PCD Tools Copper Tungsten Erosion Disc

Overview

PCD Tools Copper Tungsten Erosion Disc is a rotating electrode made of a copper tungsten alloy, primarily used in electrical discharge machining (EDM) to etch and regrind polycrystalline diamond (PCD) tools for precise machining and extended tool life. This electrode wheel is typically predominantly tungsten-based, available in grades of 70%, 75%, or 80% tungsten-copper alloy. The electrode wheel contacts the PCD workpiece in a rotating manner, generating a spark discharge through high-frequency electrical pulses to melt and remove excess material. Its high thermal conductivity prevents PCD tools from deforming due to heat damage. FANMETAL has many years of professional experience in the research, production, and export of tungsten-copper products; you can choose us with confidence.

Composition And Properties of Copper Tungsten Electrode Wheels

The main components of tungsten copper electrode wheels are tungsten (W) and copper (Cu), which are compositely formed using powder metallurgy. Instead of metallurgical bonding, the tungsten skeleton is dispersed throughout the copper matrix in a microstructure.

Tungsten: As the hard phase, it typically accounts for 70%–95% and is the core component determining the electrode wheel's high-temperature strength, wear resistance, and arc erosion resistance.

Copper: As the binder phase, it accounts for 5%–30%, primarily providing excellent electrical and thermal conductivity, while also improving the material's plasticity and processing performance.

• Excellent Electrical and Thermal Properties

Electrical Conductivity: The copper substrate possesses high electrical conductivity and low resistivity (typically <5.0×10⁻⁸ Ω・m), enabling efficient current conduction and reducing heat loss during energisation.

Thermal Conductivity: With a thermal conductivity of 180-220 W/(m・K), it rapidly dissipates heat generated during welding or discharge, preventing localised overheating that could lead to electrode wheel deformation or failure.

• Strong Resistance to Arc Erosion and Welding Resistance

Tungsten's high melting point (3410℃) and high hardness (HV≥300) make the electrode wheel resistant to ablation and melting under high-frequency arc impact.

Copper's rapid heat dissipation and low adhesion effectively prevent welding adhesion between the electrode and the workpiece, ensuring long-term stable use of the electrode wheel.

• Excellent Mechanical Properties and Thermal Stability

At room temperature, the tensile strength can reach 500-700 MPa. It possesses high hardness and excellent wear resistance, capable of withstanding the mechanical extrusion and friction during electrode wheel operation.

It has a low coefficient of thermal expansion (4-8×10⁻⁶ /℃), strong thermal shock resistance, and is not prone to cracking or deformation under repeated heating and cooling conditions.

• Machinability and Adaptability

Compared to pure tungsten, the presence of a copper matrix enhances the material's plasticity, allowing it to be machined into high-precision shapes through cutting, grinding, and other processes, making it compatible with various welding and cutting equipment.

PCD Tools Copper Tungsten Erosion Disc Technical Parameters

Copper Tungsten Erosion Wheel Core Applications

EDM PCD Tools

Copper tungsten electrodes for erosion are used to perform electrical discharge etching on stationary or slowly rotating PCD workpieces. Because the electrode wheel rotates, the discharge point constantly changes, avoiding localised overheating. This allows for efficient and high-precision grinding of the cutting edge and minimises carbon buildup. Furthermore, it is used in the machining of injection moulds and wire drawing dies, utilising the high hardness and wear resistance of tungsten copper to ensure the smoothness of the mould cavity.

Automotive Industry

In resistance seam welding and spot welding processes for automotive body, chassis, and door components, the electrode serves as a core component for conducting electricity and applying pressure. It can withstand the large current and instantaneous high temperature generated during welding, while rapidly dissipating heat to prevent the electrode from sticking to the workpiece, thus ensuring the consistency and stability of the weld. Examples include sealing seam welding of automotive fuel tanks and continuous spot welding of the vehicle floor.

Welding Industry

In the production of high-frequency induction welding of steel pipes, aluminum profiles, stainless steel profiles, etc., tungsten copper electrode wheels not only serve to conduct electricity and transmit force, but also withstand the local high temperature and arc impact generated by high-frequency induction, preventing oxidation and ablation of the electrode surface, ensuring the forming accuracy and sealing of pipe/profile welds, and are widely used in the mass production of welded pipes for construction, profiles for furniture, etc.

Aerospace Field

For micro-arc welding and precision roll welding of high-precision components such as aero-engine blades and thin-walled structural parts of spacecraft, the high-dimensional stability and resistance to extreme working conditions of tungsten-copper electrode wheels can meet the stringent processing requirements, ensuring welding accuracy and maintaining stable performance in special environments such as high temperature and high vacuum.

