Claims:
1. A method for manufacturing an aluminum-zirconium alloy conductor wire rod, the method comprising:

melting one or more aluminum ingots in a furnace at a first pre-defined temperature range, wherein each of the one or more aluminum ingots have a pre-defined percentage range of purity and wherein the melting of the one or more aluminum ingots being performed to obtain molten aluminum;

adding a plurality of alloying elements to the molten aluminum present in the furnace to obtain molten aluminum alloy, wherein the plurality of alloying elements comprises boron, copper and zirconium, wherein the plurality of alloying elements being added in a pre-defined sequence, wherein the pre-defined sequence comprises a primary addition of boron followed by addition of copper followed by addition of zirconium, wherein zirconium being added after a first pre-defined time interval after the addition of boron and wherein the first pre-defined time interval being 10 minutes to 60 minutes;

holding the molten aluminum alloy present in the furnace at a second pre-defined temperature range for a second pre-defined time interval;

stirring the molten aluminum alloy present in the furnace at a specific time interval during the holding of the molten aluminum alloy; and

grain refining the molten aluminum alloy, wherein the molten aluminum alloy being grain refined to obtain a grain refined molten aluminum alloy;

hot working a cast aluminum alloy bar, wherein the hot working of the cast aluminum alloy bar being performed at a third pre-defined temperature range, wherein the hot working of the cast aluminum alloy bar being performed to extrude the cast aluminum alloy bar into rod form;

quenching the extruded cast aluminum alloy bar of rod form by utilizing cold water at a pre-defined range of arresting temperature, wherein the extruded cast aluminum alloy bar of rod form being quenched to obtain a first plurality of aluminum alloy rods;

heat treating each of the first plurality of aluminum alloy rods at a temperature in a fourth pre-defined temperature range for a third pre-defined time interval, wherein the heat treatment of each of the first plurality of aluminum alloy rods being performed to obtain a second plurality of aluminum alloy rods, wherein the second plurality of aluminum alloy rods comprises finely precipitated Al3Zr alloy rods, wherein the fourth pre-defined temperature range being 380 °C to 420 °C and wherein the third pre-defined time interval being 20 hours to 200 hours.

cold working the second plurality of aluminum alloy rods, wherein the cold working of the second plurality of aluminum alloy rods being performed to obtain an aluminum-zirconium alloy conductor wire rod, wherein the aluminum-zirconium alloy conductor wire rod has a pre-defined conductivity range of 59 % to 60.8 % IACS, wherein the aluminum-zirconium alloy conductor wire rod has a pre-defined tensile strength range of 11 Kgf/Sq.mm to 20 Kgf/Sq.mm, wherein the aluminum-zirconium alloy conductor wire rod has a pre-defined percentage elongation range of2 % to 16 % and wherein the aluminum-zirconium alloy conductor wire rod has a pre-defined heat resistance range of 90 % to 94 %.

2. The method as recited in claim 1, wherein the first pre-defined temperature range for melting the one or more aluminum ingots being 740 °C to 750 °C.

3. The method as recited in claim 1, wherein the pre-defined percentage range of purity of the one or more aluminum ingots being 99.7 % to 100 %.

4. The method as recited in claim 1, wherein the second pre-defined temperature range for holding the molten aluminum alloy being 680 °C to 750 °C and wherein the second pre-defined time interval for holding the molten aluminum alloy being 6 hours to 24 hours.

5. The method as recited in claim 1, wherein the molten aluminum alloy being grain refined by adding one or more tiber rods, wherein the one or more tiber rods being added at a specific angle against flow of the molten aluminum alloy, wherein the one or more tiber rods being added to the molten aluminum alloy at a pre-defined speed and wherein the pre-defined speed being 20 cm/minute to 30 cm/minute.

6. The method as recited in claim 1, wherein the third pre-defined temperature range to perform hot working of the cast aluminum alloy bar being 480 °C to 540 °C.

7. The method as recited in claim 1, wherein each of the first plurality of aluminum alloy rod has a diameter in a first pre-defined nominal diameter range, wherein the first pre-defined nominal diameter range being 9.5 mm to 12.7 mm.

8. The method as recited in claim 1, wherein the pre-defined range of arresting temperature for quenching the extruded cast aluminum alloy bar of rod form being 30 °C to 40 °C.

9. The method as recited in claim 1, further comprising casting the grain refined molten aluminum alloy, wherein the casting being performed to obtain the cast aluminum alloy bar and wherein the casting being performed by pouring the grain refined molten aluminum alloy in a series of continuous strip cast roll.

