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Phosphor Bronze Wire: Cast Billet Extruded at 570-620 °C, then Cold Drawn without Annealing (Barthel, Lurgi, US 2,079,239)
Cast phosphor bronze holds a brittle tin-rich phase that made wire drawing a long round of drawing and annealing. Barthel found that extruding the casting at 570-620 °C kneads it into one soft, even phase, after which it draws straight down to wire.
Result: phosphor bronze wire, drawn without intermediate annealing.
Source: Barthel, US 2,079,239 (American Lurgi, 1937). His temperature is for about 8 % tin; our ingot has about 9 %, so the same range is ours. Not given: extrusion ratio, die sizes. Picture drawn by Youblob.
Advanced
2 days
Instructions
1
1
Cast a billet and cool it fast
Cast a billet and cool it fast
Melt the phosphor bronze and cast it into a billet, cooling it rapidly. Ours: cast in an ingot mould and quench.
Materials for this step:
Phosphor Bronze Ingot1 as requiredTools needed:
Graphite-Clay Crucible
Crucible Furnace
Ingot Mould
Quench Bucket2
2
Heat the billet to 570-620 °C
Heat the billet to 570-620 °C
Heat the billet to between about 570 and 620 °C (Barthel's range for about 8 % tin and 0.3 % phosphorus). Temperature: 500-650 °C overall; the less tin, the hotter (about 650 °C for 6 % tin).
Tools needed:
Muffle Furnace
Pyrometer3
3
Extrude it in one pass
Extrude it in one pass
Extrude the hot billet in an extrusion press. The kneading makes the metal even all through, practically all alpha. For thick products with little reduction, cold-press the billet 10-20 % first.
Tools needed:
Hydraulic Extrusion Press4
4
Cold draw to wire without annealing
Cold draw to wire without annealing
Draw the extruded rod cold through dies down to wire; Barthel's metal needs no annealing between draws. Ours: a steel drawplate with drawing lubricant, one hole smaller each pass.
Tools needed:
Steel Drawplate
Wire Drawing LubricantMaterials
1- 1 as requiredPlaceholder
Tools Required
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