A conductive electrode wire for use in an electric discharge machine (EDM) is provided, comprising a core wire comprised of one single metal or an alloy of multiple metals with a coating deposited by the electro-plasma process, wherein such coatings are alloys of zinc and nickel. A process for treating a surface of an electrically conductive workpiece, such as a core wire, is also provided.

A conductive electrode wire for use in an electric discharge machine (EDM) is provided, comprising a core wire comprised of one single metal or an alloy of multiple metals with a coating deposited by the electro-plasma process, wherein such coatings are alloys of zinc and nickel. A process for treating a surface of an electrically conductive workpiece, such as a core wire, is also provided.

The present invention relates to a wire electrode for spark-erosion cutting having a core (2), which contains a metal or a metal alloy, and a covering layer (3), surrounding the core (2), which comprises regions the morphology of which corresponds to block-like particles, which are spatially separated, at least over a portion of their circumference, from each other and/or the core material by cracks, characterized in that, viewed in a wire cross section perpendicular or parallel to the wire longitudinal axis, the portion amounting to more than 50% of the surface area of a region with the morphology of a block-like particle contains a copper-zinc alloy with a zinc concentration of 58.5-67 wt.-%, wherein, in a view perpendicular to the wire surface, the proportion of the surface formed by the block-like particles is more than 20% and less than 50% of the entire surface of the wire electrode and the block-like particles the surface area of which in each case lies in the range of 25-250 μm.sup.2 in total make up a proportion of more than 50% of the surface area of all block-like particles.

The present invention relates to a wire electrode for spark-erosion cutting having a core (2), which contains a metal or a metal alloy, and a covering layer (3), surrounding the core (2), which comprises regions the morphology of which corresponds to block-like particles, which are spatially separated, at least over a portion of their circumference, from each other and/or the core material by cracks, characterized in that, viewed in a wire cross section perpendicular or parallel to the wire longitudinal axis, the portion amounting to more than 50% of the surface area of a region with the morphology of a block-like particle contains a copper-zinc alloy with a zinc concentration of 58.5-67 wt.-%, wherein, in a view perpendicular to the wire surface, the proportion of the surface formed by the block-like particles is more than 20% and less than 50% of the entire surface of the wire electrode and the block-like particles the surface area of which in each case lies in the range of 25-250 μm.sup.2 in total make up a proportion of more than 50% of the surface area of all block-like particles.

An object of the present invention is to improve machining speed by realizing both conductive properties and discharge performance with regard to an electrode wire for wire electric discharge machining, the electrode wire being obtained by plating a steel wire with a copper-zinc alloy. Another object is to suppress the occurrence of separation, cracking, and the like of plating in a wire-drawing step of an electrode wire. An electrode wire for wire electric discharge machining of the present invention includes a steel wire (11) serving as a core wire, and a plating layer (12) that covers the steel wire and that is composed of a copper-zinc alloy, in which an average zinc concentration of the plating layer is 60% to 75% by mass, a conductivity of the plating layer is 10% to 20% IACS, and a wire diameter is 30 to 200 μm.

An object of the present invention is to improve machining speed by realizing both conductive properties and discharge performance with regard to an electrode wire for wire electric discharge machining, the electrode wire being obtained by plating a steel wire with a copper-zinc alloy. Another object is to suppress the occurrence of separation, cracking, and the like of plating in a wire-drawing step of an electrode wire. An electrode wire for wire electric discharge machining of the present invention includes a steel wire (11) serving as a core wire, and a plating layer (12) that covers the steel wire and that is composed of a copper-zinc alloy, in which an average zinc concentration of the plating layer is 60% to 75% by mass, a conductivity of the plating layer is 10% to 20% IACS, and a wire diameter is 30 to 200 μm.

Methods for forming an electrode for use in forming a honeycomb extrusion die. The method includes forming, by means of an additive manufacturing process, an electrode includes a base having a web extending from the base. The web defines a matrix of cellular openings. The method further includes forming a secondary electrode having a plurality of pins. The plurality of pins are shaped and arranged so as to mate with the matrix of cellular openings defined by the web of the electrode. The method further includes machining the electrode using the secondary electrode to smooth surfaces of the electrode formed by the additive manufacturing process.

An electrode includes a metallic electrode body that has a surface region that is enriched in at least one of aluminum or chromium. The aluminum and/or chromium that is vaporized from the surface region suppresses vaporization loss of aluminum or chromium from the machined surface of the metallic workpiece during electric discharge machining.

An electrode includes a metallic electrode body that has a surface region that is enriched in at least one of aluminum or chromium. The aluminum and/or chromium that is vaporized from the surface region suppresses vaporization loss of aluminum or chromium from the machined surface of the metallic workpiece during electric discharge machining.

A manufacturing method of a textured and coated electrode wire, comprising: selecting a copper-zinc alloy as a core material, preparing, by means of electroplating/hot-dipping, a metal zinc coating on a surface of the wire material, then performing pre-treatment on the coated electrode wire by means of discontinuous diffusion annealing to obtain a coated electrode wire material having a multi-layer structure of Zn/β-brass & γ-brass/α-brass, and then using multiple cold drawing treatments and a stress-relief annealing treatment to modify the electrode wire and obtain a textured and coated electrode wire material. Compared to conventional copper alloy electrode wires and zinc-coated electrode wires, the material has advantages of a fast cutting speed, low cutting cost, low environmental pollution, etc., wherein the cutting speed increases by 12% or more when compared with copper alloy electrode wire, the wire breakage rate during cutting processes decreases by 30%, and the replacement time interval of an ion-exchange resin filter for cooling water increases by 10%.