Millennium Steel & Wire has commercialized a process of cleaning, heat treating, galvanizing, coating and cooling the steel faster than any existing current technology employed in the industry. Our company utilizes this unique modern technology to produce coated wire of superior quality that is completely uniform in diameter without welds, burrs or Lumps of zinc. This process is environment friendly and does not require the use of any gas, hazardous vapors, acid, flux or waste water treatment.

The skillful integration of continuous rod pay-off, blast cleaning ,induction heating, MHD galvanizing, quenching, wire drawing and coiling or spooling , all managed by touch screen PC, provides a truly efficient continuous process for a galvanized wire manufacturer.

Wire coating using MS ZincAl process offers the following advantages over traditional coatings:

Superior corrosion protection
MHD Galvanized or MS ZincAl coated wire provides a higher degree of corrosion resistance. The zinc coating on wire coated using the traditional hot-dip process is composed of a brittle and hard ZnFe alloy layer at the steel interface and a free zinc layer on top of it; a MHD coating exhibits a variable composition over the depth of the layer, thereby resulting in more pure zinc per gram of coating.

Minimal Gamma Layer
MHD coated wire produced by “Millennium Steel” has an extremely thin Gamma phase, which is the brittle layer of material found beneath conventional zinc coatings. The fact that the Gamma layer is virtually non-existent on our wire is especially important for manufacturers of formed wire products as no cracking will occur at the zinc/metal interface during the process.

Self healing properties
MHD coatings have superior galvanic protection and “self curing” properties which provide significantly better protection to damaged or injured parts. This makes MHD galvanized wire ideal for use in the manufacture of collated nails as the corrosion protection is maintained (unlike hot-dipped galvanized zinc coatings) in the nail head and nail point areas.

Improved formability
The molecular structure of the MHD Galvanized or MS ZincAl coated wire provides better formability when compared to classical zinc coated wire. The crystals have a lemellar structure (parallel to the axis of the wire) compared to a dendrite structure (perpendicular to the axis of the wire).

Uniform finish
All of the wire produced using the MHD process is drawn from galvanized rod. This process provides the most uniform diameter and consistent finish available to the industry. This is of particular importance to manufacturers of wire products that use equipment requiring the wire to travel through dies and tools. Conventional manufacturers first draw the rod down to wire and then hot-dip galvanize resulting in inconsistent diameters and zinc weights, burs and welds. Non-uniform wire traveling through dies and tools results in multiple stoppages, breaks, shattered dies and zinc burs.

Consistent Quality / Higher Productivity
The coating on the wire is very smooth and consistent and this helps in longer tool life on the nail making and nail collating machines. This feature also results in higher production outputs on the collating machines and greatly reduces scrap generation.