What is Wire Cloth Made Of?

What is Wire Cloth Made Of?

Wire mesh and metal cloth are produced using a range of different base materials:

Metal and Alloy Wire

Metal and alloy wires are produced through a wire drawing process. In this process, a metal rod or larger wire is drawn through a series of progressively smaller dies to decrease its diameter and create a finer wire.

Although the process resembles metal extrusion, in wire drawing, the metal is pulled rather than pushed, which helps to minimize the reduction in area or diameter. Excessive reductions can cause the wire to yield. Typically, industrial wire drawing achieves area reductions between 15% and 45%.

Wire drawing imparts a great amount of cold work and strain hardening. The cold work can produce high carbon steel wire with extremely high strengths of 580 Ksi (4000 MPa).

Wire Drawing Process

Metal wire is commonly round in cross-section, but it can also be manufactured in various shapes. After drawing, wire can be rolled with smooth rollers to create flat wire with rounded edges. Using contoured rollers, wire can be shaped into square, rectangular, oval, hexagonal, or triangular cross-sections.

Metal Sheet and Foil Manufacturing

Metal sheets and foils can be used to create mesh or screen-like materials. Metal sheets are made by cold rolling, where an alloy is pressed between steel rolls to thin and shape the metal. While hot rolling can achieve annealing or recrystallization during the reduction process, it typically results in a surface finish and tolerance that are not as refined as those from cold rolling. Depending on the alloy and the extent of reduction, intermediate annealing steps may be necessary.

Metal sheets and foils can be slit into narrow ribbons or flat wire-like shapes. Additionally, metal sheets can be perforated and expanded to create nonwoven metal fabrics, such as mesh or screens.

Metallic or Metal Fiber Manufacturing

Metal or metallic fibers are defined as any manufactured fibers made entirely from metal or alloys, including metal-coated plastic fibers and plastic-coated metal fibers. These metallic fibers serve as a raw material for producing wire or metal cloth.

Metallic fibers are finer than most metal wires. Metallic fibers typically have diameters ranging from 1 to 100 microns (0.00004 to 0.004 inches). American Wire Gauge (AWG) sizes range from 40 to 0000 (4/0 or “four aught”) gauge (0.0031 to 0.46 inches).

Metallic fibers are produced through various methods, including:

Bundle drawing

Thousands of wires are packed into a tube, which is then drawn through a die. The tube is subsequently removed by acid etching, leaving behind metallic fibers. This process produces octagonal fibers with diameters as small as 200 nanometers.

Foil Shaving

Fibers as fine as 14 microns are created through a foil shaving process. In this method, steel wool is formed by cutting wire, and the resulting fibers feature a triangular cross-section. This unique shape enhances the cutting and cleaning efficiency of the steel wool.

Machining

The machining process can create fibers as small as 10 microns with remarkable stability.

Melt Spinning

Molten metal is poured onto a cooled, spinning copper roll, which produces fibers ranging from 40 to 250 microns.

Metallic Coating

Carbon or polymer fibers can be coated with metal through various techniques, including electrodeposition, electroplating, and thin film deposition methods such as PVD or evaporation.

Monofilaments, Strands and Yarns

In many industrial applications, wire is utilized as monofilament to create or weld wire cloth materials. Wires can be twisted together to form strands or multiple wire bundles.

Strands are also combined to create wire rope, a structural component used to support suspension bridges. In certain architectural applications, wire cloth made from strands and/or wire is utilized where enhanced strength or the appearance of strength is needed.

Metallic fibers can be utilized directly to create metal cloth or twisted into metallic yarns. This yarn is then woven to produce metal fabrics with a finer weave compared to traditional wire cloth. Metallic fiber textiles are effective for filtering finer micron particles. Additionally, they are employed in various applications such as electrical cables, fuel cell electrodes, fire protection systems, high-temperature insulation, EMI/EMC shielding, and composite reinforcement.

Blends or Hybrid Weaves

Blends or hybrid weaves incorporate one metal wire or metal fiber interlaced with non-metallic fibers, yarns, strands, or monofilaments. These weaves are employed in specialized applications where neither metal nor synthetic fibers alone are adequate. The non-metallic components can include natural fibers like cotton and silk, as well as glass fibers, ceramic fibers, carbon fibers, and synthetic materials such as polyamide (nylon), polyester, polytetrafluoroethylene (PTFE), and polyetheretherketone (PEEK).

Blend or Hybrid Weave of Metal Wire and Non-metallic Fibers

Wire Metal and Alloy Types

Aluminum

Aluminum is among the lightest structural metals, with a density that is 35% lower than that of steel. It boasts high ductility, making it easy to shape and form.

Aluminum offers better corrosion resistance compared to steel, particularly when anodized. However, it does not match the corrosion resistance of stainless steel. Additionally, aluminum is softer and more susceptible to abrasion and wear.

Aluminum is valuable for architectural and aerospace applications, but its alloy is not suitable for filtration or screening of powders or solids.

