Production of Ultrafine Wire by Augmented Hydrostatic Extrusion

本研究的目的是系统地研究在现有装置上利用软材料生产超细线材的拉拔-增压静液挤压工艺。该方案将包括：(A)对每平方英寸63,000磅的超细钢丝增压静液挤压实验室装置的稳定性进行优化；(B)包括流体动力润滑效应在内的工艺上限分析；(C)展示挤压超细铝、铝硅和金丝以及包覆陶瓷超导线材的机组能力，包括确定压下率、模角、速度、潜在润滑/压力介质和其他变量对工艺的影响的实验研究。实验和分析工作的结合是该计划的基础。分析将提高对过程的理解，而试验阶段将展示新信息的效用和改进的过程能力。完整的计划将定义用于生产超细线材的增强型静液挤压的能力和局限性。这项研究将通过发展对过程的理解来扩大速度和减速的上限。这种理解将导致控制系统算法的发展，以及它的实施。

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.