Cold rolling process routes for production of profile wire in copper, copper based and copper coated materials

Transcription

1 Cold rolling process routes for production of profile wire in copper, copper based and copper coated materials Enzo Stucchi Wire Rolling Technology IWCC Technical Seminar 2014 Mumbai, India 3 to 4 March 2014

2 mission: serving metals industry We, at DEM, are specialized in providing advanced solutions in ROLLING for COLD as well as for HOT forming of FERROUS and NON FERROUS materials supporting Metal Industries, including COPPER MANUFACTURERS, to better serve their customers

3 milestones in COPPER technology A complete Flat Wire Rolling (FWR) line is installed in Italy for production of copper electroconductors starting from cast wire rod A complete Profile Wire Rolling (PWR) line is installed in Europe for production of superconductors used for giant magnets to be installed in the first nuclear fusion power plant under international ITER project

4 milestones in COPPER technology : Cold Rolling Technology is supplied to North America for production of thin strip used in copper clad busbars and PV ribbon : commissions succesfully a complete Cold Rolling Line in Germany for production of thin square and rectangular shapes in Cu based alloys used as hi-tech wire.

5 Cold rolling process routes for production of profile wire in copper, copper based and copper coated materials CASE STUDIES: 1. Flat copper wire in hardening grades (Cu ETP1 Number CW004A) 2. Flat and square profiles in Brass, Bronze, Nickel-Silver and other Copper alloys 3. Thin strip in Cu OF or Cu ETP grades

6 Copper profiles Flat copper wire hardening grade (Cu ETP1 Number CW004A): - Applications, in general - bare copper strips, used in electrical connections in general - paper insulated copper conductors, used as winding for electrical transformers, reactors etc. - glass yarn insulated copper strips, used in alternators, turbo alternators - glass yarn+polyester yarn copper strips, used in electric dry windings - polyimide film insulated copper strips, used for stator-rotor windings - Sizes, in general: - thickness 3,5 mm - width 4 to 30 mm - Packaging, in general: - on standard spools, all commercial sizes - weights, as required, generally up to 3000 kg

7 Copper profiles: process route 1. Soft cast rod copper in coils is processed to hardened pre-drawn wire on spools ready-for-rolling 2. Pre-drawn wire or pre-rolled annealed flat strip are uncoiled in flyers or spool decoilers to enter the 3-stands Flattening Rolling Line built with horizontal rolls and equipped with Easy & Quick Rolls changing device

8 Copper profiles: process route 3. Flat strip is rolled following a descending reduction concept with final skinpass. Intermediate edgers control the width. Heat removal by spraying of emulsion on product and rolls. 4. After flat strip material is cleaned on surface, laser takes measurement of width and thickness. In case of repeated deviation, on-line correction under load takes place in last working stand and edger. Then, strip is coiled.

9 performances Speed: up to 600 m/min Starting material from 0.6 mm to 20 mm in diameter Production in bars possible: straightening, fine cut-to-length and unloading devices available. Coiling up to 5000 kg Tolerance achieved: Thickness : 0,01 mm Width and corners: ½ standard Less hardening to get mechanical properties: hence less cost for annealing compared to drawing process and higher speed

10 Copper based materials Flat and square profiles in Brass, Bronze, Nickel Silver and other Copper alloys: - Applications, in general - electro-erosion wire - electronic wire - welding and brazing wire - special applications: optics, etc. - Sizes, in general: - flat profile, thickness 1,0 mm - flat profile, width 5,0 mm - square, from 0,35 mm to 1,4 mm - Packaging, in general: - std. DIN 355 to DIN 800, metallic or plastic spools - weights, as required, generally up to 1000 kg

11 Copper based material: process route 1. Round wire from melting-casting process is paid off in a high speed horizontal de-coiler. 2. The paid off wire is then calibrated on-line in a drawing die to pre-set exactly the starting material prior to being formed in Profile Rolling Stands.

12 Copper profiles: process route 3. Round wire is rolled down to flat or square Profile Rolling Stands (turk heads) equipped with high precision rolls. The stands are driven and pulled. Heat removal by oil spraying of oil and submerged dancers. 4. Measurement of width and thickness between stands and before spooling. Oil removal via air wiping and detergent. Traverse oscillated coiling with fixed rolling axis. Automatic spool changing.

13 performances Speed: up to 1200 m/min Starting material from 0.48 mm to 2,00 mm in diameter Coiling: traverse oscillated, perfect coiling 0,002 mm (2µ)! Tolerance achieved: Thick/Width: 0,002 mm (2µ) No romboidity Less hardening to get mechanical properties: hence less cost for annealing compared to drawing process and higher speed

14 Copper thin strip used for coating and PV ribbon Thin strip in Cu OF or Cu ETP grades: - Applications, in general - copper clad conductors - ribbon for solar cells - Sizes, in general: - flat strip, thickness 0,63 mm - flat strip, width 15,0 mm - Packaging, in general: - coreless coils (no spools), traverse wound, with or without cardboard - weights, as required, generally up to 2000 kg

15 Copper thin strip: process route 1. Cast rod copper in soft state is paid off. 2. The copper rod is rolled down in a 4-stands Flattening Rolling Line built with horizontal rolls and equipped with Easy & Quick Rolls changing device.

16 Copper thin strip: process route 3. Flat strip is rolled following a descending reduction concept. Intermediate edgers control the width. Heat removal by spraying of emulsion and submerged dancers, as required. 4. Flat strip is measured on width and thickness. In case of repeated deviation, on-line correction under load takes place in last working stand. Then, strip is coiled and automatically unloaded

17 performances Speed: up to 600 m/min Starting material from 3 mm to 5,00 mm in diameter Coiling: traverse oscillated, perfect coiling Ready-made packaging for downstream processing Tolerance achieved: Thickness : ±0,01 Width: ±0,05

18 Micro Rolling Cassettes A solution purposefully developed to replace traditional drawing dies used on all-type multi-pass drawing lines for non ferrous metals. Full interchangeable: any existing drawing line can be adapted to receive Micro Rolling Cassettes provided there is room enough to match the wire pass line. No intermediate annealing required when using Micro Rolling Cassettes (with dies even two intermediate annealings needed).

19 market: the world

20 LOCATION Wire Rolling Technology Viale del Lavoro, 23 Z.I.U. Lauzacco Pavia di Udine - Italy info@demgroup.com Enzo Stucchi e.stucchi@demgroup.com PREVIOUS

21 Thank you ' (0 SEE YOU IN DÜSSELDORF AT WIRE 2014 BOOTH 11H41