Ultra fine stainless steel wires, with diameters as small as 0.018mm, offer exceptional properties like high elasticity, flexibility, and resistance to wear, heat, and corrosion. They are used in textiles for high-end fabrics, filter materials for industrial applications, conductive plastics, and radiation-proof fabrics. These wires enhance durability and performance in industries like electronics
The application of ultra fine stainless steel wire
Introduction:
Stainless steel is one of the significant inventions of the 20th century. After nearly a century of research and development, it has evolved into a series of steel grades with over 3,000 variations. In the special steel system, stainless steel has unique properties and a wide range of applications, playing a role that other special steels cannot replace. Stainless steel can almost encompass any other type of special steel.
Stainless steel ultra fine wires are wire diameter above 0.018mm, produced through a special process that involves the composite assembly of metal wires, multiple bundling and drawing, annealing, and solution treatment. Each strand contains thousands to tens of thousands of individual wires. The surface area of stainless steel ultra fine wires is very large, giving them extraordinary performance in terms of internal structure, magnetism, heat resistance, and melting point. The diameter of stainless steel ultra fine wires can reach 1-2 ultra fine meters, with an elongation rate of over 1%, and the fiber strength can reach 1200-1800 MPa.
Due to the significant changes in the internal structure, physical and chemical properties, and surface characteristics of stainless steel ultra fine wires during the drawing process, these wires not only possess the inherent advantages of metallic materials, such as high elastic modulus, high bending, and tensile strength, but also exhibit some unique properties and wide-ranging applications not found in non-stainless steel ultra fine wires. Compared to organic and inorganic fibers, stainless steel ultra fine wires offer higher elasticity and flexibility (the softness of an 8µm stainless steel fiber is comparable to that of a 13µm hemp fiber), flexibility, and adhesiveness (with proper surface treatment, they bond well with other materials, making them suitable for any composite material). They also demonstrate superior wear resistance, high-temperature resistance (continuous use at temperatures up to 600°C in an oxidizing environment), corrosion resistance (resistant to HNO3, alkalis, and organic solvents), better breathability, conductivity, magnetism, thermal conductivity, self-lubrication, and sintering properties.
Moreover, the unique environmental friendliness and recyclability of stainless steel ultra fine wires greatly enhance their value in societal production and daily life. Composite materials made from stainless steel ultra fine wires as the base material are widely used in the electronics, chemical, machinery, military, textile, food, and pharmaceutical industries, opening up broad application prospects. As an emerging fiber material, stainless steel ultra fine wires have garnered significant attention from government departments and various industries
Production Methods:
The production methods of stainless steel ultra fine wires include the traditional wire drawing and cutting method, as well as melt extraction, bundle drawing, scraping, and cutting methods. Currently, the smallest fiber diameter can reach 0.5 ultra finemeters, and the length can extend to several tens or even hundreds of meters. After drawing, stainless steel ultra fine wires usually undergo annealing to make them softer and more suitable for a wide range of applications.
1.Application :Ultra Fine Stainless Steel Wire Textile Products
Ultra Fine Stainless steel wires are finer than human hair, softer than cotton, and have a better feel than silk. They are characterized by their fineness and softness, in addition to the inherent bright and vivid metallic luster, as well as their special conductive and electromagnetic shielding properties. In recent years, the application of stainless steel ultra fine wires in the textile industry has been increasing. The specific uses are as follows:
1.1 Stainless Steel Ultra fine Wire Textiles
Stainless steel ultra fine wire textiles are high-end fabrics formed by embedding stainless steel ultra fine wires, produced through advanced wire drawing technology, into fabrics. These textiles primarily include polyester-cotton, nylon-cotton, nylon-polyester, and all-cotton stainless steel ultra fine wire fabrics, with stainless steel ultra fine wire content typically ranging from 3% to 8%. Generally, the higher the proportion of stainless steel ultra fine wires under the same technological level, the higher the cost.
