How to Select Wire End Brushes

Wire end brushes are used for cleaning and surface-finishing recessed areas. These power brushes are also used for polishing, deburring, and surface preparation. Industrial applications for wire end brushes include removing scale and slag, polishing dies and molds, cleaning castings, and preparing surfaces for welding. These wire brushes are also used to improve the surface finish of spot faces, machined features with flat surfaces.

Typically, wire end brushes are used with high-speed, handheld power tools such as electric drills. Some wire brushing tools are also used with CNC equipment. During product selection, industrial buyers need to evaluate product specifications such as filament material, wire size, and brush tool diameter. Buyers must also consider that there are different types of wire end brushes, and that some fill styles and brush tool designs are better suited for more aggressive brushing applications.

Filament Material and Wire Size

Brush Research Manufacturing (BRM) supplies American-made wire end brushes with carbon steel (CS) or stainless steel (SS) filaments. Often, carbon steel end brushes are used for cleaning or polishing softer metals such as brass or copper.  Stainless steel end brushes are used with aluminum, stainless steel, and higher-strength alloys such as those found in the aerospace, defense, and shipbuilding industries. Unlike carbon steel brushes, stainless steel filaments won’t leave deposits or residues that can rust.

In addition to filament material, wire size is an important specification to consider. As a rule, select the smallest possible wire size for your application. End brushes with smaller filaments provide more cutting tips per square inch, and last longer than larger-diameter filaments because of wire fatigue. For more aggressive brushing, consider not just the wire size, but also the brush’s fill density (solid or knotted) and operating speed. Do not, however, exceed the maximum safe free speed (MSFS).

Diameter and Brush Tool Style

As a full line supplier of surface finishing solutions, BRM offers different types of wire end brushes in various tool diameters. For example, solid wire end brushes come in sizes ranging from 1/2” to 1”. In addition to cleaning and polishing, non-banded versions of these power brushes are used for surface blending. For less flare and more precise control of filament tips, BRM supplies banded solid-fill wire end brushes.

Knotted wire end brushes are recommended for more aggressive brushing applications, such as removing carbon deposits from heads. When banded, these end brushes offer less flare and better control of filament tips. BRM wire end brushes also include brushing tools with coated cup-style bodies that help protect workspaces. In deep well applications, the coated cup protects adjoining surfaces from marring and scratching. Finally, BRM offers circular flared brushes for side cutting action.   

For more information about wire end brushes, visit the BRM website or watch this short video called BRM End Brushes – Made in USA.  The Brush Research YouTube channel also features a video entitled How to Make an End Brush.