Compax® PCD Wire Die Blanks
Compax® PCD wire die blanks are premium high-quality diamond products used in the wire drawing process to compress the wire and shape and reduce its diameter. Due to its high degree of hardness and wear resistance, die blanks made of PCD can handle tougher environments and draw fine and ultrafine wires used on brass-plated wires, such as tire cords, saw wires, and welding wires.
PCD wire die blanks produce an exceptionally smooth and precise surface finish, critical for achieving the desired mechanical properties and performance characteristics for wire cords. Along with the surface finish, it is also highly resistant to thermal damage, which is essential when drawing wire at extremely high speeds.
PCD wire die blanks helps provide a longer tool lifespan by reducing the need for frequent die replacement and minimizing downtime and production costs. It is available in metal-filled and thermally stable grades with a wide range of sizes from submicron to 50 microns.
Product Groups
Hyperion Code: Compax®
Wire Material: Various
Description: Self-supported sub-micron die blanks manufactured from polycrystalline diamond (PCD) with an ultrafine grain microstructure available in sizes D-6 and D-12.
Hyperion Code: Compax®
Wire Material: Various
Description: The polycrystalline diamond (PCD) core is integrally bonded to a cemented tungsten carbide support ring. Grades are available with diamond grain sizes ranging from 3 to 50 micron and with dimensional sizing from D-12 to D-36.
Hyperion Code: Compax® (MF)
Wire Material: High carbon steel
Description: Self-supported and electrically conductive (metal filled) PCD die blanks are available in 5 and 25 micron diamond grain sizes with dimensional sizing from D-6 to D-30.
Hyperion Code: Compax® (TS)
Wire Material: Tungsten/molybdenum
Description: Self-supported and thermally stable PCD die blanks are available in 5 and 25 micron diamond grain sizes with dimensional sizing from D-6 to D-30.
Hyperion Code: Compax®
Wire Material: Various
Description: Self-supported sub-micron die blanks manufactured from polycrystalline diamond (PCD) with an ultrafine grain microstructure available in sizes D-6 and D-12.
Hyperion Code: Compax®
Wire Material: Various
Description: The polycrystalline diamond (PCD) core is integrally bonded to a cemented tungsten carbide support ring. Grades are available with diamond grain sizes ranging from 3 to 50 micron and with dimensional sizing from D-12 to D-36.
Hyperion Code: Compax® (MF)
Wire Material: High carbon steel
Description: Self-supported and electrically conductive (metal filled) PCD die blanks are available in 5 and 25 micron diamond grain sizes with dimensional sizing from D-6 to D-30.
Hyperion Code: Compax® (TS)
Wire Material: Tungsten/molybdenum
Description: Self-supported and thermally stable PCD die blanks are available in 5 and 25 micron diamond grain sizes with dimensional sizing from D-6 to D-30.
PCD Wire Die Blanks Applications
PCD wire die blanks are used as the drawing die due to their high level of wear resistance, thermal conductivity, and hardness. In addition, they can maintain their shape and size under high pressure and temperatures, allowing them to achieve consistent wire diameters and reduce downtime due to die wear or failure.
PCD wire die blanks are used in various applications involving wire drawing, including manufacturing electrical wires, cables, steel cords, tire cords, tire bead wires, and more. They also can be found in the production of medical devices, such as precision springs and other components that require fine or ultrafine wire diameters.
PCD Wire Die Blanks Products
Different types of PCD wire die blanks are utilized for various applications. For example, carbide-supported PCD wire die blanks are tungsten carbide-supported die blanks with diamond grains ranging from 3 to 50 microns. Profiling the geometry is performed using shaping needles with electrical discharge machining (EDM) or ultrasonic machines with diamond abrasives. Diamond abrasives are also used for polishing the final die.
Metal filled or electrically conductive PCD die blanks are self-supported and available in 5- to 25-micron grain sizes and enhance the PCD's ability to bond to other materials, which is useful for applications such as wire bonding and electroplating. The metal layer also improves thermal conductivity, benefiting cutting or drilling applications.
Thermally stable PCD wire die blanks are designed to maintain structural integrity and hardness even at high temperatures. Developed by adding a small amount of tungsten carbide to the PCD material, thermally stable blanks are suitable for high-temperature cutting or drilling applications, such as machining aluminum or other nonferrous metals.
Frequently Asked Questions about Compax® PCD Wire Die Blanks
Compax® PCD wire die blanks are premium polycrystalline diamond products used in wire drawing applications to shape and reduce the diameter of wires and generate fine or ultrafine wires for unprecedented consistency for specialized wire drawing machines.
Compax® PCD die blanks can be used to draw a wide range of wire materials, including copper, aluminum, steel, and other alloys.
The benefits of using Compax® PCD die blanks include high wear resistance, consistent diameter control, durability, ability to draw fine and ultrafine wires, thermal stability, and chemical stability, which results in efficient and cost-effective wire production.
Compax® PCD die blanks are available in various shapes and sizes, including round, square, and rectangular shapes, and can be customized to meet specific wire drawing requirements. In addition, it is available in various metal filled and thermally stable grades in grain sizes from submicron to 50 microns.
Compax® PCD die blanks are used in various applications involving wire drawing, including manufacturing electrical wires, cables, steel cords, tire cords, tire bead wires, and more.
Compax® PCD wire die blanks are high-quality premium products with high wear resistance, consistent diameter control, durability, and efficient and cost-effective wire production. Other wire drawing products may not offer the same level of performance and durability.
