Research On The New Casting-Extrusion Technology To Fabricate Aluminum/Copper Clad Composite Wire

Aluminum/copper clad composite wire (shorted by copper-clad aluminum conductor) is a kind of metallic core composite material. The red copper and pure aluminum are used as the sheath and core respectively. And the interface between aluminum and copper is bonded tightly. The composite wire is widely used in telecommunication, architecture, lightweight electromagnetic wire as well as cable conductor fields. It not only has the advantages of less weight, convenience for transportation and installment, abundance of resources and low cost, but also improves the stability and reliability of cables.In this paper, on the basis of aluminum/copper clad composite extrusion processing technology and substantial domestic and foreign literatures, finite element analysis software DEFORM was used. With a focus on the difference between traditional method and casting-extrusion method, the finite element numerical simulation of extrusion process was carried out. As a result, the low-pressure casting method was proved to be much superior.In this paper, several preparation work before cold extrusion process was introduced firstly. And the related theory was studied as well, including: the design of extrusion process scheme for aluminum/copper clad composite, the design and analysis of the extrusion dies, the ascertainment of extrusion parameters and the simple introduction of the briefly defects observed in extrusion process.The emphasis of the paper is that the extrusion technology of aluminum/copper clad composite simulated by DEFORM. And advantages of low pressure casting-cold extrusion technology were concluded. Major analysis of simulation results were included as follows: copper wall thickness, extrusion speed and the friction factor's influence on the quality of extruded products, thinning rate of copper tube after extrusion and the extrusion defects. Finally, the study on test production was made, including the study of extrusion process, the measurement of extrusion force and the metallurgical structure before and after extrusion process. By means of comparison between experimental test and finite simulation, the feasibility and superiority of casting-extrusion method were verified.