TY - JOUR T2 - Journal of Mining and Metallurgy, Section B: Metallurgy TI - Melt quality induced failure of electrical conductor (EC) grade aluminum wires VL - 53 IS - 1 SP - 75 EP - 81 PY - 2017 DO - 10.2298/JMMB151006030K AU - A. Khaliq AU - M.A. Rafiq AU - H.T. Ali AU - F. Ahmed AU - S. Mehmood AU - J. Grandfield AU - S.A. Ranjha AD - aFaculty of Science, Engineering and Technology, Swinburne University of Technology, Melbourne, Australia; bMetallurgical and Materials Engineering Department, University of Engineering and Technology, Lahore, Pakistan; cAdvanced Composites Centre for Innovation and Science (ACCIS), Department of Aerospace Engineering, University of Bristol, Bristol, UK; dNorthern Ireland Advanced Composites & Engineering Centre, Belfast, UK eGrandfield Technologies Pty Limited, Coburg, Victoria, Australia" AB - The failure of electrical conductor grade (EC) aluminum during wire drawing process was investigated. The fractured aluminum wires were subjected to Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) analyses for an initial examination. Thermodynamic analyses of molten aluminum interaction with refractories was also carried out using FactSage at 710 oC to predict the stable phases. The SEM/EDX analyses has revealed the inclusions in aluminum matrix. The typical inclusions observed were Al2O3, Al3C4 (Al-Carbide) and oxides of refractories elements (Al, Mg, Si and O) that have particle size ranging up to 5 µm. The transition metal boride particles were not identified during SEM/EDX analyses these might be too fine to be detected with this microscope. The overall investigation suggested that the possible cause of this failure is second phase particles presence as inclusions in the aluminum matrix, and this was associated with the poor quality of melt. During wire drawing process, these inclusions were pulled out of the aluminum matrix by the wire-drawing forces to produce micro-voids which led to ductile tearing and final fracture of wires. It was recommended to use ceramic foam filters to segregate inclusions from molten aluminum. KW - Aluminum wire drawing KW - Inclusions KW - Ductile fracture KW - Scanning electron microscope (SEM) KW - Oxides and carbides N1 - Correspondence Address: A. Khaliq, Faculty of Science, Engineering and Technology, Swinburne University of Technology, Melbourne, Australia email: aks1445@gmail.com N1 - J. Min. Metall. Sect. B-Metall. 53 (1) B (2017) 75-81. DOI:10.2298/JMMB151006030K PB - Technical Faculty in Bor SN - 14505339 (ISSN) LA - English J2 - J. Min. Metall. Sect. B Metall. M3 - Article ER