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We are often asked by our customers to explain the differences between materials to help them make an informed decision on selecting the most suitable product for their application or project. A common question is: what are the differences between expanded metal, perforated metal, welded wire and woven wire mesh?
In this blog, Ian Hutchinson, Product Manager at The Expanded Metal Company, compares each product&#;s characteristics.
Expanded metal mesh is produced through bespoke tooling, which simultaneously slits and stretches material (stainless steel, mild steel, aluminium etc) fed from coil or plate. This produces no waste and in fact offers a greater yield of finished material than that which is originally fed into the process. Expanded metal mesh is also homogeneous by design, in that it is one single piece of material with no welds to break or wires to fray.
The expanded metal mesh manufacturing process can produce an array of mesh patterns, not solely limited to diamond shapes. Mesh strands exhibit an angular tilt that gives a three dimensional appearance: this offers practical benefits including aesthetic appeal (so it is ideal for use in architecture and interior design) and added grip (making it suitable for use in walkways, ramps and flooring). Raised mesh can also be used as a key to serve as a substrate for render and plaster.
It is also common for conventional expanded metal to then undergo a secondary process which involves flattening it to form a completely two dimensional flat sheet. Flattened mesh can be used in applications including filtration, machine guards, animal flooring, speaker grilles and electromagnetic screens.
Much like expanded metal, perforated metal is produced through piercing the material with bespoke tooling to offer an array of shapes such as circles, squares and diamonds. However, unlike expanded metal, perforated metal is punched and not stretched and therefore produces waste material. This clearly has cost implications &#; especially if high value raw materials are used in the manufacturing process.
Welded wire mesh is produced by feeding an array of metal wire from independent spools, which are then appropriately spaced and welded in place. Welded wire mesh is an economical product, however its welds are prone to becoming areas of weakness when strength and longevity are to be considered &#; for instance in security fencing applications. Due to the nature of the welding process, material suitability is also limited.
The production of woven wire mesh involves weaving metal wire at 90 degree intervals which result in a perpendicular, repetitive arrangement akin to weaving fabric for clothing. The process lends itself well to achieving very fine apertures. However, the process relies heavily on tension rather than mechanical fixing, which means woven wire is prone to fray and not ideally suited to formed components.
Economy
Strength
Longevity
Aesthetics
Conductivity
Grip
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Formability
Expanded Metal Mesh
Perforated Metal Mesh
Woven Wire Mesh
You can view our full range of expanded metal here
Need a more cost effective alternative to perforated metal mesh, why not consider our Experf range?
Need an expanded metal alternative to 50x50x3 welded wire mesh, how about our Square Mesh range?
Need a more reliable alternative to woven wire mesh for formed components, why not consider our Micromesh Range?
Filtration and separation technologies are critical to many applications that cover a broad cross-section of consumer and industrial products. There are literally millions of uses for filtration and separation that touch our day-to-day lives.
Comparing three forms of metals&#; properties and qualities
When it comes to filtration methods that require strength, heat-resistance and durability, three forms of metal make up the vast majority of solutions for these requirements: perforated metal, expanded metal and wire mesh. Each type offers effective filtration. However, there are different properties and qualities of each that should be considered when determining which is optimal for an application.
Perforated metal is metal that has had holes or openings punched through it, either via an all-across press or another method such as CNC punching or laser cutting. The unique qualities of perforated metal for filtration or separation include:
Versatility: Perforated metal offers the greatest overall versatility in pattern, shape, material type and hole gauge among the three materials discussed here. When the amount of open area (the hole that allows the passage of air, light, liquids, etc.) is critical to the efficient operation of the application, perforated metal can provide the greatest control of open area.
Strength: While all three methods offer high structural strength, perforated metal is the only method that can be freestanding. This is because perforated metal can be manufactured with nonperforated borders at its outer edges, providing greater stability. Expanded metal and wire mesh must be attached to stabilizing frames.
Weight: Since material is removed during the manufacturing process, perforated metal will weigh much less than expanded metal when using comparative materials. Further, it has great strength-to-weight ratio properties, meaning the weight is lowered but the strength is not significantly compromised. This is an important distinction for weight-sensitive applications.
Expanded metal is produced by cutting a pattern of slits in metal coil, then stretching (or expanding) it so that the slits become diamond-shaped holes. Expanded metal is typically a thinner material than the other methods described here due to the nature of the process. However, this metal type offers a number of advantages and unique properties.
Configuration options: Although the distinctive diamond-shaped pattern of expanded metal cannot be changed, expanded metal pieces can be configured in different ways. Standard expanded metal retains a 3-D raised, slightly twisted configuration of the piece after the stretching process. The metal can be further processed to flatten any strands of the diamond configuration that may be raised or at an angle.
Strength: The one-piece construction, along with the configuration of the diamond shapes, provides a great deal of structural integrity. Expanded metal is often used for industrial uses such as flooring, steps, walls and gates for this reason.
Wire mesh can be of woven (interlocked) or welded construction. In either case, wire mesh consists of strands of metal wire fastened together to form a mesh sheet. Some unique properties of wire mesh include:
Flexibility: Wire mesh is also sometimes called wire cloth, and it can be woven in such a way that it provides the same flexibility of cloth. For applications where a non-rigid construction is required, with the same filtration properties of metal, wire mesh is often the right choice.
Gauge and construction versatility: Wire mesh can be manufactured with large openings (for applications such as fences) or nearly invisible openings (when higher rates of filtration are required). In addition, wire mesh offers some flexibility in opening shapes, though not as many options as perforated metal.
While each of these metals have unique strengths, it&#;s important to understand the specific requirements of the application to determine which will work best for you. If you are working on a project and are unsure of what type of metal to use, consider reaching out to a metal manufacturer to consult with during the selection process.
Jake Holeva is business development manager at Hendrick Manufacturing, Carbondale, Pa. To learn more, visit www.hendrickcorp.com or call (570) 267-.
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