U.S. patent number 3,586,751 [Application Number 04/819,559] was granted by the patent office on 1971-06-22 for circular electric service cable.
This patent grant is currently assigned to Southwire Company. Invention is credited to Roger J. Schoerner.
United States Patent |
3,586,751 |
Schoerner |
June 22, 1971 |
CIRCULAR ELECTRIC SERVICE CABLE
Abstract
An electric service cable of substantially circular
cross-sectional configuration and including a pair of conductors
extending in side-by-side relationship and defining flat juxtaposed
surfaces and rounded remote surfaces. Insulation material surrounds
the pair of conductors, a stranded tubular sheath surrounds the
conductors and their insulating materials, and outside insulation
materials surround the tubular conductor. In order to enable the
cable to be bent during installation, its conductors are fabricated
of aluminum or copper having good elongation properties.
Inventors: |
Schoerner; Roger J.
(Carrollton, GA) |
Assignee: |
Southwire Company (Carrollton,
GA)
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Family
ID: |
27123820 |
Appl.
No.: |
04/819,559 |
Filed: |
April 28, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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814183 |
Apr 7, 1969 |
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779376 |
Nov 27, 1968 |
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730933 |
May 21, 1968 |
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Current U.S.
Class: |
174/115;
174/113R |
Current CPC
Class: |
C22C
21/00 (20130101); B22D 11/0602 (20130101); H01B
7/226 (20130101); H01B 9/00 (20130101); C22F
1/04 (20130101); H01B 1/023 (20130101) |
Current International
Class: |
C22F
1/04 (20060101); H01B 9/00 (20060101); H01B
1/02 (20060101); H01B 7/18 (20060101); B22D
11/06 (20060101); H01B 7/22 (20060101); C22C
21/00 (20060101); H01b 007/00 () |
Field of
Search: |
;75/138
;174/113,110,110.44,115,117 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
"Alloy Digest Aluminumec," June 1961, Filing Code: AL-104 Pages
1--2, ENGINEERING ALLOYS DIGEST INC. Upper Montclair, N.J. copy in
Group 111.
|
Primary Examiner: Goldberg; E. A.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my copending
application Ser. No. 814,183, filed Apr. 7, 1969 which is in turn a
continuation-in-part of my copending application Ser. No. 779,376
filed Nov. 27, 1968 which in turn is a continuation-in-part of my
copending application Ser. No. 730,933 now abandoned filed May 21,
1968.
Claims
I claim:
1. Electric Service Cable of substantially circular outside
cross-sectional configuration including a pair of aluminum alloy
conductors extending side-by-side and defining in cross section
flat juxtaposed surfaces and arcuate remote surfaces substantially
defining a circular surface with each other, said conductors having
a minimum conductivity of 61 percent IACS and consisting
essentially of from about 0.55 to about 0.95 weight percent iron,
from about 0.01 to about 0.15 weight percent silicon, from about
0.0001 to less than 0.05 weight percent each of trace elements
selected from the group consisting of vanadium, copper, manganese,
magnesium, zinc, boron, and titanium, and from about 98.95 to about
99.4399 weight percent aluminum, said alloy containing from about
0.004 to about 0.15 total weight percent trace elements and having
an iron to silicon ratio of 8:1 or greater.
2. Electric Service Cable of claim 1 wherein the silicon content is
from 0.01 to 0.15 weight percent, the individual trace element
content is from 0.0001 to 0.05 weight percent, and the total trace
element content is from 0.004 to 0.15 weight percent.
3. Electric Service Cable of claim 1 wherein the conductors are
covered with an insulating material selected from the group
consisting of poly(vinyl chloride), neoprene, polypropylene, and
polyethylene.
