Copper Wire Manufacturing for Industrial Applications
Copper is a very useful metal considering its wide scale application. It is used extensively as a manufacturing material in the production of engineering equipment, electrical circuits and medical utilities. There are more than 50 different types of copper wires that require elaborate classification. The basic point of differentiation is the way these copper wires are insulated. They could be: Bare copper wires Insulted/ shielded wires
Each type of wire has its own setoff applications. The copper wires are mostly recognised for their finishing and insulation that meet the required safety guidelines. In each industry, the safety compliances are different, and the copper wires have to necessarily meet them without any failure.
Each type of copper wires are manufactured using the most advanced engineering technology that combines the best of sciences- Metallurgy, Mining and material physics. They are built to endure heavy stress and strain, in addition to resist any effect of corrosion when subjected to acids, alkali, salts, moisture and/or hydrocarbons. Manufacturing of copper wires All copper wires are manufactured using a complex set of processes. The manufacturing process involves the following steps-
Wire drawing The molten copper metal is reduced to circular wires with diameters ranging from a few millimetres to inches. The wire drawing process is done by extruding the copper rod through a series of synthetic dies, mostly made of abrasive material like corundum and diamond.
Annealing The drawn copper wires are often found to be brittle and too rigid to be used for industrial purposes. In order to give the bare and shielded copper wires a bit of flexibility, they are annealed. Annealing is a metallurgical process done using heat. It is done on the wires to enhance their ductility and other physical properties, to ensure they are fit for all kinds of industrial applications.
Copper wires are usually subjected to different types of annealing process depending on the amount of impurity present in the crystals. They are: Normalization: It is done to improve the machinability of the annealed copper wires, and often follows other heat treatments. Sub-critical annealing: Mostly done for braided copper wires, this annealing process is done at a temperature slightly lower than the critical temperature of superconductors. Full annealing and short-cycle annealing: It is a short-term process that involves subsequent cooling after heating and then again heating within a span of 8 hours.
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