Due to the embedded stainless steel ultra fine wires, these textiles exhibit a uniquely attractive style, a smooth and soft feel, and bright and vivid colors. They emit a shiny, noble metallic luster with excellent reflective effects, which are more pronounced under sunlight and artificial light. The high elastic modulus of stainless steel ultra fine wires gives these textiles a unique memory and wrinkle effect, creating a pleated appearance. The slow release of shape memory in these fabrics allows them to gradually return to their original shape, similar to the movement of spacewalking, while the dynamic effect of natural wrinkles is another highlight. The combination of light refraction and motion enhances the visual and artistic appeal of these yarns, with variations in depth and texture, from rough to smooth, and changes in twist further enhancing the shape memory effect. In high-end fashion design, the application of stainless steel ultra fine wires is considered the finishing touch, adding lively colors, brilliant luster, and health benefits such as radiation protection and anti-static properties, making them a favorite in the future fashion market.
Stainless steel ultra fine wire textiles can be used not only for making high-end men's and women's clothing, showcasing the wearer's elegant, noble, and romantic temperament and high-end taste, but also have other broader applications. Pure stainless steel ultra fine wire textiles can be used to make pillow seals, dust bags, hot workpiece conveyor belts, thermal insulation curtains, and heat-resistant cushions. Blended stainless steel ultra fine wire textiles can be used to make high-pressure shielding clothing, anti-static workwear, anti-static carpets, electromagnetic wave protection clothing and covers, maternity wear, medical surgical gowns, and more. Additionally, stainless steel ultra fine wire textiles can be used to create fake military targets and radar decoys to confuse the enemy during combat.
The special properties and wide range of applications of stainless steel ultra fine wire textiles have led to increasing market demand. This demand has given rise to some non-standardized, small-scale stainless steel ultra fine wire manufacturers. The stainless steel ultra fine wires processed by these small factories often do not meet the usage standards of textile machinery in terms of tensile strength, yield strength, elongation coefficient, surface smoothness, and wire diameter. Textiles made from substandard stainless steel ultra fine wires are prone to issues such as creases, "mosquito mouths," and broken wires. Creases are localized folds in the metal wire on the fabric surface, creating irreversible marks; "mosquito mouths" are loops or kinks in the metal wire, leaving gaps in the fabric; broken wires refer to metal wires that snap or twist, leaving visible wire ends. These issues severely affect the quality of the finished fabric and cause irreparable losses to fabric processing companies.
China's stainless steel ultra fine wire manufacturing industry started relatively late, and research on textile-specific stainless steel ultra fine wires is still in its infancy. Laiwu Longzhi Industrial and Trade Co., Ltd. is the first established stainless steel ultra fine wire processing manufacturer in China to research, develop, and produce textile-specific stainless steel ultra fine wires. After nearly ten years of effort by the company's research team, they have finally developed high-quality, textile-specific stainless steel ultra fine wires that meet or even exceed the standards of the textile industry. These wires are made from imported 316L high-quality stainless steel, drawn with natural diamond dies and fully computer-controlled ultra fine-drawing equipment, pioneering the application of stainless steel ultra fine wires in the textile industry. Their high-end quality and extremely high utilization rate have won unanimous recognition from new and old customers worldwide, making them the preferred product for many textile and apparel companies.
1.2 Stainless Steel Ultra fine Wire Radiation-Proof Fabric
Our Stainless steel ultra fine wire is free of mercury and lead,so it's very safe for fabric and garments,stainless steel ultra fine wire radiation-proof fabric utilizes the unique and stable electromagnetic shielding properties of stainless steel ultra fine wires. The manufacturing process is as follows: first, stainless steel ultra fine wires with diameters between 3µm and 50µm are woven into a stainless steel ultra fine wire mesh. This mesh is then sandwiched between two layers of natural fabric, and finally, it is stitched or sewn into a single-layer fabric. The stitching not only protects the stainless steel ultra fine wire mesh but also forms aesthetically pleasing decorative patterns.