4. Electric Service Cable of substantially circular outside
cross-sectional configuration including a pair of aluminum alloy
conductors extending side-by-side and defining in cross section
flat juxtaposed surfaces and arcuate remote surfaces substantially
defining a circular surface with each other, said conductors having
a minimum conductivity of 61 percent IACS and containing
substantially evenly distributed iron aluminate inclusions in a
concentration produced by the presence of about 0.45 to about 0.95
weight percent iron in an alloy mass consisting essentially of
about 98.95 to about 99.4399 weight percent aluminum, from about
0.01 to about 0.15 weight percent silicon and from about 0.0001 to
less than 0.05 weight percent each of trace elements selected from
the group consisting of vanadium, copper, manganese, magnesium,
zinc, boron, and titanium, the total trace element content being
from about 0.004 to about 0.15 weight percent, the iron aluminate
inclusions having a particle size of less than 2,000 angstrom
units, and the iron to silicon ratio being at least 8:1.
5. Electric Service Cable of claim 4 wherein the silicon content is
from 0,01 to 0.15 weight percent, the individual trace element
content is from 0.0001 to 0.05, and the total trace element content
is from 0.004 to 0.15 weight percent.
6. Electric Service Cable of claim 4 wherein the conductors are
covered with an insulating material selected from the group
consisting of poly(vinyl chloride), neoprene, polypropylene, and
polyethylene.
7. Electric Service Cable of substantially circular outside
cross-sectional configuration including a pair of conductors
extending side-by-side and defining in cross section flat
juxtaposed surfaces and arcuate remote surfaces substantially
defining a circular surface with each other, insulation material
extending about and between each of said conductors and a tubular
conductor surrounding said pair of conductors their insulation
material, said the tubular conductor being formed from an aluminum
alloy which has a minimum electrical conductivity of 61 percent
IACS and consists essentially of about 0.55 to about 0.95 weight
percent iron, from about 0.01 to about 0.15 weight percent silicon,
from about 0.0001 to less than 0.05 weight percent each of trace
elements selected from the group consisting of vanadium, copper,
manganese, magnesium, zinc, boron, and titanium, and from about
98.95 to about 99.4399 weight percent aluminum, said alloy
containing from about 0.004 to about 0.15 total weight percent
trace elements and having an iron to silicon ratio of 8:1 or
greater.
8. Electric Service Cable of claim 7 wherein the silicon content is
from 0.01 to 0.15 weight percent, the individual trace element
content is from 0.0001 to 0.05 weight percent, and the total trace
element content is from 0.004 to 0.15 weight percent.
9. Electric Service Cable of claim 7 wherein the insulation
material is selected from the group consisting of poly(vinyl
chloride), neoprene, polypropylene, and polyethylene.
10. Electric Service Cable of substantially circular outside
cross-sectional configuration including a pair of conductors
extending side-by-side and defining in cross section flat
juxtaposed surfaces and arcuate remote surfaces substantially
defining a circular surface with each other, insulation material
extending about and between each of said conductors and a tubular
conductor surrounding said pair of conductors and their insulation
material said tubular conductor being formed from an aluminum alloy
which has a minimum electrical conductivity of 61 percent IACS and
contains substantially evenly distributed iron aluminate inclusions
in a concentration produced by the presence of about 0.45 to about
0.95 weight percent iron in an alloy mass consisting essentially of
about 98.95 to about 99.4399 weight percent aluminum; from about
0.01 to about 0.15 weight percent silicon; and about 0.0001 to less
than 0.05 weight percent each of trace elements selected from the
group consisting of vanadium, copper, manganese, magnesium, zinc,
boron, and titanium, the total trace element content being from
about 0.004 to about 0.15 weight percent, the iron aluminate
inclusions having a particle size of less than 2,000 angstrom
units, and the iron to silicon ratio being at least 8:1.
11. Electric Service Cable of claim 10 wherein the silicon content
is from 0.01 to 0.15 weight percent, the individual trace element
content is from 0.0001 to 0.05 weight percent and the total trace
element content is from 0.004 to 0.15 weight percent.
12. Electric Service Cable of claim 10 wherein the tubular
conductor is covered with an insulating material selected from the
group consisting of poly(vinyl chloride), neoprene, polypropylene,
and polyethylene.
