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The Book of Terms

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The Book of TermsThe WJI Book of Wire & Cable Terms: an interactive experience of learning and sharing
This book, written by industry volunteers and containing more than 5,000 entries, is an asset for newcomers to wire and cable.

At the same time, it also represents an opportunity for industry veterans to give back by either updating or adding to the more than 5,000 entries. This is an honor system process. Entries/updates must be non-commercial, and any deemed not to be so will be removed. Share your expertise as part of this legacy project to help those who will follow. Purchase a printed copy here.

   

 

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Weight Correction Factor

The correction factor necessitated by uneven geometric forces placed on cables in conduits. This is used in computing pulling tensions and sidewall loads.

Weight Per Unit Length

See Length, Weight Per Unit.

Weight Percentage of Plating

See Plating, Weight Percentage.

Wein Bridge

See Bridge.

Weld

The joining of materials by fusion or recrystallization across the interface of those materials using heat or pressure or both, with or without filler material.

Weld Breaks

Breaks in wires that are due to failure of the butt weld that spliced the trailing end of one wire to the leading end of another wire to maintain a continuous process. A break for this reason appears as a 90 degree or as a “fish-mouth. This is usually a result of a poor welding technique or faulty equipment. Such breaks often occur in the first few die reductions on a wiredrawing machine.

Weld Flash

Debris and excess material from welding sparks fusing around the weld during welding operation. In wire butt-welding, the flash must be removed before the wire is sent to the next operation.

Welding

1) A process that joins metals by the application of a flame or an electric current to heat and fuse the metal edges to be joined using the material from a welding wire or rod to complete the joint. 2) A process using pressure and/or current to heat and fuse the edges of the pieces to be welded without the use of any other material, as in spot or butt welding.

Welding Cable

Very flexible cable used for leads to the rod holders or arc-welders.

Welding of Metal Wires

The welding process to join metal wires must be done carefully to suit the characteristics of each metal to be joined. Some of those aspects are noted in the following listings.

Welding of Metal Wires, Brass

Brass wire has similar welding characteristics to light alloys, due to its good conductivity and low specific electrical resistance, although this varies considerably with the specification of the brass. From a resistance welding point of view, the harder the brass, the easier it is to weld.

Welding of Metal Wires, Galvanized

Welding of Metal Wires, Galvanized.

Welding of Metal Wires, Light Alloy

In fabricating articles from light alloy wire, the timing control must be of the fully synchronous electronic type, fitted with step less phase shift heat regulation with the possible addition of “slope” control. Welding currents for light alloys are necessarily high due to the high heat conductivity and low electrical resistance of this range.

Welding of Metal Wires, Medium-Carbon Steel

A spot or projection weld in a steel having a carbon content of 0.20 percent or a low-alloy steel will tend to be crystalline in structure and consequently brittle if it has not been sub­jected to some form of post-heating to nor­malize the heat affected zone.

Welding of Metal Wires, Stainless Steel

Very precise weld timing apparatus must be employed in fabricating articles from stainless steel wire, as the weld setting is most critical.

Welding Rod

1) Rod (rolled, extruded, or cast) produced for use in joining metals by welding. 2) Rod that is manufactured to special requirements as to chemical composition and surface cleanliness for use in joining metals by welding.

Welding Wire

Material that has been manufactured to special requirements as to chemical composition and surface cleanliness for use in joining metals by welding.

Welding, Butt

Two rods or wires joined end-to-end, particularly to allow for the continuous drawing of coils of wire. Typically, the tail end of a rod or wire coil in process is welded to the lead end of a new coil so production can continue without interruption. Butt-welding is performed with either electric resistance welding machines or cold pressure welding machines. A butt weld can be made in most ferrous and nonferrous wire materials.

Welding, Cold

A welding process which uses high pressure and plastic deformation to produce metallurgical bonds. The process works at room temperature and does not require electrical or other auxiliary heat. The materials to be welded must have sufficient ductility to permit the required plastic deformation, and must not work harden easily.

Welding, Cross Wire

Welding where a point contact is provided by the natural incidence of the two wires, and consequently a localized area offers high resistance to the flow of welding current. This type of joint, therefore, is projection welding. The interfaces rapidly reach welding heat, and, mechanical pressure is available to forge the joint into a homogeneous weld with a strength factor comparable to the parent material.
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