Determination of optimal parameters technological process of polling of copper wire with alloy POS-61 Chimica Techno Acta LETTER published by Ural Federal University 2022, vol. 9(2), No. 202292S7 eISSN 2411-1414; chimicatechnoacta.ru DOI: 10.15826/chimtech.2022.9.2.S7 1 of 3 Determination of optimal parameters for the technological process of polling of copper wire with alloy POS-61 V.V. Aleksandrova * , M.V. Kuzmin , A.O. Patianova , V.L. Semenov , R.I. Alexandrov Chuvash State University named after I. N. Ulyanov, Cheboksary 428015, Russia * Corresponding author: valek_1996@mail.ru This paper belongs to the MOSM2021 Special Issue. © 2021, the Authors. This article is published open access under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/). Abstract The development of the technique for the manufacture of round cop- per wire coated with "tin-lead" alloy is considered. The optimal pa- rameters such as the temperature of the "tin-lead" alloy melt, the linear speed for tinning of the wire with a round copper alloy and the diameter of the diamond die were determined. The test results of the experimental wire samples are presented. Keywords technological process alloy tin lead tinning round copper wire Received: 03.11.21 Revised: 14.06.22 Accepted: 16.06.22 Available online: 21.06.22 Key findings ● The round copper wire coated with POS 61 alloy is used as shielding elements in cable and wire products. ● According to the results of tests the optimal technological process parameters of tinning the wire are determined. ● During the tests it turned out that 8 samples of experimental round copper wire meet the estab- lished requirements 075-11-2019-047-TT on consumer properties. 1. Introduction The most important factor in ensuring and increasing an organisation's competitiveness is the development of in- novative products with parameters that are ahead of exist- ing consumer requirements at the time of market entry [1]. The developed products, according to their character- istics, must satisfy the consumers, needs in terms of the required and the desired parameters, thus forming the necessary “quality profile” [2]. Chuvashkabel Plant JSC is not an exception. The plant management and personnel are focused on the production of innovative and high technology products [3], in particu- lar, wire with unique characteristics used as braiding in cable products for various purposes. This research is focused on round copper wire coated with POS-61 alloy. This wire is used as a shield in cable and wire products. The developed tinning technology must provide the wire with characteristics indicated in Table 1. Round copper wire samples with POS-61 coating are con- sidered to have passed the tests if their indicators meet the requirements specified in Table 1. The controlled parameters of the POS-61 coated round copper wire also include the appearance: the wire should have a smooth surface and a continuous coating along the entire wire length. Table 1 List of required parameters for the round copper wire coated with POS-61. Options Values Wire diameter, mm 0.12−0.003 +0.005 0.15−0.003 +0.005 0.20−0.003 +0.005 0.30−0.005 +0.007 Coating thickness, microns 1.0−0.5 +0.2 Tensile strength wire, N/mm2 Not less 196 Elongation at break, % 0.12 mm – 10–25%; 0.15 mm – 10–25%; 0.20 mm – 10–25%; 0.30 mm – 15–30% Resistivity, Оhmm10–6 No more 0.0180 http://chimicatechnoacta.ru/ https://doi.org/10.15826/chimtech.2022.9.2.S7 http://creativecommons.org/licenses/by/4.0/ https://orcid.org/0000-0002-4278-4056 https://orcid.org/0000-0003-3880-9510 https://orcid.org/0000-0002-9785-4058 https://orcid.org/0000-0002-9869-6602 https://orcid.org/0000-0002-8335-9996 https://crossmark.crossref.org/dialog/?doi=https://doi.org/10.15826/chimtech.2022.9.2.S7&domain=pdf&date_stamp=2022-6-21 Chimica Techno Acta 2022, vol. 9(2), No. 202292S7 LETTER 2 of 3 2. Materials and Methods Research tests were carried out on 36 samples with a total weight of 50.4 kg and five parallel measurements for each wire sample. During the tests, five experimental wire samples with a length of at least 1000 mm were taken from each wire batch. During the tests, we were guided by the following documents:  preliminary technological documentation PBMI.05171.00002;  route map 075-11-2019-047-1.2.1-MK;  program and test procedure E PBMI.00002 PM2;  act of making experimental samples. Each experimental sample of a round copper wire with a POS-61 coating was obtained under various technological modes of coating the wire MT 0.12, MT 0.15, MT 0.20 and MT 0.30 with the solder made of the POS-61 alloy. The production of high quality round copper wire coat- ed with various alloys, including POS-61, is provided by:  the correct choice of wire grade as a raw material;  the correct choice of alloy (solder), which will be applied to the base, depending on the purpose, design fea- tures and materials used;  the optimal flux choice [4], which is designed to remove the oxide film from the surfaces of wire and alloy (solder), to protect the surface of wires and solder (alloy) from oxidation during the alloy (solder) deposition and to reduce the surface tension of the straightened alloy (sol- der) at the boundary metal – alloy (solder) – flux;  the surfaces, high-quality preparation of the base metal and alloy (cleaning, preliminary tinning);  temperature control, speed and time of alloy (sol- der) deposition on the base;  absence of foreign impurities and foreign inclusions in the alloy and the flux [5–6]. 