If you’re looking for a fast, cost-effective way to make your electrical connections, EDM wire is the way to go. Its speed doubles without increasing wire consumption, and it provides superior surface finishes. Its superior performance makes it the wire of choice for many electrical contractors. And the best part is that EDM wire is available in a wide range of metals, including copper, brass, zinc, and alpha-phase brass.
Brass
The brass-EDM wire is made with a steel core, which has high strength and fracture resistance. The zinc-rich brass cladding also provides good cutting qualities. These features make this wire an excellent choice for challenging applications. The wire’s tensile strength can range from 290,000 to 116,000 psi, and it is suitable for tall parts and applications that require fine straightness. It also has a good flushing ability, which means that it can be used even in poor flushing conditions.
Brass EDM wire is available from a variety of manufacturers. One of the most popular manufacturers is Hitachi, which provides standard, soft, and super-soft brass wires for EDM applications. These wires offer unmatched quality and consistency and are priced competitively.
Copper
Whether you are looking for copper wire for a specific application or need an EDM wire with high tensile strength, you have plenty of options. The hardness of a wire is its ability to resist breaking or stretching and is measured in pounds per square inch of cross-sectional area. High-tensile wires are ideal for fine and small-diameter wires, where edge straightness is a priority.
Copper EDM wires are designed for wire EDM machining and are manufactured by Senor Metals Pvt., a leading manufacturer of wire drawing and machining machinery. The high zinc content of these wires makes them ideal for EDM applications, and they also minimize the risk of wire breakage.
Zinc
A Wire-EDM process is a versatile tool for machining nickel-based superalloys. It can be used to reduce or completely eliminate deposited zinc from a part. In this process, the part is submerged in a nitric or phosphoric acid solution, which dissolves the zinc. The part is then washed with water. After a short period of time, the part is exposed to an oxidizing agent.
The first metal is a relatively volatile metal such as cadmium, lead, bismuth, or tin. The second substance is typically steel, brass, carbon, or copper. The first metal layer has an initial thickness of 5 to 20 micrometers, and the second layer is about one-half of the original thickness. The overall diameter of the coated wire is typically about 0.185 millimeters.
Alpha phase brass
Standard brass EDM wires are made from a binary-copper-zinc alloy, with a zinc content of 35 to 40 weight percent. This increased zinc content increases the electrodes’ electrical conductivity and lowers the energy required to vaporize the zinc. This type of brass is easier to deform than beta-phase brass. Most common binary Cu/Zn alloys have a zinc content of 35% to 37%, with alpha-phase brass containing the highest amount of zinc.
Alpha-phase brass wire is the most commonly used type of brass wire for eddy current applications. Its high zinc content makes it a highly corrosion-resistant material that withstands high current levels. However, this material is not compatible with arc-welded constructions.
Coated EDM wire
Coated EDM wire is a type of wire with a thin layer of pure zinc coating. It has a copper or brass core, and the coating is applied electro-galvanically to ensure uniform thickness. Coated wires can also be made by hot-dipping, which is less precise, but is often less expensive.
Coated EDM wire is a versatile material used for precision machining. It is a good choice for applications that require high accuracy and good process stability. Its high-quality coating ensures durability and excellent cutting performance. These wires are more durable and faster than brass wires.
Zinc-coated brass EDM wire acts as a shield against heat to prevent damage to the brass wire. Since zinc has a lower melting point than brass, it absorbs heat and prevents overheating. This helps the wire avoid damaging the workpiece.
