Safety lock wire, also known as wire locking or safety wire, is a type of positive locking device that prevents fasteners from loosening or falling out due to vibration and other stresses.
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The primary purpose of safety lock wire is to secure fasteners and other components, providing an added layer of safety and security in various industries, most notably in aerospace and defense.
The concept of safety lockwire dates back as early as the advent of aviation. Early aircraft were subjected to intense vibrations, which often caused fasteners to loosen, resulting in mechanical failures. To combat this, a safety lock wire was introduced.
Over the years, the use of safety wiring has extended beyond aerospace, finding its place in any application where safety and security are of utmost importance. Today, it continues to play an essential role in maintaining operational safety and efficiency, testifying to its enduring relevance in the mechanical world.
Whether you need aluminum wire, stainless steel wire, copper wire, or brass safety wire, knowing more about this topic is essential for you to make the right assessment and get the best products. Read on to find out everything.
Stainless steel lock wire is a popular choice when it comes to installing safety wire due to its high resistance to heat and corrosion. Made from 304 stainless steel, it’s famous for its tensile strength and its ability to perform under extreme conditions, making it perfect for use in industries such as aerospace and defense.
This safety wire is easy to work with, resists fraying, and holds its shape well. There will be variants on the results you get depending on whether you rely on a single-wire method, a double-wire method, and other electrical systems for you to get the results you want. However, it’s still one of the most popular alternatives.
Inconel Lockwire is known for its high temperature and corrosion resistance, making it an ideal choice for industries that work in more demanding environments.
It’s made from a family of superalloys composed of nickel and chromium and can retain its strength even when exposed to temperatures up to 2000°F. This type of lockwire is particularly beneficial in applications, such as fastening critical components in aircraft engines, where high heat is common.
Monel Lockwire is made from a series of nickel-copper alloys. Known for its excellent strength and corrosion resistance, particularly against seawater and acids, this type of lock wire is often used in marine and chemical applications.
Despite its strength, Monel Lockwire is also highly malleable, making it easier to secure fasteners in tight or awkward spaces.
The wire gauge and thickness of the safety wire are critical aspects of its performance and strength. With a diameter of 0.047 inches, this specific lockwire is designed to provide the right balance between flexibility and sturdiness.
The thickness allows the wire to be effectively threaded through fasteners, without compromising its resistance to stress or strain.
Thicker wires tend to have greater strength, but they may lack the flexibility needed for secure installation. Hence, selecting the right gauge and thickness is a defining factor for the effectiveness of the safety wire.
Safety lockwire works primarily through the application of tension and torque. Once threaded and twisted around the fasteners, the tension in the wire prevents the loosening of these components.
The wire is designed to maintain this tension, even under conditions of high vibration or sudden impact. Furthermore, the torque applied during the installation process ensures that the wire is tightly wound and secures the fasteners effectively.
However, it is crucial to consider the torque limit of the wire to avoid over-tightening, which could lead to the wire’s failure. Therefore, understanding and applying the correct tension and torque is key to maximizing the effectiveness of the safety lock wire.
The aviation industry heavily relies on safety lock wire. It is primarily used to secure fasteners on aircraft, ensuring that vibrations or other factors do not loosen during flight.
The usage of safety lockwire in this industry is not only a standard practice but a regulatory requirement to maintain aircraft safety and integrity.
In the automotive industry, safety lock wire is extensively used to secure elements of high-performance vehicles, racing cars, and motorcycles.
These vehicles often undergo severe vibrations and stresses, leading to the loosening of fasteners. Safety lockwire helps prevent any such incidents and ensures the proper functioning of vehicles, especially in high-stakes racing environments.
Safety lockwire also finds significant application in the oil and gas industry. It is used in securing fasteners and fittings in oil rigs, pipelines, and processing facilities.
The conditions in these facilities can be extremely harsh, with high pressures, vibrations, and corrosive elements. Safety lockwire ensures that the fasteners do not loosen or fall off, preventing possible leaks or accidents, and maintaining the integrity and safety of the entire operation.
Proper installation of the safety wire is as important as the lock wire itself. There are several techniques to secure fasteners effectively, where the most common are the Double Twist Method and the Single Twist Method.
The Double Twist Method is commonly used when securing two or more fasteners together. After threading the wire through the fasteners, equal lengths of the wire are twisted together between the fasteners.
The twisting creates a tight bond, preventing the fasteners from loosening under stress or vibration. This method is typically used in scenarios where multiple fasteners are in close proximity.
The Single Twist Method, on the other hand, is typically used when the lockwire is securing a single fastener. In this method, the wire is threaded through the hole of the fastener and then twisted around itself, forming a loop.
