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AUGUST 2008

WIRE JOURNAL

I N T E R N A T I O N A L w w w. w i r e n e t . o r g

Wire China preview Wire Expo wrapup

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL


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WIRE JOURNAL

®

I N T E R N A T I O N A L

Editorial . . . . . . . . . . . . . . . . 6 Calendar . . . . . . . . . . . . . . . . 8

CONTENTS

Volume 41 | Number 8 | August 2008

F EA T UR E S

Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26

Wire China 2008 preview

. . . . .38

Fastener Update . . . . . . . . . 28

Both the organizers and the exhibitors are expecting a strong turnout by attendees when this event is held September 23-26, 2008, in Shanghai, China.

WAI News . . . . . . . . . . . . . . 30

Mexico 2008 ITC preview . . . . .48

Chapter Corner . . . . . . . . . . 34 Mordica Lecture . . . . . . . . . . 74 Technical Papers . . . . . . . 82-92 Products/Media . . . . . . . . . . 93 Classified . . . . . . . . . . . . . . 99 Career Opportunities . . . . . . 99 Advertisers’ Index . . . . . . . 102

This article previews the WAI’s International Technical Conference that will be held October 20-22, 2008, in Monterrey, Mexico.

Wire Expo 2008 wrapup

. . . . . .60

This review of Wire Expo 2008 includes highlights at the event, held June 7-11 in Pittsburgh, Pennsylvania, USA, as well as comments from attendees.

TE C HNI C AL P A P ER S The Mobile Impact Tester for cold heading research at Ivaco Rolling Mills Michel Hone, icholas ickoletopoulos and Darryl Seaman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Fire refined copper rod production in a clean environment Giulio Properzi and Vladimir Djukic . . . . . . . . . . . . . 88

Cover: The WAI returns October 20-22-to Mexico, where it will hold its International technical Conference in Monterrey. The preview begins on p. 48.

AUGUST 2008 | 3


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INSIDE THIS ISSUE

CONTENTS

CEO

AND T HE LION

. . . . . .22

Prysmian Group CEO Valerio Battista draws the eyes on the lion for the traditional Chinese Lion Dance for a ceremony celebrating the start-up of the company’s new plant in Tianjin, China.

HAVE A CUSTOM SHAPED WIRE APPLICATION? Get a Custom Solution!

MO RD I C A L EC T UR E

. . . . . .74

This presentation at Wire Expo 2008 by Dr. Bhaskar Yalamanchili traces his experiences and successes in the wire and cable industry, emphasizing the value of having focused goals and following through.

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Strong trees have deep roots. That’s why you can trust Cabmach. It was born from the experience and success of Mario Frigerio, the world wide leader in the ferrous wire industry that for 110 years has been engineering and producing state-of-the-art machinery with the right formula: care, reliability, high quality. A combination already achieved by Frigeco, the non ferrous wire division of Mario Frigerio. www.mariofrigerio.it

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EDITORIAL

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WIRE JOURNAL

EDITORIAL

®

Mexico: ITC location has much to offer industry There is more than one reason for you to attend the upcoming International Technical Conference (ITC) in Monterrey, Mexico, October 20-22, 2008. The conference, sponsored by the Asociación Nacional de Transformadores de Acero A.C. (ANTAAC), the Departamento de Turismo de Nuevo León (OCVMTY), the Instituto Tecnológico de Estudios Superiores de Monterrey (ITESM) and WAI, will continue the success of two prior ITCs, (Queretaro in 2004, Mexico City in 1998), with dozens of technical papers and a memorable steel museum tour. But there is another reason to be there, and that is because Mexico may well be the place where your company should be. Many wire and cable companies today have problems selling their products because of the recession, the high price of the raw materials, the production costs like electricity and labor, freight, currency exchange and more. To compensate for these conditions, companies should turn their eyes to other countries. In this case, Mexico is the key. Companies in the U.S. and Canada can use it as the springboard to Central and South American countries, and companies there can use Mexico as the same springboard to get the big super markets of the U.S. and Canada. Europe also can turn to Mexico. The strong euro currency has made it difficult to sell outside their neighborhood and there is more interest in joint ventures with companies in America to help to introduce their material and equipment in this market to see how much of a piece of the market it can get. An article in the preview that starts on p. 48 has lots of good information about why your company should consider Mexico. The ITC is a good place to start or learn more. It will be the chain for you to meet people, colleagues, customers and suppliers, and the location is only 1.5 hours driving from the U.S. border in Laredo, Texas. So let’s go, let’s participate. The trip is more affordable compared to many parts of the world. You cannot miss it! So, make your hotel and airplane reservations and send your registration form to the WAI and enjoy the Monterrey Show.

