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EDM Electrode / Wire Material:
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Your choices are...
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Copper Tungsten
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Copper tungsten materials are composites of tungsten and copper. They are produced using powder metallurgy processes. Copper tungsten is very expensive compared to other electrode materials, but useful in making deep slots under poor flushing conditions, and in EDM machining of tungsten carbide. Copper tungsten materials are also used in resistance welding electrodes and some circuit breaker applications.
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Copper Zirconium Diboride (CuZrB2)
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Copper zirconium diboride materials are composites of zirconium diboride particles in a copper matrix. They are produced using powder metallurgy processes. These materials are very expensive, but have much lower erosion rates than copper or graphite electrode materials. Copper zirconium diboride has erosion rates similar to copper tungsten, but can provide higher machining rates.
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Graphite
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Graphite brush-material grades are used in applications that require low friction. They are used at very-low current densities and very-high peripheral speeds. Graphite, flake graphite, and graphitic carbon have a hexagonal, crystalline structure that cleave or shears easily, making graphite a soft material and effective lubricant. A form of carbon, graphite has an anisotropic hexagonal crystal structure.
Graphite is the most commonly used EDM electrode material because of its good machinability, wear resistance, and low cost. Like carbon, graphite is a non-metallic substance with an extremely-high sublimation temperature which provides resistance to high-temperature arcs. Fine, grain-sized graphite tends to have better erosion and wear performance, but costs more.
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Molybdenum
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Molybdenum is used to make small, whole EDM electrodes and EDM wire for specialized applications. Molybdenum is a refractory metal with good strength and arc erosion resistance due to the metal's high melting point (2610oC).
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Silver Tungsten
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Contact materials consist of tungsten carbide particles dispersed in a matrix of silver. Silver and tungsten carbide are mutually insoluble. Tungsten carbide provides excellent erosion resistance and good anti-welding characteristics in high-power applications. For circuit breaker applications, silver tungsten carbide is better than silver tungsten because the formation of oxides leads to high contact resistance during high cycle applications.
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Tellurium Copper
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Tellurium copper is useful in EDM machining applications requiring a fine finish. Tellurium copper has a machinability that is similar to brass and better than pure copper.
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Tungsten
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Tungsten is a refractory metal with elevated temperature strength. Tungsten has a high melting point (3410oC) and high resistance to arcs (low EDM wear), but also low conductivity. Tungsten's brittle nature and high melting point often results in fabrication methods that use grinding or powder metal techniques.
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Tungsten Carbide
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Tungsten carbide materials are compounds of a tungsten metal and carbon, usually cemented together with a metal binder. Metal carbides have high hardness and wear resistance, which makes them useful for EDM electrodes, wire guides or ferrules and other wear applications. Metal carbides often use cobalt, nickel or other metal bonds between grains (cemented carbides), resulting in increases toughness compared to a pure carbide or ceramic.
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Specialty / Other
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Other unlisted, specialized or proprietary brush materials.
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Brass
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Brass is an alloy of copper and zinc. Brass materials are used to form EDM wire and small tubular electrodes. Brass does not wear as well as copper or tungsten, but is much easier to machine and can be die-cast or extruded for specialized applications. EDM wire does not need to provide EDM wear or arc erosion resistance since new wire is fed continuously during the EDM wiring cutting process.
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Copper (Cu)
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Copper is second only to silver in terms of bulk electrical conductivity. Copper has better strength than silver, but offers inferior oxidation resistance. Often, copper is used as a base metal in electrical contact and electrode applications. Copper is also used to manufacture EDM electrodes.
Copper has better EDM wear resistance than brass, but is more difficult to machine than either brass or graphite. Copper is also more expensive than graphite. Copper is useful in the EDM machining of tungsten carbide, or in applications requiring a fine finish.
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Search Logic:
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All products with ANY of the selected attributes will be returned as matches. Leaving all boxes unchecked will not limit the search criteria for this question; products with all attribute options will be returned as matches.
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EDM Electrode / Wire Type:
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Your choices are...
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Application Specific / Custom
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Products are fabricated in the form of a custom or application-specific shape.
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Bar Stock
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The contact material is provided in the form of bar stock.
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Coated Wire
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Coated wire has an outer coating of zinc or copper-zinc for improved corrosion resistance, spark formation and flush characteristics. Coated wire is sometimes called "speed wire" due the increased metal cutting rates the material provides.
