Phosphorus Copper Alloy Wire Casting Crack Prevention
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Solution Overview
Problem
The existing methods for producing copper alloy wires containing iron and phosphorus using a belt wheel-type continuous casting apparatus often result in cracking due to the difference between molten copper temperature and solidifying temperature, especially when using a graphite mold, and there is a limitation in reducing the molten copper temperature since less soluble elements like iron are added.
Innovation Solution
The method involves adding less soluble elements like iron at a high temperature and then reducing the molten copper temperature by adding phosphorus, allowing for appropriate casting with bending in the belt wheel-type continuous casting apparatus, thereby preventing cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the molten copper temperature is reduced to prevent cracking during bending in the belt wheel-type continuous casting apparatus, then casting quality is improved, but the less soluble elements like iron cannot be properly melted and added
Solution Approach 1:
The patent divides the alloying process into two separate stages: first adding less soluble elements (Fe, Ni, Co, Cr) at high temperature (1100-1200°C) in the heating furnace, then adding phosphorus at lower temperature (1050-1100°C) in the tundish. This segmentation allows each element to be added at its optimal temperature, preventing cracking while ensuring complete melting of less soluble elements.
Solution Approach 2:
The patent performs preliminary melting of less soluble elements by adding them to molten copper in the heating furnace before the copper is transferred to the tundish. This preliminary action ensures that elements with high melting points are completely dissolved before the temperature is reduced for phosphorus addition and casting, preventing cracking during subsequent bending operations.
2Stability of the object's composition
If the molten copper temperature is maintained at high level to melt less soluble elements, then element dissolution is improved, but cracking occurs during cooling and bending in the continuous casting process
Solution Approach 1:
The patent segments the alloying process into two distinct phases: high-temperature phase for adding less soluble elements (Fe, Ni, Co, Cr) to ensure complete dissolution, and low-temperature phase for adding phosphorus and performing casting to prevent cracking. This temporal and spatial segmentation resolves the contradiction between complete element dissolution and crack prevention.
Solution Approach 2:
The patent changes the temperature parameter dynamically during the casting process. The heating furnace maintains high temperature (1100-1200°C) for element dissolution, then the tundish operates at lower temperature (1050-1100°C) for phosphorus addition and casting. This parameter change strategy ensures both complete element dissolution and crack-free casting.
3Ease of manufacture
If a graphite mold is used for casting the copper alloy, then traditional casting method is maintained, but cracks occur due to the bending process in the belt wheel-type apparatus
Solution Approach 1:
The patent performs preliminary cooling of the molten copper by adding phosphorus in the tundish before the copper enters the casting mold. This preliminary action reduces the temperature difference between molten copper and the mold, preventing thermal shock and cracking during the bending process in the belt wheel-type continuous casting apparatus.
Solution Approach 2:
The patent changes the temperature parameter by cooling the molten copper before casting. Phosphorus is added at 1050-1100°C in the tundish, which is lower than the traditional casting temperature, reducing thermal stress and preventing cracks during bending in the continuous casting process while maintaining ease of manufacture.
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
This approach enables continuous production of phosphorus-containing copper alloy wires with reduced cracking and cost, ensuring high-quality wire production by maintaining the less soluble elements in a melted state and adjusting the molten copper temperature for successful casting.
Implementation Method 1
the molten copper is heated by a heating furnace to a high temperature
Implementation Method 2
after decreasing the temperature of the molten copper... the temperature of the molten copper is reduced
Implementation Method 3
the molten copper is bent during casting... cracks are likely to occur during cooling
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
Provided is a method of continuously producing a phosphorus-containing copper alloy wire by adding phosphorus or an element which is less soluble than phosphorus to molten copper. The method includes: adding an element less soluble into a heating furnace for maintaining molten copper sent from a melting furnace at a predetermined high temperature; transferring the molten copper sent from the heating furnace to a tundish; adding phosphorus to the molten copper after decreasing the temperature of the molten copper in the tundish; supplying the molten copper from the tundish to a belt wheel-type continuous casting apparatus; and rolling a cast copper material output from the belt wheel-type continuous casting apparatus, thereby continuously producing a phosphorus-containing copper alloy wire.