Single-Step Shear-Based Deformation Processing of Electrical Conductor Wires

Issahaq, Mohammed Naziru; Chandrasekar, Srinivasan; Trumble, Kevin P.

doi:10.1115/1.4048984

Single-Step Shear-Based Deformation Processing of Electrical Conductor Wires

Journal Article · Wed Dec 16 23:00:00 EST 2020 · Journal of Manufacturing Science and Engineering

DOI:https://doi.org/10.1115/1.4048984· OSTI ID:1848604

Issahaq, Mohammed Naziru ^[1]; Chandrasekar, Srinivasan ^[2]; Trumble, Kevin P. ^[3]

School of Materials Engineering, and Center for Materials Processing and Tribology, Purdue University, West Lafayette, IN 47907; OSTI
School of Industrial Engineering, and Center for Materials Processing and Tribology, Purdue University, West Lafayette, IN 47907
School of Materials Engineering, and Center for Materials Processing and Tribology, Purdue University, West Lafayette, IN 47907

Abstract

Commercial electrical conductor wires are currently produced from aluminum alloys by multi-step deformation processing involving rolling and drawing. These processes typically require 10 to 20 steps of deformation, since the plastic strain or reduction that can be imposed in a single step is limited by material workability and process mechanics. Here, we demonstrate a fundamentally different, single-step approach to produce flat wire aluminum products using machining-based deformation that also ensures adequate material workability in the formed product. Two process routes are proposed: (1) chip formation by free-machining (FM), with a post-machining, light drawing reduction (<20%) to achieve desired finish and (2) constrained chip formation by large strain extrusion machining (LSEM). Using commercially pure aluminum conductor alloys (Al 1100 and EC1350) as representative material systems, we demonstrate key features of the machining-based processing, including (a) single-step processing to achieve flat wire geometries, (b) surface finish (Ra = 0.2 to 1.0 μm) comparable to that of commercial wire products made by drawing/rolling, (c) deformation control independent of wire size, and (d) hardness increases of 50–150% over that of annealed wires, while retaining high electrical conductivity (>56% IACS). The wire microstructure, which can also be varied via the large-strain deformation parameters, is correlated with mechanical and electrical properties. Implications for commercial manufacture of flat wire products are discussed.

Research Organization:: Purdue Univ., West Lafayette, IN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

DOE Contract Number:: EE0007868

OSTI ID:: 1848604

Journal Information:: Journal of Manufacturing Science and Engineering, Journal Name: Journal of Manufacturing Science and Engineering Journal Issue: 5 Vol. 143; ISSN 1087-1357

Publisher:: ASME

Country of Publication:: United States

Language:: English

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