Wire Drawing Guide - Expometals

TOOLMAKER SOLUTIONS

Wire Drawing Guide

Your full-line of wire drawing solutions

WIR

E D

RAW

ING

APP

LICA

TIO

NS

& FA

ILU

RE

MO

DES

CU

STO

MER

SU

PPO

RT

MAT

ERIA

LS

WELCOME TO HYPERION

COMPLETE DRAWING SOLUTIONS

PCD AND VERSIMAX: MATERIAL & PROCESS

- PCD MATERIAL & PROCESS

- PCD CATALOGUE

- VERSIRION AND VERSIMAX MATERIAL

- PCD MATERIAL ISSUES

CEMENTED CARBIDE: MATERIAL & PROCESS

- CEMENTED CARBIDE MATERIAL & PROCESS

- CEMENTED CARBIDE MATERIAL DEFECTS

- CEMENTED CARBIDE CATALOGUE

- WEAR PARTS

DIAMOND COMPOUNDS

- SLURRIES

- PASTES

- MICRON POWDER GRADES

APPLICATIONS

- APPLICATION KNOWLEDGE

- APPLICATIONS GUIDELINES

- BEST PRACTICES

- FAILURE MODES

- WIRE DEFECTS

FAQ’S

INTERNATIONAL STANDARDS

CONVERSION TABLES AND FORMULAS

RECYCLING AND SUSTAINABILITY

WORDS INDEX

06

10

14

14

22

24

25

27

27

36

39

45

47

47

48

49

52

52

55

57

59

66

70

71

72

73

74

TABLE OF CONTENTS

3WIRE DRAWING GUIDE

WIRE DRAWING

CVD diamond

Corrosion resistant seal rings

CIC integral rolls introduced

Submicron grade H3F for wire drawing

Grade DZ05 for flow control

Diffusion bonding of CC bodies for

wear parts

Grade DZ10 for can tooling

HPHT gem diamonds

Coated diamond for precision wire sawing

V-Series PCBN grades, new

for steel turning

Grade AM60 for CFRP machining & Grade AM70 for titanium

machining

Intelligent rotary cutters, quick anvil change

PBA rotary cutters concept

Grade TC03/C3D for drawing die nibs

1st diamond synthesis

1st PCD cutters (for oil & gas)

Introduction of grade H10F

6 WIRE DRAWING GUIDE

OUR HERITAGEPROUD PAST, PROMISING FUTURE

CVD diamond

Corrosion resistant seal rings

CIC integral rolls introduced

Submicron grade H3F for wire drawing

Grade DZ05 for flow control

Diffusion bonding of CC bodies for

wear parts

Grade DZ10 for can tooling

HPHT gem diamonds

Coated diamond for precision wire sawing

V-Series PCBN grades, new

for steel turning

Grade AM60 for CFRP machining & Grade AM70 for titanium

machining

Intelligent rotary cutters, quick anvil change

PBA rotary cutters concept

Grade TC03/C3D for drawing die nibs

1st diamond synthesis

1st PCD cutters (for oil & gas)

Introduction of grade H10F

7

WIR

E D

RAW

ING

WIRE DRAWING


YOUR DRAWING PARTNERHyperion is your full-line provider of cemented tungsten carbide, tungsten carbide powders, diamond and cubic boron nitride materials for your material-removal and wear-protection applications. In addition to innovative materials, Hyperion offers our extensive knowledge, unique services and application development capabilities to support our customers’ competitive needs.

With advanced production capabilities in powder processing, sintering, high-pressure high-temperature synthesis, coating and finishing, Hyperion can satisfy all your needs for drawing solutions.

Hyperion is truly a global and fully integrated manufacturer, with locations in the Americas, Europe and Asia. Our expansive and experienced global sales network provides local support, so your wire drawing solutions are available when you need them.

HYPERION GLOBAL Hyperion’s MBG® diamond offers a solution for grinding high performance materials such as glass, stone and electronic materials. The shapes range from well-defined crystals to highly friable, irregular shapes that can be customized for any application.

Hyperion’s worldwide network of manufacturing facilities offers customers the very latest in material technology and productivity with unparalleled customer service.

9WIRE DRAWING

WIR

E D

RAW

ING

DRAWING THEORY AND DRAWING LINEDrawing process refers to reduction of metals section by the application of stress in tension.

Drawing die is a tool with a specially shaped hole through which wire is pulled to reduce its diameter.

Traction force σd pulls the wire through the reduction cone. The reaction σb, decomposes in force P (compress the wire deforming its material under ratio r) and the friction µP. Friction stresses are reduced with better lubrication.

When a wire is drawn (reduced), the material grains deform and elongate, causing the wire to be harder and less ductile.

To return the material to its original hardness and ductility, the material is annealed. During annealing, grains recrystallize and grain growth can occur.

After annealing, the wire can again be drawn.

Starting stock

Final work sizeα

αDf

A0 A1σm

μP

μP

σb σd

P

P

D0F

L C

r = 1 - A1 A0

FERRITIC STEEL

AUSTENITIC STEEL

AUSTENITIC-FERRITIC STEEL

InternalResidual

Stress

Strength,Hardness& Ductility

Microstructureand Grain Size

Recovery(Grains recover

slightly fromcold-working)

InternalResidual Stress

Strength

DuctilityHardness

GrainGrowth

Grain Growth(Larger grains grow

at the expense of the smaller grains)

Recrystallization(New grains form)

TUNGSTEN CARBIDE

Hyperion’s drawing nibs are known for their impeccable geometry and unique and consistent grade composition. We offer not only a wide range of standard dimensions but also the unique ability to partner with you to create a special design for your needs.

PCD BLANKS

Hyperion’s self-supported and carbide supported die blanks portfolio covers a wide range of dimensions and applications for wire drawing. The unique material properties provide very good abrasion resistance and the ability to achieve a high quality surface finish.

CARBIDE ROUGH CORE DIES

Hyperion’s wide offering of wet and dry drawing dies is designed according to industry standards or customer specifications. Our unique hot and cold casing processes are capable of handling high volumes and provide:

• Increased die life• Better stress balance• Improved heat dissipation.

VERSIRION™ AND VERSIMAX™

Hyperion is introducing the Versirion series, a revolutionary silicon carbide and polycrystalline diamond (PCD) made by a state-of-the-art high pressure high temperature process and is based on the Versimax composite. Versirion and Versimax exhibit superior wear resistance, high temperature performance and thermal stability by combining the best of tungsten carbide and PCD.


HYPERION - YOUR COMPLETE DRAWING SOLUTION PROVIDER

COMPLETE DRAWING OFFER

1-HOT ROLLS 2-SHAVING DIES BLANKS 3/4-CARBIDE DIES AND BLANKS

5-COMPAX® BLANKS FOR SUPPORTED AND SELF-SUPPORTED PCD DIES

6-VERSIRION™ AND VERSIMAX™ BLANKS1-HOT ROLLS 2-SHAVING DIES BLANKS 3/4-CARBIDE DIES AND BLANKS

5-COMPAX® BLANKS FOR SUPPORTED AND SELF-SUPPORTED PCD DIES

6-VERSIRIONVERSIMAX

BLANKS

DIAMOND AND DIAMOND COMPOUNDS

Starting with the highest quality of raw materials, Hyperion uses advanced engineering methods to manufacture diamonds with specific characteristics of strength and toughness. State-of-the-art micronizing techniques assure the diamond powders have precisely defined sizes, shapes and surface properties for polishing dies.

Hyperion’s offering of diamond pastes and compounds are a combination of premium diamond powder and superior lubricants, creating the optimal polishing products.

WEAR PARTS

Hyperion’s wide range of fully finished and ready-to-use wear parts (e.g., guide wheels, guide bushes, etc.) for the wire industry can be manufactured according to your drawing.

11WIRE DRAWING

WIR

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HYPERION - YOUR COMPLETE DRAWING SOLUTION PROVIDER

7-WEAR PARTS AND COLD ROLLING PROCESS 8-DIAMOND COMPOUNDS

6-VERSIRION™ AND VERSIMAX™ BLANKS 7-WEAR PARTS AND COLD ROLLING PROCESS 8-DIAMOND COMPOUNDS

6-VERSIRION™ AND VERSIMAX™ BLANKS

MATERIALS

120Shock wavesynthesis

LiquidcarbonDiamond

Pres

sure

(GPa

)

Temperature (K)

HPHTsynthesisCatalytic

HPHT synthesis

MetastableCVD diamond

Graphite

30

25

20

15

10

5

00 1000 2000 3000 4000 5000

PCD SINTERING

Residual Cobalt(etched)

Diamond Powder Blend

Cemented WCCobalt

HYPERION - COMPAX® PCD FROM START TO FINISH

CONSISTENCY THROUGH SIX SIGMA QUALITY CONTROL

WHAT IS PCD?

Hyperion’s diamond micron powders are created in a single, continuous manufacturing process. Starting with the highest quality of raw materials, Hyperion uses advanced engineering methods to manufacture diamonds with specific characteristics of strength and toughness. State-of-the-art micronizing techniques assure the diamond micron powders have precisely defined sizes, shapes and surface properties. The result is unprecedented consistency and uniformity from the initial diamond source to the final product.

Hyperion’s micron powders offer consistency and repeatability derived from the engineering invested in our proprietary Six Sigma controlled manufacturing processes.

CARBON-DIAMOND PHASE DIAGRAM

At high temperature and pressure, cobalt melts and “sweeps” into

the powder bed

The cobalt promotes carbon-carbon bonding between

diamond crystals


Fine Grain

Medium Grain

Coarse Grain

Fine surface finish requirements

• Tough to draw wire

• Small/medium die sizes

• Tire cord and wire saw.

General purpose applications

• Moderate surface finish and abrasion requirements

• Medium die sizes

• Stainless steel and welding wire.

Intermediate and rod breakdown

• Non-critical finish requirements

• Larger die sizes

• Stranding, bunching and cabling.

SUBMICRON

25 MICRON

12 MICRON

5 MICRON

50 MICRON

PCD GRAIN SIZESPCD GRADE APPLICATION

15MATERIALS

MAT

ERIA

LS

BlendBuild

capsule

Cemented WC ring Metal cup

Buildcell

Inspection,packaging& shipping

A

B

Finishing

Steel coverA/BPCD blank

Brazingmedia

Steel case

HPHT sintering

Highpressure

Hightemperature

Diamond feedSealed capsule (cup)

Sintered wire die compact

Finished wire die

Brazing the PCD blank

Machining entrance & exit

core

Laser inner die shape Ultrasonic polishing

Blended powder

Cell

MBS®/Borazon® crystals

Loading

Milling

Pressing

Grading

Wire EDM cutting

Cleaning

Finishing

Blending

Quality control

This process is fully integrated within Hyperion, from powder to finished parts.

