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Overhead power cabling. The conductor consists of seven strands of steel (centre, high tensile strength), surrounded by four outer layers of aluminium (high conductivity). Sample diameter 40 mm A wire is a flexible strand of
metal A metal (from ancient Greek, Greek μέταλλον ''métallon'', "mine, quarry, metal") is a material that, when freshly prepared, polished, or fractured, shows a lustrous appearance, and conducts electrical resistivity and conductivity, e ...
. Wire is commonly formed by drawing the metal through a hole in a
die Die, as a verb, refers to death, the cessation of life. Die may also refer to: Games * Die, singular of dice, small throwable objects used for producing random numbers Manufacturing * Die (integrated circuit), a rectangular piece of a semicondu ...
or draw plate.
Wire gauge Wire gauge is a measurement of wire diameter. This determines the amount of electric current the wire can safely carry, as well as its electrical resistance and weight. Types of wire gauge Wire gauges may be broadly divided into two groups ...
s come in various standard sizes, as expressed in terms of a gauge number. Wires are used to bear mechanical loads, often in the form of wire rope. In electricity and telecommunications signals, a "wire" can refer to an electrical cable, which can contain a "solid core" of a single wire or separate strands in stranded or braided forms. Usually cylindrical in geometry, wire can also be made in square, hexagonal, flattened rectangular, or other cross-sections, either for decorative purposes, or for technical purposes such as high-efficiency voice coils in loudspeakers. Edge-wound coil springs, such as the Slinky toy, are made of special flattened wire.


History

upleft, Wire wrapped jewelry In
antiquity Antiquity or Antiquities may refer to: Historical objects or periods Artifacts *Antiquities, objects or artifacts surviving from ancient cultures Eras Any period before the European Middle Ages (5th to 15th centuries) but still within the histo ...
, jewelry often contains large amounts of wire in the form of chains and applied decoration that is accurately made and which must have been produced by some efficient, if not technically advanced, means. In some cases, strips cut from metal sheet were made into wire by pulling them through perforations in stone beads. This causes the strips to fold round on themselves to form thin tubes. This strip drawing technique was in use in
Egypt Egypt ( ar, مصر , ), officially the Arab Republic of Egypt, is a List of transcontinental countries, transcontinental country spanning the North Africa, northeast corner of Africa and Western Asia, southwest corner of Asia via a land bridg ...
by the
2nd Dynasty The Second Dynasty of ancient Egypt (or Dynasty II, c. 2890 – c. 2686 BC) is the latter of the two dynasties of the Egyptian Archaic Period, when the seat of government was centred at Thinis. It is most known for its last ruler, ...
(c. 2890 – c. 2686  BCE). From the middle of the 2nd millennium BCE most of the
gold Gold is a chemical element with the symbol Au (from la, aurum) and atomic number 79. This makes it one of the higher atomic number elements that occur naturally. It is a bright, slightly orange-yellow, dense, soft, malleable, and ductile ...
wires in
jewellery Jewellery ( UK) or jewelry ( U.S.) consists of decorative items worn for personal adornment, such as brooches, rings, necklaces, earrings, pendants, bracelets, and cufflinks. Jewellery may be attached to the body or the clothes. From a w ...
are characterised by seam lines that follow a spiral path along the wire. Such twisted strips can be converted into solid round wires by rolling them between flat surfaces or the strip wire drawing method. The strip twist wire manufacturing method was superseded by drawing in the ancient Old World sometime between about the 8th and 10th centuries AD. There is some evidence for the use of drawing further East prior to this period. Square and hexagonal wires were possibly made using a swaging technique. In this method a metal rod was struck between grooved metal blocks, or between a grooved punch and a grooved metal anvil. Swaging is of great antiquity, possibly dating to the beginning of the 2nd millennium BCE in Egypt and in the Bronze and Iron Ages in Europe for torcs and
fibulae The fibula or calf bone is a leg bone on the lateral side of the tibia, to which it is connected above and below. It is the smaller of the two bones and, in proportion to its length, the most slender of all the long bones. Its upper extremity i ...
. Twisted square-section wires are a very common filigree decoration in early Etruscan jewelry. In about the middle of the 2nd millennium BCE, a new category of decorative tube was introduced which imitated a line of granules. True beaded wire, produced by mechanically distorting a round-section wire, appeared in the Eastern Mediterranean and Italy in the seventh century BCE, perhaps disseminated by the Phoenicians. Beaded wire continued to be used in jewellery into modern times, although it largely fell out of favour in about the tenth century CE when two drawn round wires, twisted together to form what are termed 'ropes', provided a simpler-to-make alternative. A forerunner to beaded wire may be the notched strips and wires which first occur from around 2000 BCE in Anatolia. Wire was drawn in England from the medieval period. The wire was used to make wool cards and pins, manufactured goods whose import was prohibited by Edward IV in 1463. The first wire mill in Great Britain was established at Tintern in about 1568 by the founders of the
Company of Mineral and Battery Works The Company of Mineral and Battery Works was, (with the Society of the Mines Royal), one of two mining monopolies created by Elizabeth I. The Company's rights were based on a patent granted to William Humfrey on 17 September 1565. This was repl ...
, who had a monopoly on this. Apart from their second wire mill at nearby Whitebrook, there were no other wire mills before the second half of the 17th century. Despite the existence of mills, the drawing of wire down to fine sizes continued to be done manually. According to a description in the early 20th century, " re is usually drawn of cylindrical form; but it may be made of any desired section by varying the outline of the holes in the draw-plate through which it is passed in the process of manufacture. The draw-plate or
die Die, as a verb, refers to death, the cessation of life. Die may also refer to: Games * Die, singular of dice, small throwable objects used for producing random numbers Manufacturing * Die (integrated circuit), a rectangular piece of a semicondu ...
is a piece of hard cast-iron or hard steel, or for fine work it may be a
diamond Diamond is a solid form of the element carbon with its atoms arranged in a crystal structure called diamond cubic. Another solid form of carbon known as graphite is the chemically stable form of carbon at room temperature and pressure, b ...
or a
ruby A ruby is a pinkish red to blood-red colored gemstone, a variety of the mineral corundum ( aluminium oxide). Ruby is one of the most popular traditional jewelry gems and is very durable. Other varieties of gem-quality corundum are called ...
. The object of utilising precious stones is to enable the dies to be used for a considerable period without losing their size, and so producing wire of incorrect diameter. Diamond dies must be rebored when they have lost their original diameter of hole, but metal dies are brought down to size again by hammering up the hole and then drifting it out to correct diameter with a punch."


