Basics of Wire Mesh

What are the basics of wire mesh?

Wire mesh is produced by intertwining, weaving, or welding wires of different thicknesses to form evenly spaced parallel rows and intersecting columns. Commonly referred to as wire fabric, wire cloth, or hardware mesh, it is created by weaving wire on industrial looms, resulting in square or rectangular openings between the wires. Alternatively, welded wire mesh is made by using electric welders to join parallel longitudinal wires at their intersections.

There are a limitless number of shapes, sizes, and configurations of wire mesh made from an assortment of highly durable and resilient materials whose major function is to separate, screen, structure, and shield various applications and processes. The types of wire include galvanized steel, stainless steel, aluminum, steel, and copper alloy wire. The type of application, necessary tensile strength, durability, longevity, and required flexibility are some of the factors used to determine the desired type and style of wire.

How Wire Mesh is Made

Wire mesh is manufactured through two main processes: weaving and welding. Wire weaving resembles the cloth weaving process on a loom, whereas welding involves joining wires at their intersections. Both methods are carried out using automated, pre-programmed machinery.

Wire Weaving

Near the end of the 17th century, woven wire cloth for the mining and pulp industries came into high demand, leading to the development of wire weaving looms. Over the centuries, the use for wire mesh has advanced beyond mines and pulp mills to architecture, plastic extrusion, aggregate screening, and filtration processing. The rise in demand has led to the modern industrial wire weaving industry.

• Weaving Loom — Weaving looms weave mesh rolls with widths of 48”, 60”, 72”, 98”, or wider. The loom has a warp beam, heddle frames, a reed, a rapier for transporting weft wire, and a take-up mechanism.

  Manufacturers use looms to weave meshes of standard and custom patterns. The completed mesh rolls are cut to varying lengths depending on the needs of customer specifications. Wires woven horizontally or lengthwise are warp wires, while wires woven vertically or crosswise are referred to as weft wires or shute wires, terms commonly used in textile manufacturing.

• Warp Beam — The warp beam is a cylindrical drum wrapped with the warp wires. The warp beam's tension must be meticulously controlled to avoid elongation of the woven mesh. The number of warp wires varies depending on the mesh width and must be kept the same length.
• Heddle Frames — The heddle frames separate the wires that are fed by the warp beam. Most looms have two heddle frames, with one used to lift half of the warp wires while the other pulls the warp wires down. The heddle frames change position as the weft wires move across the warp wires.
• Rapier Band — The weft wires are carried across the full width of the cloth by the rapier at each cycle of the heddle frame. It feeds a single weft wire between the sets of warp wires.
• Reed — The reed keeps the warp wires from the warp beam in place and accurately spaced and separated. Once the weft wire moves across the warp wires, the reed beats the weft wires tightly in place in the wire cloth.
• Take-Up — The take-up mechanism is a set of rollers that takes the fabric away from the loom with a pickup roller and two other rollers that work together to wind the cloth to the cloth roller. The fabric is wound in single layers with a smooth flat surface created by it being passed through the set of rollers.

After assembling the loom and loading the warp beam, the weaving process operates automatically. As the loom initiates, the warp beam unwinds gradually and evenly. Simultaneously, the take-up mechanism rolls up the finished fabric in sync with the warp beam’s unwinding. This coordinated movement ensures consistent tension on the warp wires, which is essential for producing high-quality fabric.

Welded Wire Mesh

Wire mesh is welded through a semi-automatic process that joins the intersections of the woven wires. Welding machines are programmed to fuse the connections at the horizontal and vertical wire intersections. Various welding techniques are employed, including resistance welding, tungsten inert gas (TIG) welding, plasma welding, and soldering.

• Weld Mesh Machine — The process of wire mesh welding begins with feeding wires into a weld mesh machine, which is much like the heddle frames and reeds of wire weaving.
• Wire Spools — Separate spools of wire are fed through a straightener. Pre-cut wires that match the dimensions of the wire mesh are placed separately from the wires fed from the spools. Since the wires are coming off spools, whether pre-cut or fed from them, they are mechanically straightened to lay flat on the welding surface.
• Mechanical Placement — The pre-cut wires are laid flat across the wires being fed from the spools. The wires are perpendicular to each other at right angles in mesh welding.
• Welding — Once the wires are positioned, the programmed welding process begins and applies a uniform weld at each cross-section.
• Process Completion — The collection of the final wire mesh from the welding process can be in rolls, like wire weaving, or sheets that are trimmed to size and placed in piles of wire mesh panels.