HYPERION‘S PCD MANUFACTURING PROCESS

PCD BLANK MANUFACTURING PROCESS

SELF-SUPPORTED PCD BLANK MANUFACTURING

TUNGSTEN CARBIDE SUPPORTED PCD BLANK MANUFACTURING


Pressure ≤ 55 kbar

Temperature > 1300ºC

Time < 1 hour

Pressure at the center of the earth

Pressure of powder metal forming

Pressure of current successful synthesis of diamond

Pressure at which pressure washers function as a water jet cutter

Pressure at which pressure washers force out water

Atmospheric pressure at earth’s sea level

Pressure of near earth outer space

3,600,000 bar 52,000,000 psi

1,200 bar 30,000 psi

55,000 bar 800,000 psi

600 bar 8,700 psi

100 bar 1,500 psi

1 bar 15 psi

1 x 10-9 bar 1.5 x10-8 psi

HYPERION‘S PCD MANUFACTURING PROCESS

PCD BLANK MANUFACTURING PROCESS

17MATERIALS

HPHT PROCESS DETAILS

MAT

ERIA

LS

WIRESURFACE

FINISH

WEAR RESISTANCE +

+

MFU

/TSU

(0.9

μm

)

MF/

TS/S

uppo

rted

(5 μ

m)

Supp

orte

d (2

5 μm

)

Supp

orte

d (3

μm

)

Supp

orte

d (1

2 μm

)

Supp

orte

d (5

0 μm

)


HYPERION‘S PCD BLANKS PRODUCT MAP

SUB-MICRON PROPERTY MEASUREMENT

CURRENT SUB-MICRON PRODUCT

% W% Co

Wea

r Res

ista

nce

Wea

r Rat

e (m

g/m

in)

Hyperion Supplier B Supplier A0

4

8

2

6

10

1214

% C

o or

W

Comp. Grd 2 Comp. Grd 1 Hyperion0

10

20

5

15

25

30

ABRASION TEST RESULTS X-RAY FLUORESCENCE RESULTS FOR METAL CONTENT

Target applicationsBrass-plated wire (tire cord, saw wire)Welding wireFine finishing applicationsGlass scribing

Typical diamond grain size 0.9 μm

Typical diamond content 91%

STANDARD PRODUCT OFFERINGS

ADDMA No. Product Dimensions (mm)diameter x thickness Metal Filled Thermally

StableMaximum Recommended

Hole Size (mm)

D6 3.1 x 1.00 5010-MFU 5010-TSU 0.5

D12 3.1 x 1.5 5015-MFU 5015-TSU 1.0

The unique material properties provide very good abrasion resistance and the ability to achieve a high quality surface finish.

19MATERIALS

HYPERION‘S PCD BLANKS PRODUCT MAP SUB-MICRON PCDSUB-MICRON MICROSTRUCTURES

MAT

ERIA

LS

Wear Resistance Wear Rate

The unique material properties provide: • The ability to generate a high quality polished surface in minimal time• Consistent long life.

1000x magnification SEM image of a 5025 sample.

WEA

R M

ICR

O-IN

CH

SH 5025 LOW COST PRODUCT

0

10

50

30

70

20

60

40

80

90

ABRASIVE WEAR COMPARISON

SH 5025 Die Material Low Cost Die Material1000X 1000X

Low Cost Product: 186 nm

Compax 5025 35 nm


HYPERION‘S PCD QUALITY

MF Grade • Metal filled, contains catalyst metal

• Thermally stable to 700ºC and electrically conductive.

TS Grade • Catalyst metal removed by leaching process

• Thermally stable to 1050ºC

• Can be mounted using high temperature, high strength metal setting powders

• Not electrically conductive.

• PCD Grain Size: 3 µm, 5 µm, 12 µm, 25 µm & 50 µm

• Contains metal catalyst in PCD structure

• Do not exceed 700ºC in die mounting operations

• Electrically conductive.

Free standing polycrystalline diamond

Typically lower cost than WC supported blanks

Sizes: D6 through D18

Average PCD Grain Size: 5 µm & 25 µm & submicron

Two Grades: thermally stable (TS) & metal filled (MF)

PCD core integrally bonded to a WC support ring

WC support leads to enhanced strength of PCD core

Allows for larger PCD core

Sizes: D12 through D36

21MATERIALS

HYPERION‘S PCD QUALITY HYPERION‘S PCD BLANKS

SELF-SUPPORTED DIE BLANKS

CARBIDE SUPPORTED DIE BLANKS

MAT

ERIA

LS


HYPERION‘S PCD BLANKS CATALOGUE

TUNGSTEN CARBIDE-SUPPORTED DIE BLANKS

ADDMA

NOMINAL DIAMOND

DIAMETER X THICKNESS

(mm)

GRAIN SIZE PRODUCT DIMENSIONS [mm]

3 µm 5 µm 12 µm 25 µm 50 µm TOOL BLANK DIAMETER

DIAMOND DIAMETER

DIAMONDTHICKNESS

RECOM-MENDED

BORE SIZE (mm)*

D12 1.5 x 1.5 5235 3.99 ± 0.013 1.4 1.5 ± 0.10 0.05 0.01 0.05 0.20 0.8

D15 4.0 x 2.3 5823 5123 5223 5430 8.12 ± 0.013 3.8 2.24 ± 0.05 0.05 0.01 0.08 0.40 1.8

D18 4.0 x 2.9 5829 5129 5229 5435 8.12 ± 0.013 3.8 2.84 ± 0.05 0.05 0.01 0.10 0.40 2.3

D21 7.0 x 4.0 5840 5240 5530 13.65 ± 0.013 6.8 3.86 ± 0.05 0.05 0.01 0.14 0.50 3.5

D24 7.0 x 5.313.0 x 7.0

5853 52535225

55355725

13.65 ± 0.01324.13 ± 0.025

6.812.7

5.13 ± 0.056.98 ± 0.25

0.050.10

0.0100.050

0.180.30

0.500.60

4.65.2

D27 13.0 x 8.7 5108 5208 5730 24.13 ± 0.025 12.7 8.70 ± 0.25 0.10 0.05 0.30 0.60 5.8

D30 13.0 x 11.618.6 x 13.5

5111 52115913

5735 24.13 ± 0.02534.00 ± 0.025

12.718.2

11.60 ± 0.2513.5 ± 0.50

0.100.10

0.0500.050

0.400.45

0.600.75

7.611.2

D33 18.6 x 15.518.6 x 17.5

59155917

34.00 ± 0.02534.00 ± 0.025

18.218.2

15.50 ± 0.5017.5 ± 0.50

0.100.10

0.0500.050

0.520.59

0.750.75

12.012.5

D36 18.6 x 18.5 5918 34.00 ± 0.025 18.2 18.50 ± 0.50 0.10 0.05 0.62 0.75 12.7

* Maximum recommended bore size for non-ferrous wire. Hard-ferrous wire die size normally should not exceed 65% of this diameter.

SELF-SUPPORTED DIE BLANKS

ADDMA

NOMINAL DIAMOND

DIAMETER X THICKNESS

(mm)

GRAIN SIZE PRODUCT DIMENSIONS [mm]

Sub µm 5 µm 25 µm DIAMOND DIAMETER

DIAMONDTHICKNESS

RECOMMENDEDBORE SIZE

(mm)*

D6 3.1 x 1.0 5010-MFU 5010-TSU 5010-MF 5010-TS 5010-MFC 5010-TSC 3.1 ± 0.38 1.0 ± 0.13 0.08

(within diameter

limits)

0.13 0.5

D12 3.1 x 1.5 5015-MFU 5015-TSU 5015-MF 5015-TS 5015-MFC 5015-TSC 3.1 ± 0.38 1.5 ± 0.13 0.08 0.13 1.0

D15 5.2 x 2.5 5025-MF 5025-TS 5025-MFC 5025-TSC 5.2 ± 0.64 2.5 ± 0.13 0.08 0.25 1.5

D18 5.2 x 3.5 5035-MF 5035-TS 5035-MFC 5035-TSC 5.2 ± 0.64 3.5 ± 0.13 0.08 0.25 2.0

D21 7.0 x 4.0 7040-MF 7040-MFC 7 ± 0.64 4 ± 0.13 0.08 0.25 3.5

D247.0 x 5.3 7053-MF 7053-MFC 7 ± 0.64 5.3 ± 0.13 0.08 0.25 4.6

13.0 x 7.0 1370-MF 1370-MFC 13 ± 0.64 7 ± 0.13 0.08 0.25 5.2

D27 13.0 x 8.7 1387-MF 1387-MFC 13 ± 0.64 8.7 ± 0.13 0.08 0.25 5.8

D30 13.0 x 11.6 1311-MF 1311-MFC 13 ± 0.64 11.6 ± 0.13 0.08 0.25 7.6

18.6 x 13.5 1813-MF 1813-MFC 18.6 ± 0.64 13.5 ± 0.13 0.08 0.25 11.2

To view the complete catalog, please visit www.HyperionMT.com.

23MATERIALS

HYPERION‘S PCD BLANKS CATALOGUE VERSIRION™

Hyperion is introducing the Versirion™ series, a revolutionary silicon carbide and polycrystalline diamond (PCD) composite with increased wear property and thermal stability. Versirion™ is made by a state-of-the-art high pressure high temperature process and is based on the Versimax™ composite developed for wire drawing and wear application.

VERSIRION™ AND VERSIMAX™

Versirion and Versimax exhibit superior wear resistance, high temperature performance and high strength approaching that of Co-sintered PCD, with the addition of superior thermal stability. Versirion exhibits the most superior corrosion resistance.

MAIN ADVANTAGES- Superior thermal stability compared to that of PCD- Significantly reduced coeºcient of thermal expansion (CTE) mismatch- Thermally stable up to 1400°C, which creates less risk of failures during application - Easy to process:

- Electrically conductive: EDM processability allows flexibility in cutting various geometries- Larger sizes than unsupported PCD: diameter - 35 mm, height - 35 mm- Does not require polishing of the bore to achieve the surface finish of the wire- Ability to be easily brazed or shrink fitted into casing

- Versatility: ferrous and non-ferrous wires - Wear resistance comparable to that of PCD and corrosion resistance slightly better than that of PCD.

