Oelheld Dielectric Fluids

EcoSpark 105

EcoSpark 105 is a **high-performance dielectric fluid** specifically formulated for **EDM die-sinking applications**.
It combines a **high metal removal rate** with **low electrode wear**, ensuring **efficient machining** across a **wide range of applications**.
Whether for **precision machining** or **heavy roughing tasks**, EcoSpark 105 provides **stable ignition, superior cooling**, and **long fluid life**.

This dielectric is particularly **ideal for operations requiring a minimum flash point of 100°C**, significantly reducing **steam formation**
during the spark ignition process. Additionally, its **low viscosity** ensures **optimal flushing** and compatibility with **all common EDM filters**.

Advantages of EcoSpark 105

• High Metal Removal Rate: Increases efficiency while maintaining precision.
• Wear Reduction: Extends electrode life and reduces operational costs.
• Wide Application Range: Suitable for both **fine finishing** and **rough cut machining**.
• Small Refill Quantities: Optimized for extended use, reducing consumption.
• High Flash Point (>100°C): Improves safety and reduces vaporization during machining.
• Excellent Cooling and Flushing: Ensures stable performance in high-speed EDM operations.

Technical Specifications

Product Name	Density at 15°C (g/cm³)	Viscosity at 40°C (mm²/s)	Flash Point (°C)	Application
EcoSpark 105	0.81	2.3	105	EDM machining in fine finishing and rough cut applications.

IonoPlus Series

The IonoPlus Series is a high-performance dielectric fluid line tailored for EDM die-sinking applications.
These advanced fluids are formulated to support a wide range of machining processes, from fine finishing to roughing operations.
With a synthetic production method that ensures purity and consistency, IonoPlus dielectrics are odorless, color-stable,
and easily filtered for extended usability.

The innovative technology behind IonoPlus fluids reduces wear, lowers refill consumption, and ensures higher material removal rates.
Whether used for micro-work with the smallest spark gaps or for roughing operations that demand aggressive flushing, this series delivers maximum efficiency.

Advantages of IonoPlus Dielectrics

• Odorless & Clear: Maintains color stability and avoids chemical breakdown during use.
• Higher Metal Removal Rates: Increases efficiency by ensuring optimal spark performance.
• Extended Dielectric Lifespan: Designed to resist contamination and filtration-friendly.
• Lower Refill Quantities: Optimized for reduced consumption and sustainable operation.
• Superior Wear Reduction: Protects electrodes and workpieces for longer tool life.

Technical Specifications

Product Name	Density at 15°C (g/cm³)	Viscosity at 40°C (mm²/s)	Flash Point (°C)	Application
IME-ET	0.77	1.4	63	EDM machining in the finest finishing applications with the smallest spark gap (micro work).
IME-ZK	0.79	2.0	82	Designed for roughing and finishing applications, ensuring high removal rates.
IME-MH	0.79	2.0	82	Optimized for roughing and finishing operations, ensuring enhanced performance.
IME-GL	0.82	3.8	125	Designed for roughing applications in the finishing sector, requiring optimal flushing conditions.

Optimized Erosion Times

The advanced formulation of IonoPlus dielectrics results in more controlled spark discharges
and faster material removal. As seen in the comparison below, switching to IonoPlus fluids
can increase regular ignitions per unit while reducing inconsistencies during EDM machining.

The unique filtration-friendly composition of IonoPlus ensures cleaner electrodes,
improved spark discharge, and enhanced flushing properties
for high-efficiency EDM operations.

IME Series

The IME Series is a high-performance dielectric fluid range specifically designed for
EDM die-sinking applications. These fluids have undergone extensive testing and have been
proven effective in real-world machining environments. They are explicitly recommended by leading EDM
manufacturers due to their high dielectric strength, odorless composition, and clear transparency.

The IME Series features dielectric fluids with **pharmaceutical-grade purity**, virtually free from aromatic compounds,
making them resistant to discoloration and degradation during the EDM process. Whether used in **rough-cut operations**
or **precision finishing**, IME dielectric fluids maintain exceptional stability, ensuring a **long service life** and
**high cooling efficiency**.

Key Benefits

• High metal removal performance: Optimized for efficiency in EDM machining.
• Excellent surface quality: Delivers smooth and precise finishes.
• Transparent & odorless: Clean and clear fluids for optimal working conditions.
• Long-lasting dielectric service life: Resists degradation, reducing fluid change intervals.
• Superior cooling and flushing properties: Enhances machining precision and tool life.

Technical Specifications

Product Name	Density at 15°C (g/cm³)	Viscosity at 40°C (mm²/s)	Flash Point (°C)	Application
IME 56	0.77	1.3	56	EDM machining for finest applications and EDM drilling.
IME 63	0.77	1.3	63	EDM machining in finest applications with the smallest spark gap.
IME 82	0.77	2.0	82	EDM machining in fine finishing and rough cut applications.
IME 110	0.78	2.5	110	EDM machining in fine finishing and rough cut applications.
IME 126	0.82	3.6	114	EDM machining in rough cut applications with optimal flushing conditions.

IonoFil Series

The IonoFil Series is a high-performance dielectric fluid range specifically designed for **wire EDM (Electrical Discharge Machining) applications**.
Unlike conventional EDM fluids, IonoFil prevents **cobalt leaching**, ensuring superior surface quality and increased tool lifespan.
Engineered with **hydrocarbon-based technology**, IonoFil enables **smaller spark gaps**, resulting in **improved accuracy and finer finishes**.

