Numerical simulation of temperature field in horizontal core-filling continuous casting for copper cladding aluminum rods

The steady-state temperature field of horizontal core-filling continuous casting （HCFC） for producing copper cladding aluminum rods was simulated by finite element method to investigate the effects of key processing parameters on the positions of solid-liquid interfaces （SLIs） of copper and aluminum. It is found that mandrel tube length and mean withdrawing speed have significant effects on the SLI positions of both copper and aluminum. Aluminum casting temperature （TAI） （1003-1123 K） and secondary cooling water flux （600-900 L.h-1） have little effect on the SLI of copper but cause the SLI of aluminum to move 2-4 mm. When TA1 is in a range of 1043-1123 K, the liquid aluminum can fill continuously into the pre-solidified copper tube. Based on the numerical simulation, reasonable processing parameters were determined.

Microstructures and properties analysis of dissimilar metal joint in the friction stir welded copper to aluminum alloy

This paper mainly concentrated on the feasibility of friction stir welding of dissimilar metal of aluminum alloy to copper （I2） and a preliminary analysis of welding parameters influencing on the microstructures and properties of joint was carried out. The results indicated that the thickness of workpiece played an important role in the welding parameters which could succeed in the friction stir welding of dissimilar metal of copper to aluminum alloy, and the parameters were proved to be a narrow choice. The interfacial region between copper and aluminum in the dissimilar joint was not uniformly mixed, constituted with part of incomplete mixing zone, complete mixing zone, dispersion zone and the most region＇ s boundary was obvious. Meantime a kind banded structure with inhomogeneous width was formed. The intermetallic compounds generated during friction stir welding in the interfacial region were mainly CugAl4, Al2Cu etc, and their hardness was higher than oihers.

Fabrication of Superhydrophobic Surfaces on Aluminum Alloy Via Electrodeposition of Copper Followed by Electrochemical Modification

Superhydrophobic aluminum surfaces have been prepared by means of electrodeposition of copper on aluminum surfaces, followed by electrochemical modification using stearic acid organic molecules. Scanning electron microscopy(SEM) images show that the electrodeposited copper films follow "island growth mode" in the form of microdots and their number densities increase with the rise of the negative deposition potentials. At an electrodeposition potential of-0.2 V the number density of the copper microdots are found to be 4.5×104cm^(-2)that are increased to 2.9×105cm^(-2)at a potential of-0.8 V. Systematically, the distances between the microdots are found to be reduced from 26.6 μm to 11.03 μm with the increase of negative electrochemical potential from-0.2 V to-0.8 V. X-ray diffraction(XRD) analyses have confirmed the formation of copper stearate on the stearic acid modified copper films. The roughness of the stearic acid modified electrodeposited copper films is found to increase with the increase in the density of the copper microdots. A critical copper deposition potential of-0.6 V in conjunction with the stearic acid modification provides a surface roughness of 6.2 μm with a water contact angle of 157?, resulting in superhydrophobic properties on the aluminum substrates.

Microstructure of aluminum/copper clad composite fabricated by casting-cold extrusion forming

An aluminum/copper clad composite was fabricated by the casting-cold extrusion forming technology and the microstructures of the products were observed and analyzed.It is found that aluminum grains at the interface are refined in the radial profiles of cone-shaped deformation zone,but the grains in the center maintain the original state and the grain size is non-uniform.A clear boundary presents between the refined area and center area.In contrast,the copper grains in the radial profiles have been significantly refined.In the center area of the copper,the grains are bigger than those at the boundary.On the surface of the deformable body,the grain size is the smallest,but with irregular grain morphology.After the product is entirely extruded,all the copper and aluminum grains are refined with small and uniform morphology.In the center area,the average diameter of aluminum grains is smaller than 5 μm,and the copper grain on the surface is about 10 μm.At the interface,the grain size is very small,with a good combination of copper and aluminum.The thickness of interface is in the range of 10-15 μm.Energy spectrum analysis shows that CuAl3 phase presents at the interface.

