Traxit FAQ: Wire drawing lubricants, processes and applications

Dry drawing lubricants are powdered lubricants used in wire drawing. They are applied to the wire surface in the drawing box and drawn into the die along with the wire. Under pressure and at elevated temperatures, they form a lubricating film that influences friction, heat generation and tool wear during the process.

During dry drawing, the wire absorbs the powder and carries it into the forming zone within the drawing die. The effect under heat and pressure depends, amongst other things, on the wire material, pre-treatment, drawing speed, drawing die, temperature range and the composition of the drawing lubricant.

Dry drawing lubricants are used for steel, stainless steel and non-ferrous metal wires, for example in welding wire, spring wire or wire rope. Appropriate optimisation can help to ensure stable drawing conditions, more uniform surfaces and reduced tool wear.

The appropriate dry drawing lubricant is not selected on the basis of material or diameter alone. The decisive factor is the entire process, comprising the wire material, start and end diameters, reductions, pre-treatment, drawing speed, die technology and subsequent application.

Factors to be considered include the surface finish, drawing die wear, temperature development, further processing, desired cleanliness, existing plant equipment and the target quality of the wire. Only the combination of these factors reveals which system is technically suitable.

Technical advice is particularly useful for new wire grades, quality issues, high speeds, special surface requirements or a change in drawing lubricant. This ensures that the selection is tailored to the specific process.

Calcium- and sodium-based dry drawing lubricants are powdered lubricants used in the wire drawing process. They differ primarily in terms of water solubility, lubricant adhesion, melting behaviour and temperature stability. This makes them suitable for different processes, depending on the drawing speed, degree of deformation, wire diameter and desired final surface finish.

Calcium soaps are less water-soluble and generally adhere more strongly to the wire surface. They usually have a lower melting point and are frequently used at lower drawing speeds and where high degrees of deformation occur in the drawing die. Sodium soaps are more readily soluble in water, tend to be more temperature-stable and usually have a higher melting point. They are frequently used at higher drawing speeds, with thinner wires or when using pressure drawing dies.

The choice between calcium soap, sodium soap or a mixed system depends on the specific wire drawing process. Key criteria include film stability, temperature behaviour, drawing speed, cleanliness, further processing and requirements for the final surface. Appropriate selection ensures stable drawing conditions, adequate lubricant carry-over and a surface quality suited to the process.

The choice of drawing lubricant is important because it forms the lubricating film between the wire and the drawing die. This lubricating film affects friction, temperature build-up, tool wear, process stability and the wire surface.

A suitable drawing lubricant must be compatible with the wire material, pre-treatment, drawing sequence, drawing die, speed, temperature range and end use. If these factors are not properly matched, surface defects, wear or process fluctuations may increase.

A process-specific assessment is advisable if the aim is to improve die service life, surface finish, resource utilisation, drawing compound consumption or process stability. The drawing lubricaant should always be considered in conjunction with the die, the drawing line and the wire.

Wet drawing lubricants are liquid lubricants used in the wire drawing process. They are often used, diluted with water, in drawing baths where the wire and drawing dies come into contact with the wet drawing lubricant. This forms a lubricating film on the surface of the wire, which aids lubrication and cooling during wet drawing.

During wet drawing, the wire passes through the wet drawing lubricant in the bath. The drawing die is also located in the bath. The lubricating film reduces friction, temperature build-up and wear in the drawing die. At the same time, the wet drawing lubricant helps to dissipate heat. Its effectiveness depends, amongst other things, on concentration, product quality, filtration, cooling capacity, plant design, wire material, pre-treatment and drawing speed.

Wet drawing lubricants are primarily used for fine and ultra-fine wires, bright wires and high-speed processes. They are particularly relevant where there are high demands on cooling, cleanliness, surface quality, fine final diameters and stable process control. A wet drawing lubricant tailored to the application can help to stabilise drawing conditions, influence the wire surface in a manner appropriate to the process, and better support the requirements of subsequent processing.

Key factors for selecting the appropriate wet drawing lubricant:

• Wire material and pre-treatment
• Drawing speed and plant design
• Cooling capacity and filtration system
• Requirements for the wire surface and subsequent processing

Coating agents are pre-treatment layers applied to the wire surface. They facilitate the absorption and adhesion of the drawing lubricant and act as a link between the wire and the lubricant. In this way, they influence the formation of the lubricating film within the drawing die.

The coating creates a surface to which the drawing lubricant can adhere more effectively and be transported into the drawing die. Typical systems include phosphating or alternative coatings, which are tailored to the drawing lubricant and the process.

Coating agents are particularly important in dry drawing processes with high demands on lubrication, surface quality and process stability. The coating, drawing lubricant and pre-treatment should be regarded as an integrated system.

