WO2024113467A1 - Électrode à fil et procédé de préparation associé - Google Patents

Électrode à fil et procédé de préparation associé Download PDF

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Publication number
WO2024113467A1
WO2024113467A1 PCT/CN2023/071409 CN2023071409W WO2024113467A1 WO 2024113467 A1 WO2024113467 A1 WO 2024113467A1 CN 2023071409 W CN2023071409 W CN 2023071409W WO 2024113467 A1 WO2024113467 A1 WO 2024113467A1
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Prior art keywords
wire
layer
zinc alloy
phase
zinc
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PCT/CN2023/071409
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English (en)
Chinese (zh)
Inventor
罗孝奇
舒文恬
梁志宁
吴桐
陈益波
林火根
仇方超
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宁波博德高科股份有限公司
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Publication of WO2024113467A1 publication Critical patent/WO2024113467A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
    • B23H7/02—Wire-cutting
    • B23H7/08—Wire electrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
    • B23H7/22—Electrodes specially adapted therefor or their manufacture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H7/00—Processes or apparatus applicable to both electrical discharge machining and electrochemical machining
    • B23H7/22—Electrodes specially adapted therefor or their manufacture
    • B23H7/24—Electrode material

Definitions

  • the invention belongs to the field of electric spark wire cutting processing, and in particular relates to an electrode wire and a preparation method thereof.
  • WEDM wire electro-discharge machining
  • Wire EDM is a process of machining workpieces based on the discharge principle of electric sparks.
  • the workpiece Before machining, the workpiece is connected to the positive pole of a pulse power supply, and the electrode wire is connected to the negative pole of a high-frequency pulse power supply as a tool electrode.
  • the workpiece is cut using spark discharge.
  • the machining accuracy and speed of this process are closely related to the performance of the electrode wire.
  • the performance of electrode wire products has been greatly improved from the initial pure copper electrode wire to the currently commonly used coated electrode wire. However, the cutting speed of the existing coated wire will be significantly reduced after the alloy layer is consumed.
  • the invention provides an electrode wire and a preparation method thereof, which are used to solve the problem in the prior art that the cutting speed of the electrode wire is significantly reduced after the alloy layer is consumed.
  • an electrode wire comprising: a core material, the core material is a copper alloy; an intermediate layer, which is located outside the core material; and a surface layer, which is located outside the intermediate layer; wherein the intermediate layer is a copper-zinc alloy; and the core material has irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloy inside.
  • the present invention has the following beneficial effects: The inventor has found that the cutting speed of the existing plated wire will be significantly reduced after the alloy layer is consumed because the existing core material generally contains ⁇ -phase copper-zinc alloy, which has poor electrical conductivity and poor gasification flushing effect during the discharge process. Therefore, the cutting speed is significantly reduced after the alloy layer is consumed.
  • the present invention forms irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloys inside the core material. Both the ⁇ -phase copper-zinc alloy and the ⁇ '-phase copper-zinc alloy have good electrical conductivity, which can improve the electrical conductivity of the electrode wire. In this way, the discharge frequency when the electrode wire is used for electric spark wire cutting can be greatly improved, and the corresponding processing speed will be greatly improved.
  • the zinc content of the ⁇ -phase and/or ⁇ '-phase copper-zinc alloy is higher, and the gasification flushing effect generated during the discharge process is better than that of the ⁇ -phase copper-zinc alloy.
  • the core material itself can still maintain a high cutting speed due to its good electrical conductivity and high zinc content.
  • part of the irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloy located near the middle layer of the core material is connected to the middle layer.
  • the ⁇ -phase and/or ⁇ '-phase copper-zinc alloy located near the middle layer in the core material in the final prepared electrode wire is larger in size and connected to the middle alloy layer, which can further improve the conductivity (current transmission efficiency) and the flushing effect during the discharge process.
  • the area of the irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloy accounts for 2-80% of the area of the core material.
  • the irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloy containing the above ratio can give full play to the role of the ⁇ -phase and/or ⁇ '-phase copper-zinc alloy in the core material, ensuring high conductivity of the electrode wire and a sustained and stable high cutting speed.
  • the area of the irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloy accounts for 10-60% of the area of the core material.
