Wire mesh and wire cloth are highly versatile products made from a network of interlaced wires.
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Wire cloth is generally flexible with a smooth cloth-like consistency. Most specifications use thinner wire diameters that create very small to small micronic openings. As a result, this material is a perfect medium for screening and filtration applications.
Wire mesh on the other hand incorporates larger openings and thicker wire diameters. These materials are ideal for cages, fencing, and ventilation covers.
By changing the opening size and wire diameter a variety of specifications are available to accommodate many applications, whether it’s a mesh panel for architectural installations or a heavy-duty wire mesh product for industrial purposes.
Woven wire mesh is a (often steel) metal mesh made using special weaving equipment, intricately weaving metal wires together to form a cohesive structure.
Typically, wire cloth utilizes a plain weave construction meaning the wires just pass over one another at each intersection.
For mesh with larger openings and thicker diameters, there is an entire crimping process prior to configuring the weaving loom. This process pulls coiled wire from a rack into the crimping machine. The wire is first straightened and then crimped to a specific profile using a set of toothed wheels. The wire is then accurately cut to the desired length and width ready to be woven.
Depending on your requirements, these special weaving looms can construct various woven wire mesh specifications, incorporating metal wires of different materials and diameters.
Stainless steel wire mesh has many attributes, making it highly desirable for a number of applications.
Besides stainless steel, other materials are available to create woven wire mesh, including:
Individuals looking to get woven wire mesh must know the three fundamentals to get the right product for their needs, including wire mesh product specifications and metal varieties.
You may hear terminologies such as 4 or 100 mesh count when shopping for wire cloth, which refers to the number of openings in an inch.
Knowing the mesh count will help you get a solution that allows you to have control over what passes through the mesh. For example, if you’re working at an oil rig, you would need a mesh with 100 openings or more, depending on what you want to filter out.
Typically, for finer filtration, oil rigs use meshes with many small opening sizes to filter out sand and other impurities when pumping out oil from the ground.
For heavy-duty wire mesh, this might be a measurement in fractions of an inch to determine the opening or mesh centers. This is ideal for aggregate sizing and sifting applications.
Wire diameter is the thickness of each wire which determines the following:
If the wires are thicker, there will be a smaller open space, making the weave durable and more resistant to harsher conditions. However, thinner wires may allow for more open space but could result in more wear and tear depending on the application.
There are different specifications of wire meshes depending on the wire diameters. For example, working with coarse aggregates, you would likely want a thick wire diameter better suited to withstand material processing. However, a slightly thinner wire diameter would be ideal for as machine guard to protect the operator and equipment while allowing for ventilation.
The opening size is the distance between the wires.
Knowing the mesh count and opening size can help determine your required micron rating. For filtration, micron rating is crucial as it gives the user more control over the medium.
The following are some common types of woven wire mesh:
Each type has its unique properties. For example, the lock crimp offers greater stability, while the flat top crimp features a smooth top allowing for a better flow of materials. Besides the types mentioned above, you can also find various architectural patterns for your creative installations.
There are many woven wire cloth types you can choose from, including:
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In conclusion, woven wire mesh, with its intricate weave and utilization of various raw materials, stands as a testament to human ingenuity in creating versatile materials to serve diverse industrial and creative needs. This article has shed light on the fundamentals of woven wire mesh, detailing its manufacturing process, materials used, and key considerations in selecting the appropriate mesh for specific applications, including stainless steel and aluminum wire mesh.
The distinction between wire cloth and wire mesh, underscores the tailored functionalities each offers, whether for screening and filtration purposes or structural applications like fencing and ventilation. Moreover, understanding mesh count, wire diameters, and opening sizes empowers users to make informed decisions aligning with their requirements, whether for fine filtration in oil rigs or robust protection in industrial settings.
Furthermore, the exploration of different types of woven wire mesh, from plain crimp to lock crimp, reveals the rich diversity of options available, each with its unique properties suited to various demands. Likewise, the array of woven wire cloth types, such as plain square woven and Dutch twill weave, showcases the breadth of creative possibilities and functional adaptations achievable with this versatile material.
