Copper Alloy Wire Dual Fibrous Structure for High Strength
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Solution Overview
Problem
Copper alloy wires with existing zirconium content have insufficient ultimate tensile strength, particularly when thinned, necessitating a higher strength solution.
Innovation Solution
A copper alloy wire with 3.0 to 7.0 atomic percent zirconium is cast into a bar-shaped ingot and drawn to a reduction of area of 99.00% or more, forming a matrix phase-composite phase fibrous structure with copper-zirconium compound phases and copper phases arranged alternately, and containing 5% to 25% amorphous phases, enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If copper alloy wires with existing zirconium content are used, then electrical conductivity is maintained, but ultimate tensile strength is insufficient particularly when thinned
Solution Approach 1:
The patent changes the zirconium content parameter from existing levels to specifically 3.0 to 7.0 atomic percent, and changes the microstructural parameters by creating a dual fibrous structure with alternating copper matrix phases and composite phases. This parameter optimization resolves the contradiction by achieving both high strength (1300 MPa or more) and reliability in thinned wires
Solution Approach 2:
The patent creates a composite phase structure consisting of copper-zirconium compound phases and copper phases arranged alternately in a fibrous configuration. This composite material approach resolves the contradiction by combining the ductility of copper matrix with the strength of copper-zirconium compounds, achieving ultimate tensile strength of 1300 MPa or more while maintaining reliability in thinned wire applications
2Strength
If zirconium content is increased to improve strength, then ultimate tensile strength increases, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes the zirconium content parameter to a specific range of 3.0 to 7.0 atomic percent, avoiding both too low (insufficient strength) and too high (excessive complexity and cost) extremes. This precise parameter control resolves the contradiction by achieving high strength while maintaining manageable manufacturing complexity
Solution Approach 2:
The patent creates local quality variations by forming alternating copper matrix phases and composite phases with copper-zirconium compounds in a fibrous structure. This local differentiation of material properties within the alloy resolves the contradiction by concentrating strengthening phases where needed while maintaining overall compositional simplicity
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 resulting copper alloy wire achieves increased ultimate tensile strength up to 1,300 MPa or more and maintains electrical conductivity, suitable for thin wires and various applications including high-performance motors and electronic devices.
Implementation Method 1
a casting step of casting the melt into an ingot having a secondary dendrite arm spacing (secondary DAS) of 10.0 μm or less
Implementation Method 2
a wire drawing step of cold-drawing the ingot to a reduction of area of 99.00% or more
Implementation Method 3
a wire drawing step of cold-drawing the ingot to a reduction of area of 99.00% or more
Implementation Method 4
subjecting an alloy containing 0.01% to 0.50% by weight of zirconium to solution treatment, drawing the alloy to the final diameter, and subjecting the wire to predetermined aging treatment. This copper alloy wire has Cu3Zr precipitated in copper matrix phases
Data Source
AI summary
The zirconium content of the alloy composition of a copper alloy wire is 3.0 to 7.0 atomic percent; and the copper alloy wire includes copper matrix phases and composite phases composed of copper-zirconium compound phases and copper phases. The copper matrix phases and the composite phases form a matrix phase-composite phase fibrous structure and are arranged alternately parallel to an axial direction as viewed in a cross-section parallel to the axial direction and including a central axis. The copper-zirconium compound phases and the copper phases in the composite phases also form a composite phase inner fibrous structure and are arranged alternately parallel to the axial direction at a phase pitch of 50 nm or less as viewed in the above cross-section. This double fibrous structure presumably makes the copper alloy wire densely fibrous to provide a strengthening mechanism similar to the rule of mixture for fiber-reinforced composite materials.