Welded mesh is more robust, durable, and stronger than woven wire mesh, and is typically made from thicker wires that can endure the welding process. The welding technique imparts increased rigidity and durability to the mesh, making it well-suited for applications such as fencing, cages, and concrete reinforcement sheets.

Types of Wire Mesh

Wire mesh varieties are categorized based on their manufacturing methods, properties, functions, and weave patterns. Each type is tailored to meet specific requirements for strength, weight, and finish. Key factors in selecting the appropriate wire mesh include its finish, metal type, and pattern, with the finish and metal type being the primary considerations.

Welded Wire Mesh

Welded wire mesh consists of square-shaped grid patterns formed by welding the wires together. This method produces a sturdy mesh suitable for various uses, including security fencing, warehouse shelving and storage, lockers, animal enclosures in veterinary clinics and shelters, room dividers, and pest traps.

Welded wire mesh is:

1. Durable and capable of withstanding changes in weather
2. Held securely and firmly in place without creep or shifting
3. Customizable to fit any dimensional needs or specifications

When welded wire mesh is made from stainless steel, it has stainless steel’s durability and corrosion resistance.

Galvanized Wire Mesh

Galvanized wire mesh is created from plain or carbon steel wire that undergoes galvanization, a process where a zinc coating is applied. This zinc layer serves as a protective barrier against rust and corrosion. Galvanized wire mesh can be made by either using galvanized wire or by applying galvanization to plain steel wire after it has been woven or welded. While galvanizing the mesh post-processing is more expensive, it results in a higher-quality product.

Galvanized wire mesh is well-suited for a variety of applications including agricultural and gardening fencing, greenhouses, architectural uses, building and construction, security barriers, window guards, and infill panels. Its cost-effectiveness makes it a popular choice among the different types of wire mesh.

Vinyl-Coated Wire Mesh

The application of a vinyl coating to welded or woven wire mesh creates a strong barrier for very flexible wire mesh. Vinyl-coated wire mesh is stable over a wide range of temperatures, is not degraded by exposure to the sun, and is resistant to scrapes, abrasions, and impact.

Wire mesh with a vinyl coating often appears to be plastic and is sometimes called plastic mesh. This coating not only enhances the visual appeal of the mesh but also provides significant benefits, including durability, resistance to rust and corrosion, and protection against water and other external elements. The vinyl layer effectively seals the wires, ensuring long-lasting performance.

Welded Steel Bar Gratings

Welded steel bar gratings are created through forge welding at very high temperatures. During this process, vertical bars are positioned across a series of horizontal bars, and they are fused together, forming a strong and durable connection capable of withstanding severe conditions. These gratings are made from either carbon steel or stainless steel, offering exceptional strength, durability, and rigidity.

Engineered for heavy-duty applications and long-term use, welded steel bar gratings are commonly used in various settings, including landing mats, bridge decking, ventilation grilles, ramps, sidewalks, and industrial floors. The panels come in widths of two to three feet and lengths of two feet, with bar sizes ranging from 1” to 6” in depth and thicknesses from 0.25” to 0.50”.

Stainless Steel Wire Mesh

Stainless steel wire mesh benefits from the advantageous properties of stainless steel, offering high-quality protection and performance. While steel is commonly used for wire mesh production, it tends to rust when exposed to air. Stainless steel, however, incorporates chromium, which imparts rust resistance and shields the metal from oxidation, making it a superior alternative.

In wire mesh manufacturing, stainless steel is valued for its reliability, strength, and durability. Its resistance to rust makes it suitable for various outdoor applications, consistently providing robust performance and longevity. This makes stainless steel one of the most favored types of wire mesh.

Stainless steel wire mesh can be either welded or woven. Common grades used include 304, 304L, 316, 316L, 321, 347, and 430, with wire diameters ranging from 0.0085 inch (0.216 mm) to 0.307 inch (7.8 mm). The mesh openings vary based on the type, with openings smaller than 0.25 inch (6.35 mm) classified as wire cloth. Key considerations for wire mesh include the percentage of open area and the mesh weight.

Grade 316 stainless steel is a high-grade alloy ideal for marine environments, offering excellent resistance to corrosion, acids, saltwater, and seawater. It is available in fine, medium, or coarse sizes. On the other hand, grade 304 stainless steel, while less resistant to corrosion compared to grade 316, is highly workable and more cost-effective.

Wire Mesh Patterns

The pattern of wire mesh influences its functionality and suitability for different applications. There are numerous standard weave patterns, as well as custom designs tailored for specific uses. A key distinction among these patterns is whether the wire is crimped or not. Crimping involves mechanically altering the shape of the weft or warp wires, which can affect the mesh’s overall performance and appearance.

Crimped Wire Mesh

Crimped wire mesh features a square or rectangular weave and is produced using a crimping mesh machine. The manufacturing process involves compressing the wire so that the weft wire overlaps the warp wire and vice versa. This crimping technique creates a bending effect, causing the wires to interlock and wrap over one another.

• Pre-Crimp — Pre-crimped weaves are crimped with small folds or ridges that are added before the wire is woven to increase the strength and rigidity of the wire mesh. The process prevents the weft and warp wires from moving and keeps them secure.
• Lock Crimp — Lock crimp is another pre-crimp process that uses the grooves from the crimping process to lock the weave together at the intersections of the weft and warp wires. As with pre-crimping, the final weave is sturdier and immovable.
• Inter-Crimp — With inter-crimp, the warp and weft wires are crimped with additional crimps added between the intersections. It is a process used with fine wire with large openings to ensure the weft and warp wires are accurately and properly locked to provide additional rigidity.

Non-Crimped Wire

Non-crimped wire mesh, also known as plain wire mesh, is created through a straightforward over-under weaving of the warp and weft wires. This method results in a smooth, even surface with a simple appearance. Traditionally, non-crimped or plain wire mesh features a higher mesh count.

Plain weave wire mesh is one of the most widely used types. It typically exhibits a 3 x 3 weave pattern or finer. This pattern is commonly found in screening applications, such as screen doors and window screens.

Double Weave Wire Mesh

Double weave wire mesh is an advanced form of the pre-crimped weave pattern. In this method, warp wires weave over and under two weft wires simultaneously, resulting in a more resilient mesh. This enhanced durability makes double weave wire mesh suitable for heavy-duty applications such as vibrating screens in mining, agricultural fences, and screens for barbecue pits.

Flat Top Weave Wire Mesh

Flat top weave features non-crimped warp wires combined with crimped weft wires, creating a durable, lockable mesh with a flat surface. This design ensures a long service life due to the absence of protruding wires that could wear down. The minimal flow resistance of flat top weave makes it a preferred choice for architectural and structural applications that require a smooth surface. It is commonly used in vibrating screens due to its robust and efficient performance.

Twill Weave Wire Mesh

The twill weave pattern is well-suited for weaving heavier and larger diameter wires. This pattern is created by alternating the warp wires over and under two weft wires or vice versa, resulting in a staggered, diagonal effect. The warp wires are inverted at the intersections, enhancing the stability, rigidity, and strength of the mesh. As the weave progresses, it forms a distinctive appearance with parallel diagonal lines.

Twill weave wire mesh can support heavier loads and perform fine filtering. It is a basic component of the production of filters, colanders for aliments, chemical production, shielding, and mosquito nets. For filtering processes, it is made of stainless steel grades 304 and 316 due to their resistance to acids and wear.

Dutch Weave Wire Mesh

Dutch weave wire mesh differs from plain and twill weave patterns in that it features weft wires of a different diameter compared to the warp wires. The warp wires are thicker, providing greater tensile strength, while the weft wires are finer, enhancing the mesh’s filtering capabilities. This combination of increased strength and finer openings makes Dutch weave wire mesh particularly effective as a filtering cloth.

The Dutch weaving process can be executed in either a plain or twill pattern, each offering unique characteristics suited to various applications.

• Plain Dutch Weave Wire Mesh — Plain dutch weave combines the dutch weave process with plain wire weave. Using two different diameter wires, the coarse warp wire passes over and under the weft wire while the weft wire passes over and under the warp wire. The main advantages of plain dutch weave wire mesh are mechanical stability, finer wire openings, and exceptionally high tensile strength.

  

  
  

• Twill Dutch Weave Wire Mesh — Twill dutch weave is a combination of regular twill weave and dutch weave. The weft wire alternately passes over and under two warp wires creating a fine mesh in the direction of the warp wire, with the warp wires forming a coarser mesh in the same weave. Twill dutch weave is superior to normal twill weave due to the finer openings and the ability to support heavier loads for filtering applications.

  The advantages of twill dutch weave wire mesh are its better filtering potential, tensile strength, the ability to filter exceptionally fine materials, and its stability.

  

  
  
• Reverse Dutch Woven Wire Mesh — Reverse dutch woven wire mesh is the same as plain dutch woven wire mesh. The difference between the two weaves is how the weft and warp are woven, with the warp and weft wires being reversed. Thin warp wires are placed close together and woven with thicker weft wires, which creates higher strength in the warp wires. The reverse dutch weave is used in applications that need wire mesh with acoustic properties, mechanical strength, and throughput filtration.

Off Count Wire Mesh

Off count wire mesh features a mesh pattern where the number of openings differs between the horizontal and vertical directions, resulting in a rectangular rather than square grid. This type of wire mesh is often used in sifting and sizing applications to enhance productivity, particularly in situations where minor inaccuracies are acceptable.

Stranded Weave Wire Mesh

Stranded weave wire mesh employs small-diameter bundles of weft and warp wires arranged in a plain square pattern. The use of multiple wires results in a dense, twill-style weave that offers exceptional strength and tightness. This dense structure is particularly effective for applications requiring microfiltration cloth.

Mesh Count

Mesh count is a fundamental concept in the wire mesh manufacturing industry, referring to the number of openings per linear inch in the mesh. To determine the mesh count, count the number of openings within one linear inch from the center of one wire to the center of the next. This measurement is typically represented by a number, such as 4 for a 4 by 4 mesh or 20 for a 20 by 20 mesh, indicating the quantity of openings within a linear inch.

Wire Mesh Edges

Wire mesh edges come in two types: raw and selvage. During the weaving process, the weft wires form an edge along the length of the roll to prevent the mesh from unraveling. In raw edge mesh, these weft wires are exposed at the edge.

Selvage edge wire mesh, on the other hand, features a finished border that enhances the mesh's stability and provides safety during handling. Various methods are used to create selvage edges, including looping the wires at the mesh's perimeter.

What types of wire are used to make wire mesh?

The primary material for wire mesh is the wire itself, which can be made from a range of ferrous and non-ferrous metals. Wire used in mesh production comes in various gauges, with the gauge number indicating the wire's thickness. Lower gauge numbers correspond to thicker wires, while higher numbers indicate thinner wires.

For plain and crimped wire mesh, the gauge of the shute or weft wires matches the gauge of the warp wires. However, in Dutch woven wire mesh, the weft and warp wires have different gauges. Stranded wire mesh, on the other hand, consists of very fine wires twisted together into bundles.

In addition to gauge, the choice of metal affects the type and application of the wire mesh. Wire is manufactured by drawing raw metal through a die or draw plate. While most wire mesh uses cylindrical wires, other shapes such as square, hexagonal, and rectangular are also utilized.

Carbon Steel in Wire Mesh

Carbon plain steel is one of the more popular metal wires used to manufacture wire mesh. It is mainly iron with a small amount of carbon and is a low-cost, versatile metal used for window guards, screens, and separation screens for mining. Carbon steel can be zinc coated to make galvanized steel wire or powder coated with plastic.

Stainless Steel in Wire Mesh

Stainless steel wire mesh is renowned for its strength, durability, and attractive shiny finish, making it a popular choice for architectural applications. Various grades of stainless steel are used in its production, with grades 316 and 304 being the most widely utilized.

• Grade 304 — has excellent corrosion, heat, and oxidation resistance and is one of the most widely used metal wires in the production of wire mesh. Much of its appeal is due to its very reasonable price.
• Grade 316 — has excellent corrosion, oxidation, and heat resistance at temperatures of 1000 degrees Fahrenheit or higher. Additionally, it resists pitting in chloride environments due to its molybdenum content.
• Grade 310 – has excellent temperature properties, good ductility and weldability, and exceptional toughness. Grade 310 wire is reserved for use with custom-made wire mesh.
• Grade 321 — is austenitic 18/8 stainless steel that is stabilized with titanium. It is used for wire mesh for oil refineries.
• Grade 347 — is also an 18/8 austenitic stainless steel but is stabilized with niobium and tantalum to improve its resistance to corrosion.

Aluminum Wire in Wire Mesh

Aluminum is favored for its lightweight, flexibility, malleability, corrosion resistance, and affordability, making it the most popular non-ferrous metal for wire mesh production. Pure aluminum, such as grade 1000, is rarely used; instead, aluminum is typically alloyed with metals like copper, magnesium, zinc, or silicon to enhance its strength and other properties.

The most commonly used alloys for aluminum wire mesh are 1350, 5056, and 6061, each providing specific benefits for various applications.

Copper in Wire Mesh

Copper wire mesh is valued for its ductility, malleability, and excellent thermal and electrical conductivity. It is commonly employed in applications such as radio frequency interference shields in Faraday cages and various electrical uses. Unlike aluminum, copper is rarely used in its pure form and is typically alloyed to enhance its natural properties.

Copper undergoes color changes when exposed to salt, moisture, and sunlight, shifting from salmon-red to various shades of brown, gray, and eventually to blue-green or gray-green. To maintain its appearance and control the oxidation process, copper wire mesh is often treated with coatings and chemicals.

Brass in Wire Mesh

Brass, an alloy of copper and zinc, is used in wire mesh manufacturing and is known in the industry as 270 yellow brass or 260 high brass. 270 yellow brass comprises 65% copper and 35% zinc, while 260 high brass contains 70% copper and 30% zinc. The higher zinc content in brass wire mesh enhances its tensile strength, abrasion resistance, and produces a more hardened mesh.

Industrial-grade brass wire mesh typically has a yellow hue, making it a popular choice for decorative and artistic applications in architectural projects.

Bronze in Wire Mesh

Bronze, an alloy of copper with 90% copper and 10% zinc, shares many of the properties of copper, such as malleability, ductility, and durability. However, bronze offers greater resistance to corrosion compared to brass and is harder and less malleable than pure copper. It is commonly used in industrial applications like filtering and also in various architectural applications.

The metals and alloys mentioned are among the most commonly used for manufacturing wire mesh. However, custom wire mesh can also be made from other metals such as titanium, Hastelloy, Monel 400, nichrome, Inconel, and tungsten. In essence, any ferrous or non-ferrous metal that can be drawn into wire can be utilized to produce wire mesh.

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What are the uses for wire mesh?

Wire mesh is highly versatile and can be tailored to meet a wide range of requirements, leading to its extensive use in various applications. In industrial settings, wire mesh serves as protective shielding, components of filtration and separation systems, and support for railings. It is a crucial element in filtration systems used in wastewater treatment facilities, petrochemical plants, and juice production processes.

Beyond industrial applications, wire mesh has been commercially utilized for many years. It provides protection against insects and is used in the construction of animal enclosures. Various forms of wire mesh are employed in products like screen doors, window screens, screen partitions, and decorative screens.

Industries that commonly rely on wire mesh include:

• Agriculture
• Automotive
• Building
• Chemical
• Coal
• Construction
• Food and Beverage
• Mining
• Petrochemical
• Plastics
• Pharmaceuticals
• Textiles

Wire mesh is used in both commercial and residential settings for various applications, including:

• Security Screens
• Fireplace Screens
• Stairwell Screens
• Gutter Guards
• Fencing
• Bird Screens
• Ventilations
• Window Screens
• Dog Cages
• Bird Feeders

What are the benefits of wire mesh?

1. Easy Installation — Wire mesh is flexible and pliable to easily insert or connect to a wall, railing, or flat surface.
2. Electronics Storage — Computers, monitors, and other electronics have to be placed in well-ventilated storage areas. Wire mesh makes it possible for delicate and sensitive electronics to be held securely with limited access.
3. Convenience — Wire mesh can be used as partitions to separate work positions but afford easy accessibility. It can be easily removed or rearranged to meet the needs of changing organizational dynamics.
4. Visibility — In warehousing, wire mesh can be used to separate items but make them easily detectable and visible for retrieval. The use of wire mesh removes time-consuming searches and inventory checks.
5. Customer Area Partitions — Wire mesh can be used to allow customer interaction while preventing them from entering the work area.
6. Strengthening and Support — In the construction industry, wire mesh is added to a building to provide extra support and backing for walls and ceilings.
7. Cost-Effective — Wire mesh is a cost-effective way to replace panels, shelves, and supports. It is easy to maneuver and place. The superior strength of wire mesh makes it a positive alternative to other forms of filtering and support materials.

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