Wire for electric discharge machining

A process for producing a coated wire for use in electric discharge machining from an electrically conductive core wire having an original diameter, comprising:

• placing a movable core wire within a reaction chamber, wherein the reaction chamber includes an anode, and wherein the core wire is the cathode;
• establishing a gap between the anode and core wire;
• applying an aqueous electrolyte into the reaction chamber through orifices in the anode onto the core wire to establish an electrically conductive path between the anode and core wire;
• applying a DC voltage to the electrically conductive medium in excess of 30 VDC, so that a gas/vapor phase and a liquid phase fills the reaction chamber;
• adjusting the voltage to establish an electro-plasma discharge sufficient to cause positive ions in the electrically conductive medium to become concentrated near the surface of the core wire and cause micro-zonal melting of the surface of the core wire in the area of discreet plasma bubbles;
• operating the reaction chamber to cause positive ions of one or more coating metals to be deposited to move toward the core wire by kinetic energy created by the implosion of the plasma bubbles;
• coating the core wire to produce a coated wire having a coating thickness of at least twelve microns (12 μm);
• and
• drawing the coated wire to a final diameter of between sixty percent (60%) and eighty-five percent (85%) reduction of the original diameter of the core wire after which the core wire is not exposed.