10. The method as recited in claim 1, further comprising solidifying the plurality of aluminum alloy bar, wherein the solidification being performed at a pre-defined cooling rate, wherein the pre-defined cooling rate being in a range of 30 °C to 40 °C per minute with 2.5 metric ton/hour mill output speed and wherein the solidification being performed by utilizing one or more water cooled rolls.
, Description:TECHNICALFIELD
[0001] The present disclosure relates to a field of overhead electrical transmission technology and, in particular, relates to a method for manufacturing of aluminum-zirconium alloy conductor wire rod used in overhead power transmission lines.

BACKGROUND
[0002] Nowadays, the utilities around the world have moved electrical power through increasingly more complex supply grids by means of transmission and distribution (T&D) cables/conductors. These cables/conductors consist of a conductive element of aluminum alloy wires wrapped around a core of steel wire, which bears the structural load. Increasing the transmission capacity known as “ampacity” of a transmission line requires unprecedented expense. As demand for power grows, utilities must modify existing towers, to accommodate additional conductors or bear the additional load of larger-diameter, heavier conductors. Eventually, they are faced with replacing the existing towers with new, larger towers, or acquiring rights of way for additional trunk lines. The latter can be a legal nightmare in both densely populated urban/suburban areas and sparsely inhabited but environmentally regulated public lands, such as national parks, wilderness preserves and other no-build zones. Therefore, recent attempts to develop high current carrying capacity & high thermal resistance aluminum zirconium alloy rods are made. These aluminum zirconium alloy rods are used as a conductive wire for overhead conductors.
[0003] The conventional overhead electric power conductors have limited continuous operating temperature range and low thermal resistance at above 100 °C operating. In addition, these existing overhead conductors are unable to carry high current carry capacity. There have been attempts to produce aluminum alloy conductors which are suitable for continuous operating temperature of 210°C. These efficient aluminum based Al3Zr alloy overhead electric conductors possess high current carrying capacity and high thermal resistance.
[0004] The prior arts have tried to come up with manufacturing methods to address these problems. In one of the prior art with patent numberCN101604563A, a method for manufacturing a heat-resistant aluminum alloy wire for a power cable is disclosed. The manufacturing method includes the steps of adding the alloying elements into fused aluminum of a shaft furnace, casting the mixture after smelting into a cast strip and thermally rolling the cast strip. In addition, the method includes cold-drawing processing, annealing in the cold-drawing process, adopting recrystallization and thermal treatment before final cold-drawing, and later performing trace cold-drawing processing.
[0005] In another prior art with the patent numberCN100535146C, the method for producing a highly conductive ultra-resistant aluminum alloy wire is disclosed. The method includes addition of zirconium, iron in molten aluminum liquid electrician, according to the weight percentage, zirconium Zr: 0.3-0.6%, Iron: 0.10-0.25%, select electrician molten aluminum: silicon Si=0.08%; titanium Ti, vanadium V, manganese Mn, Cr sum =0.01%. Further, the method includes continuous casting and rolling production line to produce a heat-resistant Aluminum rods. In addition, the method includes heat-resistant aluminum alloy rods temperature of 400 ? -430 ?, the processing time of 50 hours. Moreover, the method includes wire drawing, stranding produce a highly conductive ultra-resistant aluminum alloy conductor.
[0006] The above mentioned prior arts and other prior arts are found to be inefficient. Traditionally, these high temperature/thermal resistance conductors are manufactured by utilizing conventional aluminum ingots or billets. These conventional aluminum ingots or billets are melted, alloyed, refined and further fed into the general casting and rolling operations to obtain alloy rods. These alloy rods are then heat treated and cold worked to obtain overhead electric power conductors. However, due to these prior manufacturing processes, these aluminum zirconium wires may not have good thermal resistance properties and other physical properties.
[0007] In light of the above stated discussion, there is a need for a method that overcomes the above stated disadvantages.

OBJECT OF THE DISCLOSURE
[0008] A primary object of the present disclosure is to provide a method for manufacturing of an aluminum-zirconium alloy conductor wire rod
[0009] Another object of the present disclosure is to provide the aluminum-zirconium alloy conductor wire rod having enhanced heat resistance capacity at high temperature.
[0010] Yet another object of the present disclosure is to provide the aluminum-zirconium alloy conductor wire rod having enhanced conductivity.
[0011] Yet another object of the present disclosure is to provide the aluminum-zirconium alloy conductor wire rod having enhanced strength.
[0012] Yet another embodiment of the present disclosure is to provide the aluminum-zirconium alloy conductor wire rod for use in overhead power conductors.
[0013] Yet another embodiment of the present disclosure is to provide a low cost manufacturing method of aluminum-zirconium alloy conductor wire rod.

