Effect of large deformation on microstructure and properties of copper alloy wire

Cu–Ag alloy wire with different deformations and Ag contents of 1%, 2%, and 4% are prepared using vacuum continuous casting technology combined with cold drawing and intermediate annealing processes. The evolution of microstructure, electrical properties, and mechanical properties of the Cu–Ag alloy wire is investigated, and a relationship model between wire diameter, Ag content, and alloy wire properties is established. The results showed that the directionally solidified billets exhibited good elongation and are suitable for drawing fine wire. As the Ag content increased, the twinning content inside the Cu–Ag alloy wire also increased significantly. It is found through Strain++ characterization that there is non-uniform deformation within the wire, and the tensile and compressive strains that exist interactively tend to aggregate within the twins. The properties of the Cu–Ag alloy wire with different diameters varied significantly at different stages of deformation, showing a pronounced size effect below 1 mm. With decreasing wire diameter or increasing Ag content, the DC resistance, resistivity, and tensile strength of the Cu–Ag alloy wire gradually increased, while the conductivity decreased. The effect of Ag content on elongation is not significant. Statistical analysis revealed that the established performance model had high predictive accuracy and could provide references for the optimization of production processes for Cu–Ag alloy wire.