Hyperion Wire Drawing Guide

TOOLMAKER SOLUTIONS
Wire Drawing
Guide
Your full-line of wire

drawing solutions
TABLE OF CONTENTS
WIRE DRAWING
WELCOME TO HYPERION 06
COMPLETE DRAWING SOLUTIONS 10
PCD AND VERSIMAX: MATERIAL & PROCESS 14
- PCD MATERIAL & PROCESS 14
- PCD CATALOGUE 22
- VERSIRION AND VERSIMAX MATERIAL 24
- PCD MATERIAL ISSUES 25
CEMENTED CARBIDE: MATERIAL & PROCESS 27
- CEMENTED CARBIDE MATERIAL & PROCESS 27
MATERIALS
- CEMENTED CARBIDE MATERIAL DEFECTS 36
- CEMENTED CARBIDE CATALOGUE 39
- WEAR PARTS 45
DIAMOND COMPOUNDS 47
- SLURRIES 47
- PASTES 48
- MICRON POWDER GRADES 49
APPLICATIONS 52
APPLICATIONS & FAILURE MODES

- APPLICATION KNOWLEDGE 52
- APPLICATIONS GUIDELINES 55
- BEST PRACTICES 57
- FAILURE MODES 59
- WIRE DEFECTS 66
FAQ’S 70
INTERNATIONAL STANDARDS 71
CUSTOMER SUPPORT
CONVERSION TABLES AND FORMULAS 72
RECYCLING AND SUSTAINABILITY 73
WORDS INDEX 74
WIRE DRAWING GUIDE 3

WIRE DRAWING
OUR HERITAGE
PROUD PAST, PROMISING FUTURE
HPHT gem
diamonds
CVD diamond
Gra
for ca
1st PCD cutters

(for oil & gas)
Diffusion bonding
of CC bodies for
wear parts
Grade DZ05
for flow control
CIC integral rolls

introduced
1st diamond
synthesis
Introduction of
grade H10F
Submicron grade H3F
Corrosion resistant for wire drawing
seal rings
6 WIRE DRAWING GUIDE

Coated diamond
for precision V-Series PCBN
wire sawing grades, new
for steel
turning
WIRE DRAWING
Intelligent rotary cutters,
quick anvil change
Grade AM60 for CFRP

machining & Grade
AM70 for titanium
machining
m
ds
Grade TC03/C3D for

drawing die nibs
PBA rotary
cutters concept
Grade DZ10
for can tooling
WIRE DRAWING 7
YOUR DRAWING PARTNER
Hyperion is your full-line provider of cemented tungsten carbide, tungsten carbide powders, diamond and cubic
boron nitride materials for your material-removal and wear-protection applications. In addition to innovative
materials, Hyperion offers our extensive knowledge, unique services and application development capabilities to
support our customers’ competitive needs.
With advanced production capabilities in powder processing, sintering, high-pressure high-temperature synthesis,
coating and finishing, Hyperion can satisfy all your needs for drawing solutions.
Hyperion is truly a global and fully integrated manufacturer, with locations in the Americas, Europe and Asia. Our
expansive and experienced global sales network provides local support, so your wire drawing solutions are available
when you need them.
HYPERION GLOBAL
Hyperion’s MBG® diamond offers a solution for grinding high performance
materials such as glass, stone and electronic materials. The shapes range
from well-defined crystals to highly friable, irregular shapes that can be
customized for any application.
Hyperion’s worldwide network of manufacturing facilities offers customers

the very latest in material technology and productivity with unparalleled
customer service.

DRAWING THEORY AND DRAWING LINE
Drawing process refers to reduction of metals section by the application of stress in tension.
Drawing die is a tool with a specially shaped hole through which wire is pulled to reduce its diameter.
Traction force σd pulls the wire through the reduction cone. The reaction σb, decomposes in force P (compress the
WIRE DRAWING
wire deforming its material under ratio r) and the friction µP. Friction stresses are reduced with better lubrication.
P
Starting stock α
Df
μP
σb σd
D0 A0 σm A1
F μP
α LC
Final work size
P
A1
r=1- A0
When a wire is drawn (reduced), the material grains deform and elongate, causing the wire to be harder and less ductile.
FERRITIC STEEL
AUSTENITIC STEEL
AUSTENITIC-FERRITIC STEEL
To return the material to its original hardness and ductility, the material is annealed. During annealing, grains
recrystallize and grain growth can occur.
After annealing, the wire can again be drawn.
Internal
Residual
Stress Internal
Residual
Stress
Strength, Strength
Hardness
& Ductility
Hardness
Ductility
Microstructure
and Grain Size
Grain
Growth
Recovery Recrystallization Grain Growth

(Grains recover (New grains form) (Larger grains grow
slightly from at the expense of the
cold-working) smaller grains)
WIRE DRAWING 9
HYPERION - YOUR COMPLETE DRAWING SOLUTION PROVIDER
5-COMPAX® BLANKS FOR

SUPPORTED AND SELF- 6-VER
1-HOT ROLLS 2-SHAVING DIES BLANKS 3/4-CARBIDE DIES AND BLANKS SUPPORTED PCD DIES VERSI
COMPLETE DRAWING OFFER

BLANKS
TUNGSTEN CARBIDE CARBIDE ROUGH CORE DIES
Hyperion’s drawing nibs are known for their impeccable Hyperion’s wide offering of wet and dry drawing dies is
geometry and unique and consistent grade composition. designed according to industry standards or customer
We offer not only a wide range of standard dimensions specifications. Our unique hot and cold casing processes
but also the unique ability to partner with you to create a are capable of handling high volumes and provide:
special design for your needs. • Increased die life
PCD BLANKS • Better stress balance
• Improved heat dissipation.
Hyperion’s self-supported and carbide supported die
blanks portfolio covers a wide range of dimensions VERSIRION™ AND VERSIMAX™
and applications for wire drawing. The unique material Hyperion is introducing the Versirion series, a revolutionary
properties provide very good abrasion resistance and the silicon carbide and polycrystalline diamond (PCD) made
ability to achieve a high quality surface finish. by a state-of-the-art high pressure high temperature
process and is based on the Versimax composite.
Versirion and Versimax exhibit superior wear resistance,
high temperature performance and thermal stability by
combining the best of tungsten carbide and PCD.

WIRE DRAWING
6-VERSIRION™ AND
VERSIMAX™ BLANKS 7-WEAR PARTS AND COLD ROLLING PROCESS 8-DIAMOND COMPOUNDS
DIAMOND AND DIAMOND COMPOUNDS WEAR PARTS

Starting with the highest quality of raw materials, Hyperion’s wide range of fully finished and ready-
Hyperion uses advanced engineering methods to to-use wear parts (e.g., guide wheels, guide bushes,
manufacture diamonds with specific characteristics of etc.) for the wire industry can be manufactured
strength and toughness. State-of-the-art micronizing according to your drawing.
techniques assure the diamond powders have
precisely defined sizes, shapes and surface properties
for polishing dies.
Hyperion’s offering of diamond pastes and compounds

are a combination of premium diamond powder and
superior lubricants, creating the optimal polishing
products.
WIRE DRAWING 11
MATERIALS
HYPERION - COMPAX® PCD FROM START TO FINISH
Hyperion’s diamond micron powders are created in a single, continuous manufacturing process. Starting with the
highest quality of raw materials, Hyperion uses advanced engineering methods to manufacture diamonds with
specific characteristics of strength and toughness. State-of-the-art micronizing techniques assure the diamond
micron powders have precisely defined sizes, shapes and surface properties. The result is unprecedented consistency
and uniformity from the initial diamond source to the final product.
CONSISTENCY THROUGH SIX SIGMA QUALITY CONTROL

Hyperion’s micron powders offer consistency and repeatability derived from the engineering invested in our
proprietary Six Sigma controlled manufacturing processes.
WHAT IS PCD?
CARBON-DIAMOND PCD SINTERING
PHASE DIAGRAM
120 Diamond Powder Blend
Shock wave
synthesis
Cobalt
30 Cemented WC
Liquid
Diamond carbon At high temperature and pressure, The cobalt promotes carbon-
25
Pressure (GPa)
cobalt melts and “sweeps” into carbon bonding between

HPHT the powder bed diamond crystals
Catalytic synthesis
20 HPHT synthesis
15
Metastable Residual Cobalt
CVD diamond (etched)
10
5
Graphite
0
0 1000 2000 3000 4000 5000
Temperature (K)

PCD GRAIN SIZES
PCD GRADE APPLICATION
Fine Grain
Fine surface finish requirements
• Tough to draw wire
• Small/medium die sizes
• Tire cord and wire saw.
SUBMICRON
5 MICRON
MATERIALS
Medium Grain
General purpose applications
• Moderate surface finish and abrasion requirements
• Medium die sizes
• Stainless steel and welding wire.
12 MICRON
Coarse Grain
Intermediate and rod breakdown
• Non-critical finish requirements
• Larger die sizes
• Stranding, bunching and cabling.
25 MICRON
50 MICRON
MATERIALS 15
HYPERION‘S PCD MANUFACTURING PROCESS
SELF-SUPPORTED PCD BLANK MANUFACTURING
MBS®/Borazon® crystals Milling Cleaning Grading Blending
Loading Pressing Finishing Wire EDM cutting Quality control
This process is fully integrated within Hyperion, from powder to finished parts.
PCD BLANK MANUFACTURING PROCESS

TUNGSTEN CARBIDE SUPPORTED PCD BLANK MANUFACTURING
Cemented
WC ring Metal cup
Cell
Build Build
Blend capsule cell
Sealed capsule (cup)

Diamond feed Blended powder
High
pressure
Inspection,
packaging HPHT
& shipping Finishing sintering
A
High
Finished wire die Sintered wire die temperature
B compact
Steel cover
A/B
PCD blank
Steel case Brazing

media
Brazing the PCD Machining Laser inner die shape Ultrasonic polishing
blank entrance & exit
core

HPHT PROCESS DETAILS
Pressure ≤ 55 kbar
Temperature > 1300ºC
Time < 1 hour
3,600,000 bar 52,000,000 psi Pressure at the center of the earth
MATERIALS
Pressure of current successful
55,000 bar 800,000 psi synthesis of diamond
1,200 bar 30,000 psi Pressure of powder metal forming
Pressure at which pressure washers

600 bar 8,700 psi function as a water jet cutter
Pressure at which pressure washers

100 bar 1,500 psi force out water
Atmospheric pressure at earth’s

1 bar 15 psi sea level
1 x 10-9 bar 1.5 x10-8 psi Pressure of near earth outer space
MATERIALS 17
18
WIRE
FINISH
SURFACE
+
WIRE DRAWING GUIDE

MFU/TSU (0.9 μm)
Supported (3 μm)
MF/TS/Supported (5 μm)
Supported (12 μm)
WEAR RESISTANCE
HYPERION‘S PCD BLANKS PRODUCT MAP
Supported (25 μm)
Supported (50 μm)
+
SUB-MICRON PCD
SUB-MICRON MICROSTRUCTURES
SUB-MICRON PROPERTY MEASUREMENT
ABRASION TEST RESULTS X-RAY FLUORESCENCE RESULTS

FOR METAL CONTENT
MATERIALS
14 30
12
Wear Rate (mg/min)
25
Wear Resistance
10
20
% Co or W
8
15
6
10
4
2 5
0 0
Hyperion Supplier B Supplier A Comp. Grd 2 Comp. Grd 1 Hyperion
Wear Resistance Wear Rate % Co %W
CURRENT SUB-MICRON PRODUCT
Brass-plated wire (tire cord, saw wire)

Welding wire
Target applications
Fine finishing applications
Glass scribing
Typical diamond grain size 0.9 μm
Typical diamond content 91%
STANDARD PRODUCT OFFERINGS
Product Dimensions (mm) Thermally Maximum Recommended

ADDMA No. Metal Filled
diameter x thickness Stable Hole Size (mm)
D6 3.1 x 1.00 5010-MFU 5010-TSU 0.5
D12 3.1 x 1.5 5015-MFU 5015-TSU 1.0
The unique material properties provide very good abrasion resistance and the ability to achieve a high
quality surface finish.
MATERIALS 19
HYPERION‘S PCD QUALITY
ABRASIVE WEAR COMPARISON
90 Low Cost Product: 186 nm
80
70
WEAR MICRO-INCH
60
50
40 Compax 5025 35 nm
30
20
10
SH 5025 LOW COST

PRODUCT
The unique material properties provide:

• The ability to generate a high quality polished surface in minimal time
• Consistent long life.
SH 5025 Die Material 1000X Low Cost Die Material 1000X
1000x magnification SEM image of a 5025 sample.