  • the area of the irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloy accounts for 10-50%, 15-40%, 15-50%, 15-60%, 20-50%, 20-60% or 30-60% of the area of the core material.
  • the intermediate layer is a ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy layer and/or a ⁇ -phase copper-zinc alloy layer.
  • the middle layer has cracks.
  • a tip can be formed at the crack.
  • discharge is easier at the tip. Therefore, when performing wire EDM, the reaction time of the electrode wire to generate sparks can be reduced, thereby increasing the discharge frequency and speeding up the wire EDM.
  • the cracks can increase the contact area between the middle layer and the working fluid, making the flushing speed faster, thereby shortening the interval between two discharges, further increasing the discharge frequency, and speeding up the wire cutting speed.
  • the surface layer contains zinc, which ensures that the surface layer has excellent gasification and flushing effects, thereby increasing the cutting speed.
  • the surface layer also contains carbon.
  • the presence of carbon increases the conductivity of the electrode wire and increases the cutting speed.
  • the carbon content in the surface layer is ⁇ 0.5%, and the zinc content in the surface layer is ⁇ 60%.
  • the above contents ensure that there are enough carbon and zinc elements in the surface layer, which is conducive to the relevant components to fully play their role.
  • the present invention also adopts the following technical solution: a method for preparing an electrode wire, comprising the following steps:
  • S101 zinc-plating the surface of the brass busbar, thereby forming a zinc-plated layer on the surface of the busbar, and manufacturing a first wire blank;
  • the second wire blank is stretched and stress-relief annealed to produce a finished electrode wire, wherein the core material has irregular ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy inside.
  • a specific brass busbar is selected, and after electroplating, heat treatment and stretching processes, an irregular ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy can be generated in the core material inside the electrode wire.
  • Both the ⁇ -phase copper-zinc alloy and the ⁇ ’-phase copper-zinc alloy have good electrical conductivity and can improve the electrical conductivity of the electrode wire, so that the discharge frequency when the electrode wire is used for electric spark wire cutting can be greatly improved, and the corresponding processing speed will be greatly improved.
  • the ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy has a higher zinc content, and the gasification flushing effect generated during the discharge process is better than that of the ⁇ -phase copper-zinc alloy. Therefore, even if the structure outside the core material is consumed as the processing process proceeds, the core material itself can still maintain a high cutting speed due to its good electrical conductivity and high zinc content.
  • the heat treatment temperature in step S102 is 130-400°C
  • the heat treatment time is 1-50h
  • the intermediate layer formed is a ⁇ -phase and/or ⁇ '-phase copper-zinc alloy layer and/or a ⁇ -phase copper-zinc alloy layer.
  • the present invention also adopts the following technical solution: a method for preparing an electrode wire, comprising the following steps:
  • S204 heat treating the third wire blank to prepare a fourth wire blank, wherein the fourth wire blank has a core material, an intermediate layer and a surface layer from inside to outside in sequence;
  • S205 The fourth wire blank is stretched and stress-relief annealed to produce a finished electrode wire, wherein the core material has an irregular ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy.
  • a specific brass busbar is selected, and after electroplating, heat treatment and stretching processes, an irregular ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy can be generated in the core material inside the electrode wire.
  • Both the ⁇ -phase copper-zinc alloy and the ⁇ ’-phase copper-zinc alloy have good electrical conductivity and can improve the electrical conductivity of the electrode wire, so that the discharge frequency when the electrode wire is used for electric spark wire cutting can be greatly improved, and the corresponding processing speed will be greatly improved.
  • the ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy has a higher zinc content, and the gasification flushing effect generated during the discharge process is better than that of the ⁇ -phase copper-zinc alloy. Therefore, even if the structure outside the core material is consumed as the processing process proceeds, the core material itself can still maintain a high cutting speed due to its good electrical conductivity and high zinc content.
  • the heat treatment temperature in step S202 is 130-250° C.
  • the heat treatment time is 1-50 h
  • the formed copper-zinc alloy layer is a ⁇ -phase copper-zinc alloy layer.
  • the heat treatment temperature in step S204 is 300-500°C
  • the heat treatment time is 1-50h
  • the intermediate layer formed is a ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy layer.
  • the brass busbar has a Cu content of 58.5-60%.
  • the brass busbar with the above Cu content can ensure that a large amount of irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloy is formed in the core material during the subsequent heat treatment process.
