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Research of the Laboratory Wire Drawing Process of Zinc

Article  in  Key Engineering Materials · February 2016

DOI: 10.4028/www.scientific.net/KEM.682.367

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Key Engineering Materials Submitted: 2015-07-14
ISSN: 1662-9795, Vol. 682, pp 367-371 Revised: 2015-09-30
doi:10.4028/www.scientific.net/KEM.682.367 Accepted: 2015-10-10
© 2016 Trans Tech Publications, Switzerland Online: 2016-02-15

Research of the laboratory wire drawing process of zinc

Michał Jabłoński1,a, Tadeusz Knych1,b, Andrzej Mamala1,c, Beata Smyrak1,d,
Beata Ciejka1,e
1
AGH University of Science and Technology, Faculty of Non-Ferrous Metals
A. Mickiewicza Av. 30, 30-059 Krakow, Poland
a
jablonsk@agh.edu.pl, btknych@agh.edu.pl, camamala@agh.edu.pl, dsmyrak@agh.edu.pl
e
bciejka@student.agh.edu.pl

Keywords: zinc, wire drawing process, continuous casting and rolling

Abstract. The paper present results of the research on the laboratory drawing process of zinc
obtained in industrial conditions in the CCR by Properzi method. The force drawing, mechanical
properties before and after process was measured and formability limit in drawing process was
specified. Because the wire drawing process was on hot (above the recrystallization temperature)
the material didn’t work hardening as a function of strain which reduces the ductility and breaking
just after the die. The microscopic images of microstructure reveal the presence of large twins
recrystallization reflecting the dynamic renewal structure.

Introduction
Zinc is one of the more commonly occurring elements on Earth, and its technical characteristic
decided to apply anti-corrosion coatings. It is used as zinc coatings in the automotive and
construction industries (car bodies, guard rails, suspension bridge, metal roofs e.c.t.). Galvanizing is
the process of laying down a thin layer of zinc on the surface of a second metal so the thin layer of
zinc protects element from corrosion. The use of a protective coating, e.g. on steel extend the
service life (from 3 to 5×), and resulting in saving a significant amount of electrical energy required
to produce the steel. Moreover, zinc is subject recycled easily, without losing the quality of its
physical and chemical properties, which protects the environment from the increased exploitation of
ore in order to obtain pure zinc and impurities derived from the processing of the ore itself.
There are several methods of obtaining protective coatings: electrochemically or as molten zinc by
hot-dip galvanizing or spraying. Depending on the type and use of the product, place of forming a
coating, each of the methods have their advantages and disadvantages. In the case of coating large
components fairly well suited method of hot-dip galvanizing, coating outside- metal spraying or
electrolytic process where there is a small consumption of zinc. The advantage of metal spraying is
the ability to application it on construction site regardless the size of the elements or dimensional,
possibility implementation of correction coating on the welds or in places mechanical damage, high
resistance against mechanical defects. Coatings obtained by this method have a higher durability
and its thickness depending on the operational requirements. Metal spraying eliminates the risk of
thermal deformation of protected elements [1,2]. The method consists in obtaining a protective
layer by applying the molten zinc particles to the prepared surface of the protected subject using
oxy-acetyl (flame metallization) or electric arc (plasma metallization). The quality of the surface is
obtained as a result of increasing its roughness and its purity (no visible traces of rust, technological
oils, dirt).
For metal spraying is used zinc rod obtained in the CCR process, which is drawing on suitable
diameter. It is important to have appropriate mechanical properties of wire which can causes
blocking mechanism for the combustion gun [3].

All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of Trans
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368 Engineering and Technology on Non-Ferrous Metals

Experimental procedures
The material used for testing was obtained in continuous casting and rolling by Properzi method in
ZM Silesia SA. The feedstock to melting process was the zinc plates N1 and N2 which have been
loaded into a gas-fired furnace. The next step was the refining and sedimentation process of
impurities after which followed casting of molten zinc on the rotary crystallizer, intensively cooled
by water. After crystallization ingot was hot rolled in the temperature range from 200 to 300 °C for
nine stand mills using the emulsion to cool the ingot. In hot rolling process was obtained rod of
5.5 mm diameter which coiled on metal spools or packing to cardboard barrels with a weight range
100-250 Mg. The zinc rod was drawing to the wire with a diameter of 1.0 mm (average drawing
ratio was 1.2). Wire drawing process was carried out at the laboratory chain drawbench of 0.1 m/s
drawing speed using conical dies (2α=18o) made of sintered carbides and lubricant based on
mineral oil.
The mechanical properties (tensile strength, yield strength and elongation at break) were determined
in uniaxial tension at ambient temperature. Test speed was 50 mm/min and gauge length of a test
piece was 100 mm. Electrical properties of the samples were examined on the RESISTOMAT®
model 2304 (Burster). Before measurement the samples were conditioned for six hours at a
temperature of 20 oC, the gauge length was 1 m. The microstructure of samples were investigated
by use of Nikon Epiphot 200 in different magnification. Before observation samples were ground
and polished.

Results and discussion

Chemical composition of zinc rod was carried out on the optical emission spectrometer (OES) and
show high purity of zinc (table. 1).