Effect of equal-channel angular pressing on pitting corrosion resistance of anodized aluminum-copper alloy

The effect of equal-channel angular pressing(ECAP) on the pitting corrosion resistance of anodized Al-Cu alloy was investigated by electrochemical techniques in a solution containing 0.2 mol/L AlCl3 and also by surface analysis.Anodizing was conducted for 20 min at 200 and 400 A/m2 in a solution containing 1.53 mol/L H2SO4 and 0.018 5 mol/L Al2(SO4)3·16H2O at 20 ℃.Anodized Al-Cu alloy was immediately dipped in boiling water for 20 min to seal the micro pores present in anodic oxide films.The time required before initiating pitting corrosion of anodized Al-Cu alloy is longer with ECAP than without,indicating that ECAP process improves the pitting corrosion resistance of anodized Al-Cu alloy.Second phase precipitates such as Si,Al-Cu-Mg and Al-Cu-Si-Fe-Mn intermetallic compounds are present in Al-Cu alloy and the size of these precipitates is greatly decreased by application of ECAP.Al-Cu-Mg intermetallic compounds are dissolved during anodization,whereas the precipitates composed of Si and Al-Cu-Si-Fe-Mn remain in anodic oxide films due to their more noble corrosion potential than Al.FE-SEM and EPMA observation reveal that the pitting corrosion of anodized Al-Cu alloy occurs preferentially around Al-Cu-Si-Fe-Mn intermetallic compounds,since the anodic oxide films are absent at the boundary between the normal oxide films and these impurity precipitates.The improvement of pitting corrosion resistance of anodized Al-Cu alloy processed by ECAP appears to be attributed to a decrease in the size of precipitates,which act as origins of pitting corrosion.

Orthogonal tests of copper-clad aluminum bimetal continuous casting by nitrogen pressure core-illing

To provide theoretical basis and practical guidance for preparing composite rods by direct continuous casting, copper-clad aluminum composite rods of external copper layer diameter 12 mm and inner aluminum core diameter 8 mm were manufactured. Orthogonal tests consisted of three factors and three levels were carried out to research the effects of melting copper temperature, continuous casting speed and nitrogen pressure on the performance of composite rods. Results showed that nitrogen pressure is the most important factor in influencing the surface quality; continuous casting speed is the most important factor in influencing copper & aluminum inter diffusion amount. Nitrogen pressure can noticeably improve the surface quality and make the rods easily be drawn out, but the surface quality does not show visible improvement when the nitrogen pressure is above 0.05 MPa. Measured by tests, the compound layer can be divided into three types according to its cladding layer degree: deficient cladding, normal cladding and excess cladding. The diameter of normal copper-clad aluminum composite rods can be successfully drawn less than 0.6 mm without annealing.

Vision-based detection of weld pool width in TIG welding of copper-clad aluminum cable

In order to realize automatic control of the width of weld pool, a visual sensor system for the width of weld pool detection is developed. By initiative arc light, the image of copper plate weld pool is taken back of the torch through the process of weakening and filtering arc light. In order to decrease the time of processing video signals, analog circuit is applied in the processing where video signals is magnified, trimmed and processed into binary on the datum of dynamic average value, therefore the waveform of video signals of weld pool is obtained. The method that is used for detecting the width of weld pool is established. Results show that the vision sensing method for real-time detecting weld pool width to copper-clad aluminum wire TIG welding is feasible. The response cycle of this system is no more than 50 ms, and the testing precision is less than 0. 1 mm.