13. Electric Service Cable of claim 7 wherein the pair of
conductors are formed from an aluminum alloy having a minimum
electrical conductivity of 61 percent IACS and consisting
essentially of about 0.55 to about 0.95 weight percent iron, from
about 0.01 to about 0.15 weight percent silicon, about 0.0001 to
less than 0.05 weight percent each of trace elements selected from
the group consisting of vanadium, copper, manganese, magnesium,
zinc, boron, and titanium, and from about 98.95 to about 99.4399
weight percent aluminum, said alloy containing about 0.004 to about
0.15 total weight percent trace elements and having an iron to
silicon ratio of 8:1 or greater.
14. Electric Service Cable of claim 13 wherein the pair of
conductors has a silicon content of from 0.01 to 0.15 weight
percent, an individual trace element content of from 0.0001 to 0.05
weight percent, and a total trace element content of from 0.004 to
0.15 weight percent.
15. Electric Service Cable of claim 10 wherein the pair of
conductors are formed from an aluminum alloy having a minimum
electrical conductivity of 61 percent IACS and containing
substantially evenly distributed iron aluminate inclusions in a
concentration produced by the presence of about 0.45 to about 0.95
weight percent iron in an alloy mass consisting essentially of
about 98.95 to about 99.4399 weight percent aluminum; from about
0.01 to about 0.15 weight percent silicon; and about 0.0001 to less
than 0.05 weight percent each of trace elements selected from the
group consisting of vanadium, copper, manganese, magnesium, zinc,
boron, and titanium, the total trace element content being from
about 0.004 to about 0.15 weight percent, the iron aluminate
inclusions having a particle size of less than 2,000 angstrom
units, and the iron to silicon ratio being at least 8:1.
16. Electric Service Cable of claim 15 wherein the pair of
conductors has a silicon content of from 0.01 to 0.15 weight
percent, an individual trace element content of from 0.0001 to 0.05
weight percent, and a total trace element content of from 0.004 to
0.15 weight percent.
Description
BACKGROUND OF THE INVENTION
Electric service cable of the type used for service entrance cable
to houses, office buildings or the like usually comprises three
conductors insulated from one another, two of the conductors for
providing electric service, and one of the conductors for grounding
purposes. Typically, the two conductors providing the electrical
service are coated with an insulating material so as to insulate
all three conductors from one another, and the three conductors are
gathered together and surrounded with an outside insulating
material. The three conductors are gathered with the larger
insulated electric service conductors being placed in longitudinal
side-by-side relationship and the grounding conductor either
comprising a single wire fitted into the longitudinal groove or
recess formed by the converging surfaces of the insulated
conductors, or comprising a tubular conductor surrounding the
insulated conductors. Since the single wire grounding conductor is
usually not individually insulated, its overall cross-sectional
area is substantially less than the overall cross-sectional areas
of the electric service conductors and their surrounding insulation
materials, and the configuration of the three juxtaposed cables is
usually somewhat oval in cross section, so that when the outside
insulation is applied to the three gathered cables, the outside
configuration of the assembly is also substantially oval,
Similarly, when the tubular grounding conductor is used, the
outside configuration of the assembly will also be substantially
oval.
While one recess or groove formed by the outside merging surfaces
of the insulation surrounding the paired electric service cables is
substantially filled with the single wire grounding conductor, the
opposite groove or recess on the other side of the paired electric
service conductors is not filled, and neither of the recesses is
filled in the service cable having the tubular grounding conductor.
Thus, a substantial amount of "dead" space is present in the prior
art service cable, and the cross-sectional area of the service
cable is significantly larger than it would be without the dead
space.
While the oval electric service cable has been widely utilized in
the past, it has certain disadvantages. The oval cross-sectional
configuration makes the cable difficult to bend across its wider
thickness, so that the installer of the cable is usually required
to twist the cable so it can be bent across its narrower thickness.
When holes are formed in the studs and joints of a building to pull
the cable through to a junction, the holes are usually round in
cross section so that the holes must be of significantly larger
cross-sectional area than the cross-sectional area of the oval
cable. Furthermore, when the oval cable is pulled through a round
hole, the sliding friction between the cable and its hole is
applied primarily only to a small portion of the rounded
longitudinal surfaces of the cable, while the flattened
longitudinal surfaces of the cable encounters substantially no
friction. Thus, the rounded surfaces of the cable are required to
bear substantially all of the damage done to the cable from sliding
friction, with virtually no help being derived from the flattened
surfaces.