SUMMARY
[0014] In an aspect, the present disclosure provides a method for manufacturing of an aluminum-zirconium alloy conductor wire rod. The method includes a step of melting the one or more aluminum ingots in a furnace at a first pre-defined temperature range to obtain molten aluminum. Further, the method includes the step of adding a plurality of alloying elements to the molten aluminum present in the furnace to obtain molten aluminum alloy. Furthermore, the method includes the step of holding the molten aluminum alloy present in the furnace at a second pre-defined temperature range for a second pre-defined time interval. In addition, the method includes the step of stirring the molten aluminum alloy present in the furnace at a specific time interval during the holding of the molten aluminum alloy. Moreover, the method includes the step of grain refining the molten aluminum alloy. Further, the method includes the step of hot working of cast aluminum alloy bar to extrude the cast aluminum alloy bar into rod form. In addition, the method includes the step of quenching the extruded cast aluminum alloy bar of rod form by utilizing cold water at a pre-defined range of arresting temperature. The extruded cast aluminum alloy bar of rod form is quenched to obtain a first plurality of aluminum alloy rods. Furthermore, the method includes the step of heat treating each of the first plurality of aluminum alloy rods at a temperature in a fourth pre-defined temperature range for a third pre-defined time interval. The heat treatment of each of the first plurality of aluminum alloy rods is performed to obtain a second plurality of aluminum alloy rods. Moreover, the method includes the step of cold working the second plurality of aluminum alloy rods. The cold working of the second plurality of aluminum alloy rods is performed to obtain the aluminum-zirconium alloy conductor wire rod. Further, each of the one or more aluminum ingots have a pre-defined percentage range of purity. The plurality of alloying elements includes boron, copper and zirconium. In addition, the plurality of alloying elements is added in a pre-defined sequence of a primary addition of boron followed by addition of copper followed by addition of zirconium. Moreover, zirconium is added after a first pre-defined time interval after the addition of boron. The first pre-defined time interval is 10 minutes to 60 minutes. The hot working of the cast aluminum alloy bar is performed at a third pre-defined temperature range. Furthermore, the second plurality of aluminum alloy rods include finely precipitated Al3Zr alloy rods. The fourth pre-defined temperature range is380 °C to 420 °C and the third pre-defined time interval is20 hours to 200 hours. Moreover, the aluminum-zirconium alloy conductor wire rod has a pre-defined conductivity range of 59 % to 60.8 % IACS. The aluminum-zirconium alloy conductor wire rod has a pre-defined tensile strength range of 11 Kgf/Sq.mm to 20 Kgf/Sq.mm. The aluminum-zirconium alloy conductor wire rod has a pre-defined percentage elongation range of 2 % to 16 %. In addition, the aluminum-zirconium alloy conductor wire rod has a pre-defined heat resistance range of 90 % to 94 %.
[0015] In an embodiment of the present disclosure, the first pre-defined temperature range for melting the one or more aluminum ingots is 740 °C to 750 °C.
[0016] In an embodiment of the present disclosure, the pre-defined percentage range of purity of the one or more aluminum ingots being 99.7% to 100 %.
[0017] In an embodiment of the present disclosure, the second pre-defined temperature range for holding the molten aluminum alloy is 680 °C to 750 °C. In addition, the second pre-defined time interval for holding the molten aluminum alloy is 6 hours to 24 hours.
[0018] In an embodiment of the present disclosure, the molten aluminum alloy is grain refined by adding one or more tiber rods. The one or more tiber rods are added at a specific angle against flow of the molten aluminum alloy. In addition, the one or more tiber rods are added to the molten aluminum alloy at a pre-defined speed. In an embodiment of the present disclosure, the pre-defined speed being 20 cm/minute to 30 cm/minute.
[0019] In an embodiment of the present disclosure, the third pre-defined temperature range to perform hot working of the cast aluminum alloy bar is 480 °C to 540 °C.
[0020] In an embodiment of the present disclosure, each of the first plurality of aluminum alloy rod has a diameter in a first pre-defined nominal diameter range. The first pre-defined nominal diameter range is 9.5 mm to 12.7 mm.
[0021] In an embodiment of the present disclosure, the pre-defined range of arresting temperature for quenching the extruded cast aluminum alloy bar of rod form is 30 °C to 40 °C.
[0022] In an embodiment of the present disclosure, the method further includes casting the grain refined molten aluminum alloy. The casting is performed to obtain the cast aluminum alloy bar. In addition, the casting is performed by pouring the grain refined molten aluminum alloy in a series of continuous strip cast roll.
[0023] In an embodiment of the present disclosure, the method further includes solidifying the cast aluminum alloy bar. The solidification of the cast aluminum alloy bar is performed at a pre-defined cooling rate. The pre-defined cooling rate is in a range of 25 °C to 40 °C per minute with 2.5 metric ton/hour mill output speed. In addition, the solidification is performed by utilizing one or more water cooled rolls.