Effect of preparation methods of aluminum emulsions on catalytic performance of copper-based catalysts for methanol synthesis from syngas

Various Cu/ZnO/Al2O3 catalysts have been synthesized by different aluminum emulsions as aluminum sources and their pertormances tor methanol synthesis from syngas have been investigated. The influences of preparation methods of aluminum emulsions on physicochemical and catalytic properties of catalysts were studied by XRD, SEM, XPS,N2 adsorption-desorption techniques and methanol synthesis from syngas. The preparation methods of aluminum emulsions were found to influence the catalytic activity, CuO crystallite size, surface area and Cu0 surface area and reduction process. The results show that the catalyst CN using the aluminum source prepared by addition the ammonia into the aluminum nitrate （NP） exhibited the best catalytic performance for methanol synthesis from syngas.

Effect of continuous induction annealing on the microstructure and mechanical properties of copper-clad aluminum flat bars

Copper-clad aluminum （CCA） flat bars produced by the continuous casting-rolling process were subjected to continuous induction heating annealing （CIHA）, and the effects of induction heating temperature and holding time on the microstructure, interface, and mechanical properties of the fiat bars were investigated. The results showed that complete recrystallization of the copper sheath occurred under CIHA at 460℃ for 5 s, 480℃ for 3 s, or 500℃ for 1 s and that the average grain size in the copper sheath was approximately 10.0 μm. In the case of specimens subjected to CIHA at 460-500℃ for longer than 1 s, complete recrystallization occurred in the aluminum core. In the case of CIHA at 460-500℃ for 1-5 s, a continuous interracial layer with a thickness of 2.5-5.5 μm formed and the thickness mainly increased with increasing annealing temperature. After CIHA, the interracial layer consisted primarily of a Cu9A14 layer and a CuA12 layer; the average interface shear strength of the CCA flat bars treated by CIHA at 460-500℃ for 1-5 s was 45-52 MPa. After full softening annealing, the hardness values of the copper sheath and the aluminum core were HV 65 and HV 24, respectively, and the hardness along the cross section of the CCA flat bar was uniform.

Manufacturing process and microstructure of copper-coated aluminum wires

Copper-coated aluminum wires exhibit good electrical conductivity, high thermal conductivity, low contact resistance of copper and low density, and provide economic advantages over aluminum. However, there are some problems in the manufacring processes of hot-dip copper-coated aluminum wires, such as the difficulties in controlling coating process. In this work, the hot-dip copper-coating method of aluminum wires was investigated for producing copper-coated aluminum wire composites. The interface microstructure between the aluminum wire and the copper coating layer was analyzed by scanning electron microscopy （SEM） and energy-dispersive X-ray spec- trometry （EDS）. Five different fluxing agents were tested. Experimental results show that appropriate conditions for the hot-dip process are determined as the liquid copper temperature of 1085℃ and the treatment time less than 1 s. A success in hot-dip copper-coated aluminum wires is achieved by hot-dipping a low-melting-point metal into a high-melting-point metal liquid, which is significant for the further devel- opment and application of copper-coated aluminum wire composites.

Thick Target Neutron Production on Aluminum and Copper by 40 MeV Deuterons

The thick target neutron yields （TTNYs） of deuteron-induced reaction on AI and Cu isotopes are analyzed by combining the improved nuclear models and particle transport effects. The modified Glauber model is employed mainly to produce the peak of double differential cross section for the breakup process, and the exciton model and the Hauser-Feshbach theory are used for the statistical processes. The thin-layer accumulation method is used to calculate the TTNYs considering the neutron attenuation effects in the target. The calculated results are compared with the existing experimental data, and the analysis method can predict the TTNY data well at the deuteron energy of 40 MeV.

On the direct use of recovered scrap copper and saving copper with aluminum in the Chinese cable industry

The copper consumption by the Chinese cable industry amounted to 354×104 t in 2006, taking over 70 % of the total copper consumption in China in that year. At present, making copper rod directly from recovered scrap copper and saving copper with aluminum have become topics of general interests in the Chinese cable industry. The quality of the copper conductors in the industry is declining, resulting in sharp decrease in the rate of qualified wire and cable products. More and more copper wires are drawn from the rods made directly from scrap copper. The manufacturers know well some of the wires or rods are unqualified products though, they continue to use or produce products not complying with standards in order to make profits. Now the consumption of copper-clad-aluminum and copper-clad-steel is growing gradually. In 2006, the consumption of copper-clad-aluminum in China amounted to ca. 5×104 t. But in some applications, neither the common understanding between buyer and supplier nor the results of feasibility study are achieved in the product orientation and technical/economic feasibility in terms of saving copper with aluminum. This paper presents the status-quo, problems arisen and suggestions in terms of making copper rod directly from recovered scrap copper and saving copper with aluminum, in a view to promote these two topics of general interests to go toward a virtuous circle.