Production

Wire is often reduced to the desired diameter and properties by repeated drawing through progressively smaller dies, or traditionally holes in draw plates. After a number of passes the wire may be annealed to facilitate more drawing or, if it is a finished product, to maximise ductility and conductivity. Electrical wires are usually covered with insulating materials, such as plastic, rubber-like polymers, or varnish. Insulating and jacketing of wires and cables is nowadays done by passing them through an extruder. Formerly, materials used for insulation included treated cloth or paper and various oil-based products. Since the mid-1960s, plastic and polymers exhibiting properties similar to rubber have predominated. Two or more wires may be wrapped concentrically, separated by insulation, to form coaxial cable. The wire or cable may be further protected with substances like paraffin, some kind of preservative compound, bitumen, lead, aluminum sheathing, or steel taping. Stranding or covering machines wind material onto wire which passes through quickly. Some of the smallest machines for cotton covering have a large drum, which grips the wire and moves it through toothed gears; the wire passes through the centre of disks mounted above a long bed, and the disks carry each a number of bobbins varying from six to twelve or more in different machines. A supply of covering material is wound on each bobbin, and the end is led on to the wire, which occupies a central position relatively to the bobbins; the latter being revolved at a suitable speed bodily with their disks, the cotton is consequently served on to the wire, winding in spiral fashion so as to overlap. If many strands are required the disks are duplicated, so that as many as sixty spools may be carried, the second set of strands being laid over the first. For heavier cables that are used for electric light and power as well as submarine cables, the machines are somewhat different in construction. The wire is still carried through a hollow shaft, but the bobbins or spools of covering material are set with their spindles at right angles to the axis of the wire, and they lie in a circular cage which rotates on rollers below. The various strands coming from the spools at various parts of the circumference of the cage all lead to a disk at the end of the hollow shaft. This disk has perforations through which each of the strands pass, thence being immediately wrapped on the cable, which slides through a bearing at this point. Toothed gears having certain definite ratios are used to cause the winding drum for the cable and the cage for the spools to rotate at suitable relative speeds which do not vary. The cages are multiplied for stranding with many tapes or strands, so that a machine may have six bobbins on one cage and twelve on the other.


Forms


Solid

Solid wire, also called solid-core or single-strand wire, consists of one piece of metal wire. Solid wire is useful for wiring breadboards. Solid wire is cheaper to manufacture than stranded wire and is used where there is little need for flexibility in the wire. Solid wire also provides mechanical ruggedness; and, because it has relatively less surface area which is exposed to attack by corrosives, protection against the environment.


