Melt Quality induced Failure of Electrical Conductivity (EC) grade Aluminum Wires

  • Abdul Khaliq Swinburne University of Technology Melbourne, Australia
  • Muhammad Asif Rafiq Department of Metallurgical and Materials Engineering University of Engineering and Technology Lahore
  • Hafiz Tauqeer Ali Bristol University
  • Furqan Ahmad Department of Metallurgical and Materials Engineering University of Engineering and Technology Lahore
  • Shahid Mehmood Swansea University
  • John Grandfield Grandfield Technologies Pty Limited Coburg Victoria
  • Sagheer Abbas Ranjha Swinburne University of Technology Melbourne

Abstract


The failure of electrical conductivity grade (EC) aluminum during wire drawing process was investigated. The fractured aluminum wires were subjected to scanning electron microscopic (SEM) and energy dispersive X-ray (EDX) analysis for initial examination. Thermodynamic analysis of molten aluminum interaction with refractories was also carried using FactSage at temperatures of 710oC to predict stable phases. The SEM analysis revealed the presence of 2nd phase particles as inclusions in the cracked openings either in the form of deformed elongated or debris of oxides. The possible types of inclusions identified with EDX were Al2O3, Al3C4 (Al-Carbide), refractory bricks elements (Al, Mg, Si and O). The microscopic analysis of the polished samples revealed that these inclusions were fine ranging from 0.1 µm to 30 µm in size. The presence of transition metal borides particles was not identified during SEM analysis which may be fine enough to be detected with this microscope. The overall investigation suggested that the possible cause of this failure is the presence of 2nd phase particles as inclusions in the aluminum matrix, and it was associated with the poor quality of melt. During wire drawing process, these inclusions were pulled out of aluminum matrix by the wire-drawing forces to produce micro-voids which led to ductile tearing and final fracture of wires. It was recommended to use ceramic foam filters to isolate inclusions from molten aluminum.

Author Biography

Abdul Khaliq, Swinburne University of Technology Melbourne, Australia

Dr. Abdul Khaliq is working as a Research Assistant and Sessional Teaching Staff at Swinburne University of Technology, Melbourne. Dr. Khaliq is also an Assistant Professor in the Department of Metallurgical and Materials Engineering University of Engineering and Technology Lahore, Pakistan. Dr. Khaliq obtained his PhD degree in Metallurgical Engineering from Swinburne University of Technology Melbourne in 2013. Dr. Khaliq, recently completed a Postdoctoral Research Fellowship on the “Extraction of Valuable Metals from Electronic Waste”, a cluster project funded by CSIRO Australia. He has also completed MSc degree in Sustainable Engineering-Energy Systems and Environment from University of Strathclyde, Glasgow, UK.

Dr. Khaliq has recognized himself in the field of process metallurgy especially the thermodynamic and kinetic modeling of metallurgical processes. Other expertise are metals refining, process flowsheet development, techn-economic analysis, phase equilibria, energy efficient and sustainable processing of metals and alloys.

Dr. Khaliq has been an outstanding researcher in the field of process metallurgy. His research has made a significant impact on the industrial processes including boron treatment of molten aluminum. Dr. Khaliq has published more than 25 research articles (Journals, Conference Proceedings and Technical Reports) that are highly regarded in the research community. Dr. Khaliq is actively engaged in research and has secured 3 small grants mainly from industry. Currently, Dr. Khaliq is engaged with Siltech Pty Melbourne, to investigate the recycling and refining of residues from petrochemical and metallurgical industries. He has working experience with companies including Outotec (Australia), Umicore (Belgium), Silvercity Mines (Australia), Universal Cables (Malaysia) and Grandfield Technologies (Australia).

Dr. Khaliq have secured CAST CRC and SUPRA Awards for his PhD study and DFID Shared Scholarship for his MSc Degree. These scholarships are merit based and highly competitive. He is a member of Pakistan Engineering Council (PEC), Energy Institute, UK, VETASSESS and Engineering Australia.

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Published
2016/12/31
How to Cite
Khaliq, A., Rafiq, M. A., Ali, H. T., Ahmad, F., Mehmood, S., Grandfield, J., & Ranjha, S. A. (2016). Melt Quality induced Failure of Electrical Conductivity (EC) grade Aluminum Wires. Journal of Mining and Metallurgy, Section B: Metallurgy, 53(1), 75-81. Retrieved from https://aseestant.ceon.rs/index.php/jmm/article/view/9199
Issue
Vol. 53 No. 1 (2017)
Section
Original Scientific Paper

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