2016年7月27日星期三

LASER SURFACE PREPARATION OF ALUMINUM CONDUCTOR APPLIED IN CABLES MANUFACTURING

Joining carbon fiber composites and aluminum for lightweight cars and other multi-material high-end products could become less expensive, and the joints more robust, using a new laser surface-preparation method developed by researchers at the Oak Ridge National Laboratory (ORNL).
The process, developed by a team led by ORNL senior R&D staff member Adrian Sabau, replaces the practice of preparing a surface for bonding by hand using abrasive pads, grit blasting and environmentally harmful solvents. The team found that using a laser to remove layers of material from such surfaces improves the performance of the joints and provides a path toward automation for high-volume use.
Sabau says “Our technique is vastly superior to the conventional surface preparation methods, combined with the potentially dramatic reduction in the cost of carbon fiber polymer composites, this represents an important step toward increasing the use of this lightweight high-strength material in automobiles, which could reduce the weight of cars and trucks by 750 pounds.”
The surface treatment of aluminum and carbon fiber polymer composite is a critical step in the adhesive joining process, which directly affects the quality of bonded joints. Aluminum surfaces typically contain oils and other contaminants from production rolling operations, while carbon fiber surfaces often contain mold releases.
“These surface contaminants affect surface energies and the quality of adhesion, so it is critical that they are removed,” says Sabau, adding that the laser also penetrates into the top resin layer, leaving individual carbon fibers exposed for direct bonding to the adhesive and increasing the surface area for better adhesion.
Testing of single-lap, shear-joint specimens showed that strength, maximum load and displacement at maximum load were increased by 15%, 16% and 100%, respectively, over those measured for the baseline joints. Moreover, joints made with laser-structured surfaces could absorb approximately 200% more energy than conventionally prepared baseline joints, the researchers report.
Sabau notes that the process also doubles the energy absorption in the joints, which has implications for crash safety and potential use in armor protection for people and vehicles.
A project partner of Magna International, Tim Skszek says “The results are most encouraging, enabling the automated processing of a multi-material carbon fiber-aluminum joint. With this work, we were able to focus on addressing the gaps in technology and commercial use, and we look forward to applying these findings to products.”
Caledonian Single-core Automotive cable (Model: FLALRYW) to ISO 6722 Class C standard is one of the Automotive cables used aluminum and aluminum alloy as conductor. It’s PVC insulated and suitable for application inside the engine compartment. Aluminium conductor applied in automotive cables manufacturing has some special properties: hot pressure resistance, considerable weight savings compared to copper, etc.
Caledonian also have other cable products used aluminium in cables manufacturing:
  1. Trackside Signalling Aluminium Power Cables to BR880: the conductors used sector shaped solid plain aluminium to IEC 60228 class 2 or 5 standard.http://www.caledoniancable.com/English/product/Railway_Cables/Power_Control/Signalling_Aluminium.htm
  2. Cables with aluminium wire armour. Aluminium wire armour can protect cables from damage with lighter weight than copper wires. Such as 400Hz Airport Cables 7-core With Aluminium Wire Armour to BS 6724 and BS 5467 standard.
    http://www.caledoniancable.com/english/product/airport_cable/airport_lighting_cables/7-core_Aluminium.html
Or 600/1000V, PVC Insulated Cables according to IEC 60502-1 with aluminium wire                armourd.
http://www.caledoniancable.com/product/other%20standards/IEC_60502- 1_Cable/XLPE_Insulated_Cables_IEC%2060502-1(unarmoured).htm
  1. Cables with Aluminium/Polyester Tape. In cables construction, Aluminium/Polyester Tape can be used as overall screen to avoid the electromagnetic interference. Such as the Multipair Overall Screened Cables, they have pairs laid up in an aluminum/polyester tape with a tinned copper drain wire, and are suitable for used as audio, control and instrumentation cables.
    http://www.caledoniancable.com/product/Belden%20Equivalent%20Cables/8718.htm

Caledonian Cables Ltd is an ISO 9001 approved manufacturer of electric cables. We specialise in the manufacture of a wide range of cables. Armored, non-armored, underwater and overhead cables are produced to international quality standards or composite construction to customers’ specification incorporating other services when required. Any enquiries, please feel free to contact us, email: sales@caledoniancable.com

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