STATEMENT OF THE DISCLOSURE
[0024] The present disclosure relates to a method for manufacturing of an aluminum-zirconium alloy conductor wire rod. The method includes a step of melting the one or more aluminum ingots in a furnace at a first pre-defined temperature range to obtain molten aluminum. Further, the method includes the step of adding a plurality of alloying elements to the molten aluminum present in the furnace to obtain molten aluminum alloy. Furthermore, the method includes the step of holding the molten aluminum alloy present in the furnace at a second pre-defined temperature range for a second pre-defined time interval. In addition, the method includes the step of stirring the molten aluminum alloy present in the furnace at a specific time interval during the holding of the molten aluminum alloy. Moreover, the method includes the step of grain refining the molten aluminum alloy. Further, the method includes the step of hot working of cast aluminum alloy bar to extrude the cast aluminum alloy bar into rod form. In addition, the method includes the step of quenching the extruded cast aluminum alloy bar of rod form by utilizing cold water at a pre-defined range of arresting temperature to obtain a first plurality of aluminum alloy rods. Furthermore, the method includes the step of heat treating each of the first plurality of aluminum alloy rods at a temperature in a fourth pre-defined temperature range for a third pre-defined time interval. The heat treatment of each of the first plurality of aluminum alloy rods is performed to obtain a second plurality of aluminum alloy rods. Moreover, the method includes the step of cold working the second plurality of aluminum alloy rods. The cold working of the second plurality of aluminum alloy rods is performed to obtain the aluminum-zirconium alloy conductor wire rod. Further, each of the one or more aluminum ingots have a pre-defined percentage range of purity. The plurality of alloying elements includes boron, copper and zirconium. In addition, the plurality of alloying elements is added in a pre-defined sequence of a primary addition of boron followed by addition of copper followed by addition of zirconium. Moreover, zirconium is added after a first pre-defined time interval after the addition of boron. The first pre-defined time interval is 10 minutes to 60 minutes. The hot working of the cast aluminum alloy bar is performed at a third pre-defined temperature range. Furthermore, the second plurality of aluminum alloy rods include finely precipitated Al3Zr alloy rods. The fourth pre-defined temperature range is 380 °C to 420 °C and the third pre-defined time interval is 20 hours to 200 hours. Moreover, the aluminum-zirconium alloy conductor wire rod has a pre-defined conductivity range of 59 % to 60.8 % IACS. The aluminum-zirconium alloy conductor wire rod has a pre-defined tensile strength range of 11 Kgf/Sq.mm to 20 Kgf/Sq.mm. The aluminum-zirconium alloy conductor wire rod has a pre-defined percentage elongation range of 2 % to 16 %. In addition, the aluminum-zirconium alloy conductor wire rod has a pre-defined heat resistance range of 90 % to 94 %.

BRIEFDESCRIPTIONOFFIGURES
[0025] Having thus described the disclosure in general terms, reference will now be made to the accompanying figures, wherein:

[0026] FIG. 1 illustrates a flow chart of manufacturing an aluminum-zirconium alloy conductor wire rod, in accordance with various embodiments of the present disclosure;
[0027] FIG. 2 illustrates the flow chart for processing one or more input materials during the manufacturing of the aluminum-zirconium alloy conductor wire rod, in accordance with various embodiment of the present disclosure;
[0028] FIG. 3A illustrates a table of electrical, mechanical and thermal properties of the aluminum-zirconium alloy conductor wire rod, in accordance with various embodiment of the present disclosure;
[0029] FIG. 3B illustrates the table of electrical, mechanical and thermal properties of the aluminum-zirconium alloy conductor wire rod, in accordance with another embodiment of the present disclosure; and
[0030] FIG. 4 illustrates a flowchart for manufacturing the aluminum-zirconium alloy conductor wire rod, in accordance with various embodiment of the present disclosure.

