How is copper wire is made?

Wire is generally made by pulling a rod through progressively smaller dies until it reaches the correct diameter. This work hardens the alloy and can make it too hard and stiff to use. Most wire is annealed after drawing to soften it and make it more usable. Annealing is done at a temperature of around 70 - 80% of the melting temperature on a scale that starts at absolute zero (-273.15 degrees Celsius or 0 Kelvin). Annealing allows the atoms to rearrange themselves into a lower energy state. For a work hardened material the dislocations can sort themselves out and even disappear as new, much more perfect crystals arise. Copper work hardens so much that it is normally annealed one or more times between drawing steps. For electrical wire it is generally drawn to final size after the last annealing - this gives a smooth, shiny surface and a wire that has some stiffness, but not too much.

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