HYPERION‘S PCD BLANKS
SELF-SUPPORTED DIE BLANKS
Free standing polycrystalline diamond
Typically lower cost than WC supported blanks
Sizes: D6 through D18
Average PCD Grain Size: 5 µm & 25 µm & submicron
Two Grades: thermally stable (TS) & metal filled (MF)
MF Grade
• Metal filled, contains catalyst metal
MATERIALS
• Thermally stable to 700ºC and electrically conductive.
TS Grade
• Catalyst metal removed by leaching process
• Thermally stable to 1050ºC
• Can be mounted using high temperature, high strength metal setting powders
• Not electrically conductive.
CARBIDE SUPPORTED DIE BLANKS
PCD core integrally bonded to a WC support ring
WC support leads to enhanced strength of PCD core
Allows for larger PCD core
Sizes: D12 through D36
• PCD Grain Size: 3 µm, 5 µm, 12 µm, 25 µm & 50 µm

• Contains metal catalyst in PCD structure
• Do not exceed 700ºC in die mounting operations
• Electrically conductive.
MATERIALS 21
HYPERION‘S PCD BLANKS CATALOGUE
SELF-SUPPORTED DIE BLANKS

NOMINAL GRAIN SIZE PRODUCT DIMENSIONS [mm]
DIAMOND
ADDMA DIAMETER X RECOMMENDED
DIAMOND DIAMOND
THICKNESS Sub µm 5 µm 25 µm BORE SIZE
DIAMETER THICKNESS
(mm) (mm)*
D6 3.1 x 1.0 5010-MFU 5010-TSU 5010-MF 5010-TS 5010-MFC 5010-TSC 3.1 ± 0.38 1.0 ± 0.13 0.08 0.13 0.5
D12 3.1 x 1.5 5015-MFU 5015-TSU 5015-MF 5015-TS 5015-MFC 5015-TSC 3.1 ± 0.38 1.5 ± 0.13 0.08 0.13 1.0
D15 5.2 x 2.5 5025-MF 5025-TS 5025-MFC 5025-TSC 5.2 ± 0.64 2.5 ± 0.13 0.08 0.25 1.5
D18 5.2 x 3.5 5035-MF 5035-TS 5035-MFC 5035-TSC 5.2 ± 0.64 3.5 ± 0.13 0.08 0.25 2.0
D21 7.0 x 4.0 7040-MF 7040-MFC 7 ± 0.64 4 ± 0.13 0.08 (within 0.25 3.5
diameter
7.0 x 5.3 7053-MF 7053-MFC 7 ± 0.64 5.3 ± 0.13 0.08 limits) 0.25 4.6
D24
13.0 x 7.0 1370-MF 1370-MFC 13 ± 0.64 7 ± 0.13 0.08 0.25 5.2
D27 13.0 x 8.7 1387-MF 1387-MFC 13 ± 0.64 8.7 ± 0.13 0.08 0.25 5.8
D30 13.0 x 11.6 1311-MF 1311-MFC 13 ± 0.64 11.6 ± 0.13 0.08 0.25 7.6
18.6 x 13.5 1813-MF 1813-MFC 18.6 ± 0.64 13.5 ± 0.13 0.08 0.25 11.2
TUNGSTEN CARBIDE-SUPPORTED DIE BLANKS

NOMINAL GRAIN SIZE PRODUCT DIMENSIONS [mm]
DIAMOND
RECOM-
ADDMA DIAMETER X
TOOL BLANK DIAMOND DIAMOND MENDED
THICKNESS 3 µm 5 µm 12 µm 25 µm 50 µm
DIAMETER DIAMETER THICKNESS BORE SIZE
(mm)
(mm)*
D12 1.5 x 1.5 5235 3.99 ± 0.013 1.4 1.5 ± 0.10 0.05 0.01 0.05 0.20 0.8
D15 4.0 x 2.3 5823 5123 5223 5430 8.12 ± 0.013 3.8 2.24 ± 0.05 0.05 0.01 0.08 0.40 1.8
D18 4.0 x 2.9 5829 5129 5229 5435 8.12 ± 0.013 3.8 2.84 ± 0.05 0.05 0.01 0.10 0.40 2.3
D21 7.0 x 4.0 5840 5240 5530 13.65 ± 0.013 6.8 3.86 ± 0.05 0.05 0.01 0.14 0.50 3.5
7.0 x 5.3 5853 5253 5535 13.65 ± 0.013 6.8 5.13 ± 0.05 0.05 0.010 0.18 0.50 4.6
D24
13.0 x 7.0 5225 5725 24.13 ± 0.025 12.7 6.98 ± 0.25 0.10 0.050 0.30 0.60 5.2
D27 13.0 x 8.7 5108 5208 5730 24.13 ± 0.025 12.7 8.70 ± 0.25 0.10 0.05 0.30 0.60 5.8
13.0 x 11.6 5111 5211 5735 24.13 ± 0.025 12.7 11.60 ± 0.25 0.10 0.050 0.40 0.60 7.6
D30
18.6 x 13.5 5913 34.00 ± 0.025 18.2 13.5 ± 0.50 0.10 0.050 0.45 0.75 11.2
18.6 x 15.5 5915 34.00 ± 0.025 18.2 15.50 ± 0.50 0.10 0.050 0.52 0.75 12.0
D33
18.6 x 17.5 5917 34.00 ± 0.025 18.2 17.5 ± 0.50 0.10 0.050 0.59 0.75 12.5
D36 18.6 x 18.5 5918 34.00 ± 0.025 18.2 18.50 ± 0.50 0.10 0.05 0.62 0.75 12.7
* Maximum recommended bore size for non-ferrous wire. Hard-ferrous wire die size normally should not exceed 65% of this diameter.
To view the complete catalog, please visit www.HyperionMT.com.

VERSIRION™
Hyperion is introducing the Versirion™ series, a revolutionary silicon carbide and polycrystalline diamond (PCD)
composite with increased wear property and thermal stability. Versirion™ is made by a state-of-the-art high pressure
high temperature process and is based on the Versimax™ composite developed for wire drawing and wear application.
VERSIRION™ AND VERSIMAX™

Versirion and Versimax exhibit superior wear resistance, high temperature performance and high strength
approaching that of Co-sintered PCD, with the addition of superior thermal stability. Versirion exhibits the most
superior corrosion resistance.
MAIN ADVANTAGES
- Superior thermal stability compared to that of PCD
- Significantly reduced coefficient of thermal expansion (CTE) mismatch
- Thermally stable up to 1400°C, which creates less risk of failures during application
- Easy to process:
- Electrically conductive: EDM processability allows flexibility in cutting various geometries
- Larger sizes than unsupported PCD: diameter - 35 mm, height - 35 mm
- Does not require polishing of the bore to achieve the surface finish of the wire
MATERIALS
- Ability to be easily brazed or shrink fitted into casing
- Versatility: ferrous and non-ferrous wires
- Wear resistance comparable to that of PCD and corrosion resistance slightly better than that of PCD.
MAIN APPLICATIONS FOR FERROUS AND NON-FERROUS WIRES

- Drawing - Bunching - Compacting - Wear applications - Stranding - Extrusion
WEAR RESISTANCE TEST RESULTS

1.4
1.2
Normalized Wear Rate
1.0
0.8
0.6
0.4
0.2
0.0
Microstructure PCD5 VMX20 VRW10 VRW5
MATERIALS 23
VERSIRION™ AND VERSIMAX™ PRODUCT OFFERING
AVERAGE
GRADE APPLICATION(S)
GRAIN SIZE
- Low carbon steel

Versirion™ (VRW5) - Tire cord
Fine Grain - Aluminum
- Copper with higher surface finish requirement
- Low carbon steel

- Coated steel
Versirion (VRW10)
™
Medium Grain
- Aluminum
- Copper with lower surface finish requirement
- Bunching
- Stranding
- Wear application
Versimax™ Coarse Grain
- Compacting
- High pressure
- High temperature
VERSIRION™ AND VERSIMAX™ BLANK SIZES

Versirion and Versimax wire die blanks are self-supported and do not have carbide support rings. Both are available
in custom sizes and shapes and are prepared according to customer specifications.
Simple shapes (cylinders, rectangular or triangular prisms, etc.) and more complicated geometries (conical shapes,
hollow cylinders, negative features, etc.) can be produced.
Versimax can be attached to tungsten carbide or steel by furnace brazing. Tools can also be produced by press
fitting, heat shrink fitting, adhesive bonding or mechanical fixturing.
Contact your Hyperion account manager to review your application and determine the best fabrication method for
your needs.
PARALLELISM PERPENDICULARITY
ADDMA DIAMETER (mm) THICKNESS (mm) ROUNDNESS
D6 3.1 1.0 0.08 0.13 0.05
D12 3.1 1.5 0.08 0.13 0.05
D15 5.2 2.5 0.08 0.25 0.05
D18 5.2 3.5 0.08 0.25 0.05
D21 7.0 4.0 0.08 0.25 0.05
D24 13.0 7.0 0.10 0.3 0.05
D27 13.0 8.7 0.10 0.3 0.05
D30 18.6 13.5 0.10 0.4 0.05
D33 18.6 15.5 0.10 0.5 0.05
D36 18.6 18.5 0.10 0.6 0.05
TM 23.0 15.0 0.10 0.38 0.05
TM 25.0 20.0 0.10 0.51 0.05
TM 30.0 22.0 0.10 0.56 7.6
TM 35.0 25.0 0.10 0.64 11.2
TM = Tailor-made
Unless otherwise specified all parts are cut with an EDM external hook.