3. Results and Discussion Chuvashkabel Plant JSC proposed to produce experimental wire samples to determine the optimal parameters of the technological mode of manufacturing round copper wire coated with POS-61 alloy. As mentioned above, it is based on variations in the tem- perature of the POS-61 alloy melt, linear velocity, diamond wire diameter and flux grades (Table 2). Table 2 Technological modes of obtaining the round copper wire with POS-61 coating. Nominal diameter of copper wire, mm Melt temperature, °С Linear speed, m/min Diamond die diameter, mm 0.12−0.003 +0.005 0.15−0.003 +0.005 0.20−0.003 +0.005 0.30−0.005 +0.007 185 215 245 110 125 140 0.187 0.238 0.385 Table 3 shows an example, which is one of the varia- tions in the manufacturing modes of round copper wire with a POS-61 coating, used as a braid in cable products for various purposes. Table 4 shows the tests results of an experimental pro- totype of a round copper wire with a POS-61 coating, manufactured with the parameters of the technological mode indicated in Table 3. Based on the 36 experimental sample results of the studies performed, obtained at different parameters of the tinning technological process, it is proposed to use the following optimal modes:  first mode: melt temperature – 185±5 °С, linear speed – 110±5 m/min;  second mode: melt temperature – 215±5 °С, linear speed – 125±5 m/min. The first mode allows increasing the productivity of manufacturing of the round copper wire coated with pure tin or POS61 alloy at lower power consumption. The second mode allows obtaining a better quality sol- der coating with a narrow range of variation in the coating thickness and wire diameter. Table 3 Modes of manufacturing the experimental samples of round copper wire with POS-61 coating at a temperature of 395 °C. No. wire sample Diameter of copper wire, mm Melt temperature POS-61, °С Linear speed, m / min Diamond die di- ameter, mm E-МТ- 0.15- POS- 61-31 0.15−0.003 +0.005 215±5 110±5 0.238 Table 4 Test results of an experimental sample of POS-61 E-MT-0.15-POS61-31 coated round copper wire. Options Meaning and tolerances Sample test results No. 1 No. 2 No. 3 No. 4 No. 5 Diameter of wire, mm 0.15−0.003 +0.005 0.156 0.155 0.156 0.156 0.156 Quality and continuity of the coating the solution should be lighter than the control Correct Correct Correct Correct Correct Coating thickness, microns 1.0−0.5 +0.2 1.1 1.0 1.2 1.1 1.0 Tensile strength of wire, N/mm2 not less 196 215 210 210 215 220 Elongation at break, % 20−10 +5 23 22 22 23 24 Specific resistance, Оhmm10–6, no more 0.0180 0.01725 0.01714 0.01722 0.01716 0.01715 Chimica Techno Acta 2022, vol. 9(2), No. 202292S7 LETTER 3 of 3 4. Conclusions Thus, during the tests, it turned out that 8 samples of ex- perimental round copper wire with coatings POS61 E-MT- 0.12-POS61-12, E-MT-0.12-POS61-14, E-MT-0.15-POS61-30, E-MT-0.15-POS61-32, E-MT-0.20-POS61-48, E-MT-0.20- POS61-50, E-MT-0.30-POS61-66 and E-MT-0.30-POS61-68 met the established requirements 075-11-2019-047-TT of consumer properties. Supplementary materials No supplementary materials are available. Funding The research was carried out by the Chuvash State Univer- sity within the implementation of a comprehensive project under the contract No. 2019/0837/1202–19 dated Septem- ber 19, 2019 with the financial support of the Ministry of Education and Science of Russia under the Agreement No. 075-11-2019-047 dated November 25, 2019 and Russian Foundation for Basic Research (RFBR), project number 20- 33-90269. https://www.rfbr.ru/rffi/eng. Acknowledgments None. Author contributions Conceptualization: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Data curation: A.V.V., K.M.V., P.A.O. Formal Analysis: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Funding acquisition: K.M.V., S.V.L., A.R.I. Investigation: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Methodology: K.M.V., S.V.L., A.R.I. Project administration: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Resources: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Software: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Supervision: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Validation: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Visualization: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Writing – original draft: A.V.V., K.M.V., P.A.O., S.V.L., A.R.I. Writing – review & editing: A.V.V., P.A.O. Conflict of interest The authors declare no conflict of interest. Additional information Author IDs: M.V. Kuzmin, Scopus ID 55758896300; A.O. Patianova, Scopus ID 57202283653; V.L. Semenov, Scopus ID 57190025583; R.I. Alexandrov, Scopus ID 57219838682. Website: Chuvash State University, https://www.chuvsu.ru/. References 1. 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Vestnik Kazanskogo Tekhnol Univ. 2013;16(1):136– 138. 6. Nikolaeva NP, Kuzmin MV, Koltsov NI, inventors; Chuvash State University named after I. N. Ulyanov, assignee. Method of obtaining epoxy polyurethanes. Russian Federation patent RU 2457220 C1. 2012 Jul 27. https://www.scopus.com/authid/detail.uri?authorId=55758896300 https://www.scopus.com/authid/detail.uri?authorId=57202283653 https://www.scopus.com/authid/detail.uri?authorId=57190025583 https://www.scopus.com/authid/detail.uri?authorId=57219838682 https://www.chuvsu.ru/