Antonio Ayala Mexico ITC Chairman WAI First Vice President

I N T E R N A T I O N A L

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli Senior Graphic Designer | Bill Branch Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing Services | Janice E. Swindells Proofreader | Livia Jacobs Circulation Manager | Jan Valois Publications Advisory Board Antonio Ayala | J.J. Lowe, Mexico Ferruccio Bellina | TKT Group/President ACIMAF, Italy Anand Bhagwat | Wire and Cable Services, India Malcom Michael | Australasian Wire Association, Australia Don Schollin | Q-S Technologies, USA Ken Scott | UK Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA WAI Executive Committee Liaison Dane Armendariz | Henkel Corporation Technical Advisors John Drummond | Scotia Group Nate Rosebrooks | Fluid Coating Technology R. M. Shemenski | RMS Consulting, Inc.

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Single copies: $6 in the U.S.; all other countries $7. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2008 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL


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CALENDAR

CALENDAR

September 18-20, 2008: Cable & Wire 2008 Istanbul, Turkey. To be held at the CNR Expo Center, this event will present cable accessories, wiring harnesses, machines and electro-insulating materials, equipment and production machines. Contact: Mediaforce Fuarcilik Ltd. Sti., tel. 90-212-465-65-45; info@mediaforceonline. com; www.mediaforceonline.com. September 23-26, 2008: wire China Shanghai, China. wire China will be held at the Shanghai New International Exhibition Center. Contact: Messe Düsseldorf North America, tel. 001-312-781-5180; fax 001-312-781-5188; info@mdna.com; ww.mdna.com. October 15-17, 2008: Spring World 2008 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center, this event is sponsored by the Chicago Association of Spring Manufacturers (CASMI). Contact: Tom Renk, tel. 847-433-1335; info @casmi.org; www.casmi.org. October 20-22, 2008: ITC Mexico Monterrey, Mexico. To be held at the Crown Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, a plant tour and networking opportunities. November 3-5, 2008: Electrical Manufacturing Expo Orlando, Florida, USA. To be held at the Gaylord Palms Convention Center, this event is put on by the Electrical Manufacturing & Coil Winding Association. Contact: Chuck Thurman, tel. 619-435-3629; cthurman @emcwa.org, www.electricalmanufacturing.org. November 9-12, 2008: 57th IWCS™ Conference and Symposium Providence, Rhode Island, USA. The IWCS returns to the Rhode Island Convention Center. Contact: Internet www.iwcs.org; phudak@iwcs.org; tel. 001-732-389-0990. November 20-22, 2008: Wire & Cable India 2008 Mumbai, India. Contact: Cheryl Fernandes, Business Fairs, Confederation of Indian Industry, tel. 91-2224931790, ext. 470; fax 91-22-24939463; www. ciionline.org. April 25-30, 2009: Interwire 2009 Cleveland, Ohio, USA. To be held at the International Exposition Center (I-X Center), Interwire incorporates: Interwire Trade Exposition, the technical program and the WAI’s 79th Annual Convention. It addresses ferrous and nonferrous manufacturing, and electrical/data/voice segments as well as wire forming and related wire and wire products. Contact: WAI, tel. 001-203-453-2777; fax 001203-453-8384; www.wirenet.org. ■

