The fine surface defect structure of commercial EC grade aluminum magnet wire has been characterized and four basic component types have been identified. A grading system has been established for each of the component defects. Intermediate process surface characterization studies and laboratory drawing experiments have been performed to clarify the origin of the defects. The potential role of drawing lubrication in repairing or compounding the defect structure has been demonstrated and the mechanics of a drawing related repair process have been clarified through study of the effects of rod drawing on hardness indentations.

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