Copper

Copper boasts excellent electrical and thermal conductivity, with only silver surpassing it among pure metals. This superior conductivity makes copper ideal for conductive braids, electrodes, and various electrical and shielding applications. However, its softness and lower tensile strength can restrict its use in filtering and screening applications.

Copper possesses antimicrobial and anti-fouling properties, making it increasingly valuable in hospitals and medical devices. These properties help ensure that surfaces contacted by patients and healthcare professionals are safer and more hygienic.

In seawater, copper wire mesh screens are resistant to fouling and will not accumulate barnacles or marine growth. Copper root barrier screens are designed to prevent tree roots from penetrating beneath sidewalks and pavement. The roots will encounter the screen and cease to grow further.

Copper can be treated to develop attractive patina colors, making it ideal for consumer product designs and architectural applications.

Brass

Brass is an alloy composed of copper and zinc, with zinc enhancing the strength of copper. Compared to pure copper, brass is easier to cast, machine, and work with. Brass is categorized into high and low brass based on zinc content, with high brass containing more than 33% zinc. The terms "high brass" and "low brass" originate from the era when shotgun shells were made from paper.

Bronze

Bronze is an alloy composed primarily of copper combined with tin, silicon, aluminum, lead, chromium, zirconium, and other metals. These alloying elements enhance the metal’s strength and give it specific properties based on the elements used. Compared to pure copper, bronze can be easier to work with due to its improved machinability and versatility.

Phosphor bronzes are composed of tin and a small amount of phosphorus, which enhances their properties. These bronzes are particularly well-suited for weaving into very fine mesh screens due to their strength and resistance to cold working. Compared to brass, phosphor bronze offers superior durability and is commonly used to manufacture fine Fourdrinier wire screens for papermaking.

Bronze can be treated to develop stunning patina colors, enhancing its appeal for consumer products and architectural designs.

Galvanized Steel

Galvanized steel is coated with zinc to safeguard the underlying steel wire. This coating process is achieved through methods such as electrogalvanization or molten zinc dipping. Zinc dipping provides a thicker coating, offering extended protection for the steel. Galvanized steel can be used to create woven wire cloth. However, welded wire cloth cannot be manufactured with galvanized steel wire due to:

The zinc coating will evaporate during welding, resulting in porosity in the weld.

The steel in the weld zone and surrounding metal will not have a protective zinc coating. The weld joint must be recoated with zinc.

The zinc vapor generated during welding can cause zinc chills when inhaled by welders.

Welded wire mesh is usually galvanized after welding to overcome these problems.

Nickel or Nickel Alloy

Nickel and nickel alloys have outstanding high temperature strength and oxidation resistance properties even at red hot temperatures. Nickel alloys also have excellent corrosion resistance in acid and chemical environments where other metals fail. Nickel alloy mesh, filters, and strainers are used in chemical process and aerospace applications. InconelⓇ and HastelloyⓇ are common nickel based alloys.

Monel is an alloy composed of copper and nickel, renowned for its exceptional corrosion resistance. It retains some of the antimicrobial properties of copper. Due to its durability and resistance to harsh environments, Monel wire mesh and nickel materials are frequently utilized in food processing application.

Stainless Steel

Stainless steel is an iron alloy containing at least 10.5% chromium. When the alloy is cut or ground, it quickly forms a protective oxide film. This passive chromium oxide layer helps prevent further corrosion. Additionally, the inclusion of nickel in stainless steel stabilizes the austenite phase, enhancing its ductility and formability. Nickel also contributes to improved corrosion resistance.

Austenitic stainless steel alloys must contain at least 12% chromium and low carbon levels to ensure passivity and corrosion resistance after welding. Common welding grades include 304L, 316L, and Columbium-stabilized 347 stainless steels. The 304L grade, also known as 18-8 stainless steel, comprises approximately 18% chromium and 8% nickel. The 316L grade contains higher nickel levels (10–12%) and includes molybdenum (2–3%), making it more suitable for environments with chlorides, such as saltwater.

Stainless steel wire cloth and metal mesh are used in various applications, including chemical processing filters and strainers. They are also employed in architectural fabrics to diffuse light and add decorative elements.

Steel

Low carbon steel is highly malleable and cannot be hardened through heat treatment. In contrast, high carbon and alloy steels can be hardened to achieve high levels of strength and hardness. High carbon steel, in particular, can be drawn through dies to produce extremely strong wire.

Titanium or Titanium Alloy

Titanium offers superior corrosion resistance compared to stainless steel and is significantly lighter, with a density that is only 60% of steel’s. Its exceptional fatigue strength and high strength-to-weight ratio make titanium and its alloys highly valuable for aerospace applications.

Titanium's exceptional corrosion resistance makes it ideal for chemical process applications where stainless steels are inadequate. It performs well in environments with seawater and other chloride salt solutions, hypochlorite, wet chlorine, nitric acid, and even fuming acids.

Titanium offers superior biocompatibility compared to stainless steel. Therefore, a woven titanium mesh is a preferable option for implant applications.