  • the electroplating solution for zinc plating contains a carbohydrate organic additive, and the concentration of the additive in the electroplating solution is 8-25g/L.
  • the carbohydrate organic additive can slow down the crystallization process of the zinc plating layer, making the zinc plating layer denser, brittler and harder, so that in the subsequent stretching process, the zinc plating layer is easier to break, and the internal middle layer and busbar are easier to squeeze out of the zinc plating layer, that is, the internal core material and middle layer of the electrode wire finally made are easier to expose from the surface layer.
  • the exposed core material and middle layer can improve the conductivity efficiency of the surface layer during the initial processing and improve the processing speed.
  • the additive is a mixture of one or more of maltose, lactose, dextrin and sucrose.
  • FIG1 is a schematic diagram of a partial cross section of an electrode wire produced by the preparation method provided by the present invention.
  • FIG2 is an electron microscope image of a cross section of the inner core material of the electrode wire produced in Example 1;
  • FIG3 is a partial cross-sectional schematic diagram of another electrode wire produced by the preparation method provided by the present invention.
  • FIG4 is an electron microscope image of a cross section of the inner core material of the electrode wire produced in Example 7;
  • FIG5 is a partial cross-sectional schematic diagram of another electrode wire produced by the preparation method provided by the present invention.
  • FIG6 is a cross-sectional metallographic image of the inner core material of the electrode wire produced in Example 13.
  • core material 10. irregular ⁇ -phase copper-zinc alloy, 2. middle layer, 20. crack, 21. ⁇ -phase copper-zinc alloy layer, 22. ⁇ -phase copper-zinc alloy layer, 3. surface layer.
  • the inventors have found that the cutting speed of the existing plated wire will be significantly reduced after the alloy layer is consumed because the existing core material generally contains ⁇ -phase copper-zinc alloy, which has poor electrical conductivity and poor gasification flushing effect during the discharge process. Therefore, the cutting speed is significantly reduced after the alloy layer is consumed.
  • the present invention forms irregular ⁇ -phase and/or ⁇ '-phase copper-zinc alloys inside the core material. Both the ⁇ -phase copper-zinc alloy and the ⁇ '-phase copper-zinc alloy have good electrical conductivity, which can improve the electrical conductivity of the electrode wire. In this way, the discharge frequency when the electrode wire is used for electric spark wire cutting can be greatly improved, and the corresponding processing speed will be greatly improved.
  • the zinc content of the ⁇ -phase and/or ⁇ '-phase copper-zinc alloy is higher, and the gasification flushing effect generated during the discharge process is better than that of the ⁇ -phase copper-zinc alloy.
  • the core material itself can still maintain a high cutting speed due to its good electrical conductivity and high zinc content.
  • a brass busbar with a Cu content in the range of 58.5-62% is selected during the preparation process, and only through the preparation method provided by the present invention can the core material of the manufactured electrode wire have irregular ⁇ -phase and/or ⁇ ’ copper-zinc alloy.
  • the above-mentioned irregular shape in the present invention means that after the electrode wire is cross-cut, when the cross section of the electrode wire is viewed through a scanning electron microscope, the planar shape of the ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy inside the core material has no specific shape.
  • the ⁇ -phase and/or ⁇ ’-phase copper-zinc alloy can be in the shape of long strips, curved strips, blocks, etc.
  • the heat treatment process alloys the core material to form the ⁇ phase and/or ⁇ ' copper-zinc alloy, controls the crystal grain size of the generated ⁇ phase and/or ⁇ ' copper-zinc alloy by the heat treatment process, and controls the degree of stretching of the ⁇ phase and/or ⁇ ' copper-zinc alloy by the stretching process, that is, the proportion of the area of the irregular ⁇ phase and/or ⁇ ' copper-zinc alloy to the area of the core material can be controlled.
  • the intermediate layer can be a ⁇ phase or a ⁇ phase or a ⁇ phase + a ⁇ phase, wherein the ⁇ phase can also be a ⁇ ’ phase.
  • the following embodiments are all expressed as ⁇ phases, that is, the ⁇ phase below means that one or both of the ⁇ phase and the ⁇ ’ phase have ⁇ phases and/or ⁇ ’ copper-zinc alloys.
