Making steel rod consists of using an electro arc furnace which uses a batch melting process. This produces batches of molten steel known as heats. The first step is to prepare buckets of scrap according to the needs of making C1006 rod. These are added to a charged furnace to insure there is a proper melt-in chemistry. The scrap must be layered in the bucket according to size and density to help with the formation of a liquid pool of steel. Once the liquid is at temperature it is poured into continuous casting billets. These billets are allowed to solidify and then are brought to a rolling mill. They are reduced to a rod the size of a pencil and then wound into large coils. This rod is now ready for the wire mill.
Starting next week WCJ Pilgrim Wire will start a series of blogs focused solely on the the making of Stitching Wire. This will take you from the steel rod stage of production all the way to the finished good.
WCJ Pilgrim Wire does not use lead in the production of making stitching wire at any stage!!! We are CPSIA compliant and are currently working with the CPSC to get our wire exempt from testing requirements. Some wire manufacturers still use a lead bath process for making their wire. This process uses the lead itself in the cooling before galvanizing. We use an air method that doesn't not use lead. It is very interesting to find out who the mills are that are still using the lead bath process. Make sure you know that your wire is CPSIA compliant. Make sure to ask for there certification.