The remaining end of the wire is then twisted back onto itself to lock the loop in place. This is a simpler process but is also effective in preventing the disengagement of the fastener.
While the above methods are standard, it is vital to adjust your technique depending on specific applications. For example, the direction of the twist and the tightness of the wire may depend on the direction of rotation of the fastener, its size, and its material.
Always ensure to consult the guidelines provided by the manufacturer or industry standards for specific applications.
At American Wireworks, we take the issue of compliance and standards very seriously. This ensures that the products we supply are safe, reliable, and of the highest quality.
Our safety wires are produced in full compliance with the directives of the National Aerospace Standards (NASM) and the Defense Federal Acquisition Regulation Supplement (DFARS). These bodies set stringent safety, quality, and technical standards for products used in the aerospace and defense industries.
To underscore our commitment to quality and safety meet all necessary certification requirements. This includes the MS20995C47 specifications and the NASM 20995 standards. These certifications affirm our lockwire’s suitability for use in securing fasteners in high-stress environments.
Our in-house quality control measures are comprehensive and thorough. We conduct rigorous checks at every stage of the manufacturing process, from sourcing of raw materials to packaging of the final product. This ensures that only defect-free, high-performance lockwire reaches our clients. Our commitment to quality control has made us a trusted supplier in the aerospace and defense industries.
Safety lock wire offers several significant benefits, making it an indispensable tool in various industries, especially aerospace and defense. Here are some key advantages:
The primary advantage of safety lock wire is the enhanced safety it provides. It keeps critical fasteners, such as nuts, bolts, and turnbuckles, securely in place, reducing the risk of these pieces loosening and causing mechanical failures.
This heightened level of safety is crucial, especially in industries where even the slightest mechanical failure can have catastrophic consequences.
Safety lockwire is specifically designed to combat the detrimental effects of vibration, a common issue in aerospace and defense environments.
By keeping the fasteners intact under conditions of high vibration, the safety wire effectively prevents vibrational loosening, ensuring the continued secure operation of the components.
Safety lockwires, particularly those made of stainless steel, boast superior corrosion resistance. This quality makes them highly durable even in challenging environments, significantly extending the lifespan of the components they secure. The corrosion-resistant nature of safety lock wire minimizes the need for frequent replacements, offering long-term reliability and cost-efficiency.
To reiterate, traditional safety wire plays a vital role in industries like aerospace and defense. This high-quality locking wire helps secure fasteners and prevent their dislocation, a critical safety measure given the stressors common in such work environments.
Overall, safety wire helps you ensure that there will be no safety hazard that can harm you. Just as first aid kits and portable fire extinguishers are needed in certain industries, safety wire is part of making sure you’re always safe. It helps you reinforce your emergency equipment.
Furthermore, American Wireworks is renowned for its commitment to quality, reliability, and customer focus, offering both in-stock and custom wire options to cater to a variety of needs.
The importance of safety in high-stress fields like aerospace and defense cannot be overstated. Using superior-quality lockwire significantly reduces the risk of mechanical failure and, therefore, improves safety standards. It is vital to choose a reputable and trusted supplier, such as American Wireworks, when procuring these mission-critical components.
Doing so ensures not only the quality of the product but also the peace of mind and confidence to perform tasks without worrying about equipment failure.
What is Lock Wire? Lock wire is a crucial safety tool for ensuring mechanical stability. Bolts, screws, nuts, and other types of fasteners will gradually loosen over time, especially in applications that produce high levels of vibrations.
Applications like sports cars, aircraft turbine engines, and even weaponry can benefit greatly from the implementation of safety wire. Braking mechanisms, throttle systems, and even flight controls depend on lockwire to prevent serious mechanical failures and keep people safe, hence the name “safety wire.”
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Lock wire’s central purpose is to prevent the loosening of nuts, bolts, and other fasteners. To wire lock nuts and bolts, you thread it through two or more fasteners, ensuring they remain as secure as possible. Safety wiring prevents the loosening of fasteners by counteracting it with more tightening. The common application method for the installation of safety wire involves twisting two strands of wire together with a “Double Twist” configuration.
However, it is important to avoid using safety tie wire for applications that involve excess chafing, tension, or fatigue outside of the wire’s intended tightening function.
Malin Lock Wire
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Performing safety wire installation involves choosing one of two methods: double-twist or single-wire.
For the double-twist application method, the diameter of the wire depends on the type of fasteners. Parts with hole diameters exceeding .045 inches require wiring of .032 inches in diameter. Those with hole diameters between .045 and .062 inches and spacing of fewer than 2 inches between each part require wire double-strand wire of .020 inches in diameter.
