Methods for applying aluminum coating layer to a core of copper wire

Abstract

Methods of applying aluminum coating layers over copper wires are disclosed. A first method may include applying aluminum powder to the surface of a rod, passing the rod through a first set of compression rolls thereby forcing the aluminum powder into a compacted preform around the rod, and heating the rod covered by the preform at 550° C. to 620° C. Further, the heated preform coated rod is passed through a second set of compression rolls thereby obtaining an aluminum coated copper rod. A second method includes disposing a copper rod inside an aluminum tube having an inner layer formed of brazing aluminum alloy, reducing the diameter of the tube's inner surface to match the copper rod, and heating the composite tube-rod such that the inner layer of the brazing alloy fuses to the rod. Another method includes passing the copper rod through a spray of metallic aluminum.

1 - 14 . (canceled) 
     
     
         15 . A method of applying aluminum coating layers over a copper core rod, the method comprising:
 passing the copper rod at a predetermined speed through a spray of metallic aluminum.   
     
     
         16 . The method of  claim 15 , wherein the spray of metallic aluminum is produced by the atomization of an aluminum wire in a plasma spray applicator or an arc spray applicator. 
     
     
         17 . The method of  claim 15 , wherein the applying of the aluminum coating layer is performed in a continuous process. 
     
     
         18 . The method of  claim 15 , further comprising cleaning and grit blasting the copper rod prior to the passing step. 
     
     
         19 . The method of  claim 15 , further comprising cooling the aluminum-clad copper rod. 
     
     
         20 . The method of  claim 15 , further comprising coiling the aluminum-clad copper rod. 
     
     
         21 . The method of  claim 15 , further comprising wire drawing the aluminum-clad copper rod. 
     
     
         22 . The method of  claim 15 , wherein the resulting aluminum coating is in the range of 1% to 10% of a diameter of the copper rod. 
     
     
         23 . A method of applying aluminum coating layers over a copper core rod, the method comprising:
 grit blasting the copper rod;   passing the grit blasted copper rod at a predetermined speed through a spray of metallic aluminum;   cooling the aluminum-clad copper rod; and   wire-drawing the aluminum-clad copper rod.   
     
     
         24 . The method of  claim 23 , wherein the spray of metallic aluminum is produced by the atomization of an aluminum wire in a plasma spray applicator or an arc spray applicator. 
     
     
         25 . The method of  claim 23 , wherein the applying of the aluminum coating layer is performed in a continuous process. 
     
     
         26 . The method of  claim 23 , further comprising coiling the aluminum-clad copper rod. 
     
     
         27 . The method of  claim 23 , wherein the resulting aluminum coating is in the range of 1% to 10% of a diameter of the copper rod.