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research-article

A Long Wavelength Model for Manufacturing of Continuous Metal Microwires by Thermal Fiber Drawing from a Preform

[+] Author and Article Information
Jingzhou Zhao

Department of Mechanical and Aerospace Engineering, University of California, Los Angles, 404 Westwood Plaza, Los Angeles, CA 90095; Department of Mechanical Engineering, Western New England University, 1215 Wilbraham Road, Springfield, MA 01119
jingzhou.zhao@ucla.edu
jingzhou.zhao@wne.edu

Xiaochun Li

Department of Mechanical and Aerospace Engineering, University of California, Los Angles, 404 Westwood Plaza, Los Angeles, CA 90095
xcli@seas.ucla.edu

1Corresponding author.

ASME doi:10.1115/1.4038433 History: Received March 25, 2017; Revised November 01, 2017

Abstract

Thermal drawing from a preform recently emerges as a scalable manufacturing method for the high volume production of continuous metal micro wires for numerous applications. However no model can yet satisfactorily provide effective understanding of core diameter and continuity from process parameters and material properties during thermal drawing. In this paper, a long wavelength model is derived to describe the dynamics of a molten metal micro-jet entrained within an immiscible, viscous, nonlinear free-surface extensional flow . The model requires numerical data (e.g. drawing force and cladding profile) be measured in real-time. Examination of the boundary conditions reveals that the diameter control mechanism is essentially volume conservation. The flow rate of molten metal is controlled upstream while the flow velocity is controlled downstream realized by solidification of the molten metal. The dynamics of the molten metal jet are found to be dominated by interfacial tension, stress in the cladding, and pressure in the molten metal. Taylor's conical fluid interface solution [1] is found to be a special case from this model. A dimensionless capillary number Ca=2Fa/(?A(0)) is suggested to be used as the indicator for the transition from continuous mode (i.e. viscous stress dominating) to dripping mode (i.e. interfacial tension dominating). Experimental results showed the existence of a critical capillary number Ca_cr, above which continuous metal microwires can be produced, providing the first ever quantitative predictor of the core continuity during preform drawing of metal microwires.

Copyright (c) 2017 by ASME
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