  • the zinc content in the surface layer is ⁇ 60%, and the carbon content is ⁇ 0.5%.
  • the present invention provides two preparation methods.
  • the following examples 1-12 adopt the first preparation method, wherein the cross-section of the finished electrode wire prepared in examples 1-6 is shown in reference to FIG1, and the cross-section electron microscope image of the inner core material of the electrode wire prepared by the preparation method of example 1 is shown in FIG2; the cross-section of the finished electrode wire prepared in examples 7-12 is shown in reference to FIG3, and the cross-section electron microscope image of the inner core material of the electrode wire prepared by the preparation method of example 7 is shown in FIG4.
  • the following examples 13-18 adopt the second preparation method, and the cross-section of the finished electrode wire prepared by the preparation method of example 13 is shown in reference to FIG5, wherein the cross-section metallographic image of the inner core material of the electrode wire prepared by the preparation method of example 13 is shown in FIG6.
  • the present invention cross-cuts the electrode wire product before observation, and uses a metallographic etchant, ferric chloride hydrochloric acid alcohol solution, to corrode the cross-section of the electrode wire to be observed, and then uses a scanning electron microscope or a metallographic microscope to observe.
  • Embodiment 1 provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 0.8 mm, wherein the Cu content in the brass busbar is 59.5%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 5 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 8 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 8 g/L;
  • S102 heat treating the first wire billet at a temperature of 140° C. for 40 h, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 22;
  • the second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG1 , and the electron microscope image of the cross-sectional diagram is shown in FIG2 , in which the irregular ⁇ -phase copper-zinc alloy 10 can be seen.
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 35-60%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 35-60%.
  • the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is different, so the above 35-60% refers to 35%, 60% and multiple ratio values between 35% and 60% obtained after multiple measurements.
  • the measurement principle of the ratio of the area of the ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 in the subsequent embodiments is the same as this, and will not be repeated in detail.
  • Embodiment 2 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 1.2 mm, wherein the Cu content in the brass busbar is 61%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 10 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 10 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 10 g/L;
  • S102 heat treating the first wire billet at a temperature of 200° C. for 10 h, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG1 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 12-35%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 12-35%.
  • Embodiment 3 provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 0.8 mm, wherein the Cu content in the brass busbar is 58.5%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 8 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein no sugar organic additive is added to the electroplating solution for electroplating;
  • S102 heat treating the first wire billet at a temperature of 160° C. for 20 h, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG1 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m square is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the square is 1 ⁇ m.
  • the ratio of points on the square that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 2-24%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 2-24%.
  • Embodiment 4 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 0.5 mm, wherein the Cu content in the brass busbar is 62%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 5 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 25 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 25 g/L;
  • S102 heat treating the first wire billet at a temperature of 130° C. for 50 h, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG1 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 18-45%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 18-45%.
  • Embodiment 5 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provide a brass busbar with a wire diameter of 0.65 mm, wherein the Cu content in the brass busbar is 60%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 3 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 8 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 8 g/L;
  • S102 heat treating the first wire billet at a temperature of 150° C. for 18 hours, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse mutually during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG1 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 10-25%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 10-25%.
  • Embodiment 6 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 1 mm, wherein the Cu content in the brass busbar is 62%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 7 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 20 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 20 g/L;
  • S102 heat treating the first wire billet at a temperature of 180° C. for 14 hours, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG1 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 10-32%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 10-32%.
  • Embodiment 7 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provide a brass busbar with a wire diameter of 1 mm, wherein the Cu content in the brass busbar is 60%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 12 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 10 g/L;
  • S102 heat treating the first wire billet at a temperature of 320° C. for 16 hours, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 21 and a ⁇ -phase copper-zinc alloy layer 22;
  • the second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG3 , and the electron microscope image of the cross-sectional diagram is shown in FIG4 , in which the irregular ⁇ -phase copper-zinc alloy 10 can be seen.
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 22-55%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 22-55%.
  • Embodiment 8 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 1.2 mm, wherein the Cu content in the brass busbar is 59.5%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 10 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 22 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 22 g/L;
  • S102 heat treating the first wire billet at a temperature of 250° C. for 50 h, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse mutually during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 21 and a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG3 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 20-45%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 20-45%.
