Melt quality induced failure of electrical conductor (EC) grade aluminum wires
The failure of electrical conductor grade (EC) aluminum during wire drawing process was investigated. The fractured aluminum wires were subjected to Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) analyses for an initial examination. Thermodynamic analyses of molten alu...
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| Format: | Article |
| Language: | English |
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University of Belgrade, Technical Faculty, Bor
2017-01-01
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| Series: | Journal of Mining and Metallurgy. Section B: Metallurgy |
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| Online Access: | http://www.doiserbia.nb.rs/img/doi/1450-5339/2017/1450-53391600030K.pdf |
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| author | Khaliq A. Rafiq M.A. Ali H.T. Ahmed F. Mehmood S. Grandfielde J. Ranjha S.A. |
| author_facet | Khaliq A. Rafiq M.A. Ali H.T. Ahmed F. Mehmood S. Grandfielde J. Ranjha S.A. |
| author_sort | Khaliq A. |
| collection | DOAJ |
| description | The failure of electrical conductor grade (EC) aluminum during wire drawing
process was investigated. The fractured aluminum wires were subjected to
Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) analyses
for an initial examination. Thermodynamic analyses of molten aluminum
interaction with refractories was also carried out using FactSage at 710°C to
predict the stable phases. The SEM/EDX analyses has revealed the inclusions
in aluminum matrix. The typical inclusions observed were Al2O3, Al3C4
(Al-Carbide) and oxides of refractories elements (Al, Mg, Si and O) that have
particle size ranging up to 5 μm. The transition metal boride particles were
not identified during SEM/EDX analyses these might be too fine to be detected
with this microscope. The overall investigation suggested that the possible
cause of this failure is second phase particles presence as inclusions in the
aluminum matrix, and this was associated with the poor quality of melt.
During wire drawing process, these inclusions were pulled out of the aluminum
matrix by the wiredrawing forces to produce micro-voids which led to ductile
tearing and final fracture of wires. It was recommended to use ceramic foam
filters to segregate inclusions from molten aluminum. |
| format | Article |
| id | doaj-art-8b9f4584ab4e4c2d8dc8cbba9bc8469d |
| institution | Kabale University |
| issn | 1450-5339 2217-7175 |
| language | English |
| publishDate | 2017-01-01 |
| publisher | University of Belgrade, Technical Faculty, Bor |
| record_format | Article |
| series | Journal of Mining and Metallurgy. Section B: Metallurgy |
| spelling | doaj-art-8b9f4584ab4e4c2d8dc8cbba9bc8469d2025-02-02T10:34:11ZengUniversity of Belgrade, Technical Faculty, BorJournal of Mining and Metallurgy. Section B: Metallurgy1450-53392217-71752017-01-01531758110.2298/JMMB151006030K1450-53391600030KMelt quality induced failure of electrical conductor (EC) grade aluminum wiresKhaliq A.0Rafiq M.A.1Ali H.T.2Ahmed F.3Mehmood S.4Grandfielde J.5Ranjha S.A.6Swinburne University of Technology, Faculty of Science, Engineering and Technology, Melbourne, Australia + University of Engineering and Technology, Metallurgical and Materials Engineering Department, Lahore, PakistanUniversity of Engineering and Technology, Metallurgical and Materials Engineering Department, Lahore, PakistanUniversity of Bristol, Department of Aerospace Engineering, Advanced Composites Centre for Innovation and Science (ACCIS), Bristol, UKUniversity of Engineering and Technology, Metallurgical and Materials Engineering Department, Lahore, PakistanNorthern Ireland Advanced Composites & Engineering Centre, Belfast, UKGrandfield Technologies Pty Limited, Coburg, Victoria, AustraliaSwinburne University of Technology, Faculty of Science, Engineering and Technology, Melbourne, AustraliaThe failure of electrical conductor grade (EC) aluminum during wire drawing process was investigated. The fractured aluminum wires were subjected to Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) analyses for an initial examination. Thermodynamic analyses of molten aluminum interaction with refractories was also carried out using FactSage at 710°C to predict the stable phases. The SEM/EDX analyses has revealed the inclusions in aluminum matrix. The typical inclusions observed were Al2O3, Al3C4 (Al-Carbide) and oxides of refractories elements (Al, Mg, Si and O) that have particle size ranging up to 5 μm. The transition metal boride particles were not identified during SEM/EDX analyses these might be too fine to be detected with this microscope. The overall investigation suggested that the possible cause of this failure is second phase particles presence as inclusions in the aluminum matrix, and this was associated with the poor quality of melt. During wire drawing process, these inclusions were pulled out of the aluminum matrix by the wiredrawing forces to produce micro-voids which led to ductile tearing and final fracture of wires. It was recommended to use ceramic foam filters to segregate inclusions from molten aluminum.http://www.doiserbia.nb.rs/img/doi/1450-5339/2017/1450-53391600030K.pdfaluminum wire drawinginclusionsductile fracturescanning electron microscope (SEM)oxides and carbides |
| spellingShingle | Khaliq A. Rafiq M.A. Ali H.T. Ahmed F. Mehmood S. Grandfielde J. Ranjha S.A. Melt quality induced failure of electrical conductor (EC) grade aluminum wires Journal of Mining and Metallurgy. Section B: Metallurgy aluminum wire drawing inclusions ductile fracture scanning electron microscope (SEM) oxides and carbides |
| title | Melt quality induced failure of electrical conductor (EC) grade aluminum wires |
| title_full | Melt quality induced failure of electrical conductor (EC) grade aluminum wires |
| title_fullStr | Melt quality induced failure of electrical conductor (EC) grade aluminum wires |
| title_full_unstemmed | Melt quality induced failure of electrical conductor (EC) grade aluminum wires |
| title_short | Melt quality induced failure of electrical conductor (EC) grade aluminum wires |
| title_sort | melt quality induced failure of electrical conductor ec grade aluminum wires |
| topic | aluminum wire drawing inclusions ductile fracture scanning electron microscope (SEM) oxides and carbides |
| url | http://www.doiserbia.nb.rs/img/doi/1450-5339/2017/1450-53391600030K.pdf |
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