Trolley Wire and Its Manufacturing Process

We all have seen those copper wires, which provide electricity to the metro railways, which are enclosed with a thick insulator covering. These wires in general sense is also called as copper trolley wires. These types of wires are mostly used in transit, generally in urban areas. The main areas of application of these wires are, railroads, light rail transits etc. But these types of wires are widely used in the mining sector where, motor cars and the cranes which go under, have these types of wirings to provide electricity. Now, in this article we will talk about the manufacturing process of these trolley wires, but, before going in to the details of the manufacturing process, we should know that, the manufacturing process of the trolley wires is very complex, just like cadmium copper, copper rod and other copper wires.

Now, coming into the manufacturing process of the trolley wires, the first step that every manufacturer has to follow is to, take a copper wire and then dip it in to molten copper or copper alloy, which will make a dense foliage of copper in the surface area of the wire, which as a resultant give the initial copper clad copper wire. Now, after the copper clad wire has cooled down, it is subjected to the next step and that is rolling by a caliber roll. Now, the rolling process actually goes on up till that time, when the wire has got hot again. Now, this hot wire is again dipped in to the molten copper-alloy or molten copper, and then given another coating of copper over the initial one. This is also called the second copper clad copper wire, or the final copper wire. The last step to finish the manufacturing process of trolley wires are, to hot roll the copper wire in 850 to 750 degrees Celsius, with a ratio of 40%. After this, the hot wire needs to be rolled in ice, to cool up the temperature. The reduction of area is calculating to be something around 20% by the cooling process.

After learning about the manufacturing process, it is important for you to know about the metals or the components that is required for the process. Since, trolley wires are made to be very tough, therefore they have 99.9% copper, and only 0.1% of the total composition as some other metal. The other metals can be any one of the metal from the following,

  • Chromium
  • Tin
  • Zirconium
  • Manganese
  • Magnesium
  • Tellurium
  • Cadmium

Now, you may ask, why copper wires? Why not some other metal? This is because, copper wires have a great conductivity, and also is very durable. Moreover, they are also resistant to corrosion, and hence, are also durable.

Though the above is the trademark process of manufacturing copper wires, some of the other companies also can manufacture their own copper wires, and this has been done by a top-notch mining company, who manufactured a copper wire for their own patented use, which is being marketed as to have the highest tensile strength in the market.

Advance Trolleys is Australia’s leading manufacturer of industrial trolley, and hence, has the best range of products available. Call them to know more.

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