Wire EDM of aluminum 6061 is effective for intricate profiles and tight-tolerance features that are difficult to achieve with conventional milling. Aluminum's high conductivity enables fast cutting.
| Parameter | Value |
|---|---|
| Achievable Tolerances | ±0.005 mm |
| Surface Finish | Ra 0.4-1.0 μm |
| Cutting Speed | Fast — high conductivity |
| Feed Rate | Auto-tuned by EDM controller |
| Tooling Recommendations | Brass wire 0.20-0.25mm for general work. Coated wire for faster cutting. |
Use brass wire for best surface finish
Flushing is critical — aluminum produces heavy debris
Multiple skim cuts for tight tolerances
Slower settings reduce recast layer
Complex profiles
Thin-wall features
Tight-tolerance slots
Keyways
Splines
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