SUMMARY OF THE INVENTION
Briefly described, the present invention comprises an electric
service cable of substantially circular cross-sectional
configuration, which is bendable in virtually any direction, and
which is of smaller diameter and cross-sectional area than the
conventional oval electric service cable. A pair of insulated "D"
-shaped conductors are prepared from aluminum or copper having good
elongation properties, such as from aluminum alloy wires containing
substantially evenly distributed iron aluminate inclusions in a
certain concentration. The conductors are placed with their flat
sides in abutment, and a stranded grounding cable surround the
paired "D" -shaped cables. The assembly is then coated with
insulating material.
Thus, it is an object of this invention to provide an aluminum
alloy service cable which is substantially circular in
cross-sectional configuration, and which is smaller in
cross-sectional area then the conventional oval cable.
Another object of this invention is to provide an electric service
cable which requires less insulating material than the conventional
cable and defines virtually no "dead" space.
Another object of this invention is to provide an electric service
cable that is safer under overloaded conditions, which is easier to
pull through circular openings of a building structure, and which
is bendable in virtually any direction.
Another object of this invention is to provide an electric service
cable which requires a smaller amount of insulating material per
running foot of cable, which is economical to manufacture, and
which is convenient and safe in use.
Other objects, features and advantages of the present invention
will become apparent upon reading the following specification, when
taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional view of the electric service cable,
FIG. 2 is a cross-sectional view of a prior art electric service
cable.
FIGS. 3a, 3b, 3c, 3d, 3e, and 3f are cross-sectional views of the
electric service cable as it is prepared and assembled.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in more detail to the drawing, in which like numerals
indicate like parts throughout the several views, FIG. 1 shows the
electric service cable 10 which includes a pair of electric service
conductors 11 and 12, insulation 13 surrounding conductor 11,
insulation 14 surrounding conductor 12, tubular sheath 15
surrounding conductors 11 and 12 and their insulation, insulating
tape 16 surrounding tubular sheath 15, and jacket 17 surrounding
tape 16. The pair of electric service conductors 11 and 12 each
define a cross-sectional configuration similar to a segment
subtended by a chord on a circle, and include flat surfaces 19 and
20 and rounded surfaces 21 and 22, respectively. Each segment is
generally "D" -shaped and is less than one-half of a circle in
cross section, and their respective insulation coatings 13 and 14
conform in shape to their outside surfaces. Ideally, the thickness
of the insulation 13 and 14 adjacent flat surfaces 19 and 20 of the
conductors is gauged so that conductors 11 and 12 are spaced apart
a distance so that their curved surfaces 21 and 22 define a circle
with each other; that is, the curved surfaces 21 and 22 of
conductors 11 and 12 define with each other a circle, except for
the gap between the conductors. Similarly, the outer curved
surfaces 25 and 26 of insulation 13 and 14 define with each other a
circle generally concentric to the circle formed by the outer
surfaces of conductors 11 and 12.
Tubular sheath 15 comprises the grounding conductor of service
cable 10 and is fabricated by stranding circular wires 28 to form a
tubular protective sheath about service conductors 11 and 12 and
their respective insulation. After sheath 15 has been stranded, it
is wrapped with an insulating tape, such as high
temperature-resistant polyethylene terephthalate tape, and
insulating jacket 17, such as polyvinyl chloride, extends about and
protects both tubular sheath 15 and insulating tape 16. Of course,
jacket 17 must be fabricated from a substance that is capable of
withstanding abrasion and friction.
FIG. 2 shows a typical prior art electric service cable 30 which
includes a pair of electric service conductors 31 and 32,
insulating material 33 and 34 surrounding conductors 31 and 32,
protective grounding sheath 35, wrapping 36, and outside insulating
material 38. Conductors 31 and 32 are generally circular in
cross-sectional configuration, and grounding sheath 35 defines
grooves or dead spaces 39 with the converging surfaces of
insulating materials 33 and 34. When outer insulating material 38
is applied to the assembly, the overall configuration of cable 30
is oval in cross section.
