This article will take an in-depth look at metal mesh.
The article will bring more detail on topics such as:
In this segment, we delve into the concept of metal mesh, exploring its creation process and essential design considerations.
"Wire mesh" commonly pertains to structures constituted from multiple metallic wires that are connected using various techniques, forming either flat or three-dimensional frameworks. This versatile material is widely used in transportation, fencing, display setups, and protective barriers, serving significant roles across both industrial applications and everyday use.
Sheets of metal mesh are fabricated from an assortment of materials such as stainless steel, galvanized steel, plain carbon steel, aluminum, copper, bronze, brass, among other specialized metals. These materials are processed into wires of differing gauges, which are then woven or interlinked to produce uniform parallel rows and intersecting columns.
Also known as wire fabric, wire cloth, or hardware mesh, wire mesh is manufactured by weaving wire on machinery designed for industrial looms, creating square or rectangular gaps between each strand. In the case of welded wire mesh or cloth, the intersecting wires are fused together at junctions using electric welders.
Iron-derived steel has unique and beneficial attributes. Notably, stainless steel is completely rust-proof and incredibly durable, making it an optimal choice for various industry applications. Steel wires are particularly ideal for creating wire mesh and similar products due to their notable ductility, strength, and flexibility.
Wire mesh is among the antiquities in steel production, with its utility evident over thousands of years. As global economies expand, steel wire mesh sees varied new uses such as fencing, barricades, safety covers for machines, cages, grills, sifters, and shelving solutions.
Iron welded wire mesh is indispensable in concrete reinforcement. Companies generating steel wires supply them to secondary producers who transform them into mesh using weaving or welding techniques.
Important considerations include:
Recognizing temperature thresholds is critical when deploying heat-resistant wire mesh in high-temperature settings. Since any ductile metal or alloy can be employed for woven wire mesh, choosing the right material for each task is essential. High-temperature capacities include stainless steel grade 304 (1500°F or 815.5°C); Inconel (1800°F or 982°C); nickel (2700°F or 1482°C); and tungsten (5000°F or 2760°C).
While many wire cloth variants can corrode, materials like titanium and certain specialized alloys such as Hastelloy, Inconel, and Nichrome offer enhanced protection against corrosive conditions.
Viscosity is a vital factor in water treatment, oil processing, and chemical filtration. Efficient filtering is noted with less dense fluids. For optimal results with highly viscous fluids, the appropriate mesh type and size must be chosen. Note that viscosity often shifts with temperature changes.
The size of particles is a significant criterion when deciding on wire mesh. Select mesh count, aperture size, and wire thickness according to the particle size intended for retention. Use test sieves for achieving specific particulate measurement.
As substances pass through a filter, pressure decreases and contaminants are eliminated. The selected filter media has a significant impact on this pressure drop rate. Upon reaching a certain drop point, filter replacement is necessary. Aligning wire mesh selections with your pressure drop requirements aids in cost reduction and fewer contamination incidents.
Viscosity, pressure drop, and flow rate are interlinked. Choose the appropriate mesh aligning with specific flow rate needs while considering the mesh's open area percentage.
The type of pollutants encountered affects decisions on material, wire diameter, mesh density, tolerance levels, aperture size, and wire weave style.
Mesh settings may need adjustments based on usage. In production, wire mesh baskets and sieves assess and measure specific gravity of filtered substances. These products, usually brass or stainless steel, should be selected based on specific gravity testing requirements.
Various types of metal mesh include:
Expanded wire mesh is created by feeding metal sheets into an expanding machine, which cuts and stretches the sheets to form a patterned mesh. This process results in a mesh with uniformly shaped holes, providing a strong, robust, and consistent structure. The final product is a heavy-duty and durable wire mesh.
Expanded wire mesh comes in different forms that are easy to weld and have a long service life. Unlike perforated metals, it provides better airflow, making it suitable for applications requiring thermal regulation. Its affordability, lightweight nature, and minimal waste during manufacturing contribute to its widespread use.
Woven wire mesh features a pattern of intersecting wires similar to fabric weaving. Typically, a robust sheet is formed by interlacing the wires over and under perpendicular wires. This type of mesh is commonly referred to as Plain Weave Mesh. For applications requiring greater flexibility, a "Twill Weave" can be used, where the wire alternates between crossing over two parallel wires and then under the next pair, creating a more pliable sheet.
Instead, the wires are fed into a loom-like device that weaves a straight wire across the chosen pattern. After bending the wires in one direction, the next straight wire is threaded through the pattern. This process is repeated until the wire mesh sheet reaches the desired dimensions, at which point the finished sheet is trimmed to size.
Steel welded wire mesh is created using precise, semi-automatic welding equipment. This machine features a chamber that can supply welds at predicted intersections, which in the case of a mesh are the spots where steel wires aligned horizontally and vertically cross.
First, a set of parallel stainless steel welding wires is fed into the machine, followed by another set of parallel wires positioned perpendicular to the first. The machine then welds the intersection of these two sets of wires at a 90-degree angle.
Electrical resistance generates sufficient heat to create the welds. After welding one section, additional parallel wires are introduced into the machine to proceed with the process. This continues until the desired length of welded mesh is achieved, at which point the mesh is trimmed to the specified dimensions.
Mechanical Positioning — Cut wires are arranged horizontally across wires drawn from spools, forming right angles with each other. Once the wires are properly aligned, the automated welding process starts, ensuring consistent welds at each intersection.
Final Steps — After welding, the wire mesh can either be rolled up, similar to wire weaving, or cut into sheets of the desired size. These sheets can be stacked to form wire mesh panels. Welded mesh is generally heavier, more durable, and stronger than woven wire mesh and is made with thicker wires that can endure the welding process.
To create a robust barrier from flexible wire mesh, a vinyl coating is applied to either welded or woven wire mesh. This vinyl-coated wire mesh offers resistance to impacts, scratches, and abrasions, while also maintaining stability across a broad range of temperatures.
Wire mesh is occasionally called plastic mesh due to its vinyl coating, which can make it appear plastic-like. Vinyl-coated wire mesh is durable, long-lasting, and resistant to rust and corrosion, all while offering an attractive appearance. Additionally, the coating protects the wires from environmental factors such as moisture.
Galvanized wire mesh is made from raw or carbon steel wire that is coated with zinc through a galvanizing process. This zinc coating acts as a protective barrier against corrosion and rust. Galvanized wire mesh can be produced from either woven or welded plain steel wire that has been galvanized afterward.
Galvanizing the wire mesh after it has been prepared results in a higher-quality wire mesh but costs more than the other two processes. Galvanized wire mesh is perfect for window guards, infill panels, greenhouse fencing, agricultural and gardening fencing, building and construction fencing, and security fencing. It is one of the more often utilized varieties of wire mesh because of its price.
Stainless steel wire mesh offers superior performance and protection and has all the benefits of stainless steel. Wire mesh is frequently made of steel; however, steel rusts quickly when exposed to air. With the addition of chromium, stainless steel, which is made of the same components as steel, is resistant to rust and shielded from oxidation.
Stainless steel is well-regarded for its reliability, strength, and long lifespan when used in wire mesh production. Its resistance to rust makes it suitable for any outdoor application. Due to its robustness and durability, stainless steel is one of the most commonly used wire mesh materials. It can be either welded or woven, similar to other wire mesh types. Stainless steel wire mesh is available in grades such as 304, 316, and 316L, with wire diameters ranging from 0.22 to 0.105 inches (0.55 to 2.66 mm) and apertures from 0.25 inch to 1 inch (6.35 to 25.4 mm).
Grade 316 stainless steel, a high-quality alloy, is used for maritime applications due to its excellent corrosion resistance. It comes in fine, medium, or coarse diameters and is resistant to acids, saltwater, and seawater. While grade 304 stainless steel is more affordable and easier to work with, it does not offer the same level of corrosion resistance as grade 316.
Wire netting fences are a type of wire netting commonly seen in various applications. For instance, rectangular nettings are frequently used to enclose properties. In forestry and agriculture, hexagonal netting is employed to fence woodland areas and protect them from animals. This type of netting also serves as slope reinforcement and a protective measure against avalanches and rockfalls. Additionally, circular braids, a distinct type of netting, are used to shield wires from electromagnetic interference and to reinforce hoses and cables.
This chapter will cover the materials used to make metal mesh and the various mesh patterns.
Wire, the main element of wire mesh, is made from different ferrous and non-ferrous metals. It comes in various gauges, which measure the wire's thickness. A lower gauge number denotes a thicker wire, while a higher gauge number indicates a thinner wire.
The wire gauge is consistent for both shute (weft) and warp wires in plain and crimped wire mesh. However, for Dutch weave wire mesh, the weft and warp wires have different gauges. Stranded wire mesh is composed of bundles made from very thin gauge wires twisted together.
The type and application of wire mesh are influenced by both the metals used and the wire gauge. Wire for mesh is produced by drawing raw metal through a die or draw plate. Besides cylindrical wires, wire mesh can also be made using rectangular, square, and hexagonal wires.
Steel, an alloy of iron and carbon, can adopt either a body-centered cubic or face-centered cubic crystalline structure depending on the temperature. The unique properties of steel and cast iron arise from the interaction between the iron allotropes and the primary carbon alloying element.
Elongation, or ductility, refers to a material's ability to be stretched or compressed without breaking. It is measured as a percentage of the original length and falls between tensile and yield strength. This property allows steel to be drawn into wires, which are then used to create metal mesh.
Copper wire mesh is highly valued for its excellent thermal and electrical conductivity, as well as its flexibility and malleability. It is commonly used in electrical applications and Faraday cages to shield against radio frequency interference. Like aluminum, which is seldom used in its pure form, copper is usually alloyed to enhance its natural properties.
Exposure to salt, moisture, and sunlight causes copper to change color from salmon-red to brownish-gray and eventually to blue-green or gray-green. To prevent this discoloration, copper wire mesh is treated with coatings and chemicals that either slow down or control the oxidation process.
Bronze is an alloy composed of 90% copper and 10% zinc. It retains many of copper's properties, such as malleability, ductility, and toughness. Compared to copper, bronze is tougher and less flexible, and it offers better corrosion resistance than brass. It is commonly used in industrial applications for filtration and architectural purposes.
Wire mesh is commonly made from the alloys and metals previously mentioned. In addition, specialized wire meshes can be crafted from materials like titanium, Hastelloy, Monel 400, nichrome, Inconel, and tungsten. Essentially, wire mesh can be produced from any ferrous or non-ferrous metal that can be drawn into wire.
Aluminum is inexpensive, lightweight, malleable, flexible, and resistant to corrosion. It is the most often used non-ferrous metal for making wire mesh; aluminum grade 1000, or pure aluminum, is rarely used to make aluminum wire mesh. To boost aluminum's strength and enhance some of its other features, most aluminum is alloyed with other metals like copper, magnesium, zinc, or silicon in certain amounts. The three alloys 1350, 5056, and 6061 are used most frequently to make aluminum wire mesh.
Brass, an alloy of copper and zinc, is used in wire mesh production in forms such as 270 yellow brass and 260 high brass. 270 yellow brass contains 65% copper and 35% zinc, while 260 high brass is made up of 70% copper and 30% zinc. Brass wire mesh is known for its high tensile strength, excellent abrasion resistance, and increased toughness due to the higher zinc content. Its distinctive yellow color makes industrial-grade brass wire mesh a popular choice for decorative and architectural applications.
The various patterns for metal mesh include:
The twill weave pattern is ideal for weaving thicker and larger diameter wires. In this pattern, the warp wires alternate over and under two weft wires, or vice versa. This method involves reversing the warp wire at the intersections, resulting in a rigid, strong, and stable wire mesh. As the pattern develops, it creates a staggered effect that appears as parallel diagonal lines.
Wire mesh with a twill weave is effective in filtering small particles and supporting heavier loads. It is commonly used in the production of filters, food colanders, chemical screens, and mosquito nets. Stainless steel grades 304 and 316, known for their resistance to acids and durability, are frequently employed in filtration applications.
A crimping mesh machine is used to produce crimped wire mesh with square or rectangular patterns. The process involves compressing the warp wires so they wrap over the weft wires, and vice versa. This crimping action bends the wires, causing them to interlock and wrap around each other.
Pre-crimped weaves involve crimping the wire before weaving, adding small folds or ridges to enhance the mesh's rigidity and strength. This process helps keep the weft and warp wires securely in place and prevents them from shifting.
The pre-crimping technique secures the weave at the intersections of the weft and warp wires by utilizing the grooves created during crimping. This results in a final weave that is stronger and more stable, similar to the effects of pre-crimping.
In the inter-crimp method, both weft and warp wires are subjected to an additional crimp between their intersections. This technique employs fine wire with broad apertures, ensuring that the wires are securely locked together and providing increased rigidity.
Non-crimped wire features a basic over-under weave of weft and warp wires, resulting in a wire mesh with a smooth and consistent surface. This type of mesh, known as plain weave, typically has a higher mesh count. Plain weave is one of the most commonly used wire mesh types, suitable for patterns with mesh sizes of 3 x 3 or smaller. It is often used for screening applications, including window screens and screen doors.
The flat top weave creates a robust wire mesh with a smooth, flat surface by using crimped weft wires and non-crimped warp wires. This design eliminates protruding wires, enhancing its durability and extending its abrasive life. With its low flow resistance, flat top weave wire mesh is ideal for architectural and structural applications that require a smooth finish. Common applications include vibrating screens.
Dutch weave wire mesh stands out from twill and plain weave mesh due to its unique construction. In Dutch weave, the weft wires are finer and have smaller diameters compared to the coarser warp wires, which enhances tensile strength. The finer weft wires improve filtering efficiency by creating smaller openings. Dutch weave wire mesh is often chosen for filtration applications because of its strength and precision. Both plain and twill Dutch weaving techniques offer distinct advantages tailored to specific application needs.
Plain Dutch weave wire mesh features a combination of a plain wire weave with the Dutch weave technique. In this mesh, the finer weft wire passes over and under the coarser warp wire, and vice versa. The main advantages of plain Dutch weave wire mesh include its mechanical stability, smaller openings, and exceptional tensile strength.
Wire mesh with a twill Dutch weave pattern merges a traditional twill weave with the Dutch weave technique. In this pattern, the finer weft wire alternates over and under two warp wires, creating a delicate mesh, while the coarser warp wires form a more robust mesh. The twill Dutch weave is preferred for its ability to support heavier loads and provide finer apertures compared to a standard twill weave, making it ideal for filtering applications.
Reverse Dutch woven wire mesh is similar to plain Dutch woven wire mesh but with the warp and weft wires switched. In this pattern, the warp wires are more robust as they are closely spaced and woven tightly with heavier weft wires. This configuration provides increased mechanical strength and is suitable for applications requiring acoustic properties, high durability, and efficient filtration.
Wire mesh edges can be classified into two types: raw and selvage. When wire mesh is woven, the weft wires form an edge along the roll's length to prevent unraveling. In a raw edge, these weft wires remain exposed at the mesh's edge.
Selvage edge wire mesh features a finished border that enhances the mesh's stability and ensures safety for those handling it. One common method of creating a selvage edge involves looping the wires along the mesh's edge.
This chapter will explore the advantages and uses of metal mesh.
Two- or three-dimensional structures made of two or more metallic wires joined by a number of methods are called "wire meshes." Wire mesh items are frequently used for carrying, displaying, fencing, and armoring in various environments. Thus, wire mesh is an essential part of both industry and everyday life.
Stainless steel, galvanized steel, plain carbon steel, aluminum, copper, bronze, brass, and other specialty metals are among the substances used to make metal mesh sheets. To create parallel rows and crossing columns that are roughly similar in size, wires of various thicknesses are braided, entangled, or connected together.
Before deciding on an application, it is vital to understand the metal mesh type and pattern, including the type of wire.
Wire mesh is fabricated by the intertwining, weaving, or welding of wires of various thicknesses to create proportionally equal parallel rows and intersecting columns. Also known as wire fabric, wire cloth, or...
Hardware cloth is a woven mesh made by interlacing various sizes of wire to form a metal fabric that can be used for animal cages, fence material, strainers, and filtering screens. The differences between the various types of hardware cloth...
Welded wire mesh is a series of wires that are welded where the individual wires cross. The openings of the mesh varies depending on the type of wire used and the function of the mesh. Regardless of size and wire, welded wire mesh is permanent and...
Wire cloth is a woven (or nonwoven) sheet or web material with a series of openings across the surface. Wire cloth is also known as: Metal Fabric or Metal Cloth; Wire Mesh, Metal Mesh, or Alloy Mesh...
Expanded metal is a sheet metal mesh. It is made by stretching a slitted sheet of malleable metal. The orientation of the slits is perpendicular to the direction of the stretch. The result of such stretching is an array of holes on the slits - to give a mesh form...
Perforated aluminum consists of an aluminum sheet which has been manually or mechanically pierced or punched using CNC (computerized numerical control) technology in order to produce shapes and patterns of various sizes...
Perforated metals are sheets of metal that have had decorative shapes, and holes punched or stamped into their surface for practical or aesthetic purposes. The perforation of metal sheets takes several forms and includes a variety of geometrical patterns and designs...
A perforated metal is a piece of sheet metal that has been stamped, fabricated, or punched to create a pattern of holes, slots, and various aesthetic shapes. A wide range of metals are used in the perforating metal process, which include steel, aluminum, stainless steel, copper, and titanium...
Perforated stainless steel is cut, punched, or stamped to produce a precise pattern of holes or apertures. It is used for functional reasons, such as filtration or ventilation, and aesthetic ones, such as architectural accents...
Perforated metals are sheets of metal that have had decorative shapes, and holes punched or stamped into their surface for practical or aesthetic purposes. The perforation of metal sheets takes several forms and includes a variety of geometrical patterns and designs...
Wire baskets are made from a series of wires that are woven together or welded to form a shape of a basket. They can also be defined as containers that are made by use of an openwork pattern of metal...
Wire shaping is a complex method that encompasses a wide range of dimensions, forms, and textures. The technique of creating a usable product by wire bending and shaping is known as custom wire forms...
Wire forming is a method for applying force to change the contour of wire by bending, swaging, piercing, chamfering, shearing, or other techniques. The various techniques for wire forming can produce any type of shape, form, or configuration...
A wire handle is attached to a bucket, pail, or other type of container to make it easy to lift the container and transport it. They are made of durable and sturdy metals capable of lifting several pounds...
A wire rack is a level wire form utilized to stock and exhibit a number of products, usually retail. The bottom surface on which such goods are stored is made of several latticed or interlaced metal strands...