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 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® 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 |
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® 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. |
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