Aluminum alloy wire rod, aluminum alloy stranded wire, coated wire, wire harness and manufacturing method of aluminum alloy wire rod

• US 9,773,580 B2
• Filed: 04/24/2015
• Issued: 09/26/2017
• Est. Priority Date: 03/29/2013
• Status: Active Grant

• Current Assignee: Furukawa Automotive Systems Incorporated (Furukawa Electric Company Limited), Furukawa Electric Company Limited
• Original Assignee: Furukawa Automotive Systems Incorporated (Furukawa Electric Company Limited), Furukawa Electric Company Limited
• Inventors: Yoshida, Sho, Sekiya, Shigeki, Susai, Kyota, Mitose, Kengo
• Primary Examiner(s): King, Roy
• Assistant Examiner(s): LUK, VANESSA TIBAY
• Application Number:
  US14/695,934
• Publication Number:
  US 20150235729A1
• Time in Patent Office: 886 Days
• CPC Class Codes: C22C 21/00 Alloys based on aluminium
• CPC Class Codes: C22C 21/02 with silicon as the next major constituent
• CPC Class Codes: C22C 21/08 with silicon
• CPC Class Codes: C22F 1/00 Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working apparatus for mechanical working of metal B21, B23, B24
• CPC Class Codes: C22F 1/04 of aluminium or alloys based thereon
• CPC Class Codes: C22F 1/043 of alloys with silicon as the next major constituent
• CPC Class Codes: C22F 1/047 of alloys with magnesium as the next major constituent
• CPC Class Codes: C22F 1/05 of alloys of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
• CPC Class Codes: H01B 1/02 mainly consisting of metals or alloys
• CPC Class Codes: H01B 1/023 Alloys based on aluminium
• CPC Class Codes: H01B 13/00 Apparatus or processes specially adapted for manufacturing conductors or cables
• CPC Class Codes: H01B 13/0016 for heat treatment
• CPC Class Codes: H01B 7/0045 Cable-harnesses
• CPC Class Codes: Y10T 428/2927 including structurally defined particulate matter

Abstract

An aluminum alloy wire rod has a composition consisting of Mg: 0.10 to 1.00 mass %, Si: 0.10 to 1.00 mass %, Fe: 0.01 to 1.40 mass %, Ti: 0.000 to 0.100 mass %, B: 0.000 to 0.030 mass %, Cu: 0.00 to 1.00 mass %, Ag: 0.00 to 0.50 mass %, Au: 0.00 to 0.50 mass %, Mn: 0.00 to 1.00 mass %, Cr: 0.00 to 1.00 mass %, Zr: 0.00 to 0.50 mass %, Hf: 0.00 to 0.50 mass %, V: 0.00 to 0.50 mass %, Sc: 0.00 to 0.50 mass %, Co: 0.00 to 0.50 mass %, Ni: 0.00 to 0.50 mass %, and the balance: Al and incidental impurities. A dispersion density of compound particles having a size of 20-1000 nm is 1 particle/μm² or higher. In a distribution of the compound particles in the aluminum alloy wire rod, a maximum dispersion density of the compound particles is less than or equal to five times a minimum dispersion density of the compound particles.

Claims

1. An aluminum alloy wire rod having a composition consisting of Mg:

0.30 mass % to 0.70 mass %, Si;

0.30 mass % to 0.70 mass %, Fe;

0.01 mass % to 1.40 mass %, Ti;

0.000 mass % to 0.100 mass %, B;

0.000 mass % to 0.030 mass %, Ag;

0.00 mass % to 0.50 mass %, Au;

0.00 mass % to 0.50 mass %, Mn;

0.00 mass % to 1.00 mass %, Cr;

0.00 mass % to 1.00 mass %, Zr;

0.00 mass % to 0.50 mass %, Hf;

0.00 mass % to 0.50 mass %, V;

0.00 mass % to 0.50 mass %, Sc;

0.00 mass % to 0.50 mass %, Co;

0.00 mass % to 0.50 mass %, Ni;

0.00 mass % to 0.50mass %, and the balance;

Al and incidental impurities,

wherein a dispersion density of compound particles having a particle size of 20 nm to 1000 nm is greater than or equal to 1 particle/μ

m² and

in a distribution of the compound particles in the aluminum alloy wire rod, a maximum dispersion density of the compound particles is less than or equal to five times a minimum dispersion density of the compound particles.

2. The aluminum alloy wire rod according to claim 1, wherein the composition consists of at least one element selected from a group consisting of Ti:

0.001 mass % to 0.100 mass % and B;

0.001 mass % to 0.030 mass %.

3. The aluminum alloy wire rod according to claim 1, wherein the composition consists of at least one element selected from a group consisting of Ag:

0.01 mass % to 0.50 mass %, Au;

0.01 mass % to 0.50 mass %, Mn;

0.01 mass % to 1.00 mass %, Cr;

0.01 mass % to 1.00 mass %, Zr;

0.01 mass % to 0.50 mass %, Hf;

0.01 mass % to 0.50 mass %, V;

0.01 mass % to 0.50 mass %, Sc;

0.01 mass % to 0.50 mass %, Co;

0.01 mass % to 0.50 mass %, and Ni;

0.01 mass % to 0.50 mass %.

