Aliminium magnet wire

For producing aluminum enameled wire one of the most important thing is how to clean the wire before enamel coating. We are interested to know more about this.

We want to produce aluminum enameled wire but we have had bad experiences. Could you please help us and give some more information about this?

Thank you
Mohsen

Hello Mohsen,

Because I am not a magnet wire expert, we are fortunate enough to have a magnet wire expert to provide technical information on occasion and I have advised him of this thread. He is very busy however and I note he has not replied at this point in time.

Therefore, as a first approach, I suggest you contact Boockman Engineering GmbH in Germany www.boockmann.com/ and explain to them your precise requirement including wire sizes. Moreover give them the complete specification data on the aluminum drawing oil you are using. Finally, ask them to recommend the correct solvent you should be using.

On their web site, go to the Helicord section on the bottom left of the front page.

Cleaning aluminum wire for enameling can be challenging but not impossible. Some use an ultrasonic machine. Other use their regular pre-annealer. Some use a combination of the two. Challenge with typical pre-annealer is to get the wire hot enough that the quench water dries before it gets to the applicator. Aluminum wire is very soft so it is essential that you have a separate enamel supply and drain for the first pass. If you try to run all base coat passes through the same applicator and enamel supply you run the risk of contaminating the enamel with aluminum dust and this will cause the wire to fail dielectric testing.

We getting shininess prancer in the magnet wire of SWG 25 and SWG 27 of f class


A Few Notes
1) We think that prancing is chattering.
2) We think that SWG is the mostly obsolete British Standard Wire Gauge aka the Imperial Wire Gauge.
3) This is just a statement and no request for information or help was made.
4) Mr. Burke's note is clear and to the point. His advice works in all cases here.
Moderator

I'm sorry I've tried responding a couple of times and it doesn't show up.

While it varies with applicator design, typically for large wire on vertical systems the enamel dies should have some free floating ability. This will help the wire to be centered in the die opening and provide a uniform coating . It also depends upon the die design. As the wire is wetted by the enamel or varnish and enters the die, there is a build up of pressure in the die. This hydrostatic pressure will cause the die to move. You don't care so much that if moves but that it stays straight? It cannot cock to one side or bounce up and down (chatter). If the die is fixed in a rigid position and cannot move at all it places greater emphasis on the alignment of the wire into the die. Enameling does have the benefit of the wire making multiple passes through the applicator and there is some rotation of the wire as it makes the various passes during the process so it tends to even out the concentricity of the coating.