DETAILEDDESCRIPTION
[0031] In the following description, for purposes of explanation, numerous specific details are set for thin order to provide a thorough understanding of the present technology. It will be apparent, however, to one skilled in the art that the present technology can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form only in order to avoid obscuring the present technology.
[0032] Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in atleast one embodiment of the present technology. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.
[0033] Moreover, although the following description contains many specifics for the purpose of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to said details are within the scope of the present technology. Similarly, although many of the features of the present technology are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the present technology is set forth without any loss of generality to, and without imposing limitations upon, the present technology.
[0034] FIG. 1 illustrates a flowchart 100 of manufacturing an aluminum-zirconium alloy conductor wire rod, in accordance with various embodiment of the present disclosure. The aluminum-zirconium alloy conductor wire rod is a finely precipitated Al3Zr alloy conductor wire. In an embodiment of the present disclosure, the aluminum-zirconium alloy conductor wire rod is utilized to manufacture overhead power conductors. In general, the overhead power conductors are used to transmit and distribute electrical power over long distances. In an embodiment of the present disclosure, the overhead power conductor is a super thermal alloy conductor invar reinforced. In another embodiment of the present disclosure, the overhead power conductor is any suitable conductor.
[0035] The flowchart 100 includes a plurality of processing steps for manufacturing the aluminum-zirconium alloy conductor wire rod. The plurality of processing steps includes a feeding step 102, an alloying step 104, a casting step 106 and a solidification step 108. In addition, the plurality of processing steps includes a hot working step 110, a quenching step 112, a heat treatment step 114 and a cold working step 116. Each step of the plurality of processing steps is performed in a pre-defined manner to manufacture the aluminum-zirconium alloy conductor wire rod. The plurality of processing steps may include more or less number of steps that will enable to achieve the object of the present disclosure within the technological scope of the present disclosure.
[0036] The feeding step 102 includes a transfer of one or more aluminum ingots to a furnace. The one or more aluminum ingots are transferred to the furnace in the feeding step 102 by utilizing a feeding unit. The feeding unit is any device or assembly that is configured to load, carry and transfer the one or more aluminum ingots to the furnace. Further, each aluminum ingot of the one or more aluminum ingots have a pre-defined percentage range of purity. The pre-defined percentage range of purity of the one or more aluminum ingots is 99.7 % to 100 %.In addition, each aluminum ingot may be characterized by weight. In an embodiment of the present disclosure, the one or more aluminum ingots have equal weight. In another embodiment of the present disclosure, the one or more aluminum ingots have different weight. In addition, each aluminum ingot of the one or more aluminum ingots are characterized by shape and size. In an embodiment of the present disclosure, the one or more aluminum ingots transferred to the furnace are of uniform shape and size. In another embodiment of the present disclosure, the one or more aluminum ingots transferred to the furnace are of non-uniform shape and size.
[0037] Further, the alloying step 104 is performed to form an aluminum alloy having a plurality of alloying elements. In general, an alloying element is defined as a metallic or a non-metallic element added in specified or standard amounts to a base metal to make an alloy. In an embodiment of the present disclosure, the one or more aluminum ingots are used as a source of base metal. Furthermore, the alloying step 104 includes a pre-defined number of sub-steps. The pre-defined number of sub-steps is required for preparation of the aluminum alloy (discussed below in the detailed description of FIG. 2).
[0038] Furthermore, the aluminum alloy obtained as a product after the alloying step 104 is subjected to cast in the casting step 106 (described below in the detailed description of FIG. 2). In an embodiment of the present disclosure, the casting step 106 utilizes a continuous roll casting process (stated below in the detailed description of FIG. 2). In another embodiment of the present disclosure, the casting step 106 involves any suitable casting process. Moreover, the casting step 104 is performed to obtain a cast aluminum alloy bar.
[0039] Further, the cast aluminum alloy obtained during the casting step 106 is in molten state. The cast aluminum alloy is solidified in the solidification step 108 (discussed below in the detailed description of FIG. 2). The solidification step 108 prepares the cast aluminum alloy bar for the hot working step 110. Further, the cast aluminum alloy bar is rolled by performing the hot working step 110 (described below in the detailed description of FIG. 2). In an embodiment of the present disclosure, the hot working step 110 is performed by utilizing hot rolling mill. Moreover, the hot working step 110 is performed to extrude the cast aluminum alloy bar into rod form (discussed below in the detailed description of FIG. 2).