In comparison with the disclosed invention of FIG. 1, the prior art
service cable has a longer diameter which extends across conductors
31 and 32 and which is larger than the diameter of service cable
10, and a short diameter which extends from the flat outer surfaces
of the service cable which may be slightly smaller than the
diameter of service cable 10. Also, the cross sectional area of the
prior art cable of FIG. 2 is substantially larger than the
cross-sectional area of the service cable 10. In comparison, the
flat surfaces 23 and 24 of insulating materials 13 and 14 of
service cable 10 abut and substantially support each other across
their entire flat surfaces, while insulating materials 33 and 34 of
the cables 31 and 32 of the prior art service cable 30 abut each
other on a point or a longitudinal line extending along the length
of the service cable. Thus, the portions of the insulating
materials of service cable 10 which extend between the conductors
are not likely to become compressed or crushed, while the same is
not true of the rounded conductors of the prior art. When the
service cables of the prior art and of the disclosed invention are
overloaded and become excessively hot, the insulating materials of
the prior art of FIG. 2 will tend to break down along the line of
contact, particularly if they have become compacted or crushed,
whereas under similar conditions the insulating materials between
the service conductors 11 and 12 will resist rapid breakdown
because of their flat abutment with each other and their resistance
to becoming compacted or crushed; that is, the flat configuration
of the abutting insulation materials between service conductors 11
and 12 will normally not be damaged or destroyed by twisting or
crushing the service cable as when installing the service cable in
a building, and this portion of the insulation will virtually
always maintain its thickness, whereas the bending or crushing of
the prior art service cable 30 occasionally functions to compress
or crush, crack or tear the insulating material between conductors
31 and 32, so that conductors 31 and 32 come into contact with each
other, or so that the heat from the conductors more easily
deteriorates the insulating material.
In further comparison, when the prior art service cable of FIG. 2
is installed in a building structure, it is usually inserted
through various holes in the studs, walls, and other support
elements of the building structure, and since these holes are
almost always round holes formed by drills, etc., the sliding
friction between the inner surfaces of the holes and the outer
surfaces of the service cable will virtually always be felt
primarily on the relatively small rounded side surfaces of the
cable, with virtually no frictional contact being encountered by
the flat outside surfaces. Thus, only small portions of the outside
surface of the prior art service cable must withstand virtually all
of the friction occurring between the cable and the surfaces of the
holes through which the cable is passed. Also, when the prior art
service cable is pulled through a hole in the building structure
and then guided in a different direction, it is necessary for the
workmen to orient the cable so that it will bend across its smaller
dimension as it passes from the hole in the building structure in
order to prevent excessive frictional wear on the outside surface
of the cable and to allow the workmen to pull with less force, so
that the hazard of stretching and breaking the cable is
reduced.
As is shown in FIGS. 3a-3f, electric service cable 10 is formed by
first forming conductors 11 and 12 with a flat side and a curved
side (FIG. 3a), coating the conductors with their respective
insulating materials (FIG. 3b), placing the insulated conductors 11
and 12 in juxtaposition where the flat surfaces of their insulating
materials about each other (FIG. 3c), stranding the tubular sheath
15 about the juxtaposed conductors (FIG. 3d), applying the
insulating tape 16 about the tubular sheath (FIG. 3e), and applying
protective jacket 17 about insulating tape 16. Under normal
conditions conductors 11 and 12 will be fabricated and stored in
coils, and the steps shown in FIGS. 3b, 3c, 3d, 3e, and 3f will be
carried out continuously, by continuously passing conductors 11 and
12 through a coating stage to apply insulating materials 13 and 14,
guiding the conductors into abutment with each other, stranding the
tubular sheath 15 about the conductors, applying the insulating
tape 16 about the sheath, and applying the jacket 17 about the
insulating tape. Of course, the flat sides of conductors 11 and 12
after they have been coated with the insulating materials aids in
properly aligning and guiding conductors into their respective
positions with respect to each other.
