Copper Alloy Wire Composition for Strength-Elongation Balance
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Solution Overview
Problem
There is a demand for a copper alloy wire that balances strength and elongation effectively, while existing copper alloy wires face challenges in maintaining high strength with adequate elongation and productivity due to uneven distribution of compounds during manufacturing, leading to wire breakage and reduced productivity.
Innovation Solution
A copper alloy wire with a composition of 0.05% to 1.6% iron, 0.01% to 0.7% phosphorus, and 0.05% to 0.7% tin, with a crystal grain size difference of 1.0 μm or less, manufactured through continuous casting, conform extrusion, wire drawing, and heat treatment at 350°C or more, achieving a balance of strength, elongation, and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the copper alloy wire is made with higher strength through specific composition and processing, then tensile strength is improved, but elongation at break deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition parameters (Fe: 0.05-1.6%, P: 0.01-0.7%, Sn: 0.05-0.7%) and processing parameters (conform extrusion reduction of area ≥50%, extrusion temperature ≥350°C, heat treatment temperature ≥350°C) to achieve a balance between tensile strength and elongation, resolving the contradiction between strength improvement and elongation deterioration
Solution Approach 2:
The patent applies local quality by creating a uniform crystal grain structure throughout the wire cross-section with controlled grain size difference (≤1.0 μm), ensuring consistent mechanical properties and preventing localized weak points that would reduce overall elongation while maintaining high strength
2Ease of manufacture
If conventional manufacturing processes are used, then production is simpler, but wire breakage increases and productivity decreases
Solution Approach 1:
The patent applies preliminary action by performing conform extrusion with ≥50% reduction of area before wire drawing to pre-distribute compounds uniformly and refine the crystal structure. This preliminary structural preparation prevents wire breakage during subsequent drawing operations and eliminates the need for complex intermediate treatments, thereby improving productivity while maintaining manufacturing simplicity
Solution Approach 2:
The patent utilizes phase transitions by controlling the material through phase transformations during conform extrusion (≥350°C) and heat treatment (≥350°C). These controlled phase transitions enable uniform compound distribution and crystal grain refinement, preventing wire breakage and improving productivity without requiring complex manufacturing processes
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 copper alloy wire achieves a good balance of high tensile strength, elongation, and conductivity, with reduced wire breakage and improved manufacturability, enabling high productivity and suitable use in covered wires and stranded conductors.
Implementation Method 1
a first step of manufacturing a casting material formed of a copper alloy by continuous casting
Implementation Method 2
a second step of subjecting the casting material to conform extrusion to manufacture a linear extruded material
Implementation Method 3
a third step of subjecting the extruded material to wire drawing to manufacture a drawn wire material
Implementation Method 4
a fourth step of subjecting the drawn wire material to heat treatment to manufacture a heat-treated material
Implementation Method 5
subjecting the drawn wire material to heat treatment at 350° C. or more
Data Source
AI summary
Disclosed herein is a copper alloy wire being a wire rod formed of a copper alloy and having a tensile strength of 400 MPa or more, an elongation at break of 5% or more, a conductivity of 60% IACS or more, and a wire diameter of 0.5 mm or less, wherein the copper alloy has a composition containing 0.05% by mass or more and 1.6% by mass or less of iron, 0.01% by mass or more and 0.7% by mass or less of phosphorus, and 0.05% by mass or more and 0.7% by mass or less of tin with the balance being copper and unavoidable impurities, the copper alloy has a structure containing crystals, and a crystal grain size difference determined as a difference between a maximum crystal grain size and a minimum crystal grain size in a cross-section is 1.0 μm or less.