Metal Mesh: Types, Materials, Patterns, Benefits and ...

Metal Mesh

Contact Companies

Please fill out the following form to submit a Request for Quote to any of the following companies listed on

If you are looking for more details, kindly visit titanium woven wire mesh distributor.

Get Your Company Listed on this Power Page

Introduction

This article will take an in-depth look at metal mesh.

The article will bring more detail on topics such as:

• Principle of Metal Mesh
• Types of Metal Mesh
• Types of Materials in Metal Mesh and Mesh Patterns
• Benefits and Applications of Metal Mesh
• And much more...

Chapter 1: Principle of Metal Mesh

This chapter will discuss what metal mesh is, how it is made, and the design considerations.

What is Metal Mesh?

The term "wire mesh" refers to structures made from multiple metallic wires connected in either two-dimensional or three-dimensional forms. These wire meshes are widely used across various settings for carrying, displaying, fencing, and armoring, making them an essential part of both industry and daily life.

Metal mesh sheets are created using materials such as stainless steel, galvanized steel, plain carbon steel, aluminum, copper, bronze, brass, and other specialty metals. Different thicknesses of wires are intertwined, woven, or joined to form proportional rows and intersecting columns.

The wire mesh creation process, also known as wire fabric, wire cloth, or hardware mesh, involves weaving wire on commercial looms, leaving gaps between the wires that can either be square or rectangular. An electric welder is used to join longitudinal wires where they intersect, forming welded wire mesh or cloth.

How Metal Mesh is Made

Steel, primarily produced from iron, possesses unique and desirable properties. Particularly, stainless steel is entirely rust-resistant and highly durable, making it ideal for various economic functions. The combination of excellent ductility and tensile strength makes steel wires optimal for creating wire mesh and other products.

Wire mesh is one of the earliest and simplest items made from steel, having been used for millennia. The ever-expanding global economies have found new applications for wire mesh, including fencing, barricading, machine safety covers, cages, grills, sifters, and shelves.

Reinforcing concrete with iron welded wire mesh serves another significant purpose. Steel wire manufacturers supply these wires to secondary-level ancillaries, which create the mesh through welding or weaving.

Design Considerations for Metal Mesh

• The mesh's essential characteristics, such as spacing, opening size, and mesh count, are determined by its application. In some cases, wire cloth is specified by mesh size or opening size.
• The difference between woven and welded construction significantly affects the toughness and durability of metal cloth, with welded wire cloth being the most robust.
• Weaving impacts the strength and durability of different types of woven wire fabric.
• The choice of metal or metal alloy is influenced by the working environment's temperature, humidity, and exposure to elements like marine salt spray.
• The material selection is also guided by the media processed, whether wet slurries, dry non-corrosive powders, acids, or corrosive chemicals.
• The diameter of the round wire, the width of the flat wire, or the breadth of the ribbon is crucial. Despite using different wire gauge systems, the wire diameter should be numerically specified in inches or microns to avoid confusion.
• The mesh size measures the number of wires over a unit length, typically a linear inch. The mesh count, calculated from wire center to wire center, determines the size of the mesh. For larger wire mesh, the size is determined by the space between adjacent wires, such as 1-inch mesh or 2-inch mesh.

Considerations when Choosing Metal Mesh (or Wire Cloth)

The considerations include:

Temperature

Understanding temperature limits is crucial for fireproof wire mesh in high-temperature applications. Since any malleable metal or alloy can create woven wire mesh, selecting the best one for the specific procedure is essential. For example, stainless steel grade 304 has a maximum working temperature of 1500°F (815.5°C), Inconel at 1800°F (982°C), nickel at 2700°F (1482°C), and tungsten at 5000°F (2760°C).

Corrosive Effects

While most wire cloths are prone to corrosion, some materials, including titanium and alloys like Hastelloy, Inconel, and Nichrome, can withstand more corrosive environments.

Viscosity

Viscosity is crucial in wastewater treatment, oil handling, and other petrochemical filtering. Filters can handle thinner, less dense fluids more efficiently. To achieve the best results, consider the type and size of wire mesh required for processing highly viscous materials. Viscosity often relates directly to temperature.

Particulate Matter Size

Consider particle size when selecting the ideal wire mesh. Mesh count, aperture size, and wire diameter can be determined using retained particles' size. Purchasing test sieves ensures that retained particulate matter sizes meet requirements.

Pressure Drop Requirements

When materials pass through a filter, the pressure decreases and impurities are eliminated. The filter media you select significantly impacts the pressure drop rate. The filter will eventually need replacing when the pressure decrease reaches a certain level. Effective wire mesh solutions reduce costs and contamination risks while meeting pressure drop criteria.

Flow Rates

Viscosity, pressure drop, and flow rate are closely connected. The open area percentage should be considered when choosing the appropriate mesh product for procedures that specify a required flow rate.

