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In the manufacture of Alumoweld, a high purity aluminum powder is compacted around a high-strength steel rod. By subsequent application of heat and pressure, a bimetallic rod with a dense, inseparably welded cladding is obtained. The strong continuous weld between the aluminum and steel is carefully controlled to avoid an iron-aluminum alloy interface which would be brittle and susceptible to cracking under repeated bending. Such cracking is characteristic of hot-dipped aluminum coatings, but is not a problem with the patented Alumoweld Powder Process.
After cladding, the bimetallic rod is drawn to finished wire sizes without changing the proportions of aluminum and steel. The finished wire maintains its continuous ductile weld and dense uniform aluminum cladding which provides superior corrosion resistance and good electrical conductivity. The quality of the wire is demonstrated by the fact that a minimum aluminum thickness of ten percent of the radius is specified, while other coated materials specify coatings in weight per unit area. The latter method does not protect against unequal distribution and possible areas of thin coating.
Ductile and Permanent Weld
Alumoweld's controlled atomic-weld process eliminates the brittle aluminum-iron compound typically found at the interface of aluminum-covered steel wires – a compound that can crack and cause an insecure bond between the two metals. Alumoweld's process maintains sufficient diffusion between the two metals to insure a positive, inseparable weld. This feature of the manufacturing process assures the ductility, dependability, and permanence of finished Alumoweld.
Thick aluminum covering
Alumoweld is produced in a grade with the concentric aluminum covering comprising 25 percent of the cross-sectional area of the wire and ten percent of the wire radius. This high proportion of aluminum offers an excellent degree of electrical conductivity and permanently protects the high strength of the steel core.
Electronic quality controls
Quality control procedures incorporated in the manufacturing process are further assurance of the uniformity and dependability of Alumoweld. We perform in-process checks at every step of the manufacturing process, using the most modern electronic devices to insure cladding continuity, thickness of covering, and overall quality of the finished wire. In addition, each step in the process serves to cross-check preceding steps. This self-inspecting feature of the manufacture of Alumoweld is further verified with careful inspection and testing of the finished wire.
Traceability
Alumoweld is uniquely positioned to provide you with manufacturing information that other suppliers simply cannot provide. We use a state-of-the-art computer system to establish complete traceability throughout the manufacturing process – a system that expedites the production process and documents customer order information.
At every manufacturing workstation, operators scan bar codes on raw materials, in-process materials, as well as finished goods. The system automatically generates shipping paperwork and labels, minimizing errors and expediting delivery to the customer site.
If you ever need to trace an Alumoweld order back to its original production run, we have the information to help you.
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