Stranded

Stranded copper wire Stranded wire is composed of a number of small wires bundled or wrapped together to form a larger conductor. Stranded wire is more flexible than solid wire of the same total cross-sectional area. Stranded wire is used when higher resistance to metal fatigue is required. Such situations include connections between circuit boards in multi-printed-circuit-board devices, where the rigidity of solid wire would produce too much stress as a result of movement during assembly or servicing; A.C. line cords for appliances; musical instrument cables; computer mouse cables; welding electrode cables; control cables connecting moving machine parts; mining machine cables; trailing machine cables; and numerous others. At high frequencies, current travels near the surface of the wire because of the '' skin effect'', resulting in increased power loss in the wire. Stranded wire might seem to reduce this effect, since the total surface area of the strands is greater than the surface area of the equivalent solid wire, but ordinary stranded wire does not reduce the skin effect because all the strands are short-circuited together and behave as a single conductor. A stranded wire will have higher resistance than a solid wire of the same diameter because the cross-section of the stranded wire is not all copper; there are unavoidable gaps between the strands (this is the circle packing problem for circles within a circle). A stranded wire with the same cross-section of conductor as a solid wire is said to have the same equivalent gauge and is always a larger diameter. However, for many high-frequency applications, ''
proximity effect Proximity effect may refer to: * Proximity effect (atomic physics) * Proximity effect (audio), an increase in bass or low frequency response when a sound source is close to a microphone * ''Proximity Effect'' (comics), a comic book series written by ...
'' is more severe than skin effect, and in some limited cases, simple stranded wire can reduce proximity effect. For better performance at high frequencies, litz wire, which has the individual strands insulated and twisted in special patterns, may be used. The more individual wire strands in a wire bundle, the more flexible, kink-resistant, break-resistant, and stronger the wire becomes. However, more strands increases manufacturing complexity and cost. For geometrical reasons, the lowest number of strands usually seen is 7: one in the middle, with 6 surrounding it in close contact. The next level up is 19, which is another layer of 12 strands on top of the 7. After that the number varies, but 37 and 49 are common, then in the 70 to 100 range (the number is no longer exact). Larger numbers than that are typically found only in very large cables. For application where the wire moves, 19 is the lowest that should be used (7 should only be used in applications where the wire is placed and then does not move), and 49 is much better. For applications with constant repeated movement, such as assembly robots and headphone wires, 70 to 100 is mandatory . For applications that need even more flexibility, even more strands are used (welding cables are the usual example, but also any application that needs to move wire in tight areas). One example is a 2/0 wire made from 5,292 strands of No. 36 gauge wire. The strands are organized by first creating a bundle of 7 strands. Then 7 of these bundles are put together into super bundles. Finally 108 super bundles are used to make the final cable. Each group of wires is wound in a helix so that when the wire is flexed, the part of a bundle that is stretched moves around the helix to a part that is compressed to allow the wire to have less stress. Prefused wire is stranded wire made up of strands that are heavily tinned, then fused together. Prefused wire has many of the properties of solid wire, except it is less likely to break.


Braided

A braided wire consists of a number of small strands of wire braided together. Braided wires do not break easily when flexed. Braided wires are often suitable as an electromagnetic shield in noise-reduction cables.