MAIN APPLICATIONS FOR FERROUS AND NON-FERROUS WIRES- Drawing - Bunching - Compacting - Wear applications - Stranding - Extrusion

MATERIALS

Microstructure M

ATER

IALS

WEAR RESISTANCE TEST RESULTS

Nor

mal

ized

Wea

r Rat

e

PCD5 VMX20 VRW10 VRW50.0

0.2

0.6

0.4

0.8

1.0

1.2

1.4


VERSIRION™ AND VERSIMAX™ PRODUCT OFFERING

VERSIRION™ AND VERSIMAX™ BLANK SIZESVersirion and Versimax wire die blanks are self-supported and do not have carbide support rings. Both are available in custom sizes and shapes and are prepared according to customer specifications.

Simple shapes (cylinders, rectangular or triangular prisms, etc.) and more complicated geometries (conical shapes, hollow cylinders, negative features, etc.) can be produced.

Versimax can be attached to tungsten carbide or steel by furnace brazing. Tools can also be produced by press fitting, heat shrink fitting, adhesive bonding or mechanical fixturing.

Contact your Hyperion account manager to review your application and determine the best fabrication method for your needs.

GRADE APPLICATION(S) AVERAGE GRAIN SIZE

Versirion™ (VRW5) Fine Grain

- Low carbon steel- Tire cord- Aluminum- Copper with higher surface finish requirement

Versirion™ (VRW10) Medium Grain

- Low carbon steel- Coated steel- Aluminum- Copper with lower surface finish requirement

Versimax™ Coarse Grain

- Bunching- Stranding- Wear application- Compacting- High pressure - High temperature

ADDMA DIAMETER (mm) THICKNESS (mm)PARALLELISM

PERPENDICULARITYROUNDNESS

D6 3.1 1.0 0.08 0.13 0.05

D12 3.1 1.5 0.08 0.13 0.05

D15 5.2 2.5 0.08 0.25 0.05

D18 5.2 3.5 0.08 0.25 0.05

D21 7.0 4.0 0.08 0.25 0.05

D24 13.0 7.0 0.10 0.3 0.05

D27 13.0 8.7 0.10 0.3 0.05

D30 18.6 13.5 0.10 0.4 0.05

D33 18.6 15.5 0.10 0.5 0.05

D36 18.6 18.5 0.10 0.6 0.05

TM 23.0 15.0 0.10 0.38 0.05

TM 25.0 20.0 0.10 0.51 0.05

TM 30.0 22.0 0.10 0.56 7.6

TM 35.0 25.0 0.10 0.64 11.2

TM = Tailor-madeUnless otherwise specified all parts are cut with an EDM external hook.

25MATERIALS

PCD MATERIAL ISSUES- Generating properly processed PCD blanks requires special processing of feedstock, blend and cell components, as

well as careful control of the HPHT process and finishing methods.

- Errors or issues with any of the above will result in failure of parts or result in parts out of specification for strength and microstructure properties.

- Our 100% Product Inspection Process and the Cross Functional Production Team ensures the best quality product.

- Following is the typical inspection criteria:

HPHT PROCESS ISSUES

- Visible effects: diamond growth - Nominal cause: HPHT process temperature

above request.

- Visible effects: delamination - Nominal cause: HPHT process temperature

below request.

- Visible effects: horizontal cracking - Nominal cause: HPHT process temperature

below request.

X-RAY (TS BLANKS) PCD SINTER QUALITY

DiameterThicknessParallelismPerpendicularityConcentricityRoundness

Edge ChipsPits & Depressions

Finish & Color

CracksMetal InclusionsOversize Control

MAT

ERIA

LS


above request.


above request.

- Visible effects: misconcentricity between PCDblank and carbide ring

- Nominal cause: mistake during wire cutting.

- Visible effects: metal filled inclusion - Nominal cause: result of issue with the feed.

- Visible effects: ‘bottle cap’ marks or chipping - Nominal cause: Laser induced damage.

Poor laser process.

- Visible effects: ‘bottle cap’ marks or chipping - Nominal cause: Laser induced damage.

Poor laser process.


PCD MATERIAL ISSUES

HPHT PROCESS ISSUES

OTHERS

2727MATERIALS

CEMENTED CARBIDECemented carbide is one of the most successful composite engineering materials ever produced. Cemented carbide’s unique combination of strength, hardness and toughness satisfies the most demanding applications.

A key feature of the cemented carbide is the potential to vary its composition so that the resulting physical and chemical properties ensure maximum resistance to wear, deformation, fracture, corrosion and oxidation. In addition, the wide variety of shapes and sizes that can be produced using modern powder metallurgical processing offers tremendous scope to design cost-effective solutions to many of the problems of component wear and failure encountered in both the engineering and domestic environment.

MAT

ERIA

LS



THE MATERIAL WITH STAYING POWERThe most valuable property of cemented carbide is that it offers a safer and more dependable solution than any other known material to one of the toughest problems which engineers have to contend with – reliability.

Reliability is often a problem of wear. Wear resistance is the most outstanding feature of cemented carbide. Cemented carbide can also withstand deformation, impact, heavy load, high pressure, corrosion and high temperature. Cemented carbide is often the only material that can fulfill these requirements.

It has long been a well-known fact that the use of cemented carbide provides an optimal solution in the case of tools for metal cutting and rock drilling. Over the years, cemented carbides have also proven their superiority in a great number of other tooling and engineering applications.

Polycrystalline Diamond (PCD)

Polycrystalline Cubic Boron Nitride (PCBN)

Toughness

Har

dnes

s

High Speed Steel

Stellite

Cemented Carbide

SiC

Al2O3

Si3N4

The most commonly used materials are shown schematically relative to their hardness and toughness properties. Polycrystalline diamond (PCD) is the hardest of all, followed by polycrystalline cubic boron nitride (PCBN) and ceramics (A12O3, SiC, SIALON etc.). The super-hard materials all suffer from lower toughness and poor resistance to sudden fracture. The cemented carbides have a unique combination of high hardness and good toughness within a wide range and thus constitute the most versatile hard materials group for engineering and tooling applications.

Recognizing the need for high quality, Hyperion micron powders offer consistency and repeatability derived from the engineering invested in our proprietary Six Sigma controlled manufacturing process.

ENGINEERING MATERIALS

CONSISTENCY THROUGH SIX SIGMA QUALITY CONTROL

2929MATERIALS

Hyperion offers in-house hot and cold casing, which guarantees the best possible die performance in any application. Our unique hot and cold casing processes are capable of handling high volumes and provide:

- Better stress balance - Improved heat dissipation - Increased die life

OUR PROCESS

HYPERION‘S CARBIDE MANUFACTURING PROCESS

Cold Casing Hot Casing

Hyperion has been manufacturing dies since 1947, giving us experience in a wide variety of user applications. Our fully integrated manufacturing process allows us the flexibility to produce small test batches as well as mass production volumes. Our advanced, in-house tooling shop is able to adapt our production to any customer requirement.

SIZES AND STANDARDS

Casing size can be adapted to your needs. All standard nibs, as well as customer specific sizes, can be adapted.

TAILOR-MADE

This process is fully integrated within Hyperion, from powder to finished parts.

MAT

ERIA

LS

Ultrafine< 0.5 µm

Extra fine0.5 - 0.9 µm

Fine1.0 - 1.3 µm

Medium1.4 - 2.0 µm

Medium coarse2.1 - 3.4 µm

Coarse3.5 - 5.0 µm

Extra coarse> 5.0 µm

5 µm

Grades for WD

HYPERION CARBIDE GRAIN SIZE CLASSIFICATION

Hyperion uses the following grain size classification for all standard grades.


HV30

ULTRAFINE

EXTRA FINE

MEDIUM

H3F

C3D

H11N

RS1T

6UD

H15F

H6F

H6N

2000

1500

1000

0 5 15 Co (wt%)10

H10F

WET

DRY

EXC

ELLE

NT

NO

TR

ECO

MM

END

ED

TOUGHNESS GALLING RESISTANCE WEAR RESISTANCE CORROSION RESISTANCE

C3D

6UD

RS1TH11N

H15F

C3D

H3F

6UD

GO

OD

C3D

6UD

H3F

H6F

H6N

H6F

H10FH6F

H10F

H11N

H15F

H3F

C3D

6UD

RS1T

H15F

H6N/ H11N

H10F

H15F

H6N/ H11N

HYPERION CARBIDE GRADES

3131MATERIALS

MAT

ERIA

LS

Welding Wire

Sawing Wire

Tire Cord

Ø 9 mm 5 2.5 0.5 0.3 0.14 0.12 Ø 0.08 mm

DRY WET

H10F / H6N

H10F / H6N

H10F

H3F/6UD

H3F/C3D

H3F / 6UDH6F

H6F

H6F

PCD

RS1T

H3F/6UD

Standard

H11N

H15F

H6N

H10F

H6F

RS1T

H3F

6UD

C3D

1 20 3 54 6 7 98 10 11 12 1413 15 16 1817 2019 21 22 23 2524INNER DIAMETER (mm)

DRY

WET

Standard for large diameters d1 > 11 mm.

Cold drawn bars, tubes and shapes large diameters.

Dry drawing. Standard grade for d1 > 3 mm.

Dry drawing of tire cord, welding wire and high carbon wire.

Wet and dry drawing of welding wire, dry drawing tire cord. Standard grade for d1 > 3 mm.

Wet drawing of coated high carbon steels (Zn & brass). Dry drawing of stainless steel.

Wet drawing of high carbon, tire cord, welding wire and sawing wire.



Dry drawing. Standard grade for d1 > 3 mm.

Dry drawing of tire cord, welding wire and high carbon wire.

Wet and dry drawing of welding wire, dry drawing tire cord. Standard grade for d

Wet drawing of coated high carbon steels (Zn & brass). Dry drawing of stainless steel.RS1T

H3F Wet drawing of high carbon, tire cord, welding wire and sawing wire.


Wet drawing of coated high carbon steels (Zn & brass). Dry drawing of stainless steel.


CARBIDE GRADE APPLICATION EXAMPLES

3333MATERIALS

HYPERION 6UD

Hyperion 6UD is the high performance grade for fine wire wet drawing. It is an ultrafine cemented carbide in combination with special additives that maximizes corrosion resistance without loosing toughness. The Hyperion Sinter-HIP process guarantees premium carbide quality.