Their key functions in the process are:

• Improving the adhesion of the drawing lubricant to the wire surface
• Stabilising the lubricating film in the drawing die, enabling higher drawing speeds
• Reducing friction and wear
• Promoting a uniform wire surface

Oil- and volatile organic compound (VOC)-free corrosion protection refers to a method for the temporary preservation of wire without the use of conventional oil-based protective agents or volatile organic compounds. The protective film is applied either directly during or immediately after the production process.

The protective effect depends on the wire material, surface, moisture, packaging, storage duration, transport conditions and process control. Therefore, corrosion protection should always be assessed within the context of the entire process chain.

This approach is relevant for wire producers who require temporary surface protection without conventional oil films. Potential benefits include fewer additional handling steps, cleaner surfaces and better integration into existing processes.

The key advantages are:

• High process stability through clean and controlled application
• Reduction in additional process steps and work stages
• Consistent and reproducible wire surface quality
• Potential energy and cost efficiency through integration into the production process
• Compliance with increasing environmental and occupational health and safety requirements by avoiding the use of oil and volatile organic compounds (VOCs)

Optimising drawing lubricants involves specifically tailoring the lubricant, the wire drawing process and the application requirements to one another. Factors taken into account include drawing lubricant consumption, lubricant film formation, friction, temperature, tool wear, wire surface finish and process stability.

Optimisation begins with an analysis of the existing process: wire material, pre-treatment, drawing dies, reduction sequence, speed, temperature, dust generation, emulsion maintenance and consumption data. Based on this, the product and process parameters are adjusted.

Optimisation is advisable in cases of high wear, surface problems, dust, an unstable emulsion, high energy costs, fluctuating quality or a desire for more controllable process costs. Results should always be evaluated on the basis of specific process data.

A dry drawing lubricant can influence energy costs during wire drawing, as it helps determine friction, heat generation and the tensile force required within the drawing die. Whether measurable effects occur depends on the specific process and on reliable process data.

A stable lubricating film can improve the contact between the wire and the drawing die. Key factors include wire material, reduction ratio, drawing speed, die condition, pre-treatment, temperature and lubricant film formation.

This issue is particularly relevant in energy-intensive drawing processes, at high speeds, during long drawing sequences or in efficiency projects. Statements regarding energy consumption should be assessed on a process-specific basis and not made in general terms.

A drawing lubricant influences die service life and tooling costs through the quality of the lubricating film within the die. A stable lubricating film reduces direct contact between the wire and the tool and can minimise wear, temperature spikes and surface defects.

Drawing dies are subjected to stress from pressure, friction, temperature and particles. If lubrication, drawing lubricant carry-over or pre-treatment are not appropriate, wear and tooling costs may increase.

This issue is particularly relevant in cases of high die wear, short service life, frequent set-ups or demanding surface finishes. Whether costs are reduced should be assessed on the basis of process and tooling data.

The drawing lubricant influences the wire surface because it controls the contact between the wire and the drawing die. A stable lubricating film can reduce roughness, scratches, grooves and uneven residues.

Surface defects are often caused by disrupted lubricant film formation, particles, unsuitable pre-treatment, worn drawing dies or incorrect process windows. The drawing lubricant is an important influencing factor, but not the only one.

This issue is relevant for welding wire, stainless steel wire, bright wires and speciality wires where surface quality is critical. In the event of roughness, scratches or cleanliness issues, the entire wire drawing process should be inspected.

The TOTAL USE concept is based on customer consulting tailored to the customer-specific drawing process. Based on the overall process, we analyze how the drawing lubricant can be used for longer in production without loss of quality. Customer projects have shown that lubricant savings of up to 20% can be achieved.

A wet drawing lubricant influences drawing performance because it provides both lubrication and cooling during wet drawing. It controls friction, drawing force, temperature rise, die wear and the wire surface.

Performance depends on concentration, product quality, filtration, cooling capacity, plant design, wire material and process parameters. A stable emulsion must therefore be regularly monitored and maintained.

Wet drawing lubricants are particularly important for fine and ultra-fine wire, bright wire, high-speed processes and where there are high demands on cooling, cleanliness and surface quality.

An optimally adjusted wet drawing lubricant offers the following advantages:

• Reduction of friction and drawing forces
• Stabilization of process temperature at high speeds
• Extension of die and tool service life
• Improved wire surface quality
• Enabling higher drawing speeds and finer final diameters

Conversely, an emulsion that is not optimally adjusted can lead to unstable processes, increased wear or quality issues. The key lies in striking the right balance between concentration, cooling, filtration and adaptation to the process parameters.