With the development of the national economy and advancements in science and technology, the application of wired and wireless devices has surrounded our living environment with various electromagnetic waves. Our bodies are subjected to different degrees of electromagnetic radiation harm, and in some specialized industries, electromagnetic radiation can even be life-threatening. Electromagnetic wave pollution is likely to become the fourth serious pollution source after environmental, water, and air pollution. In this urgent situation, various radiation-proof products have emerged, among which radiation-proof fabrics are the most popular and effective. Currently, there are four types of radiation-proof fabrics on the market: stainless steel ultra fine wire radiation-proof fabric, multi-element (nano) radiation-proof fabric, copper/nickel ion radiation-proof fabric, and silver fiber radiation-proof fabric.
Stainless steel ultra fine wire radiation-proof fabric offers high radiation protection and additional advantages such as aesthetic appeal, durability in washing, ease of coloring, good breathability, stable shielding performance, and reasonable manufacturing costs. It is currently the most commonly used radiation-proof fabric. Multi-element (nano) radiation-proof fabric, although theoretically effective in radiation protection, cannot be washed and has high production costs, making it generally suitable only as an interlayer shielding material in clothing. Copper/nickel ion radiation-proof fabric is similar to multi-element radiation-proof fabric but falls short in feel and color, and is rarely used in garment production. Silver fiber radiation-proof fabric is heavily promoted by various merchants for its radiation protection capabilities, often exaggerated. Objectively, silver fiber radiation-proof fabric has comparable radiation protection performance to stainless steel ultra fine wire radiation-proof fabric, but it is costlier and available only in limited colors, making it suitable primarily for use as ion fabric in garments. Additionally, some manufacturers, driven by high profits, mix low-cost, poor-performance metallized coated fabrics with genuine silver fiber radiation-proof fabric, misleading consumers and resulting in a market where silver fiber radiation-proof fabric often does not live up to its reputation.
1.3 Stainless Steel Ultra fine wire Antibacterial Health Textile Fabric
Stainless steel ultra fine wires possess excellent antibacterial properties, with a significant and long-lasting antibacterial effect. Due to the strong ionic nature of the metal, stainless steel ultra fine wire textile fabric can release 5,000 to 8,000 negative ions per square centimeter. Medical tests have proven that stainless steel ultra fine wire products can inhibit and kill various strains of bacteria, and the antibacterial effect is satisfactory.
2.Stainless Steel Ultra fine wire Filter Material
Stainless steel ultra fine wire filter material, also known as stainless steel ultra fine wire sintered felt, represents another significant application of stainless steel ultra fine wires.
The stainless steel ultra fine wire sintered felt is produced using extremely fine stainless steel ultra fine wires (with diameters precise to the micrometer level) laid out in a non-woven manner and then sintered at high temperatures. This material consists of different pore size layers, forming a pore gradient that can achieve extremely high filtration accuracy and a greater dirt-holding capacity. The stainless steel ultra fine wire sintered felt features a three-dimensional network, porous structure, high porosity, large surface area, and uniform pore size distribution, ensuring continuous filtration performance.
Compared to traditional powder metallurgy filtration materials, stainless steel ultra fine wire felt offers higher strength, larger dust-holding capacity, and longer service life. When compared to wire mesh filtration materials, it provides higher filtration accuracy, better breathability, larger specific surface area, and stronger capillary action. This effectively addresses the issues of easy clogging and damage of metal nets and the fragility and low flow rate of powder filter products. It also offers superior temperature and pressure resistance compared to ordinary filter paper and cloth, making it especially suitable for harsh conditions involving high temperatures, high viscosity, high precision, and corrosive media.
Characteristics of Stainless Steel Ultra fine wire Sintered Felt:
1. High Dirt-Holding Capacity and Filtration Accuracy:** Slow pressure increase and extended replacement cycles.
2. High Porosity and Excellent Permeability:** Minimal pressure loss and large flow rate.
3. Corrosion and High-Temperature Resistance:** Resistant to acid, alkali, organic solvents, and drugs, with long-term use at temperatures up to 480°C.