8 | WIRE JOURNAL INTERNATIONAL

WI R E A SS O C I A T I O N IN T ER N A TI O N A L E V EN T S For more information, contact the WAI, USA. Tel. 001-203453-2777; fax 001-203-453-8384; Internet www.wirenet.org. September 11, 2008: New England Chapter’s 14th Annual Golf Tournament Paxton, Massachusetts, USA. The chapter will return to the Kettle Brook Golf Club. See p. 36. September 25, 2008: Mid-South Chapter’s 7th Seventh Annual Golf Tournament Florence, Alabama, USA. The chapter will go to a new course, part of the Robert Trent Jones Trail. October 15, 2008: Western Chapter’s 8th Annual Wild West Shootout Industry Hills, California, USA. The chapter will return to the Industry Hills Golf Club. October 20-22, 2008: ITC Mexico Monterrey, Mexico. To be held at the Crown Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, a wire museum tour and networking opportunities. See preview that begins on p. 48. October 30, 2008: Southeast Chapter’s 7th Annual Golf Tournament Conover, North Carolina, USA. The chapter will return to the Rock Barn Golf and Spa. November 11, 2008: Reconvene Providence, Rhode Island, USA. WAI will hold its second annual business meeting of the year in conjunction with the IWCS show. See p. 30. April 25-30, 2009: Interwire 2009 Cleveland, Ohio, USA. To be held at the International Exposition Center (I-X Center), Interwire incorporates: Interwire Trade Exposition, the technical program and the WAI’s 79th Annual Convention. It addresses ferrous and nonferrous manufacturing, and electrical/data/voice segments as well as wire forming and related wire and wire products. Contact: WAI, tel. 001-203-453-2777; fax 001203-453-8384; www.wirenet.org.


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INDUSTRY NEWS

INDUSTRY NEWS Bekaert to close Belgium plant as part of reorganization in Europe

Prysmian-led consortium lands major power cable contract in Qatar

Citing a continuing trend of tire manufacturers moving from Western to Central Europe, NV Bekaert SA announced that it plans a reorganization of its steel cord production in Belgium, a decision that calls for the closure of its plant in Lanklar and the transfer of production of steel cord from its plant in Waregem. A press release said that the company has informed its Belgian works councils about its plans to reorganize its steel cord activities in Belgium. The Lanklaar plant closing, it said, will affect 136 jobs. The Waregem plant produces steel cord as well as woven steel cord products, the former of which will be shifted to Aalter, the latter to Zwevegem, it said. “If Bekaert is to retain its competitiveness as a group in the long run, it is vital for the company to reorganize its steel cord production in Western Europe, which is still heavily concentrated in Belgium, a release said. “This requires a joint approach involving all the steel cord plants concerned. The difficult market conditions particularly affect the plant in Lanklaar, which is largely engaged in the production of semi-finished products for Bekaert’s tire cord manufacturing platform in Central Europe. This calls for structural measures to be taken by which management feels compelled to announce the intention to close the plant.” “We acknowledge that this will be very painful for those concerned but market conditions force us to take action now, so that we can establish a more robust basis for a sustainable future for the Bekaert group,” said Patrick De Keyzer, General Manager Steelcord Technology & Operations Europe & Turkey. Once the changes take place, Bekaert’s Aalter plant, the release said, will continue “to specialize even more in the production and development of advanced steel cord products.” The release said that recent structural changes in the steel cord market have an immediate impact on the competitiveness of Bekaert as a group. Bekaert notes, for instance, that the process whereby its customers – specifically the tire manufacturers – are transferring their production activities from Western to Central Europe appears to be continuing, it said. “Competitors in the production of steel cord also carry on building up their presence and position in Central Europe,” the release said.” Increasingly, therefore, customers are looking to locally-based suppliers who can supply them at lower cost so that they can be competitive in these growth markets. In short, Bekaert is facing sustained pressure on selling prices for steel cord products in Europe.”

A Prysmian-led consortium has been awarded an approximately US$264 million order for a power transmission system expansion project by the Qatar General Electricity & Water Corporation (KAHRAMAA), with Prysmian’s part of the contract worth around US$136 million. The project, which also involve Nexans, requires the provision of engineering, procurement, construction, installation and commissioning services for high voltage and extra-high voltage underground power cables on various circuits for a total of 131 km of 220 kV and 77 km of 132 kV cable and associated accessories, as part of the power transmission system expansion (Phase VIII) project, a press release said. The installation of the first circuits will start in 2008 and the scheduled completion date is January 2010, it said. “Together with other significant power cable projects for which we have been recently awarded, this project further confirms our strong capabilities to meet the increasing needs of developing new power grids in this strategic area,” said Fabio Romeo, Prysmian’s head of Energy Business. The release said that Qatar, situated on the Arabic Gulf with its abundant petroleum and natural gas reserves, posts double-digit growth rates and invests continuously in the country’s infrastructure. This project, it notes, will help further the Qatar Power Transmission Expansion project that is designed to reinforce the main transmission networks and to secure the power supply to industrial and domestic sectors. Prysmian has made a strong expansion in the Middle East region, with Middle East offices and facilities in Dubai and Abu Dhabi (UAE) Doha (Qatar), Manama (Bahrain) and Kuwait, the release said. It added that the company is currently involved in the construction of the submarine high voltage power connection between Saudi Arabia and Bahrain, with the GCCIA (Gulf Cooperation Council Interconnection Authority).

Mexican steel wire company plans to open Texas plant

A Mexican steel wire rope manufacturer plans to open a plant in Belton, Texas, that would produce 3,000 tons of rope, local city officials report. Cynthia Hernandez, interim director of Belton Economic Development Corp., said that High Performance Ropes of America (HPRA), which is owned by Alumoclad de Mexico, a small privately held company based in Queretaro, wants to invest $10.9 million to create a manufacturing plant in Belton that would employ 145 people. The company, she said, has offered $1.2 million to purchase a 40,000-sq-ft building on 5.1 acres.

Does your company have news that belongs here? E-mail it to the WJI at editorial@wirenet.org.

10 | WIRE JOURNAL INTERNATIONAL


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INDUSTRY NEWS

Open House celebrates new Champlain Cable facility Champlain Cable Company recently hosted more than 125 guests at an Open House celebrating the official opening of its new 80,000-sq-ft facility, located less than one mile from the Zaragosa International Bridge in El Paso, Texas. Attendees included suppliers, customers, politicians and business associates from all over North America and Europe, reported the company, which is based in Colchester, Vermont. Champlain Cable President Dick Hall explained that one reason his company made the investment in Texas was practicality. “We evaluated all expansion options and locals and chose El Paso over Vermont mostly due to logistics. Most of our suppliers and customers are in the south.”

Marking the opening of the new Champlain Cable Company (CCC) plant office are (l-r): CCC V.P. of Operations William Reichert; AIAC CEO Jack Wisniewski; AIAC Chairman Leonard Levie; Greater El Paso Chamber of Commerce’s Mark Ropella; CCC President Dick Hall; Upper Rio Grande at Work CEO Lorenzo Reyes; CCC Plant Manager Charlie Hill and El Paso Real Estate Development Company President Bob Cook. The company, whose 200,000-sq-ft Colchester plant has about 150 employees, manufactures high performance wire and cable for automotive, industrial and telecom sectors, is certified to TS-16949 and ISO-14001 and is RoHS compliant. Its specialty is creating wire and cable using its own unique irradiated cross-linked compounds. “This is an expansion and not a move,” Hall said. “Virtually all of the equipment was purchased and not moved. What this means in terms of production/new employees is that the first phase will increase our capacity by 30% to 50% and will require about 25 new hires.” Driving the expansion, Hall said, is that sales have grown threefold since Champlain Cable Company was bought by AIAC, taking the company private in 2003.

AUGUST 2008 | 11


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“We were at capacity,” Hall said. He noted that the company has made a commitment to R&D and other areas that made the record revenues possible. Further, the investment “has provided a pipeline of new products that will propel Champlain Cable Corporation to new heights over the next several years.” The building was actually occupied in February 2007, Hall said, adding that the long lead time was due to the installation of electron beam, under beam handling equipment and vault construction. “The vault alone consumed over 1,000 cubic yards of concrete,” he said. He further explained that the El Paso site was selected with future expansion in mind. “In phase two with another electron beam and associated equipment we can actually double our production there,” he said.

NEC and Sumitomo report plans to buy cable firm from Longreach Group

Japan’s NEC Corp. and Sumitomo Electric Industries plan to buy a Japanese undersea cable maker, OCC Corp., from an investment fund managed by the Longreach Group. Reuters reports that NEC, which is expecting growing demand for fiber-optic connections, plans to take about 75 percent of OCC Corp.’s holding company, with Sumitomo Electric taking the remaining 25 percent. The price was not disclosed for OCC, which it reported that Longreach bought from the state-owned turnaround fund Industrial Revitalization Corp. of Japan. NEC, which holds a 20 percent share of the global undersea cable market, hopes the acquisition will help it expand its cable sales to Tyco and Alcatel-Lucent, which each hold about a 40 percent market share, the report said.

