Analysis Of Magnet Wire

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1.0 Introduction

A wire is defined as a single, flexible strand or rod of metal which is typically cylindrically-shaped. The core applications of wire, both single- or multi-stranded wire, are to withstand or carry mechanical loads in construction sector, whereas in electrical and electronic field are used to transmit electricity and telecommunications signals. For examples, from view of construction, wires are either braided or fixated together to form a bundle of strands, namely multi-stranded wire or conventionally known as cable, that can be utilized to construct structural buildings such as suspension bridges, holding pillars of skyscrapers, and etc. On the other hand, wires are also mainly used as the “bridge” to conduct electricity
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It is used in the construction of transformers, inductors, motors, speakers, hard disk head actuators, electromagnets, and other applications which desire tight coils of wire. Magnet wire is preferred in the condition where the electrical setup requires high performance of power thus high number of coils of wires, but essentially to be fitted into a compacted space such as motor generators and transformers.

Figure 2: Magnet wire

3.0 Material Analysis on Magnet Wire
3.1 Wire Interior

Material Properties:

Commonly, the magnet wire uses copper as the main material, while occasionally aluminium. Physically, copper has a yellowish red appearance and when polished develops a bright metallic lustre. Copper possesses a face-centred-cubic (FCC) crystal structure, with Atomic Packing Factor (APF) of 0.74. Copper is tough, ductile, and malleable material. Ductile is a solid’s ability to deform under tensile stress without breaking. It exhibits opposite characteristic to brittle. High ductility enables copper to be easily shaped into thin wire.

Generally the advantages of copper and its alloy include:
• Excellent electrical conductivity
• Excellent heat conductivity
• Good corrosion resistance
• Good machinability
• Retention of mechanical and electrical properties at cryogenic temperatures.
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Polyimide is a polymer of imide monomers. Polyimides have diverse applications in areas demanding rugged organic materials such as high temperature fuel cells, displays, and various military roles, due to their high heat resistance. A typical polyimide named Kapton is synthesized by condensation of pyromellitic dianhydride and 4,4’-oxydianiline.

Thermosetting polyimides are in yellowish orange colour. Normally polyimides are compounded with graphite or glass fiber to get reinforcements to increase the flexural strengths. Thermoset polyimides exhibit low creep and high tensile strength, meaning this material has relative high endurance against high temperature and strains. This polymer coating has very good heat resistance and flame combustion. These properties enable polyimide to carry its job under harsh operating conditions.

Generally the advantages of copper and its alloy include:
• Good chemical resistance
• Good thermal stability
• Excellent mechanical properties
• Excellent heat resistance

Material

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