4. Ease of Processing, Forming, and Welding:** Customizable to produce reinforced, thickened, protective mesh, and other specifications according to user requirements.
Due to these characteristics, stainless steel ultra fine wire sintered felt is widely used in various fields, including:
- Filtration of polymer polymers
- Petrochemical industry
- High-temperature gas dust removal in electronics
- Refinery filtration processes
- Viscose filtration
- Pre-filtration for ultrafilters
- Vacuum pump protection filters
- Filter membrane supports
- Catalyst carriers
- Automotive airbags
- Fuel filtration for aircraft and ships
- Hydraulic system filtration.
3. Stainless Steel Ultra fine wire Conductive Plastic
Plastic is typically considered a poor conductor of electricity and is often used to insulate wires. However, recent discoveries by researchers in Australia reveal that covering a layer of plastic with an ultra-thin metal film made of stainless steel ultra fine wires and integrating it into the surface of a polymer using an ion beam can produce a low-cost, high-strength, flexible, and conductive plastic film. This breakthrough was achieved by a team led by Professor Paul Meredith and Associate Professor Ben Powell from the University of Queensland, along with Professor Adam Micolich from the University of New South Wales. Their findings have been published in the journal "ChemPhysChem." The experiments forming the basis of this research were conducted by former University of Queensland doctoral student Andrew Stephenson.
To demonstrate the potential applications of this material, the team produced a resistance thermometer using the material, adhering to industrial standards. Comparative tests with similar platinum resistance thermometers showed that products made with the new material displayed comparable, if not superior, performance.
"The interesting thing about this material is that it retains almost all the advantages of polymers—mechanical flexibility, high strength, and low cost—while also exhibiting good conductivity, which is not typically a characteristic of plastic," said Professor Micolich. "This material opens up a new realm for plastic conductors."
In recent years, conductive plastics have garnered interest, with numerous studies highlighting their benefits due to three notable advantages: 1) no need for secondary processing; 2) simultaneous completion of shielding and forming products (saving labor and cost); and 3) safety and reliability over long-term use (such as in environments with vibrations and humidity) without the peeling or falling off associated with surface methods.
Stainless steel ultra fine wire-filled conductive plastics are a major focus of current conductive plastic research, primarily used for electromagnetic wave shielding. With the advancement of integrated circuits and large-scale integrated circuit technology, digital electronic devices have transitioned from industrial to consumer applications. As electronic circuits and components become increasingly integrated, miniaturized, and high-speed, their signal levels decrease, making them more susceptible to interference from external electromagnetic waves. Additionally, electronic devices emit electromagnetic waves, potentially causing malfunctions and interference with image and sound quality. Since the 1980s, plastic has largely replaced metal for electronic equipment casings due to its lightweight, high strength, corrosion resistance, ease of processing, high production efficiency, and low overall cost. However, plastic is an insulator and allows electromagnetic waves to pass through, creating an urgent need for research into imparting electromagnetic wave shielding capabilities to plastic casings.
4. Stainless Steel Ultra fine wire Reinforced Composite Materials
Stainless steel ultra fine wires, when die-cast with aluminum alloy, can be used as materials for automotive engine connecting rods. Compared to traditional materials, this composite material maintains the same strength and stiffness while reducing weight by 30%. Stainless steel ultra fine wires, as semi-metallic, asbestos-free friction materials, are widely used in the brakes of cars, mining machinery, and forging machinery. These materials primarily consist of short metal fibers with diameters ranging from 20 to 300 microns and lengths from 2 to 30 millimeters. Bearings made from steel fibers offer better self-lubrication than traditional powder metallurgy bearings, making them suitable for use in environments with vacuum, high temperatures, or without oil supply. Additionally, adding steel fibers to cement to create steel fiber concrete can significantly enhance the quality of buildings.
The integration of stainless steel ultra fine wires into various composites brings several advantages:
1. Automotive Application:
Engine Connecting Rods: The composite of stainless steel ultra fine wires and aluminum alloy in engine connecting rods not only reduces the weight of the component but also maintains essential mechanical properties. This weight reduction contributes to overall vehicle efficiency and performance.
