Cerium-Oxide Tungsten Wire Rods for Fine-Diameter High Strength
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Solution Overview
Problem
Conventional tungsten alloy wire rods have limitations in tensile strength, toughness, and processing difficulties, making them unsuitable for high-strength, fine-diameter applications in fields like cutting of semiconductor materials and high-temperature furnaces.
Innovation Solution
A tungsten alloy wire rod with a diameter of up to 100 μm and tensile strength greater than 3,800 MPa is developed, incorporating tungsten and cerium oxide, along with other metallic elements, using a process involving doped powder making, pressing, sintering, and cogging to enhance strength and toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional high-carbon steel wires are used to achieve high strength, then tensile strength can reach 4,500 MPa, but the diameter cannot be processed below 50 μm due to processing limits
Solution Approach 1:
The patent changes the material composition parameters by incorporating tungsten powder (97-99.9 wt%) and cerium oxide (0.1-3 wt%) to create a tungsten-based alloy wire rod that can be processed to diameters of 10-100 μm while maintaining tensile strength above 3,800 MPa, overcoming the 50 μm processing limit of high-carbon steel wires
Solution Approach 2:
The patent uses composite materials by combining tungsten powder with cerium oxide additive to create a sintered alloy wire rod with enhanced mechanical properties, achieving both high strength and fine diameters that cannot be obtained with conventional high-carbon steel wires alone
2Ease of operation
If stainless steel wire ropes are used for mechanical applications, then flexibility can be achieved, but they fail at extremely small bending radii due to bending stresses in multiple cycles
Solution Approach 1:
The patent changes the material composition by using tungsten (97-99.9 wt%) with high inherent toughness and adding cerium oxide (0.1-3 wt%) to improve ductility and reduce brittleness, enabling the wire rod to withstand repeated bending at small radii without failure while maintaining flexibility
Solution Approach 2:
The tungsten-cerium oxide composite structure combines the high strength and toughness of tungsten with the ductility-enhancing effects of cerium oxide, creating a material that resists bending fatigue and maintains reliability under cyclic flexing conditions
3Strength
If conventional tungsten wires are used to achieve high strength, then tensile strength can reach 4,000 MPa, but they have poor toughness and complex production processes making mass production difficult
Solution Approach 1:
The patent segments the production process into standardized stages: mixing tungsten powder with cerium oxide additive, pressing into billets, sintering, and drawing. This segmented approach simplifies the complex conventional tungsten wire production while enabling mass production of wire rods with tensile strength above 4,000 MPa and improved toughness
Solution Approach 2:
The patent changes the production parameters by using a cerium oxide-containing additive during the sintering process, which simplifies the overall manufacturing complexity compared to conventional tungsten wire production while achieving tensile strength greater than 4,000 MPa and improved toughness
4Length of moving object
If fine-diameter wire rods with high strength are needed for cutting applications, then wire diameter should be reduced below 100 μm, but conventional materials cannot achieve both fineness and high tensile strength greater than 3,800 MPa
Solution Approach 1:
The patent changes the material composition parameters by using high-purity tungsten powder (97-99.9 wt%) combined with cerium oxide (0.1-3 wt%) and optimizing the sintering and drawing parameters, enabling the production of wire rods with diameters of 10-100 μm that maintain tensile strength above 3,800 MPa
Solution Approach 2:
The patent employs composite materials consisting of tungsten powder reinforced with cerium oxide additive, which enhances the mechanical properties of fine-diameter wire rods, achieving both the required fineness (10-100 μm) and high tensile strength (>3,800 MPa) for cutting applications
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The alloy wire rod achieves high tensile strength, elastic ultimate strength, and improved push-pull toughness, enabling effective cutting of hard materials and durable applications in high-temperature environments, while facilitating mass production of fine-diameter wires.
Implementation Method 1
The preparation method includes doped powder making, pressing, sintering, and cogging
Implementation Method 2
the staged drying at least includes 2 temperature stages, and the 2 temperature stages are divided with 100° C. as a division line and include heat drying below 100° C. first and then heat drying above 100° C.
Data Source
AI summary
The present disclosure relates to an alloy wire rod and a preparation method and application thereof. The alloy wire rod is made of a tungsten alloy, and the tungsten alloy contains tungsten and an oxide of cerium. The alloy wire rod has a wire diameter of equal to or less than 100 μm; and the alloy wire rod has a tensile strength of greater than 3,800 MPa. The wire diameter of the alloy wire rod is equal to or less than 60 μm; the diameter of a push-pull core wire of the alloy wire rod is less than 350 μm; the elastic ultimate strength of the alloy wire rod is greater than 2,500 MPa; and the tensile strength of the alloy wire is greater than 4,200 MPa. In the present disclosure, the alloy wire rod having ultra-high strength and good toughness is obtained by doping an oxide of cerium.