Contaminant Types

Specific pollutants will influence the material used, the wire diameter, the density of the wire mesh, the tolerance, the opening size, and the type of weave.

Specific Gravity

Wire cloth parameters must frequently be adjusted depending on the purpose. Wire cloth mesh baskets and sieves are used in numerous manufacturing processes to gauge and test the specific gravity of filtered materials. These items, often made of brass or stainless steel, must be ordered according to your specific gravity testing requirements.

Chapter 2: Types of Metal Mesh

The different types of metal mesh include:

Expanded Wire Mesh

Expanded wire mesh is produced by placing metal sheets in an expanding machine that cuts the pattern of the wire mesh into the sheets and spreads or expands the pattern. This process results in a strong, sturdy, and uniform mesh with a heavy-duty and durable structure.

The various forms of expanded wire mesh are easy to weld and offer a long life. Unlike perforated metals, expanded wire mesh allows for better airflow, making it ideal for projects that require thermal regulation. It is also widely used due to its low cost, lightweight, and minimal production waste.

Weaved Wire Mesh

Weaved wire mesh consists of intersecting wires arranged to resemble a fabric weave. Typically, a sturdy sheet is formed by weaving the wires over and under perpendicular wires. Known as Plain Weave Mesh, this pattern can also be modified to a "Twill Weave" for applications requiring a more flexible sheet. This involves alternating the weaving over two parallel wires and then under the following pair of parallel wires.

The wires are fed into a device similar to a loom, which weaves a straight wire across the pattern of choice. Upon bending, another straight wire completes the pattern, and the machine continues this process until achieving the desired dimensions. The resulting wire mesh sheet is then trimmed to size.

Welded Wire Mesh

Welded wire mesh is created using precise, semi-automatic welding equipment. This machine welds the intersections of steel wires aligned horizontally and vertically.

One alignment of parallel stainless steel welding wire is fed into the machine, followed by another set of perpendicular wires. The machine then welds the 90-degree junction of the two wires together.

Electrical resistance generates enough heat for the weld. Once complete, another length of parallel wires is fed into the apparatus, continuing the welding process. The operation stops once the desired length of welded mesh is achieved, and the mesh is trimmed to size.

Mechanical Positioning — Cut wires are laid out level across wires fed from spools. The wires, at right angles and perpendicular during mesh welding, are positioned for programmed welding to perform a uniform weld at each cross-section.

Final Steps — After welding, the wire mesh can be rolled or cut into appropriate sheet sizes, which can be stacked in rows to create wire mesh panels. Welded mesh, heavier and more robust than woven wire mesh, can only be produced with larger wires capable of withstanding the welding process.

Vinyl Wire Mesh

A vinyl coating applied to welded or woven wire mesh creates a sturdy barrier for very flexible wire mesh. Vinyl-coated wire mesh is resistant to impacts, scrapes, abrasions, and maintains stability over a wide temperature range.

Often referred to as plastic mesh due to its vinyl coating, it is resilient, long-lasting, rust- and corrosion-resistant, and has an attractive appearance. Vinyl coating protects the wires from contaminating elements like water.

Galvanized Wire Mesh

During the galvanizing process, raw or carbon steel wire is coated with zinc. The zinc layer prevents corrosion and rusting. Galvanized wire mesh can be made from galvanized wire or plain steel wire that is either woven or welded and then galvanized.

Galvanizing the wire mesh after preparation results in higher quality but at a higher cost. Galvanized wire mesh is ideal for window guards, infill panels, greenhouse fencing, agricultural and gardening fencing, building and construction fencing, and security fencing, making it a commonly used wire mesh type.

Stainless Steel Wire Mesh

Stainless steel wire mesh offers outstanding performance and protection. While steel is frequently used in wire mesh production, it rusts quickly when exposed to air. Stainless steel, which includes chromium, is resistant to rust and oxidation.

Renowned for its reliability, sturdiness, and durability, stainless steel is suitable for any outdoor application due to its rust resistance. Its durability and strength make it the most widely used type of wire mesh. Stainless steel can be welded or woven, and the grades used include 304, 316, and 316L, with wire diameters ranging from 0.22 to 0.105 inches (0.55 to 2.66 mm) and apertures from 0.25 inch to 1 inch (6.35 to 25.4 mm).

Stainless steel grade 316, a superior alloy for maritime purposes, is available in fine, medium, or coarse diameters. It offers excellent corrosion resistance and remains unaffected by acids or seawater. Although grade 304 stainless steel is workable and less expensive than grade 316, it lacks the same corrosion resistance.

Are you interested in learning more about titanium woven wire mesh dealer? Contact us today to secure an expert consultation!

