Wire Manufacturing

Metal wire has a broad range of uses in many sectors from industry to construction. The cables responsible for relaying Internet coverage in our homes are made from metal wire. Our power grid would be virtually non-existent without the reliance of good conductor metal cables. Even the electrical appliances we use in our homes contain metal wire components. Read on to discover more about the different types of metal wires and how they are manufactured.

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What is wire and where is it manufactured?


A wire refers to a piece of flexible component that resembles a thick string which is made from a metal substance. Most of the wires we use are manufactured in plants owned by prominent firms in the metal making industry. Such facilities usually boast a multitude of equipment including furnaces, heat insulators, industrial cooling towers and rolling mills. A majority of wire making factories are located away from the cities and towns for both legal and practical reasons.


Which metals are used in cable production?


Not all metals or alloys possess the properties necessary to produce useful wire. When determining the suitability of a metal or alloy, we primarily assess its ductility and its strength in tension. The primary metals involved in wire production include iron, silver, copper, platinum, aluminium and gold. The metals above can also be combined to form alloys namely, steel, brass and bronze to make superior wires. There are also special purpose wires made from metals such as tungsten, commonly found in vacuum filament tubes


How is metal wire manufactured?


The process begins by feeding the raw material, which could be iron, copper or aluminium into the furnace for heating. Upon heating, the material undergoes treatment and stretching to produce an initially large wire. Next, the cable is run through a series of a series of diamond dies to produce multiple wires that are different in diameter.


Heavier wires meant for industrial and electrical use are generally fed into a large bobbin which twists the wire into shape. The finished cable is coated in liquid steel for added strength and protection. For coaxial cables, two or more wires can be wrapped together which is then followed coating using an insulating material such plastic or rubber to produce a jacketed wire.


What is essential for a factory manufacturing metal wire?


Plant and machinery common in wire manufacturing plants include furnaces, industrial cooling plants, heat insulators, rolling mills and bobbins. Furnaces are primarily for heating the raw material to the desired temperature to make it malleable. Cooling plants then eject heat after formation of the base wire. Wire drawing machines then pull wire from the base component. Rolling mills and bobbins are for twisting the wire into shape.


Types of wire


The major variations of wire include solid, braided and stranded cables. A solid wire is essentially a single strand. A Stranded wire features many small wires wrapped together to create a larger wire. It is more expensive to manufacture than a solid wire. Braided wires are created by braiding many small strands of wire together. This wire has excellent flexibility and is a better conductor than the solid variant.