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<p>The purpose of this study is to develop an integrated low-operation-technology process for manufacturing projection welding electrodes from a metal matrix composite based on copper reinforced with nanosized chromium particles (Cu-MMNCr). This technology ensures an optimal balance between product quality, cost, and production efficiency. The goal is achieved through combined numerical modeling and experimental investigations of casting, hot stamping, quenching, and aging processes. The proposed technology is based on a systematic “material-process-structure-properties” approach implemented in three stages: (1) development of a technology for introducing a tabletized ligand containing Cu powder and nanosized Cr powder into molten copper; (2) investigation of high-temperature thermomechanical treatment within the integrated casting-stamping-quenching process, including analysis of gravitational casting and experimental study of chromium particle distribution in the cast blank; (3) complex modeling of the integrated casting-stamping process with cooling hole punching, evaluating the stressed-deformed and thermal states of the electrode after stamping, as well as analyzing the structure and properties of the material after hot deformation, quenching, and aging. As a result, an optimized electrode manufacturing technology has been created, combining casting, stamping, quenching, and aging processes. The main advantage is the improvement of operational characteristics: increased number of welded joints, enhanced hardness (HB) and microhardness (HV), and improved electrical conductivity. Furthermore, a patented technology (Patent No. 2412035 RF) has been developed, allowing for recycling of secondary copper feedstock, thus enhancing production sustainability and cost-effectiveness.</p>

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Step-by-step evaluation of properties and structure during production of welding electrodes from a copper metal matrix composite

  • 期刊论文

  • 发表日期：

    2025年11月11日

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  • Ivan Nikolaevich Dovzhenko,
  • Sergey Leonidovich Busygin,
  • Nikolay Nikolaevich Dovzhenko,
  • Alexander Mikhailovich Tokmin,
  • Aleksandr Igorevich Demchenko,
  • Marina Vladimirovna Voroshilova

摘要

The purpose of this study is to develop an integrated low-operation-technology process for manufacturing projection welding electrodes from a metal matrix composite based on copper reinforced with nanosized chromium particles (Cu-MMNCr). This technology ensures an optimal balance between product quality, cost, and production efficiency. The goal is achieved through combined numerical modeling and experimental investigations of casting, hot stamping, quenching, and aging processes. The proposed technology is based on a systematic “material-process-structure-properties” approach implemented in three stages: (1) development of a technology for introducing a tabletized ligand containing Cu powder and nanosized Cr powder into molten copper; (2) investigation of high-temperature thermomechanical treatment within the integrated casting-stamping-quenching process, including analysis of gravitational casting and experimental study of chromium particle distribution in the cast blank; (3) complex modeling of the integrated casting-stamping process with cooling hole punching, evaluating the stressed-deformed and thermal states of the electrode after stamping, as well as analyzing the structure and properties of the material after hot deformation, quenching, and aging. As a result, an optimized electrode manufacturing technology has been created, combining casting, stamping, quenching, and aging processes. The main advantage is the improvement of operational characteristics: increased number of welded joints, enhanced hardness (HB) and microhardness (HV), and improved electrical conductivity. Furthermore, a patented technology (Patent No. 2412035 RF) has been developed, allowing for recycling of secondary copper feedstock, thus enhancing production sustainability and cost-effectiveness.