The history of wire mesh and wire mesh manufacturing
The manufacture of wire meshes has its roots in the most traditional textile production technologies, such as weaving and knitting. Wire weaving on looms for industrial purposes appeared in the early part of the 18th Century. In those years, the steam-driven loom for textile weaving was invented: this new technology rapidly transferred to the wire industry, in particular for automated wire weaving processes. A driving force behind the development of wire meshes was the growing paper industry, as an endless wire mesh belt allowed the processing of pulp much faster than before. The result was that paper needed for newspapers, journals, and books could be produced at higher speeds and in larger quantities than ever.
Wire mesh also plays an important role in the “Davy lamp”, which was invented by the chemist Humphry Davy in 1815. It was designed to reduce the danger of flammable gas explosions and to warn about carbon monoxide presence in mines. This safety lamp was crucial for the development of the coal and iron ore mining industry, and thus for the progress in steel making in the 19th century. Woven wire mesh, therefore, was key to the development of the industrial revolution. In the early 20th century, with the widespread availability of electricity, modern welding methods – such as resistance welding – arose and opened the way to welded wire mesh manufacturing. In the first decades of the 20th century, increasing military demand for military aircraft, tanks, vehicles, and gas mask filters caused an economic increase in the wire mesh industry.
Manufacture of wire mesh and packaging types
Different types of machines such as welding, weaving, netting or knitting machines are used to link the mesh wires to one another. The selection of a wire mesh type depends on the specific application requirements. Flat mesh products arrive on the market in the form of coils or stacks.
Welded wire mesh
Welded wire mesh is manufactured via automated CNC machines by welding lengths of straightened wires together at intersections. The wires are arranged in a grid pattern on a welding machine which uses automatic electric resistance welding to join the wires. This involves applying pressure and passing an electric current through the contact points, causing the wires to heat up and fuse. A shear cuts the mesh panel once it reaches its specified length. Then, a transporting device extracts the final products from the welding line and stacks them for the following transportations. Different diameter and wire spacing configurations allow great panel customization to accommodate any need.
This mesh type offers strength and rigidity, making it suitable to reinforce concrete structures holding concrete firm. Welded wire mesh is also used for security fencing and for goods carrying and displaying devices. Welded steel wire mesh is also used in conveyor belt systems. The wires are embedded within the conveyor belt's material and provide strength, durability, and resistance to stretching and breaking.
Woven wire mesh
Woven wire mesh is made by weaving warp and weft wires together in an over-and-under pattern, resulting in a mesh structure with specific openings. This type of wire mesh is used for sieving, insect screens and conveyor belts. It is essential for the filtration of liquids, gasses, and solids in industries such as petrochemical, food, paper, and water treatment. Architectural wire mesh is used for decorative applications in interior design and facades.
Net wire mesh
Net wire mesh (also known as wire nettings) is manufactured via chain link machines that loop different wires into one another according to specific patterns (for example hexagonal). Such mesh, also known as chicken wire, is available in various dimensions. The applications range from poultry enclosures and garden fencing (hence its name) to stucco netting in construction and erosion control projects.
Knit wire mesh
Knit wire mesh is made from continuous wire in the form of intermeshing stitches. The manufacturing technology is based on principles similar to garment knitting. A sleeve which is produced using the circular knitting method is processed further as a web which is laid flat. These webs can be further processed by being folded and placed in position to form packages. The small contact surfaces at the contact points resulting from the profile produce a meshwork which is three-dimensionally flexible with optimum elasticity and stretching characteristics. The applications range from industrial damping elements via filter inserts and catalytic converters to medical applications such as stents.
Literature
About textile weaving:
Valeriy Choogin, Palitha Bandara, Elena Chepelyuk: Mechanisms of Flat Weaving Technology. 1st Edition. Woodhead Publishing, 2013
ISBN: 9780857097804
eBook ISBN: 9780857097859
Introduction To Weaving Technology.
https://textilelibrary.wordpress.com/2011/04/09/introduction-to-weaving-technology/
Emel Önder, Ömer Berk Berkalp: Weaving Technology II
https://web.itu.edu.tr/~berkalpo/Weaving_Lecture/Weaving_Chapter1a_06S.pdf
About resistance welding:
Hongyan Zhang, Jacek Senkara: Resistance Welding. Fundamentals and Applications. Taylor & Francis Inc; New edition, 2011.
ISBN-10: 1439853711
ISBN-13: 978-1439853719
Nigel Scotchmer: The Other Resistance Process: Cross Wire Welding. In: Welding Journal, December 2007, pages 36-39.
https://www.researchgate.net/publication/294463669_The_other_resistance_process_Cross_wire_welding
For helping us compile the information, we thank -Ing. Konrad Dengler, technical journalist and translator specialized in industrial topics.