Methods of manufacturing composite materials, composite wires, and welding electrodes
The present disclosure provides a method of manufacturing a composite material. The method can include compacting a copper alloy powder into a plurality of substantially uniform compressed sub-assemblies such that the copper alloy powder has a density that is greater than 50%. The plurality of compressed sub-assemblies can be layered relative one another within an aperture of a shell, the plurality of compressed sub-assemblies to form a consecutive assembly of compacted copper alloy. The shell may include one of the following: a precipitation hardened copper alloy, copper alloy, and carbon steel. The consecutive assembly can be sealed within the shell to form a billet. The billet can be hot-extruded to form a rod, and the extruded rod can be further drawn to form a composite wire of a desired diameter. The composite wire may be used to create a composite welding electrode.
1. A method of manufacturing a composite material, comprising:
compacting a copper alloy powder into a plurality of substantially uniform compressed sub-assemblies such that the copper alloy powder of the plurality of compressed sub-assemblies has a packing density that is greater than 50%;
providing a layer of un-compacted copper alloy powder within an aperture of a shell;
layering the plurality of compressed sub-assemblies relative one another within the aperture of the shell, the plurality of compressed sub-assemblies forming a consecutive assembly of compacted copper alloy; and
sealing the consecutive assembly within the shell to form a billet;
wherein the shell comprises one of the following: a precipitation hardened copper alloy, copper alloy, and carbon steel;
wherein the plurality of compressed sub-assemblies are layered on the layer of the copper alloy powder.
2. The method of claim 1 , wherein the shell is made of CuZr and the powder is dispersion strengthened copper.
3. The method of claim 1 , wherein the packing density of the copper alloy powder of the plurality of compressed sub-assemblies is greater than 65%.
4. The method of claim 1 , further comprising thermally heat treating the compressed sub-assemblies prior to layering the plurality of compressed sub-assemblies within the shell.
5. The method of claim 1 , further comprising purging the consecutive assembly with nitrogen.
6. The method of claim 5 , further comprising heating the billet to above ambient temperature of the consecutive assembly during the purging of the consecutive assembly.
7. The method of claim 1 , further comprising hot-extruding the billet to form a rod.
8. The method of claim 7 , wherein the billet is heated to a temperature above 900° C.
9. The method of claim 7 , further comprising drawing the extruded rod to form a composite wire having a desired diameter.
10. The method of claim 9 , further comprising deforming the wire into a composite welding electrode.
11. The method of claim 10 , wherein the composite welding electrode comprises:
a composite body having a tip portion and an end portion, the composite body including:
a shell defining a cavity through the end portion, the shell comprising a first metal that includes one or more of the following: a precipitation hardened copper alloy, copper alloy, and carbon steel;
a core within the shell, the core extending through the shell from the tip portion to the cavity, the core comprising a second metal that includes dispersion strengthened copper;
wherein the core and shell have a metallurgical bond formed from co-extrusion.
12. The method of claim 9 , wherein the core and the shell have a metallurgical bond formed from co-extrusion.
13. The method of claim 1 , wherein the compressed sub-assemblies are substantially uniform in shape and size.
14. The method of claim 1 , wherein the compressed sub-assemblies are cylindrical.
15. The method of claim 1 , wherein the compressed sub-assemblies are compressed prior to layering the plurality of compressed sub-assemblies relative one another within the shell.
16. A method of manufacturing a composite material, comprising:
compacting a copper alloy powder into a plurality of substantially uniform compressed sub-assemblies such that the copper alloy powder of the plurality of compressed sub-assemblies has a packing density that is greater than 65%;
providing a layer of un-compacted copper alloy powder within an aperture of a shell;
layering the plurality of compressed sub-assemblies relative one another within the aperture of the shell, the plurality of compressed sub-assemblies forming a consecutive assembly of compacted copper alloy;
sealing the consecutive assembly within the shell to form a billet;
hot-extruding the billet at a temperature above 900° C. to form a rod; and
drawing the extruded rod to form a composite wire having a desired diameter;
wherein the shell is made of CuZr and the powder is dispersion strengthened copper;
wherein the core and the shell have a metallurgical bond formed from co-extrusion;
wherein the compressed sub-assemblies are compressed prior to layering the plurality of compressed sub-assemblies relative one another within the shell; and
wherein the plurality of compressed sub-assemblies are layered on the layer of the copper alloy powder.