Metal deforming – With use of control means energized in response to activator... – Metal deforming by use of roller or roller-like tool element
Patent
1991-05-06
1995-11-07
Larson, Lowell A.
Metal deforming
With use of control means energized in response to activator...
Metal deforming by use of roller or roller-like tool element
72200, 72206, 72256, 7234296, 148432, 148576, 148684, B21B 116, B21B 1500, B21C 2308
Patent
active
054638860
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
The invention concerns a process for manufacturing soldering rods which contain at least 60 weight-% copper, preferably at least 80 weight-%, and at least one alloy component of the group phosphorus and silver by forming a block of a corresponding copper alloy into a wire at temperatures below the eutectic point.
Copper alloys of the above composition play a very special role as hard solders in soldering technology. Copper-phosphorus and copper-silver-phosphorus alloys are particularly preferred because of their low melting points and their low viscosity. According to DIN 8513 conventional copper alloys include LCU-P6 (6% phosphorus, rest copper) and LCU-P8 (8% phosphorus, rest copper). Also used are copper-silver alloys with a silver percentage between 2 and 15 wt. % (rest copper, optionally containing traces of tin, zinc and lead).
Both the phosphorus-containing and the silver-containing soldering alloys cause significant problems during the manufacture of the soldering rods which are obtained by cutting the wires into segments. Whereas the phosphorus-containing soldering material becomes more and more brittle with an increasing phosphorus content, the silver-containing soldering material is relatively ductile but is slow in gaining fluidity so that the forming speed is limited. Both the brittleness and the slow forming speed obstruct an economical manufacture of soldering rods which have to be produced from a block of a correspondingly large cross section into wires of a smaller cross section by means of extrusion. The diameter and/or cross section of these wires must then subsequently be reduced again by rolling and/or drawing.
Present manufacturing processes make use of completely alloyed cylindrical blocks, also referred to as "slugs", which have a length of 300 mm, a diameter of 83 mm and a weight of approximately 11.8 kg. These blocks are heated up to temperatures between 550 and 600.degree. C. and, by means of extrusion, they are simultaneously formed into several individual wires of desired final dimensions. Between 10 and 20 individual wires are simultaneously produced depending on the cross section of the wire. The handling of the wire bundles, however, which have to be withdrawn from the extruder, is difficult and renders a large-scale industrial production almost impossible. Already the extrusion involves a material loss of more than 5%.
There is further loss of material during the continued manufacture. The bundles of wires that are withdrawn are bonded together more or less strongly due to material adhesion. They are usually cut to conventional lengths of 385 or 500 mm, for example, by shearing or stamping. The quality of these individual rods which are obtained by cutting through an entire bundle of wires is by far not satisfactory with respect to the quality of the cut. Consequently, the cutting results in further loss of material which amounts to approximately 10% of the initially used material.
The rods that were cut to length and provided with dark oxide films must subsequently be pickled in diluted sulfuric acid, then rinsed with water and after the rinsing barrel-polished with wood chips to regain a metallic shine. This process also involves an extraordinary amount of labor and cost since it requires complicated processes for the disposal of sulfuric acid and sulfate solutions to meet requirements of environmental protection.
Although the above described loss of material is only temporary since the alloy can be recovered again by melting, this "recycling" still constitutes a major cost factor that can not be transferred to the customer. Ultimately, the remelting, due to the energy consumption involved, is also an environmental load to be avoided.
Another method that has been applied is the use of extrusion processes to produce wires of larger diameters where the cross section is then reduced by means of rolling and/or drawing thus obtaining, for example, prismatic cross sections such as square cross sections. However, these measures involve an extraordina
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Dies, Dr. Ing. Kurt, Kupfer und Kupferlegierungen in Der Technik, Springer Publishing, 1967, pp. 655-663.
Larson Lowell A.
Rothenberger Werkzeuge-Maschinen GmbH
Schoeffler Thomas C.
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