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Machining Copper Tungsten Electrodes: A Comprehensive Guide to Techniques and Applications

Copper tungsten electrodes are an essential component in many industrial applications, particularly in electrical discharge machining (EDM) and resistance welding. These electrodes combine the excellent thermal and electrical conductivity of copper with the durability and high melting point of tungsten, making them ideal for use in high-heat and high-wear environments. In this comprehensive guide, we will explore the various techniques and applications of machining copper tungsten electrodes, providing insights into the best practices for achieving optimal performance and longevity.

Introduction to Copper Tungsten Electrodes

Copper tungsten is a composite material made by infiltrating tungsten particles with molten copper. The resulting material has a unique combination of properties, including high thermal and electrical conductivity, low thermal expansion, and excellent resistance to arc erosion. These properties make copper tungsten electrodes ideal for use in demanding industrial applications, such as EDM and resistance welding.

Electrical Discharge Machining (EDM)

EDM is a non-traditional machining process that uses electrical discharges to remove material from a workpiece. In this process, a copper tungsten electrode is used to generate a series of controlled electrical sparks, which erode the workpiece material. The electrode and workpiece are submerged in a dielectric fluid, which helps to cool and flush away the eroded material.

Copper tungsten electrodes are widely used in EDM applications due to their excellent electrical and thermal conductivity, which allows for efficient energy transfer and minimal electrode wear. Additionally, their high melting point and resistance to arc erosion make them well-suited for use in high-heat environments, such as those encountered during the EDM process.

Resistance Welding

Resistance welding is a process that uses electrical current and mechanical pressure to create a strong, permanent bond between two metal surfaces. In this process, a copper tungsten electrode is used to apply both the electrical current and the mechanical pressure required to create the weld.

Copper tungsten electrodes are commonly used in resistance welding applications due to their excellent electrical conductivity, which allows for efficient energy transfer and minimal heat generation. Additionally, their high melting point and resistance to arc erosion make them well-suited for use in high-wear environments, such as those encountered during the resistance welding process.

Machining Copper Tungsten Electrodes

Machining copper tungsten electrodes can be challenging due to the material's hardness and abrasiveness. However, with the right techniques and equipment, it is possible to achieve precise and consistent results. In this section, we will explore some of the most common machining techniques used to create copper tungsten electrodes, including grinding, electrical discharge machining (EDM), and laser machining.


Grinding is a common method for shaping and finishing copper tungsten electrodes. This process involves using an abrasive wheel or belt to remove material from the electrode surface, resulting in a smooth and precise finish. Diamond grinding wheels are often used for this purpose, as they provide excellent cutting performance and long tool life.

When grinding copper tungsten electrodes, it is essential to use a coolant to minimize heat generation and prevent damage to the electrode material. Additionally, care should be taken to avoid excessive grinding pressure, as this can cause the electrode to overheat and result in reduced performance.

Electrical Discharge Machining (EDM)

As previously mentioned, EDM is a non-traditional machining process that uses electrical discharges to remove material from a workpiece. This process can also be used to shape copper tungsten electrodes, providing a high degree of precision and control.

When using EDM to machine copper tungsten electrodes, it is essential to use a suitable dielectric fluid to minimize electrode wear and ensure optimal performance. Additionally, care should be taken to select the appropriate EDM parameters, such as voltage, current, and pulse duration, to achieve the desired material removal rate and surface finish.

Laser Machining

Laser machining is another non-traditional machining process that can be used to shape

CNC Copper Machining

CNC Machining Copper Material is good electrical conductivity, thermal conductivity, it is soft and good for machining as it has high plasticity, it is easily and rapidly to carry out desired shape as machining cutter can run faster than other steel materials, and also reach high precision.

Copper has a shiny reddish-orange finish, which varies slightly based on the surface finish method. Copper can be media-blasted and polished to achieve many different cosmetic surface finishes.

CNC Machining Copper Parts are widely used in the manufacture of electrical wires, cables, electric brushes, electric spark, and other electrical devices and products.

CNC Copper Machining

Benefits of CNC Copper Machining

1/ CNC Machining Copper Parts are excellent in electricity conductivity, supporting very good electric function

2/ CNC Machining Copper Parts are soft, easy to design into different shape, also suitable for many processes

3/ Copper is easy for cutting and machining, its production efficiency is much higher than steel series

4/ Good propriety for bending and shaping

5/ Heat transferring function very good, high resistance, temperature stability, long durable using

6/ Stable surface, non-surface treatment is durable, electroplating is also used on copper parts

CNC Copper Machining

Composition And Property of CNC Machining Copper

Copper Property Alloy Type Content Melting Point Hardness Tensile Strength Density
Cu-based Zn, Sn, Si, Al, Ni 1083°C HB35-45 Low 8.9 g/cm3

Common Materials Code of CNC Machining Copper

Copper Alloy Workable Processes Surface Finishing for Copper Parts Materials Code
CNC Turning, CNC Milling, CNC Drilling, Molding, Forging, Fabrication, Welding, etc. Passivation, Anodizing, Plating, Chemical Polishing, etc. Copper 110
Copper 101
Copper 145
other more Copper Alloy

Asianstar: Professional CNC Machining Supplier

From year of 2005, Asianstar Company establish the CNC Machining Factory in Guangdong Province, China.
We mostly provide CNC Turning, Milling, Drilling, Grinding, and Multi Machining processes service on various materials.
With the Belief of becoming a key supplier in the supply-chain of Precision Components, we strictly control our product quality, keep high precision on our components production, buildup the whole-process QC System and submit the satisfaction for every order.
By long term development, we have buildup partnership with world-wide clients, supporting our partners in Designing, Optimizing, Producing and Testing on each type of components.


Advantages of Asianstar CNC Copper Machining

Strong Facilities

Asianstar many CNC and stamp machines allow us to produce various copper parts, different sizes, and structures are all well done by suitable solution

Long-term Skills

Asianstar professional engineers team has experience from year 2005, producing copper parts for world wide electric products

Stable Quality

Asianstar QC system and QC tools guarantee our products are perfect result. We have procedures to control copper parts quality during production

Competitive Price

Asianstar aim to buildup partnership with clients, always choose best suitable facilities to carry out the components in competitive prices


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CNC Machining Brass material is used for wide range components, we support clients to produce a variety of parts such as gears, locks, electronics, pipe fittings, etc.

CNC Copper Machining


CNC Machining Copper material is soft and easy to machining on different shape of components. We mostly produce copper components for electric devices by machining and stamping

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CNC Machining Aluminum materials is one of our most used materials. We support clients to turning, drilling or milling on aluminum material from size 0.5mm to 470mm

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Stainless Steel

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