HIGH PERFORMANCE

Hyperion 6UD is used in high performance drawing processes for:- Saw wires- Tire cords - All ultra tensile wires - Finest wire diameters.

Hyperion 6UD prevents:- Corrosion wear- Friction- Wear in small bores.

Hyperion 6UD benefits include:- Increased die life- Less energy consumption- Longer batch sizes- Lower quality rods quality can be used.

HYPERION GRADE 6UD

GRADE PREVENTS

GRADE BENEFITS

PERFORMANCE CHART

Low Medium High

Wear resistance

Toughness

Corrosion resistance

Hardness

Available in standard ISO, JIS and DIN or tailor-made to your design.

MAT

ERIA

LS


HYPERION C3D

Hyperion C3D is the new super performance grade with never-before-seen properties for tungsten carbide. It is an ultrafine cemented carbide in combination with special additives that maximizes corrosion resistance and exhibits extreme wear resistance. The Hyperion sinter-HIP process guarantees premium carbide quality.

SUPER PERFORMANCE

Hyperion C3D is used in super performance drawing processes for:- Welding wire- Low and high carbon steel - PC strand.

HYPERION GRADE C3D

Hyperion C3D prevents corrosion and wear out by: - Very low Co leaching- Integrity of the carbide matrix ensures

the material wear resistance.

Performance improvements:- Die life increased up to 5 times vs those of standard grades- Less machine downtime- Lower quality rods can be used- High polishing speed.

GRADE PREVENTS

GRADE IMPROVEMENTS

PERFORMANCE CHART

Low Medium High

Wear resistance

Thermal conductivity

Corrosion resistance

Hardness


3535MATERIALS

HYPERION C3D SUPER PERFORMANCE


HYPERION C3D STANDARD GRADES

Corrosion testing with commonly used emulsions in the markets has shown the following results:

CORROSION RESULTS

HYPERION GRADE C3DHyperion C3D corrosion results:- Very low Co leaching- WC grain sharp edges - Integrity of the carbide matrix

ensures the material wear resistance.

STANDARD GRADESStandard carbides corrosion results: - Massive Co leaching- WC etched away leaving the Co exposure - Structure heavily attacked which could lead to grain drop out.

MAT

ERIA

LS


MAIN MATERIAL DEFECTSETA PHASE

RECRYSTALLIZATION

CARBON PRECIPITATION

- Definition: Wrong Carbon balance (lack of carbon) - Causes:

- Oxidation of the RTP before pressing- Oxidation of the green blanks awaiting for sintering- Low RTP Quality poor C control on the RTP manufactured process- Oxidizing atmosphere in the sintering furnace

- Effect: - Stress concentration point

- Solution: - Isolate the sintering trays with graphite protections.

- Definition: Heterogeneous WC grain size - Causes:

- Sintering process at too high temperature- Bad quality of the raw powder

- Effects: - Big WC grains could be pulled out easily by the wire material- Scratches in the wire surface or premature failure of the nib

- Solution: - Extreme control in the sintering parameters and the quality

of the ‘ready-to-press’ powder.

- Definition: Wrong carbon balance (excess of carbon) - Causes:

- Incorrect parameters in sintering process- Effects:

- Weak point in the material- Stress concentration point

- Solution: - Let oxidizing the more susceptible grades.

EXTRA FINE GRAIN

MEDIUM GRAIN

3737MATERIALS

MAIN MATERIAL DEFECTSPOROSITY

Co LAKE

- Definition (according to ISO4504): - PorosityA: pores < 10 µm- PorosityB: pores between 10 and 25 µm- Macroporosity: pores > 25 µm

- Causes: - Lack of force during pressing- Impurities or contamination of powder- Low sintering temperatures- Lack of vacuum/pressure during sintering- Not using HIP

- Effect: - Premature failure of die or scratches in the wire surface

- Solutions: - SinterHIP- RTP quality control.

- Definition: Co accumulation- Depending on the customer, Co accumulations can be up to 25 µm

- Cause: - Wrong sintering parameters

- Effects:- Weak point in the material - Stress concentration point.

MAT

ERIA

LS


MAIN MATERIAL DEFECTSCONTAMINATION• Definition:

- Traces of other chemical components (steel, organics, impurities, etc.)- Local grain size changes- Varying Co%, etc.

- Causes: - Impurities in the powder- Lack of cleanliness between production batches

- Effects: - Weak point in the material- Stress concentration point.

COMBINATION OF DEFECTS- Material defects never come alone- It is quite normal to find combinations of several defects in one sample- Hyperion quality controls 100% of the sintering batches.

* Hyperion superior quality in raw material powder and excellent process control are the basis for material consistency.

EXTRA COARSE GRAIN

CARBON

FINE GRAIN

3939MATERIALS

* Hyperion superior quality in raw material powder and excellent process control are the basis for material consistency.

HYPERION NIBS FOR WIRE DRAWING DIES

CARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD ISO

Hyperion cemented carbide drawing nibs are known for their impeccable geometry and unique and consistent grade composition. We offer not only a huge range of standard dimensions but also a superior quality in special designs.

10x8 to 20x17 NibISO

TOLERANCES FOR d2 AND h2

TOLERANCES FOR d1 d1 From To Tolerance

0.10 0.29 0/-0.03

0.30 0.49 0/-0.04

0.50 0.69 0/-0.05

0.70 0.99 0/-0.06

1.00 1.50 0/-0.07

1.51 3.00 0/-0.08

3.01 5.09 0/-0.09

CASING CHAMFER

h2 εº bz Tolerance

≤ 8 15º 12% h2 ±3% h2

10, 12, 13 15º 11% h2 ±3% h2

17 15º 8% h2 ±3% h2

l3 From To Tolerance

< 0.51 +0.25/0

0.51 1.02 +0.30/0

1.03 1.50 +0.40/0

1.51 2.50 +0.50/0

> 2.50 +0.60/0

TOLERANCES FOR 2α AND 2γ

Angle Tolerance

2α ± 1º

2γ ± 5º

* Faces will not be ground.

Nibd2 x h2

As Sintered d2 h2

Ground*d2

Nominal Tolerance Nominal Tolerance Nominal Tolerance

10x8 9.65 ±0.15 8.00±0.20

9.55 +0.015/0

12x10 12.00 +0.040/+0.010 10.00 12.00

+0.018/014x12 13.91 ±0.10 12.00

±0.30

13.70

16x13 15.80 ±0.15 13.00 15.54

20x17 19.75 ±0.15 17.00 19.50 +0.021/0

TOLERANCES FOR l3(nibs with round bearing)

MAT

ERIA

LS


HYPERION NIBS FOR WIRE DRAWING DIESCARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD ISO

NIB ORDERING CODE

d2 x h2 Code / Grade 2α d1 l2 l3 l4 2β R ∅E 2γ

10x8 WDINR10...126F / H6F 12º

0.20 0.601.201.301.401.501.601.701.80

0.250.70

_______

0.300.80

_______

0.350.90

_______

0.401.00

_______

0.501.10

_______

0

1.801.801.751.661.731.751.601.661.55

5.75.75.7555

5.24.74.8

6.86.87.17.17.17.17.36.97.1

90º

12x10 WDINR12...126F / H6F 12º1

0.650,25

0.90.60.2

0.80.5_

0.750.4_

0.70.3_

___

1.9522

8.68.98.9

8 90º

14x12 WDINR14...126F / H6F 12º

0.600.901.001.101.201.301.701.802.452.60

0.70____

1.40_

1.90_

2.90

0.80____

1.50_

2.00__

_______

2.20__

_______

2.40__

__________

0

2.402.582.402.592.402.552.532.403.212.40

10.510.310.510.310.51010

10.510

10.5

101010

10.210101010

10.410

75º

16x13

WDINR16...12F / H6F 12º

0.250.350.400.700.800.901.101.301.501.601.902.252.402.803.40

0.30_

0.45__

1.001.201.40

_1.70

__

2.50__

__

0.50____________

__

0.55____________

__

0.60____________

_______________

0

3333333

2.902.902.902.902.85

333

10.610.610.610.610.610.310.31010109.79.79.29

8.6

12.112.212.312.512

12.212.412

12.212.312

12.412

11.711.8

75º

WDINR16...14F / H6F 14º 2.502.60

__

__

__

__

__ 0.64

0.663.13

38

8.111.712 75º

WDINR16...16F / H6F 16º 3.00 _ _ _ _ _ 0.78 3.12 7.7 11.7 75º

WDINR16...16F / H6F 16º 3.97 _ _ _ _ _ 0.99 3 8.1 13.4 75º

20x17 WDINR20...12F / H6F 12º

0.700.800.901.001.101.301.401.601.802.002.402.652.703.053.203.60

____

1.20___________

________________

________________

________________

________________

0

4.254.254.254.24.24.24.24.2

4.154.14.1

4.054.05

444

13.513.513.513.213.213.213.213.212.912.612.612.312.31212

11.7

15.115.215.314.915

15.215.315.515.114.815.214.915

14.815

14.9

60º

With outer diameter as sintered or ground. All dimensions in mm.