Electronic Component Manufacturing

In the micro-resistance welding and electroforming processes of precision electronic components such as integrated circuit lead frames and connector pins, miniaturised welding wheels can achieve precise conductivity and pressure control, while rapidly dissipating heat to prevent electronic components from failing due to overheating, thus ensuring product yield and reliability.

Why Copper Tungsten Is Ideal for EDM on PCD

 

PCD material is an insulator and cannot be formed by traditional cutting processes. It requires the use of electric arc discharge in electrical discharge machining to remove the material.

① It stably conducts the discharge current, ensuring uniform output of arc energy and achieving high-precision forming of the PCD tool cutting edge.

② Compared to pure copper electrodes, its wear resistance is improved by 3-5 times; compared to pure tungsten electrodes, its thermal shock resistance is superior, significantly extending the service life of the electrode wheel and reducing processing costs.

③ Under repeated discharge and alternating heating and cooling conditions, the external dimensions show almost no deformation, maintaining the stability of the discharge gap over a long period, ensuring the sharpness and geometric accuracy of the cutting edge.

④ It can be adapted to the forming processing of PCD tools of different specifications, balancing processing efficiency and finished product quality.

How Copper Tungsten Electrode Wheels Are Used in PCD Parts

Working Principle: Based on the spark thermal effect generated by pulsed discharge, high-temperature plasma is generated through high-frequency electrical pulses between the electrode wheel and the PCD workpiece, melting and vaporising the PCD material to achieve non-contact precision removal.

Specific Process: First, a tungsten-copper electrode wheel is prepared, ensuring high density and uniformity through powder metallurgy processes (such as static pressing and high-temperature sintering). Then, it is installed in EDM equipment (such as a disc etching machine), adjusting parameters including voltage, current, pulse width, gap, and rotation speed. Next, the electrode wheel rotates close to the PCD workpiece, and the pulsed power supply breaks down the working fluid to generate a spark discharge, etching the material and rinsing away residue with coolant. Finally, multiple cycles of machining and finishing are performed to achieve micron-level precision and surface smoothness.

• Rough Machining: Using a large discharge current and open-circuit voltage, most of the excess material on the PCD blank is quickly removed, initially forming the tool shape.
• Semi-Finishing: Discharge parameters are reduced, and the contour is refined to prepare for finishing, while also reducing subsequent surface defects.
• Finishing: Using tiny discharge energy in conjunction with the high-speed rotation of the electrode wheel, the PCD cutting edge is finely ground, and finally, the surface residue is removed by cleaning.

Quality Control in Copper Tungsten Electrode Manufacturing

1. The purity, particle size, and morphology of tungsten powder, copper powder, and auxiliary additives are carefully controlled to prevent the introduction of impurities or powder defects.
2. A ball milling process is employed to ensure uniform dispersion of the two powders and high-density green body formation, preventing compositional segregation or structural defects during subsequent sintering.
3. During the high-temperature sintering stage, parameters such as temperature (1100-1300℃), atmosphere, and heating rate are strictly controlled to prevent defects such as porosity, copper loss, and uneven microstructure.
4. Turquoise carbide tools are used for turning and milling to remove most of the excess material, preventing excessive machining stress that could lead to material cracking. Sufficient cooling with coolant is required during machining to prevent thermal deformation.
5. Comprehensive performance testing (density, hardness, tensile strength, conductivity), non-destructive testing (ultrasonic testing), and a final visual inspection are performed.

PCD Tools Copper Tungsten Erosion Disc Pictures

Video

Copper Tungsten VS Other Electrode Materials

Related News

Copper Tungsten Electrode Wheel, Tungsten Copper Erosion Wheel To Thailand

Recently, a batch of copper-tungsten electrode wheels produced by FANMETAL was shipped to Bangkok, Thailand, and successfully delivered to a local metal processing company. This customer is engaged in welding automotive and electronic components. Previously, their electrode wheels experienced rapid wear and poor stability, impacting production efficiency and costs. Our technical team utilised high-quality tungsten-copper composite materials and employed processes such as vacuum casting to improve product durability and conductivity. This resulted in a lifespan increase of over 60% and a 30% improvement in current stability, reducing downtime. The customer expressed satisfaction with the product's performance and the customised service, and plans to expand the cooperation. We will continue to optimise our products and services to meet the customised needs of different overseas customers.

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