Exploring of Brush Wire | Best Use Applications

What exactly is brush wire? Brush wire is in high demand for superior twisted-in-wire brushes. Twisted-in-wire brushes are also known as twisted brushes, tube brushes, bottle brushes, pipe brushes, spiral brushes, and power cleaning brushes. If you couldn’t tell by the countless names, there are countless uses for wire brushes. Brush wire is most commonly used in cleaning applications, as a way to knock off dust, dirt, rust, or other debris from a surface. 

a brush wire stem from brookfield wire company

These brushes can be used manually by simply turning them by hand, or they can be inserted into power tools for use at a higher speed. Below are some specific use cases for brush wire: 

  • Cleaning the internal portion of tubes, pipes, and cylinders
  • Cleaning medical equipment and devices
  • The removal of gases during vacuum distillation
  • Cleaning hydraulic nozzles and fittings
  • Plastics manufacturing
  • Slug removal
  • And much more

Brush Wire Design Choice

From stem, to bristle type, to bristle count, there are a lot of ways a wire brush can be customized to suit the needs of the customer. There are dozens of types of wire brushes, each made differently according to its purpose. As a general rule, wire brushes are made by inserting bristle material between the stem wires. Afterward, the stem wires are tightly twisted to secure the filament.

Four main considerations must be taken into account when designing a superior brush. Among them are stem design, materials, lengths, and diameters.

The specification you choose depends on the flexibility, stiffness, and corrosion resistance you need. In addition to all those design aspects, the style of bristle crimping can also be considered. There are three types of bristle crimping: gear, pin, and straight hank. During abrasive cleaning, crimping, or waved, bristles extend the life of the brush. Straight bristles, on the other hand, are softer and more flexible.

Types of Wire Brush Stems

While there are many stem designs, three main designs are more prominent than the others:

  • Single-Spiral Single-Stem: Single layer of filament between two stem wires.
  • Single-Spiral Double-Stem: A filament between four stem wires with two stem wires on each side. This results in a stronger base and a higher filament density.
  • Double-Spiral Double-Stem: Two layers of the chosen fill bristles twisted between four stem wires. Perpendicular layers with a single stem wire in each quadrant result in the strongest and highest density brush.

Types of Brush Fills

The make-up of the brush bristles and fills is perhaps the single most influential factor in determining what purpose your brush wire will fulfill. There are several options available, including aluminum, copper, phosphor bronze, brass, nickel, and silver.

  • Brass Wire Brushes: Brass offers a delicate brushing action that is rust and spark resistant.
  • Phosphor Bronze Wire Brushes: It is similar to brass but retains its shape better.
  • Carbon Steel Wire Brushes: Suitable for dry environments where abrasion is required. Carbon is used for deep cutting when aggressive abrasion is needed.
  • Stainless Steel Wire Brushes: Rust-proof, durable, and ideal for applications that involve stainless steel and aluminum. Another benefit? It won’t leave ferrous deposits behind.
  • Oil Tempered Wire (Flat Wire) Brushes: The most aggressive brushing material is flat wire.

Finding Good Brush Wire

Find a manufacturer you can trust. A great brush will make all the difference in your cleaning and treatment applications.