PCD MATERIAL ISSUES
- Generating properly processed PCD blanks requires special processing of feedstock, blend and cell components, as
well as careful control of the HPHT process and finishing methods.
- Errors or issues with any of the above will result in failure of parts or result in parts out of specification for strength and
microstructure properties.
- Our 100% Product Inspection Process and the Cross Functional Production Team ensures the best quality product.
- Following is the typical inspection criteria:
X-RAY (TS BLANKS) PCD SINTER QUALITY
Diameter Edge Chips Cracks

Thickness Pits & Depressions Metal Inclusions
Parallelism Finish & Color Oversize Control
Perpendicularity
Concentricity
Roundness
HPHT PROCESS ISSUES
MATERIALS
- Visible effects: delamination - Visible effects: horizontal cracking
- Nominal cause: HPHT process temperature - Nominal cause: HPHT process temperature
below request. below request.
- Visible effects: diamond growth

- Nominal cause: HPHT process temperature
above request.
MATERIALS 25
PCD MATERIAL ISSUES
HPHT PROCESS ISSUES
- Visible effects: diamond growth - Visible effects: diamond growth

- Nominal cause: HPHT process temperature - Nominal cause: HPHT process temperature
above request. above request.
OTHERS
- Visible effects: ‘bottle cap’ marks or chipping - Visible effects: ‘bottle cap’ marks or chipping
- Nominal cause: Laser induced damage. - Nominal cause: Laser induced damage.
Poor laser process. Poor laser process.
- Visible effects: misconcentricity between PCD - Visible effects: metal filled inclusion
blank and carbide ring - Nominal cause: result of issue with the feed.
- Nominal cause: mistake during wire cutting.

CEMENTED CARBIDE
Cemented carbide is one of the most successful composite engineering materials ever produced. Cemented
carbide’s unique combination of strength, hardness and toughness satisfies the most demanding applications.
A key feature of the cemented carbide is the potential to vary its composition so that the resulting physical and
chemical properties ensure maximum resistance to wear, deformation, fracture, corrosion and oxidation. In addition,
the wide variety of shapes and sizes that can be produced using modern powder metallurgical processing offers
tremendous scope to design cost-effective solutions to many of the problems of component wear and failure
encountered in both the engineering and domestic environment.
MATERIALS
MATERIALS 27
THE MATERIAL WITH STAYING POWER
The most valuable property of cemented carbide is that it offers a safer and more dependable solution than any
other known material to one of the toughest problems which engineers have to contend with – reliability.
Reliability is often a problem of wear. Wear resistance is the most outstanding feature of cemented carbide. Cemented
carbide can also withstand deformation, impact, heavy load, high pressure, corrosion and high temperature. Cemented
carbide is often the only material that can fulfill these requirements.
It has long been a well-known fact that the use of cemented carbide provides an optimal solution in the case of
tools for metal cutting and rock drilling. Over the years, cemented carbides have also proven their superiority in a
great number of other tooling and engineering applications.
Polycrystalline Diamond (PCD)

Hardness
Polycrystalline Cubic Boron Nitride (PCBN)
SiC
Al2O3
Si3N4
Cemented Carbide
High Speed Steel
Stellite
Toughness
ENGINEERING MATERIALS
The most commonly used materials are shown schematically relative to their hardness and toughness properties.
Polycrystalline diamond (PCD) is the hardest of all, followed by polycrystalline cubic boron nitride (PCBN) and
ceramics (A12O3, SiC, SIALON etc.). The super-hard materials all suffer from lower toughness and poor resistance to
sudden fracture. The cemented carbides have a unique combination of high hardness and good toughness within
a wide range and thus constitute the most versatile hard materials group for engineering and tooling applications.
CONSISTENCY THROUGH SIX SIGMA QUALITY CONTROL

Recognizing the need for high quality, Hyperion micron powders offer consistency and repeatability derived from
the engineering invested in our proprietary Six Sigma controlled manufacturing process.

HYPERION‘S CARBIDE MANUFACTURING PROCESS
This process is fully integrated within Hyperion, from powder to finished parts.
OUR PROCESS
Hyperion offers in-house hot and cold casing, which guarantees the best possible die performance in any
application. Our unique hot and cold casing processes are capable of handling high volumes and provide:
- Better stress balance - Improved heat dissipation - Increased die life
MATERIALS
Cold Casing Hot Casing
SIZES AND STANDARDS

Hyperion has been manufacturing dies since 1947, giving us experience in a wide variety of user applications.
Our fully integrated manufacturing process allows us the flexibility to produce small test batches as well as mass
production volumes. Our advanced, in-house tooling shop is able to adapt our production to any customer
requirement.
TAILOR-MADE
Casing size can be adapted to your needs. All standard nibs, as well as customer specific sizes, can be adapted.
MATERIALS 29
HYPERION CARBIDE GRAIN SIZE CLASSIFICATION
Hyperion uses the following grain size classification for all standard grades.
Ultrafine Extra fine Fine Medium Medium coarse Coarse Extra coarse
< 0.5 µm 0.5 - 0.9 µm 1.0 - 1.3 µm 1.4 - 2.0 µm 2.1 - 3.4 µm 3.5 - 5.0 µm > 5.0 µm
5 µm
Grades for WD

HYPERION CARBIDE GRADES
HV30
WET
6UD
C3D
2000
ULTRAFINE
H6F DRY
H3F
H10F
1500 H15F
H6N RS1T EXTRA FINE
H11N
1000 MEDIUM
0 5 10 15 Co (wt%)
MATERIALS
EXCELLENT
C3D C3D
H11N
RS1T 6UD
H15F
H3F 6UD
H6N
GOOD
C3D H6F H3F

H10F
6UD H10F H6F
H6F
RECOMMENDED
H3F RS1T H10F

H11N
NOT
6UD H6N/ H11N H6N/ H11N

H15F
C3D H15F H15F
TOUGHNESS GALLING RESISTANCE WEAR RESISTANCE CORROSION RESISTANCE
MATERIALS 31
CARBIDE GRADE APPLICATION EXAMPLES
WET
C3D Wet drawing of high carbon, tire cord, welding wire and sawing wire.
6UD Wet drawing of high carbon, tire cord, welding wire and sawing wire.
H3F Wet drawing of high carbon, tire cord, welding wire and sawing wire.
RS1T Wet drawing of coated high carbon steels (Zn & brass). Dry drawing of stainless steel.
H6F Wet and dry drawing of welding wire, dry drawing tire cord. Standard grade for d1 > 3 mm.
H10F Dry drawing of tire cord, welding wire and high carbon wire.
H6N Dry drawing. Standard grade for d1 > 3 mm.
H15F Cold drawn bars, tubes and

shapes large diameters.
Standard for large
H11N DRY diameters d1 > 11 mm.
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
INNER DIAMETER (mm)
Standard
DRY WET
RS1T
Tire Cord H10F / H6N H6F H3F / 6UD
H3F/6UD
Sawing Wire H10F / H6N H6F H3F/6UD PCD
Welding Wire H10F H6F H3F/C3D
Ø 9 mm 5 2.5 0.5 0.3 0.14 0.12 Ø 0.08 mm

HYPERION 6UD
HIGH PERFORMANCE
Hyperion 6UD is the high performance grade for fine wire wet drawing. It is an ultrafine cemented carbide in
combination with special additives that maximizes corrosion resistance without loosing toughness. The Hyperion
Sinter-HIP process guarantees premium carbide quality.
HYPERION GRADE 6UD

Hyperion 6UD is used in high performance drawing processes for:
- Saw wires
- Tire cords
- All ultra tensile wires
- Finest wire diameters.
GRADE PREVENTS
Hyperion 6UD prevents:
- Corrosion wear
- Friction
MATERIALS
- Wear in small bores.
GRADE BENEFITS
Hyperion 6UD benefits include:
- Increased die life
- Less energy consumption
- Longer batch sizes
- Lower quality rods quality can be used.
PERFORMANCE CHART
Toughness
Wear resistance
Hardness
Corrosion resistance
Low Medium High
Available in standard ISO, JIS and DIN or tailor-made to your design.
MATERIALS 33
HYPERION C3D
SUPER PERFORMANCE
Hyperion C3D is the new super performance grade with never-before-seen properties for tungsten carbide. It is an
ultrafine cemented carbide in combination with special additives that maximizes corrosion resistance and exhibits
extreme wear resistance. The Hyperion sinter-HIP process guarantees premium carbide quality.
HYPERION GRADE C3D

Hyperion C3D is used in super performance drawing processes for:
- Welding wire
- Low and high carbon steel
- PC strand.
GRADE PREVENTS
Hyperion C3D prevents corrosion and wear out by:
- Very low Co leaching
- Integrity of the carbide matrix ensures
the material wear resistance.
GRADE IMPROVEMENTS
Performance improvements:
- Die life increased up to 5 times vs those of standard grades
- Less machine downtime
- Lower quality rods can be used
- High polishing speed.
PERFORMANCE CHART
Thermal conductivity
Wear resistance
Hardness
Corrosion resistance
Low Medium High

HYPERION C3D SUPER PERFORMANCE
CORROSION RESULTS
Corrosion testing with commonly used emulsions in the markets has shown the following results:
HYPERION GRADE C3D STANDARD GRADES

Hyperion C3D corrosion results: Standard carbides corrosion results:
- Very low Co leaching - Massive Co leaching
- WC grain sharp edges - WC etched away leaving the Co exposure
- Integrity of the carbide matrix - Structure heavily attacked which could lead to grain drop out.
ensures the material wear
resistance.
HYPERION C3D STANDARD GRADES
MATERIALS
MATERIALS 35
MAIN MATERIAL DEFECTS
ETA PHASE
- Definition: Wrong Carbon balance (lack of carbon)
EXTRA FINE GRAIN
- Causes:
- Oxidation of the RTP before pressing
- Oxidation of the green blanks awaiting for sintering
- Low RTP Quality poor C control on the RTP manufactured process
- Oxidizing atmosphere in the sintering furnace
- Effect:
- Stress concentration point
MEDIUM GRAIN
- Solution:
- Isolate the sintering trays with graphite protections.
CARBON PRECIPITATION
- Definition: Wrong carbon balance (excess of carbon)
- Causes:
- Incorrect parameters in sintering process
- Effects:
- Weak point in the material
- Stress concentration point
- Solution:
- Let oxidizing the more susceptible grades.
RECRYSTALLIZATION
- Definition: Heterogeneous WC grain size
- Causes:
- Sintering process at too high temperature
- Bad quality of the raw powder
- Effects:
- Big WC grains could be pulled out easily by the wire material
- Scratches in the wire surface or premature failure of the nib
- Solution:
- Extreme control in the sintering parameters and the quality
of the ‘ready-to-press’ powder.