2. riction Materials:
Brakes and Machinery: Asbestos-free friction materials containing stainless steel ultra fine wires are used in braking systems for vehicles and machinery. The metal fibers in these materials provide high friction and durability, essential for safety and reliability in automotive and industrial applications.
3. Bearings:
- Fiber Bearings: Bearings made from stainless steel ultra fine wires offer superior self-lubrication, making them ideal for extreme conditions such as high temperature, vacuum, or where traditional lubrication methods are impractical. These bearings enhance the performance and longevity of machinery operating under challenging conditions.
4. Construction:
- Steel Fiber Concrete: The incorporation of steel fibers into concrete significantly enhances the material's structural integrity. This steel fiber concrete is used in various construction applications to improve durability, reduce cracking, and increase the load-bearing capacity of structures.
The advancements in stainless steel ultra fine wire composites reflect the material's versatility and potential to enhance performance across multiple industries, from automotive to construction.
5.Stainless Steel Ultra fine wire Anti-Counterfeiting Materials
Each stainless steel ultra fine wire emits a unique microwave signal, a characteristic that has been utilized for range identification and anti-counterfeiting purposes. Barcodes made from stainless steel ultra fine wires have stronger identification capabilities compared to those made from metal powder. Special paper produced by mixing stainless steel ultra fine wires with pulp is now used for bank statements, bills, securities, and official correspondence. Additionally, stainless steel ultra fine wires are employed in anti-counterfeiting measures for personal identification documents such as ID cards, passports, and credit cards.
Applications of Stainless Steel Ultra fine wire in Anti-Counterfeiting:
1. **Enhanced Barcodes**:
- **Identification**: Barcodes incorporating stainless steel ultra fine wires are more robust and have enhanced recognition features. These barcodes provide a higher level of security compared to traditional metal powder barcodes, making them suitable for high-security environments.
2. **Specialized Paper**:
- **Bank and Financial Documents**: Mixing stainless steel ultra fine wires with pulp to produce specialized paper adds a layer of security to bank statements, bills, and securities. This specialized paper is more difficult to counterfeit, ensuring the authenticity of important financial documents.
- **Official Correspondence**: The use of stainless steel ultra fine wire paper for official letters and documents helps prevent forgery and ensures that communications are genuine and traceable.
3. **Personal Identification**:
- **ID Cards and Passports**: Embedding stainless steel ultra fine wires in personal identification documents, such as ID cards and passports, enhances their security. The unique microwave signals emitted by the wires make these documents difficult to counterfeit and easy to verify.
- **Credit Cards**: Incorporating stainless steel ultra fine wires in credit cards adds an extra layer of security against fraud, ensuring that the cards are authentic and traceable.
The unique properties of stainless steel ultra fine wires make them ideal for a wide range of anti-counterfeiting applications, providing enhanced security and reliability across various sectors.
6.Stainless Steel Ultra fine wire Sound-Absorbing Materials
Stainless steel ultra fine wire felts, formed by laying and sintering thin stainless steel ultra fine wires, are effective sound-absorbing materials in specialized environments. Traditional sound-absorbing materials are often ineffective under high temperatures and high decibel conditions. In contrast, stainless steel ultra fine wire felts are highly effective due to their high-temperature resistance and unique porous, interconnected void structure. This structure alters the sound propagation path, reducing the energy of the sound waves and achieving noise reduction. A typical application is in reducing noise from aircraft engines and turbines.
