A process to fabricate ultra-fine grain metal wire, comprising: inserting a plurality of metal strands into a flexible elastic polyurethane sheath having an accommodating slot for each of the strands of metal to form a sheathed strand assembly; equal channel angular pressing (ECAP pressing) the sheathed strand assembly through an ECAP die having a plurality of die channels corresponding to the plurality of metal strands. The process is designed to improve electric conductance and mechanical properties of elongated metal parts and is especially applicable to optimize the conductance and tensile strength of copper cables, wires, strings, and rods.

A torsion bar is provided that is easy, quick, and cost effective to manufacture. The torsion bar may extend along an axis and have a first end and a second end that is spaced from the first end. The torsion bar may have an active section positioned between the first and second ends. The active section may also have a length defined along the axis. A cross-section transverse to the axis may define a contour of the torsion bar where the contour may be uniform along the length of the active section. The contour may define at least one of a polygon and a polygon-like shape.

Disclosed is a method for forming a square-wire conductor, which includes: providing a circular conductor with a diameter d; passing the conductor through a gap of a longitudinal calendaring roller to longitudinally calender the conductor up and down to form a conductor with flat upper and lower surfaces, the gap L1 of the longitudinal calendering roller is 0.886 d to 0.911 d; longitudinally and transversely straightening the conductor; passing the conductor through a gap of a transverse calendering roller to transversely calender the conductor left and right to form a conductor with flat left and right surfaces, the gap L2 of the transverse calendering roller is 0.886 d to 0.911 d; and longitudinally and transversely straightening the conductor.

A process to fabricate ultra-fine grain metal wire, comprising: inserting a plurality of metal strands into a flexible elastic polyurethane sheath having an accommodating slot for each of the strands of metal to form a sheathed strand assembly; equal channel angular pressing (ECAP pressing) the sheathed strand assembly through an ECAP die having a plurality of die channels corresponding to the plurality of metal strands. The process is designed to improve electric conductance and mechanical properties of elongated metal parts and is especially applicable to optimize the conductance and tensile strength of copper cables, wires, strings, and rods.

According to the invention, the electrode wire (1) for electric discharge machining comprises a metal core (2), in one or more layers of metal or metal alloy. On the metal core (2), a coating (3) having an alloy different from that of the metal core (2) contains more than 50 wt % zinc. The coating (3) comprises copper-zinc alloy (3a) of fractured γ phase, and covers the majority of the metal core (2). The coating (3) contains covered pores (5a, 5b, 5c, 5d, 5e) larger than 2 μm.

A tie rod forming apparatus includes a frame for supporting a material holding unit that releasably holds tie rod stock material, and a feed bed in structural communication with the material holding unit. The feed bed selectively accepts and manipulates the tie rod stock material. A cutting assembly is provided in operative communication with the feed bed, and an operator interface module is in communication with the material holding unit and the cutting assembly. The material holding unit selectively dispenses the tie rod stock material to the feed bed, and the cutting assembly manipulates a portion of the dispensed tie rod stock material, in dependence upon parameters communicated by the operator interface module.

A method for manufacturing an aluminum wire is provided. The aluminum wire includes an inner-layer conductor having one or a plurality of inner-layer alloy wires including aluminum and an outer-layer conductor having a plurality of outer-layer alloy wires including aluminum and provided on the inner-layer conductor. The method includes an outer-layer twisting step of twisting, over the inner-layer conductor, the outer-layer alloy wires provided on the inner-layer conductor, and an outer-layer rotational compression step of compressing the outer-layer alloy wires twisted in the outer-layer twisting step while being rotated in the same direction as the direction of the twisting in the outer-layer twisting step.

A cored wire for refining molten metal includes a reactive core material that is in the form of a solid rod. A non-reactive particulate material radially surrounds the solid core material, and an exterior metal jacket radially surrounds the particulate material. The particulate material may include wood or other material that when introduced into the molten metal, undergoes thermal decomposition to release carbon dioxide, hydrocarbons, or combinations thereof as a shroud around the core material.

A method for manufacturing a wire includes: preparing a tubular outer layer body including a magnetic metal containing iron; preparing a metal core body having an outer diameter that is 85.1% or more and 99.4% or less of an inner diameter of the tubular outer layer body; mechanically polishing an inner surface of the tubular outer layer body and an outer surface of the metal core body; treating at least one of the inner surface of the tubular outer layer body and the outer surface of the metal core body with hydrochloric acid; obtaining a preform by disposing the metal core body inside the tubular outer layer body; and obtaining a wire by drawing the preform through a wire drawing die.

A cored wire for refining molten metal includes a reactive core material that is in the form of a solid rod. A non-reactive particulate material radially surrounds the solid core material, and an exterior metal jacket radially surrounds the particulate material. The particulate material may include wood or other material that when introduced into the molten metal, undergoes thermal decomposition to release carbon dioxide, hydrocarbons, or combinations thereof as a shroud around the core material.