Tungsten needles are typically made through a process known as wire drawing, which involves the following steps:
Material selection: High-purity tungsten wire is chosen as the starting material for making tungsten needles. The tungsten wire should have the desired diameter and chemical composition suitable for the intended application.
Wire cleaning: The tungsten wire is thoroughly cleaned to remove any contaminants or impurities that may affect the quality of the final product. Cleaning methods can include chemical cleaning, ultrasonic cleaning, or mechanical cleaning.
Wire drawing: The cleaned tungsten wire is then drawn through a series of dies to reduce its diameter and achieve the desired needle size. The wire is pulled through the die, which has a smaller opening, using a wire drawing machine. This process is repeated several times until the desired diameter is reached.
Annealing: After the wire drawing process, the tungsten wire may undergo an annealing step. Annealing involves heating the wire to a specific temperature and then slowly cooling it to relieve internal stresses and improve its ductility. This step helps enhance the mechanical properties of the wire and makes it more suitable for subsequent processing.
Pointing and sharpening: The drawn tungsten wire is then pointed and sharpened to create a needle-like shape. This can be done through various methods, including mechanical grinding, electrochemical etching, or laser ablation. The sharpening process creates a fine and precise tip on the tungsten needle.
Surface finishing: Depending on the application, the tungsten needles may undergo additional surface finishing processes. This can include polishing, coating, or passivation treatments to improve their surface smoothness, corrosion resistance, or other specific properties.
Quality control: Throughout the manufacturing process, quality control measures are implemented to ensure the dimensional accuracy, surface quality, and overall quality of the tungsten needles. This may involve inspection of the diameter, tip sharpness, surface finish, and other critical parameters.
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