Composite Feedstock Wire Roll Forming for Mixing Proportion Control
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Solution Overview
Problem
Existing methods for producing feedstock wires from metal strips with differing yield points face challenges such as elongation issues, creasing, and changes in mixing proportions during roll forming, leading to inconsistent wire composition and difficulty in achieving a completely filled wire shape with a nickel jacket.
Innovation Solution
The method involves separating the deformation process into two stages, where the metal strip forming the jacket is first deformed alone to a preliminary shape, and then the second metal strip is introduced and jointly formed to the final shape, avoiding excessive elongation by controlling pressure and using a W-shape trough formation to center and clamp the second metal strip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple metal strips with differing yield points are processed together in roll forming, then productivity is improved, but manufacturing precision deteriorates due to differing elongations and relative movements
Solution Approach 1:
The roll forming process is segmented into two distinct stages: a first forming stage where only the jacket metal strip is processed, and a second forming stage where both the jacket strip and core strip are processed together. This segmentation allows each stage to be optimized for its specific purpose, preventing the dimensional inconsistencies that would result from processing both strips simultaneously throughout the entire forming process.
Solution Approach 2:
The jacket metal strip undergoes preliminary forming in the first forming stage to achieve the desired cross-sectional shape and dimensions before the core metal strip is introduced. This preliminary action ensures that the jacket strip is already properly formed and positioned, allowing it to effectively constrain the core strip during subsequent joint processing without suffering from the core strip's different elongation characteristics.
2Device complexity
If metal strips with differing yield points are processed together, then manufacturing complexity is reduced, but reliability deteriorates due to creasing and material push-out
Solution Approach 1:
The jacket metal strip is pre-formed to the final cross-sectional shape in the first forming stage before the core strip is introduced. This preliminary action creates a stable, pre-shaped jacket that can reliably contain the core strip during subsequent processing, preventing creasing and material push-out that would occur if both strips were formed simultaneously from flat stock.
Solution Approach 2:
The forming process is divided into two sequential stages: first forming the jacket strip alone to establish its final shape, then introducing the core strip for joint processing. This segmentation eliminates the reliability issues of simultaneous processing while maintaining relatively simple equipment requirements.
3Ease of manufacture
If the softer metal strip is introduced early in roll forming, then ease of manufacture is improved, but manufacturing precision deteriorates due to excessive elongation and mixing proportion changes
Solution Approach 1:
The jacket metal strip is pre-formed to the final cross-sectional shape and dimensions before the core strip is introduced. This preliminary action establishes a stable geometric framework that controls the final mixing proportions, allowing the softer core strip to be added without disrupting the jacket's shape or the overall material distribution in the composite wire.
Solution Approach 2:
The process is segmented so that the jacket strip is completely formed first, establishing precise dimensional control, then the core strip is introduced for a second forming stage. This segmentation prevents the softer core strip from causing elongation or proportion changes during the critical jacket-forming operations.
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 prevents disproportionate elongation of the softer metal strip, maintains the desired mixing proportion, and allows for the production of a feedstock wire with a predominantly nickel jacket, suitable for thermal spraying applications.
Implementation Method 1
metal strips are guided between profiled rollers, whereby the profile shape is applied to the metal strips
Implementation Method 2
clearances are provided, by a limitation of the width of this strip, which are filled by transversely flowing material
Data Source
AI summary
A method for producing a feedstock wire is produced from a first metal strip and at least one further metal strip by roll forming, wherein in particular the first metal strip and the at least one further metal strip are made of differing metals, preferably of differing meals having differing yield points, wherein a jacket, which in the final shape completely surrounds the at least one further metal strip in the circumferential direction, is formed from the first metal strip in a plurality of passes by roll forming using a plurality of roll stands, and wherein, first, exclusively only the first metal strip is formed to a preliminary shape in a plurality of passes using a first group of roll stands and, thereafter, the first metal strip and the at least one further metal strip are jointly formed to the final shape in a second group of roll stands.