Manufacturing method of textured and coated electrode wire

Abstract

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%.

Claims

1. A method of preparing a textured coated electrode wire, comprising: Step (i), preparing a metal zinc plating layer on a surface of a brass electrode wire by electroplating or hot dip plating to form a galvanized electrode wire; step (ii), pre-drawing the galvanized electrode wire by a cold drawing technique to form a pre-drawn galvanized electrode wire; step (iii), treating the pre-drawn galvanized electrode wire by a two-stage discontinuous heat treatment in a vacuum or an inert atmosphere furnace to form a coated electrode wire having a multilayer structure of Zn/p-brass & y-brass/a-brass; and step (iv), cold drawing the coated electrode wire to prepare the textured coated electrode wire wherein the processes of the electroplating or hot dip plating in step (i), the discontinuous heat treatment in step (iii), and the cold drawing in step (iv) are so controlled as to prepare the textured coated electrode wire having regular transverse texture and microcracks on its surface, having a cutting speed more than 12% faster than that of an uncoated brass electrode wire, and having a tensile strength of 900 MPa to 1200 MPa and an elongation of 1% to 5%; wherein the two-stage discontinuous heat treatment of step (iii) comprises selecting a bell-type vacuum heat treatment furnace as the vacuum or an inert atmosphere furnace; placing the pre-drawn galvanized electrode wire into said heat treatment furnace; diffusion treating the pre-drawn galvanized electrode wire first at 150° C. to 200° C. and then at 300° C. to 400° C. for a period of 80-500 minutes, thereby forming the Zn/13-brass & v-brass/a-brass multilayer structure.

2. The method of claim 1, whereinthe obtained plated prepared textured coated electrode wire has a contact angle with water of 120°.

3. The method of claim 1, wherein the brass electrode wire of step (i) has a diameter of 1.0 mm to 1.5 mm.

4. The method of claim 3, wherein the electroplating of step (i) comprises adjusting plating current, voltage and time so as to obtain the galvanized electrode wire having a zinc layer thickness of 2 μm to 20 μm.

5. The method of claim 3, wherein the hot dip plating of step (i) is adjusted so as to obtain the galvanized electrode wire having a zinc layer thickness of 2 μm to 20 μm.

6. The method of claim 1, wherein step (ii) pre-drawing by the cold drawing technique is operated so as to obtain the pre-drawn galvanized electrode wire having a diameter of 0.5 mm to 1.0 mm.

7. The method of claim 6, wherein the cold drawing technique of step (ii) comprises controlling parameters of number of drawing passes, diameter ratio before and after drawing and drawing speed so as to obtain the pre-drawn galvanized electrode wire having a diameter of 0.5 mm to 1.0 mm.

8. The method of claim 1, wherein the cold drawing of step (iv) comprises adjusting parameters selected from the group consisting of number of drawing passes, diameter ratio of the brass electrode wire diameter before drawing to that after drawing, and drawing speed, so that the coated brass electrode wire has a diameter of 0.15 mm to 0.5 mm and has a textured structure with Zn/β-brass & γ-brass/α-brass multilayer and a capability of having different elongations.

9. The method of claim 8, wherein the cold drawing of step (iv) comprises 5 drawing passes, each pass at a drawing speed of 600 m/min to 1500 m/min, followed by a stress relief annealing treatment at a voltage of 20 to 50 V and a current of 5 to 30 A.

Description

DESCRIPTION OF FIGURES

(1) FIG. 1 is a schematic view showing the preparation process of the textured plating electrode wire in Example 1;

(2) FIG. 2 is a diagram showing the microstructure and the composition of the wire blank having a multilayer structure in Example 1;

(3) FIG. 3 is a surface topographical view of the plated electrode wire with a transversely texture in Example 1;

(4) FIG. 4 is a graph showing the comparison of the cutting speeds of different electrode wires in Example 1.

DETAILED DESCRIPTION OF THE INVENTION

(5) The invention will now be further described with reference to the drawings and embodiments.