4141MATERIALS

HYPERION NIBS FOR WIRE DRAWING DIESCARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD JIS

NIB ORDERING CODE


9x6 WDJNR09...12M / H3F 12º

0.100.120.150.160.170.200.210.250.260.270.340.550.851.001.20

_0.13

__

0.18_

0.22__

0.280.350.600.901.101.30

_0.14

__

0.19_

0.23__

0.290.400.65

__

1.40

______

0.24__

0.300.450.70

__

1.50

_________

0.320.500.75

___

_________

0.33_

0.80___

1.0

0 1.0 _

5.0

6.26.06.26.06.16.26.16.26.16.26.2

90º

1.71.71.72.6

3.96.66.67.07.0

12x8

WDJNR12...12M / H3F

12º

0.500.80

0.550.85

0.600.90

0.650.95

0.70_ 0.75_ 6.8(l1 + l2)

0 _ _ 5.2 8.1+d1_

WDJNR12...12B / H3F

1.001.50

1.051.60

1.10_ 1.20_ 1.30_ 1.40_ 5.9(l1 + l2)

0.9

_ _

4.07.1+d1

_

1.70 1.80 1.90 _ _ _5.7

(l1 + l2)1.1

3.92.00 _ _ _ _ _

3.38.5

2.10 _ _ _ _ _ 5.5 (l1 + l2) 1.3 6.5+d1

WDJNR12...16M / H3F

16º

0.500.90

0.550.95

0.60_ 0.70_ 0.75_ 0.80_ 6.8(l1 + l2)

0 5.4 8.1+d1

WDJNR12...16B / H3F1.70 1.80 1.90 _ _ _

5.7(l1 + l2)

1.14 7.1+d1

2.00 _ _ _ _ _3.5

8.02.10 _ _ _ _ _ 5.5 (l1 + l2) 1.3 6.0+d1

0.10

0.15

0.170.20

0.25

0.550.35 0.40 0.45

1.001.20 1.50

0.600.901.10

0.800.700.50

0.30

15x10

WDJNR15...12M / H6F

12º

0,500,90

0,70_

0,75_

0,80_

__

__ 8.5

(l1 + l2)0

_ _

6.5 10.6+d1

_

WDJNR15...12B / H6F

1,001,602,002,102,603,003,10

1,101,70

_

2,202,70

__

1,201,80

_

2,302,80

__

1,301,90

_

2,40___

1,40__

2,50___

1,50______

7.6 (l1 + l2)0.9

5.2 9.7+d17.4

(l1 + l2)1.1

4.610.6

7.2 (l1 + l2) 1.3 8.7+d17.1

(l1 + l2)1.4

4.110.6

6.9 (l1 + l2) 1.6 7.6+d1

WDJNR15...16B / H6F 16º

1,602,002,102,603,003,103,604,004,104,60

1,70_

2,202,70

_

3,203,70

_

4,304,70

1,80_

2,302,80

_

3,303,80

_

4,404,80

1,90_

2,402,90

_

3,403,90

_

4,50_

__

2,50__

3,50____

__________

7.4(l1 + l2)

1.1

4.811.5

7.2 (l1 + l2) 1.3 8.7+d17.1(l1 + l2)

1.4

4.310.7

6.9 (l1 + l2) 1.6 7.7+d16.7

(l1 + l2)1.8

4.610.6

6.5 (l1 + l2) 2.06.6+d16.6 (l1 + l2) 2.2

20x14 WDJNR20...16B / H6N 16º

1,702,002,102,603,003,103,604,004,104,605,005,206,00

1,80_

2,202,70

_3,203,70

_4,204,70

_5,40

_

__

2,302,80

_3,303,80

_4,304,80

_5,50

_

__

2,402,90

_3,403,90

_4,404,90

___

__

2,50__

3,50__

4,50____

_____________

11.0 (l1 + l2) 1.1

_ _

8.1 13.7+d1 _10.6(l1 + l2)

7.6 12.7+d11.3

1.4

75º10.2(l1 + l2)

7.1 11.7+d11.6

1.8

7.3 10.7+d12.0

2.2

7.9 9.6+d12.32.5

9x6 to 20x14 NibJIS

MAT

ERIA

LS


HYPERION NIBS FOR WIRE DRAWING DIESCARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD DIN

NIB ORDERING CODE


12x10

WDSNR12...12M / H6F 12º

_

0.350.40

0.20_

0.50

0.30_

0.60

__

0.70

__

0.80

__

0.902.9 0

2.12.22.1

90º 6.57.06.87.0

90º

WDSNR12...14M / H6F 14º

1.001.601.802.40

1.101.701.902.50

1.20_

2.00_

1.30_

2.10_

1.40_

2.20_

1.50_

2.30_3.6 0 1.9 90º 6.5

7.67.68.28.2

90º

16x13

WDSNR16...08M / H6F 8º

0.700.800.901.001.101.201.30

____

1.15_

1.50

_______

_______

_______

_______

2.82.82.83.42.8

3.642.8

0

2.62.72.62.52.62.52.6

60º 8.0

8.58.08.57.98.57.88.5

75º

WDSNR16...12M / H6F 12º

0.200.601.001.601.702.903.603.80

0.300.701.10_

1.80___

0.400.801.20_

1.90___

0.500.901.30_

2.10___

__

1.40_

2.25___

__

1.50_____

2.53.03.33.33.63.94.54.0

0

2.92.92.62.62.62.32.32.3

60º 8.0

8.28.28.78.78.7

10.010.010.0

75º

WDSNR16...14M / H6F 14º 1.001.60

1.101.70

1.20_ 1.30_ 1.40_ 1.50_ 3.4 0 2.6 60º 8.0 8.7 75º

WDSNR16...14B / H6F 14º1.802.302.90

1.902.40_

2.002.50_

2.102.60_

2.202.70_

_

2.80_

3.02.82.8

50% d1

2.3 60º 8.0 9.3 75º

WDSNR16...16B / H6N 16º

3.003.604.204.80

3.203.804.405.00

3.404.004.605.20

____

____

____

3.5

1.51.61.71.8

2.3 60º 8.0 10.5 75º

0.20 0.30

0.40 0.50 0.60

1.00 1.10 1.201.601.80 2.00 2.20

1.70

0.70 0.80 0.90

1.30 1.40 1.50

0.20

0.70

0.90

0.601.001.601.70 1.80 1.90 2.10 2.25

1.10 1.20 1.30 1.40 1.50

1.00

3.00

4.203.60

4.80

1.60

2.302.90

2.502.40 2.60 2.70 2.80

1.70

1.901.80 2.00 2.10 2.20

1.10

1.30 1.50

1.15

0.30

1.10

3.20

4.403.80

5.00

0.40

1.20

3.40

4.604.00

5.20

0.50

1.30 1.40 1.50

0.70 0.80 0.90

20x17

WDSNR20...12M / H6N 12º

1.201.402.003.053.954.254.90

1.301.50_

3.20_

4.40_

_

1.60_

3.35_

4.55_

_

1.802.603.50_

4.70_

__

2.703.65_

__

__

2.90____

4.95.77.06.46.47.26.2

0

3.93.93.13.13.13.1

3.97

60º 8.0

10.410.410.412.312.312.312.5

60º

WDSNR20...14B / H6N 14º

1.802.002.503.003.65

__

2.60_

3.85

_

2.202.70_

_

_

2.302.80_

_

_

2.40___

_____

5.66.25.85.05.0

50% d150% d150% d1

1.51.6

3.52.82.82.82.8

60º 8.0

10.310.310.312.212.2

60º

WDSNR20...16B / H6N 16º

3.203.604.205.006.007.207.40

3.403.804.405.206.20_

7.60

_

4.004.605.406.40_

7.80

__

4.805.606.60_

_

___

5.806.80_

_

____

7.00__

5.35.76.26.26.26.26.2

1.51.61.71.82.02.02.0

2.8 60º 8.0

12.212.212.213.013.813.815.2

60º

1.802.002.50

5.00

7.206.00

7.40

4.20

3.00

3.60

3.65

3.20

2.202.70

5.406.40

7.80

4.604.00

2.60

5.206.20

7.60

4.403.80

3.85

3.40

2.302.80

5.606.60

4.80

2.40

5.806.80 7.00

1.201.402.003.053.954.25

1.301.50 1.60

3.20

4.40 4.55 4.70

3.35 3.50

1.802.60 2.70 2.90

12x10 to 30x24 NibDIN

4343MATERIALS

CARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD DIN

With outer diameter as sintered or ground. All dimensions in mm. Standard HYPERION stock

NIB ORDERING CODE


25x20

WDSNR25...12M / H6N 12º

2.202.402.602.803.003.253.653.80

________

________

________

________

________

6.777

7.55.87.57

6.5

0 4.2 60º 8.0

12.812.812.812.812.812.814

14.5

60º

WDSNR25...16B / H6N 16º

3.804.004.404.80_

_

5.806.207.007.608.60

_

4.20____

6.006.40_

7.808.80

____

5.40__

6.607.408.009.00

_______

6.80_

8.20_

_________

8.40_

___________

5.35.66.54.95.95.96.96.36.86.87.8

1.51.61.61.71.71.81.82.02.02.02.0

4.04.04.04.04.04.03.73.73.43.43.4

60º 8.0

14.515.015.015.015.015.015.016.316.317.317.3

60º

30x24 WDSNR30...16B / H6N 16º

2.502.803.203.503.804.004.204.404.605.00_

6.006.807.407.80_

8.80_

9.6010.00_

_

11.80

_________

5.205.80_

_

7.60__

9.00__

10.20_

11.4012.00

___________

6.40___

8.60_______

___________

6.60________

11.00__

_______________________

_______________________

5.806.405.806.305.805.706.005.207.008.47.46.98.49.08.19.3

10.411.29.5

10.09.6

10.69.9

1.61.61.61.61.61.61.61.61.61.71.82.02.02.02.02.02.02.02.22.22.32.42.4

6.15.85.85.65.45.25.25.04.84.64.64.64.64.64.64.64.64.64.64.64.64.64.6

60º 8.0

14.915.016.016.017.017.517.517.517.517.218.718.718.718.718.718.718.718.719.819.821.221.221.2

60º

4.40

5.806.207.00

6.40 6.607.40

6.806.00

5.40

7.608.60

5.005.80

6.006.807.407.80

10.00

8.80

9.60

11.80

10.20

11.40

9.00

12.00

11.00

8.60

7.60

6.40 6.60

5.20

4.80

3.00

4.003.80

2.20

8.009.00

7.808.80

4.20

8.20 8.40

HYPERION NIBS FOR WIRE DRAWING DIES

MAT

ERIA

LS


HYPERION NIBS FOR WIRE DRAWING DIESLARGE STANDARD NIBS

CASING CHAMFER

TOLERANCES FOR d2 AND h2

Nibd2 x h2

d1 (recommended)nominal

Grade Available

min. max.

35x24 12 16 H6N / H11N

40x24 15 19 H6N / H11N

45x25 18 22 H6N / H11N

50x25 21 25 H6N / H11N

55x27 24 28 H6N / H11N

60x27 27 31 H6N / H11N

65x27 29 34 H6N / H11N

Nibd2 x h2

d1 (recommended)nominal

Grade Available

min. max.

