Abstract: An electrode wire for use in an electrical discharge machining apparatus includes a metallic core and a layer of gamma phase brass disposed over the metallic core. Particles of beta phase brass are interspersed within the gamma phase brass layer. An oxide layer including zinc is disposed over the gamma phase brass layer.

Abstract: An apparatus for an electrical discharge machine for milling a shaped cavity in a workpiece includes a hollow electrode having a metallic inner shell with at least one passage for receiving dielectric fluid. A layer including at least one brass alloy is provided over the inner sheel and exhibits a zinc content greater than a zinc content of the inner shell.

Abstract: An electrode wire for use in an electrical discharge machining apparatus includes a metallic core and a layer of gamma phase brass disposed over the metallic core. Particles of beta phase brass are interspersed within the gamma phase brass layer. An oxide layer including zinc is disposed over the gamma phase brass layer.

Abstract: A gamma phase brass coated EDM wire electrode is processed to produce distinct particulate of the brittle gamma phase alloy where these particulate have a uniquely describable distribution of geometric parameters. The distribution of particles determined by analyzing random cross sections of the wire electrode using standard optical metallographic procedures contains a minimum number of particles with a minor axis of less than 1.5 ?m and a higher proportion of larger aspect ratio (quotient of the values of major axis and minor axis] particles. Such wire electrodes are found to contain less loose debris than electrodes described in the prior art, i.e. are cleaner than prior art gamma wires without suffering any degradation in cutting speed performance.

Abstract: An electrode wire for use in an electrical discharge machining apparatus includes a core having a surface and one of a metal, an alloy of a metal, and a combination of a metal and alloy of a metal. An adherent coating of graphite is metallurgically bonded to the surface of the core.

Abstract: An EDM wire having an outer coating of gamma phase brass with an overlayer of continuous unalloyed zinc or ductile epsilon phase brass entrapping the gamma phase and a process for manufacturing the EDM wire is provided. A second process for synthesizing a ductile epsilon phase brass coating on the aforementioned and other substrates is also provided. The first process includes coating a copper bearing metallic core with zinc. The zinc coating is then converted to gamma phase brass via a diffusion anneal and subsequently re-coated with zinc prior to being cold drawn to its finish diameter.

Abstract: An EDM wire having an outer coating of gamma phase brass with an overlayer of continuous unalloyed zinc or ductile epsilon phase brass entrapping the gamma phase and a process for manufacturing the EDM wire is provided. A second process for synthesizing a ductile epsilon phase brass coating on the aforementioned and other substrates is also provided. The first process includes coating a copper bearing metallic core with zinc. The zinc coating is then converted to gamma phase brass via a diffusion anneal and subsequently re-coated with zinc prior to being cold drawn to its finish diameter. The process of converting a zinc coating to a ductile epsilon phase brass includes heat treating the wire at a temperature low enough to minimize or eliminate changes in the mechanical properties of the composite wire.

Abstract: An EDM wire having an outer coating of epsilon phase brass and a process for manufacturing the EDM wire is provided. The process includes coating a copper bearing metallic core with zinc. The zinc coating is then converted to epsilon phase brass by heat treating the wire at a temperature low enough to minimize or eliminate any resulting changes in the mechanical properties of the wire. The coated core wire may be drawn to a finish size prior to heat treatment which will result in a wire with a substantially continuous epsilon phase coating.