Production of Ultrafine Wire by Augmented Hydrostatic Extrusion

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The purpose of this research is to perform a systematic study of drawing-augmented hydrostatic extrusion for the production of ultrafine wire from soft materials on an existing unit. The program will include: (A) Stability optimization of the 63,000 pound per square inch laboratory unit for augmented hydrostatic extrusion of ultrafine wires; (B) Upper-bound analysis of the process including hydrodynamic lubrication effects; (C) Demonstration of unit capabilities for extruding ultrafine aluminum, aluminum-silicon, and gold wire and for cladding of ceramic super-conductor wires, including experimental studies to determine the effects of reduction ratios, die angles, speed, potential lubrication/pressure media and other variables on the process. The combination of both the experimental and analytical work is fundamental to the program. The analysis will improve the understanding of the process, while the experimental phase will demonstrate the utility of new information and improved process capability. The complete program will provide a definition of the capabilities and limitations of augmented hydrostatic extrusion for the production of ultrafine wire. This research will extend the upper limits on speed and reduction through the development of the understanding of the process. This understanding will lead to the development of algorithms for the control system, as well as to its implementation.