POROSITY
- Definition (according to ISO4504):
- PorosityA: pores < 10 µm
- PorosityB: pores between 10 and 25 µm
- Macroporosity: pores > 25 µm
- Causes:
- Lack of force during pressing
- Impurities or contamination of powder
- Low sintering temperatures
- Lack of vacuum/pressure during sintering
- Not using HIP
- Effect:
- Premature failure of die or scratches in the wire surface
- Solutions:
- SinterHIP
- RTP quality control.
MATERIALS
Co LAKE
- Definition: Co accumulation
- Depending on the customer, Co accumulations can be up to 25 µm
- Cause:
- Wrong sintering parameters
- Effects:
- Stress concentration point.
MATERIALS 37
CONTAMINATION
• Definition:
- Traces of other chemical components (steel, organics, impurities, etc.)
- Local grain size changes
- Varying Co%, etc.
- Causes:
- Impurities in the powder
- Lack of cleanliness between production batches
- Effects:
- Stress concentration point.
COMBINATION OF DEFECTS
- Material defects never come alone
- It is quite normal to find combinations of several defects in one sample
- Hyperion quality controls 100% of the sintering batches.
EXTRA COARSE GRAIN
CARBON
FINE GRAIN
* Hyperion superior quality in raw material powder and excellent process control are the basis for material consistency.

HYPERION NIBS FOR WIRE DRAWING DIES
Hyperion cemented carbide drawing nibs are known for their impeccable geometry and unique and consistent grade
composition. We offer not only a huge range of standard dimensions but also a superior quality in special designs.
CARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD ISO

ISO
10x8 to 20x17 Nib
MATERIALS
TOLERANCES FOR d2 AND h2
Nib As Sintered Ground*
d2 x h2 d2 h2 d2
Nominal Tolerance Nominal Tolerance Nominal Tolerance
10x8 9.65 ±0.15 8.00 9.55 +0.015/0
±0.20
12x10 12.00 +0.040/+0.010 10.00 12.00
14x12 13.91 ±0.10 12.00 13.70 +0.018/0
16x13 15.80 ±0.15 13.00 ±0.30 15.54
20x17 19.75 ±0.15 17.00 19.50 +0.021/0
* Faces will not be ground.
TOLERANCES FOR d1 TOLERANCES FOR l3 (nibs with

round bearing)
d1 From To Tolerance l3 From To Tolerance

0.10 0.29 0/-0.03 < 0.51 +0.25/0
0.30 0.49 0/-0.04 0.51 1.02 +0.30/0
0.50 0.69 0/-0.05 1.03 1.50 +0.40/0
0.70 0.99 0/-0.06 1.51 2.50 +0.50/0
1.00 1.50 0/-0.07 > 2.50 +0.60/0
1.51 3.00 0/-0.08

3.01 5.09 0/-0.09
TOLERANCES FOR 2α AND 2γ CASING CHAMFER

Angle Tolerance h2 εº bz Tolerance
2α ± 1º ≤8 15º 12% h2 ±3% h2
2γ ± 5º 10, 12, 13 15º 11% h2 ±3% h2
17 15º 8% h2 ±3% h2
MATERIALS 39
CARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD ISO
NIB ORDERING CODE
d2 x h2 Code / Grade 2α d1 l2 l3 l4 2β R ∅E 2γ
0.20 0.25 0.30 0.35 0.40 0.50 1.80 5.7 6.8

0.60 0.70 0.80 0.90 1.00 1.10 1.80 5.7 6.8
1.20 _ _ _ _ _ 1.75 5.7 7.1
1.30 _ _ _ _ _ 1.66 5 7.1
10x8 WDINR10...126F / H6F 12º 1.40 _ _ _ _ _ 0 1.73 5 7.1 90º
1.50 _ _ _ _ _ 1.75 5 7.1
1.60 _ _ _ _ _ 1.60 5.2 7.3
1.70 _ _ _ _ _ 1.66 4.7 6.9
1.80 _ _ _ _ _ 1.55 4.8 7.1
1 0.9 0.8 0.75 0.7 _ 1.95 8.6

WDINR12...126F / H6F 12º 0.65 0.6 0.5 0.4 0.3 _ 2 8.9 8 90º
12x10
0,25 0.2 _ _ _ _ 2 8.9
0.60 0.70 0.80 _ _ _ 2.40 10.5 10

0.90 _ _ _ _ _ 2.58 10.3 10
1.00 _ _ _ _ _ 2.40 10.5 10
1.10 _ _ _ _ _ 2.59 10.3 10.2
1.20 _ _ _ _ _ 2.40 10.5 10
14x12 WDINR14...126F / H6F 12º _ _ _ 0 75º
1.30 1.40 1.50 2.55 10 10
1.70 _ _ _ _ _ 2.53 10 10
1.80 1.90 2.00 2.20 2.40 _ 2.40 10.5 10
2.45 _ _ _ _ _ 3.21 10 10.4
2.60 2.90 _ _ _ _ 2.40 10.5 10
0.25 0.30 _ _ _ _ 3 10.6 12.1

0.35 _ _ _ _ _ 3 10.6 12.2
0.40 0.45 0.50 0.55 0.60 _ 3 10.6 12.3
0.70 _ _ _ _ _ 3 10.6 12.5
0.80 _ _ _ _ _ 3 10.6 12
0.90 1.00 _ _ _ _ 3 10.3 12.2
1.10 1.20 _ _ _ _ 3 10.3 12.4
WDINR16...12F / H6F 12º 1.30 1.40 _ _ _ _ 0 2.90 10 12 75º
1.50 _ _ _ _ _ 2.90 10 12.2
1.60 1.70 _ _ _ _ 2.90 10 12.3
1.90 _ _ _ _ _ 2.90 9.7 12
16x13
2.25 _ _ _ _ _ 2.85 9.7 12.4
2.40 2.50 _ _ _ _ 3 9.2 12
2.80 _ _ _ _ _ 3 9 11.7
3.40 _ _ _ _ _ 3 8.6 11.8
_ _ _ _ _
2.50 _ _ _ _ _ 0.64 3.13 8 11.7
WDINR16...14F / H6F 14º 75º
2.60 0.66 3 8.1 12
WDINR16...16F / H6F 16º 3.00 _ _ _ _ _ 0.78 3.12 7.7 11.7 75º
WDINR16...16F / H6F 16º 3.97 _ _ _ _ _ 0.99 3 8.1 13.4 75º
0.70 _ _ _ _ _ 4.25 13.5 15.1

0.80 _ _ _ _ _ 4.25 13.5 15.2
0.90 _ _ _ _ _ 4.25 13.5 15.3
1.00 _ _ _ _ _ 4.2 13.2 14.9
1.10 1.20 _ _ _ _ 4.2 13.2 15
1.30 _ _ _ _ _ 4.2 13.2 15.2
1.40 _ _ _ _ _ 4.2 13.2 15.3
1.60 _ _ _ _ _ 4.2 13.2 15.5
20x17 WDINR20...12F / H6F 12º _ _ _ _ _ 0 60º
1.80 4.15 12.9 15.1
2.00 _ _ _ _ _ 4.1 12.6 14.8
2.40 _ _ _ _ _ 4.1 12.6 15.2
2.65 _ _ _ _ _ 4.05 12.3 14.9
2.70 _ _ _ _ _ 4.05 12.3 15
3.05 _ _ _ _ _ 4 12 14.8
3.20 _ _ _ _ _ 4 12 15
3.60 _ _ _ _ _ 4 11.7 14.9
With outer diameter as sintered or ground. All dimensions in mm.

CARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD JIS
JIS
9x6 to 20x14 Nib
NIB ORDERING CODE
0.10 _ _ _ _ _ 6.2
0.12 0.13 0.14 _ _ _ 6.0
0.15 _ _ _ _ _ 6.2
0.16 _ _ _ _ _ 6.0
0.17 0.18 0.19 _ _ _ 6.1
0.20 _ _ _ _ _ 1.0 5.0 6.2
0.21 0.22 0.23 0.24 _ _ 6.1
0.25 _ _ _ _ _ _ 6.2
9x6 WDJNR09...12M / H3F 12º 0 1.0 90º
_ _ _ _ _ 6.1
0.26 6.2
0.27 0.28 0.29 0.30 0.32 0.33 6.2
MATERIALS
0.34 0.35 0.40 0.45 0.50 _
0.55 0.60 0.65 0.70 0.75 0.80 1.7 6.6
0.85 0.90 _ _ _ _
1.7 6.6
1.00 1.10 _ _ _ _ 3.9
1.7 7.0
1.20 1.30 1.40 1.50 _ _
2.6 7.0
0.50 0.55 0.60 0.65 0.70 0.75 6.8 _ _ _
WDJNR12...12M / H3F 0.80 0.85 0.90 0.95 _ _ (l1 + l2)
0 5.2 8.1+d1
1.00 1.05 1.10 1.20 1.30 1.40 5.9 0.9 4.0
1.50 1.60 _ _ _ _ (l1 + l2)
12º 7.1+d1
_ _ _
WDJNR12...12B / H3F 1.70 1.80 1.90 5.7 3.9
_ _ _ _ _ (l1 + l2)
1.1
2.00 8.5
12x8 _ _ _ _ _ 3.3
2.10 5.5 (l1 + l2) 1.3 _ _ 6.5+d1 _
0.50 0.55 0.60 0.70 0.75 0.80 6.8 0 5.4 8.1+d1
WDJNR12...16M / H3F 0.90 0.95 _ _ _ _ (l1 + l2)
_ _ _
16º 1.70 1.80 1.90 5.7 4 7.1+d1
_ _ _ _ _ (l1 + l2)
1.1
WDJNR12...16B / H3F 2.00 8.0
_ _ _ _ _ 3.5
2.10 5.5 (l1 + l2) 1.3 6.0+d1
_ _
0,50 0,70 0,75 0,80 _ _ 8.5
WDJNR15...12M / H6F _ _ _ 0 6.5 10.6+d1
0,90 (l1 + l2)
1,00 1,10 1,20 1,30 1,40 1,50 7.6 (l1 + l2) 0.9
5.2 9.7+d1
1,60 1,70 1,80 1,90 _ _
7.4 1.1
12º 2,00 _ _ _ _ _ (l1 + l2) 10.6
WDJNR15...12B / H6F 2,10 2,20 2,30 2,40 2,50 _ 7.2 (l1 + l2) 1.3 4.6
_ _ _ 8.7+d1
2,60 2,70 2,80 7.1
_ _ _ _ _ (l1 + l2) 1.4
3,00 10.6
3,10 _ _ _ _ _ 4.1
6.9 (l1 + l2) 1.6
_ _ _ _ 7.6+d1 _
15x10 1,60 1,70 1,80 1,90 7.4
_ _ _ _ _ 1.1
2,00 (l + l )
1 2 11.5
2,10 2,20 2,30 2,40 2,50 _ 7.2 (l1 + l2) 1.3 4.8
_ _ 8.7+d1
2,60 2,70 2,80 2,90 7.1
_ _ _ _ _ 1.4
3,00 (l1 + l2) 10.7
WDJNR15...16B / H6F 16º 3,10 3,20 3,30 3,40 3,50 _ 4.3
6.9 (l1 + l2) 1.6
_ _ 7.7+d1
3,60 3,70 3,80 3,90 6.7
_ _ _ _ _ 1.8
4,00 (l1 + l2) 10.6
4,10 4,30 4,40 4,50 _ _ 6.5 (l1 + l2) 2.0 4.6
_ _ _ 6.6+d1
4,60 4,70 4,80 6.6 (l1 + l2) 2.2
1,70 1,80 _ _ _ _ 11.0 (l1+ l2) 8.1 13.7+d1
_ _ _ _ _ 1.1 _
2,00
_ 10.6 7.6 12.7+d1
2,10 2,20 2,30 2,40 2,50 (l1 + l2)
1.3
2,60 2,70 2,80 2,90 _ _
_ _ _ _ _ 1.4
3,00
3,10 3,20 3,30 3,40 3,50 _ 1.6 7.1 11.7+d1
20x14 WDJNR20...16B / H6N 16º 3,60 3,70 3,80 3,90 _ _ _ _
_ _ _ _ _ 1.8
4,00
_ 10.2 75º
4,10 4,20 4,30 4,40 4,50 2.0 7.3 10.7+d1
_ _ (l1 + l2)
4,60 4,70 4,80 4,90
_ _ _ _ _ 2.2
5,00
5,20 5,40 5,50 _ _ _ 2.3 7.9 9.6+d1
6,00 _ _ _ _ _ 2.5
MATERIALS 41
CARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD DIN
DIN
12x10 to 30x24 Nib
NIB ORDERING CODE
_ _ _ _
0.20 0.30 2.1 7.0
_ _ _ _ _
WDSNR12...12M / H6F 12º 0.35 2.9 0 2.2 90º 6.5 6.8 90º
0.40 0.50 0.60 0.70 0.80 0.90 2.1 7.0
12x10
1.00 1.10 1.20 1.30 1.40 1.50 7.6
_ _ _ _
1.60 1.70 7.6
WDSNR12...14M / H6F 14º 3.6 0 1.9 90º 6.5 90º
1.80 1.90 2.00 2.10 2.20 2.30 8.2
_ _ _ _
2.40 2.50 8.2
_ _ _ _ _
0.70 2.8 2.6 8.5
_ _ _ _ _
0.80 2.8 2.7 8.0
_ _ _ _ _
0.90 2.8 2.6 8.5
_ _ _ _ _
WDSNR16...08M / H6F 8º 1.00 3.4 0 2.5 60º 8.0 7.9 75º
_ _ _ _
1.10 1.15 2.8 2.6 8.5
_ _ _ _ _
1.20 3.64 2.5 7.8
_ _ _ _
1.30 1.50 2.8 2.6 8.5
_ _
0.20 0.30 0.40 0.50 2.5 2.9 8.2
_ _
0.60 0.70 0.80 0.90 3.0 2.9 8.2
1.00 1.10 1.20 1.30 1.40 1.50 3.3 2.6 8.7
_ _ _ _ _
1.60 3.3 2.6 8.7
WDSNR16...12M / H6F 12º _ 0 60º 8.0 75º
1.70 1.80 1.90 2.10 2.25 3.6 2.6 8.7
_ _ _ _ _
16x13 2.90 3.9 2.3 10.0
_ _ _ _ _
3.60 4.5 2.3 10.0
_ _ _ _ _
3.80 4.0 2.3 10.0
1.00 1.10 1.20 1.30 1.40 1.50

