Copper MMC Billet Layout for Uniform Graphene Extrusion
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Solution Overview
Problem
Existing methods for producing enhanced conductive Metal Matrix Composites (MMCs) face challenges in achieving consistent and homogeneous properties, particularly in copper-based MMCs with graphene additives, which are crucial for industrial-scale production.
Innovation Solution
The development of novel billet preparation methods that enhance the distribution of non-metallic materials within the billet, ensuring more consistent and predictable solid phase extruded materials. These methods involve specific configurations of wires, powders, and coatings to improve the homogeneity of the MMCs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional extrusion methods are used to produce copper-based MMCs with graphene additives, then production can proceed with existing equipment, but the resulting material shows inconsistent and non-homogeneous properties
Solution Approach 1:
The billet is divided into multiple segments or layers, each containing graphene additives distributed at specific concentrations. This segmentation allows for controlled integration of non-metallic materials throughout the copper matrix, ensuring homogeneous distribution and consistent material properties after extrusion.
Solution Approach 2:
Graphene additives are pre-distributed and integrated into the copper billet before the extrusion process begins. This preliminary action ensures that the non-metallic materials are already homogeneously distributed in the matrix, eliminating inconsistency issues that would otherwise require complex post-processing or specialized extrusion equipment.
2Reliability
If graphene additives are added to copper to enhance electrical conductivity, then conductivity can be improved, but the distribution of graphene becomes non-uniform leading to inconsistent material properties
Solution Approach 1:
Different regions of the billet are designed with specific local concentrations of graphene additives. By controlling the local quality and distribution of non-metallic materials in different zones of the billet, the invention ensures uniform integration throughout the final extruded product, achieving consistent electrical conductivity and reliable material properties.
3Use of energy by moving object
If solid phase processing is used to combine metals and non-metallic materials, then energy consumption is reduced compared to molten metallurgy, but achieving homogeneous integration of additives remains difficult
Solution Approach 1:
The homogeneous distribution of graphene additives is achieved through preliminary preparation of the billet structure before extrusion. By pre-integrating non-metallic materials into the metal matrix in a controlled manner, the invention eliminates the need for high-energy molten metallurgy processes while still achieving uniform material integration and consistent composite properties.
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 proposed billet designs result in enhanced electrical conductivity and mechanical properties, achieving consistent conductivity improvements of up to 4.15% over pure copper, with minimal variance, making them suitable for large-scale industrial production.
Implementation Method 1
Solid phase processes operate by plastically deforming the extruded metal. During solid phase processes, non-metallic materials are integrated with the metal or metal alloy while the metal or metal alloy is plasticized, thereby creating metal matrix composites
Implementation Method 2
Hot metal extrusion is a forming process in which a pre-material, known as a billet, is first heated, then forced through a die. This imparts the die shape to the extruded metal as it passes through the die
Implementation Method 3
A relatively new type of extrusion is known as friction extrusion (FE), which operates at even lower temperatures than HME, but still within the range of plastic phase for metals
Data Source
AI summary
A billet adapted for use in a solid phase extrusion process to produce an extrudate, the billet including a billet body formed from Copper or Copper-Silver alloy, where the body defines a longitudinal void that extends along a longitudinal length of the body, powdered Graphene or powdered Carbon nano-tubes or nano-crystalline Carbon powder positioned in the longitudinal void and distributed evenly along the longitudinal length of the body, and where the weight percentage of the Carbon material relative to the metal in the body is between 10 ppm and 250 ppm, and where the billet is configured such that, after extrusion through the solid phase extrusion process to produce the extrudate, the extrudate has consistent conductivity is consistently greater than the conductivity of the Copper or Copper-Silver alloy.