The production of cut-resistant tungsten wire is a complex and delicate process, mainly involving multiple steps and processes. The following are the main steps in the production of cut-resistant tungsten wire:
- Raw material preparation
Tungsten powder preparation: The raw material of cut-resistant tungsten wire is usually high-purity tungsten powder. These tungsten powders can be prepared by a variety of methods, such as heating and decomposing ammonium paratungstate (APT) in a roasting furnace to produce blue crystalline tungsten oxide, and then reducing it to tungsten powder in a hydrogen reduction furnace. The average particle size of tungsten powder conventionally used to produce tungsten wire is 2~5 microns.
Doping treatment: In order to improve the performance of tungsten wire, such as anti-sagging and enhanced toughness, tungsten powder may need to be doped. Doping elements may include potassium, rhenium, etc., which can be evenly mixed into tungsten powder by solution spraying, stirring, etc.
- Molding and sintering
Pressing molding: After the doped or undoped tungsten powder is fixed and weighed, it is placed in a mold and pressed using an isostatic press to form a tungsten billet with a certain specification and density. The grain size, density, and performance of the tungsten billet made by isostatic pressing are uniform, and the billet strength is high.
Sintering: The pressed tungsten billet is placed in a sintering furnace for sintering. During the sintering process, a solid-phase reaction occurs between the tungsten powder particles to form a dense tungsten bar. The density of the sintered tungsten bar increases, usually reaching more than 17.7g/cm³, and has good mechanical properties and processing properties.
- Processing and wire drawing
Swaging and rolling: The sintered tungsten bar is processed by swaging or rolling to become a round rod-shaped tungsten bar for wire drawing. The swaging and rolling process can improve the internal structure and surface quality of the tungsten bar, and improve its tensile strength and toughness.
Wire drawing: The processed round rod-shaped tungsten rod is placed in the wire drawing machine for wire drawing. Lubricants (such as graphite) are added during the wire drawing process to reduce friction and wear. Through multiple wire drawing, the tungsten rod is gradually drawn to the required diameter (usually between 20 microns and 1 mm). The tungsten wire after wire drawing has a smooth surface, precise size and stable performance.
- Post-processing and testing
Post-processing: The tungsten wire after wire drawing may need post-processing, such as cleaning, drying, winding and winding, etc., to ensure that its surface is clean and free of impurities, and is easy to store and transport.
Testing: The quality of the produced cut-resistant tungsten wire is tested, including diameter measurement, tensile strength test, anti-sagging performance test, etc., to ensure that it meets the relevant standards and requirements.
- Precautions
Safety: Safety operating procedures must be strictly followed during the production process to avoid accidents. Such as wearing protective equipment (gloves, goggles, etc.), ensuring that the work area is clean and tidy, etc.
Quality control: Each production link needs to strictly control the quality to ensure that the purity of raw materials, process parameters, equipment status, etc. meet the requirements to improve the quality and performance of cut-resistant tungsten wire.
Environmental protection: Waste and waste gas generated during the production process need to be properly handled to meet environmental protection requirements.
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