Superior Essex to close French plant

Superior Essex reported that Essex SAS will shut down its plant in Chauny, France, according to a Securities and Exchange Commission filing on July 3. A press release said that Essex SAS employs 130 people, and that restructuring charges for the closing are estimated at $18.8 million. Superior Essex, which agreed to a $90 million buyout offer from LS Cable, had previously announced the consolidation and restructuring of its North American Magnet Wire operations. This included the closure of its facility in Vincennes, Indiana, combined with the expansion of its facilities in Franklin, Tennessee, and Torreon, Mexico.

vide carbon neutral, renewable electricity for more than 415,000 homes, equivalent to the approximate domestic demand of Suffolk, wire services reported.. The contract calls for JDR to provide more than 200 km of 33kV 3-phase power cables that will provide the essential link between the 3.6 MW turbine generators and the Gabbard and Galloper offshore substations. The cables, it said, which will include fiber optics and terminations, will be supplied during the course of 2009 and 2010 from both its facility at Littleport in Cambridgeshire and from its new deepwater quayside facility at Hartlepool Dock, it said. The cables, it noted, will weigh up to 2,200 metric tons and be be spooled directly from the factory to offshore cable laying vessels moored on the deep water quay.

China: steady growth projected for insulated wire and cable through 2011

A new report from The Freedonia Group, a U.S.-based industry research firm, projects that annual demand for insulated wire and cable in China will near $49 billion for 2011. A press release said that gains will be driven by investment in the power grid, telecom and building construction sectors as well as increased demand for products that require insulated wire and cable. Those factors and a desire by the Chinese government to continue its growth requires expanding and modernizing the country’s utilities infrastructure, including power grids and telecom networks, it said. “This is providing significant opportunities for power, electronic and fiber optic cable suppliers,” the release said. Power wire and cable is expected to remain the largest product segment and post the fastest growth through 2011, led by projects such as one that calls for China to have established a backbone network of ultra-high voltage power transmission by 2020, it said. The report said that the outlook is also good for fiber optic cable and electronic wire, once again led by increased demand for telecom, computer networking and data communication capabilities. Because of such factors, the electric utilities market for insulated wire and cable is expected to post the fastest rate of growth, it said. “Favorable gains will also accrue in electronic and electrical equipment markets, where demand is supported by an expanding communication

U.K. company wins wind farm contract U.K.-based JDR reports that it has been awarded a contract by Fluor Ltd. to supply cables for the Greater Gabbard offshore wind farm, a development that it said when completed in 2011 will be the world’s largest such project. The wind farm, under development by Airtricity, the renewable energy development division of Scottish and Southern Energy Plc (SSE), will be the first U.K. offshore wind farm to be built outside territorial waters and will pro-

12 | WIRE JOURNAL INTERNATIONAL

Insulated wire and cable demand in China. Chart courtesy of The Freedonia Group.


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The long-buried secret of reliable power delivery.

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INDUSTRY NEWS

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network and a growing electrical sector.” Other strong markets, the report said, include wire and cable in building construction, industrial equipment and transportation applications, sectors that will be bolstered by further increases in construction expenditures and industrial and transportation equipment production. For more details, contact: The Freedonia Group, Inc., tel. 440.684.9600, www.freedoniagroup.com.

SEA Wire and Cable to expand plant SEA Wire and Cable reports that it is expanding its plant in Madison, Alabama, USA, a project that calls for the company to double its building size at a cost projected to range from $3.5 million to $4 million. The company, which distributes wire and cable, has a 45,000-sq-ft facility and will be adding a 45,000-sq-ft office/warehouse that will connect with the current building, a press release said. The business employs 75 people and is likely to add 20 to 30 jobs (administrative, sales and warehouse workers) over the next year to accommodate the growth, it said. The project is expected to be completed within a year. Founded in 1970 in Madison by the late Gary Griffin, SEA Wire and Cable is owned by Dana Town, Griffin’s daughter.