Example 1

(6) As shown in FIGS. 1-4, the method of preparing the textured coated electrode wire provided in this example was carried out according to the following steps:

(7) Step (1), preparing a zinc plating layer on the surface of the copper-zinc alloy core material: firstly, the cleaned zinc alloy core material (Cu/Zn: 60/40) was subjected to electroplating/hot dip plating treatment, and a zinc plating having a thickness of 5 μm was obtained by adjusting the galvanizing process;

(8) Step (2), pre-drawing treatment: selecting the above-mentioned plating electrode wire as a starting material, and performing pre-drawing treatment by cold drawing technology to obtain a electrode wire blank having a diameter of 0.5 mm;

(9) Step (3), diffusion heat treatment: the electrode wire blank obtained in step (2) was subjected to diffusion heat treatment by a discontinuous heat treatment method, and a process of 150° C. to 200° C. and 300° C. to 400° C. two-stage temperature for 250 minutes was selected for thermal diffusion treatment. After thermal diffusion, the zinc plating layer and the copper-zinc alloy core material underwent an interdiffusion reaction to form an electrode wire blank having a Zn/β-brass & γ-brass/α-brass multilayer structure;

(10) Step (4), cold drawing treatment: selecting the wire blank having a multilayer structure treated by the diffusion heat treatment in step (3), and drawing the above-mentioned wire into a micro-texture electrode wire of 0.3 mm at a drawing speed of 1000 m/min. The wire was then subjected to stress relief annealing at a voltage of 30 V and a current of 10 A to obtain a textured plated electrode wire.

(11) The textured plated electrode wire obtained by the method of preparing the textured plated electrode wire provided in the example has regular transverse cracks and a certain microporosity.

(12) Data analysis: FIG. 2 is a schematic structural view and a micrograph of the wire blank having a multi-layer structure in the example, and it can be seen that the wire blank has a three-layer structure; FIG. 3 is a surface topography of the plated electrode wire having a horizontal texture in the example, and it can be seen that the electrode wire has regular transverse cracks; FIG. 4 is a comparison chart of the cutting speed of different electrode wires, and it can be seen that the cutting speed of the electrode wire in the example is 12.35% faster than that of the brass wire, which is obviously advantageous.

(13) At the same time, the electrode wire coating provided by this example has a regular transverse texture, which gives the electrode wire material a better cooling effect and a higher cutting rate, and significantly improves the performance of the electrode wire, for example, compared with the galvanized wire, the cutting speed is increased by more than 12%, the number of cutting breaks is reduced by 30%, and the replacement time of the cooling water ion resin filter is extended by 10%.

(14) The cross-sectional structure of the textured coated electrode wire is a copper-zinc alloy core material and a regular transversely textured galvanized layer structure. The textured galvanized electrode wire has a tensile strength of 900 MPa to 1200 MPa and an elongation of 1% to 5%. The contact angle of the textured coating electrode wire with water is about 120°, which is significantly higher than that of the galvanized wire, thereby increasing the cooling effect of water. The number of times of cutting break of the textured coating electrode wire is 30% lower than that of the galvanized wire, and the replacement time of the cooling water ion resin filter is extended by 10%.

Example 2

(15) The method of preparing the textured coated electrode wire provided in this example was carried out according to the following steps:

(16) Step (1), preparing a zinc plating layer on the surface of the copper-zinc alloy core material: firstly, the cleaned zinc alloy core material (Cu/Zn: 60/40) was subjected to electroplating/hot dip plating treatment, and a zinc plating having a thickness of 10 μm was obtained by adjusting the galvanizing process;

(17) Step (2), pre-drawing treatment: selecting the above-mentioned plating electrode wire as a starting material, and performing pre-drawing treatment by cold drawing technology to obtain a electrode wire blank having a diameter of 0.8 mm;

(18) Step (3), diffusion heat treatment: the electrode wire blank obtained in step (2) was subjected to diffusion heat treatment by a discontinuous heat treatment method, and a process of 150° C. to 200° C. and 300° C. to 400° C. two-stage temperature for 300 minutes was selected for thermal diffusion treatment. After thermal diffusion, the zinc plating layer and the copper-zinc alloy core material underwent an interdiffusion reaction to form an electrode wire blank having a Zn/β-brass & γ-brass/α-brass multilayer structure;

(19) Step (4), drawing treatment: selecting the wire blank having a multilayer structure treated by the diffusion heat treatment in step (3), and drawing the above-mentioned wire into a micro-texture electrode wire of 0.3 mm at a drawing speed of 1000 m/min. The wire was then subjected to stress relief annealing at a voltage of 30 V and a current of 10 A to obtain a textured plated electrode wire.