7.Stainless Steel Ultra fine wire Battery Electrode Materials
In the global market, nickel-metal hydride (Ni-MH) batteries typically use foam nickel as the anode support material. However, foam nickel, produced through electrochemical methods, results in Ni-MH batteries with fewer charge-discharge cycles (less than 500 cycles), low energy, and unstable voltage, which hinders their development. Stainless steel ultra fine wire felts made from nickel fibers offer high strength, strong metallurgical bonding, and a large specific surface area. Ni-MH batteries made with these felts exhibit high charge-discharge cycles (more than 1000 cycles), stable voltage, large capacity, and excellent current impact resistance, making them suitable for high-current environments. Replacing foam nickel with nickel fiber felts has become a development direction for Ni-MH batteries. Companies like Toshiba in Japan have adopted nickel fiber felts in Ni-MH battery production. China has also imported a production line using nickel fiber felts for Ni-MH batteries and another line using nickel fiber felts for Ni-Cd batteries from the US-based N-S company.
Additional Applications of Stainless Steel Ultra fine wire
Apart from the above common applications, stainless steel ultra fine wires have numerous other uses in daily life and industry, such as:
- **Burners**: Using FeCr alloy fiber felts in burners maximizes the effective surface area for gas combustion. Compared to traditional ceramic or metal burners, these have a longer lifespan, better combustion efficiency, and good formability.
- **Catalysts and Carriers**: Stainless steel ultra fine wires are used in the production of catalysts and their carriers, providing large surface areas and durability.
- **Heat Exchangers**: Their high thermal conductivity and strength make them suitable for efficient heat exchange processes.
- **Gas-Liquid Separation**: The unique structure of ultra fine wire felts facilitates effective separation in various industrial processes.
- **High-Temperature Sealing**: They offer excellent sealing properties under extreme conditions, ensuring the integrity of high-temperature systems.
These diverse applications highlight the versatility and importance of stainless steel ultra fine wires across different sectors, contributing to technological advancements and improving product performance.
8.Development Prospects of Stainless Steel Ultra fine wire
Stainless steel ultra fine wire, with its unique and superior properties, is one of the new high-tech fiber materials with significant advancements internationally. It has a broad range of applications in civilian, industrial, and military fields, indicating a promising development prospect.
#### Historical Development in China
China's research on stainless steel ultra fine wire and its products began in 1979. Initially, due to technical challenges and raw material issues, the quality of domestically produced stainless steel ultra fine wires lagged far behind international counterparts. Over the next few decades, China's stainless steel ultra fine wire industry progressed from relying on imported raw materials to achieving domestic production and eventually exporting finished products.
#### Current Status
Today, China's stainless steel ultra fine wire manufacturing has not only achieved full localization but also boasts numerous production bases with a comprehensive range of products and specifications. Some blended products have started to enter the international market.
#### Future Prospects
1. **Increasing Demand**: As China's petroleum and chemical industries continue to develop, and as secondary energy materials rise, the demand for stainless steel ultra fine wires and their products will surge.
2. **Quality of Life Improvements**: With the improvement of living standards, there will be a growing demand for high-quality, durable materials in various applications, from consumer goods to industrial uses.
3. **Industrial Applications**: The need for high-performance materials in sectors like aerospace, automotive, electronics, and construction will drive further advancements in stainless steel ultra fine wire technology.
4. **Military and Defense**: The unique properties of stainless steel ultra fine wires make them ideal for advanced military applications, such as in protective clothing, communications, and defense equipment.
#### Strategic Importance
The industrialization of stainless steel ultra fine wires and their products in China has significant practical importance. It supports the development of high-tech industries and aligns with the national strategy of enhancing technological self-reliance and advancing manufacturing capabilities. The ability to produce high-quality stainless steel ultra fine wires domestically reduces dependency on imports and strengthens China's position in the global market.
#### Innovation and Research
Continued innovation and research are crucial to maintaining and expanding the applications of stainless steel ultra fine wires. Efforts should focus on:
- Enhancing production techniques to improve quality and reduce costs.
- Developing new applications and expanding existing ones.
- Collaborating with international partners to stay at the forefront of technological advancements.
#### Conclusion
Stainless steel ultra fine wires have a bright future in China, with extensive applications across various sectors. As research and development continue to advance, and with increasing domestic and international demand, the stainless steel ultra fine wire industry is poised for significant growth and development. This progress will contribute to the broader goals of industrial modernization and economic development in China.