Copper Wire Manufacturing for Industrial Applications

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Copper Wire Manufacturing for Industrial
Applications
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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
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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.
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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-
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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.
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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.
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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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