70x30 32 37 H11N

75x30 35 41 H11N

80x30 39 45 H11N

85x33 43 49 H11N

90x33 47 53 H11N

100x35 51 61 H11N

TOLERANCES FOR d2 TOLERANCES FOR l3

l3 From To Tolerance

< 1.02 +0.15/-0.15

1.03 1.50 +0.20/-0.20

1.51 2.50 +0.25/-0.25


Angle Tolerance

2α ± 1º

2γ ± 5º

(nibs with round bearing)

d1 From To Tolerance

0.10 0.29 0/-0.03

0.30 0.49 0/-0.04

0.50 0.69 0/-0.05

0.70 0.99 0/-0.06

1.00 1.50 0/-0.07

1.51 3.00 0/-0.08

3.01 5.09 0/-0.09

5.10 7.09 0/-0.10

7.10 10.14 0/-0.12

10.15 12.00 0/-0.15

CARBIDE GRADE PROPERTIESCarbide Grade Co (%wt) Hardness (HV30) Density (g/cm3) WC Grain Size

6UD 6 2050 14.75 Ultrafine

H3F 3 1925 15.30 Extra fine

H6F 6 1775 14.90 Extra fine

H6N 6 1600 15.00 Fine

H10F 10 1600 14.50 Extra fine

H11N 11 1250 14.40 Fine

H15F 15 1380 13.95 Extra fine

Nibd2 x h2

As Sintered d2 h2

Ground*d2

Nominal Tolerance Nominal Tolerance Nominal Tolerance

9x6 9.00 +0.25/+0.05 6.00±0.20

9 +0.015/0

12x10 12.00 +0.32/+0.12 10.00 12.00+0.018/0

16x13 16.00 0/-0.30 13.00±0.30

15.65

20x17 20.00 +0.10/-0.30 17.00 19.65

+0.021/025x20 25.00 +0.50/+0.10 20.00±0.40

25.00

30x24 30.00 +0.60/+0.20 24.00 30.00

* Faces will not be ground.

Nib Height of Chamfer, bz

d2 x h2 εº Nominal Tolerance

9x6

15º

1.3 +0.15/-0.15

12x10 1.1 +0.30/-0.30

16x13 1.5 +0.30/-0.30

20x17 1.5 +0.30/-0.30

25x20 2.1 +0.30/-0.30

30x24 20º 2.4 +0.40/-0.40

4545MATERIALS


WEAR PARTSENGINEERED PRODUCTSTailor-made according to your drawing. Fully finished parts ready-to-use or blanks are available.

- Straightening rollers- Wire guides- Cabling dies- Shaving dies- Die blanks with starter holes- Plugs and mandrels- Injection nozzles / extrusion tools- Calibrating pins - Gauges / measuring pins? - Flattening rollers- Profiling rolls.

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SHAVING DIES

-Y0 +Y0

β0

α0

WC shaving dieSteel housing

Chips

D (mm) H (mm) d (mm) 2a (º) 2b (º) 2g (º) GRADE

16,18+/-0,01 7,4+/-0,12 5,95 13 18 0 MP1016,18+/-0,01 7,4+/-0,12 5,35 13 18 0 MP1016,18+/-0,01 7,4+/-0,12 6,95 13 18 0 MP1016,18+/-0,01 7,4+/-0,12 7,95 13 18 0 MP1016,18+/-0,01 7,4+/-0,12 3,95 13 18 0 MP1016,18+/-0,01 7,4+/-0,12 4,35 13 18 0 MP1016,18+/-0,01 7,4+/-0,12 3,60 13 18 0 MP1016+0,7/+0,3 12+0,6/0,3 5,35 13 18 0 ES3516,19+/-0,01 7,0+0,55/+0,3 5,80 13 18 0 ES3516,19+/-0,01 7,0+0,55/+0,3 7,40 13 18 0 ES3516,19+/-0,01 7,0+0,55/+0,3 6,40 13 18 0 ES3516,19+/-0,01 7,0+0,55/+0,3 8,40 13 18 0 ES35

Pr

SHAVING DIE ANGLE

Pr Tool reference plane±Y0 Tool orthogonal chip angle

β0 Tool orthogonal key angleα0 Tool orthogonal clearance angle

Draw-peeling – also known as shaving – is a cutting procedure. The cutting edge in this case is a draw-peeling tool/shaving die. This is a static tool with a circular blade. The geometry is similar to that of a regular drawing die in the wire industry. The main difference is that, in contrast to the transformative geometry of the drawing die, there is a cutting edge in the draw-peeling tool. A descaling and a coating that is usually required for steel wire is not necessary in front of this cutting operation.

Shaving operation shall guarantee:- To remove continuously a uniform thickness of metal - At high speed- Separating the removed layer into a plurality of strips and said strips being removed radially from the rod - Produce a smooth surface thereon.

Hyperion offers a wide range of shaving rough blanks made of two Cemented Carbide grades MP10 and ES35.

4747MATERIALS

SLURRY FORMULAS SUSPENSION FORMULAS

K285T Water soluble K285T Water solubleK400 Oil soluble K1500 Oil solubleK450 Water / Oil soluble

DIAMOND POWDERS DESCRIPTION SUGGESTED APPLICATION INDUSTRY

SJK-5 A monocrystal, diamond powder used in slurries and suspensions Lapping

AerospaceCeramics

GlassLensesOptics

SapphireSemi-conductorSilicon carbide

Tungsten carbide

RJK-1 A multi-crystal, more friable than a monocrystal Lapping and polishing

Poly Polycrystalline diamond available in sizes < 10 μm Polishing

HYPERION DIAMOND COMPOUNDSSLURRIES

DIAMOND SIZE AVAILABILITY

LIGHT CONCENTRATION MEDIUM CONCENTRATION HEAVY CONCENTRATION

Finishing

125 mL 500 mL 1 gallon250 mL 1.000 mL 5 gallon bucket

Removal

Micron0-1/2

Mesh100.000

Micron1-3

Mesh11,000

Micron4-8

Mesh3.000

Micron0-2

Mesh14.000

Micron3-5

Mesh6.500

Micron6-12

Mesh1.800

Micron20-30

Mesh800

Micron30-60

Mesh400

Micron8-12

Mesh1.700

Micron20-40

Mesh575

Micron50-70

Mesh270

Micron0-1

Mesh60.000

Micron2-4

Mesh8.000

Micron5-10

Mesh2.500

Micron10-20

Mesh1.200

YOU CHOOSE THE FORMULA

YOU CHOOSE THE CONCENTRATION

YOU CHOOSE THE CONTAINER SIZE

WE ADD SUPERIOR DIAMOND POWDERS

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1/4m

icron

0-1/2

mes

h 100.0

00

4m

icron

3-5

mes

h 6.50

0

15m

icron

10-20

mes

h 1.20

0

1/2m

icron

0-1

mes

h 60.00

0

6m

icron

4-8

mes

h 3.00

0

25m

icron

20-30

mes

h 600

1m

icron

0-2

mes

h 14.00

0

7.5m

icron

5-10

mes

h 2.50

0

30m

icron

20-40

mes

h 575

2m

icron

1-3

mes

h 11.00

0

9m

icron

6-12

mes

h 1.80

0

45m

icron

30-60

mes

h 400

3m

icron

2-4

mes

h 8.00

0

10m

icron

8-12

mes

h 1.70

0

60m

icron

50-70

mes

h 270

HYPERION DIAMOND COMPOUNDSPASTES: DIAMOND POWDER + CARRIER

PRODUCT IDENTIFICATION DESCRIPTION RECOMMENDED USES

K700 WS Products Water soluble- When exceptional cleaning is required- When petroleum contamination is prohibited- Specimen preparation

K210 OS Products Oil soluble- Controlled lapping for carbide drawing dies

and cold heading dies- Numerous other polishing applications

G400 WOS Products Water / Oil soluble- Compliments the use of oil and water for achieving

more productive results- Facilitates cleaning

5 gram

5 gram

18 gram

50 gram

50 gram

200 gram

10 gram

25 gram

25 gram

100 gram

TUBE SIZES

JAR SIZES

4949MATERIALS

HYPERION DIAMOND COMPOUNDSDIAMOND MICRON POWDER GRADESHYPERION SLURRY

GRM DIAMOND

DIAMOND (FOR COMPOUND MANUFACTURING)

Retains sizeMaintains effectivenessReadily availableNot easily crushed

HYPERION DIAMOND

GRM (Standard Grade) UNCOATED

Few cutting points

Susceptible to crushing

Becomes smaller with use

Limited availability

MONOCRYSTALLINE MICRON DIAMOND

POLYCRYSTALLINE MICRON DIAMOND

Hyperion slurry is comprised of diamond particles containing more surface cutting points than a typical monocrystalline micron and polymicron diamond.

Hyperion slurry achieves higher material removal rates and better surface finish due to the surface characteristics of the diamond.

The diamond surface is covered with small cutting points, which reduce surface roughness of the workpiece.

In addition to the diamond characteristics, the slurry formulation can be tailored to optimize performance for specific operating conditions and workpieces.

GRM diamond satisfies a broad range of size, shape and surface demands while providing a satisfactory surface finish. GRM diamond is a desirable option if tight tolerances are not mandatory.

APPLICATIONSPolishing of wire dies, stones and gems.

DIAMOND SIZES AND STANDARDS

- Standard size offering ranges from 0.5 μm to 80 μm (mean size)- Available in metal or resin bond diamond grades- Sold in 50 to 5,000 carat containers- Custom particle size distributions are available upon request.

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APPLICATIONS & FAILURE MODES


APPLICATION KNOWLEDGE

HYPERION

PCD

Hyperion offers a wide range of premium products for the wire drawing industry, from polycrystalline diamond (PCD) and carbide blanks to rough core dies and diamond compounds.

TUNGSTEN CARBIDESteel cord for rubber reinforcement, sawing wire, bead wire, welding wire, galvanized wire, stainless steel, spring wire, etc.

Stainless steel, welding wire, sawing wire, tire cord, electrical wire and medical wire applications.

VERSIMAX™ AND VERSIRION™

Hyperion’s Versimax and Versirion are unique solutions for drawing and compacting applications for various ferrous and non-ferrous materials.

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5353APPLICATIONS & FAILURE MODES

CUSTOMER COST SPLIT

COST SPLIT FOR STEEL CORD

60%25%

7%3%5% 0.5%

Rod material

Power (water, gas & electricity)

Packaging & transport

Drawing dies

Others

Auxiliary material (lubricants, etc.)


