The process parameters that need to be controlled during the tungsten wire preparation process mainly include process parameters in material selection, smelting, forging, drawing and other links. The selection and control requirements of these parameters will be introduced in detail below.
1. Material selection
Material selection is the first step in the tungsten wire preparation process. The quality and purity of raw materials directly affect the performance and quality of the final product. Therefore, in the material selection process, it is necessary to select tungsten raw materials that meet the requirements. The purity of tungsten raw materials is usually required to be above 99.9%, and the use of tungsten raw materials containing impurity elements must be avoided.
2. Smelting
Smelting is one of the important links in the preparation process of tungsten wire. Parameters such as melting temperature, smelting time, and smelting atmosphere will all affect the performance of tungsten wire.
1. Melting temperature: Melting temperature is one of the key factors affecting the quality of tungsten wire. If the melting temperature is too low, the impurity and gas content in the tungsten wire will be high, affecting its performance; if the melting temperature is too high, the grains of the tungsten wire will become coarse, reducing its strength and elasticity. Therefore, during the smelting process, the smelting temperature needs to be strictly controlled, usually between 3300-3600°C.
2. Melting time: Melting time is also one of the important factors affecting the quality of tungsten wire. If the melting time is too short, the tungsten raw material will not be completely melted or the melting will be uneven, affecting the quality of the tungsten wire; if the melting time is too long, the impurity and gas content in the tungsten wire will be high, and it will also increase energy consumption and Cost of production. Therefore, during the smelting process, the smelting time needs to be reasonably controlled, usually between 1-2 hours.
3. Melting atmosphere: The melting atmosphere is also one of the important factors affecting the quality of tungsten wire. If the smelting atmosphere contains too much oxygen, water vapor and other gases, the gas content in the tungsten wire will be high, affecting its performance; if the smelting atmosphere contains too many reducing gases, the impurity content in the tungsten wire will be high. On the high side. Therefore, during the smelting process, the smelting atmosphere needs to be strictly controlled, and high-purity argon or helium is usually used as the protective gas.
3. Rotary forging
Rotation is one of the important links in the preparation process of tungsten wire. Parameters such as swaging temperature, swaging speed, and swaging pressure will all affect the performance of tungsten wire.
1. Swinging temperature: Swinging temperature is one of the key factors affecting the quality of tungsten wire. If the swaging temperature is too low, the plasticity of the tungsten wire will be poor and it will easily break or be incompletely deformed; if the swaging temperature is too high, the grains of the tungsten wire will become coarse, reducing its strength and elasticity. Therefore, during the rotary forging process, the rotary forging temperature needs to be strictly controlled, usually between 1200-1600°C.
2. Swinging speed: Swinging speed is also one of the important factors affecting the quality of tungsten wire. If the swaging speed is too slow, it will lead to low production efficiency; if the swaging speed is too fast, it will cause stress concentration on the tungsten wire, which may easily break or cause incomplete deformation. Therefore, during the rotary forging process, the rotary forging speed needs to be reasonably controlled, usually between 1-3 rpm.
3. Swinging pressure: Swinging pressure is one of the important factors affecting the quality of tungsten wire. If the swaging pressure is too low, the diameter of the tungsten wire will be uneven or too thin; if the swaging pressure is too high, the grains of the tungsten wire will become coarse, reducing its strength and elasticity. Therefore, during the rotary forging process, it is necessary to strictly control the magnitude and changing trend of the rotary forging pressure.
4. Pulling
Drawing is the last process in the preparation process of tungsten wire. Drawing temperature, drawing speed, drawing force and other parameters will affect the performance of tungsten wire.
1. Drawing temperature: Drawing temperature is one of the key factors affecting the quality of tungsten wire. If the drawing temperature is too low, the plasticity of the tungsten wire will be poor and it will easily break or be incompletely deformed; if the drawing temperature is too high, the grains of the tungsten wire will become coarse, reducing its strength and elasticity. Therefore, during the drawing process, the drawing temperature needs to be strictly controlled, usually between 800-1200°C.
2. Drawing speed: Drawing speed is also one of the important factors affecting the quality of tungsten wire. If the drawing speed is too slow, it will lead to low production efficiency; if the drawing speed is too fast, it will cause stress concentration on the tungsten wire, which may easily break or cause incomplete deformation. Therefore, during the drawing process, it is necessary to reasonably control the size and changing trend of the drawing speed.
3. Drawing force: Drawing force is one of the important factors affecting the quality of tungsten wire. If the pulling force is too small, the diameter of the tungsten wire will be uneven or too thin; if the pulling force is too large, the grains of the tungsten wire will become coarse, reducing its strength and elasticity. Therefore, during the drawing process, it is necessary to strictly control the size and changing trend of the drawing force, and also pay attention to the tension adjustment between different batches of tungsten wires to ensure the continuous and stable production of tungsten wires. In addition, it is also necessary to timely adjust the tungsten wires during the drawing process. Replace the mold to ensure the smoothness and accuracy of the mold to ensure the quality and performance of the tungsten wire. In summary, high strength and high elasticity are produced.
4. Mold material and surface treatment: The selection of mold material and surface treatment also have an important impact on the quality of tungsten wire. Generally speaking, mold materials should choose materials with high strength, high hardness, and good wear resistance, such as carbide, high-speed steel, etc. At the same time, the surface treatment of the mold is also very important. Chrome plating, tungsten plating, carburizing and other treatment methods can be used to improve the hardness and wear resistance of the mold, thereby ensuring the quality and performance of the tungsten wire.
5. Cooling method: During the drawing process, the choice of cooling method will also affect the quality of tungsten wire. If forced cooling methods such as water cooling or air cooling are used, the temperature change of the tungsten wire during the drawing process can be reduced, thereby avoiding grain growth and performance degradation caused by temperature changes. Therefore, during the drawing process, it is necessary to choose an appropriate cooling method according to the actual situation.
6. Storage and handling of tungsten wire: During the preparation process, tungsten wire needs to be stored and handled. During storage, care must be taken to avoid contamination and oxidation of the tungsten wire. Vacuum packaging or moisture-proof packaging can be used. When handling, care must be taken to avoid mechanical damage or chemical corrosion to the tungsten wire, and appropriate protective measures can be taken.
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