WDSNR16...14M / H6F 14º _ _ _ _ 3.4 0 2.6 60º 8.0 8.7 75º
1.60 1.70
_
1.80 1.90 2.00 2.10 2.20 3.0
50%
WDSNR16...14B / H6F 14º 2.30 2.40 2.50 2.60 2.70 2.80 2.8 2.3 60º 8.0 9.3 75º
_ _ _ _ _ d1
2.90 2.8
_ _ _
3.00 3.20 3.40 1.5
_ _ _
3.60 3.80 4.00 1.6
WDSNR16...16B / H6N 16º _ _ _ 3.5 2.3 60º 8.0 10.5 75º
4.20 4.40 4.60 1.7
_ _ _
4.80 5.00 5.20 1.8
_ _ _ _
1.20 1.30 4.9 3.9 10.4
_ _
1.40 1.50 1.60 1.80 5.7 3.9 10.4
_ _
2.00 2.60 2.70 2.90 7.0 3.1 10.4
_
WDSNR20...12M / H6N 12º 3.05 3.20 3.35 3.50 3.65 6.4 0 3.1 60º 8.0 12.3 60º
_ _ _ _ _
3.95 6.4 3.1 12.3
_ _
4.25 4.40 4.55 4.70 7.2 3.1 12.3
_ _ _ _ _
4.90 6.2 3.97 12.5
_ _ _ _ _
1.80 5.6 50% d1 3.5 10.3
_ _
2.00 2.20 2.30 2.40 6.2 50% d1 2.8 10.3
_ _
20x17 WDSNR20...14B / H6N 14º 2.50 2.60 2.70 2.80 5.8 50% d1 2.8 60º 8.0 10.3 60º
_ _ _ _ _
3.00 5.0 1.5 2.8 12.2
_ _ _ _
3.65 3.85 5.0 1.6 2.8 12.2
_ _ _ _
3.20 3.40 5.3 1.5 12.2
_ _ _
3.60 3.80 4.00 5.7 1.6 12.2
_ _
4.20 4.40 4.60 4.80 6.2 1.7 12.2
_
WDSNR20...16B / H6N 16º 5.00 5.20 5.40 5.60 5.80 6.2 1.8 2.8 60º 8.0 13.0 60º
6.00 6.20 6.40 6.60 6.80 7.00 6.2 2.0 13.8
_ _ _ _ _
7.20 6.2 2.0 13.8
_ _ _
7.40 7.60 7.80 6.2 2.0 15.2

CARBIDE NIBS FOR WIRE DRAWING DIES - HYPERION STANDARD DIN
NIB ORDERING CODE
_ _ _ _ _
2.20 6.7 12.8
_ _ _ _ _
2.40 7 12.8
_ _ _ _ _
2.60 7 12.8
_ _ _ _ _
2.80 7.5 12.8
WDSNR25...12M / H6N 12º _ _ _ _ _ 0 4.2 60º 8.0 60º
3.00 5.8 12.8
_ _ _ _ _
3.25 7.5 12.8
_ _ _ _ _
3.65 7 14
_ _ _ _ _
3.80 6.5 14.5
_ _ _ _ _
3.80 5.3 1.5 4.0 14.5
25x20 _ _ _ _
4.00 4.20 5.6 1.6 4.0 15.0
_ _ _ _ _
4.40 6.5 1.6 4.0 15.0
_ _ _ _ _
4.80 4.9 1.7 4.0 15.0
_ _ _ _ _
5.40 5.9 1.7 4.0 15.0
_ _ _ _ _ _
WDSNR25...16B / H6N 16º 5.9 1.8 4.0 60º 8.0 15.0 60º
_ _ _ _
5.80 6.00 6.9 1.8 3.7 15.0
_ _
6.20 6.40 6.60 6.80 6.3 2.0 3.7 16.3
_ _ _ _
7.00 7.40 6.8 2.0 3.4 16.3
_
7.60 7.80 8.00 8.20 8.40 6.8 2.0 3.4 17.3
_ _ _
8.60 8.80 9.00 7.8 2.0 3.4 17.3
_ _ _ _ _
MATERIALS
2.50 5.80 1.6 6.1 14.9
_ _ _ _ _
2.80 6.40 1.6 5.8 15.0
_ _ _ _ _
3.20 5.80 1.6 5.8 16.0
_ _ _ _ _
3.50 6.30 1.6 5.6 16.0
_ _ _ _ _
3.80 5.80 1.6 5.4 17.0
_ _ _ _ _
4.00 5.70 1.6 5.2 17.5
_ _ _ _ _
4.20 6.00 1.6 5.2 17.5
_ _ _ _ _
4.40 5.20 1.6 5.0 17.5
_ _ _ _ _
4.60 7.00 1.6 4.8 17.5
_ _ _ _
5.00 5.20 8.4 1.7 4.6 17.2
_ _ _ _ _
5.80 7.4 1.8 4.6 18.7
_ _ _
30x24 WDSNR30...16B / H6N 16º 6.00 6.40 6.60 6.9 2.0 4.6 60º 8.0 18.7 60º
_ _ _ _ _
6.80 8.4 2.0 4.6 18.7
_ _ _ _
7.40 7.60 9.0 2.0 4.6 18.7
_ _ _ _ _
7.80 8.1 2.0 4.6 18.7
_ _ _ _ _
8.60 9.3 2.0 4.6 18.7
_ _ _ _
8.80 9.00 10.4 2.0 4.6 18.7
_ _ _ _ _ _
11.2 2.0 4.6 18.7
_ _ _ _ _
9.60 9.5 2.2 4.6 19.8
_ _ _ _
10.00 10.20 10.0 2.2 4.6 19.8
_ _ _ _ _
11.00 9.6 2.3 4.6 21.2
_ _ _ _ _
11.40 10.6 2.4 4.6 21.2
_ _ _ _
11.80 12.00 9.9 2.4 4.6 21.2
With outer diameter as sintered or ground. All dimensions in mm. Standard HYPERION stock
MATERIALS 43
LARGE STANDARD NIBS
Nib d1 (recommended) Grade Available Nib d1 (recommended) Grade Available

d2 x h2 nominal d2 x h2 nominal
min. max. min. max.

35x24 12 16 H6N / H11N 70x30 32 37 H11N
40x24 15 19 H6N / H11N 75x30 35 41 H11N
45x25 18 22 H6N / H11N 80x30 39 45 H11N
50x25 21 25 H6N / H11N 85x33 43 49 H11N
55x27 24 28 H6N / H11N 90x33 47 53 H11N
60x27 27 31 H6N / H11N 100x35 51 61 H11N
65x27 29 34 H6N / H11N
TOLERANCES FOR d2 AND h2

Nib As Sintered Ground*
d2 x h2 d2 h2 d2
Nominal Tolerance Nominal Tolerance Nominal Tolerance
9x6 9.00 +0.25/+0.05 6.00 9 +0.015/0
±0.20
12x10 12.00 +0.32/+0.12 10.00 12.00
+0.018/0
16x13 16.00 0/-0.30 13.00 15.65
±0.30
20x17 20.00 +0.10/-0.30 17.00 19.65
25x20 25.00 +0.50/+0.10 20.00 25.00 +0.021/0
±0.40
30x24 30.00 +0.60/+0.20 24.00 30.00
* Faces will not be ground.
TOLERANCES FOR d2 TOLERANCES FOR l3 (nibs with

round bearing) TOLERANCES FOR 2α AND 2γ
d1 From To Tolerance l3 From To Tolerance Angle Tolerance
0.10 0.29 0/-0.03 < 1.02 +0.15/-0.15 2α ± 1º
0.30 0.49 0/-0.04 1.03 1.50 +0.20/-0.20 2γ ± 5º
0.50 0.69 0/-0.05 1.51 2.50 +0.25/-0.25
0.70 0.99 0/-0.06

