Manufacturing Process of Copper Wires

Copper metal is been largely use by copper wire manufacturers for making copper wires. Even though the metal has to undergo various stages before it is converted into wire. The series of steps involve in the manufacturing process of theses special cables include a set of quality standards. The first step implies mining and crushing of metal to form copper wire. Second step involves grinding of the crushed ore in large machines that transform the metal in to powder by acting on it in cylindrical and rotating manner, after this copper is concentrated by removing the waste slag from it. The process of copper wire manufacturing includes series of steps. Initially it is worked upon to form copper rods which are later transformed into wires.

The oxide ore are been leached in weak acid solution that forms a weak copper sulfate solution. This copper laden solution is been treated in an electrolytic process tank. This process is referred to as electro winning. The next process is referred to as smelting, the recycled copper is smelted. Heat and the chemical reducing agents are used in the process for changing the oxidation state of copper metal. With the purification of copper this stage results in ninety nine percent pure copper. After smelting electrolytic refining and electro winning is done, here copper ions are electrolytically migrated from anodes to the "starter sheets". The cathodes formed are finally casted into wire rods.

Then the wire drawing process from these rods is started, the rods are been pulled through a drawing die. The narrower ends of the die forces the copper rod’s to shrink in diameter and be of longer length. This process is repeated several times by making use of progressively smaller drawing dies.

After this its time for annealing process an important part of copper wire manufacturing. Contrary to the drawing process, here heat is applied to copper metal. This process is meant for bringing the needed flexibility to the wire. The wire has to undergo electric furnace for getting back its flexibility that is been lost in the process of drawing. After annealing process the metal re-crystallized into its original structure. By electroplating process the special cables such as tinned, braided or coated wires are formed, however technically after annealing process the wire is ready to use but there are numerous kinds of wires that can be formed from the copper wires.