Because of the protective function of tubular sheath 15 and because
of the decreased hazard of deterioration of the insulation between
service conductors 11 and 12 due to crushing and overload
conditioning, a thinner application of insulating material 13 and
14 may be applied about conductors 11 and 12 in comparison with the
insulation required about the conductors of the prior art of FIG.
2. Thus, the cross-sectional area of electric service cable 10 can
be even further reduced because of the smaller insulation materials
required.
While it is desired that the electric service cable be of circular
cross-sectional configuration, it will be understood that its
actual shape may be noncircular. The noncircular shape results from
many manufacturing and handling conditions. For instance, the
conductors may not be perfectly formed, the insulation material
between the paired conductors may be more than necessary to
displace the curved surfaces of the paired conductors beyond a
circular arrangement, as the conductors may be tightly packed
together along one length of the cable and loosely held together in
another length of cable. Generally speaking, however, the
cross-sectional configuration will be substantially circular as
opposed to decidedly oval as in the prior art.
In order to bend the service cable without having to exert extreme
force and without hazard of having the conductors crack or break,
it is desirable to have the conductors fabricated from a metal
having a high percentage of elongation while retaining high tensile
strength and conductivity. Various metals are available, including
aluminum and copper, which are suitable for use as the conductors
in that they have acceptable levels of conductivity, elongation,
and tensile strength. A metal highly suitable for use in the
service cable is prepared from an aluminum alloy comprising less
than about 99.70 weight percent aluminum, more than about 0.30
weight percent iron, and no more than 0.15 weight percent silicon.
Preferably, the aluminum content of the present alloy comprises
from about 98.95 weight percent to less than about 99.45 weight
percent aluminum with particularly superior elongation properties
and tensile strength being achieved when from about 99.15 to about
99.40 weight percent aluminum is employed. Preferably, the iron
content of the present alloy comprises about 0.45 weight percent to
about 0.95 weight percent with particularly superior results being
achieved when from about 0.50 weight percent to about 0.80 weight
percent iron is employed. Preferably, no more than 0.07 weight
percent silicon is employed in the alloy of the present conductor.
The ratio between the percentage iron and percentage silicon must
be 1.99:1 or greater. Preferably, the ratio between percentage iron
and percentage silicon is 8:1 or greater. Thus, if the present
aluminum alloy conductor contains an amount of iron within the low
area of the present range for iron content, the percentage of
aluminum must be increased rather than increasing the percentage of
silicon outside the ratio limitation previously specified. It has
been found that a properly processed individual conductor having
aluminum alloy constituents which fall within the above-specified
ranges possesses an acceptable conductivity of at least 61 percent
IACS and improved tensile strength and percent ultimate elongation
when compared to conductors prepared from conventional electrically
conductive alloys.
The present individual aluminum alloy conductors are prepared by
initially melting and alloying aluminum with the necessary amounts
of iron or other constituents to provide the requisite alloy for
processing. Normally the content of silicon is maintained as low as
possible without adding additional amounts to the melt. Typical
impurities or trace elements are also present within the melt but
only in trace quantities such as less than 0.05 weight percent each
with a total content trace impurities generally not exceeding 0.15
weight percent. Of course, when adjusting the amounts of trace
elements, due consideration must be given to the conductivity of
the final alloy since some trace elements, affect conductivity more
severely than others. The typical trace elements include vanadium,
copper, manganese, magnesium, zinc, boron and titanium. If the
content of titanium is relatively high (but still quite low
compared to the aluminum, iron and silicon content), small amounts
of boron may be added to tie up the excess titanium and keep it
from reducing the conductivity of the wire. Iron is the major
constituent added to the melt to produce the alloy of the present
invention. Normally about 0.50 weight percent iron is added to the
typical aluminum component used to prepare the present alloy. Of
course, the scope of the present invention includes the addition of
more or less iron together with the adjustment of the content of
all alloying constituents.