[0040] Further, each of the extruded cast aluminum alloy bar of rod form is quenched in the quenching step 112 (as described below in the detailed description of FIG. 2). Each of the extruded cast aluminum alloy bar of rod form is quenched for maintaining characteristics of the plurality of alloying elements. Moreover, the extruded cast aluminum alloy bar of rod form is quenched to obtain a first plurality of aluminum alloy rods. Furthermore, each of the first plurality of aluminum alloy rods is heat treated in the heat treatment step 114 (discussed below in the detailed description of FIG. 2). Each of the first plurality of aluminum alloy rods is heat treated to obtain a second plurality of aluminum alloy rods. In an embodiment of the present disclosure, the second plurality of aluminum alloy rod is a finely precipitated Al3Zr alloy rod. Furthermore, each of the second plurality of aluminum alloy rod is cold worked in the cold working step 116 (described below in the detailed description of FIG. 2).
[0041] FIG. 2 illustrates the flow chart for processing one or more input materials during the manufacturing of the aluminum-zirconium alloy conductor wire rod, in accordance with various embodiment of the present disclosure. The one or more aluminum ingots have the pre-defined range of impurity. In an embodiment of the present disclosure, the pre-defined range of impurity is 0.00 % to 0.2 % by weight. Moreover, the aluminum alloy is prepared in the alloying step 104.
[0042] The alloying step 104 includes a melting step 202, an element addition step 204, a holding step 206, a stirring step 208 and a grain refining step 210. In the melting step 202, the one or more aluminum ingots of the pre-defined percentage purity range are melted in the furnace. The melting step 202 is performed to obtain molten aluminum. In melting step 202, the one or more aluminum ingots are melted at a first pre-defined temperature range. In an embodiment of the present disclosure, the first pre-defined temperature range is 740 °C to 750 °C. In an embodiment of the present disclosure, the one or more aluminum ingots is melted by utilizing a melting and holding furnace.
[0043] Further, the element addition step 204 includes the addition of the plurality of alloying elements to the molten aluminum present in the furnace. The plurality of alloying elements includes boron, copper, iron and zirconium. The molten aluminum alloy is obtained after addition of boron, copper, iron and zirconium in a pre-defined quantity and in a pre-defined sequence. The element addition step 204 introducesthe pre-defined sequence of addition of the plurality of alloying elements. The pre-defined sequence of addition includes a primary addition of boron followed by addition of copper followed by addition of zirconium. The pre-defined sequence of addition is initiated by an addition of boron to the molten aluminum present in the furnace. The addition of boron improves the conductivity of the molten aluminum by removing a plurality of transition elements present in the molten aluminum. The plurality of transition elements includes but may not be limited to titanium, and vanadium.
[0044] Furthermore, the molten aluminum homogeneously dissolves added amount of boron. Moreover, the plurality of transition elements chemically reacts with added quantity of boron to form a plurality of metal boride particles. The plurality of metal boride particles are fine particles that are distributed homogeneously in the molten aluminum. In addition, the plurality of metal boride particles agglutinates and settles at the bottom of the molten aluminum alloy present in the furnace. The pre-defined sequence of addition is seconded by the addition of copper to the molten aluminum present in the furnace. The addition of copper is performed after the addition of boron. The addition of copper in the molten aluminum increases tensile strength of the aluminum alloy.
[0045] The addition of copper is succeeded by the addition of zirconium in the molten aluminum present in the furnace. In an embodiment of the present disclosure, the addition of zirconium is performed after the addition of boron and copper. In addition, the addition of zirconium is performed after a first pre-defined time interval after the addition of boron. The first pre-defined time interval is 10 minutes to 60 minutes. The addition of zirconium after the first pre-defined time interval reduces the possibility of reaction between boron and zirconium. Moreover, the addition of zirconium in the pre-defined sequence of addition improves the thermal resistance of the molten aluminum alloy. In addition, the thermal resistance of molten aluminum alloy is improved by formation ofAl3Zr precipitates.
[0046] Further, the holding step 206 includes holding of the molten aluminum alloy that is obtained from the addition step 204. The holding step 206 is performed in the furnace. The holding step 206 is performed at a second pre-defined temperature range. In an embodiment of the present disclosure, the second pre-defined temperature range is 680 °C to 750 °C. In addition, the holding step 206 is performed for a second pre-defined time interval. In an embodiment of the present disclosure, the second pre-defined time interval is about 6 hours to 24 hours.
[0047] Furthermore, the stirring step 208 is performed in the second pre-defined time interval associated with the holding step 206. The molten aluminum alloy is stirred in the furnace at a specific time interval during the holding step 206. In an embodiment of the present disclosure, the stirring step 208 is performed simultaneously with the holding step 206. In addition to gas refining, slag standing of the molten aluminum alloy is performed during the holding step 206. The slag standing of the molten aluminum alloy is performed at the second pre-defined temperature range.