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Electrode Block / Billet
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Products are large blocks, billets or other raw stock forms of graphite, copper, tungsten, tungsten-copper, brass wire or other materials used to form EDM electrodes or arc furnace electrodes.
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Solid Rod Stock
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Products are solid rod stock.
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Tapping Electrodes
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Products are prefabricated for EDM machining of female or internal threads.
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EDM Drilling Electrode
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Products are solid rod or hollow tube-shaped electrodes for drilling or trepanning applications. Tube-shaped electrodes with a single bore or multiple bores are used for drilling or trepanning applications.
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Tube - Multi-channel
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Products are tube stock with multiple bores or channels.
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Tube - Offset Bore / Rotabore
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Products are tube stock with a single, offset bore. Rotabore tube is used with a specialized holder that rotates the electrode during the EDM cutting process.
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Tube - Single Bore
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Products are tube stock with a single, concentric bore.
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Wire
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Products are provided as wire or wire stock. EDM wire is used in traveling-wire EDM machines. EDM wire does not need to provide EDM wear or arc erosion-resistance since new wire is fed continuously during the EDM wire-cutting process.
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Other
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Other unlisted, specialized, or proprietary forms or shapes.
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Search Logic:
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All products with ANY of the selected attributes will be returned as matches. Leaving all boxes unchecked will not limit the search criteria for this question; products with all attribute options will be returned as matches.
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Fine / Ultrafine Structure?
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Fine-grain or ultrafine structures tend to have better erosion and wear performance.
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Search Logic:
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"Required" and "Must Not Have" criteria limit returned
matches as specified. Products with optional attributes
will be returned for either choice.
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OD / Width
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This is the outer diameter (OD) or width of a component or stock-form material such as a pad, block, strip, bar, plate, or tube. This measurement may also represent the outer diameter or width of fabricated components such as electrodes or contact tips. According to ISO, EN or DIN brush standards, the brush width is the axial dimension, parallel to the motor or generator shaft.
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Search Logic:
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User may specify either, both, or neither of the "At Least" and "No More Than" values. Products returned as matches will meet all specified criteria.
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Length
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This is the length of a component or stock form material such as a pad, block, strip, bar, rod, plate, or tube. Typically, length is the largest dimension of the component. According to ISO, EN or DIN brush standards, the brush length is the radial dimension, or the dimension perpendicular to the commutator or slip ring.
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Search Logic:
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User may specify either, both, or neither of the "At Least" and "No More Than" values. Products returned as matches will meet all specified criteria.
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Thickness
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The thickness is typically the smallest dimension of a pad, block, strip, sheet, or plate material. According to ISO, EN or DIN brush standards, thickness is defined as the dimension tangential, or in the same rotation direction as the commutator or slip ring.
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Search Logic:
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User may specify either, both, or neither of the "At Least" and "No More Than" values. Products returned as matches will meet all specified criteria.
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Resistivity
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Resistivity is the inverse of conductivity.
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Search Logic:
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User may specify either, both, or neither of the "At Least" and "No More Than" values. Products returned as matches will meet all specified criteria.
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Tensile Strength (UTS)
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Ultimate tensile strength (UTS) is the amount of applied stress required to cause a control specimen to fail under tensile load conditions.
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Search Logic:
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User may specify either, both, or neither of the "At Least" and "No More Than" values. Products returned as matches will meet all specified criteria.
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MOR / Flexural Strength
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Modulus of rupture (MOR), cross-break strength or flexural strength (3-point or 4-point) is the maximum flexural stress a bar can withstand before failure or fracture occurs. The bar is supported by two points beneath it; the load is applied by one or two points above the bar. Cross-break strength is used to evaluate the strength of ceramics or other materials that do not provide sufficient plastic deformation to reliably test tensile strength.
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Search Logic:
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User may specify either, both, or neither of the "At Least" and "No More Than" values. Products returned as matches will meet all specified criteria.
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wire edm,
electrical discharge machining,
graphite electrode,
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edm drilling,
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graphite electrode manufacture,
graphite machining,
drilling edm hole small tube,
portable edm,
wire cut edm,
edm graphite,
ram edm,
edm wire cut,
small hole edm,
conventional edm,
machining graphite,
edm hole drilling,
Brass Electrode
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