Copper-Coated Alloy Wire Additive for Copper Melt
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Solution Overview
Problem
Existing methods for adding alloy elements to copper alloys face challenges such as oxidation and incomplete dissolution, particularly for elements like Ti with higher melting points, leading to unmelted residues and quality degradation in copper alloys.
Innovation Solution
A composite wire additive is formed by wrapping an alloy element core with a copper outer layer, ensuring a weight ratio that allows the additive to melt below the copper's melting point, preventing oxidation and ensuring complete dissolution in the copper melt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If alloy elements with higher melting points than copper (e.g., Ti, Mn, Ni) are added to copper melt, then the alloy strength and electrical conductivity can be improved, but the alloy elements may remain as unmelted residues without being completely dissolved
Solution Approach 1:
The invention changes the physical state parameter of the alloy element from solid to liquid by controlling the melting process. By heating the alloy element to above its melting point before adding to the copper melt, the alloy element transforms from solid particles that would remain undissolved to liquid state that can completely mix and dissolve in the copper melt, thereby improving dissolution completeness while maintaining alloy strength
Solution Approach 2:
The invention performs preliminary melting of the alloy element before it is added to the copper melt. This preliminary action of melting the alloy element separately ensures that when it is subsequently added to the copper melt, it is already in a liquid state and can immediately and completely dissolve, preventing the formation of unmelted residues and ensuring homogeneous distribution
2Quantity of substance
If alloy elements more likely to be oxidized than copper (e.g., Mg, Ti) are added to copper melt, then the desired alloy composition can be achieved, but the alloy elements are oxidized before addition and form oxides that are not dissolved and may introduce oxygen impurities
Solution Approach 1:
The invention uses an inert or reducing atmosphere (such as argon gas or hydrogen atmosphere) during the melting and addition process to prevent oxidation of the alloy element. This inert environment displaces oxygen, preventing the formation of oxides on the alloy element surface, ensuring that the full quantity of alloy element is available for dissolution in the copper melt without contamination from oxygen impurities
Solution Approach 2:
The invention performs preliminary melting of the alloy element in a controlled inert or reducing atmosphere before adding it to the copper melt. This preliminary melting action is conducted under protective conditions that prevent oxidation, ensuring that the alloy element remains in its metallic state and does not form oxides, thereby maintaining the desired alloy composition without oxygen impurity contamination
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 effectively prevents oxidation and ensures complete dissolution of alloy elements with higher melting points, enhancing the addition yield and quality of copper alloys by melting at a lower temperature than the alloy elements themselves.
Implementation Method 1
an alloy element being more likely to be oxidized than copper, e.g., Mg, etc., are oxidized just before being added to the copper melt and form an oxide
Implementation Method 2
a weight ratio of the copper in the outer layer material and the alloy element in the core is in a range of weight ratio where the alloying-element additive has a liquid phase in a temperature range of not more than a melting point of the copper
Implementation Method 3
an alloy element is added to and dissolved in the copper melt
Data Source
AI summary
An alloying-element additive for adding an alloy element to a copper melt formed by melting a base material including a copper in manufacturing a copper alloy. The alloying-element additive includes a wire-shaped or plate-shaped core including an alloy element, and an outer layer material including a copper and covering the core. A weight ratio of the copper in the outer layer material and the alloy element in the core is in a range of weight ratio where the alloying-element additive has a liquid phase in a temperature range of not more than a melting point of the copper in a copper-alloy element phase diagram.