Aluminum extrusions including co-extruded insulated, coated and/or non-circular shaped reinforcing wires
A co-extruded part includes an aluminum extrusion and a plurality of reinforcing wires. The plurality of wires include an outer coating layer, a non-circular cross section, and/or an outer layer including woven glass fibers. The plurality of wires are arranged in the aluminum extrusion. The plurality of reinforcing wires are co-extruded with the aluminum extrusion.
1 . A co-extruded part comprising:
an aluminum extrusion; and
a plurality of reinforcing wires including an outer coating layer and arranged in the aluminum extrusion,
wherein the plurality of reinforcing wires are co-extruded with the aluminum extrusion, and
wherein the outer coating layer includes a copper-based alloy that does not melt during extrusion to create a solid-state diffusion bond.
2 . The co-extruded part of claim 1 , wherein the aluminum extrusion includes an aluminum alloy selected from a group consisting of 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and 7075.
3 . The co-extruded part of claim 1 , wherein the plurality of reinforcing wires include a material selected from a group consisting of iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and alloys thereof.
4 . The co-extruded part of claim 1 , wherein the plurality of reinforcing wires include a material selected from a group consisting of carbon steel, austenitic stainless spring steel, and martensitic stainless spring steel.
5 . A co-extruded part comprising:
an aluminum extrusion; and
a plurality of reinforcing wires including an outer coating layer and arranged in the aluminum extrusion,
wherein the plurality of reinforcing wires are co-extruded with the aluminum extrusion, and
wherein the plurality of reinforcing wires comprise helical reinforcing wires including a longitudinal helical groove.
6 . The co-extruded part of claim 1 , wherein the plurality of reinforcing wires have a circular cross section and a diameter in a range from 0.5 mm to 2 mm.
7 . The co-extruded part of claim 1 , wherein a thickness of the outer coating layer is in a range from 1 μm to 50 μm.
8 . The co-extruded part of claim 1 , wherein a surface of the outer coating layer has a surface roughness (Ra) in a range from 10% to 75% of an average thickness T of the outer coating layer.
9 . A co-extruded part comprising:
an aluminum extrusion; and
a plurality of reinforcing wires including an outer coating layer and arranged in the aluminum extrusion,
wherein the plurality of reinforcing wires are co-extruded with the aluminum extrusion, and
wherein the outer coating layer includes an insulating layer selected from a group consisting of aluminum nitride (AlN), alumina (Al 2 O 3 ), and boron nitride (BN).
10 . The co-extruded part of claim 9 , wherein the plurality of reinforcing wires have a non-circular cross section.
11 . The co-extruded part of claim 9 , wherein:
the aluminum extrusion includes an aluminum alloy selected from a group consisting of 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and 7075, and
the plurality of reinforcing wires include a material selected from a group consisting of iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and alloys thereof.
12 . The co-extruded part of claim 9 , wherein:
the aluminum extrusion includes an aluminum alloy selected from a group consisting of 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and 7075, and
the plurality of reinforcing wires include a material selected from a group consisting of carbon steel, austenitic stainless spring steel, and martensitic stainless spring steel.
13 . The co-extruded part of claim 9 , wherein:
the plurality of reinforcing wires have a circular cross section and a diameter in a range from 0.5 mm to 2 mm, and
a thickness of the outer coating layer is in a range from 1 μm to 50 μm.
14 . The co-extruded part of claim 5 , wherein the outer coating layer includes a material selected from a group consisting of zinc, zinc-magnesium, zinc-magnesium-aluminum, copper, and copper-zinc.
15 . The co-extruded part of claim 5 , wherein the outer coating layer includes a zinc-based alloy that melts during extrusion to create a liquid diffusion bond.
16 . The co-extruded part of claim 5 , wherein:
the aluminum extrusion includes an aluminum alloy selected from a group consisting of 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and 7075, and
the plurality of reinforcing wires include a material selected from a group consisting of iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and alloys thereof.
17 . The co-extruded part of claim 5 , wherein:
the aluminum extrusion includes an aluminum alloy selected from a group consisting of 6034, 6061, 6082, 6282, 7003, 6063, 6005, 6008, 1050, 3103, 3003, and 7075, and
the plurality of reinforcing wires include a material selected from a group consisting of carbon steel, austenitic stainless spring steel, and martensitic stainless spring steel.
18 . A co-extruded part comprising:
an aluminum extrusion; and
a plurality of reinforcing wires including an outer layer comprising woven glass fibers,
wherein the plurality of reinforcing wires are made of a material selected from a group consisting of iron (Fe), copper (Cu), nickel (Ni), titanium (Ti), and alloys thereof, and
wherein the aluminum extrusion and the plurality of reinforcing wires with the outer layer are co-extruded.
19 . The co-extruded part of claim 18 , wherein:
the plurality of reinforcing wires includes an outer coating layer; and
a surface of the outer coating layer has a surface roughness (Ra) in a range from 10% to 75% of an average thickness T of the outer coating layer.
20 . The co-extruded part of claim 18 , wherein the plurality of reinforcing wires have a non-circular cross section.