Avoiding breakage is a key challenge in the manufacturing process of cut-resistant tungsten wire. Here are some main measures and suggestions to help reduce or avoid the occurrence of breakage:
- Raw material selection and processing
High-purity raw materials: Select high-purity tungsten powder as raw material to reduce the adverse effects of impurities on the performance of tungsten wire. Impurities may cause tungsten wire to be more prone to cracks and breaks during processing.
Raw material pretreatment: Strict screening and grading of tungsten powder to ensure uniform particle size distribution, which helps to improve the uniformity and density of subsequent forming.
- Forming and sintering
Precisely control process parameters: During the pressing and sintering process, accurately control key process parameters such as pressing pressure, sintering temperature and time. Too high or too low temperature may cause defects and stress concentration inside the tungsten wire, thereby increasing the risk of fracture.
Mold design optimization: Design a reasonable mold shape and size to reduce the stress and deformation generated during the pressing and sintering process. The material and surface quality of the mold must also meet the requirements to avoid damage to the tungsten wire.
- Wire drawing process control
Optimize the wire drawing process: Optimize the wire drawing process by adjusting parameters such as wire drawing speed, tension, and type and amount of lubricant. Appropriate speed and tension help maintain the stability of the tungsten wire and reduce the possibility of fracture. At the same time, the use of lubricants can reduce friction and heat and protect the surface of the tungsten wire from damage.
Regular inspection and maintenance: Regularly check the operating status of the wire drawing machine and the wear of the wire drawing die. Replace severely worn dies and repair equipment failures in a timely manner to ensure the stability and continuity of the wire drawing process.
- Post-processing and testing
Post-processing process: The tungsten wire after drawing is cleaned, dried and other post-processing processes are carried out to remove impurities such as oil and oxide on the surface. This helps to improve the surface quality and corrosion resistance of the tungsten wire and reduce the breakage caused by surface defects.
Strict quality inspection: Strict quality inspection of tungsten wire, including diameter measurement, tensile strength test, surface quality inspection, etc. Ensure that the various performance indicators of tungsten wire meet the standard requirements, and timely discover and deal with potential quality problems.
- Other considerations
Environmental control: Keep the production environment clean and stable to avoid dust, oil and other impurities from polluting or damaging the tungsten wire. At the same time, control the temperature and humidity of the production environment to ensure the stability and quality of the tungsten wire during the processing.
Employee training and management: Strengthen the training and management of operators to improve their ability to control process parameters and their proficiency in equipment operation. Ensure that operators can operate according to process requirements to reduce breakage problems caused by human factors.
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