Aluminum-Magnesium Welding Wire Composition for Breakage-Free Cold Drawing

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Solution Overview

Problem

Aluminum-magnesium alloys used for welding and mechanical support suffer from poor cold metal processing, leading to breakage during cold wire drawing processes.

Innovation Solution

Modifying the alloys by reducing iron and silicon loading levels and optionally increasing chromium, combined with the use of a grain refiner with a lower boron content, improves cold wire drawing performance by enhancing microstructure homogeneity and distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional aluminum-magnesium alloys are used for welding wire, then welding strength is achieved, but cold wire drawing performance deteriorates causing breakage

Engineering Contradiction:
Improvewelding strengthVSAvoidcold wire drawing performance
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The invention changes the chemical composition parameters of the aluminum-magnesium alloy by strictly limiting iron content to 0.05% or less and silicon content to 0.05% or less, while controlling magnesium content within 3-10%. These parameter changes resolve the contradiction by creating an alloy composition that achieves both welding strength and improved cold wire drawing performance without breakage

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The invention creates an optimized composite alloy system combining aluminum, magnesium, iron, and silicon elements in specific proportions. This composite material approach allows the alloy to exhibit both the strength required for welding applications and the ductility needed for successful cold wire drawing processing

Inventive Principle:
Principle #40Composite materials

2Strength

If iron and silicon content are increased in aluminum-magnesium alloys, then alloy strength is improved, but microstructure homogeneity deteriorates causing processing defects

Engineering Contradiction:
Improvealloy strengthVSAvoidmicrostructure homogeneity
Core Design Contradiction:
StrengthVSStability of the object's composition

Solution Approach 1:

The invention applies parameter changes by setting strict upper limits on iron (0.05% or less) and silicon (0.05% or less) content in the alloy composition. This controlled parameter approach prevents microstructure inhomogeneity while maintaining adequate alloy strength through optimized magnesium content (3-10%)

Inventive Principle:
Principle #35Parameter changes

3Shape

If conventional grain refiners with high boron content are used, then grain refinement is achieved, but cold wire drawing performance deteriorates due to microstructure inhomogeneity

Engineering Contradiction:
Improvegrain structureVSAvoidcold wire drawing performance
Core Design Contradiction:
ShapeVSEase of manufacture

Solution Approach 1:

The invention changes the grain refiner composition parameters by using low boron content (0.003-0.03%) combined with titanium (0.03-0.3%) and aluminum. This parameter modification in the grain refiner produces a homogeneous microstructure that enables successful cold wire drawing while maintaining proper grain structure for welding applications

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentEP3564402B1Welding wires formed from improved aluminum-magnesium alloys
Publication Date: 2023.08.23 GENERAL CABLE TECH CORP

AI summary

Aluminum-magnesium alloys useful as welding wire and mechanical support are disclosed. The aluminum-magnesium alloys exhibit improved cold wire drawing performance. Grain refiners and methods of forming the aluminum-magnesium alloys are further disclosed.