Manufacturing and Use of Wire Rod

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This type of product is quite common and can be used in a wide variety of industries, as well as other spheres. Naturally, the main applications for wire rod are manufacturing, the energy sector, and construction.

Wire Rod Manufacturing

Wire rod is a hot-rolled wire with a diameter ranging from 5.5 to 42 mm. Rods are made of carbon steel, aluminum, and copper of ordinary quality. The cross-section of wire rod can be hexagonal, round, semicircular, or square. The main factor that determines the technical parameters is the type of material it is made of.

Wire rod is made by drawing hot metal through shafts. The shafts form and compress the metal from different sides, thus turning a piece of metal into a long, thin wire. At the end of the rolling mill, this wire is wound on a special winder, with the help of which the rod is rolled into skeins for further cooling. The production method is called ‘hot;’ however, the metal is not pre-heated – it is heated when passing through the shafts.

After rolling, the rod must be cooled. This process can go in two ways: through air or accelerated cooling. Air cooling occurs naturally in contrast to accelerated, which requires special fans. After cooling, the rod is ready for storing.

High-quality requirements are imposed on wire rod. For instance, if the rod is manufactured for further wire production, then it should be free of burrs or other deformations. If they are present, the rod can still be used for other purposes.

Apart from that, voids and bubbles may appear on the surface of the rod, significantly reducing the strength of the material. The quality of the product is also adversely affected by decarburization, which may occur when the rod is heated.

There are other mechanical defects that may occur; some of them only affect wire rod prices, while others make it unusable. Therefore, production is controlled carefully, and the rod goes through constant quality control at all stages of manufacturing.

Usage of Wire Rods

There is a variety of applications for steel wire rod, such as:

• Aviation
• Engineering
• Reinforcing concrete structures

For example, in the manufacture of reinforcement cages; square, round, or rectangular-shaped assembly clamps are made from wire rod. With the help of reinforcing cages, monolithic columns, girders, belts, cross-tops, and lintel strip foundations are reinforced.

In addition to the use of wire rod in reinforcing cages, it is also used in the manufacture of welded reinforcing mesh for monolithic structures, such as concrete floors and screeds.

Steel rods are also used when laying bearing walls or walls of brick, cinder, foam, or gas block. Depending on the concrete used for masonry, steel wire is put into each 2nd-4th layer of mortar, thereby enhancing the overall strength of the masonry. Thus, the rod performs the role of reinforcing the structure.

Apart from that, wire rod is used in the production of electrodes and wires for welding, as well as the manufacture of telegraph wires, ropes, and cables. For such applications, aluminum and copper rod fits best. Most often, such wire is used in power supply systems. In order for rod not to affect the operation of these systems, it must be plastic and well deformable. These characteristics play a key role when choosing the right diameter of the rod.

With competitive price and timely delivery, Nearyz Resources sincerely hope to be your supplier and partner.

Guest Author: Metinvest Holding

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The wire rod refers to the hot-rolled round steel with a diameter of 5-22 mm or a profiled steel of considerable section. Since it is delivered in coil form, it is also commonly known as the coil. Common wire product specifications are 5-13mm in diameter. According to the different rolling mills, it can be divided into a high-speed wire rod and ordinary wire rod.

The high-speed wire rod is rolled on high-speed wire rod mill. The production speed is fast and the disk is large (the maximum disk weight can reach 250kg), and the packaging is usually tight and beautiful.

The high-speed wire rod refers to the wire rod rolled by the "high-speed non-twist rolling mill". The rolling speed is 20-60 m/s, and each weight (disc) is 0.4-0.6 tons (generally three of six heads are seen on the market). In the rolling process, the performance of the product can only be ensured by air cooling on the cooling line.

The general wire rod is rolled by ordinary rolling mills, and the general disc weight is small. One pack is usually packaged by several sections of discs, and the package is looser and messy. Ordinary wire rod mills have been classified as backward production capacity and will be phased out.

The wire is characterized by small cross-section and large length, which requires high dimensional accuracy and surface quality. The main rolling processes are:

(1) Billet: The billet of the wire rod is mainly made of continuous casting billet, and its side length is generally 120~150mm, and the length is generally about 6~12m. In actual production, the quality of continuous casting billet is inspected by visual inspection, electromagnetic induction inspection and ultrasonic flaw detection;

(2) Heating: It is generally heated by walking beam furnace. The heating requirement is that the oxidative decarburization is small, the billet is not twisted, and no overheating are generated. Modern high-speed wire rod mills are large and long, which requires uniform heating temperature and small temperature fluctuation range.

(3) Rolling: The cross section of the wire rod is relatively simple, so the degree of specialization of the rolling mill is high. Due to the large extension of the blank to the finished product, the number of rolling stands is relatively large, generally 21 to 28, which are divided into rough rolling units. At present, the export speed of high-speed wire rod mill products has reached more than 100m/s.

(3) Finishing: Due to the high rolling speed of modern wire rods, the temperature drop during rolling is small or even temperature-raising, so the temperature after wire rod finishing is high. In order to ensure the quality of the product, it is necessary to carry out the roll control cooling. There are pearlite controlled cooling and martensite controlled cooling depending on product use.

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