RADIAL CAR TIRE COMPOSITION (WEIGHT)

RADIAL TIRE COMPOSITION

Nylon Overlays Gum StripsUndertread

Belt Wedge

Sidewall

Cushion

Body Plies

Halobutyl Liner

Apex

Toe Guard

Beads

ChaferPly Turn Up

Steel Belts

Tread

22%

29%

25%

6%

10%

3%5%

Natural rubber

Synthetic rubber

Reinforcing agent

Textile cord

Bead wire

Ingredients

Steel cord

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PCD APPLICATION GUIDELINE

WIRE DRAWING APPLICATION GUIDELINES

WIRE TYPEWIRE AREAWIRE SIZE

Range (mm)

PERCENT REDUCTION

DIE GEOMETRYDRAWING

SPEED(m/min)

RELATIVE PERFORMANCE

VERSUS

REDUCTIONANGLE

BEARINGLENGTH

(%)

TUNGSTENCARBIDE

SINGLE CRYSTAL

DIAMOND

NON-FERROUS• Copper

• Aluminum

• AluminumMagnesium Alloy

• Tin-Plated Copper(electroplated)

• Nickel 200• Tungsten• Molybdenum

1.84 - 7.600.05 - 2.051.84 - 7.600.20 - 2.05

1.84 - 4.760.20 - 1.80

0.33 - 1.650.12 - 0.620.12 - 1.02

20 - 3518 - 2118 - 3015 - 21

18 - 2215 - 26

20 - 3018 - 2218 - 22

16 - 2516 - 2016 - 2516 - 20

16 - 2018 - 22

16 - 2012 - 1612 - 16

10 - 2510 - 2510 - 2510 - 25

15 - 3010 - 25

15 - 3020 - 4020 - 40

600 - 2500600 - 3300600 - 1500600 - 2000

350 - 650300 - 1000

200 - 50030 - 8030 - 80

200 - 500X-

100 - 200X-

100 - 200X100 - 200X

--

50 - 80X

-5 - 15X

-3 - 5X

-5 - 10X

6 - 10X3 - 6X3 - 6X

FERROUS• Galvanized High

Carbon Steel• Brass-Plated High

Carbon Steel Tire Cord• Stainless Steel 316• Stainless Steel 302• Ni-Cr-Fe Alloy

(60:15:25)• Low Carbon Steel

0.24 - 1.05

0.17 - 0.400.18 - 1.600.24 - 1.600.20 - 1.20

0.88 - 2.10

15 - 20

18 - 2118 - 2118 - 2118 - 26

18 - 21

10 - 14

10 - 1610 - 1410 - 1410 - 14

8 - 14

20 - 40

20 - 4020 - 4020 - 4020 - 40

20 - 40

400 - 800

600 - 1000200 - 600200 - 600200 - 600

400 - 800

30 - 50X

10 - 30X10 - 20X8 - 15X30 - 50X

30 - 70X

-

-4 - 8X2 - 4X4 - 6X

-

Dimensional recommendation for round standard nibs:

MATERIAL DRAWING CONDITIONS

PERCENTAGE OF REDUCTION

5-8 8-12 12-16 16-25 25-35 35-45

• Lead• Zinc• Aluminum• Silver• Gold

Dry - - - - - -

Wet 14º 16º 18º 21º 24º -

• Cupper• Stainless Steel

Dry - - - - - -

Wet 12º 14º 16º 19º 22º -

• Aluminum Alloys• Nickel• Ni-Cr Alloys

Dry - - - - - -

Wet 10º 12º 14º 17º 20º -

• Brass• Bronze• Nickel-Silver• Non Alloyed Carbon

Steels (%C<0,4)

Dry 7º 9º 11º 14º 17º 20º

Wet 9º 11º 13º 16º 19º -

• Non Alloyed CarbonSteels (%C<0,4)

• Alloyed Steels• Ni-Cr Alloys for

electrical resistances • Molibdenum

Dry 6º 8º 10º 12º 15º 18º

Wet 8º 10º 12º 15º 18º -

• Tungsten Dry 10º 10º 12º 12º 14º -

NIB CASE

d2 h2

d1 sl4 2β 2γ d3 h3 l5

min max min

8 4 0,1 1 3,5 1

90º 90º 28

12

310 8 0,2 2 4 2 16

12 10 0,3 3 4,5 2,5 20

14 12 0,4 4 5 360º 75º

2822 3

43

16 13 0,5 5 5,5 3,5 43 25 4

20 17 1,5 6,5 6,75 4,5

60º 60º

43 325

25 20 2,5 9 8 553

3575

30 24 3,5 12 9 6 75 40 6

Dimensions in mm unless otherwise noted.


WC APPLICATION GUIDELINE

Dimensional recommendation for round standard nibs:

CAR

BID

E

STEE

L CA

SIN

G

DIRECTION OF SLOW CRACK

GROWTH

WIRECAP

PCDCORE

WIREENTRY

WIREEXIT

FRACTURE INITIATION


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PCD BEST PRACTICES- Recut or repolish die on observation of wear ring in area of wire contact to maximize die life.

- Filtrate lubricant to remove metal fines to maximize lubricant flow, wire finish and die life.

- Do not exceed maximum die size recommendation for blank size.

- Decrease bearing length for higher speed drawing.

- Use finer grain die blanks for improved wire surface finish and in drawing ferrous and plated wires.

- Use coarser grain die blanks for drawing larger size non-ferrous wire to provide longer die life and improved wire dimensional control.

- In high temperature drawing of tungsten and molybdenum wire, maintain reducing atmosphere in drawing zone to minimize detrimental oxidation effects and maximize die life.

- Use matched elongation die sets in multi-wire drawing machines.

VISIBLE EFFECTS NOMINAL CAUSE POSSIBLE SOLUTIONS


CARBIDE BEST PRACTICES

FAILURE MODE DRAWING DIES

- Ensure correct wire section reduction by calculation. Verify actual wire reduction vs theoretical.

- Consistency in the die set drawing progression.

- Back relief between the hearing and the exit prevents wire production against machine vibration and spring back.

- Use the correct cemented carbide in accordance with the type of drawing process, wire material and reduction.

- Use harder grades for fine wire diameters, and tougher grades for big diameters and big reduction.

- Do not exceed maximum base size recommendation per nib size. Recutting more than 10 times must be avoided.

- Every recut must ensure that any wear ring or mark from previous drawing process is removed.

- Hot casing gives the end user high and tight range of pre-stresses, close contact case ID and nib, and better balance of radial and axial pre-stresses.

VISUAL EFFECTS. DIE ANALYSIS

FAILURE CAUSES

To be taken into consideration when die failure analysis:

- Cause of failure is never absolute. Several factors play together, interacting and creating confusing effects.- It is advisable to judge based in several dies assessment.

Die breakage is usually caused by:

- Lack of mechanical support for the insert (hoop failure).

- Abnormal reduction.

- Inadequate lubrication.

- Inadequate tool material for the amount of reduction and speed (too hard or too tough).

- Tool misalignment, miscoaxiality, etc.

Some wear resistance must be always sacrificed to minimize breakage.


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PCD FAILURE MODE ANALYSISHyperion has over 30 years of experience in PCD and cemented carbide wire dies. Hyperion provides the customers with full root-cause analysis for the failures in wire drawing dies.

Hyperion has a fully equipped Materials Analysis Laboratory to investigate failures and determine the failure mode. We provide our customers with a full report containing possible root cause and failure mode and possible solutions based on the findings. We also provide supporting data in terms of micrographs and physical, chemical and mechanical dimensional properties information.

Below are some of the typical failures we find in the Compax® wire dies.

Wear ring, which is normally located at the bottom of the reduction area near the top of the bearing area, is caused by lubrication interruption, erosion due to rise in temperature and back conversion of diamond at grain boundaries.

Thermal Damage is a typical mode of failure when clogging at the entrance of the die leads to a sudden increase in the temperature leading to failure.


PCD FAILURE MODE ANALYSISDIE OR BLANK MISALIGNMENT

VERTICAL STRESS CRACKS

VISIBLE EFFECTSDie fractures in a slight U-shaped pattern.

NOMINAL CAUSEDie blank is not resting flat against the steel casing.The blank is not level when an uneven compression load is applied across the diamond surface. Mechanical stress force is applied to one side of the die blank creating a bending moment.

POSSIBLE SOLUTIONEnsure blank is well aligned when assembled on the case.

VISIBLE EFFECTSEqually spaced large vertical cracks. Usually more than two cracks.

NOMINAL CAUSEExcessive mechanical and/or thermal forces being applied to the diamond core. It is being stretched during the wire drawing application or the sizing process.

POSSIBLE SOLUTIONSGood wire reduction design, controlled brazing process between PCD blank and core, lubrication control, etc.

6161

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PCD FAILURE MODE ANALYSISLASER DAMAGE

HORIZONTAL CRACKS

VISIBLE EFFECTSThe die blanks have enlarged grain bounders, pits, crystal pullout, porosity, and small fractures through the diamond cores.

NOMINAL CAUSEThermal stresses applied during the laser process and/or during the mounting operation.

POSSIBLE SOLUTIONSImprove the laser program and machine maintenance.

DESCRIPTIONCracks travel around the bore diameter.

CAUSES- Development of wear ring serving as a stress riser.- Gaps in braze alloy after sintering cause mechanical stress.- Gaps from press fit cause mechanical stress.- Nib abrading steel casing during mounting operation.- Overheating during laser drilling or sintering process.

Wear ring generated during wire drawing process (possible lubrication interruption).

Thermal stress cracks induced during mounting operation.


CORRECT

Compax Diamond Blank Core

Tungsten Carbide Ring

INCORRECT

Compax Diamond Blank Core

Tungsten Carbide Ring

Metal Build-up


TEMPERATURE GENERATED DURING DRAWING

CARBIDE QUALITY

30ºC40ºC

50ºC

70ºC

100ºC

100ºC150ºC200ºC

300ºC

400ºC540ºC

x10x1

x50

HYPERION OTHERS

During drawing there are two primary sources of heat:- Plastic deformation- Friction- Temperature distribution inside the die varies according to many factors, such as:

- Type of material- Percentage of reduction- Lubrication- Geometry of die

Between 25 and 45% of the drawing energy is lost as heat.

Hyperion drawing nibs are known for their impeccable geometry:

- Our high precision nibs provide tight dimensional tolerance and perfect coaxiality and meeting point, even for the smallest diameters.

- Reduced grinding stock and profile quality improves grinding and polishing operation.

6363

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CARBIDE DIES FAILURE MODE ANALYSIS


Hyperion collaborates with our customers to provide a complete solution from grade selection to failure mode analysis and continuously works to provide better performing products to improve the e®ciency.

