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.
Pre-Treatment and Cleaning
Alkaline CleaningTo 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® Grade | Appearance | Foaming Performance | Pickling Temperature Range |
|---|---|---|---|
| S-AD 55 | Powder | Foaming | Ambient to 190°F |
| S-AD 85 | Liquid | Low Foaming | Ambient to 220°F |
| S-AD 3305 | Liquid | Non-Foaming | Ambient to 190°F |
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® Grade | Acid Ratio | Operating Time* | Temperature Range |
|---|---|---|---|
| M-ZN 181X | 5.5 to 7.5 | 2 to 7 minutes | 170°F to 190°F |
| M-ZN 196X | 5 to 9 | 3 to 10 minutes | 170°F to 180°F |
| M-ZN 198X | 5 to 9 | 3 to 10 minutes | 170°F to 185°F |
| M-ZN 300X | 5.5 to 7.5 | 3 to 7 minutes | 170°F to 185°F |
| M-ZN 860XT | 5.5 to 7.5 | 3 to 5 minutes | 150°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 | Form | pH | Temperature Range |
|---|---|---|---|
| M-PT 21A | Powder | 8.5 to 9.0 | 150°F to 180°F |
| M-PT 25 | Liquid | 8.5 to 9.5 | 120°F to 180°F |
| M-PT R-1 | Powder | 8.5 to 11 | 120°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® Grade | Lubricant Type | Immersion Time | Temperature | Bath Preparation (per 100 gallons) |
|---|---|---|---|---|
| L-FM 234 | Reactive | 3 to 5 | 165° to 190°F | 50 lbs. |
| L-FM 235 | Reactive | 3 to 5 | 160° to 190°F | 56 lbs. |
| L-FM T 4400 | Reactive | 3 to 5 | 165° to 190°F | 30 to 90 lbs. |
| L-FM 204 | Non-Reactive | 1 to 3 | 170° to 190°F | 33 to 50 lbs. |
| L-FM 204C | Non-Reactive | 1 to 3 | 170° to 190°F | 30 lbs. |
| L-FM 242 FS | Non-Reactive | 1 to 3 | 185° to 200°F | 75 to 200 lbs. |
