Adopt certified 6061 aluminum alloy billet as raw stock. Perform incoming quality inspection including chemical composition analysis, metallographic structure examination, surface defect scanning and dimensional verification to confirm compliance with ASTM B313 standards. Check for inclusions, porosity, cracks and surface segregation. Cut the billet to the required length for subsequent hot extrusion, and clean surface contaminants, oil stains and oxide films.
2.Hot Extrusion & Rod Rolling:
Heat the aluminum billet to the precise extrusion temperature range. Complete hot extrusion under controlled pressure and speed to produce continuous aluminum rod blank. The magnesium and silicon alloying elements form uniform solid solution during heating. Conduct online cooling and multi-pass hot rolling to refine grain structure, obtain intermediate aluminum rod with consistent diameter, then remove thick surface oxide layer by brushing and cleaning.
3.Multi-pass Cold Drawing:
Carry out progressive multi-pass cold drawing using a sequence of tungsten carbide drawing dies with gradually reduced bore size. Strictly control single-pass reduction rate and drawing speed to avoid wire breakage, surface tearing or uneven deformation. Cold drawing improves dimensional precision and surface smoothness, step by step reducing the rod to target intermediate wire diameter. Clean drawing lubricant residue after each drawing cycle.
4.Intermediate Heat Treatment (Solution & Aging / Stress Relief):
Depending on required temper, perform solution heat treatment followed by quenching and artificial aging to achieve T4 / T6 mechanical properties; for soft temper, apply stress-relief annealing. This operation adjusts internal microstructure, eliminates cold-work induced residual stress, and balances strength and ductility for further forming. Temperature and holding time are tightly monitored to guarantee stable mechanical performance batch by batch.
5.Surface Finishing & Coiling:
Remove residual lubricants and thin oxide film through alkaline cleaning and neutral rinsing. Straighten the wire to eliminate camber, twisting and local distortion. Conduct visual inspection to filter out scratches, pits and burrs. Wind the aluminum wire neatly onto spools or coil packs as per customer requirements for coil weight and inner diameter, avoiding overlapping, tangling or wire damage during winding.
6.Final Inspection & Packaging:
Implement full dimensional check and sampling mechanical testing, including wire diameter tolerance, tensile strength, yield strength and elongation. Verify surface quality and perform random corrosion spot test. Label qualified coils with alloy grade, temper, wire diameter, batch number and production date. Wrap coils with moisture-proof protective film and kraft paper, pack securely and store in dry warehouse prior to shipment.