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This type of product is quite common and can be used in a wide variety of industries, as well as other spheres. Naturally, the main applications for wire rod are manufacturing, the energy sector, and construction.
Wire rod is a hot-rolled wire with a diameter ranging from 5.5 to 42 mm. Rods are made of carbon steel, aluminum, and copper of ordinary quality. The cross-section of wire rod can be hexagonal, round, semicircular, or square. The main factor that determines the technical parameters is the type of material it is made of.
Wire rod is made by drawing hot metal through shafts. The shafts form and compress the metal from different sides, thus turning a piece of metal into a long, thin wire. At the end of the rolling mill, this wire is wound on a special winder, with the help of which the rod is rolled into skeins for further cooling. The production method is called &#;hot;&#; however, the metal is not pre-heated &#; it is heated when passing through the shafts.
After rolling, the rod must be cooled. This process can go in two ways: through air or accelerated cooling. Air cooling occurs naturally in contrast to accelerated, which requires special fans. After cooling, the rod is ready for storing.
High-quality requirements are imposed on wire rod. For instance, if the rod is manufactured for further wire production, then it should be free of burrs or other deformations. If they are present, the rod can still be used for other purposes.
Apart from that, voids and bubbles may appear on the surface of the rod, significantly reducing the strength of the material. The quality of the product is also adversely affected by decarburization, which may occur when the rod is heated.
There are other mechanical defects that may occur; some of them only affect wire rod prices, while others make it unusable. Therefore, production is controlled carefully, and the rod goes through constant quality control at all stages of manufacturing.
There is a variety of applications for steel wire rod, such as:
For example, in the manufacture of reinforcement cages; square, round, or rectangular-shaped assembly clamps are made from wire rod. With the help of reinforcing cages, monolithic columns, girders, belts, cross-tops, and lintel strip foundations are reinforced.
In addition to the use of wire rod in reinforcing cages, it is also used in the manufacture of welded reinforcing mesh for monolithic structures, such as concrete floors and screeds.
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Steel rods are also used when laying bearing walls or walls of brick, cinder, foam, or gas block. Depending on the concrete used for masonry, steel wire is put into each 2nd-4th layer of mortar, thereby enhancing the overall strength of the masonry. Thus, the rod performs the role of reinforcing the structure.
Apart from that, wire rod is used in the production of electrodes and wires for welding, as well as the manufacture of telegraph wires, ropes, and cables. For such applications, aluminum and copper rod fits best. Most often, such wire is used in power supply systems. In order for rod not to affect the operation of these systems, it must be plastic and well deformable. These characteristics play a key role when choosing the right diameter of the rod.
Guest Author: Metinvest Holding
Wire rod is mainly produced at continuous wire rod hot-rolling mills. Squares with a cross section from 100×100 mm to 200×200 mm and a length of 6-12 m (concast squares produced at continuous casting machines, as well as hot-rolled squares produced at blooming mills or heavy section mills) are used as feedstock.
Prior to rolling, steel billets are subject to heating in reheating furnaces with walking hearth, walking beams or the combined reheating systems under conditions that help to achieve minimum scaling and decarburisation of metal. At the exit of the reheating furnace, billets are subject to hydraulic descaling to remove scale from their surface.
A wire rod mill is usually a single-strand or two-strand facility consisting of a roughing train, intermediate continuous train, finishing train and cooling lines, as well as bundling, handling and finishing end. The number of mill stands in operation depends on the cross section of the billet and the final size.
The finished product section is achieved by subsequent reduction of the billet as it passes the stands complete with rolls of different gauges. The wire rod structure and properties after hot working are achieved in line at the two-stage controlled cooling units. Steel wire rod is water cooled in the first stage and air cooled in the second stage. The wire rod cooling parameters can change within a wide range depending on application, steel grades, dimensions, etc.
The rolled and cooled wire rod is then fed to a laying head (pipe) for coiling or bundling. Wire rod coils are grabbed by the chain conveyor hook and conveyed to the inspection area, where they are inspected, defected ends are removed and test samples are taken. The finished wire rod coil is repressed and bound by wire rod or strapping bands.
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