Analysis of Laser Micro Welding of Copper-Aluminum Dissimilar Metals and Its Mechanism

Micro welding of dissimilar metals can meet many performance requirements for modern engineering structures. In this experiment, laser micro welding of copper-aluminum dissimilar metals was conducted with an HWLW-300A energy negative feedback Nd:YAG pulse laser. By using the overlap welding method with copper on aluminum, with the laser energy being distributed unevenly, good weld joints were obtained. In this paper, the welding mechanism was analyzed from aspects such as welding temperature and the specific heat capacity of the solid metal. Existing defects were identified, and a feasible improvement scheme was proposed.

增强体表面改性在高导热金属基复合材料中的应用

随着电子技术的高速发展和电子器件的更新换代,电子封装材料的性能需求越来越高。金属基复合材料,尤其是铝基和铜基复合材料具有高导热、低膨胀、高稳定性等特点,是具有广阔应用前景的电子封装材料。然而,金刚石、石墨烯、硅等增强体与基体的润湿性差,或者在高温下与基体发生有害的界面反应,限制了此类高导热金属基复合材料的开发和应用。本文简述了金属基复合材料的界面研究进展,结合影响金属基复合材料界面结合的因素,提出了几种改善界面结合的方法。增强体表面改性是改善金属基复合材料界面的重要途径之一,常用工艺有磁控溅射法、化学气相沉积法、溶胶凝胶法、化学镀法等;最后,对增强体表面改性在高热导金属基复合材料中的应用进行分析和展望。

Cu对铝/钢CMT熔钎焊接头界面区组织的影响研究

采用冷金属过渡方法,以AlSi5焊丝为填充金属,在5052铝合金和镀锌钢板之间添加铜箔片进行搭接熔钎焊,使用扫描电子显微镜结合能谱分析和拉伸试验机对接头的界面区组织与性能进行研究。结果表明,未加入铜箔时,界面区组织主要由FeAl_(3)金属间化合物组成;铜箔的加入使得界面区组织中新生成了CuAl_(2)金属间化合物,同时改善了Zn在界面区的分布。Zn固溶于Al中,一定程度上抑制了Fe-Al金属间化合物产生。加入铜箔后的试样断裂位置发生改变,接头的承载能力与未加入铜箔的相近。

含碳Cu-Zn-Al乙炔选择性加氢催化剂制备及性能

采用共沉淀法制备不同Cu/Zn摩尔比铜-锌-铝水滑石前体,焙烧后经过乙炔预处理和H_(2)还原得到Cu_(m)Zn_(3-m)Al-LDO(T140-R150)催化剂(m取值为1、1.5、2、3)。对上述含碳铜-锌-铝催化剂进行N_(2)物理吸附、X射线衍射、扫描电子显微镜和透射电镜表征,研究其在大量乙烯存在时乙炔选择性加氢反应中的催化性能。结果表明:在铜-铝水滑石中引入锌,可提高前体中铜的分散度,有利于碳化铜(Cu_(x)C)加氢活性相的生成,提高乙炔选择性加氢反应的性能。催化剂最佳制备条件为:Cu/Zn摩尔比1,乙炔处理温度140℃,乙炔处理时间2 h,氢气还原温度150℃,氢气还原时间3 h。在温度100℃和压力0.1 MPa条件下,Cu_(1.5)Zn_(1.5)Al-LDO(T140-R150)催化乙炔选择性加氢反应的乙炔转化率达100%,乙烯选择性为53.9%,C4选择性为15.5%,乙烷选择性为30.6%。