HOOP FAILURE can be identified by crack runs lengthwise through the nib. Casing balances the tensile stresses over the carbide nib due to drawing forces. Failure is caused when the force required to deform the wire is greater than the strength of the die material and its mounting. Close casing with absence of oxides and cavities is advised.

BURST DIE is a result of circumferential crack at the bottom of the wear ring propagates by splitting the nib in two (also breakage can be in the form of a cone). It usually occurs when a die is left in the machine too long and the stress concentration makes that the wear ring became too deep. It is easily noticeable because the crack evolution is in the radial direction.


CARBIDE DIES FAILURE MODE ANALYSISBURST DIE

BACK CHIPPING

VISIBLE EFFECTSCircumferential crack at the bottom of the wear ring propagates by splitting the nib in two (also breakage can be in the form of a cone).

NOMINAL CAUSEIt usually occurs when a die is left in the machine too long and the stress concentration makes that the wear ring became too deep. It is easily noticeable because the crack evolution is in the radial direction.

POSSIBLE SOLUTIONSMost tension failures can be avoided with a good die maintenance program.

VISIBLE EFFECTSShows chipping in the intersection of the bearing and the back relief.

NOMINAL CAUSECaused by an improperly shaped back relief.

POSSIBLE SOLUTIONSCan be easily repaired by removing the edge of the intersection.

6565

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CARBIDE DIES FAILURE MODE ANALYSIS


ABRASIVE WEAR

ATTRITION WEAR

VISIBLE EFFECTSScratches that run the full length of the working zone of the nib in the direction the wire is drawn.

NOMINAL CAUSEWire surface irregularities remove material from the nib. The WC pulled out material can cause a groove that wears from below the wear ring through the rest of the nib.

POSSIBLE SOLUTIONSAdvisable to check the lubrication quality and wire surface defects.

VISIBLE EFFECTSDull appearance of the working cone in the first stages of the wearing process and same effects of the abrasion wear when the wearing is in advanced status.

NOMINAL CAUSEWell defined particles from nib surface are pulled out because bonding between the particle and the wire.

POSSIBLE SOLUTIONSChoose best nib grade according to the wire material to be drawn. Improve lubrication as much as possible.


WIRE DEFECTSSURFACE DEFECTS

VISIBLE EFFECTSInsu®cient amount of lubricant on the wire surface.

NOMINAL CAUSEWrong lubricant selection and lack of cooling and speed.

VISIBLE EFFECTSLongitudinal scratches and absence of carrier.

NOMINAL CAUSEDamage on the reduction cone or bearing. Wire material stuck on the die inner profile. Lack of lubrication.

VISIBLE EFFECTSGlobs and pitting.

NOMINAL CAUSEGlobs from annealing furnaces and pitting from electrolytic baths.

VISIBLE EFFECTSFlakes and pitting.

NOMINAL CAUSEMarks from the capstans, straightening rolls, guide wheels and other machine parts.

b

a

6767

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WIRE DEFECTSDEFECTS FROM DRAWING

CRACKS

V-FRACTURE

SHAPE/CAST ERRORS

WIRE QUALITY

SHAPE/CAST ERRORS

VISIBLE EFFECTSSurface or internal cracks.

NOMINAL CAUSEPoor rod quality.Surface defects on the incoming wire.Unbalanced stresses in the wire due to incorrect drawing series, bad cooling or improper drawing speed.

VISIBLE EFFECTSWire fracture in V-shape during drawing.

NOMINAL CAUSELack of lubrication / wrong area reduction.

VISIBLE EFFECTSCamber (Øa) or helix cast out of specs.

NOMINAL CAUSEProblems in wire guiding or straightening device. Incorrect capstans geometry.

VISIBLE EFFECTSWire section becomes oval or not circular.

NOMINAL CAUSEDie misalignment in the machine.

VISIBLE EFFECTSWeave wire.

NOMINAL CAUSEVibration marks: vibration dampening tools are not set correctly.Problems with straightening device.

CUSTOMER SUPPORT


FAQ

QWhat happens if a customer changes the grade for an existing nib pressing tool?

ADifferent grades could have different shrinkages. This effect could affect the final nib dimensions.

QIs hot casing better than cold casing?

A

The nib after hot casing is under compression not only in the radial but also in the axial direction. This leads to a better stress balance during the drawing process and increases the die life.

QCan Versimax and Versirion be brazed like PCD?

AYes, Versimax and Versirion can be brazed, hot cased and cold cased into the case.

QWhat is the difference between rough core die and nib? Any advantage?

AHyperion’s hot casing process and geometry guarantee perfect between case and nib. Consequently, better balance of stress and better heat conductivity are achieved. These two parameters directly increase die life.

QCan we order a small number of Hyperion WC rough core die PCD blanksto evaluate in our facility to see if it improves our productivity?

AHyperion maintains a large stock of blanks to allow customers to order small test batches. In addition, we offer our application expertise to our customers to help increase productivity.

INCH

TYPENIB CASING

Dla. Ht. Dla. Ht.

R2 .325 .330 1 .563

R3 .450 .380 1.5 .750

R4 .500 .450 1.5 .875

R5 .625 .600 2 .875

R6 .710 .700 3 1.125

R7 .768 .768 3 1.375

R8 1.000 .820 3 1.750

R9 1.187 .820 3 1.750

R10 1.500 1.000 3 2

R11 1.830 1.250 4 2.250

R12 2.185 1.375 4 2.375

R14 2.560 1.375 6 2.500

R15 3.000 1.375 6 2.500

R16 3.500 1.375 7 2.500

R17 4.000 1.500 7 2.500

R18 5.500 2.125 9 4.500

R19 6.500 2.125 11 4.500

MILLIMETER

DIN 1547 TYPE

NIB CASING

Dla. Ht. Dla. Ht.

D10-0804 8 4 28 12

D10-1008 10 8 28 16

D10-1210 12 10 28 20

D10-1412 14 12 28 22

D10-1613 16 13 43 25

D10-2017 20 17 43 32

D10-2520 25 20 53 35

D10-3024 30 24 75 40

MILLIMETER

TYPENIB CASING

Dla. Ht. Dla. Ht.

B 13 10 30 16

C 16 14 32 20

G 22 18 40 26

H 30 21 66 35

K 40 25 95 40

L 50 28 95 48

M 60 35 114 60

N 75 35 114 70

0 90 35 145 70

MILLIMETER

JIS TYPE

NIB CASING

Dla. Ht. Dla. Ht.

W101 6 4 24 7

W102 9 6 24 12

W103 12 8 30 15

W104 15 10 42 20

W105 20 14 55 24

W106 25 18 60 28

W107 30 22 70 35

W108 35 25 85 40

W109 40 27 100 45

W110 50 30 125 50

W111 60 35 145 60

W112 70 40 175 70

W113 80 45 195 80

W114 90 50 215 90

W115 100 50 230 90

W116 110 50 230 90

W117 120 55 250 100

W118 130 55 275 100

W119 140 60 295 110

W120 150 60 315 110

7171CUSTOMER SUPPORT

INTERNATIONAL STANDARDS ROUND DIE SPECIFICATION

CU

STO

MER

SU

PPO

RT

A [% of elongation]

V [volume of a given wire length]

e [miscoaxiality]

R = 1 - (d/D)2 x 100%

V = 1/4πD2L

R = x 100%Se - Ss

Se

e = • tg • [ tg (α) + tg (β) ]d1 2α

2 2β

Se Ss

A = 100 x R100 - R

100 cm 100 - A cm

h

d1

e


CONVERSION TABLE

COMMONLY USED FORMULAS

LENGTH

1 inch = 25.4 mm

MASS

1 Kg = 2.205 pounds

DENSITY

1 g/cm3 = 0.036 lb/inch3

VOLUME

1 US gallon = 3.785 liters

SPEED

1 inch/min = 0.0254 m/min

1 m/s = 60 m/min

R [% of reduction]

73CUSTOMER SUPPORT

HYPERION - RECYCLING AND SUSTAINABILITYTIME TO THINK DIFFERENTLYHyperion, through our Carbide Recycling Program, purchases used carbide tools and products from our customers to convert them into usable raw materials for future production. We use a controlled, certified chemical recycling process that ensures these “new” materials are identical to materials produced from mined ore.

Hyperion is committed to sustainability, and recycling is a great example of how we are reducing the company’s environmental footprint.

This is how you recycle your carbide (short version): you call us, we send a barrel, you fill the barrel, we pick it up, you get paid. Easy! We recycle all types of carbide (only carbide).

Please contact [email protected] or your sales agent for more information.

CU

STO

MER

SU

PPO

RT

Helps maintain raw material

resources

Supports environmental

efforts

ISO 9000, 18000 and

14001 certified

A

Abrasion 10,15,19,65Abrasive 20,65ADDMA 19,22,24Annealing 9,66

B

Back relief 58,64Bunching 15,23,24Burst 63,64

C

Cabling 15,45Casing 10,23,29,39,44,57

58,60,61,63,70,71Ceramic 28,47Co-lake 37Concentration 36,37,38,47,63,64Conductive 21,23Corrosion 23,27,28

31,33,34,35Craking 25

D

Delamination 25

E

EDM 16,23,24

Electrical 52,56Environment 27Erosion 59

F

Flakes 66Friction 9,33,62

G

Galling 31Galvanized 52,55Globs 66Grains 9,36

I

Inclusion 25,26

L

Lapping 47,48Laser 16,26,61

M

Micron powder 11,14,28,49Misalignment 58Misconcentricity 26

O

Oxidation 27,36,57

P

Pull out 36,65Pitting 66Polishing 11,16,23,34

47,48,49,62Porosity 37,61

R

Recrystallization 9,36Recut 57,58Repolish 57

S

Sawing 32,52Scratches 36,65,66Self-supported 10,16,21,22,24Slurry 47,49Spring back 58Stainless steel 32,52,55,56Stranding 15,23,24Sub-micron 19Supported 10,16,18,21Surface 15,18,20,57,60,65,66,67Suspension 47

T

Thermally stable 21,23Tire 15,19,24,32,33,52,54,55

W

Wear 8,10,11,18,19,20,23,2427,28,31,33,34,35,45,57

58,59,61,63,64,65Wear ring 57,58,59,61,63,64,65Welding 15,19,32,34,52


WORDS INDEX

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Wire Drawing Guide - Expometals

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