The wire drawing equipment used in black tungsten wire production primarily includes coarse wire drawing machines, medium wire drawing machines, fine wire drawing machines, and ultra-fine wire drawing machines, complemented by auxiliary equipment such as drawing dies, heating furnaces, and lubrication systems. These machines are selected based on the diameter and performance requirements of the tungsten wire, with strict control over temperature, lubrication, and tension during the drawing process to ensure high quality and stability of the tungsten wire.
Coarse Wire Drawing Machine
- Purpose: Used in the initial stage to draw tungsten bars or thicker tungsten wires, reducing their diameter.
- Features: Coarse wire drawing machines handle larger-diameter tungsten materials, requiring high drawing force and stability. They are equipped with robust drawing dies (e.g., cemented carbide or precision ceramic dies) to address tungsten’s high hardness and brittleness.
- Heating Method: Coarse drawing often employs slow heating (via furnace tubes and flame for uniform temperature distribution to improve workability) or rapid heating (under high-color-temperature flames, though with slightly less temperature uniformity).
Medium Wire Drawing Machine
- Purpose: Further draws coarse-drawn tungsten wire to a medium diameter.
- Features: Medium wire drawing machines require higher precision and control to ensure surface quality and dimensional consistency. The choice of die material (e.g., cemented carbide or diamond) significantly impacts processing quality.
- Process Considerations: The medium drawing stage requires strict control of drawing temperature to prevent recrystallization or wire breakage due to high temperatures or improper deformation. The recrystallization temperature of doped tungsten wire increases rapidly with greater deformation.
Fine Wire Drawing Machine
- Purpose: Produces finer tungsten wires for applications such as incandescent lamps and halogen lamps.
- Features: Fine wire drawing machines demand higher equipment precision and typically use diamond dies to ensure surface smoothness and dimensional accuracy. Precise control of tension and speed is critical to prevent wire breakage.
- Process Requirements: The fine drawing stage requires a stable lubrication system and consistent drawing temperature to maintain the physical properties of the tungsten wire.
Ultra-Fine Wire Drawing Machine
- Purpose: Produces ultra-fine tungsten wires (e.g., for photovoltaic diamond wire or high-precision applications) with diameters reaching the micrometer level.
- Features: Ultra-fine wire drawing machines are high-precision equipment, often equipped with advanced control systems and high-quality drawing dies (e.g., diamond dies). They operate in cleanroom environments to avoid impurities affecting wire quality.
- Applications: Ultra-fine tungsten wires are increasingly in demand in the photovoltaic industry (e.g., for diamond wire cutting), requiring equipment to meet high strength and cutting resistance standards.
Auxiliary Equipment
- Drawing Dies: Common dies in black tungsten wire production include cemented carbide, precision ceramic, and diamond dies. Diamond dies, due to their high hardness and wear resistance, are often used for fine and ultra-fine wire drawing.
- Heating Furnace: Controls temperature during the drawing process to ensure the tungsten wire deforms at an optimal temperature. Slow-heating furnaces provide a uniform temperature field, ideal for high-quality tungsten wire production.
- Lubrication System: Uses lubricants (e.g., graphite emulsion or specialized drawing oils) during drawing to reduce friction and protect the wire surface.
- Drawing Preparation Equipment: Includes straight drawing (chain drawing) and rotary drawing (turntable drawing) machines. Modern processes often use rotary drawing due to its higher efficiency and suitability for continuous production.
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