基于扫频电阻法的变压器绕组材质辨识方法及实验验证

变压器生产中“以铝代铜”现象危害电力系统运行安全,为了简单有效地辨别变压器绕组材质,提出了一种基于扫频电阻法的辨识方法和实验方案,并根据该方案搭建了一套变压器绕组材质检测系统。首先对基于扫频电阻法的辨识方法进行了相关理论推导和证明,之后对基于该方法的检测系统性能进行了测试,最后对不同类型变压器进行了实验验证。实验结果表明该方法能够快速高效地辨别变压器绕组材质,具有较高的工程实用价值。

铝合金与镀铜钢CMT熔钎焊技术研究

采用Al Si12药芯焊丝作为填充材料,对2 mm厚的6082铝合金与Q235B镀铜钢进行对接冷金属过渡(CMT)熔钎焊接试验,研究不同焊接速度和镀铜层厚度对接头焊缝成型、界面组织和力学性能的影响,探讨Cu元素对金属间化合物层(IMC)生长的影响。结果表明:当焊接速度为350 mm/min时,铝在钢板正反面均有良好的润湿铺展,焊缝成型美观;IMC层厚度过大或过小均会对接头性能产生不利影响,当镀铜层厚度为10μm时,IMC层厚度为2.38μm,接头抗拉强度达到峰值138.7 MPa,相较于未镀铜接头的提高了31.9%,接头断裂于铝侧热影响区。镀铜层可以抑制界面层中θ-Fe(Al,Si)_(3)相的生成,阻碍Al、Fe反应,降低IMC层厚度。适当的镀铜层厚度可以有效改善接头的力学性能。镀铜层厚度过大促使Al_(2)Cu相产生,成为接头的薄弱区域。

铜电解阴极钛板碳化硅悬浮液超声波协同清洗研究

铜电解阴极钛板作为铜电解工艺的重要组成部分,其表面质量对电解质量和效率及钛板本身使用寿命有显著影响。针对此问题,采用碳化硅悬浮液超声波协同清洗技术对钛板进行简单、高效、环保的表面处理。通过铝箔腐蚀法探究了最佳清洗参数,分析了清洗过程中的协同效应及其作用机理。通过SEM+EDS和接触角测量仪对钛板表面清洁度、微观形貌和湿润性进行表征和评价。结果表明:距离换能器78 mm、碳化硅颗粒质量分数为0.05%,粒径为70 nm、p H值为中性、温度为55℃时清洗效果最佳;碳化硅悬浮液作为清洗介质,其协同效应可以明显提高清洗效率,改善钛板表面质量;清洗前后的对比表明,协同清洗能够有效地去除钛板表面的污染物,提高表面洁净度和湿润性,恢复钛板表面微观形貌及金属光泽。研究为优化钛板清洗工艺提供参考依据。

铝基板阳极氧化封孔工艺对覆铜板性能的影响

[目的]探究铝基板阳极氧化封孔工艺对覆铜板性能的影响。[方法]先采用草酸对7075铝合金阳极氧化,再在真空条件下采用Al_(2)O_(3)溶胶或/和ZnO溶胶进行封孔处理,并在300℃下加热固化。研究了两种溶胶单独封孔或组合封孔及封孔次数对阳极氧化膜导热系数与耐电压强度的影响。此外,还采用封孔样品为基板,分别通过溅射镀铜与热压合工艺制备铝基覆铜板。[结果]采用Al_(2)O_(3)溶胶和ZnO溶胶交替封孔4次可将阳极氧化膜的耐电压强度提升2.90倍左右,但会使其导热性略微变差。通过溅射镀铜所得覆铜板的剥离强度高达1.15N/mm,并且耐热性良好。[结论]对铝基板进行阳极氧化封孔能够显著改善覆铜板的性能。