Coating agents are important for drawing performance because they enable and stabilise the absorption of drawing lubricant onto the wire surface. They improve the adhesion of the lubricant and aid the formation of a lubricating film within the drawing die.

Without a suitable coating, the drawing lubricant may adhere unevenly or fail to be transported sufficiently into the drawing die. This can lead to increased friction, surface defects, tool wear or fluctuations in quality.

Typical applications include dry drawing processes with high demands on the lubricating film, surface finish and stable drawing conditions. Optimisation is particularly important for phosphated or alternatively coated wires.

An optimally tailored coating agent improves drawing performance in several areas:

• Uniform lubricant film formation in the drawing die
• Reduction in friction and the required drawing force
• Increased process stability across multiple drawing stages
• Improved lubricant retention
• Minimisation of wire surface defects
• Extended service life of drawing dies and tools
• Higher drawing speeds

It is therefore crucial to holistically coordinate pre-treatment, carrier coating and lubricant as an integrated system in order to achieve maximum and stable drawing performance.

Various technical challenges can arise in the wire drawing process that affect product quality, process stability and profitability. Common issues include:

• Wire breaks or microcracks in the material
• Build-up or lumps in the drawing box
• Dust generation and increased strain on people and equipment
• Unsteady or unstable drawing process
• Scratches, scoring or uneven wire surfaces
• High tool wear or short die service life
• Excessive temperatures in the drawing process
• Insufficient lubricating film formation
• Fluctuating wire quality or problems in downstream processing

These challenges can have a range of causes, for example in the interaction between drawing lubricant, coating agent, material, process parameters and equipment technology.

We know these issues from practice and are happy to support you in analyzing the causes and developing a tailored solution.

Lumps or build-up occur when the drawing lubricant, temperature, humidity, powder feed, wire surface or process parameters are not optimally matched. Thermal stability, contaminants, incorrect dosing or sub-optimal process parameters often play a role.

In the drawing box, powder can agglomerate due to heat, moisture, pressure or residues. An unsuitable soap base, excessively high temperatures, residues from pre-treatment or an uneven supply of drawing lubricant can also contribute to caking.

Check the temperature, reduction ratios, powder flow, condition of the drawing lubricant, moisture content, wire surface and the drawing box guide. Clumping should be regarded as a process signal and investigated comprehensively.
 

Dust generation is caused by fine particles from drawing lubricants, metal abrasion, scale and process residues. It can be influenced by the choice of drawing lubricant, powder feed, wire pre-treatment, friction, temperature and air flow.

Dust is not just a matter of the drawing lubricant. The wire surface, transport, drawing box, plant design, extraction, filter technology and health and safety requirements all play a part.

A combination of suitable drawing lubricant selection, stable process parameters and appropriate extraction or filter technology is recommended. The aim is to reduce dust, improve cleanliness, ensure a more stable supply of drawing lubricant and create a safer working environment.

Yes, the drawing lubricant can contribute to wire breaks, micro-cracks or unstable processes if the lubricating film, friction or temperature control are not suited to the wire drawing process. However, such faults are usually caused by several factors acting simultaneously.

The material, pre-treatment, drawing dies, reduction sequence, drawing speed, condition of the equipment, temperature and lubricant film formation should all be examined. Material defects or worn tools may also be a factor.

A reliable assessment requires a holistic analysis. The drawing lubricant should be examined as a potential influencing factor, but should not be considered in isolation from the wire, tooling, pre-treatment and process parameters.

Cooling problems, wear and unstable emulsions in the wet draw are often caused by an unsuitable or inadequately maintained wet drawin lubricant. Factors influencing this include concentration, water quality, product quality, filtration, contaminants, temperature and cooling capacity.

In the wet drawing process, the medium must lubricate and cool. If the concentration, filter condition, water and/or product quality, or temperature deviate from the required levels, the lubricating film can become unstable, increasing the risk of wear or quality issues.

Regular monitoring of concentration, temperature, filtration, contaminants, and water and product quality is crucial. The wet drawing lubricant, filtration, cooling and equipment should be regarded as an integrated system.

Typical influencing factors include:

• Incorrect emulsion concentration
• Inadequate filtration or contaminants in the system
• Temperature rise due to insufficient cooling capacity
• An unstable emulsion or poor water quality
• Inappropriate calibration for the wire material and drawing parameters

To ensure efficient and reliable process optimisation, emulsion parameters, process conditions and the plant design should be analysed holistically and specifically coordinated with one another.

Uneven draw lubricant uptake occurs when the coating agent is not uniform, does not adhere sufficiently, or is not compatible with the draw lubricant. This may be caused by pre-treatment, film thickness, surface cleanliness, temperature, dwell time or coating agent quality.

