bulk cold heading wire from brookfield wire company

Cold Heading

Brookfield Wire manufactures cold heading wire to withstand swedging, heading, and forming with superior quality. The cold heading wire process involves molding wire into a specific shape without the need for heat. A piece of wire is struck while inserted into a die, and the force of the hit causes the metal to pour into a restricted die cavity.

Extensively found throughout the manufacturing and construction industries, the cold forming process is an ideal solution for fastener and cold heading applications including bolts, nuts, screws, fasteners, electrical contacts, rivets, nails, and more.

At Brookfield, we manufacture our heading wire with top-grade, raw materials and can draw it to size using our extensive wire drawing services. Additionally, we proudly offer DFARS-compliant materials. Quality is our standard in everything we do.

Big Savings on Bulk Cold Heading Wire

Discover how much you can save buying cold heading wire in bulk from Brookfield.

Cold Heading Benefits

Cold heading wire and cold forming have many benefits, including flexibility. Metal wire components can undergo the “one die, multiple blow” method where the part is hit multiple times while remaining in a single die. On the other hand, the metal wire components are progressively transferred from die to die.

We call this method multi-die forming. Additionally, cold forming is consistent and limits scrap. With the material flowing to fill the die cavity and dimensional tolerances defined by the tooling, there is little to no scraps leftover. The cold heading wire process delivers higher yields than other standard processes, reducing costs and increasing production.

High productivity and efficient material mean significant cost and consistency advantages. The cold heading wire process increases the native tensile strength of the materials through work hardening. This cannot be achieved by other processes that remove materials from their native shape.

Projects That Benefit From Cold Heading Wire

  • Mission-critical projects
  • High-volume requests
  • Correction of failed parts
  • High-material strength applications
  • Tight tolerances
  • Critical specifications

Top Benefits:

  • Flexibility

  • Quick Production Times

  • Reduced Waste

  • Consistency

Brookfield Wire, LLC | Wire Your Way

With over 70 years of experience, Brookfield Wire’s capabilities are extensive. We offer countless alloys, finishes, tempers, cuts, and packaging. We aim to be your provider for all wiring solutions. With quick turnaround times, competitive pricing, and global delivery, we accommodate important packaging and delivery demands.

Available Wire Packaging:

Bulk Spools, l lb. and 5 lb. Spools , Bulk Coils and 1/4 lb. Handi-Pak Coils, New England Butt, Wardwell 16 & 24 Carrier and Hacoba.

 

Commonly Asked Questions About Cold Heading

In cold heading (or cold forming) metal is formed using progressive steps to form net-shaped or nearly net-shaped components. A cold headed part has smooth continuous surfaces and enhances the grain flow of the material, which results in a stronger part.

Although most stainless steels can be cold extruded, some types are better suited to cold heading than others. UNS- S30430, 305, and 384 are the most commonly used stainless steels for cold heading.

Cold Heading Quality (CHQ) Wires are made from annealed wire rods by drawing and forming them.

Cold forming is the process of forging metals at temperatures close to room temperature, without any added heat. Cold forming involves forming metal at high pressures and speeds into tool steel or carbide dies. Hardness, yield, and tensile strengths of the metal are increased through cold working.

Wire made of stainless steel is often used for screws, rivets, bolts, and nails, as it can be formed cold to take the desired shape. Wire can be cold headed without needing to be heated in order to achieve a given shape.

Cold heading is a metal forming process that involves shaping metal at or near room temperature to create various components, such as fasteners, screws, and bolts, primarily from wire or rod stock. The “cold” in cold heading indicates that the process doesn’t require the metal to be heated to high temperatures, in contrast to hot forming methods. Cold heading is widely used in the manufacturing industry to produce a wide range of components and fasteners with precision and efficiency.

The cold heading process typically begins with a coil of metal wire or a straight rod serving as the feedstock. The material used is often steel, aluminum, brass, or other metals suitable for cold forming. The feedstock is cut into individual lengths, each of which will become a single formed part. These lengths are then sent through a cold heading machine, where they undergo the shaping process.

In the cold heading machine, the metal piece is clamped between a die and a punch. The punch exerts force on the end of the metal, causing it to flow plastically and take the shape of the die cavity. This process can encompass creating various features, including heads, threads, or intricate shapes, making it versatile for a wide range of components. After cold heading, excess metal, known as “flash,” may be produced, which is subsequently removed during a trimming step to leave the formed part with the desired shape and dimensions.

For certain fasteners like bolts and screws, thread rolling may be performed after the cold heading process to create threads on the part. Quality control measures are commonly applied to ensure that the formed parts meet the required specifications, including dimensions, tolerances, and overall quality.

Cold heading is favored in industries where high production rates, minimal material waste, precision, and enhanced mechanical properties are essential. It is commonly used in the manufacturing of fasteners, such as screws, bolts, and rivets, and finds applications in various sectors, including automotive, aerospace, construction, and consumer goods manufacturing. The process’s efficiency and ability to produce high-quality metal components make it a valuable method in the manufacturing world.

Hot heading is characterized by its operation at elevated temperatures, typically exceeding the recrystallization point of the metal being utilized. This heating process renders the metal more malleable and easier to deform, resulting in a softened state. As a result, hot heading is well-suited for materials that are challenging to shape at room temperature. The advantages of hot heading include the ability to form intricate and complex shapes with precision. It enhances the mechanical properties of the formed parts. Nevertheless, this method consumes more energy due to the need for heating and can result in higher material waste. It may also be relatively slower due to the heating and cooling cycles involved.

On the other hand, cold heading is characterized by its operation at or near room temperature, where the metal retains its original properties and hardness. In this process, the metal remains less ductile and more rigid compared to hot heading, making it particularly suitable for applications where strength and hardness are essential. The main advantages of cold heading are its efficiency, requiring less energy, and producing minimal material waste. This method is ideal for high-volume production of fasteners and simpler parts. Cold heading is generally faster than hot heading and is often used for mass production. However, it may not be the best choice for parts with intricate or complex shapes, as achieving fine details can be challenging. Additionally, the mechanical properties of cold-headed parts may not be as enhanced as those produced through hot heading.