In essence, woven wire mesh epitomizes versatility and ingenuity, offering a blend of functionality, durability, and aesthetic appeal across industries ranging from industrial to architectural. As technology advances and demands evolve, woven wire mesh continues to adapt, remaining an indispensable tool in the arsenal of engineers, designers, and artisans worldwide.
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Galvanized stainless steel is an incredibly durable and resistant material. Pipes, nails, beams, plates, bars, rods, and other industrial products are often galvanized to ensure decades of strength and corrosion prevention.
Wire mesh plays a critical role in thousands of commercial and industrial applications. Galvanized screens, in particular, provide a lot of value, as they're adaptable, long-lasting, and reasonably priced.
The Process of Making Galvanized Wire Mesh
A thick, robust outer layer of zinc is what makes galvanized hardware cloth so strong and resilient. How does it acquire this coating? It can be done in a couple of ways: hot-dipping and electrogalvanizing. Each process is outlined below.
Hot-Dipping
1. The stainless steel is cleaned with a sodium hydroxide solution to remove dirt, debris, oil, and other residues.
2. An acidic solution is then used to remove any mill scale, rust, contaminants, and other surface impurities.
3. A zinc ammonium chloride cleaning agent (also known as a "flux") is applied to the surface to prevent oxidation. This solution remains on the steel, as it helps the zinc stick.
4. Next, the stainless steel is dipped into a vat of molten zinc (which has been liquified at an extremely high temperature).
5. The steel remains in the vat until it reaches the same temperature as the hot zinc.
6. After being removed from the vat, the stainless steel is rapidly cooled in a special tank.
Hot-dip galvanizing creates a physical and chemical bond between the steel and the zinc. This is what's called a zinc-steel alloy.
Electrogalvanizing
Unlike hot-dipping, electrogalvanizing (or electrolytic galvanizing) is a cold process. Zinc particles are used to create an organic solvent, which is applied to the steel surface.
This causes a reaction between the substances, resulting in a zinc-steel alloy. When the solvent evaporates, the zinc remains on the metal. Electrogalvanizing generally leaves a thinner zinc layer than the hot-dipping method.
Spangle
When larger pieces of steel are galvanized, the zinc coating can often be seen with the naked eye. This is what's called "spangle," which has a crystalized, snowflake-like appearance. The crystallites are present with wire mesh screens, but they're usually too small to see.
Galvanizing Before vs. After Manufacturing Mesh
Stainless steel can be galvanized either before or after it's fabricated into wire mesh. When galvanizing occurs first, the metal is drawn down the desired diameter. The individual metal wires are coated with zinc and then woven or welded into screens. Welding can burn the zinc layer off at the joints, in which case it may need to be galvanized again.
When fabrication comes first, pre-woven steel products are dipped into molten zinc or coated with a solvent. This is usually the more costly option, particularly if mesh products are custom ordered and then galvanized. However, it ensures the mesh screens retain their protective coating.
Industrial Uses for Galvanized Mesh
What is wire mesh used for after it's galvanized? Due to its notable durability and corrosion-resistance, the material is an important component of many industrial applications.
Galvanized stainless steel screens are used for:
- Agriculture and farming
- Archaeology
- Fencing, enclosures, and safety
- Gardening, greenhouses, and landscaping
- Gutter guards, soffit screens, and foundation vents
- HVAC applications
- Particle
- Pest-control
- Retention walls
- Roofing, ceilings, infill panels, drywall, and insulation
Galvanized hardware cloth is technically a type of stainless steel mesh. However, the material is often given its own category, as it has distinct features and advantages.
Galvanized Wire Screens and Mesh Products from TWP Inc.
TWP Inc. has been a leading supplier of wire mesh materials for over 50 years. Our women-owned company holds a certification from the International Organization for Standardization (ISO), which requires us to adhere to the highest standards in the industry.
We're proud to offer a broad range of stainless steel mesh materials, including galvanized, welded, poly-coated, and sintered. TWP Inc. carries industrial-grade hardware cloth in many shapes, sizes, weaves, wire diameters, opening sizes, and finishes.
We also offer a range of services, including slitting, disc sizing, and laser cutting. Additionally, TWP Inc. can accommodate custom sizes, shapes, and quantities. Order yours today.
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