Tips for Controlling Oxidation and Pitting on a Wire EDM
Additives, machine settings, workpiece materials and current technology are factors in avoiding common problems with unwanted rust and surface defects.
Share
Additives:
Additives do help in controlling oxidation and pitting of a variety of materials. These products help a great deal when cutting a workpiece with pre-polished surfaces.
Set the water conductivity to 5 microS or less, which is typically recommended for carbide, PCD, titanium, and fine finishes (<10 micro inches). This will also help keep bluing to a minimum on older non-anti-electrolysis generators.
Check water pH. Acidic detergents used to clean parts and tank will have a dramatic effect on parts rusting and will reduce the life of the deionization bottles.
Mix Workpiece Materials
With all the new and old types of alloys available, material incompatibility may cause surface issues. However, EDM field technicians have yet to document an instance where this situation has occurred.
New Machines
Most current wire EDMs are equipped with Anti-Electrolysis generators, some better then others. It basically comes down to how good the technology is and how fine of a surface finish the generator is capable of producing. A machine that is capable of producing a super fine finish (< 5 micro inches) can generate optimum surface integrity.
One example is the GF AgieCharmilles CUT 1000 that can machine parts with zero corrosion. The CUT 1000 is available in an oil version. With this feature, there is absolutely no electrolysis, corrosion and virtually zero recast.
Related Content
Ballbar Testing Benefits Low-Volume Manufacturing
Thanks to ballbar testing with a Renishaw QC20-W, the Autodesk Technology Centers now have more confidence in their machine tools.
Read More
The Future of High Feed Milling in Modern Manufacturing
Achieve higher metal removal rates and enhanced predictability with ISCAR’s advanced high-feed milling tools — optimized for today’s competitive global market.
Read More
How to Mitigate Chatter to Boost Machining Rates
There are usually better solutions to chatter than just reducing the feed rate. Through vibration analysis, the chatter problem can be solved, enabling much higher metal removal rates, better quality and longer tool life.
Read More
How to Determine the Currently Active Work Offset Number
Determining the currently active work offset number is practical when the program zero point is changing between workpieces in a production run.
Read MoreRead Next
Shop Tour Video: You've Never Seen a Manufacturing Facility Like This
In the latest installment of our “View From My Shop” series, explore Marathon Precision’s multi-process approach to manufacturing, where blacksmiths and hand-forged dies meet state-of-the-art CNC machining. Discover how restoring classic muscle cars and building custom art projects creates a dynamic shop culture — and draws top talent to this unique and innovative metalworking facility.
Read More
Why We Ask Machine Shop Leaders to Speak at TASC – The Automated Shop Conference
TASC is our industry’s premier peer-to-peer automation stage where America’s shop leaders refine the art of metalworking and CNC machining. For conference speakers, it's also an opportunity to showcase your skills and gain exposure for your business. Here are five why stepping into the spotlight at TASC could be your smartest move toward elevating your shop.
Read More
Setting Up the Building Blocks for a Digital Factory
Woodward Inc. spent over a year developing an API to connect machines to its digital factory. Caron Engineering’s MiConnect has cut most of this process while also granting the shop greater access to machine information.
Read More