Electrode wire for electric discharge machining and manufacturing method of the same

• US 7,723,635 B2
• Filed: 09/08/2005
• Issued: 05/25/2010
• Est. Priority Date: 04/01/2005
• Status: Active Grant

• Current Assignee: Opec Engineering Co. Ltd., Sunfil Korea Co., Ltd.
• Original Assignee: MACT Company Limited
• Inventors: Shin, Hyun-Sik
• Primary Examiner(s): Hoang; Tu B
• Assistant Examiner(s): JENNISON, BRIAN W
• Application Number:
  US11/222,072
• Publication Number:
  US 20060219666A1
• Time in Patent Office: 1,720 Days
• Field of Search: 219/69.11
• US Class Current: 219/69.15
• CPC Class Codes: B23H 7/08 Wire electrodes
• CPC Class Codes: Y10T 428/12493 Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
• CPC Class Codes: Y10T 428/12535 with additional, spatially distinct nonmetal component

Abstract

Enhanced electrode discharge machining properties of an electrode wire are achieved when the electrode wire comprises a coil, a covering layer formed on a periphery of the coil, and grains formed on the covering layer. The grains comprise a copper-zinc alloy including about 0.01 to 0.5 weight % of at least one additive element selected from the group consisting of aluminum, tin, magnesium, lanthanum, cerium, nickel, manganese, titanium, and zirconium.

Claims

1. An electrode wire for electric discharge machining, comprising:

a core;

a covering layer formed on a periphery of the core; and

grains formed on the covering layer, wherein the grains comprise a copper-zinc alloy including about 0.01 to 0.5 weight % of at least one additive element selected from the group consisting of aluminum, tin, magnesium, lanthanum, cerium, nickel, manganese, titanium, and zirconium,

wherein the core comprises copper and a trace of unavoidable impurities, or comprises about 10 to 40 weight % of zinc, with the balance being of copper and a trace of unavoidable impurities,

wherein the covering layer comprises about 37 to 49.5 weight % of zinc, with the balance being of copper and a trace of unavoidable impurities,

wherein the grains comprise about 49.5 to 58 weight % of zinc, and about 0.01 to 0.5 weight % of the at least one additive element, with the balance being of copper and a trace of unavoidable impurities, and

wherein the grains are spaced from one another on a periphery of the covering layer and the covering layer is formed between the grains to surround the grains.

2. The electrode wire of claim 1, further comprising an oxide layer covering the grains and a portion of the covering layer which is exposed between the grains.

3. The electrode wire of claim 1, wherein the covering layer has a thickness of about 2 to 3 μ

m.

4. The electrode wire of claim 1, wherein the electrode wire has a diameter of about 0.15 to 0.3 mm.

5. An electrode wire for electric discharge machining, comprising:

a core;

a covering layer formed on a periphery of the core; and

grains formed on the covering layer, wherein the core comprises copper or an a phase copper-zinc alloy, the covering layer comprises an (alpha+beta) phase copper-zinc alloy or a beta phase copper-zinc alloy, and the grains comprise a (beta+gamma) phase copper-zinc alloy,

wherein the grains are spaced from one another on a periphery of the covering layer and the covering layer is formed between the grains to surround the grains.

6. The electrode wire of claim 5, wherein the grains have an average grain size of about 3 to 5 μ

m.

7. The electrode wire of claim 5, wherein the covering layer has a thickness of about 2 to 3 μ

m.

8. A manufacturing method of an electrode wire for electric discharge machining, comprising steps of:

forming a coating layer on a periphery of a core comprising copper or a copper-zinc alloy by dipping the core in a galvanizing bath of molten zinc including about 0.01 to 0.5 weight % of at least one additive element selected from the group consisting of aluminum, copper, tin, magnesium, lanthanum, cerium, nickel, manganese, titanium, and zirconium;

performing heat treatment on the core having the coating layer at about 300 to 950°

C.;

drawing the electrode wire is further included after the step of performing heat treatment; and

annealing the electrode wire at about 400 to 500°

C. is further included after the step of drawing,

wherein the electrode wire comprises;

a core;

a covering layer formed on a periphery of the core; and

grains formed on the covering layer, wherein the grains comprise a copper-zinc alloy including about 0.01 to 0.5 weight % of at least one additive element selected from the group consisting of aluminum, tin, magnesium, lanthanum, cerium, nickel, manganese, titanium, and zirconium,

wherein the core comprises copper and a trace of unavoidable impurities, or comprises about 10 to 40 weight % of zinc, with the balance being copper and a trace of unavoidable impurities,

wherein the covering layer comprises about 37 to 49.5 weight % of zinc, with the balance being of copper and a trace of unavoidable impurities,

wherein the grains comprise about 49.5 to 58 weight % of zinc, and about 0.01 to 0.5 weight % of the at least one additive element, with the balance being of copper and a trace of unavoidable impurities, and

wherein the grains are spaced from one another on a periphery of the covering layer and the covering layer is formed between the grains to surround the grains.

9. The method of claim 8, wherein during the step of performing the heat treatment, the core having the coating layer is passed through a thermos tunnel.