What is the difference between wire mesh and welded mesh?

Upon searching "What is the difference between wire mesh and welded mesh?" on Google, it reveals that both woven wire mesh and welded wire mesh are widely utilized materials in various industries, each with distinct characteristics and applications that affect their performance and cost-effectiveness.

In industries such as plastic extrusion, pharmaceuticals, roadways, and high-rise construction, the proper use of mesh plays a crucial role in project success. With numerous mesh options to choose from, including woven and welded varieties, it falls upon engineers and project managers to determine the best fit for their specific needs. The questions to consider include the intended use of the mesh, materials to be processed, and time constraints.

This article will clarify what is meant by welded mesh and woven wire mesh, detail their manufacturing processes, and discuss their applications and relative costs. By the end, you will better understand which type of mesh is more suitable for your requirements.

Understanding Woven Wire Mesh

Woven wire mesh is created by interlacing a set number of metal wires according to a specific pattern to produce sheets or rolls of wire cloth. Key customizable parameters include wire diameter, aperture size, micron rating, weave pattern, as well as width and length.

Manufacturing Process of Wire Mesh

The production of woven wire mesh involves wrapping a predetermined amount of wires around a beam that fits into a specialized loom. The warp wires are separated into multiple sets within heddle frames depending on the desired weave pattern. As the loom operates, a wire called the shute wire is threaded through the traversing warp wires, locking it into place through the loom's up and down motion.

Applications of Woven Wire Mesh

One significant benefit of woven wire mesh is its finer openings, which makes it ideal for filtration, particle analysis, or screen printing applications. The smaller diameter of the wires used in woven mesh allows for the creation of tighter openings than what can typically be achieved with welded mesh.

What Is Welded Wire Mesh?

Welded wire mesh consists of steel wires that are permanently bonded at their intersections using various welding techniques, such as TIG and spot welding. This method creates a mesh where the size of openings remains constant.

Manufacturing Process of Welded Wire Mesh

The manufacturing process for welded wire mesh begins with spools of wire, which are fed into a welding machine. These wires are straightened and cut to meet specific width requirements. The mesh is formed by laying these cut wires across the long wires fed from the spools and applying a weld at each intersection. Depending on the desired end product, welded wire mesh can either be rolled or cut into specific sizes for various applications.

Applications of Welded Wire Mesh

Welded wire mesh is known for its strength and rigidity due to the use of thicker wires necessary for the welding process. This makes it particularly well-suited for perimeter fencing, protective cages for animals and machinery, as well as concrete reinforcement applications.

Cost Comparison: Woven vs. Welded Wire Mesh

The production processes for woven and welded wire mesh greatly differ. While woven wire mesh primarily relies on automated machinery, producing welded mesh requires more manual labor, thereby raising costs. Thus, the material utilized and the labor intensity plays a crucial role in the overall expenses, with welded mesh generally being more costly than woven mesh.

Which Mesh Option Is Right for Your Needs?

Choosing between welded mesh and woven wire mesh largely depends on the intended application. If you require a robust and durable solution, particularly in harsh or corrosive environments, welded wire mesh could be the appropriate choice. Conversely, for applications needing small mesh openings or a more cost-effective solution, woven wire mesh—often made from stainless steel and available with shorter lead times—might meet your needs better.

Implementing the Right Wire Mesh Specification

Woven and welded wire mesh might appear similar, yet they have different production processes and applications. Knowing the right specifications is just as essential as selecting the right type of mesh. Woven wire mesh is ideal for filtration and screening tasks, while welded wire mesh excels in applications requiring robust structural integrity.

With over 140 years of experience working with woven wire mesh, W.S. Tyler is well-positioned to assist you in identifying the optimal mesh solution for your materials. For further insights, review our article on How to Pick the Right Woven Wire Mesh (Mesh Count, Wire Diameter, and Micron Rating).