Effect of Gap Size on Coating Extrusion of Pb-GF Composite Wire by Theoretical Calculation and Experimental Investigation

A new method using lead coated glass fiber to produce continuous wire for battery grid of electric vehicles （EVs） and hybrid electric vehicles （HEVs） was introduced. Under equal flow, both the maximum and minimum theoretical value of gap size were studied and estimation equation was established. The experimental results show that the gap size is a key parameter for the continuous coating extrusion process. Its maximum value （Hmax） is 0.24 mm and the minimum one （Hmin） is 0.12mm. At a gap size of 0.18 mm, the maximum of metal extrusion per unit of time and optimal coating speed could be obtained.

Effect of extrusion ratio on coating extrusion of Pb-GF composite wire by numerical simulation and experimental investigation

The extrusion ratio is one of the key parameters for manufacturing the lead-glass fiber(Pb-GF)composite wire by coating extrusion.The effect of extrusion ratio on coating extrusion of Pb-GF composite wire was studied by finite element numerical simulation with the use of the DEFOEM simulation software.The simulation result shows that the higher the extrusion ratio,the higher the effective stress that the glass fiber bears during extrusion.It is also observed that the extrusion force increases with the increase of the extrusion ratio.The extrusion experiment of Pb-GF composite wire reveals that extrusion ratio is changed by changing the quantity of glass fiber and composite diameter.The rule that increasing the extrusion ratio enhances the coating speed limit suggests that the load on the glass fiber increases with increasing extrusion ratio.Both the simulation and the extrusion experiments show that the extrusion force increases with increasing extrusion ratio.

Giant Magneto-impedance Effect in Composite Wires with Different Core Layer

Composite structure materials were potential sensing elements for magnetic sensors due to Giant magnetoimpedance(GMI) effect. Two kinds of composite wires with different magnetic/non-magnetic structures were fabricated by using electroless deposition methods and the magnetoimpedance properties were investigated. The maximum GMI ratio of 114% was acquired at 60 MHz in the composite wires with a ferromagnetic core, whereas, 116% of maximum GMI ratio was found in the composite wires with a conductive core at low frequency of 600 k Hz. These results exhibit that the GMI ratio reaches the maximum when magnetoresistance ratio ?R/R and magnetoinductance ratio ?X/X make the comparative contributions to the total magnetoimpedance(MI). The obvious GMI effect obtained in the composite wires with conductive core frequency may provide a candidate for applications in magnetic sensors, especially at low frequencies.

Optimization analysis on gap size of molding for Pb-GF composite wire

Under the condition of equal flow, the maximum and minimum theoretical values of gap size were studied and an estimation equation was established for the clad extrusion of the brittle core cladded by plastic metal materials. The results show that the gap size is a key parameter for the continuous clad extrusion and the molding speed. Its maximum value (Hmax) is 0.24mm and the minimum one (Hmin) is 0.12mm. At a gap size of 0.18mm, the maximum of metal extrusion per unit of time and the optimal coating speed can be obtained.

Cross-sectional structure, microstructure and mechanical property evolutions of brass cladding pure copper stranded wire composite during drawing

A solid/liquid continuous casting and composite technology was used to produce d8.5 mm brass cladding pure copper stranded wire composite billet and the composite billet was then drawn. The results showed that the composite billet had good surface quality, metallurgical bonding interface between brass and pure copper as well as elongation of 53.1%. Synergistic deformation degree between pure copper wire and brass cladding layer was high during drawing. With an increase of the total deformation amount, the plastic deformation of the pure copper wire reduced triangular arc gaps between the pure copper wires and the triangular arc gaps were fully filled at 50%. When the total deformation amount was increased to 63%, dislocation cells and microbands successively formed in the pure copper wire. In the brass cladding layer, planar dislocation networks, twins and shear bands formed successively, and the main deformation mechanisms were dislocation sliding, twinning and shear deformation. The tensile strength increased from 240 MPa of the composite billet to 519 MPa of the one with the deformation amount of 63%, but the elongation decreased from 53.1% to 3.2%. A process of solid/liquid continuous casting and composite forming→drawing can work as a new compact method to produce brass cladding pure copper stranded wire composite as railway through grounding wire.

High-performance carbon fiber/gold/copper composite wires for lightweight electrical cables

In this study,we synthesized high-performance Carbon Fiber/Gold/Copper(CF/Au/Cu)composite wires by using a 2-step deposition method via sputtering and electrodeposition.After Au was sputtered on PANbased CFs as a pre-treatment,the wettability and surface reactivity of the CFs were improved,resulting in a homogeneous deposition of Cu on their surface.At different Cu electrodeposition time,the resulting CF/Au/Cu composite wires could possess a high strength of up to 3.27 GPa(~10 times stronger than copper wires)while their electrical conductivity could be as high as 4.4×10^5 S/cm(~75%of that for copper).More importantly,since the composite wires were lightweight(up to 70%lower than Cu mass density),they are a promising candidate to substitute conventional heavy metal wires in the future electrical applications.