Uses

Wire has many uses. It forms the raw material of many important manufacturers, such as the wire netting industry, engineered springs, wire-cloth making and wire rope spinning, in which it occupies a place analogous to a textile fiber. Wire-cloth of all degrees of strength and fineness of mesh is used for sifting and screening machinery, for draining paper pulp, for window screens, and for many other purposes. Vast quantities of
aluminium Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. It ha ...
, copper, nickel and
steel Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistan ...
wire are employed for telephone and data cables, and as conductors in electric power transmission, and heating. It is in no less demand for fencing, and much is consumed in the construction of suspension bridges, and cages, etc. In the manufacture of stringed musical instruments and scientific instruments, wire is again largely used. Carbon and stainless spring steel wire have significant applications in engineered springs for critical automotive or industrial manufactured parts/components. Pin and hairpin making; the needle and fish-hook industries; nail, peg, and rivet making; and carding machinery consume large amounts of wire as feedstock. Not all metals and metallic alloys possess the physical properties necessary to make useful wire. The metals must in the first place be ductile and strong in tension, the quality on which the utility of wire principally depends. The principal metals suitable for wire, possessing almost equal ductility, are platinum,
silver Silver is a chemical element with the symbol Ag (from the Latin ', derived from the Proto-Indo-European ''h₂erǵ'': "shiny" or "white") and atomic number 47. A soft, white, lustrous transition metal, it exhibits the highest electrical ...
,
iron Iron () is a chemical element with symbol Fe (from la, ferrum) and atomic number 26. It is a metal that belongs to the first transition series and group 8 of the periodic table. It is, by mass, the most common element on Earth, right in ...
, copper, aluminium, and
gold Gold is a chemical element with the symbol Au (from la, aurum) and atomic number 79. This makes it one of the higher atomic number elements that occur naturally. It is a bright, slightly orange-yellow, dense, soft, malleable, and ductile ...
; and it is only from these and certain of their alloys with other metals, principally brass and bronze, that wire is prepared. By careful treatment, extremely thin wire can be produced. Special purpose wire is however made from other metals (e.g. tungsten wire for light bulb and
vacuum tube A vacuum tube, electron tube, valve (British usage), or tube (North America), is a device that controls electric current flow in a high vacuum between electrodes to which an electric potential difference has been applied. The type known as ...
filaments, because of its high melting temperature). Copper wires are also plated with other metals, such as tin, nickel, and silver to handle different temperatures, provide lubrication, and provide easier stripping of rubber insulation from copper. Metallic wires are often used for the lower-pitched sound-producing "strings" in stringed instruments, such as
violin The violin, sometimes known as a '' fiddle'', is a wooden chordophone ( string instrument) in the violin family. Most violins have a hollow wooden body. It is the smallest and thus highest-pitched instrument ( soprano) in the family in regu ...
s,
cello The cello ( ; plural ''celli'' or ''cellos'') or violoncello ( ; ) is a bowed (sometimes plucked and occasionally hit) string instrument of the violin family. Its four strings are usually tuned in perfect fifths: from low to high, C2, G2, ...
s, and
guitar The guitar is a fretted musical instrument that typically has six strings. It is usually held flat against the player's body and played by strumming or plucking the strings with the dominant hand, while simultaneously pressing selected string ...
s, and percussive string instruments such as
piano The piano is a stringed keyboard instrument in which the strings are struck by wooden hammers that are coated with a softer material (modern hammers are covered with dense wool felt; some early pianos used leather). It is played using a keyboa ...
s, dulcimers, dobros, and cimbaloms. To increase the mass per unit length (and thus lower the pitch of the sound even further), the main wire may sometimes be helically wrapped with another, finer strand of wire. Such musical strings are said to be "overspun"; the added wire may be circular in cross-section ("round-wound"), or flattened before winding ("flat-wound"). Examples include: * ''Hook-up wire'' is small-to-medium gauge, solid or stranded, insulated wire, used for making internal connections inside electrical or electronic devices. It is often tin-plated to improve solderability. * '' Wire bonding'' is the application of microscopic wires for making electrical connections inside semiconductor components and integrated circuits. * ''Magnet wire'' is solid wire, usually copper, which, to allow closer winding when making electromagnetic coils, is insulated only with varnish, rather than the thicker plastic or other insulation commonly used on electrical wire. It is used for the winding of motors,
transformer A transformer is a passive component that transfers electrical energy from one electrical circuit to another circuit, or multiple circuits. A varying current in any coil of the transformer produces a varying magnetic flux in the transformer' ...
s, inductors, generators,
speaker Speaker may refer to: Society and politics * Speaker (politics), the presiding officer in a legislative assembly * Public speaker, one who gives a speech or lecture * A person producing speech: the producer of a given utterance, especially: ** In ...
coils, ''etc.'' (''For further information about copper magnet wire, see: Copper wire and cable#Magnet wire (Winding wire).''). * '' Coaxial cable'' is a cable consisting of an inner conductor, surrounded by a tubular insulating layer typically made from a flexible material with a high dielectric constant, all of which is then surrounded by another conductive layer (typically of fine woven wire for flexibility, or of a thin metallic foil), and then finally covered again with a thin insulating layer on the outside. The term coaxial comes from the inner conductor and the outer shield sharing the same geometric axis. Coaxial cables are often used as a transmission line for radio frequency signals. In a hypothetical ideal coaxial cable, the electromagnetic field carrying the signal exists only in the space between the inner and outer conductors. Practical cables achieve this objective to a high degree. A coaxial cable provides extra protection of signals from external electromagnetic interference and effectively guides signals with low emission along the length of the cable which in turn affects thermal heat inside the conductivity of the wire. * ''Speaker wire'' is used to make a low-resistance electrical connection between loudspeakers and audio amplifiers. Some high-end modern speaker wire consists of multiple electrical conductors individually insulated by plastic, similar to Litz wire. * '' Resistance wire'' is wire with higher than normal resistivity, often used for heating elements or for making wire-wound resistors. Nichrome wire is the most common type.


See also

* High-voltage cable * Barbed wire * Chicken wire * Razor wire * Tinsel wire * Wollaston wire


References


External links

* {{Authority control Wire Hardware (mechanical)