Picture this: you are in the midst of optimizing a filtration system to improve its performance when subjected to extreme pressure and harsh chemicals. All without sacrificing precision.
Achieving such performance requires the use of materials like woven wire mesh. When using said material, operational success falls on one key property: the wire diameter of the weave.
But wire diameter should you be using?
For over 150 years, W.S. Tyler has leveraged its wire weaving expertise to help make the world a cleaner, safer palace through innovative solutions. Whether crafting new technology or refining existing systems, we ensure you select a wire diameter that delivers unparalleled results.
With that, this article will provide insight into the ins and outs of the wire diameter of woven wire mesh, empowering you to navigate the factors that will influence the wire diameter you will use for your next project. You will learn:
Woven wire mesh is a versatile material methodically engineered to provide indispensable screening/filtration performance. Using meticulous weaving techniques, hundreds of metal wires are interwoven, forming pore openings that are rigid, uniform, and precise.
Tailored to accommodate your exact needs, virtually every aspect of woven wire mesh can be mathematically customized. This includes parameters such as mesh count, weave types, alloy, and, in regards to this article, wire diameter.
This level of customization allows wire mesh to help overcome concerns surrounding flow rates, structural support, and overall system efficiency. In turn, the material is used in a wide range of industries, including the automotive, medical, and architectural industries.
When working with woven wire mesh, wire diameter describes the thickness of the wires in the weave. It is one of the more critical specifications to keep in mind as it directly impacts the strength, durability, cut point, and general performance of your mesh solution.
More importantly, your wire diameter will determine how well a particular weave will withstand your process. The wire diameter of woven wire mesh is pivotal to how well the material withstands high-pressure loads, extreme temperatures, and corrosive atmospheres.
That being said, when you are customizing your specifications, it should be noted that wire diameter will alter parameters such as weight, thickness, and percentage of open area. This can affect the filtration efficiency and flow capacity of the mesh.
Before arriving at your facility, various prediction tools are employed to measure the wire diameter of your wire mesh. While several tools can be used, micrometers, digital calipers, and laser measurement systems are the most commonly used.
Now, before being measured, any coatings and loose debris are removed from the surface of the mesh to ensure an accurate measurement.
When using a micrometer or caliper, the spindle of the micrometer or jaws of the caliper are carefully closed around the surface of the mesh. When using a laser measurement system, a non-contact laser is directed at the wires, and the reflected light is used to measure their diameter.
Regardless of the tool, measurements are taken at several points of the weave to pinpoint variations. While this may sound as if inconsistencies are going to be prominent, it is essential to know that measurements are taken following standards set by organizations such as ASTM and ISO.
This ensures the wire diameter of your mesh falls within tolerance, which ultimately delivers accurate and repeatable results.
To that end, when you analyze the wire diameter measurement of your mesh, you will find that wire diameter is generally expressed in millimeters, micrometers, and thousandths of an inch. The unit of measurement will depend on your region and industry standards.
To achieve wire mesh performance that promotes operational success, your mesh must feature the perfect balance between the wire diameter, mesh count, and opening size. The mesh count, being the number of openings in a linear inch, and wire diameter collectively control the opening size, or amount of space between wires, of your mesh.
A good rule of thumb is that the thicker the wire diameter used, the smaller the opening size for a given mesh count. While the thicker wire will increase the strength of the weave, the percentage of open area and flow capacity will decrease.
On the other hand, the thinner the wire diameter used, the bigger the opening size. This means improved flow and filtration capacity; however, at the same time, durability decreases.
With this in mind, finding the perfect balance is crucial to achieving the performance you need.
One of the more popular benefits of using woven wire mesh is its ability to be woven using a long list of alloys. While typically woven using 300 series stainless steel, wire mesh can be fabricated using alloys like brass, aluminum, Hastelloy, and much more.
Looking for more information regarding wire mesh alloys? Read the following article:
That said, the alloy you choose will affect the wire diameter that can be achieved. Each alloy offers its own level of strength, corrosion resistance, flexibility, etc.
Naturally, this means each alloy has its own threshold of how much it can be drawn. A good example that demonstrates this is the wire drawing capacity of stainless steel compared to the capacity of brass.
Stainless steel has high tensile strength and incredible resistance to harsh environments, allowing it to be drawn to finer wire diameters. Brass, on the other hand, has inherent properties that render it vulnerable to becoming brittle the more it is drawn.
Put simply, the properties of the alloy ultimately control the minimum and maximum wire diameter that can be achievable.
Selecting a wire diameter that will best fit your operation requires you to identify and balance the strength, durability, flow capacity, filtration capacity, and any other key operational requirements of the application. These requirements should be correlated with the mesh count, alloy, opening size, and other fundamental properties of your wire mesh.
When you begin the selection process, you should first consider the environment your mesh will be subjected to. This should include things like chemical exposure, extreme operational temperatures, and the properties of the materials that come into contact with the mesh.
The wire diameter should be based on the mesh, specifically the alloy used, its ability to combat corrosion, its tensile strength, and its durability. The mechanical loads and pressure of your operation should also be taken into consideration.
Now, because wire mesh is a major invest that can shape the success of your operation, selecting the wire diameter can be daunting. To help, you can consult with an industry expert to help guide you and ensure the diameter you choose accommodates the needs of your operation.
Selecting a suitable wire diameter for your application ensures your wire mesh delivers peak performance, efficiency, and durability. Additionally, the right wire diameter will enable your mesh to withstand the mechanical stress and environmental conditions of your operation.
Ultimately, this will extend the lifespan of the wire mesh, eliminating concerns about constant maintenance and replacement expenses.
Not to mention, selecting the best possible wire diameter works to afford peak filtration and separation efficiency. This does three things:
There are several risks that can hinder your operational success when the wire diameter selection process is neglected. This includes inconsistent operation, poor performance, and weakened structural integrity.
Utilizing a wire that is too thin and your wire mesh components are at risk of premature failure. In turn, you will be left with costly and unexpected downtime.
At the same time, using a wire diameter that is too thick, you can bottleneck your system with restricted flow or filtration capacity. This can cause blinding/pegging of the wire mesh, system failure, and overall operational inefficiency.
Stepping away from the operation of your system and using an incorrect wire diameter can mean your process fails to meet regulatory or industry standards. This increases safety concerns, especially in critical applications.
Wire diameter is the backbone of a woven wire mesh solution in the same way that every aspect of your system works towards operational success. Regardless if you are screening particles or providing structural support, selecting the diameter of your weave methodically will empower your operation to run smoothly and efficiently.
Here at W.S. Tyler, we strive to provide custom wire mesh solutions that help you push boundaries, innovate, and gain confidence in the quality of the products you deliver to your customers.
Now, the key to unlocking the full potential of your process is to gain an understanding of how the other mesh specifications, like mesh count and micron, affect the performance of your mesh. For more insight into the relationship between these critical specifcaitons, read the following article and discover how they contribute to accurate and repatealbe results: