Cu-Ag Conductive Wire Processing for High Strength and Conductivity
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Solution Overview
Problem
Existing Cu—Ag alloys used in conductive wires fail to achieve a conductivity of not less than 88% IACS and a tensile strength of not less than 800 MPa while maintaining a low concentration of added metal elements, such as Ag, in the alloy.
Innovation Solution
A method for manufacturing conductive wires involves continuous casting of a conductive alloy material with a casting rate of 40 mm/min to 200 mm/min, followed by diameter reduction and heat treatment to achieve a tensile strength reduction of 90% to 100% and a logarithmic strain of 7.8 to 12.0, resulting in a conductive wire with a Cu—Ag alloy having an Ag concentration of 0.5 to 1.0 mass%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Ag concentration is increased to improve tensile strength, then tensile strength increases, but conductivity decreases and cost increases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the Ag concentration within a specific range (0.01-1.0 mass%) and controlling the crystal grain size within a specific range (1-10 μm). By changing these parameters to optimal values, the invention achieves tensile strength of 800 MPa or more and conductivity of 88% IACS or more, resolving the contradiction between strength and Ag concentration.
Solution Approach 2:
The patent creates a composite microstructure consisting of fine crystal grains with uniform Ag distribution. This composite structure at the micro level allows the material to achieve both high strength through grain boundary strengthening and high conductivity through uniform electron flow paths, while maintaining low Ag concentration.
2Reliability
If Ag concentration is increased to improve conductivity, then conductivity improves, but tensile strength may decrease and cost increases
Solution Approach 1:
The patent achieves high conductivity (88% IACS or more) by controlling Ag concentration at 0.01-1.0 mass% and crystal grain size at 1-10 μm. This parameter optimization ensures sufficient conductivity while minimizing Ag usage, resolving the contradiction between conductivity and Ag concentration.
Solution Approach 2:
The patent creates local uniformity in Ag distribution within the crystal grains and at grain boundaries. This local quality control ensures that Ag is evenly distributed to provide consistent conductivity throughout the material without requiring high overall Ag concentration.
3Strength
If conventional casting and processing methods are used, then manufacturing is simpler, but the required conductivity and tensile strength cannot be achieved simultaneously
Solution Approach 1:
The patent incorporates Ag into the molten Cu before casting, and performs heat treatment at specific temperature ranges (100-500°C for 1 hour or 500-700°C for 10 seconds) to pre-establish the fine crystal grain structure and uniform Ag distribution. This preliminary action during manufacturing ensures the final product achieves the required properties without complex post-processing.
Solution Approach 2:
The patent specifies precise parameter ranges for manufacturing: Ag concentration (0.01-1.0 mass%), casting temperature, heat treatment temperature (100-700°C) and time (10 seconds-1 hour). By controlling these parameters within optimal ranges, the invention achieves high strength and conductivity through a relatively simple manufacturing process.
4Quantity of substance
If Ag concentration is reduced to降低成本, then cost decreases, but tensile strength and conductivity become insufficient
Solution Approach 1:
The patent achieves the optimal balance by setting Ag concentration at 0.01-1.0 mass% (minimal amount) while controlling crystal grain size at 1-10 μm. This parameter combination achieves 88% IACS or more conductivity with minimal Ag usage, resolving the contradiction between low Ag concentration and high conductivity.
Solution Approach 2:
The patent ensures uniform Ag distribution at the local level within crystal grains and at grain boundaries. This local uniformity maximizes the effectiveness of minimal Ag addition, providing sufficient conductivity enhancement without requiring high overall Ag concentration.
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 method produces conductive wires with a conductivity of not less than 88% IACS and a tensile strength of not less than 800 MPa, while maintaining a low concentration of added metal elements, thereby enhancing economic efficiency and performance.
Implementation Method 1
conducting a continuous casting of a conductive alloy material at a casting rate of not less than 40 mm/min and not more than 200 mm/min to form a conductive wire with a primary diameter
Implementation Method 2
heat treating the conductive wire with the secondary diameter so that tensile strength thereof is reduced to not less than 90% and less than 100% of tensile strength before the heat treating
Implementation Method 3
reducing a diameter of the conductive wire with the secondary diameter and the reduced tensile strength to generate a logarithmic strain of 7.8 to 12.0 therein to form a conductive wire with a tertiary diameter
Data Source
AI summary
A method for manufacturing a conductive wire includes conducting a continuous casting of a conductive alloy material at a casting rate of not less than 40 mm/min and not more than 200 mm/min to form a conductive wire with a primary diameter, the conductive alloy material containing not more than 1.0 mass % of an added metal element, reducing a diameter of the conductive wire with the primary diameter to form a conductive wire with a secondary diameter, heat treating the conductive wire with the secondary diameter so that tensile strength thereof is reduced to not less than 90% and less than 100% of tensile strength before the heat treating, and reducing a diameter of the conductive wire with the secondary diameter and the reduced tensile strength to generate a logarithmic strain of 7.8 to 12.0 therein to form a conductive wire with a tertiary diameter.