device for connecting to a metal wire and the electric pulse generator, and a repair cavity therein; the repair device further comprising an adjustment device for adjusting the repair cavity to a hypoxic environment; the electric pulse generator generates electric pulses with a current intensity of 1.75A-400A; the frequency of the electric pulses is 100Hz-2000Hz; the electric pulses are unidirectional pulse waves; and the duty cycle of the electric pulses is 5%-20%. The wiring components are provided in two groups, the two groups of wiring components are respectively positive wiring components and negative wiring components, and the positive wiring components and the negative wiring components are spaced apart along the length direction of the junction box; The positive electrode wiring component and the negative electrode wiring component are fixed in the junction box, or the positive electrode wiring component and / or the negative electrode wiring component are arranged in the junction box via a sliding connection structure, and the distance between the positive electrode wiring component and the negative electrode wiring component is adjustable; The junction box is provided with an inert gas input hole and an inert gas output hole. The outer shape of the junction box is a rectangular parallelepiped, and the inert gas input hole and the inert gas output hole are arranged diagonally relative to the junction box. Before the electric pulse generating device is powered on, the pipeline for inputting argon gas is first opened for a period of time. An inert gas output pipe is provided at the inert gas output hole. A one-way valve is provided at the inert gas output hole or the inert gas output pipe. The inert gas fills the repair cavity to form a positive pressure, so that the repair cavity maintains a low-oxygen environment. Then, the electric pulse generating device with parameters set in advance is turned on. The electric pulse generating device applies electric pulses to the metal wire to heal the microcracks of the metal wire. After the treatment is completed, the electric pulse generating device is first closed, and then the pipeline for inputting argon gas is closed.

4. The device for repairing micro cracks on the surface of a metal wire using electric pulses as claimed in claim 3, characterized in that: The wiring device includes a base that can clamp metal wire and a pressure plate, and the pressure plate is connected to the base through a locking piece; the positive wiring device is connected to the positive pole of the electric pulse generating device, and the negative wiring device is connected to the negative pole of the electric pulse generating device.

5. A repair system for repairing micro cracks on the surface of a metal wire using electric pulses, characterized in that: The device comprises the repairing device for repairing micro cracks on the surface of a metal wire using electric pulses as claimed in claim 3 or 4, wherein the repairing system further comprises an electric pulse generating device connected to the wiring device.

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