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have been replaced by gold and silver.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 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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