1.00 1.50 0/-0.07
CARBIDE GRADE PROPERTIES
1.51 3.00 0/-0.08
Carbide Grade Co (%wt) Hardness (HV30) Density (g/cm3) WC Grain Size
3.01 5.09 0/-0.09
6UD 6 2050 14.75 Ultrafine
5.10 7.09 0/-0.10
H3F 3 1925 15.30 Extra fine
7.10 10.14 0/-0.12
H6F 6 1775 14.90 Extra fine
10.15 12.00 0/-0.15
H6N 6 1600 15.00 Fine
H10F 10 1600 14.50 Extra fine
H11N 11 1250 14.40 Fine
H15F 15 1380 13.95 Extra fine
CASING CHAMFER
Nib Height of Chamfer, bz
d2 x h2 εº Nominal Tolerance
9x6 1.3 +0.15/-0.15
12x10 1.1 +0.30/-0.30
16x13 15º 1.5 +0.30/-0.30
20x17 1.5 +0.30/-0.30
25x20 2.1 +0.30/-0.30
30x24 20º 2.4 +0.40/-0.40

WEAR PARTS
ENGINEERED PRODUCTS
Tailor-made according to your drawing. Fully finished parts ready-to-use or blanks are available.
- Straightening rollers
- Wire guides
- Cabling dies
- Shaving dies
- Die blanks with starter holes
- Plugs and mandrels
- Injection nozzles / extrusion tools
- Calibrating pins
- Gauges / measuring pins?
- Flattening rollers
- Profiling rolls.
MATERIALS
MATERIALS 45
SHAVING DIES
Draw-peeling – also known as shaving – is a cutting procedure. The cutting edge in this case is a draw-peeling tool/
shaving die. This is a static tool with a circular blade. The geometry is similar to that of a regular drawing die in
the wire industry. The main difference is that, in contrast to the transformative geometry of the drawing die, there
is a cutting edge in the draw-peeling tool. A descaling and a coating that is usually required for steel wire is not
necessary in front of this cutting operation.
Shaving operation shall guarantee:

- To remove continuously a uniform thickness of metal
- At high speed
- Separating the removed layer into a plurality of strips and said strips being removed radially from the rod
- Produce a smooth surface thereon.
SHAVING DIE ANGLE
Steel housing -Y0 +Y0

WC shaving die
β0
α0
Pr
Chips Pr Tool reference plane β0 Tool orthogonal key angle

±Y0 Tool orthogonal chip angle α0 Tool orthogonal clearance angle
Hyperion offers a wide range of shaving rough blanks made of two Cemented Carbide grades MP10 and ES35.
D (mm) H (mm) d (mm) 2a (º) 2b (º) 2g (º) GRADE

16,18+/-0,01 7,4+/-0,12 5,95 13 18 0 MP10
16,18+/-0,01 7,4+/-0,12 5,35 13 18 0 MP10
16,18+/-0,01 7,4+/-0,12 6,95 13 18 0 MP10
16,18+/-0,01 7,4+/-0,12 7,95 13 18 0 MP10
16,18+/-0,01 7,4+/-0,12 3,95 13 18 0 MP10
16,18+/-0,01 7,4+/-0,12 4,35 13 18 0 MP10
16,18+/-0,01 7,4+/-0,12 3,60 13 18 0 MP10
16+0,7/+0,3 12+0,6/0,3 5,35 13 18 0 ES35
16,19+/-0,01 7,0+0,55/+0,3 5,80 13 18 0 ES35
16,19+/-0,01 7,0+0,55/+0,3 7,40 13 18 0 ES35
16,19+/-0,01 7,0+0,55/+0,3 6,40 13 18 0 ES35
16,19+/-0,01 7,0+0,55/+0,3 8,40 13 18 0 ES35

HYPERION DIAMOND COMPOUNDS
SLURRIES
YOU CHOOSE THE FORMULA
SLURRY FORMULAS SUSPENSION FORMULAS

K285T Water soluble K285T Water soluble
K400 Oil soluble K1500 Oil soluble
K450 Water / Oil soluble
YOU CHOOSE THE CONCENTRATION
LIGHT CONCENTRATION MEDIUM CONCENTRATION HEAVY CONCENTRATION
Finishing Removal
MATERIALS
WE ADD SUPERIOR DIAMOND POWDERS
DIAMOND POWDERS DESCRIPTION SUGGESTED APPLICATION INDUSTRY

Aerospace
A monocrystal, diamond powder
SJK-5 Lapping Ceramics
used in slurries and suspensions
Glass
Lenses
A multi-crystal, more friable
RJK-1 Lapping and polishing Optics
than a monocrystal
Sapphire
Semi-conductor
Polycrystalline diamond available Silicon carbide
Poly Polishing
in sizes < 10 μm
Tungsten carbide
YOU CHOOSE THE CONTAINER SIZE
125 mL 250 mL 500 mL 1.000 mL 1 gallon 5 gallon bucket
DIAMOND SIZE AVAILABILITY
Micron Micron Micron Micron Micron Micron Micron Micron Micron Micron Micron Micron Micron Micron Micron
0-1/2 0-1 0-2 1-3 2-4 3-5 4-8 5-10 6-12 8-12 10-20 20-30 20-40 30-60 50-70
Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh
100.000 60.000 14.000 11,000 8.000 6.500 3.000 2.500 1.800 1.700 1.200 800 575 400 270
MATERIALS 47
PASTES: DIAMOND POWDER + CARRIER
PRODUCT IDENTIFICATION DESCRIPTION RECOMMENDED USES
- When exceptional cleaning is required

K700 WS Products Water soluble - When petroleum contamination is prohibited
- Specimen preparation
- Controlled lapping for carbide drawing dies

K210 OS Products Oil soluble and cold heading dies
- Numerous other polishing applications
- Compliments the use of oil and water for achieving

G400 WOS Products Water / Oil soluble more productive results
- Facilitates cleaning
TUBE SIZES
5 gram 10 gram 18 gram 25 gram 50 gram
JAR SIZES
5 gram 25 gram 50 gram 100 gram 200 gram

00 2
.0 -1
.0 -2
.0 -3
00 4
0
0. 1/
00
00
00
8. 2-
0
60 0
14 0
11 1
es ro 1/4
es cro /2
10 0-
es cro 1
es cro 2
m ic 3
h n
h n
h n
h n
m mi 1
h n
es ro
m mic
m mi
m mi
m
50 0
80 2
70 2
50 5
00 8
2. -1
1. -1
1. -1
6. 3-
3. 4-
0
0
es ron .5
es ron 0
h 5
h 6
h 8
m ic 4
m ic 6
m ic 9
m ic 1
h n
h n
m ic 7
es ron
es ro
es ro
m
m
0 0
0 0
5 0
0 0
0 0
20 2
60 -3
57 -4
40 -6
27 -7
1. 0-
h 20
h 20
h 30
h 50
es on 5
m cro 25
m cro 30
m cro 45
m cro 60
h 1
m icr 1
es n
es n
es n
es n
i
i
m

DIAMOND MICRON POWDER GRADES
HYPERION SLURRY
Hyperion slurry is comprised of diamond particles containing more surface cutting points than a typical
monocrystalline micron and polymicron diamond.
Hyperion slurry achieves higher material removal rates and better surface finish due to the surface characteristics
of the diamond.
The diamond surface is covered with small cutting points, which reduce surface roughness of the workpiece.
In addition to the diamond characteristics, the slurry formulation can be tailored to optimize performance for
specific operating conditions and workpieces.
HYPERION MONOCRYSTALLINE POLYCRYSTALLINE

DIAMOND MICRON DIAMOND MICRON DIAMOND
Few cutting
points
Retains size
Maintains effectiveness Susceptible to
crushing
Readily available
Not easily crushed Becomes smaller
MATERIALS
with use
Limited availability
GRM DIAMOND
GRM diamond satisfies a broad range of size, shape and surface demands while providing a satisfactory surface
finish. GRM diamond is a desirable option if tight tolerances are not mandatory.
APPLICATIONS
Polishing of wire dies, stones and gems.
GRM (Standard Grade) UNCOATED
DIAMOND (FOR COMPOUND MANUFACTURING)

DIAMOND SIZES AND STANDARDS
- Standard size offering ranges from 0.5 μm to 80 μm (mean size)
- Available in metal or resin bond diamond grades
- Sold in 50 to 5,000 carat containers
- Custom particle size distributions are available upon request.
MATERIALS 49
APPLICATION KNOWLEDGE
HYPERION
Hyperion offers a wide range of premium
products for the wire drawing industry,
from polycrystalline diamond (PCD) and
carbide blanks to rough core dies and
diamond compounds.
TUNGSTEN CARBIDE
Steel cord for rubber reinforcement, sawing
wire, bead wire, welding wire, galvanized
wire, stainless steel, spring wire, etc.
PCD
Stainless steel, welding wire, sawing wire,
tire cord, electrical wire and medical wire
applications.
VERSIMAX™ AND VERSIRION™

Hyperion’s Versimax and Versirion are
unique solutions for drawing and
compacting applications for various
ferrous and non-ferrous materials.

CUSTOMER COST SPLIT
COST SPLIT FOR STEEL CORD
5% 0.5%
3% 7%

25%
60%
Rod material Auxiliary material (lubricants, etc.)
Power (water, gas & electricity) Drawing dies
Packaging & transport Others
APPLICATIONS & FAILURE MODES 53

RADIAL CAR TIRE COMPOSITION (WEIGHT)
Nylon Overlays Gum Strips

Undertread
Tread
Steel Belts Sidewall
Belt Wedge
Cushion
Body Plies
Halobutyl Liner
Ply Turn Up
Chafer
Apex
Beads
Toe Guard
RADIAL TIRE COMPOSITION
5%
3% 6%
10% 29%
25% 22%
Natural rubber Textile cord
Synthetic rubber Bead wire
Reinforcing agent Ingredients
Steel cord

PCD APPLICATION GUIDELINE
WIRE DRAWING APPLICATION GUIDELINES
RELATIVE
DIE GEOMETRY PERFORMANCE
WIRE AREA DRAWING VERSUS
PERCENT
WIRE TYPE WIRE SIZE SPEED
REDUCTION
Range (mm) BEARING (m/min) SINGLE
REDUCTION TUNGSTEN
LENGTH CRYSTAL
ANGLE CARBIDE
(%) DIAMOND
NON-FERROUS
• Copper 1.84 - 7.60 20 - 35 16 - 25 10 - 25 600 - 2500 200 - 500X -
0.05 - 2.05 18 - 21 16 - 20 10 - 25 600 - 3300 - 5 - 15X
• Aluminum 1.84 - 7.60 18 - 30 16 - 25 10 - 25 600 - 1500 100 - 200X -
0.20 - 2.05 15 - 21 16 - 20 10 - 25 600 - 2000 - 3 - 5X
• Aluminum
Magnesium Alloy 1.84 - 4.76 18 - 22 16 - 20 15 - 30 350 - 650 100 - 200X -
• Tin-Plated Copper 0.20 - 1.80 15 - 26 18 - 22 10 - 25 300 - 1000 100 - 200X 5 - 10X
(electroplated)
• Nickel 200 0.33 - 1.65 20 - 30 16 - 20 15 - 30 200 - 500 - 6 - 10X
• Tungsten 0.12 - 0.62 18 - 22 12 - 16 20 - 40 30 - 80 - 3 - 6X
• Molybdenum 0.12 - 1.02 18 - 22 12 - 16 20 - 40 30 - 80 50 - 80X 3 - 6X
FERROUS
• Galvanized High
Carbon Steel 0.24 - 1.05 15 - 20 10 - 14 20 - 40 400 - 800 30 - 50X -
• Brass-Plated High
Carbon Steel Tire Cord 0.17 - 0.40 18 - 21 10 - 16 20 - 40 600 - 1000 10 - 30X -
• Stainless Steel 316 0.18 - 1.60 18 - 21 10 - 14 20 - 40 200 - 600 10 - 20X 4 - 8X
• Stainless Steel 302 0.24 - 1.60 18 - 21 10 - 14 20 - 40 200 - 600 8 - 15X 2 - 4X
• Ni-Cr-Fe Alloy 0.20 - 1.20 18 - 26 10 - 14 20 - 40 200 - 600 30 - 50X 4 - 6X
(60:15:25)

