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ArticleName Production of aluminum alloy onboard wire with a high content of rare-earth metals produced using electromagnetic crystallization
DOI 10.17580/tsm.2022.01.09
ArticleAuthor Timofeev V. N., Usynina G. P., Lebedev V. N., Konkevich V. Yu.

Research and Production Center for Magnetohydrodynamics Ltd., Krasnoyarsk, Russia1 ; Siberian Federal University, Krasnoyarsk, Russia2:

V. N. Timofeev, Director1, Head of the Сhair for Electrical Technologies and Electrical Engineering2, Doctor of Technical Sciences


Research and Production Center for Magnetohydrodynamics Ltd., Krasnoyarsk, Russia:
G. P. Usynina, Chief Materials Scientist1, Candidate of Technical Sciences, e-mail:


JSC Special Design Bureau of the Cable Industry, Moscow, Russia:
V. N. Lebedev, Deputy General Director for Research


Moscow Aviation Institute (National Research University), Moscow, Russia:
V. Yu. Konkevich, Professor, Chair for Technologies and Systems for Automatic Design of Metallurgical Processes, Doctor of Technical Sciences


The Scientific and Production Center for Magnetic Hydrodynamics Ltd has developed an innovative technology for casting long ingots of small diameter (8–12 mm) into an electromagnetic mold (EMM) and manufacturing thin wire (0.5 mm in diameter) from them for onboard wires from 01417 alloy. Crystallization of liquid metal occurs under the influence of electromagnetic forces in an electromagnetic mold with direct supply of coolant to the ingot, due to which cooling rates are achieved that ensure the dispersion of the eutectic phases of rare earth metal aluminides, similarly to how it takes place during the crystallization of granules (~1.103...1.104 K/s). It has been established that the determining parameters in casting ingots are the power supplied to the inductor and the level of the melt above the crystallization front. For the casting to reach a steady state (the process of stabilizing the diameter of the ingot after the start of casting), it is necessary to regulate the melt level for some time. The surface quality of the ingot depends on ensuring stability of the current in the inductor during casting. Fluctuations in the current in the inductor lead to changes in the ingot`s diameter. Casting speed and metal temperature have a great influence on the structure of ingots. In contrast to the method of producing granulated wire with a thin (less than 1 mm) cross-section, which turned out to be problematic due to numerous breaks during drawing associated with the presence of oxide and foreign inclusions, the casting technology in the electromagnetic mold does not require preliminary metal filtration, since oxide and solid non-metallic inclusions are intensively squeezed out by electromagnetic forces onto the ingot`s surface. It has been established that hot deformation of a billet cast in the EMM at the Conform facility provides higher strength characteristics of the wire from the 01417 alloy after drawing compared to the cast annealed billet. Pressing provided an increase in the yield strength and relative elongation of the 01417 alloy by 2 and 2.5 times, respectively, compared with the cast state. As a result, the billet was obtained with high technological plasticity for further drawing. Electron microscopic studies of the wire have been carried out, which have shown that dispersed REM aluminides are rather uniformly distributed over the cross section of the wire with a diameter of 0.5 mm. Determination of the particle size of aluminides at ×50000 magnification showed that their size is ~96–214 nm. Wire from 01417 alloy is used by JSC “Special Design Bureau of the Cable Industry” (JSC “OKB KP”) for the manufacture of conductive cores of installation wires, providing a significant reduction in their weight.

keywords Electromagnetic crystallization, magnetohydrodynamic action, high-frequency electromagnetic field, aluminum alloys with rare-earth metals, granular technology, structure dispersion, onboard wires

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