Metallic fibers | Characteristics & Making process | Advantages & Disadvantages

Metallic fibers

Metallic fibers

Metallic fibers are made up of fibers made up of a core covered by metal, metallic alloys, plastic-coated metals, metal-coated plastics, minerals, or completely metal. Due to their origin in textile and garment applications, gold and silver fibers have been used as yarn for textile decoration since ancient times. Most recently, aluminum yarn, aluminized plastic yarn, and aluminized nylon yarn have been replaced by gold and silver. Metallic fibers are light in weight and do not tarnish. Those who use polyester film are the strongest, can be stretched enough, and are elastic and resilient. Metal fibers are usually washable, require low temperatures during ironing, and can be dry-cleaned with the most common cleaning solvents. They are resistant to attacks by insects and microorganisms.

Metallic fibers are usually combined with others for decorative effects. Such combinations are used for yarn, trimming, and ribbon knitting; in clothing such as knitwear, evening gowns, swimsuits, and neckties; And in home furnishings such as curtains, upholstery, and tablecloths. Industrial applications include automotive furnishings, theater curtains, and grills for radio and television sets.

History

Gold and silver have been used since ancient times to adorn the garments of kings, princes, nobles, and nobles. Many of these elegant textiles can be found in museums around the world. Historically, the metallic thread was made by wrapping a metal strip around a fiber core, often revealing the color of the fiber core in such a way as to improve the visual quality of the decor. Antique garments and textiles are woven from whole or part gold yarn are sometimes called gold cloth. They were woven in Byzantine weaving from the 7th to the 9th century and later in Sicily, Cyprus, Lucca, and Venice. Weaving flourished in the 12th century during the reign of Genghis Khan, while industry and commerce flourished in China and parts of the Middle East under Mongol rule. The Dobeckmum Company made the first modern metallic fiber in 1946.

Metallic fibers


Metallic fibers characteristics

I. Metallic fibers exist in different shapes and diameters. Normally, metallic fiber diameters range from 100μm to 1μm.

ii. It exists in both long, continuous fibers as well as short fibers.

iii. It has low electrical resistance compared to other fiber types, like carbon, glass, aramid, or natural fibers. For this reason, it is suitable for any application that requires electrical conductivity.

iv. It has excellent thermal resistance makes them withstand extreme temperatures.

v. It has corrosion resistance power that is achieved through the use of high-quality alloys in stainless steel or other metals.

vi. Metal fibers have other advantageous mechanical properties include high failure strain, ductility, shock resistance, fire resistance, and sound insulation.

vii. Sintered metal fiber structures and products exhibit high porous properties while being structurally strong and durable.

viii. Coated metallic filaments help to minimize tarnishing.

ix. When suitable adhesives and films are used, they are not affected by saltwater, chlorinated water in the swimming pool, or climate.

x. If possible, anything made of metal fiber should be dry-cleaned if there is no care label.

xi. Ironing can be problematic because the heat from the iron, especially at high temperatures, can melt the fibers.

xii. Good strength and hence can be used as warp or weft yarn

xiii. All metallic yarns are mothproof

xiv. Good chemical and biological resistance

Metallic fiber-making process

There are several processes are followed for making metallic fiber-

The most common technique for making metallic fiber is known as bundle drawing. Thousands of filaments are bundled together into a so-called composite wire, a tube that is pulled through the die to further reduce its diameter. The covering tube is then dissolved in acid, forming individual unbroken metal fibers. This composite wire is further stretched until the desired diameter of the individual filaments in the bundle is obtained. Bundle drawing technology allows the production of unbroken metal fiber bundles with a length of up to several kilometers. Due to the nature of the process, the cross-section of the fibers is octagonal. To achieve high-quality fibers, this technology can be fine-grained, allowing uniform, very thin fibers to spread a very narrow equivalent diameter. Special developments over the last few years have allowed this technology to be used for fiber production with diameters of 200 nm and below.

In the process of laminating, one seals a layer of aluminum between two layers of acetate or polyester film. These fibers are then cut into strips of length for the yarns and wound into bobbins. The metal can be colored and sealed in a clear film, the adhesive can be colored, or the film can be colored before laminating. There are many variations of color and effect that can be made into metallic fibers, which creates the appearance of a wide range.

With foil-shaving technology, fibers up to 14 μm in diameter and more rectangular cross-sections are possible. It forms semi-continuous bundles of fibers or staple fibers.

Types of metallic fiber products

i. Sintered media

Metallic fibers are converted into fiber media as a non-woven fleece or sintered structure consisting of fibers ranging in diameter from 1.5 to 80 μm. These perforated metal fiber media have been used for their uniqueness in highly demanding applications. The advantage of having an outstanding accessible material combination combined with high corrosion and temperature resistance is extremely valuable.

ii. Short fibers

A specially designed process allows the production of individual powder-like metallic fibers known as short fibers with a length over the diameter of 100.

iii. Polymer pellets

Other metallic fiber products are grains made from polymer pellets or metal fibers. Several bundles of fibers are glued together with different sizes and a sufficiently consistent extrusion coating is applied. After these coated bundles are cut into pellets, they can be used as additives in injection molding and extrusion to make engineered conductive/protective plastic pieces.

iv. Non-wovens

Non-woven or felt can be made with metal fibers just like traditional textile fibers. In a very limited number of cases, needle punching can be applied to block the fibers and make them feel needle-punched.

v. Yarns

A bundle of endless stainless steel fibers can be converted into yarn through the textile spinning process. There are two forms of yarn: one is low in fiber and the other is high in fiber. The previous one with a number of about 275 filaments can be converted into filament yarn by adding a twist to the bundle. Bundles with several thousand fibers are usually used to convert fibers into twisted yarns. This can be done through stretch breaking and subsequent traditional yarn-spinning technology.

Metallic fiber application

i. Metallic fiber sintered sheets are used for diesel and gasoline particulate filtration and crankcase ventilation filters. Heat-resistant textile materials are made from metal fibers for automotive glass bending processes. These metallic fiber fabrics protect the glass from high temperatures and high pressures during the bending process.

ii. These fiber filters are used for the filtration of hydraulic fluids in aircraft hydraulic systems.

iii. It can act as an antistatic fiber for textiles, which, among others, can be used in electrical protective clothing or antistatic large bags.

iv. Stainless steel metallic fiber textiles can be heated by applying electric current and can also be used for cut-resistant garments.

v. These filters are used, among others, as a protective measure to prevent the final release of radioactive steam into nuclear power plants.

vi. These fiber filters are used to refine marine fuel and lube oil.

vii. These fibers are used in communication lines such as phone lines and cable television lines.

viii. Other uses of metal fiber include tire cords, missile nose cones, work clothing such as protective suits, space suits, and cut-resistant gloves for butchers and other people working near blades.

ix. These fibers are also used in carpets.

Metallic fiber advantages

i. Metallic fibers typically have a higher melting point and are less likely to degrade under elevated temperatures.

ii. Its grades tend to be stronger, harder, and more durable than its plastic counterparts.

iii. It can be fabricated through a wider range of processes, including casting, deep drawing, welding, forging, soldering, and chipping.

iv. It is usually a cost-efficient option, particularly in high-volume or long-term production runs.

Metallic fiber disadvantages

i. Metallic fiber fabrication requires post-fabrication processes, such as finishing, painting, and deburring, which can be time-consuming or expensive.

ii. The viscosity and molten flow behavior of some metals are not suitable for creating extremely complex geometries or shapes.

iii. Metal fiber tooling costs are usually more expensive than plastic fabrication tooling.

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