After alloying, the melted aluminum composition is continuously
cast into a continuous bar. The continuous bar is then hot-rolled
to form continuous rod.
One example of a continuous casting and rolling operation capable
of producing continuous rod as specified in this application is as
follows:
A continuous casting machine serves as a means for solidifying the
molten aluminum alloy metal to provide A cast bar that is conveyed
in substantially the condition in which it solidified from the
continuous casting machine to the rolling mill which serves as a
means for hot-forming the cast bar into rod or another hot-formed
product in a manner which imparts substantial movement to the cast
bar along a plurality of angularly disposed axes.
The continuous casting machine is of conventional casting
wheel-type having a casting wheel with a casting groove partially
closed by an endless belt supported by the casting wheel and an
idler pulley. The casting wheel and the endless belt cooperate to
provide a mold into one end of which molten metal is poured to
solidify and from the other end of which the cast bar is emitted in
substantially that condition in which it solidified.
The rolling mill is of conventional type having a plurality of roll
stands arranged to hot-form the cast bar by a series of
deformations. The continuous casting machine and the rolling mill
are positioned relative to each other so that the cast bar enters
the rolling mill substantially immediately after solidification and
in substantially that condition in which it solidified. In this
condition, the cast bar is at a hot-forming temperature within the
range of temperatures for hot-forming the cast bar at the
initiation of hot-forming without heating between the casting
machine and the rolling mill. In the event that it is desired to
closely control the hot-forming temperature of the cast bar within
the conventional range of hot-forming temperatures, means for
adjusting the temperature of the cast bar may be placed between the
continuous casting machine and the rolling mill without departing
from the inventive concept disclosed herein.
The roll stands each include a plurality of rolls which engage the
cast bar. The rolls of each roll stand may be two or more in number
and arranged diametrically opposite from one another or arranged at
equally spaced positions about the axis of movement of the cast bar
through the rolling mill. The rolls of each roll stand of the
rolling mill are rotated at a predetermined speed by a power means
such as one or more electric motors and the casting wheel is
rotated at a speed generally determined by its operating
characteristics. The rolling mill serves to hot-form the cast bar
into a rod of a cross-sectional area substantially less than that
of the cast bar as it enters the rolling mill.
The peripheral surfaces of the rolls of adjacent roll stands in the
rolling mill change in configuration; that is, the cast bar is
engaged by the rolls of successive roll stands with surfaces of
varying configuration, and from different directions. This varying
surface engagement of the cast bar in the roll stands functions to
knead or shape the metal in the cast bar in such a manner that it
is worked at each roll stand and also to simultaneously reduce and
change the cross-sectional area of the cast bar into that of the
rod.
As each roll stand engages the cast bar, it is desirable that the
cast bar be received with sufficient volume per unit of time at the
roll stand for the cast bar to generally fill the space defined by
the rolls of the roll stand so that the rolls will be effective to
work the metal in the cast bar. However, it is also desirable that
the space defined by the rolls of each roll stand not be overfilled
so that the cast bar will not be forced into the gaps between the
rolls. Thus, it is desirable that the rod be fed toward each roll
stand at a volume per unit of time which is sufficient to fill, but
not overfill, the space defined by the rolls of the roll stand.
As the cast bar is received from the continuous casting machine, it
usually has one large flat surface corresponding to the surface of
the endless band and inwardly tapered side surfaces corresponding
to the shape of the groove in the casting wheel. As the cast bar is
compressed by the rolls of the roll stands, the cast bar is
deformed so that it generally takes the cross-sectional shape
defined by the adjacent peripheries of the rolls of each roll
stand.
Thus, it will be understood that with this apparatus, cast aluminum
alloy rod of an infinite number of different lengths is prepared by
simultaneous casting of the molten aluminum alloy and hot-forming
or rolling the cast aluminum bar.