  • Embodiment 9 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 0.85 mm, wherein the Cu content in the brass busbar is 62%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 15 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 25 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 25 g/L;
  • S102 heat treating the first wire billet at a temperature of 400° C. for 1 h, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 21 and a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG3 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 accounts for 56-80% of all points. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounts for 56-80% of the area of the core material 1.
  • Embodiment 10 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 0.75 mm, wherein the Cu content in the brass busbar is 61.5%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 9 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein no sugar organic additive is added to the electroplating solution for electroplating;
  • S102 heat treating the first wire billet at a temperature of 385° C. for 4 hours, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 21 and a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG3 .
  • the electrode wire provided in this embodiment was cross-cut, and the cross section of the core material 1 inside was observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m square was drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the square was 1 ⁇ m.
  • the points on the square that fell on the irregular ⁇ -phase copper-zinc alloy 10 accounted for 48-69% of all the points. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounted for 48-69% of the area of the core material 1.
  • Embodiment 11 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provides a brass busbar with a wire diameter of 1.1 mm, wherein the Cu content in the brass busbar is 60%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 11 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein no sugar organic additive is added to the electroplating solution for electroplating;
  • S102 heat treating the first wire billet at a temperature of 325° C. for 10 h, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 21 and a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG3 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m grid is drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the grid is 1 ⁇ m.
  • the ratio of points on the grid that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 30-65%. That is, in the cross section of the electrode wire, the ratio of the area of the irregular ⁇ -phase copper-zinc alloy 10 to the area of the core material 1 is 30-65%.
  • Embodiment 12 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S100 Provide a brass busbar with a wire diameter of 1 mm, wherein the Cu content in the brass busbar is 60%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 10 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 22 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 22 g/L;
  • S102 heat treating the first wire billet at a temperature of 400° C. for 4 hours, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 21 and a ⁇ -phase copper-zinc alloy layer 22;
  • S103 The second wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG3 .
  • the electrode wire provided in this embodiment was cross-cut, and the cross section of the core material 1 inside was observed using a scanning electron microscope.
  • a 20 ⁇ 20 ⁇ m square was drawn on the 10,000-fold scanning electron microscope image, and the minimum unit of the square was 1 ⁇ m.
  • the points on the square that fell on the irregular ⁇ -phase copper-zinc alloy 10 accounted for 54-76% of all the points. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounted for 54-76% of the area of the core material 1.
  • Embodiment 13 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S200 Provides a brass busbar with a wire diameter of 1.2 mm, wherein the Cu content in the brass busbar is 62%;
  • S201 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 10 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 25 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 25 g/L;
  • S205 The fourth wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG5
  • the metallographic diagram of the cross-section is shown in FIG6 , showing the irregular ⁇ -phase copper-zinc alloy 10.
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 50 ⁇ 50 ⁇ m square is drawn on the 1000x scanning electron microscope image, and the minimum unit of the square is 5 ⁇ m.
  • the ratio of points on the square that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 40-70%. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounts for 40-70% of the area of the core material 1.
  • Embodiment 14 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S200 Provides a brass busbar with a wire diameter of 1 mm, wherein the Cu content in the brass busbar is 60%;
  • S205 The fourth wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG5 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 50 ⁇ 50 ⁇ m square is drawn on the 1000x scanning electron microscope image, and the minimum unit of the square is 5 ⁇ m.
  • the ratio of points on the square that fall on the irregular ⁇ -phase copper-zinc alloy 10 to all points is 33-60%. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounts for 33-60% of the area of the core material 1.
  • Embodiment 15 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S200 Provides a brass busbar with a wire diameter of 0.8 mm, wherein the Cu content in the brass busbar is 62%;
  • S201 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 9 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 20 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 20 g/L;
  • S205 The fourth wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG5 .
  • the electrode wire provided in this embodiment was cross-cut, and the cross section of the core material 1 inside was observed using a scanning electron microscope.
  • a 50 ⁇ 50 ⁇ m square was drawn on the 1000x scanning electron microscope image, and the minimum unit of the square was 5 ⁇ m.
  • the points on the square that fell on the irregular ⁇ -phase copper-zinc alloy 10 accounted for 33-66% of all the points. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounted for 33-66% of the area of the core material 1.