Table 1. Chemical composition of zinc rod

Pb Cd Fe Cu Ti Al Sn Mg AS Zn
0.0013 0.0003 0.0009 0.0004 0.0002 0.0005 0.0002 0.00011 0.0001 99.996

The increase number of draws cause decrease the superplasticity and mechanical properties of wire
[4-6] obtained from zinc rod during drawing process (Fig. 1). The zinc has low melting and boiling
point- respectively 419.5oC (692.5K) and 907oC (1180K). Zinc is a fairly soft material neither
ductility nor malleable at room temperature. The deformation during wire drawing process causes
increase temperature of wire so zinc is on hot deformation and the wire doesn’t work hardening.
The phenomenon is compounded at the end of the process because increases cold work (drawing
ratio 1.3).
140 UTS YS E
140 100
120 a) 122 120 d) 117 90
120 113 113 114 113
110
100 80 104
80
100 74
Ø [mm]
80 67 67 70
65
UTS, YS [MPa]
σ [MPa]

5.58
80
4.96 60
E [%]

57 60
60 4.13 60 59
60 54 53
3.2 46 49 47 50
40 2.63 41 40 37
40
1.97 40
34
20 1.48
20 30
1.25
0.92
0 0 20
0 10 20 30 40 50 60 70 80 90 0 1 2 3 4
ε [%] Ø 5.58 [mm] ln(λ) [-] Ø 0.92 [mm]

Figure 1. Stress-strain curves (a) and mechanical properties (b) from true strain of zinc wire obtained in uniaxial tension
 Key Engineering Materials Vol. 682 369

During wire drawing process was measured drawing force for each of draws (Fig. 2a). Drawing
force was correlated with cross section of wires after drawing. Drawing tension increases during
deformation, especially at the end of the wire drawing process because the growing draw ratio. The
formability limit of wires obtained in wire drawing process of zinc rod is 1.5 mm diameter (true
strain 2.65). After exceeding this diameter the wire extend plastically and finally break for a
diameter of die 1.0 mm. The electrical conductivity increases (inverse resistivity) during the
deformation as a results of renewal of structure (dynamic recrystallization).
UTS YS DT 65

140
122 120 64.2
117 64
120 113 113 114 113
110
104
100
63
UTS, YS, DT [MPa]

ρ [nΩ·m]
91
80
69
60 59
60 54 53 62
46 49
41 40 52 37
40
43
40 61 60.7 60.7
34 60.5 60.5 60.5
20 25 60.3 60.3
25
60.1

0 60
0 1 2 3 4 0 1 2 3 4
Ø 5.58 [mm] ln(λ) [-] Ø 0.92 [mm] Ø 5.58 [mm] ln(λ) [-] Ø 0.92 [mm]

Figure 2. Dependence of plastic properties (ultimate tensile strength, yield stress) and drawing tension (a), electrical
resistivity (b) from true strain of zinc wire

The optical microstructures of zinc rod and wire in different magnification shows on figure 3.
Deformation during wire drawing process increases temperature of wires drawing and cause its
dynamic recrystallization (observed twins of recrystallization) [7].

a) b)

c) d)

Figure 3. The longitudinal microstructure of zinc rod (a, c) and wire made in wire drawing process (b, d)
370 Engineering and Technology on Non-Ferrous Metals

The increase number of draws cause enlargement the grain size for the wire. Moreover, on the
picture of longitudinal wire (Fig. 3d) we can see the polygon grains and twins of recrystallization.
During deformation grain size increases from 26 to 63 μm (respectively median is equal 61 and
26 μm). The grain size was calculated for 100 grains (Fig. 4).

50
45 Rod (5,58 mm)
Wire (0,92 mm)
40
35
Number of grains

30
25
20
15
10
5
0

Grain size [µm]

Figure 4. Grain size distribution of rod and zinc wires

Summary
The aim of this work was to investigate the effect of laboratory wire drawing process on structure,
mechanical and electrical properties of zinc wire used for anticorrosive protection. The feedstock
material was zinc rod obtained from the continuous casting and rolling by the Continuus-Properzi
method in ZM SILESIA SA. Based on the results of research and analysis we can draw the
following conclusions:
• laboratory wire drawing process raises the temperature, so mechanical properties of zinc
wire are reduced and electrical properties grow during strain,
• zinc is a superplasticity material which limits its deformability limit of drawing process to
1 mm diameter of wire on laboratory conditions,
• strain realized during wire drawing process causes increase grain size of zinc wire due to
renewal structure (dynamic recrystallization).
It’s planned to extended the study of annealing the zinc rod, change the geometry of the die and
condition of wire drawing process to increase the deformability limit of the zinc wire.

The work was financed by the European Funds- Operational Programme Innovative Economy
Number: 5.72180.747

References
[1] T. Knych, A. Mamala, P. Uliasz, M. Spyra, J. Lejkowski, Wire drawing process researches of
superplasticity ZnAl15 alloy assigned to the thermal metal spraying application, Rudy i Metale
Nieżelazne, 52 (2007) 782-789
[2] T. Knych, A. Mamala, P. Uliasz, M. Spyra, J. Lejkowski, Some technological aspects of ZnAl15
alloy wire production for thermal spray metallization, Hutnik Wiadomości Hutnicze, 74 (2007)
39-42
[3] ISO 14919:2015- Thermal spraying - Wires, rods and cords for flame and arc spraying -
Classification - Technical supply condition
[4] H. Conrad, J. Narayan, Mechanisms for grain size hardening and softening in Zn, Acta
Materialia, 50 (2002) 5067–5078
 Key Engineering Materials Vol. 682 371

[5] K. Pieła, W. Bochniak, A. Korbel, P. Ostachowski, L. Błaż, Influence of deformation method on

structure, mechanical properties and thermal stability of zinc, Rudy i Metale Nieżelazne, 54
(2009) 356-361
[6] Tae Kwon Ha, Jung Rak Son, Won Beom Lee, Chan Gyung Park, Young Won Chang,
Superplastic deormation of a fine-grained Zn–0.3wt.%Al alloy at room temperature, Materials
Science and Engineering, A307 (2001) 98–106
[7] C. Adamski, Z. Bonderek, T. Piwowarczyk, Microstructures of casting copper alloys and zinc,
Published by Slask, Poland (1972), Pages 265-272

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