4. The aluminum alloy wire rod according to claim 1, wherein a sum of contents of Fe, Ti, B, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co, and Ni is 0.01 mass % to 2.00 mass %.

5. The aluminum alloy wire rod according to claim 1, wherein number of cycles to fracture measured in a bending fatigue test is greater than or equal to 100,000 cycles, a conductivity is 45% to 60% IACS and an elongation is 5% to 20%.

6. The aluminum alloy wire rod according to claim 1 wherein an impact absorption energy is greater than or equal to 200 J/cm².

7. The aluminum alloy wire rod according to claim 1, wherein the aluminum alloy wire rod has a diameter of 0.1 mm to 0.5 mm.

8. An aluminum alloy stranded wire comprising a plurality of aluminum alloy wire rods as claimed in claim 1 which are stranded together.

9. A coated wire comprising a coating layer at an outer periphery of the aluminum alloy stranded wire as claimed in claim 8.

10. A wire harness comprising the coated wire as claimed in claim 9 and a terminal fitted at an end portion of the coated wire, the coating layer being removed from the end portion.

20. A method of manufacturing an aluminum alloy wire rod as claimed in claim 1, the aluminum alloy wire rod being obtained by carrying out a dissolving process, a casting process, a hot or cold working process, a first wire drawing process, an intermediate heat treatment, a second wire drawing process, a solution heat treatment and an aging heat treatment in this order,

wherein, a cooling rate of the casting process is 5°

C./s to 20°

C./s,

the intermediate heat treatment is performed in a temperature range of 300°

C. to 480°

C., an energy area of an energy applied to an aluminum alloy conductor rod in the temperature range is 180°

C.·

h to 2500°

C.·

h,

a die used in the first wire drawing process has a die half angle of 1°

to 10° and

a reduction ratio per pass of 10% to 40%, and

a die used in the second wire drawing process has a die half angle of 1°

to 10° and

a reduction ratio per pass of 10% to 40%.

11. An aluminum alloy wire rod having a composition consisting of Mg:

0.50 mass % to 1.00 mass %, Si;

0.50 mass % to 1.00 mass %, Fe;

0.01 mass % to 1.40 mass %, Ti;

0.000 mass % to 0.100 mass %, B;

0.000 mass % to 0.030 mass %, Ag;

0.00 mass % to 0.50 mass %, Au;

0.00 mass % to 0.50 mass %, Mn;

0.00 mass % to 1.00 mass %, Cr;

0.00 mass % to 1.00 mass %, Zr;

0.00 mass % to 0.50 mass %, Hf;

0.00 mass % to 0.50 mass %, V;

0.00 mass % to 0.50 mass %, Sc;

0.00 mass % to 0.50 mass %, Co;

0.00 mass % to 0.50 mass %, Ni;

0.00mass % to 0.50 mass %, and the balance;

Al and incidental impurities,

wherein a dispersion density of compound particles having a particle size of 20 nm to 1000 nm is greater than or equal to 1 particle/μ

m² and

in a distribution of the compound particles in the aluminum alloy wire rod, a maximum dispersion density of the compound particles is less than or equal to five times a minimum dispersion density of the compound particles.

12. The aluminum alloy wire rod according to claim 11, wherein the composition consists of at least one element selected from a group consisting of Ti:

0.001 mass % to 0.100 mass % and B;

0.001 mass % to 0.030 mass %.

13. The aluminum alloy wire rod according to claim 11, wherein the composition consists of at least one element selected from a group consisting of Ag:

0.01 mass % to 0.50 mass %, Au;

0.01 mass % to 0.50 mass %, Mn;

0.01 mass % to 1.00 mass %, Cr;

0.01 mass % to 1.00 mass %, Zr;

0.01 mass % to 0.50 mass %, Hf;

0.01 mass % to 0.50 mass %, V;

0.01 mass % to 0.50 mass %, Sc;

0.01 mass % to 0.50 mass %, Co;

0.01 mass % to 0.50 mass %, and Ni;

0.01 mass % to 0.50 mass %.

14. The aluminum alloy wire rod according to claim 11, wherein a sum of contents of Fe, Ti, B, Ag, Au, Mn, Cr, Zr, Hf, V, Sc, Co, and Ni is 0.01 mass % to 2.00 mass %.

15. The aluminum alloy wire rod according to claim 11, wherein number of cycles to fracture measured in a bending fatigue test is greater than or equal to 100,000 cycles, a conductivity is 45% to 60% IACS and an elongation is 5% to 20%.

16. The aluminum alloy wire rod according to claim 11, wherein the aluminum alloy wire rod has a diameter of 0.1 mm to 0.5 mm.

17. An aluminum alloy stranded wire comprising a plurality of aluminum alloy wire rods as claimed in claim 11 which are stranded together.

18. A coated wire comprising a coating layer at an outer periphery of the aluminum alloy stranded wire as claimed in claim 17.

19. A wire harness comprising the coated wire as claimed in claim 18 and a terminal fitted at an end portion of the coated wire, the coating layer being removed from the end portion.