The production process of CCA RIBBON involves a variety of technical requirements and technical difficulties, mainly including metal smelting, surface treatment, cladding technology, drawing and molding and many other aspects. The following are some of the main technical requirements and production difficulties:
- Metallurgical bonding of aluminum core and copper layer
The key to CCA RIBBON lies in the metallurgical bonding between the aluminum core and the copper layer, i.e., the copper layer and the aluminum core should form a strong inter-atomic bond rather than a simple physical cladding. The conductivity, strength and durability of CCA RIBBON can only be ensured if there is a good bond between the two metals.
Technical difficulties: The difference in melting points between aluminum and copper is large, and the surface of aluminum is prone to the formation of an oxide film, which prevents the copper layer from bonding to the aluminum. In order to achieve ideal metallurgical bonding, precise control of temperature, pressure and time is required to ensure that the copper layer forms a uniform and strong bond on the aluminum surface.
Solution: Use of a suitable cladding process (e.g. “dipping” or “calendering”) as well as an optimized annealing treatment to remove the oxide layer from the aluminium surface and to form a strong bond between the copper layer and the aluminium.
- Thickness control of the copper layer of CCA RIBBON
Technical requirements: The thickness of the copper layer of CCA RIBBON must be uniform and stable. Too thin a copper layer will lead to poor conductivity and easy to damage; too thick a copper layer may increase the manufacturing cost and weight, but also may affect the flexibility of the conductor.
Technical Difficulty: Precise control of the thickness of the copper layer is a challenge during the production process, especially during the continuous cladding and drawing process, where the stretching, compression and cooling speeds of the copper layer may be inconsistent, resulting in a non-uniform copper layer and affecting the quality of the final product.
Solution: Use high-precision drawing equipment and control systems to optimize the production process and ensure that the thickness of the copper layer is uniform and meets standards. In addition, annealing and other treatments are used to make the bond between the copper layer and the aluminum core stronger and to improve the uniformity of the copper layer.
- Surface treatment of CCA RIBBON
Technical requirements: The surface of CCA RIBBON must be smooth, free of oxides and impurities to ensure good electrical performance. Oxides on the surface of the copper layer will lead to increased contact resistance and affect the electrical conductivity.
Technical Difficulties: The surface of copper is easy to oxidize, and the oxide layer on the surface of aluminum is also very stubborn, effective measures must be taken to remove the oxide layer and prevent re-oxidation. The degree of surface cleanliness directly affects the electrical properties of CCA RIBBON.
Solution: Before the production of CCA RIBBON, the aluminum core needs to be chemically cleaned or mechanically cleaned (e.g. acid washing, sand blasting, etc.) to remove the oxide film on the aluminum surface. And on the copper layer of CCA RIBBON, chemical annealing or tin plating treatment is applied to prevent the copper layer from oxidizing. The whole production process should be carried out in a low oxygen environment to avoid oxidation.
- Annealing treatment technology
Technical requirements: Annealing is an important part in the production of CCA RIBBON, through which the flexibility of the wire can be improved, the internal stress can be reduced and fracture can be avoided. At the same time, annealing can also improve the metallurgical bonding of copper and aluminum.
Technical Difficulties: Due to the large difference between the melting points of copper and aluminum, precise control of temperature, atmosphere and time is required when annealing. Too high annealing temperatures can lead to oxidation of copper and aluminum, while too low annealing temperatures may fail to remove internal stresses, affecting the flexibility and strength of the wire.
Solution: Use automated temperature control equipment to ensure uniformity and accuracy of the annealing process and avoid over or under annealing temperatures. In addition, an inert gas (e.g. nitrogen) can be used during the annealing process to prevent oxidation.
- Drawing and molding technology
Technical requirements: The drawing process determines the final size, shape and mechanical properties of CCA RIBBON. During the drawing process, the diameter of CCA RIBBON must be precisely controlled, while avoiding defects such as breakage and scratches.
Technical difficulties: CCA RIBBON is prone to “copper layer peeling” during the drawing process, i.e., the bonding between the copper layer and the aluminum core is not strong, resulting in the shedding of the copper layer or partial fracture. In addition, the drawing process temperature, tension, lubrication and other factors may affect the quality of CCA RIBBON.
Solution: Optimize the drawing process to precisely control the drawing speed, tension and cooling process. Use specialized lubricants to reduce friction and temperature fluctuations to ensure the uniformity and mechanical properties of CCA RIBBON.
- Alloying treatment
Technical Requirements: In order to enhance the mechanical and electrical properties of CCA RIBBON, it is sometimes necessary to alloy copper or aluminum. Alloying helps to improve the strength, corrosion resistance and electrical conductivity of the material.
Technical Difficulties: The technology of alloying copper and aluminum is relatively complex, especially in the production process of CCA RIBBON, how to carry out effective alloying treatment without affecting the metallurgical bonding of CCA RIBBON is a technical difficulty.
Solution: Adopt advanced alloying technology, such as through surface alloying, coating alloying, etc., to ensure that the alloying of CCA RIBBON is uniform and does not affect the performance of raw materials.
- Anti-oxidation and anti-corrosion treatment
Technical requirements: CCA RIBBON may be subject to oxidation and corrosion during production and use, especially when the copper layer is exposed to air. Anti-oxidation and anti-corrosion are important measures to ensure the quality of CCA RIBBON.
Technical Difficulties: The anti-oxidation technology of CCA RIBBON needs to ensure that the surface of the copper layer will not be oxidized on the basis of maintaining good electrical properties. In addition, it is a challenge to prevent corrosion of the aluminum core, especially in environments with high humidity.
Solution: Prevent oxidation of CCA RIBBON by using coatings (e.g. tinning, silver plating, application of anti-corrosive oils, etc.) during the production process and protect the copper layer with a dry atmosphere or inert gas. When storing, use moisture and oxidation resistant packaging materials to keep CCA RIBBON dry.
- Optimization of the cladding process
Technical requirements: The cladding process determines the molding quality and cladding effect of CCA RIBBON, and requires that the combination of copper layer and aluminum core should be even and dense, and the thickness of copper layer should be in accordance with the standard.
Technical Difficulties: The control of temperature and pressure in the cladding process is one of the technical difficulties. If the cladding temperature is too high, it may lead to oxidation of copper and aluminum materials; if the cladding pressure is not enough, the combination between the copper layer and the aluminum core may not be strong.
Solution: Adopt advanced cladding equipment (e.g. bimetallic extruder, calender, etc.) to precisely control the temperature, pressure and time, so as to ensure the cladding process is uniform and efficient.
Summarize
The technical requirements and difficulties in the production of CCA RIBBON are mainly concentrated in the metallurgical bonding of metals, copper layer thickness control, surface treatment, annealing treatment, drawing and molding. To solve these technical difficulties, in addition to relying on advanced equipment and automated control technology, it is also necessary to optimize the process and strictly control each production link to ensure the quality and stability of the final product. The breakthrough and continuous improvement of these technical difficulties is the key to the development of CCA RIBBON industry.