The coating agent determines how well the drawing lubricant is absorbed and transported into the drawing die. Variations in pickling, descaling, rinsing, drying or coating can affect adhesion and uniformity.

The wire surface, pre-treatment, coating agent quality, film thickness, adhesion, drawing lubricant compatibility and process parameters must be checked. Only a combined assessment can reveal why drawing lubricant uptake fluctuates.

Possible causes may include:

• Inadequate or uneven coating agent quality
• Inadequate filtration or contaminants in the system
• Incompatibility between the coating agent and the drawing lubricant
• Fluctuations in pre-treatment (e.g. pickling or descaling)
• Incorrect coating thickness or poor adhesion to the wire surface
• Process variations in temperature or dwell time

The key is the holistic coordination of pre-treatment, coating agent and drawing lubricant as an integrated system to enable stable lubricant film formation and reliable wire drawing.

Wire can corrode after drawing or during storage if moisture, residues, inadequate corrosion protection, unsuitable packaging, long periods of interim storage or unfavourable storage conditions combine.

Key factors include the wire material, surface condition, chemical residues, humidity, temperature fluctuations, protective film, packaging, duration of storage and transport conditions. Drawing agents and pre-treatment can also influence susceptibility to corrosion.

The entire material flow should be taken into account: production, surface, protective film, storage, packaging and transport. Only in this way can causes be narrowed down and a suitable protection concept devised.

Modern corrosion protection concepts rely on integrated, process-reliable solutions in which the protective film is applied directly during the production process. With our new oil- and Volatile Organic Compounds (VOC)-free corrosion protection process, we offer an innovative way to reduce additional handling effort, eliminate traditional oil-based protective media and minimise potential sources of error.

We would be happy to assist you in analysing the causes and developing a suitable, process-integrated solution.

"Borax-free" means that a drawing lubricant or coating agent is formulated without borax or borate-containing components. Borax-free alternatives may be relevant where technical, regulatory, health and safety or customer-specific requirements support or necessitate their use.

The decisive factor is where borax is used in the process: in pre-treatment, coating agent or drawing lubricants. At the same time, the lubricating film, adhesion, wire surface, process stability and tool life must be technically evaluated.

Technical advice is advisable when existing systems are to be converted. "Borax-free" is a formulation characteristic, but not an automatic guarantee of performance. Each alternative should be tested in the specific wire drawing process.

Yes, TiO₂-free drawing lubricants are alternative products formulated without titanium dioxide. Whether they are suitable for a wire drawing process depends on the technical requirements and the conditions of the actual process.

Factors to be considered include wire material, pre-treatment, lubricant film formation, dust behaviour, die life, surface requirements, drawing speed and further processing. Titanium dioxide can fulfil technical functions in certain formulations.

It is advisable to seek advice if regulatory, health and safety or customer-specific requirements suggest a change is necessary. The alternative should be evaluated in an application test before a reliable recommendation is made.

Optimising drawing lubricants and process parameters involves jointly assessing the wire material, pre-treatment, reduction sequence, drawing speed, drawing dies, temperature, lubricant film, target surface finish and subsequent processing.

A drawing lubricant achieves the best results when it is suited to the entire process. For this reason, wire material, pre-treatment, drawing dies, plant conditions, surface requirements and quality targets are assessed together. On this basis, drawing lubricants, coating agents and process parameters can be specifically optimised.

Such optimisation is particularly useful during new set-ups, product changes, quality issues, optimisation projects, high drawing speeds, new wire grades or when switching drawing aids and coatings.

Using the TOTAL USE concept, Traxit Wire Lubrication analyses these interrelationships within the customer’s specific wire drawing process. On this basis, we support customers in assessing process conditions and selecting suitable drawing lubricants for their respective applications.

Vegan drawing lubricants are wire-drawing lubricants that contain no ingredients of animal origin. They can be used in suitable wire-drawing processes provided that the technical requirements regarding the lubricating film, drawing speed, temperature behaviour, wire surface and subsequent processing are met.

The vegan formulation describes the origin of certain ingredients. For technical applications, the decisive factor remains whether the product achieves the required lubrication performance and process stability in the specific wire drawing process.

Consultation is advisable if animal-free raw material requirements are to be combined with specific technical process objectives. The selection should always be based on the specific wire drawing process and the required performance.

Our products were the first in the world to receive the Vegan Trademark from the The Vegan Society. Selecting the right product depends on your process: we review your application and requirements and recommend the appropriate vegan drawing lubricant.

Visit our glossary. Find clear explanations of technical terms, processes and technologies relating to wire drawing, wire drawing tools, lubricants and cold forming.