This advanced formulation is optimized to **reduce thermal shock**, **prevent corrosion**, and **eliminate microbiological contamination**—making it the ideal solution for industries requiring **high precision, consistency, and longevity** in EDM processing.

Key Advantages of IonoFil

• No Cobalt Leaching: Prevents material damage and ensures longer tool life.
• Enhanced Surface Quality: Produces smoother finishes with minimal post-processing.
• Corrosion Protection: Prevents oxidation and degradation of workpieces and EDM machines.
• Precision Machining: Allows for smaller spark gaps and finer details.
• Microbiological Stability: Eliminates contamination risks in long-term EDM operations.
• Optimized Cooling & Flushing: Ensures efficient machining without thermal damage.

Technical Specifications

Product Name	Density at 15°C (g/cm³)	Viscosity at 40°C (mm²/s)	Flash Point (°C)	Application
IonoFil 80	0.78	2.1	>90	Optimized for general-purpose wire EDM applications, ensuring precision and efficiency.
IonoFil 100	0.79	2.9	>115	Designed for high-precision wire EDM, delivering superior surface quality and accuracy.
IonoFil 2776	0.78	2.1	>90	High-performance dielectric for demanding EDM applications requiring excellent flushing.
IonoFil 2788	0.79	3.6	>100	Provides exceptional cooling, prevents cobalt leaching, and ensures high removal rates.

Comparison: Water vs. IonoFil Dielectric

Traditional EDM processing using water-based fluids often leads to cobalt leaching, causing degradation and micro-fracturing in carbide tools.
IonoFil eliminates these risks by providing a **stable dielectric environment**, ensuring **consistent material integrity and superior finish quality**.

IonoGrind Series

The IonoGrind Series is a high-performance dielectric specifically engineered for
rotary erosion and precision grinding applications. Designed for **dual-function EDM grinding and erosion machines**,
this series enhances material removal rates while maintaining **low evaporation and minimal foaming**.
Its advanced composition ensures **maximum surface quality** and **extended grinding tool life**.

IonoGrind is particularly optimized for **PCD (polycrystalline diamond), HSS, and tungsten carbide machining**.
By integrating specialized **high-pressure additives**, it improves **cooling efficiency**, reduces **tool wear**,
and prevents **cobalt leaching**, ensuring precision in **high-performance EDM grinding applications**.

Key Advantages of IonoGrind

• High Material Removal Rates: Increases machining efficiency and reduces cycle times.
• Optimized Surface Quality: Provides a superior finish, reducing post-processing needs.
• No Cobalt Leaching: Prevents contamination and extends the lifespan of machined components.
• Extended Oil Longevity: Reduces consumption and operational costs.

Technical Specifications

Product Name	Density at 15°C (g/cm³)	Viscosity at 40°C (mm²/s)	Flash Point (°C)	Application
IonoGrind	0.84	7.3	>155	For universal grinding and EDM machines.
IonoGrind 105	0.78	2.3	>106	For universal grinding and EDM machines.
IonoGrind 165	0.82	7.5	>160	For universal grinding and EDM machines.
IonoGrind X160	0.82	6.0	>160	For universal grinding and EDM machines.

IonoVit Series

The IonoVit Series is a high-performance **dielectric fluid designed for EDM fast hole drilling**.
These specialized fluids ensure **precision, efficiency, and stability**, making them ideal for **small-diameter precision drilling**
across **aerospace, automotive, and medical manufacturing**.

IonoVit S and IonoVit 0 offer **temporary corrosion protection**, **prevent cobalt leaching**,
and **eliminate foam formation**, ensuring a **clean and controlled EDM process**.
The advanced formulation of IonoVit fluids **reduces wear, shortens processing times, and enhances flushing properties**
for improved performance in high-speed machining.

Key Advantages of IonoVit

• Temporary Corrosion Protection: Protects workpieces during machining.
• Prevents Cobalt Leaching: Ensures material integrity and precision.
• No Foam Formation: Maintains a stable and clear machining environment.
• Optimized for Small-Diameter Drilling: Supports fine hole applications as small as 0.1 mm.
• Reduced Wear and Shorter Processing Time: Increases productivity while maintaining tool longevity.

Technical Specifications

Product Name	Density at 15°C (g/cm³)	Viscosity at 40°C (mm²/s)	Flash Point (°C)	Application
IonoVit S	0.82	2.7	104	Fast hole drilling with **no foam formation** and **excellent corrosion protection**.
IonoVit 0	0.82	2.9	105	Designed for **high-speed drilling** with **temporary corrosion resistance** and **no cobalt leaching**.

Performance Comparison: IonoVit vs. Deionized Water

Extensive testing demonstrates that **IonoVit S significantly improves machining performance**
compared to deionized water. The table below showcases its **superior feed rate, reduced tool wear, and optimized EDM drilling efficiency**.

Material	Electrode	Duration (min:sec)	Wear (mm)	Feed Rate (mm/min)	Performance Advantage
Tungsten Carbide (20mm)	Copper Multichannel	3:52	160	5.17	–
IonoVit S	Copper Multichannel	2:20	105	8.57	+39.7% Faster

Water Treatment & Quality Control

To maintain **consistent drilling performance**, IonoVit fluids should be used with **filtered deionized water**.
The ideal Brix concentration is **5% – 7%**, and water conductivity should be kept below **10 µS/cm**.
Proper water management extends fluid longevity and ensures stable EDM drilling results.