• Low Carbon Steel 0.88 - 2.10 18 - 21 8 - 14 20 - 40 400 - 800 30 - 70X -
Dimensional recommendation for round standard nibs:

WC APPLICATION GUIDELINE
PERCENTAGE OF REDUCTION
DRAWING
MATERIAL
CONDITIONS 5-8 8-12 12-16 16-25 25-35 35-45
• Lead
Dry - - - - - -
• Zinc
• Aluminum
• Silver
Wet 14º 16º 18º 21º 24º -
• Gold
• Cupper Dry - - - - - -
• Stainless Steel Wet 12º 14º 16º 19º 22º -
• Aluminum Alloys Dry - - - - - -

• Nickel
• Ni-Cr Alloys Wet 10º 12º 14º 17º 20º -
• Brass
Dry 7º 9º 11º 14º 17º 20º
• Bronze
• Nickel-Silver
• Non Alloyed Carbon
Wet 9º 11º 13º 16º 19º -
Steels (%C<0,4)
• Non Alloyed Carbon

Steels (%C<0,4) Dry 6º 8º 10º 12º 15º 18º
• Alloyed Steels
• Ni-Cr Alloys for
electrical resistances Wet 8º 10º 12º 15º 18º -
• Molibdenum
• Tungsten Dry 10º 10º 12º 12º 14º -
NIB CASE
d1 s Dimensional recommendation
d2 h2 l4 2β 2γ d3 h3 l5 for round standard nibs:
min max min
8 4 0,1 1 3,5 1 12
10 8 0,2 2 4 2 90º 90º 28 16 3
12 10 0,3 3 4,5 2,5 20
28
14 12 0,4 4 5 3 22 3
60º 75º 43
16 13 0,5 5 5,5 3,5 43 25 4
20 17 1,5 6,5 6,75 4,5 43 32
53 5
25 20 2,5 9 8 5 60º 60º 35
75
30 24 3,5 12 9 6 75 40 6
Dimensions in mm unless otherwise noted.

PCD BEST PRACTICES
- Recut or repolish die on observation of wear ring in area of wire contact to maximize die life.
- Filtrate lubricant to remove metal fines to maximize lubricant flow, wire finish and die life.
- Do not exceed maximum die size recommendation for blank size.
- Decrease bearing length for higher speed drawing.
- Use finer grain die blanks for improved wire surface finish and in drawing ferrous and plated wires.
- Use coarser grain die blanks for drawing larger size non-ferrous wire to provide longer die life and improved wire
dimensional control.
- In high temperature drawing of tungsten and molybdenum wire, maintain reducing atmosphere in drawing zone
to minimize detrimental oxidation effects and maximize die life.
- Use matched elongation die sets in multi-wire drawing machines.
WIRE
ENTRY
FRACTURE INITIATION
WIRE
CAP
STEEL CASING
CARBIDE
DIRECTION
PCD OF SLOW
CORE CRACK
GROWTH

WIRE
EXIT

CARBIDE BEST PRACTICES
- Ensure correct wire section reduction by calculation. Verify actual wire reduction vs theoretical.
- Consistency in the die set drawing progression.
- Back relief between the hearing and the exit prevents wire production against machine vibration and spring back.
- Use the correct cemented carbide in accordance with the type of drawing process, wire material and reduction.
- Use harder grades for fine wire diameters, and tougher grades for big diameters and big reduction.
- Do not exceed maximum base size recommendation per nib size. Recutting more than 10 times must be avoided.
- Every recut must ensure that any wear ring or mark from previous drawing process is removed.
- Hot casing gives the end user high and tight range of pre-stresses, close contact case ID and nib, and better balance
of radial and axial pre-stresses.
FAILURE MODE DRAWING DIES

VISUAL EFFECTS. DIE ANALYSIS
To be taken into consideration when die failure analysis:
- Cause of failure is never absolute. Several factors play together, interacting and creating confusing effects.
- It is advisable to judge based in several dies assessment.
FAILURE CAUSES
Die breakage is usually caused by:
- Lack of mechanical support for the insert (hoop failure).
- Abnormal reduction.
- Inadequate lubrication.
- Inadequate tool material for the amount of reduction and speed (too hard or too tough).
- Tool misalignment, miscoaxiality, etc.
Some wear resistance must be always sacrificed to minimize breakage.
VISIBLE EFFECTS NOMINAL CAUSE POSSIBLE SOLUTIONS

PCD FAILURE MODE ANALYSIS
Hyperion has over 30 years of experience in PCD and cemented carbide wire dies. Hyperion provides the customers
with full root-cause analysis for the failures in wire drawing dies.
Hyperion has a fully equipped Materials Analysis Laboratory to investigate failures and determine the failure mode.
We provide our customers with a full report containing possible root cause and failure mode and possible solutions
based on the findings. We also provide supporting data in terms of micrographs and physical, chemical and mechanical
dimensional properties information.
Below are some of the typical failures we find in the Compax® wire dies.
Wear ring, which is normally located at the Thermal Damage is a typical mode of failure
bottom of the reduction area near the top when clogging at the entrance of the die leads
of the bearing area, is caused by lubrication to a sudden increase in the temperature leading
interruption, erosion due to rise in temperature to failure.
and back conversion of diamond at grain
boundaries.

DIE OR BLANK MISALIGNMENT
VISIBLE EFFECTS
Die fractures in a slight U-shaped pattern.
NOMINAL CAUSE
Die blank is not resting flat against the steel casing.
The blank is not level when an uneven compression load is applied across the diamond surface.
Mechanical stress force is applied to one side of the die blank creating a bending moment.
POSSIBLE SOLUTION
Ensure blank is well aligned when assembled on the case.
VERTICAL STRESS CRACKS

VISIBLE EFFECTS
Equally spaced large vertical cracks. Usually more than two cracks.
NOMINAL CAUSE
Excessive mechanical and/or thermal forces being applied to the diamond core. It is being stretched during the
wire drawing application or the sizing process.
POSSIBLE SOLUTIONS
Good wire reduction design, controlled brazing process between PCD blank and core, lubrication control, etc.

LASER DAMAGE
VISIBLE EFFECTS
The die blanks have enlarged grain bounders, pits, crystal pullout, porosity, and small fractures through the diamond
cores.
NOMINAL CAUSE
Thermal stresses applied during the laser process and/or during the mounting operation.
POSSIBLE SOLUTIONS
Improve the laser program and machine maintenance.
HORIZONTAL CRACKS
DESCRIPTION
Cracks travel around the bore diameter.
CAUSES
- Development of wear ring serving as a stress riser.
- Gaps in braze alloy after sintering cause mechanical stress.
- Gaps from press fit cause mechanical stress.
- Nib abrading steel casing during mounting operation.
- Overheating during laser drilling or sintering process.
Wear ring generated during wire drawing process Thermal stress cracks induced during mounting
(possible lubrication interruption). operation.
Compax Diamond Tungsten Carbide Ring Compax Diamond Tungsten Carbide Ring
Blank Core Blank Core
INCORRECT Metal Build-up CORRECT

TEMPERATURE GENERATED DURING DRAWING
During drawing there are two primary sources of heat:
- Plastic deformation
- Friction
- Temperature distribution inside the die varies according to many factors, such as:
- Type of material
- Percentage of reduction
- Lubrication 30ºC
40ºC
- Geometry of die
Between 25 and 45% of the drawing energy is lost as heat. 50ºC
70ºC
100ºC
150ºC
100ºC 200ºC
300ºC
540ºC 400ºC
CARBIDE QUALITY
Hyperion drawing nibs are known for their impeccable geometry:
- Our high precision nibs provide tight dimensional tolerance and perfect coaxiality and meeting point, even for the
smallest diameters.
- Reduced grinding stock and profile quality improves grinding and polishing operation.
x50
x1 x10
HYPERION OTHERS

CARBIDE DIES FAILURE MODE ANALYSIS
Hyperion collaborates with our customers to provide a complete solution from grade selection to failure mode
analysis and continuously works to provide better performing products to improve the efficiency.
HOOP FAILURE can be identified by crack runs BURST DIE is a result of circumferential crack
lengthwise through the nib. Casing balances at the bottom of the wear ring propagates by
the tensile stresses over the carbide nib due splitting the nib in two (also breakage can be
to drawing forces. Failure is caused when the in the form of a cone). It usually occurs when
force required to deform the wire is greater a die is left in the machine too long and the
than the strength of the die material and its stress concentration makes that the wear
mounting. Close casing with absence of oxides ring became too deep. It is easily noticeable
and cavities is advised. because the crack evolution is in the radial
direction.

BURST DIE
VISIBLE EFFECTS
Circumferential crack at the bottom of the wear ring propagates by splitting the nib in two (also breakage can be
in the form of a cone).
NOMINAL CAUSE
It usually occurs when a die is left in the machine too long and the stress concentration makes that the wear ring
became too deep. It is easily noticeable because the crack evolution is in the radial direction.
POSSIBLE SOLUTIONS
Most tension failures can be avoided with a good die maintenance program.
BACK CHIPPING
VISIBLE EFFECTS
Shows chipping in the intersection of the bearing and the back relief.
NOMINAL CAUSE
Caused by an improperly shaped back relief.
POSSIBLE SOLUTIONS
Can be easily repaired by removing the edge of the intersection.

ABRASIVE WEAR
VISIBLE EFFECTS
Scratches that run the full length of the working zone of the nib in the direction the wire is drawn.
NOMINAL CAUSE
Wire surface irregularities remove material from the nib. The WC pulled out material can cause a groove that wears
from below the wear ring through the rest of the nib.
POSSIBLE SOLUTIONS
Advisable to check the lubrication quality and wire surface defects.
ATTRITION WEAR
VISIBLE EFFECTS
Dull appearance of the working cone in the first stages of the wearing process and same effects of the abrasion wear
when the wearing is in advanced status.
NOMINAL CAUSE
Well defined particles from nib surface are pulled out because bonding between the particle and the wire.

POSSIBLE SOLUTIONS
Choose best nib grade according to the wire material to be drawn. Improve lubrication as much as possible.