The single-wire or single-strand safety wire installation method is more applicable in situations with closely spaced fasteners such as electrical systems. The number of fasteners you can securely wire lock depends on how many are within reach of 24 inches of wire. The single-wire method also requires the use of the largest wire that can fit in the fastener’s hole.
Additionally, aluminum wire of .031 inch diameter, copper wire of .020 inch diameter, and similar types of wire function as seals on specific forms of equipment. This includes portable fire extinguishers, first-aid kits, emergency valves, and equipment with similar construction.
Check out this video to learn more about how to lock wire bolts and other fasteners:
Tie wire is incredibly useful for tying reinforcing. During construction, tie wire is an ideal choice for short durations. For extended periods of reinforcing, safety lock wire is the better choice.
Steel tie wire is among the most common types of tie wire. The process of making a tie wire reel involves annealing the wire. Annealing wire means to heat a wire to a certain temperature and then cool it at a certain rate. The desired result of annealing wire is to increase the ability of the wire to change shape with ease.
Tie wire is commonly used in construction and other industrial sites to reinforce steel bars and as reinforcing mesh. Tie wire also has a strong resistance to the elements. Tie wire uses are also prevalent in agriculture, packaging, and mining.
Malin has a wide variety of safety lock wire options, most notably stainless steel lock wire. Contact Malin today, for any tie wire, safety lock wire, or any of our other wire options.
Malin Co. is a valuable resource for effective lock wiring products for various industries. Our products can maintain the security and tightness of fasteners in even the most intense applications. Malin Co. lockwire is a positive locking device, which helps maintain safety standards in aerospace, automotive, and many other applications.
We color code each of our lock wire products with recyclable, polyethylene containers:
Polyethylene safety wire canisters do not degrade like paper canisters, and Malin lock wire canisters will protect your wire from grease formation and corrosive materials.
In addition, we offer our safety wire products in spools, coils, and bulk purchase options to fulfill each customer’s packaging needs.
Stainless Steel Aerospace Safety Wire
Bulk Spools & Coils
Stainless Steel (302, 303, 304, 304L, 316, 316L, 410, 430)Copper & Brass Breakaway Wire
Boxed Coils
Aluminum, Brass, Nickel
Inconel Aerospace Lock Wire
Bobbins
Nickel Silver, Nitinol, Phosphorous Bronze
Oxidized Inconel Aerospace Safety Wire
Quarter-Pound Handi-Pak Coils
Copper, Chromel Carbon (Black, Galvanized)
Monel Aerospace Lockwire
Custom Spools
Inconel, Monel, Titanium
Standard materials: Stainless steel type 302/304 ASTM A 580, 305 and 316 stainless available upon request for the Aerospace Industry.
(Blue Canister)Order Now
** Other sizes and packaging options available.
Inconel lockwire/safety wire for the aerospace industry(Yellow Canister) Order Now
Part Number Nominal Diameter NASM / MS20995N20 ASTM B166 .020 NASM / MS20995N25 ASTM B166 .025 NASM / MS20995N32 ASTM B166 .032 NASM / MS20995N40 ASTM B166 .040 NASM / MS20995N51 ASTM B166 .051** Other sizes and packaging options available.
Inconel wire oxidized for the aerospace industry (Orange Canister) Order Now
Part Number Nominal Diameter NASM / MS9226-01 AMS 5687 .016 NASM / MS9226-02 AMS 5687 .020 NASM / MS9226-03 AMS 5687 .025 NASM / MS9226-04 AMS 5687 .032 NASM / MS9226-05 AMS 5687 .040 NASM / MS9226-06 AMS 5687 .051 NASM / MS9226-07 AMS 5687 .063 NASM / MS9226-08 AMS 5687 .091** Other sizes and packaging options available.
Monel safety wire for the aerospace industry (Red Canister) Order Now
Part Number Nominal Diameter NASM/MS20995NC20 ASTM B164 .020 NASM/MS20995NC25 ASTM B164 .025 NASM/MS20995NC32 ASTM B164 .032 NASM/MS20995NC40 ASTM B164 .040 NASM/MS20995NC51 ASTM B164 .051** Other sizes and packaging options available.
Malin’s tie wire brings a versatile and reliable solution to wire applications across various industries. The process of creating tie wire fortifies its strength, which is why it is so commonly used in construction projects. If you need a wire to bind objects together, create a fencing from, and even more, you can count on Malin’s tie wire products.
Malin Co. is a wire manufacturing company with ISO 9001:2015 certification, so you can trust us to meet the quality and performance standards of your project. If you are looking for safety wire in an alloy that is not listed here, we are capable of quoting for other materials. If you are unsure of what materials you are looking for, get in touch with Malin Co. today, and our team can answer any questions you have to ensure you get the best product for the job.
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