[0048] Further, the grain refining step 210 is performed. The grain refining step 210 includes grain refinement of the molten aluminum alloy. The grain refining step 210 is performed to obtain a grain refined molten aluminum alloy. The grain refined molten aluminum alloy has an improved distribution of porosity and improved mechanical properties. In addition, the grain refining step 210 is performed to improve fluidity of the molten aluminum alloy required in the casting step 106. The grain refining step 210 is performed by adding one or more tiber rods in the molten aluminum alloy. The one or more tiber rods are added at a specific angle against flow of the molten aluminum alloy. In addition, the one or more tiber rods are added to the molten aluminum alloy at a pre-defined speed. In an embodiment of the present disclosure, the pre-defined speed of adding the one or more tiber rods is 20 cm/minute to 30 cm/minute. In an embodiment of the present disclosure, the one or more tiber rods are added to the molten aluminum alloy at the time of pouring the refined molten aluminum alloy to perform the casting. The grain refining step 210is known to those skilled in the art and will not be described further for the sake of brevity.
[0049] The grain refined molten aluminum alloy is poured at a temperature in the second pre-defined temperature range. Further, the casting step 106 is performed. The casting step 106 includes the casting of the refined molten aluminum alloy. The casting step 106 is performed in a casting unit. In an embodiment of the present disclosure, the casting unit includes a series of continuous strip cast rolls. The casting step 106 is performed to obtain the cast aluminum alloy bar. The casting step 106 is known to those skilled in the art and will not be described further for the sake of brevity.
[0050] Further, the molten aluminum alloy is allowed to solidify by performing the solidification step 108. The solidification step 108 is performed by utilizing a solidification unit. In an embodiment of the present disclosure, the solidification unit includes one or more water cooled rolls. In addition, the solidification step 108 is performed at a pre-defined cooling rate. In an embodiment of the present disclosure, the pre-defined cooling rate is 30 °C to 40 °C per minute with 2.5 metric ton / hour mill output speed. The solidification step 108 is known to those skilled in the art and will not be described further for the sake of brevity.
[0051] Further, the cast aluminum alloy baris hot worked in the hot working step 110. The hot working step 110 includes hot rolling of the cast aluminum alloy bar. The hot working step 110 is performed at a third pre-defined temperature range. The third pre-defined temperature range is 480 °C to 540 °C. The hot working step 110 is performed by utilizing a hot working unit. In an embodiment of the present disclosure, the hot working unit is continuous casting and rolling production line. The hot working step 110 is performed to extrude the cast aluminum alloy bar into rod form. The hot working step 110 is known to those skilled in the art and will not be described further for the sake of brevity.
[0052] Further, the extruded cast aluminum alloy bar of rod form is quenched in the quenching step 112. The quenching step 112 is performed by utilizing cold water at a pre-defined range of arresting temperature. In an embodiment of the present disclosure, the pre-defined range of arresting temperature is 30 °C to 40 °C. Moreover, the quenching step 112 is performed to obtain the first plurality of aluminum alloy rods. Each of the first plurality of aluminum alloy rod is quenched to maintain characteristics of the plurality of alloying elements as like in solid solution. Each aluminum alloy rod of the first plurality of aluminum alloy rods has a diameter in a first pre-defined nominal diameter range. In an embodiment of the present disclosure, the first pre-defined nominal diameter range is 9.5 mm to 12.7 mm. The quenching step 112 is known to those skilled in the art and will not be described further for the sake of brevity.
[0053] Going further, the heat treatment step 114 is performed. The heat treatment step 114 includes heat treating of each of the first plurality of aluminum alloy rods. In the heat treatment step 114, zirconium finely precipitates and uniformly dispenses as Al3Zr. The uniform dispense of zirconium as Al3Zr results in an improved thermal resistance of each aluminum alloy rod. Moreover, precipitation of zirconium in the heat treatment step 114 improves the conductivity and thermal resistance of each aluminum alloy rod.
[0054] Each aluminum alloy rod of the first plurality of aluminum alloy rods is subjected to heat treatment at a fourth pre-defined temperature range. In an embodiment of the present disclosure, the fourth pre-defined temperature range is 380 °C to 420 °C. Moreover, the heat treatment step 114 is performed at the fourth pre-defined temperature range to improve the thermal resistance of each aluminum alloy rod. In addition, heat treatment step 114 is performed at the fourth pre-defined temperature range to optimize the production time. In addition, the heat treatment step 114 is performed for a third pre-defined time interval. In an embodiment of the present disclosure, the third pre-defined time interval is 20 hours to 200 hours. Moreover, each of the first plurality of aluminum alloy rods is heat treated to obtain the second plurality of aluminum alloy rods. The second plurality of aluminum alloy rods includes a finely precipitated Al3Zr alloy rods.
[0055] Going further, the cold working step 116 includes wire drawing of each aluminum alloy rod of the second plurality of aluminum alloy rods. The cold working step 116 is performed by utilizing a cold working unit. In an embodiment of the present disclosure, the cold working unit is a series of wire drawing dies. The cold working of the second plurality of aluminum alloy rods is performed to obtain an aluminum-zirconium alloy conductor wire rod. Moreover, the aluminum-zirconium alloy conductor wire rod obtained in the cold working step 116 has a pre-defined nominal diameter. In an embodiment of the present disclosure, the pre-defined nominal diameter is 4.16 mm. In another embodiment of the present disclosure, the pre-defined nominal diameter is 4.39 mm. In yet another embodiment of the present disclosure, the pre-defined nominal diameter is any suitable nominal diameter value.
[0056] Each of the aluminum-zirconium alloy conductor wire rod has conductivity in a pre-defined conductivity range. In an embodiment of the present disclosure, the pre-defined conductivity range is 59.5% to 60.5% IACS (International Annealed Copper Standard). In general, IACS is a unit of electrical conductivity for metals and alloys that is measured relative to a standard annealed copper conductor. For example, an IACS value of100%refers to a conductivity of5.80 × 107 Siemens per meter (58.0 MS/m) at 20 °C. In addition, each of the aluminum-zirconium alloy conductor wire rod has tensile strength in a pre-defined tensile strength range. In an embodiment of the present disclosure, the pre-defined tensile strength range is 11Kgf/Sq. mm (also referred to as Kilogram force per square millimeters) to 20 Kgf/Sq.mm. Furthermore, each of the aluminum-zirconium alloy conductor wire rod has a pre-defined percentage elongation range. In an embodiment of the present disclosure, the pre-defined percentage elongation range is 2 % to 16 %. Moreover, each of the aluminum-zirconium alloy conductor wire rod has heat resistance in a pre-defined heat resistance range in wire stage. In an embodiment of the present disclosure, the pre-defined heat resistance range is 90% to 94 %.
[0057] The following example of the technical aspect of the present invention will be further explained, but the content of the following is not intended to limit the scope of the present invention.
[0058] In an example, the plurality of alloying elements is added and melted by use of electrical grade aluminum (P1020A), Al-10%Zr, Al-8%B mother alloy and pure copper at 740 °C. The molten aluminum alloy obtained is subjected to continuous casting by means of casting unit to obtain the cast aluminum alloy bar. The molten aluminum alloy temperature directly before casting lies between 710 °C to 730 °C. Further, the cast aluminum alloy bar solidifies and is immediately subjected to hot rolling to extrude the cast aluminum alloy bar into rod form of 9.5 mm diameter. During the hot rolling operation, the temperature (rolling starting temperature) of the cast aluminum alloy bar is controlled between 530 °C to 545 °C. Further, the extruded cast aluminum alloy bar of rod form is quenched and processed under 400 °C heat treatment for 140 hours duration and then drawn into 4.39 mm and 4.16 mm diameter aluminum-zirconium alloy conductor wire rod. The mechanical, electrical and thermal properties of the aluminum-zirconium alloy conductor wire rod are illustrated in the table shown in the FIG. 3A and FIG. 3B.
[0059] FIG. 4illustrates a flowchart 400 for manufacturing the aluminum-zirconium alloy conductor wire rod, in accordance with various embodiment of the present disclosure. It may be noted that to explain the process steps of flowchart 400, references will be made to the system elements of the FIG. 1 and the FIG. 2. It may also be noted that the flowchart 400 may have lesser or more number of steps.
[0060] The flowchart 400 initiates at step 402. Following step 402, at step 404, the plurality of alloying elements is added to the molten aluminum present in the furnace. The addition of the plurality of alloying elements is performed to obtain the molten aluminum alloy. In addition, the molten aluminum alloy is poured for casting to obtain the cast aluminum alloy bar. Further, at step 406, the cast aluminum alloy bar is hot worked. In addition, the hot working is performed to extrude the cast aluminum alloy bar into rod form. Further, at step 408, the extruded cast aluminum alloy bar of rod form is quenched by utilizing cold water at the pre-defined range of arresting temperature. The extruded cast aluminum alloy bar of rod form is quenched to obtain the first plurality of aluminum alloy rods. Further, at step 410, the heat treatment of each of the first plurality of aluminum alloy rods is performed. The heat treatment is performed at the fourth pre-defined temperature range. The heat treatment is performed for the third pre-defined time interval. Moreover, the heat treatment of the first plurality of aluminum alloy rods is performed to obtain the second plurality of aluminum alloy rods. The flowchart 400 terminates at step 412.
[0061] The present disclosure has several advantages over a prior art. The present disclosure provides the aluminum-zirconium alloy rod having enhanced heat resistance capacity. Further, the present disclosure provides the aluminum-zirconium alloy conductor wire rod having enhanced conductivity. In addition, the present disclosure provides the aluminum-zirconium alloy wire rod having enhanced strength. Moreover, the present disclosure optimizes the production cost of the aluminum-zirconium alloy rod. In addition, the present disclosure minimizes the time required for the production of the aluminum-zirconium alloy rod.
[0062] The foregoing descriptions of specific embodiments of the present technology have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present technology to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present technology and its practical application, to thereby enable others skilled in the art to best utilize the present technology and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present technology.
[0063] While several possible embodiments of the invention have been described above and illustrated in some cases, it should be interpreted and understood as to have been presented only by way of illustration and example, but not by limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments.