Annealed Wire

Wire Ties

A variety of processing and machines are involved in production of annealed and galvanized binding wires.

Wire drawing, Wire annealing and Galvanizing are major procedures for producing of annealed wire and hdg wire.

We have complete production line for manufacture of metal wires of all sizes and forms.

Annealed wire is known for its versatility in various applications due to its softness, ductility, and malleability.

Starting Material: The process begins with a thick wire, usually made of steel or other metals. The initial wire size depends on the final product specifications.
Die Reduction: The wire is fed through a wire drawing machine equipped with multiple dies. Each die reduces the diameter of the wire step by step, bringing it to the desired thickness.Modern wire drawing machines use carbide or diamond dies to achieve precision. Automated tension controls and speed regulation systems ensure uniformity in diameter.
Tension Management: Maintaining the correct tension is crucial to avoid deformities like kinks or breaks. Advanced machines have integrated tension sensors and control systems to adjust the pulling force in real-time.
Quality Control: Throughout the drawing process, the wire undergoes continuous monitoring to detect variations in diameter and surface defects. Non-contact laser micrometers are often used for this purpose.

Heating: After drawing, the wire is heated in an annealing furnace. The furnace temperature is carefully controlled to exceed the recrystallization point of the metal, usually between 600°C to 900°C depending on the material. Machinery: Continuous annealing lines or batch furnaces are employed. These systems feature precise temperature control, ensuring consistent heat treatment.
Holding Period: Once the wire reaches the annealing temperature, it is held at this level for a specific time to allow recrystallization. Programmable logic controllers (PLCs) are used to control the timing, ensuring the wire receives uniform heating.
Cooling: Controlled cooling is essential to form stable metal grains. The wire is slowly cooled within a controlled atmosphere (such as nitrogen) to prevent oxidation. Cooling systems integrated within the annealing lines regulate the cooling rate to enhance the wire's malleability.
Quality Control: Temperature sensors and real-time data logging systems ensure that both heating and cooling stages meet predefined parameters. Metallurgical analysis is conducted post-annealing to verify grain structure and mechanical properties.

Winding: After annealing, the wire is automatically coiled into spools or coils. Proper winding is crucial to prevent tangling or deforming the wire during transportation. Precision coiling machines with adjustable speed and tension control handle this step, ensuring even layering and compact coiling.
Tension Control: The coiling process maintains uniform tension to avoid any structural damage to the wire.Tension-controlled rollers ensure that the wire is not overstretched or slack during coiling.
Quality Control: Visual inspections and tension tests are carried out to confirm that the coils are correctly wound and free from defects like overlapping or uneven layers.

Galvanizing or Other Coatings: Depending on the application, the wire may be passed through a galvanizing bath to apply a zinc coating or other specialized coatings like tin or copper.
Machinery: Galvanizing lines with automated dipping or electroplating systems ensure a uniform coating thickness, enhancing the wire’s corrosion resistance.

Material Selection: The composition of the wire material (e.g., low carbon steel, copper) directly influences its mechanical properties. Raw materials undergo chemical and physical testing before processing.
Annealing Temperature Control: Accurate control of the annealing furnace is critical for producing a uniform grain structure, which improves ductility and tensile strength.
Precision Machinery: Advanced wire drawing and annealing equipment, equipped with real-time monitoring systems, help maintain tight tolerances and consistent product quality.
Cooling Rate: Proper cooling ensures the wire attains the required malleability and strength. The use of gas-controlled cooling systems prevents oxidation during this step.
Inspection and Testing: Throughout the production line, various tests such as tensile strength measurement, surface quality checks, and microstructure analysis are conducted to ensure the final product meets the required specifications.