Polymet’s wire manufacturing processes allow for the production of the highest quality products in the industry. Our unique processing capabilities paired with our extensive R&D resources allow for us to work closely with our customers to develop wire to meet your exact needs.

Research and Development

Since our inception in 1967, research and development has been an ongoing function of the Polymet business. We were founded on a proprietary manufacturing process that included extensive research, exploration, and testing. Now, we are not only an industry leader of high quality wire products, but we also provide our customers with technical expertise and research driven solutions for their projects and applications.

The metallurgical staff and engineers at Polymet believe R&D is vital in providing customers with the quality materials and services they need. From our patented hot extruded manufacturing process, to custom alloy development projects, the material engineers at Polymet are continually involved in the advancement of Polymet products. Our ability to use an array of different and unique engineering procedures enables us to provide additional solutions and improvements to our product lines.

Polymet strives to be a continuing leader of advanced metallurgical materials. As the hardfacing, welding, and thermal spray industries evolve, we are committed to staying current in all facets of our business.

Rolled & Drawn Wire

Polymet utilizes both traditional methods of wire manufacturing – rolling and drawing. In both processes, alloyed rod stock as large as .250″ diameter is reduced down to as small as .020″ diameter.Rolling is a process in which metal stock is passed through a set of mechanically driven rolls. The process is deemed hot rolling if the metal stock is above its re-crystallization temperature and cold rolling if it is below its re-crystallization temperature. During hot rolling, the metal stock remains in a ductile and workable state, allowing for a greater amount of alteration. Because of high temperatures during rolling, the cooling process typically involves surface oxidation.

Cold rolling increases the yield strength of the metal stock, producing a denser, more compact end product. Also, the hardness is increased and the surface finish is smoother compared to hot rolling. Because of the change in the crystalline structure of the metal, ductility is affected and the metal stock must be annealed (heated) every so often to allow for workability.

Drawing is a process in which wire is pulled through either a single drawing die or series of dies. As the wire passes through the die(s), two things occur: the diameter decreases while the length increases. The volume remains constant. Drawing is classified as a cold working process because the wire is typically drawn at room temperature. Lubrication is frequently used during this process to extend die life as well as to maintain the integrity of the surface finish of the wire. Polymet, however, can implement lube-free techniques for an exceptionally cleaner wire.

Wire Processing

The benefit of using Polymet as your specialty alloy wire and rod supplier is our ability to offer a wide variety of wire processing services. We provide straightening, cutting, spooling, coiling, cleaning, flag tagging, color coding, and our proprietary abrading service. These services can be provided independently of each other and in any way that best fits the customers needs.

With our attention to detail and complete dedication to the product, Polymet offers a service that produces the cleanest material in the industry. Our wire undergoes a rigorous, labor-intensive cleaning process to ensure that our customers receive the material that is unsurpassed in quality. Our product packaging allows our customer to receive material to their exact specifications. For our spooled wire, Polymet stocks fiber and plastic spools, as well as wire baskets. For our large diameter industrial wire and rod products, we offer 200 lb and 500 lb drum packaging. Cut length wire can be flag tagged displaying color codes, alloy identifications, and important industry specifications.

We work closely with our customers to meet their demands and to produce the premium, high quality wire products they need. We specialize in providing material and services for the gas turbine, thermal spray, and industrial industries.

The Hot Extrusion Process

Our patented hot extruded manufacturing process produces wire products that are unsurpassed in quality. This process technology allows us to manufacture small diameter solid welding wire from alloys with very limited ductility.

Polymet’s hot extruded wire products are available in nickel and cobalt-based alloys, many of which are are held to the highest quality standard of specifications in the industry (General Electric, Pratt & Whitney, Rolls Royce, and Honeywell). Products that are produced through this manufacturing process can range from .012″ – .093″ diameter. These solid wire products are primarily used in the aerospace industry but are also used in lumber and valve applications.

Metal Cored Wire

The basic composition of metal cored wire is a tubular electrode comprised of an outer metal sheath with a core of powdered materials. The metal sheath can be cobalt, nickel, iron, or stainless steel-based. The sheath conducts the electrical current during the welding and thermal spray processes. Metal cored wire’s internal powder composition consists of both elemental and alloyed powders such as nickel, cobalt, chromium, tungsten, molybdenum, and manganese to name a few.During the manufacturing process, a metal strip enters a mill, forming the outer metallic sheath to house the powder core. Using a specialized feeding process, the powder is fed into the sheath in a precise manner. The wire is rolled into a tubular shape and then drawn to a final size, ranging from .045″ to .125″ diameter. Typical processes that use these wires include Submerged Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), and Wire Arc Spray/Thermal Spray.

Some of the advantages of using metal cored wires are that there are higher deposition rates, great sidewall fusion, reduced slag, reduced fumes and special alloys can be manufactured for specific applications. The product can be provided on spools, coils, or drums ranging from 25 to 500 pounds.

Custom Alloy Manufacturing

Polymet has the ability to offer a unique, custom alloy and/or custom wire specific to the application and/or process you require. Our rich history of research and development provides the foundation for constant investigation in delivering solutions to meet your material requirements.

If you are unsure about a precise chemical composition and need assistance in developing an alloy with desired characteristics, let us know. The Polymet team of metallurgists, engineers, and production specialists will work with you to develop the exact chemistry you need.

Our manufacturing capabilities allow us to provide custom alloys in small batches with short lead times. Materials can be manufactured in a variety of diameters. Additional wire processing and services are available too, such as spooling, straightening, cutting, cleaning, tagging, and packaging.

Contact us today to begin a consultation for your custom alloy development project.