Tungsten is a high-melting-point metal (melting point: 6192°F), renowned for its high tensile strength and low vapor pressure, which enable it to perform exceptionally under extreme conditions. In particular, tungsten wire retains rigidity even at small diameters, making it indispensable in precision applications.
Cut-resistant tungsten wire typically refers to tungsten wire that maintains durability during cutting processes or resists breaking when being cut. Its primary usage scenarios include the following:
1. Wire Electrical Discharge Machining (Wire EDM)
In wire EDM, tungsten wire serves as a cutting tool, eroding conductive materials via electrical discharges. Research shows that its high melting point (3422°C) and toughness make it ideal for cutting hard materials like tungsten alloys or hardened steel, especially in scenarios requiring high precision (tolerance ±1μm) and complex geometries (e.g., micro-gears, irregular molds). Additionally, its high tensile strength (up to 3500 MPa) prevents deformation when cutting thick materials (e.g., steel plates over 300mm), delivering superior cutting accuracy and surface finish (roughness Ra < 0.1μm).
2. Wire Saw Cutting
Tungsten wire is used in wire saws to cut hard and brittle materials such as metals, ceramics, stone, and semiconductors. Combined with abrasive slurries (e.g., oilor water-based suspensions of diamond particles), it achieves stress-free cutting. For instance, in sapphire wafer processing, tungsten wire saws reduce edge chipping with a material loss rate below 0.5%. In silicon wafer cutting, paired with electroplated diamond coatings, cutting speeds reach 10-15 m/s, reducing surface defect density by 60%.
3. Medical Device Manufacturing
In the medical field, tungsten wire is widely used due to its high radiopacity (clear X-ray visibility), corrosion resistance (withstands bodily fluids), and high tensile strength:
Interventional Devices: Guidewires (0.1-0.4mm diameter) leverage tungsten’s controllable rigidity and flexibility for precise navigation in minimally invasive surgeries.
Implantable Devices: Pacemaker electrodes and neurostimulation probes rely on its long-term biocompatibility.
Surgical Robotics: As drive cables, it transmits high-precision mechanical force in confined spaces.
Radiotherapy: Used for markers or targeted positioning stents, enduring radiation environments.
4. Protective and Composite Material Reinforcement
Cut-Resistant Gear: Woven into gloves or protective clothing (e.g., 0.05mm diameter monofilaments), its hardness (HV 400-500) resists blade scratches, suitable for glass processing or meat cutting.
Ballistic Materials: Combined with aramid fibers, it enhances penetration resistance in ballistic plates, with tests showing a 30% reduction in ballistic dent depth.
5. Semiconductor and Optical Device Manufacturing
Wafer Slicing: Diamond-coated tungsten wire cuts 12-inch silicon wafers, maintaining 98% tension stability at an 80μm diameter.
Optical Glass Processing: When cutting infrared lenses or laser crystals, its thermal expansion coefficient (4.5×10??/°C) matches the material, preventing thermal stress cracks.
MEMS Micromachining: Tungsten wire probes, aided by focused ion beams (FIB), enable nanoscale structure etching and inspection.
6. Extreme Environments and Research
Nuclear Industry: Used in radiation shielding meshes or reactor sensor wires, withstanding neutron irradiation and high temperatures.
High-Temperature Experiments: As suspension wire for molten metals (e.g., aluminum) in vacuum furnaces, maintaining structural stability.
Scientific Instruments: Atomic force microscope (AFM) probes use tungsten wire substrates to support nanoscale topography measurements.
