Metal Wrap
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Metal Wrap
Modern Wire Wrapping Applications and Available Tools
Developed by Bell Laboratories in the 1950s, this technique involved wrapping a wire tightly around a terminal with two sharp edges (square cross-sectional area) which could form a consistent gas-tight electrical connection without soldering. With advancements in the electronic, telecommunication and aviation industries they also demanded more reliable and inexpensive means for solderless connections. Their problem was resolved perfectly by the technique now called "Wire Wrapping". Wire wrapping is now a common method to connect signal and power terminals in today's advanced industries.
It has been used in telephone exchanges, PCB Test Fixtures, Backplane Testers, control consoles, radios, radar, sonar, , and other complex pieces of equipment that are needed in small volumes.
Mechanical & Electrical Stability : Solderless wrapped connections have excellent mechanical and electrical stability due to their gas-tight contact area. They remain stable through exposure to severe temperature changes, humidity, corrosive atmospheres and vibration. The high shearing force of the wire at the corner of the terminal and high contact pressure remove surface contamination from the wire and the terminal, producing an intimate, clean oxidation free, metal-to-metal contact with large contact area. Initial pressure at the centre of the contact area may go as high as 100,000 psi. after the wrapping is complete cold flow causes pressure to drop to approx 30,000 psi at which point the metal stabilizes and the pressure remains constant. By bending the wire around the sharp corner of the terminal, the oxide layer on both wire and terminal is crushed or sheared, and a clean oxide-free, metal to metal contact is obtained.
Easy Removal: Although wire-wrapped connections are quick and permanent with superior mechanical and electrical qualities, they may be easily removed if necessary without damage to the terminal. To remove the connection, an unwrapping tool is placed over the terminal, engaging the first turn of the connection. Rotation of the tool removes the connection in seconds.
Types of Wraps: There are two types of wraps:
Standard Wrap – Only the bare wire is wrapped around the terminal
Modified Wrap – The first one and half to two turns (wraps) are made with the insulation wrapped around the terminal. These turns are in addition to the recommended turns (wraps) of bare wire. This wrapping process increases the ability of the connection to withstand vibration and reduced wire breakage.
For more information please log onto our site http://www.tycoproducts.co.uk and see the tools we can offer like Manual, Electric, Battery-Operated or Pneumatic wire wrap guns along with the wrapping bits and sleeves.
About the Author
Tyco Products Limited is the UK based partner of Jonard Industries Corp is a World Class Manufacturer of Precision Hand Tools for the Telecom, Fiber Optic, wire wrapping tools, Jonard wire wrap guns, CATV, Wireless, and Electronic Industries. We are proud of our reputation, technical skills, dedication and our ability to meet the ever-increasing demands of our customers. Tyco Products Ltd is based in Reading England UK and is a reputable and reliable source for the above products.
How would I make realistic looking feathers out of metal? (any type of metal)?
I am doing a project for my art class and I am looking to make an Indian headdress (more specifically a War Bonnet) completely out of metal. I am having a little bit of trouble thinking of how I could make the feathers in a way that would be simple and look decently realistic. i was thinking short metal wire cut and wrapped individually over a coat hanger, but i was looking for other suggestions as well! thanks 
You need to look more at real feathers such as are used in headdresses. Wing feathers are not individual wire like things - they are linked by tiny hooks to form a nearly smooth edged sheet to move air. Feathers can be made from thin metal by embossing http://www.google.com/images?hl=en&q=embossing+metal&rlz=1B3GGGL_enUS366US366&um=1&ie=UTF-8&source=og&sa=N&tab=wi&biw=779&bih=536 the rib up the center then scribing the lines of the barbs out to the edge. If it suits you, in a few places you can cut in from the edge to provide some detail.
Thin metal - heavier than aluminum foil - is available at hardware and hobby craft stores. K&S Engineering includes it in their larger metal shapes displays. Flashing sold in hardware stores, particularly aluminum flashing thin.
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