  • Embodiment 16 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S200 Provides a brass busbar with a wire diameter of 1 mm, wherein the Cu content in the brass busbar is 59.8%;
  • S201 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 15 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 18 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 18 g/L;
  • S205 The fourth wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG5 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 50 ⁇ 50 ⁇ m square is drawn on the 1000x scanning electron microscope image, and the minimum unit of the square is 5 ⁇ m.
  • the points on the square that fall on the irregular ⁇ -phase copper-zinc alloy 10 account for 58-80% of all the points. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounts for 58-80% of the area of the core material 1.
  • Embodiment 17 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S200 Provides a brass busbar with a wire diameter of 1.1 mm, wherein the Cu content in the brass busbar is 60.6%;
  • S201 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 12 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein no sugar organic additive is added to the electroplating solution for electroplating;
  • S205 The fourth wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG5 .
  • the electrode wire provided in this embodiment was cross-cut, and the cross section of the core material 1 inside was observed using a scanning electron microscope.
  • a 50 ⁇ 50 ⁇ m square was drawn on the 1000x scanning electron microscope image, and the minimum unit of the square was 5 ⁇ m.
  • the points on the square that fell on the irregular ⁇ -phase copper-zinc alloy 10 accounted for 52-78% of all the points. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounted for 52-78% of the area of the core material 1.
  • Embodiment 18 This embodiment provides a method for preparing an electrode wire, the preparation method comprising the following steps:
  • S200 Provides a brass busbar with a wire diameter of 1 mm, wherein the Cu content in the brass busbar is 60%;
  • S201 electroplating zinc on the surface of the brass busbar, thereby forming a zinc-plated layer with a thickness of 14 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic additive, specifically, the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 18 g/L;
  • the sugar organic additive is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic additive in the electroplating solution is 18 g/L;
  • S205 The fourth wire blank is stretched and stress-relief annealed to produce a finished electrode wire with a wire diameter of 0.25 mm, wherein the core material 1 has an irregular ⁇ -phase copper-zinc alloy 10.
  • the cross-sectional schematic diagram of the finished electrode wire is shown in FIG5 .
  • the electrode wire provided in this embodiment is cross-cut, and the cross section of the core material 1 inside is observed using a scanning electron microscope.
  • a 50 ⁇ 50 ⁇ m square is drawn on the 1000x scanning electron microscope image, and the minimum unit of the square is 5 ⁇ m.
  • the points on the square that fall on the irregular ⁇ -phase copper-zinc alloy 10 account for 25-48% of all the points. That is, in the cross section of the electrode wire, the area of the irregular ⁇ -phase copper-zinc alloy 10 accounts for 25-48% of the area of the core material 1.
  • the electrode wire prepared by using the above-mentioned embodiment has an irregular ⁇ -phase copper-zinc alloy 10 in its internal core material 1.
  • the ⁇ -phase copper-zinc alloy has good electrical conductivity and can improve the electrical conductivity of the electrode wire. In this way, the discharge frequency when the electrode wire is used for electric spark wire cutting can be greatly improved, and the corresponding processing speed will be greatly improved.
  • the zinc content in the ⁇ -phase copper-zinc alloy is higher, and the gasification flushing effect generated during the discharge process is better than that of the ⁇ -phase copper-zinc alloy. In summary, even if the structure outside the core material is consumed as the processing process proceeds, the core material itself can still maintain a relatively high cutting speed due to its good electrical conductivity and high zinc content.
  • the electrode wire prepared by the above embodiment has a crack 20 in the middle layer 2, and a tip can be formed at the crack 20. According to the discharge principle, the tip is more likely to discharge. Therefore, when performing electric spark wire cutting, the reaction time of the electrode wire to generate electric sparks can be reduced, thereby increasing the discharge frequency and speeding up the electric spark wire cutting. In addition, when performing electric spark wire cutting, the crack can increase the contact area between the middle layer and the working fluid, making the flushing speed faster, thereby shortening the interval between two discharges, further increasing the discharge frequency, and speeding up the wire cutting speed.
  • Comparative Example 1 This example is used as a comparative example, and the specifications of the brass busbar in the preparation method provided in the above example are changed, specifically:
  • S100 Provide a brass busbar with a wire diameter of 0.65 mm, wherein the Cu content in the brass busbar is 65%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 3 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic compound, specifically, the sugar organic compound is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic compound in the electroplating solution is 8 g/L;
  • S102 heat treating the first wire billet at a temperature of 150° C. for 18 hours, wherein the copper element in the brass busbar and the zinc element in the galvanized layer diffuse with each other during the heat treatment process to form an intermediate layer 2, thereby manufacturing a second wire billet.
