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γ-Brass Plated Brass Wire Description

The Gamma-Brass Plated Wire is engineered specifically for slow wire EDM machines like FANUC and VOLLMER to address challenges in machining polycrystalline diamond (PCD) tools. Its core is manufactured using a hot extrusion process, ensuring uniform mechanical properties and stability during high-precision cutting. The wire’s surface is coated with a gamma-phase brass alloy, characterized by its low melting point and enhanced electrical discharge properties. This unique alloy promotes controlled erosion during sparking, optimizing material removal rates while minimizing thermal damage to the PCD workpiece. A proprietary surface treatment further refines the wire’s cleanliness, eliminating residual contaminants that typically cause burn marks or micro-cracks on the machined surface. This combination allows for smoother, burr-free finishes on ultra-hard PCD materials, critical for cutting tools used in aerospace and automotive industries. The gamma-phase coating also improves wire feed consistency in demanding applications, reducing wire breakage and downtime. Compatible with advanced EDM parameters, it supports fine-tuning of pulse duration and energy input to balance speed and surface integrity. By integrating material science with precision engineering, this wire delivers reliable performance for complex geometries, ensuring repeatability and cost-efficiency in high-value PCD tool production.

γ-Brass Plated Brass Wire Applications

1. Wire Electrical Discharge Machining (WEDM): Widely used for cutting aluminum alloys (e.g., 6061-T6) in mold manufacturing and aerospace components. Optimized parameters achieve surface roughness (Ra) of 0.8-1.2 µm with high efficiency.

2. Complex Geometry Machining: Enables precision taper cutting for intricate shapes (e.g., right-angle triangles, S-curves) by adjusting pulse parameters (discharge time: 2.04-2.66 µs, pause time: 9-17 µs), ideal for micro-components and precision tools.

3. High-Precision & Corrosion-Resistant Applications: Suitable for harsh environments (marine, chemical) due to zinc-coated corrosion resistance. Maintains conductivity (~28% IACS), ideal for sensors, connectors, and high-frequency electronics.

4. Automated & High-Speed Production: Compatible with automatic threading machines (e.g., FANUC, VOLLMER) and high-speed wire feeding (7 m/min), ensuring consistency for large workpieces (>50 mm) in automotive and energy industries.

γ-Brass Plated Brass Wire Packaging

Our products are packaged in customized cartons of various sizes based on the material dimensions. Small items are securely packed in PP boxes, while larger items are placed in custom wooden crates. We ensure strict adherence to packaging customization and the use of appropriate cushioning materials to provide optimal protection during transportation.

Packaging: Carton, Wooden Box, or Customized.

Kindly review the packaging details provided for your reference.

Manufacturing Process

1.       Testing Method

(1)    Chemical Composition Analysis - Verified using techniques such as GDMS or XRF to ensure compliance with purity requirements.

(2)    Mechanical Properties Testing - Includes tensile strength, yield strength, and elongation tests to assess material performance.

(3)    Dimensional Inspection - Measures thickness, width, and length to ensure adherence to specified tolerances.

(4)    Surface Quality Inspection - Checks for defects such as scratches, cracks, or inclusions through visual and ultrasonic examination.

(5)    Hardness Testing - Determines material hardness to confirm uniformity and mechanical reliability.

Please refer to the SAM testing procedures for detailed information.

γ-Brass Plated Brass Wire FAQs

Q1. How does it perform in Wire EDM?

Optimized for FANUC/VOLLMER machines, it achieves high precision (error <5%) for complex shapes (e.g., S-curves) and large workpieces (>50mm) using parameters like discharge time 2.04-2.66 µs and wire feed speed 7 m/min.

Q2. Why is it better for PCD tool machining?

Its gamma-phase brass coating and special surface treatment eliminate burn marks on polycrystalline diamond (PCD) tools, ensuring clean cuts and reduced thermal damage.

Q3. How does it compare to standard brass wire?

Superior in corrosion resistance (3x lifespan), machining speed (20% faster), and precision (±5% error vs. ±8-10% for standard wire).

Performance Comparison Table with Competitive Products

Related Information

1.       Common Preparation Methods

The production of Gamma-Brass Plated Brass Wire involves a specialized multi-step process tailored for precision machining of polycrystalline diamond (PCD) tools. First, a high-purity brass core is fabricated via hot extrusion at temperatures of 600-700°C to ensure uniform grain structure and mechanical stability. This core is then subjected to alkaline degreasing and acid pickling (e.g., 10% nitric acid) to achieve a contaminant-free surface. The wire is electroplated with a gamma-phase brass alloy—a low-melting-point zinc-copper composite—using pulse electrodeposition at controlled current densities (3-5 A/dm²), forming a dense, 8-12 μm thick coating optimized for enhanced spark erosion and thermal conductivity. A proprietary surface passivation step follows, involving non-ionic surfactants and ultrasonic cleaning, to eliminate residual oxides and ensure flawless cleanliness, critical for preventing burn marks during PCD machining. Post-treatment annealing at 250-300°C stabilizes the gamma-phase structure, balancing ductility and tensile strength (550-650 MPa). Advanced inline monitoring systems, including laser micrometers and XRF analyzers, validate coating uniformity (±0.5 μm) and conductivity (~30% IACS). The process integrates closed-loop electrolyte recycling and wastewater treatment to meet environmental standards. Designed for FANUC and VOLLMER slow wire EDM systems, this wire delivers consistent performance in high-precision, high-speed PCD tool production.