Application of ultra-smooth composite diamond film coated WC-Co drawing dies under water-lubricating conditions

A specific revised HFCVD apparatus and a novel process combining HFCVD and polishing technique were presented to deposit the micro-and nano-crystalline multilayered ultra-smooth diamond（USCD） film on the interior-hole surface of WC-Co drawing dies with aperture ranging from d1.0 mm to 60 mm.Characterization results indicate that the surface roughness values（Ra） in the entry zone,drawing zone and bearing zone of as-fabricated USCD coated drawing die were measured as low as 25.7,23.3 and 25.5 nm,respectively.Furthermore,the friction properties of USCD films were examined in both dry sliding and water-lubricating conditions,and the results show that the USCD film presents much superior friction properties.Its friction coefficients against ball-bearing steel,copper and silicon nitride balls（d4 mm）,is always lower than that of microcrystalline diamond（MCD） or WC-Co sample,regardless of the lubricating condition.Meanwhile,it still presents competitive wear resistance with the MCD films.Finally,the working lifetime and performance of as-fabricated USCD coated drawing dies were examined under producing low-carbon steel pipes in dry-sliding and water-lubricating conditions.Under the water-lubricating drawing condition,its production significantly increases by about 20 times compared with the conventional WC-Co drawing dies.

Fabrication and application of nano/microcrystalline composite diamond coated drawing dies using alternative carbon sources

Nano/microcrystalline composite diamond films were deposited on the holes of WC-6%Co drawing dies by a two-step procedure using alternative carbon sources, i.e., methane for the microcrystalline diamond（MCD） layer and acetone for the nanocrystalline diamond（NCD） layer. Moreover, the monolayer methane-MCD and acetone-NCD coated drawing dies were fabricated as comparisons. The adhesion and wear rates of the diamond coated drawing dies were also tested by an inner hole polishing apparatus. Compared with mono-layer diamond coated drawing die, the composite diamond coated one exhibits better comprehensive performance, including higher adhesive strength and better wear resistance than the NCD one, and smoother surface（Ra=65.3 nm） than the MCD one（Ra=95.6 nm） after polishing at the same time. Compared with the NCD coated drawing die, the working lifetime of the composite diamond coated one is increased by nearly 20 times.

Wear Characteristics of Zirconia Toughened Ceramic Drawing Dies

Wear resistance of several zirconia toughened ceramics in comparison with a metal-ceramic Co-WC has been studied in drawing wire field test. Result indicates that the harder the ceramic die, the longer the service life. Excellent wear resistance of ceramic die is obtained with a very high hardness (19 GPa). The service life is nearly three times that of Co-WC die. SEM observation on wear surfaces showed that material removal is mainly caused by plastic flow and ploughing process. But when the ceramic is composed of zirconia, alumina and some titanium carbide, micro-chipping and tribochemical reaction take place, and wear rate increases. Wear and friction induced martensite was detected by XRD. The T-M (tetragonal to monoclinic) phase transformation has a contribution to inhibiting microfracture.

Determination of a Drawing Die's Cone Angle at a Small Compression Ratio Based on the Upper Bound Theory

The value of a drawing die＇s cone angle has great influence on wire drawing. In order to determine the optimum value of a drawing die＇ s cone angle, the plastic deformation power Wi, shear deformation power Wi and friction power of contact surface Wf were calculated using the upper bound theory with a reasonable and movement permitted velocity field according to the related characteristics. Then the relation between half cone angle and unit drawing force was obtained and it was compared with the result with the spherical velocity field. The relative error of the two near the optimal value is only about 0. 26% through comparing with existing calculated results. Finally, in an ABAQUS environment the finite element modal of the wire rod with 12. 5 mm diameter in first drawing pass was established and the axial drawing force in different cone angles was obtained using the ABAQUS/Explicit explicit integration method. The finite element method （FEM） results verify the results using the upper bound theory and this indicated that the velocity field and the relation between half cone angle and unit drawing force reasonable.

THE CURVILINEARINTEGRAL PROBLEMS TO VELOCITY FIELD FOR DRAWING THROUGH PARABOLIC DIES

n this paper with Von Karmanis basic assumptions a kinematically admissible continuous velocity field has been established to drawing through parabolic dies (or called trumpet dies). Then by. using the curvilinear and the integral as a function of the upper limit an upper bound analytical solution of the drawing stress is obtained.

Properties of seven-filament Cu/Ag-sheathed(Ba,K)Fe_(2)As_(2)tapes fabricated from round and square wires

Iron-based superconductor,a promising candidate for high-field applications,has attracted significant attentions.For practical utilization,the superconducting tapes should have high transport critical current density(J_(c)),low production cost,larger mechanical strength and good homogeneity.In this study,seven-filament Cu/Agsheathed(Ba,K)Fe_(2)As_(2)tapes were fabricated from round and square wires.It is found that the tapes rolled from square wires have a desirable uniformity of filament deformation and distribution,compared with the ones rolled from round wires.Moreover,the J_c of tape was obviously improved by using square drawing dies instead of traditional round ones.For the tapes rolled from square wires annealed under ambient and 2 MPa by hot pressing,the transport J_c values reached 1.51×10^(4) A·cm^(-2)and 4.86×10^(4) A.cm^(-2)(4.2K,10T),respectively.The deformation process on the cross section of the tapes during rolling was analyzed by using the powder-flow model.These results indicate a potential application of Cu/Ag(Ba,K)Fe_(2)As_(2)tapes in high-magnetic-field region.

A novel method for making ultra-fine metal fibers and particles

A novel method based on plastic processing and equipment for preparing ultra-fine metal fibers and particles is reported.With this new method,metal fibers and particles can both be produced on the same equipment and the surfaces of the fibers and particles can be protected from oxidation by the polymers or solvents during the preparation process.Metal-alloy powders with lower melt point were filled into polymer by an extruder,followed by a die-drawing process at a temperature lower than the melt temperature of the metal alloy.Metal fibers or particles were obtained after the polymer matrix was washed away.Metal alloy fibers can be obtained when a polymer that strongly interacts with metal alloy,such as a special polyvinyl alcohol with a low alcoholysis degree,is used as the polymer matrix.Metal-alloy particles can be obtained when a polymer with weak interaction with metal alloy,such as polyethylene(PE),is used as the polymer matrix.Based on the principle of this new method,it is possible to produce finer or even nano-sized metal fibers and particles with higher melting points.