The continuous rod produced by the casting and rolling operation is
then processed in a reduction operation designed ro produce
continuous conductors of various gauges having the "D"-shaped
configuration as previously specified. The reduction operation
consists of a process whereby unannealed rod (i.e., as rolled to f
temper) is cold-drawn through a series of progressively constricted
dies without intermediate anneals to form a continuous conductor of
the desired configuration. At the conclusion of this drawing
operation, the alloy wire will have an excessively high tensile
strength and an unacceptably low ultimate elongation, plus a
conductivity below that which is industry accepted as the minimum
for use in electrical cable, i.e., 61 percent of IACS. The wire is
then annealed or partially annealed to obtain a desired tensile
strength and cooled. At the conclusion of the annealing operation,
it is found that the annealed alloy wire has the properties of
acceptable conductivity and improved tensile strength and percent
ultimate elongation. The annealing operation may be continuous as
in resistance annealing, induction annealing, convention annealing
by continuous furnaces, or radiation annealing by continuous
furnaces; or may be batch annealed in a batch furnace. In addition,
the present aluminum alloy wire may be partially annealed by
resistance or induction annealing and then additionally annealed by
batch annealing. When continuously annealing, temperatures of about
450.degree. F. to about 1200.degree. F. may be employed with
annealing F. F. times of about 5 minutes to about 1/10,000 of a
minute. Generally, however, continuous annealing temperatures and
times may be adjusted to meet the requirements of the particular
overall processing operation so long as the desired tensile
strength is achieved. In a batch annealing operation, a temperature
of approximately 450.degree. F. to about 750.degree. F. is employed
with resistance times of about 24 hours to about 30 minutes. As
mentioned with respect to continuous annealing, in batch annealing
the times and temperatures may be varied to suit the overall
process so long as the desired tensile strength is obtained.
During the continuous casting of this alloy, a substantial portion
of the iron present in the alloy precipitates out of solution as
iron aluminate intermetallic compound (FeAl.sub.3). Thus after
casting, the bar contains a dispersion of FeAl.sub.3 in a
supersaturated solid solution matrix. The supersaturated matrix may
contain as much as 0.17 weight percent iron. As the bar is rolled
in a hot-working operation immediately after casting, the
FeAl.sub.3 particles are broken up and dispersed throughout the
matrix inhibiting large cell formation. When the rod is then drawn
to its final gauge size without intermediate anneals and then aged
in a final annealing operation, the tensile strength, elongation
and bendability are increased due to the small cell size and the
additional pinning of dislocations by preferential precipitation of
FeAl.sub.3 on the dislocation sites. Therefore, new dislocation
sources must be activated under the applied stress and this causes
both the strength and the elongation to be further improved.
The properties of the present aluminum alloy wire are significantly
affected by the size of the FeAl.sub.3 particles in the matrix.
Coarse precipitates reduce the percent elongation and bendability
of the wire by enhancing nucleation and, thus, formation of large
cells which, in turn, lowers the recrystallization temperature of
the wire. Fine precipitates improve the percent elongation and
bendability by reducing nucleation and increasing the
recrystallization temperature. Grossly coarse precipitates of
FeAl.sub.3 cause the wire to become brittle and generally unusable.
Coarse precipitates have a particle size of above 2,000 angstrom
units and fine precipitates have a particle size of below 2,000
angstrom units.
When conductors fabricated by this process are used in the service
cable, the service cable can be bent in any direction without
hazard of cracking or breaking the conductors because of the
elongation properties of the conductors, yet the conductivity and
tensile strength of the conductors remains at an acceptably high
level. Fabrication of the conductors of the service cable is not
limited to the metal specifically disclosed since various soft
aluminum and copper metals can be used, such as copper or and
electrically conductive aluminum alloy comprising a minimum of
99.60 percent A1, and a maximum of 0.01 percent Mg, 0.10 percent
Cu, 0.01 percent Cr, 0.15 percent Si, 0.01 percent Mn, 0.50 percent
Fe, 0.10 percent Zn, and 0.10 percent other materials; however, the
metal specifically disclosed provides the best known combination of
bendability, electrical conductivity, and elongation.
While this invention has been described in detail with particular
reference to preferred embodiments thereof, it will be understood
that variations and modifications can be effected within the spirit
and scope of the invention as described hereinbefore and as defined
in the appended claims.
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