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    Wire Drawing A to Z - Bonderite®

    Wire drawing and manufacturing is a complex, multi-step industry requiring a range of chemical and mechanical processes.  The Bonderite® product family has engineered solutions for many of the chemical needs throughout the process — pre-cleaning, lubricating and more.  This application article will help highlight how and why Bonderite® products are the ideal solution for wire drawing.
     

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Pre-Treatment and Cleaning

Alkaline Cleaning
To prepare rod surfaces for drawing, an immersion or spray cleaning process step is critical in optimizing efficiency and consistency in final production. Bonderite® has a range of alkaline cleaners to remove a variety of soils and lubricants prior to drawing the metal.
 

    Bonderite® Grade
    Soil Types
    Application
    Substrate
    C-AK 2087X
    Steel
    Immersion & Spray
    Soap Lubricants, Polymers, Oils
    C-AK 2077X
    Steel
    Immersion
    Phosphate, Soap Lubricants, Polymers, Oils
    C-AK 2088X
    Steel
    Immersion & Spray
    Phosphate, Soap Lubricants, Polymers, Oils, Reactive Oils
    C-AK 1208X
    Steel and Aluminum 
    Immersion
    Soap Lubricants, Polymers, Oils

Acid Pickling


There are a variety of mechanical and chemical processes to remove scale and rust from the rod surface.  There are several powerful Bonderite® Acid Inhibitors that can be used in a pickling process step.  These products minimize attacks on base metal, minimize pitting and reduce the fuming experienced in pickle baths.
 

    Bonderite® GradeAppearanceFoaming PerformancePickling Temperature Range
    S-AD 55PowderFoamingAmbient to 190°F
    S-AD 85LiquidLow FoamingAmbient to 220°F
    S-AD 3305LiquidNon-FoamingAmbient to 190°F

Phosphating


It is common to see a phosphate treatment step to provide additional surface protection and adhered coating to protect tool & die life.  There are several Bonderite® grades with targeted solutions for a range of phosphating operational requirements.   A proper phosphate coating is a powerful solution that can provide:
  • Increased Overall Metal Flow 
  • Reduced Metal-on-Metal Friction
  • Improved Secondary Corrosion Protection 
  • Extended Tool/Die Life 
  • Faster Drawing Speeds & Deeper Surface Draws

    Bonderite® GradeAcid RatioOperating Time*Temperature Range
    M-ZN 181X5.5 to 7.52 to 7 minutes170°F to 190°F
    M-ZN 196X5 to 93 to 10 minutes170°F to 180°F
    M-ZN 198X5 to 93 to 10 minutes170°F to 185°F
    M-ZN 300X5.5 to 7.53 to 7 minutes170°F to 185°F
    M-ZN 860XT5.5 to 7.53 to 5 minutes150°F to 170°F

*Operating time will vary by particular application process (Bath, Strand, Tubing, Extrusion, etc.) Inquire for more information

Neutralization


Following a phosphate treatment, it is recommended to run the metal through a neutralization process.  Not only does this operation neutralize any leftover acidic phosphate, it also raises the metal temperature for the drawing step, provides additional corrosion protection & prevents drag-in for acidic metal. The specialty solutions for Bonderite® for neutralization are below.
 

    Bonderite® Grade FormpHTemperature Range
    M-PT 21APowder8.5 to 9.0150°F to 180°F
    M-PT 25Liquid8.5 to 9.5120°F to 180°F
    M-PT R-1Powder8.5 to 11120°F to 180°F

Lubrication - Reactive & Non-Reactive


When it comes to wire drawing operations there are two types of lubricants, reactive & non-reactive. Both provide surface protection from metal-on-metal contact and extend the die life cycle. Reactive lubricants are high-purity stearate soaps that react with the formed crystals to absorb into phosphated surface and delivers excellent adhesion and film strength. Non-reactive lubricants provide easier use, control and longer bath life but do not adhere as strongly. The recommended Bonderite® lubricants are listed below.

    Bonderite® GradeLubricant TypeImmersion TimeTemperatureBath Preparation
    (per 100 gallons)
    L-FM 234Reactive3 to 5165° to 190°F50 lbs.
    L-FM 235Reactive3 to 5160° to 190°F56 lbs.
    L-FM T 4400Reactive3 to 5165° to 190°F30 to 90 lbs.
    L-FM 204Non-Reactive1 to 3170° to 190°F33 to 50 lbs.
    L-FM 204CNon-Reactive1 to 3170° to 190°F30 lbs.
    L-FM 242 FSNon-Reactive1 to 3185° to 200°F75 to 200 lbs.

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