Titanium and titanium alloy wires are widely used in aerospace, petrochemicals, healthcare, automobiles, construction, and sports and leisure products. Currently, more than 80% of titanium and titanium alloy wires are used as welding wires; they can be woven into meshes for seawater filters, pure water filters, chemical filters, etc.; they are also used to manufacture fasteners, load-bearing components, springs, etc.; they are also used to manufacture medical devices, such as dental crowns and skull fixation for implants; titanium-nickel alloy wires are used to manufacture satellite antennas and eyeglass frames; and in the electroplating and water treatment industries, titanium alloy wires are used to manufacture various electrodes.
The drawing of titanium wire and titanium alloy wire is a metal plastic processing process in which a wire rod or wire blank is pulled out from the die hole of a drawing die under the action of a drawing force to produce titanium and titanium alloy wires with small cross-sections. There are several drawing processes:
(1) Fixed die drawing: Fixed die drawing is one of the main production processes for metal wires. The materials of the drawing die are mainly cemented carbide, natural diamond, synthetic diamond, and polycrystalline diamond. Single crystal natural diamond dies are commonly used in fine wire production. Titanium is a difficult material to process, not only because of its high deformation resistance and low plasticity, but also because of the adhesion problem during the processing, which has a very bad effect on the surface quality of the product. The improvement of the plasticity of titanium wire and the control of surface quality appear
In order to improve the surface quality of titanium wire, surface treatment is required before drawing to create conditions that are conducive to the large amount of lubricant adhering to the surface of the wire, that is, to form a layer of lubricant carrier. It includes surface oxidation treatment, fluorophosphate treatment, copper, chromium, nickel and tin plating and other metal films, among which oxidation treatment and coating treatment are the most common. For example, titanium wire is first slightly oxidized and annealed before drawing, then coated and dried.
(2) Roller die drawing: Since roller die drawing is done in a hole formed by non-transmission, freely rotating rollers, most of the sliding friction between the material and the die hole during fixed die drawing is converted into very small rolling friction, thereby greatly reducing the drawing friction. The disadvantage of roller die drawing is that the dimensional accuracy is not as high as that of fixed die drawing. It is suitable for coarse wire drawing, while fixed die drawing is used for finishing in fine wire drawing.
(3) Ultrasonic vibration drawing: This method was developed in the 1950s. During drawing, ultrasonic vibration is applied to the drawing die, which can effectively reduce the drawing force and improve the pass processing rate.
(4) Dieless drawing: This process uses an induction coil or laser to locally heat and soften the wire and apply tension to make the wire thinner. Its advantages are that it does not require a drawing die and lubricant, has a large deformation rate, and is highly efficient. Its disadvantages are poor dimensional uniformity of the finished product and unstable quality. (5) Pressure die drawing: This process involves installing a pressure nozzle device in front of the drawing die, which creates an automatic pressure-enhancing and forced lubrication effect during wire drawing. Its advantages include reducing wire breakage by 4/5, increasing the life of the drawing die by more than 20 times, and improving surface quality.
(5) Pressure die drawing: This process refers to a method in which a pressure nozzle device is installed in front of the drawing die to create an automatic pressure-boosting forced lubrication effect when the wire is drawn. Its advantages are that the frequency of wire breakage is reduced by 4/5, the life of the drawing die is increased by more than 20 times, and the surface quality is improved.
(6) Coating-jacketing bundle drawing: This method first coats a layer of low-carbon steel on the surface of the titanium wire, then bundles the coated titanium wire into a low-carbon steel tube, and then performs bundle drawing and intermediate annealing. After processing to the final size, the low-carbon steel jacket and coating are removed by sulfuric acid pickling. Its advantages are high efficiency and low production cost.
(7) Jacketing-chip extrusion: This process was developed by Tohoku University in Japan and is mainly used for the processing of TiNiol shape memory alloy wire. It can improve product quality and reduce production costs. First, a multilayer composite sheet composed of different metal sheets is prepared by cladding rolling. The thickness ratio of the various metal layers depends on the determined chemical composition. Then, the rolled clad sheet is cut into chips, the chips are filled into a container to make blanks, and the blanks are extruded into thin rods, which are then processed into thin wires. Finally, the composite wires are converted into the desired intermetallic compound wires through thermal diffusion treatment. (8) Continuous rolling of wires by a four-roller wire mill: This mill consists of four rollers forming a circular hole. During operation, one active roller drives the other three rollers to rotate. Multiple such stands forming a continuous rolling mill can produce titanium alloy wires, thereby significantly improving the productivity and yield of wires.
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