Wire Netting

Wire netting fences are examples of wire netting used to surround properties. Hexagonal netting is used in forestry and agriculture to protect woodland plantations from animals and mitigate slopes against avalanches and rock falls. Circular braids, another unique netting type, insulate wires from electromagnetic interference or reinforce hoses and cables.

Chapter 3: Types of Materials Used to Make Metal Mesh and Mesh Patterns

This chapter will discuss the types of materials used in making metal mesh and their patterns.

Types of Materials Used to Make Metal Mesh

Wire, the primary component of wire mesh, is produced from various ferrous and non-ferrous metals in different gauges. Lower gauge numbers indicate larger wires, while higher numbers signify thinner wires. The wire gauge for shute or weft wires and warp wires in plain and crimped wire is the same, while dutch weaved wire has various gauges. Bundles for stranded wire mesh consist of very thin gauge wires twisted together.

The type and application of wire mesh depend on the metals used and the wire gauge. By drawing raw metal through a die or draw plate, wire for wire mesh is created. In addition to cylinder-shaped wires, rectangular, square, and hexagonal wires are used to produce wire mesh.

Steel

Steel is an iron and carbon alloy that can take different crystalline forms depending on temperature. Steel has various special properties resulting from the interaction of iron allotropes with carbon. Elongation, the material's capacity to stretch or compress without breaking, allows steel to be drawn into wires for metal mesh production.

Copper Wire

Copper wire mesh, known for its thermal and electrical conductivity, is ductile and bendable. Used in electrical applications and Faraday cages, copper is often alloyed to enhance its properties. Copper wire mesh undergoes coatings to prevent color change due to oxidation from salt, moisture, and sunlight exposure.

Bronze

Bronze, a 90% copper and 10% zinc alloy, shares copper's malleability, ductility, and toughness but is tougher and less pliable with superior corrosion resistance. It is used for filtering and architectural purposes in industrial settings.

In addition to steel, copper, and bronze, other alloys like titanium, Hastelloy, Monel 400, nichrome, Inconel, and tungsten are also used to create customized wire mesh. Any ferrous or non-ferrous metal that can be shaped into a wire can make wire mesh.

Aluminum

Aluminum is inexpensive, lightweight, malleable, flexible, and corrosion-resistant, making it a popular non-ferrous metal for wire mesh production. Pure aluminum (grade 1000) is rarely used; instead, alloys such as 1350, 5056, and 6061, incorporating copper, magnesium, zinc, or silicon, enhance strength and other features.

Brass

Brass, an alloy of copper and zinc, is soft and malleable, known as 270 yellow brass (65% copper and 35% zinc) or 260 high brass (70% copper and 30% zinc). Its great tensile strength, abrasion resistance, and toughness make brass wire mesh suitable for industrial-grade applications and architectural projects due to its yellow hue.

Types of Metal Mesh Patterns

The types of metal mesh patterns include:

Twill Weave

The twill weave pattern is ideal for weaving heavier and larger diameter wires. Warp wires are woven over and under two weft wires to create the pattern or vice versa, resulting in a highly rigid, strong, and stable wire mesh with a staggering pattern.

Wire mesh with a twill weave can filter tiny particles and support greater loads. It is fundamental to manufacturing filters, food colanders, chemicals, shields, and mosquito nets. Stainless steel grades 304 and 316 are preferred for filtration operations due to their acid and wear resistance.

Crimped Wire Mesh

A crimping mesh machine uses square or rectangular weaves to create crimped wire mesh. Compressing the wire for the warp to wrap over the weft and vice versa is one step in creating crimped wire mesh. Bending during crimping causes the wires to wrap around each other.

Pre-Crimp

Pre-crimped weaves are crimped before weaving, adding tiny folds or ridges to strengthen the wire mesh's rigidity and strength. This process secures the weft and warp wires, preventing them from shifting.

Lock Crimp

This pre-crimping technique uses the grooves from the crimping process to lock the weave together at the points where the weft and warp wires connect, resulting in a stronger and immovable final weave.

Inter-Crimp

Inter-crimp involves giving the weft and warp wires a second crimp between intersections. Fine wire with wide apertures is used to ensure securely locked and rigid weft and warp wires.

Non-Crimped Wire Mesh

Non-crimped wire is a plain wire mesh woven using a straightforward over-under weave of the weft and warp wires. The finished product has a consistent, smooth surface with a simple appearance. Plain wire with higher mesh counts and 3 x 3 or smaller waves is the most widely used type, often for screening purposes like window screens.

Flat Top Weave

Flat top weave produces a solid, locking wire mesh with a non-crimped warp and a flat surface. It has a long abrasive life since no wires protrude from the top to wear. Preferred for architectural and structural applications requiring a smooth surface, flat top weave is commonly used for vibrating screens.

Dutch Weave Wire Mesh

Dutch weave wire mesh combines different diameter weft and warp wires, producing higher tensile strength and improved