Orthogonal tests of lead-clad tin bimetal continuous casting by air pressure core-filling

Abstract

To provide theoretical basis and practical guidance for preparing composite rods of external diameter no larger than 12 mm by directly continuous casting, low melting point materials of lead and tin were selected to prepare composite rods of external diameter 12 mm and inner diameter 8 mm with air pressing core filled continuous casting process. The orthogonal tests consisting of three factors and three levels were designed to investigate the parameters of melting lead temperature, continuous casting speed and air pressure that affect the performance of the composite rods. The results show that melting lead temperature is the most important factor that influences the solid/liquid interface location; continuous casting speed is the most important factor that influences the surface quality and lead and tin inter-diffusion amount; air pressure can improve the surface quality obviously and make the rods easily drawn out, but the surface quality cannot get obvious improvement when the air pressure is above 0.03 MPa. The composite rods have excellent surface quality, obvious intermediate layer, even thick clad, and metallurgical bonding interface under the condition of melting lead temperature of 375 °C, continuous casting speed of 10 mm/min, and air pressure of 0.03 MPa.

Keywords

lead-clad tin / air pressing core-filling / continuous casting / orthogonal test

References

[1] LeeJ. E., BaeD. H., ChungW. S., LeeJ. H., ChoY. R.. Effects of annealing on the mechanical and interface properties of stainless steel/aluminum/copper clad-metal sheets [J]. Journal of Materials Processing Technology, 2007, 187/188: 546-549

[2] AcarerM., DemirB.. An investigation of mechanical and metallurgical properties of explosive welded aluminum-dual phase steel [J]. Materials Letters, 2008, 62(25): 4158-4160

[3] VillasenorG. T., SanchezJ. N.. Aluminum clad zinc bimetallic planchet [J]. Materials and Design, 2008, 29(4): 798-800

[4] SasakiT. T., MorrisR. A., ThompsonG. B., SyarifY., FoxB. D.. Formation of ultra-fine copper grains in copper-clad aluminum wire [J]. Scripta Materialia, 2010, 63(5): 488-491

[5] KoD. C., LeeS. K., KimcB. M., JoH. H., JoH.. Evaluation of copper coating ratio in steel/copper clad wire drawing [J]. Journal of Materials Processing Technology, 2007, 186(1/2/3): 22-26

[6] LoI. H., TsaiW. T.. Effect of heat treatment on the precipitation and pitting corrosion behavior of 347 SS weld overlay [J]. Materials Science and Engineering A, 2003, 355(1/2): 137-143

[7] DurgutluA., GulencB., FindikF.. Examination of copper/ stainless steel joints formed by explosive welding [J]. Materials and Design, 2005, 26(6): 497-507

[8] DrozdovM., GurG., AtzmonZ., KaplanW. D.. Detailed investigation of ultrasonic Al-Cu wire-bonds: I. Intermetallic formation in the as-bonded state [J]. Journal of Materials Science, 2008, 43(18): 6029-6037

[9] WuC.-j., YuZ.-m., XieJ.-x., WuYuan.. Fabrication of Bimetal composites of copper-coated aluminum with continuous core-filling casting technology [J]. Foundry, 2004, 53(6): 432-434

[10] MarukovichE. I., BranovitskyA. M., NaY. S., LeeJ. H., ChoiK. Y.. Study on the possibility of continuous casting of bimetallic components in condition of direct connection of metals in a liquid state [J]. Materials and Design, 2006, 27(10): 1016-1026

[11] KhosravifardA., EbrahimiR.. Investigation of parameters affecting interface strength in Al/Cu clad bimetal rod extrusion process [J]. Materials and Design, 2010, 31(1): 493-499

[12] EivaniA. R., TaherA. K.. A new method for producing bimetallic rods [J]. Materials Letters, 2007, 61(19/20): 4110-4113

[13] WangQ.-n., LiuX.-h., LiuX.-f., XieJ.-xin.. Effects of annealing temperature on the microstructures and properties of copper-coated aluminum wire by cold hydrostatic extrusion [J]. Acta Metallurgica Sinica, 2008, 44(6): 675-680

[14] RheeK. Y., HanW. Y., ParkH. J., KimS. S.. Fabrication of aluminum/copper clad composite using hot hydrostatic extrusion process and its material characteristics [J]. Materials Science and Engineering A, 2004, 384(1/2): 70-76

[15] NarayanasamyR., BaskaranK., ArunachalamS., KrishnaD. M.. An experimental investigation on barreling of aluminum alloy billets during extrusion forging using different lubricants [J]. Materials and Design, 2008, 29(10): 2076-2088