Interface evolution of Cu-Ni-Si/Al-Mg-Si clad composite wires after annealing

Interface micros tructures of Cu-Ni-Si/Al-MgSi clad composite wires during isothermal annealing from 623 to 773 K were investigated.The composite wires were fabricated by a drawing process.The evolution of intermetallic compounds(IMCs)was analyzed.A continuous IMCs layer forms only after annealing for 1 min,which may be due to more IMCs nucleation points generated by deep drawing process.IMCs consist of Al_(4)Cu_(9),AlCu and Al_(2)Cu identified by energy-dispersive spectroscopy(EDS)and transmission electron microscopy(TEM).The growth activation energies of total IMCs,Al_(2)Cu,AlCu and Al_(4)Cu_(9),are 98.8,69.4,101.3 and 137.1 kJ·mol^(-1),respectively.The higher growth activation energy of Al_(4)Cu_(9)results in the higher growth rate under high temperature.However,the average interdiffusion coefficient for each IMC calculated by Wagner method shows that interdiffusion in Al_(2)Cu and AlCu is more active than that in Al_(4)Cu_(9).The higher growth rate of Al_(4)Cu_(9)may be caused by the long concentration range.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

Single-phase earth fault current distribution between optical fiber composite overhead ground wire and ordinary ground wire in transmission system

It is important for the safety of transmission system to accurately calculate single-phase earth fault current distribution.Features of double sided elimination method were illustrated.Quantitative calculation of single-phase earth fault current distribution and case verification were accomplished by using the loop method.Influences of some factors,such as single-phase earth fault location and ground resistance of poles,on short-circuit current distribution were discussed.Results show that:1) results of the loop method conform to those of double sided elimination method;2) the fault location hardly influences macro-distribution of short-circuit current.However,current near fault location is evidently influenced;and 3) the short-circuit current distribution is not so sensitive to the ground resistance of poles.

Deposition of MgB2 Superconducting Films on Different Metal Substrates

By a method of hybrid physical-chemical vapour deposition （HPCVD） on three metal substrates of stainless steel, copper and niobium, we deposit MgB2 superconducting films over 1 μm thickness. All of them have zero resistance temperatures To（O） 〉 36 K and critical current densities Jc （IOK, OT） 〉106 A/cm^2. Meanwhile, in the bending test, all the MgB2 superconducting films adhere strongly to the metal substrates without peeling off. Therefore, the MgB2 superconducting films supplied by the HPCVD method exhibit preferable electrical, magnetic and mechanical properties, and have potential applications in future.

Preparation of SiC Fiber Reinforced Nickel Matrix Composite

A method of preparing continuous（Al＋Al2O3）-coated SiC fiber reinforced nickel matrix composite was presented,in which the diffusion between SiC fiber and nickel matrix could be prevented.Magnetron sputtering is used to deposit Ni coating on the surface of the（Al＋Al2O3）-coated SiC fiber in preparation of the precursor wires.It is shown that the deposited Ni coating combines well with the（Al＋Al2O3） coating and has little negative effect on the tensile strength of（Al＋Al2O3）-coated SiC fiber.Solid-state diffusion bonding process is employed to prepare the（Al＋Al2O3）-coated SiC fiber reinforced nickel matrix with 37% fibers in volume.The solid-state diffusion bonding process is optimized and the optimum parameters are temperature of 870,pressure of 50 MPa and holding time of 2 h.Under this condition,the precursor wires can diffuse well,composite of full density can be formed and the（Al＋Al2O3） coating is effective to restrict the reaction between SiC fiber and nickel matrix.

Electrical Discharge Machining of Al2024-65 vol%SiC Composites

In the present work, the wire electrical discharge machining（WEDM） process of the 65 vol% SiCp/2024 Al composite prepared by pressure infiltration methods has been investigated. The microstructure of the machined composite was characterized by scanning electron microscope, the average surface roughness（Ra）, X-ray diffraction, X-ray photoelectron spectroscopy and transmission electron microscopy（TEM） techniques. Three zones from the surface to the interior（melting zone, heat affected zone and un-affected zone） were found in the machined composites, while the face of SiC particles on the surface toward the outside was ‘‘cut＇＇ to be flat. Increase in Al and Si but decrease in C and O were observed in the core areas of the removed particles. Si phase, which was generated due to the decomposition of SiC, was detected after the WEDM process. The irregular and spherical particles were further observed by TEM. Based on the microstructure observation, it is suggested that the machining mechanism of 65 vol% SiCp/2024 Al composite was the combination of the melting of Al matrix and the decomposition of SiC particles.

Nb_(3)Sn超导复合股线非线性力学行为研究

本文通过对Nb_(3)Sn超导复合股线在77 K和300 K下进行准静态加卸载拉伸和疲劳实验,研究了Nb_(3)Sn超导复合股线的非线性力学行为,结果表明:Nb_(3)Sn超导复合股线的准静态应力-应变曲线和能量耗散具有很强的非线性.同时,考虑塑性应变产生的损伤退化,推导了卸载过程中非线性和线性卸载模量,提出了考虑损伤的双曲面弹塑性本构模型来预测准静态加卸载应力-应变响应和能量耗散;通过疲劳损伤演化模型分析和预测Nb_(3)Sn超导复合股线在77 K和300 K下疲劳过程中的能量耗散.理论与实验结果对比表明:准静态加卸载拉伸实验中损伤退化是能量损耗产生非线性的主要原因.此外,对Nb_(3)Sn超导复合股线的疲劳断裂模式进行了分析,结果表明:Nb 3Sn芯丝组在77 K时表现为脆性断裂,在300 K时表现为韧性断裂.这些新发现为研究Nb_(3)Sn超导复合股线的非线性力学行为提供了新的视角.