WIRE DEFECTS
SURFACE DEFECTS
VISIBLE EFFECTS
Insufficient amount of lubricant on the wire surface.
NOMINAL CAUSE
Wrong lubricant selection and lack of cooling and speed.
VISIBLE EFFECTS
Longitudinal scratches and absence of carrier.
NOMINAL CAUSE
Damage on the reduction cone or bearing.
Wire material stuck on the die inner profile. Lack of lubrication.
VISIBLE EFFECTS
Globs and pitting.
NOMINAL CAUSE
Globs from annealing furnaces and pitting from
electrolytic baths.
VISIBLE EFFECTS
Flakes and pitting.
NOMINAL CAUSE
Marks from the capstans, straightening rolls, guide wheels
and other machine parts.

WIRE DEFECTS
DEFECTS FROM DRAWING
CRACKS
VISIBLE EFFECTS
Surface or internal cracks.
NOMINAL CAUSE
Poor rod quality.
Surface defects on the incoming wire.
Unbalanced stresses in the wire due to incorrect drawing
series, bad cooling or improper drawing speed.
V-FRACTURE
VISIBLE EFFECTS
Wire fracture in V-shape during drawing.
NOMINAL CAUSE
Lack of lubrication / wrong area reduction.
WIRE QUALITY

VISIBLE EFFECTS
Wire section becomes oval or not circular.
NOMINAL CAUSE
Die misalignment in the machine.
SHAPE/CAST ERRORS
VISIBLE EFFECTS
Camber (Øa) or helix cast out of specs.
NOMINAL CAUSE
Problems in wire guiding or straightening device.
Incorrect capstans geometry.
a
SHAPE/CAST ERRORS
VISIBLE EFFECTS
Weave wire.
NOMINAL CAUSE
Vibration marks: vibration dampening tools are not set correctly. b
Problems with straightening device.

CUSTOMER SUPPORT
FAQ
Q
What happens if a customer changes the grade for an existing nib pressing tool?
A
Different grades could have different shrinkages. This effect could affect the final nib dimensions.
Q
Is hot casing better than cold casing?
A
The nib after hot casing is under compression not only in the radial but also in the axial direction. This leads to a
better stress balance during the drawing process and increases the die life.
Q
Can Versimax and Versirion be brazed like PCD?
A
Yes, Versimax and Versirion can be brazed, hot cased and cold cased into the case.
Q
What is the difference between rough core die and nib? Any advantage?
A
Hyperion’s hot casing process and geometry guarantee perfect between case and nib. Consequently, better
balance of stress and better heat conductivity are achieved. These two parameters directly increase die life.
Q
Can we order a small number of Hyperion WC rough core die PCD blanks
to evaluate in our facility to see if it improves our productivity?
A
Hyperion maintains a large stock of blanks to allow
customers to order small test batches. In addition,
we offer our application expertise to our customers
to help increase productivity.

INTERNATIONAL STANDARDS ROUND DIE SPECIFICATION
INCH MILLIMETER
NIB CASING NIB CASING
TYPE TYPE
Dla. Ht. Dla. Ht. Dla. Ht. Dla. Ht.
R2 .325 .330 1 .563 B 13 10 30 16
R3 .450 .380 1.5 .750 C 16 14 32 20
R4 .500 .450 1.5 .875 G 22 18 40 26
R5 .625 .600 2 .875 H 30 21 66 35
R6 .710 .700 3 1.125 K 40 25 95 40
R7 .768 .768 3 1.375 L 50 28 95 48
R8 1.000 .820 3 1.750 M 60 35 114 60
R9 1.187 .820 3 1.750 N 75 35 114 70
R10 1.500 1.000 3 2 0 90 35 145 70
R11 1.830 1.250 4 2.250
R12 2.185 1.375 4 2.375
R14 2.560 1.375 6 2.500
R15 3.000 1.375 6 2.500
MILLIMETER
R16 3.500 1.375 7 2.500
NIB CASING
R17 4.000 1.500 7 2.500 JIS
TYPE Dla. Ht. Dla. Ht.
R18 5.500 2.125 9 4.500
W101 6 4 24 7
R19 6.500 2.125 11 4.500
W102 9 6 24 12
W103 12 8 30 15
W104 15 10 42 20
W105 20 14 55 24
MILLIMETER
W106 25 18 60 28
DIN NIB CASING W107 30 22 70 35
1547
TYPE Dla. Ht. Dla. Ht. W108 35 25 85 40
D10-0804 8 4 28 12 W109 40 27 100 45
D10-1008 10 8 28 16 W110 50 30 125 50
D10-1210 12 10 28 20 W111 60 35 145 60
D10-1412 14 12 28 22 W112 70 40 175 70
D10-1613 16 13 43 25 W113 80 45 195 80
D10-2017 20 17 43 32 W114 90 50 215 90
CUSTOMER SUPPORT
D10-2520 25 20 53 35 W115 100 50 230 90

D10-3024 30 24 75 40 W116 110 50 230 90
W117 120 55 250 100
W118 130 55 275 100
W119 140 60 295 110
W120 150 60 315 110
CUSTOMER SUPPORT 71
CONVERSION TABLE
LENGTH MASS
1 inch = 25.4 mm 1 Kg = 2.205 pounds
DENSITY VOLUME
1 g/cm3 = 0.036 lb/inch3 1 US gallon = 3.785 liters
SPEED
1 inch/min = 0.0254 m/min

1 m/s = 60 m/min
COMMONLY USED FORMULAS

R [% of reduction]
Se Ss
Se - Ss
R= x 100% R = 1 - (d/D)2 x 100%
Se
A [% of elongation]
100 cm 100 - A cm
100 x R
A=
100 - R
V [volume of a given wire length]
V = 1/4πD2L
e [miscoaxiality]
d1 2α
e= • tg • [ tg (α) + tg (β) ] e
2 2β h
d1

HYPERION - RECYCLING AND SUSTAINABILITY
TIME TO THINK DIFFERENTLY
Hyperion, through our Carbide Recycling Program, purchases used carbide tools and products from our customers
to convert them into usable raw materials for future production. We use a controlled, certified chemical recycling
process that ensures these “new” materials are identical to materials produced from mined ore.
Hyperion is committed to sustainability, and recycling is a great example of how we are reducing the company’s
environmental footprint.
Helps maintain
raw material
resources
Supports
environmental
efforts
ISO 9000,
18000 and
14001 certified
This is how you recycle your carbide (short version): you call us, we send a barrel, you fill the barrel, we pick it up, you
get paid. Easy! We recycle all types of carbide (only carbide).
Please contact recycling@hyperionmt.com or your sales agent for more information.

CUSTOMER SUPPORT
CUSTOMER SUPPORT 73
WORDS INDEX
A F R
Abrasion 10,15,19,65 Flakes 66 Recrystallization 9,36

Abrasive 20,65 Friction 9,33,62 Recut 57,58
ADDMA 19,22,24 Repolish 57
Annealing 9,66 G
S
Galling 31
B
Galvanized 52,55 Sawing 32,52
Back relief 58,64 Globs 66 Scratches 36,65,66
Bunching 15,23,24 Grains 9,36 Self-supported 10,16,21,22,24
Burst 63,64 Slurry 47,49
I Spring back 58
C Stainless steel 32,52,55,56
Inclusion 25,26
Stranding 15,23,24
Cabling 15,45
Sub-micron 19
Casing 10,23,29,39,44,57 L
Supported 10,16,18,21
58,60,61,63,70,71
Lapping 47,48 Surface 15,18,20,57,60,65,66,67
Ceramic 28,47
Laser 16,26,61 Suspension 47
Co-lake 37
Concentration 36,37,38,47,63,64
M T
Conductive 21,23
Corrosion 23,27,28 Micron powder 11,14,28,49 Thermally stable 21,23
31,33,34,35 Misalignment 58 Tire 15,19,24,32,33,52,54,55
Craking 25 Misconcentricity 26
W
D O
Wear 8,10,11,18,19,20,23,24
Delamination 25 Oxidation 27,36,57 27,28,31,33,34,35,45,57
58,59,61,63,64,65
E P Wear ring 57,58,59,61,63,64,65
Welding 15,19,32,34,52
EDM Pull out 36,65
16,23,24 Pitting 66
Electrical 52,56 Polishing 11,16,23,34
Environment 27 47,48,49,62
Erosion 59 Porosity 37,61

www.HyperionMT.com
TS-WD 1809-001 ENG A4 Copyright © Hyperion Materials & Technologies – All rights reserved

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Hyperion Wire Drawing Guide

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TOOLMAKER SOLUTIONS

Your full-line of wire

COMPLETE DRAWING SOLUTIONS 10

PCD AND VERSIMAX: MATERIAL & PROCESS 14

- PCD MATERIAL & PROCESS 14

- VERSIRION AND VERSIMAX MATERIAL 24

- PCD MATERIAL ISSUES 25

CEMENTED CARBIDE: MATERIAL & PROCESS 27

- CEMENTED CARBIDE MATERIAL & PROCESS 27

- CEMENTED CARBIDE CATALOGUE 39

- MICRON POWDER GRADES 49

APPLICATIONS & FAILURE MODES

CONVERSION TABLES AND FORMULAS 72

RECYCLING AND SUSTAINABILITY 73

WIRE DRAWING GUIDE 3

1st PCD cutters

CIC integral rolls

6 WIRE DRAWING GUIDE

Grade AM60 for CFRP

Grade TC03/C3D for

Hyperion’s worldwide network of manufacturing facilities offers customers

8 WIRE DRAWING GUIDE

After annealing, the wire can again be drawn.

Recovery Recrystallization Grain Growth

5-COMPAX® BLANKS FOR

COMPLETE DRAWING OFFER

10 WIRE DRAWING GUIDE

DIAMOND AND DIAMOND COMPOUNDS WEAR PARTS

Hyperion’s offering of diamond pastes and compounds

CONSISTENCY THROUGH SIX SIGMA QUALITY CONTROL

cobalt melts and “sweeps” into carbon bonding between

14 WIRE DRAWING GUIDE

MBS®/Borazon® crystals Milling Cleaning Grading Blending

Loading Pressing Finishing Wire EDM cutting Quality control

PCD BLANK MANUFACTURING PROCESS

Sealed capsule (cup)

Steel case Brazing

16 WIRE DRAWING GUIDE

3,600,000 bar 52,000,000 psi Pressure at the center of the earth

1,200 bar 30,000 psi Pressure of powder metal forming

Pressure at which pressure washers

Pressure at which pressure washers

Atmospheric pressure at earth’s

WIRE DRAWING GUIDE

Supported (12 μm)

Supported (25 μm)

Supported (50 μm)

SUB-MICRON PROPERTY MEASUREMENT

ABRASION TEST RESULTS X-RAY FLUORESCENCE RESULTS

CURRENT SUB-MICRON PRODUCT

Brass-plated wire (tire cord, saw wire)

Typical diamond grain size 0.9 μm

Typical diamond content 91%

STANDARD PRODUCT OFFERINGS

Product Dimensions (mm) Thermally Maximum Recommended

D6 3.1 x 1.00 5010-MFU 5010-TSU 0.5

D12 3.1 x 1.5 5015-MFU 5015-TSU 1.0

ABRASIVE WEAR COMPARISON

90 Low Cost Product: 186 nm

SH 5025 LOW COST

The unique material properties provide:

SH 5025 Die Material 1000X Low Cost Die Material 1000X

1000x magnification SEM image of a 5025 sample.

20 WIRE DRAWING GUIDE