Brass Plated Copper Wire Description
Brass Plated Copper Wire is a
specialized EDM (Electrical Discharge Machining) wire designed to deliver high
performance in precision machining applications, particularly on Charmilles
machines. It features a high-purity copper core with a uniform brass coating,
combining the excellent electrical conductivity of copper with the enhanced
surface hardness and corrosion resistance of brass.
This wire is engineered for
high-speed cutting, offering significantly faster machining speeds compared to
standard brass wire. Its stable discharge characteristics contribute to
consistent performance and high precision, making it especially suitable for
processing hard workpieces or demanding production environments.
Due to its physical properties,
Brass Plated Copper Wire excels in applications where cutting efficiency and
accuracy are critical. However, it is not compatible with automatic wire
threading systems, which may limit its use in fully automated setups.
The brass coating not only improves
wear resistance but also reduces wire consumption, leading to improved cost
efficiency over time. Overall, this wire type is an excellent choice for users
seeking to enhance cutting speed and stability without compromising on surface
quality or dimensional accuracy, particularly in semi-automated or manual wire
EDM operations.
Brass Plated Copper Wire Applications
1. Tool and Die Making: Used for precision cutting of dies,
molds, and tooling components due to its high accuracy and cutting speed.
2. Aerospace Industry: Ideal for machining complex and
high-strength alloy parts where precision and reliability are critical.
3. Automotive Industry: Used for producing intricate
components like fuel injection parts, gears, and transmission tools.
4. Medical Device Manufacturing: Suitable for machining
small, detailed parts such as surgical instruments and implants.
5. Electronics and Semiconductors: Applied in the production
of connectors, micro-components, and high-tolerance parts.
6. General Engineering: Used for cutting hard materials and
complex shapes in high-performance machining tasks.
Brass Plated Copper 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.
Brass Plated Copper Wire FAQs
Q1. What is Brass Plated Copper Wire used for?
It is primarily used in Electrical Discharge Machining
(EDM), especially for high-precision cutting in industries like tool and die,
aerospace, automotive, medical devices, and electronics.
Q2. How does it compare to standard brass wire?
Brass Plated Copper Wire offers faster cutting speeds and
more stable machining performance than standard brass wire, making it suitable
for high-demand applications.
Q3. Can it be used on any EDM machine?
It is specifically developed for Charmilles EDM machines,
though compatibility with other systems may vary depending on the machine’s
wire handling capabilities.
|
Property
|
Brass Plated Copper Wire
|
Standard Brass Wire
|
|
Core Material
|
Pure Copper (Cu)
|
Brass (Cu-Zn Alloy)
|
|
Plating/Coating
|
Brass Layer (Cu-Zn Alloy)
|
None (Homogeneous Brass)
|
|
Tensile Strength
|
500-600 MPa
|
450-550 MPa
|
|
Electrical Conductivity
|
~28% IACS
|
~20% IACS
|
|
Corrosion Resistance
|
1,500+ hours (salt spray test)
|
500 hours (salt spray test)
|
|
Surface Finish (Ra)
|
0.8-1.2 µm
|
1.2-1.8 µm
|
|
Machining Speed
|
20-30% faster
|
Baseline speed
|
|
Thermal Stability
|
Stable up to 200°C
|
Stable up to 150°C
|
|
Typical Applications
|
High-precision EDM, aerospace components
|
General machining, springs, decorative crafts
|
Related Information
1. Common Preparation Methods
Brass Plated Copper Wire is
typically produced through an electroplating process. First, high-purity copper
wire is drawn to the desired diameter and thoroughly cleaned to remove any
surface impurities. The cleaned copper wire is then passed through an
electrolytic bath containing a brass solution, where a thin, uniform layer of
brass is deposited onto the surface through controlled electrochemical
reactions. The plating thickness and quality are carefully monitored to ensure
consistent performance and adherence. After plating, the wire is rinsed, dried,
and annealed if necessary to achieve the required mechanical and electrical
properties. The final product is then spooled and inspected for quality
assurance before packaging.