(20) The textured plated electrode wire obtained by the method of preparing the textured plated electrode wire provided in the example has regular transverse cracks and a certain microporosity.

(21) It has been tested that the cutting speed of the electrode wire in this example is 1.sup.20.17% faster than that of the brass wire, which is obviously advantageous.

Example 3

(22) The method of preparing the textured coated electrode wire provided in this example was carried out according to the following steps:

(23) Step (1), preparing a zinc plating layer on the surface of the copper-zinc alloy core material: firstly, the cleaned zinc alloy core material (Cu/Zn: 63/37) was subjected to electroplating/hot dip plating treatment, and a zinc plating having a thickness of 5 μm was obtained by adjusting the galvanizing process;

(24) Step (2), pre-drawing treatment: selecting the above-mentioned plating electrode wire as a starting material, and performing pre-drawing treatment by cold drawing technology to obtain a electrode wire blank having a diameter of 0.5 mm;

(25) Step (3), diffusion heat treatment: the electrode wire blank obtained in step (2) was subjected to diffusion heat treatment by a discontinuous heat treatment method, and a process of 150° C. to 200° C. and 300° C. to 400° C. two-stage temperature for 400 minutes was selected for thermal diffusion treatment. After thermal diffusion, the zinc plating layer and the copper-zinc alloy core material underwent an interdiffusion reaction to form an electrode wire blank having a Zn/β-brass & γ-brass/α-brass multilayer structure;

(26) Step (4), drawing treatment: selecting the wire blank having a multilayer structure treated by the diffusion heat treatment in step (3), and drawing the above-mentioned wire into a micro-texture electrode wire of 0.15 mm at a drawing speed of 1000 m/min. The wire was then subjected to stress relief annealing at a voltage of 50 V and a current of 30 A to obtain a textured plated electrode wire.

(27) The textured plated electrode wire obtained by the method of preparing the textured plated electrode wire provided in the example has regular transverse cracks and a certain microporosity.

(28) It has been tested that the cutting speed of the electrode wire in this example is 12.85% faster than that of the brass wire, which is obviously advantageous.

Example 4

(29) The method of preparing the textured coated electrode wire provided in this example was carried out according to the following steps:

(30) Step (1), preparing a zinc plating layer on the surface of the copper-zinc alloy core material: firstly, the cleaned zinc alloy core material (Cu/Zn: 65/35) was subjected to electroplating/hot dip plating treatment, and a zinc plating having a thickness of 8 μm was obtained by adjusting the galvanizing process;

(31) Step (2), pre-drawing treatment: selecting the above-mentioned plating electrode wire as a starting material, and performing pre-drawing treatment by cold drawing technology to obtain a electrode wire blank having a diameter of 0.5 mm;

(32) Step (3), diffusion heat treatment: the electrode wire blank obtained in step (2) was subjected to diffusion heat treatment by a discontinuous heat treatment method, and a process of 150° C. to 200° C. and 300° C. to 400° C. two-stage temperature for 500 minutes was selected for thermal diffusion treatment. After thermal diffusion, the zinc plating layer and the copper-zinc alloy core material underwent an interdiffusion reaction to form an electrode wire blank having a Zn/β-brass & γ-brass/α-brass multilayer structure;

(33) Step (4), drawing treatment: selecting the wire blank having a multilayer structure treated by the diffusion heat treatment in step (3), and drawing the above-mentioned wire into a micro-texture electrode wire of 0.2 mm at a drawing speed of 1000 m/min. The wire was then subjected to stress relief annealing at a voltage of 20 V and a current of 5 A to obtain a textured plated electrode wire.

(34) The textured plated electrode wire obtained by the method of preparing the textured plated electrode wire provided in the example has regular transverse cracks and a certain microporosity.

(35) It has been tested that the cutting speed of the electrode wire in this example is 12.58% faster than that of the brass wire, which is obviously advantageous.

(36) It is to be understood that the above-described examples are merely illustrative of the technical concept and the features of the present invention, and are intended to enable those skilled in the art to understand the present invention and to implement the present invention, which does not limit the protection scope of the present invention. Equivalent variations or modifications made in accordance with the spirit of the invention are intended to be included within the scope of the invention.