Mersen USA has released the DarkStar particle, a carbonaceous particle designed for demanding EDM applications. According to the company, it is synthesized from readily available, highly carbonaceous raw material. The synthesized particles are said to provide adhesion while maintaining the single phase characteristics needed to facilitate machining, even when processed to the ultra-high temperatures necessary to obtain the quasi-graphitic state of an EDM graphite electrode.
DarkStar is part of the company’s Ellor DS4, an ultra-fine-grain EDM graphite. The graphite provides a density of 1.88 g/cm3, flexural strength ranging to 13,500 psi and electrical resistivity of 0.00052 Ohm-inches, with an average grain size of less than 5 microns. According to the company, incorporating the DarkStar particle enables DS4 to deliver higher-quality surface finishes and intricate detail, while being easy to machine and very strong.