  • the second wire billet has a core material 1, an intermediate layer 2, and a surface layer 3 from the inside to the outside, wherein the intermediate layer 2 is a ⁇ -phase copper-zinc alloy layer 22;
  • Comparative Example 2 This example is used as a comparative example, and the specifications of the brass busbar in the preparation method provided in the above example are changed, specifically:
  • S100 Provides a brass busbar with a wire diameter of 1 mm, wherein the Cu content in the brass busbar is 64%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 12 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic compound, specifically, the sugar organic compound is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic compound in the electroplating solution is 10 g/L;
  • Comparative Example 3 This example is used as a comparative example, and the parameters of the heat treatment in the preparation method provided in the above example are changed, specifically:
  • S100 Provides a brass busbar with a wire diameter of 0.8 mm, wherein the Cu content in the brass busbar is 59.5%;
  • S101 electroplating zinc on the surface of the brass busbar, thereby forming a zinc plating layer with a thickness of 5 ⁇ m on the surface of the brass busbar to prepare a first wire blank, wherein the electroplating solution contains a sugar organic compound, specifically, the sugar organic compound is a mixture of one or more of maltose, lactose, dextrin and sucrose, and the concentration of the sugar organic compound in the electroplating solution is 8 g/L;
  • Comparative Example 1 brass electrode wire with a wire diameter of 0.25 mm purchased from the market;
  • Comparative Example 2 A zinc-coated electrode wire with a wire diameter of 0.25 mm purchased from the market;
  • Comparative Example 3 Gamma electrode wire with a wire diameter of 0.25 mm purchased from the market;
  • the following table is a comparison table of structural characteristics of the electrode wires prepared in Examples 1 to 18, the electrode wires prepared in Comparative Examples 1 to 3, and the electrode wires purchased in Comparative Examples 1 to 3:
  • the electrode wires prepared in Examples 1 to 18, the electrode wires prepared in Comparative Examples 1 to 3, and the electrode wires purchased in Comparative Examples 1 to 3 were subjected to wire-cutting machining tests.
  • the test conditions are shown in the following table:
  • the electrode wire prepared by the preparation method provided by the present invention can improve the conductivity and gasification flushing effect of the electrode wire due to the irregular ⁇ -phase copper-zinc alloy in its internal core material, thereby significantly improving the cutting speed of electric spark wire cutting.
  • connection can be a fixed connection, a detachable connection, or an integrated connection. It can be understood that it can also be a mechanical connection, an electrical connection, etc.; of course, it can also be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal connection of two elements, or the interaction relationship between two elements.
  • connection can be a fixed connection, a detachable connection, or an integrated connection. It can be understood that it can also be a mechanical connection, an electrical connection, etc.; of course, it can also be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal connection of two elements, or the interaction relationship between two elements.

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Abstract

Électrode à fil. L'électrode à fil comprend : un matériau de noyau (1) ; une couche intermédiaire (2) qui est située à l'extérieur du matériau de noyau (1) ; et une couche de surface (3) qui est située à l'extérieur de la couche intermédiaire (2), la couche intermédiaire (2) étant composée d'un alliage de cuivre-zinc et l'intérieur du matériau de noyau présentant un alliage de cuivre-zinc à phase β et/ou à phase β irrégulière. Un procédé de préparation de l'électrode à fil comprend la réalisation de processus d'électrodéposition, de traitement thermique et d'étirage, de manière à former un alliage de cuivre-zinc à phase β à l'intérieur d'un matériau de noyau à l'intérieur de l'électrode à fil ; et en utilisant les caractéristiques de l'alliage de cuivre-zinc à phase β et d'un alliage de cuivre-zinc à phase β', la conductivité du matériau de noyau peut être améliorée, la transmission d'énergie de décharge est améliorée et une vitesse de coupe de fil est augmentée.
PCT/CN2023/071409 2022-11-29 2023-01-09 Électrode à fil et procédé de préparation associé WO2024113467A1 (fr)

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