IWG plans to consider ‘strategic alternatives’

International Wire Group, Inc. (IWG), announced that it has retained Jefferies & Company, Inc. as its exclusive financial advisor to assist the company in evaluating strategic alternatives, including a possible sale. IWG Board Chairman Mark K. Holdsworth said in a press release that the company, led by CEO Rodney D. Kent, has made great progress selling its insulated wire business, reducing operating costs for its core bare wire business, improving European operations, acquiring additional low-cost capacity and acquiring the High Performance Conductors, Hamilton Products and Global Wire businesses. “The company’s geographic presence, markets and products have all been successfully expanded and the balance sheet has been strengthened through significant debt reductions. We are now hiring Jefferies to help us analyze the various strategic alternatives in front of us, so that we can choose the path forward that most enhances shareholder value.” The release noted that the company “is unable to predict if this review of strategic alternatives will result in any transaction,” and added that no further announcements are expected unless the review results in a transaction. IWG’s most recent acquisition, announced in the July issue, was for the

14 | WIRE JOURNAL INTERNATIONAL


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U.S. business of Global Wire, which includes plants in Jewett City, Connecticut, and Littleton, New Hampshire. IWG manufactures wire products, including bare, silverplated, nickel-plated and tin-plated copper wire, for other wire suppliers, distributors and OEM manufacturers through 18 facilities located in the United States, Belgium, France and Italy.

Bekaert to sell its coating activities unit NV Bekaert SA announced that it plans to sell its Diamond-like Carbon (DLC) coating activities, part of its advanced coatings business segment, to Sulzer, a Swiss company founded in 1834. “Within the Bekaert Group, DLC’s growth opportunities and technological synergies have proven to be limited over time,” a press release said, noting that growth potential could best be done by “a significant player in the broader tribological thin films (TTF) market.” Bekaert’s DLC business has six production plants: in Belgium (Zulte), France (Limoges and Bons-enChablais), Germany (Herford) and the U.S. (Amherst, NY and Research Triangle Park, NC), the release said. “The potential deal with Sulzer covers all 164 people now working for Bekaert DLC.” Diamond-like carbon coatings are used to reduce wear and friction in a wide range of industrial applications such as machine parts, automotive components and molds for plastics and metals. The DLC business, the release said, accounts for less than 1% of Bekaert’s consolidated sales in 2007.

Date set for return of wire Düsseldorf in 2010

When wire Düsseldorf returns to the fairgrounds in Germany in 2010, it will be joined once again by its sister show tube but not METAV, the automation show that was part of the 2008 staging. An announcement by Messe Düsseldorf set the dates for wire 2010 and Tube 2010 as April 12-16. “The successful trade fair duo will not be held in conjunction with METAV in 2010,” it said, with no further comment. The addition of the METAV show had created some challenges in terms of hall locations and hotel space but the German fairgrounds has staged much larger shows. The announcement focused on the success of wire 2008 and noted that “the product range at wire 2010 will focus again on current technologies for wire, cable and fiberglass machines, the areas of spring manufacturing and metal forming as well as all aspects surrounding wires and cables.”

16 | WIRE JOURNAL INTERNATIONAL


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CALL FOR PAPERS The Wire Association International (WAI), Inc. invites authors to help define its 2009 technical program offerings by submitting an abstract today. Technical and practical topics welcome.

April 25-30, 2009 Cleveland, Ohio, USA

Accepted authors have the benefit of complimentary meeting registration, a year’s free membership to WAI, and a copy of the Conference Proceedings materials. Authors have access to the conference sessions, exhibit hall, and

Abstract Deadline September 2, 2008 Author Notification October 6, 2008 Paper Deadline December 1, 2008

opening reception. In addition, most participants find that the experience of presenting a paper and the exposure that follows is mutually beneficial to the author and his or her company. Whether your field of expertise is in a ferrous, nonferrous, electrical, fiber optic, or general discipline, WAI wants to hear from you. Why not share your expertise, your current research findings, and your viewpoint with your industry colleagues at Interwire 2009? Submit your abstract today! Log on instructions are on the abstract form on the reverse side.

Interwire 2009 is organized by The Wire Association International, Inc. 1570 Boston Post Road • P.O. Box 578 • Guilford, CT 06437-0578 USA Tel.: (001) 203-453-2777 • Fax: (001) 203-453-8384 • Web site: www.wirenet.org


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CALL FOR PAPERS

Abstrac ts In order for the Wire Association’s Technical Papers Committee to properly assess the scope and content of your proposed technical article, please submit a 75 word abstract, typed in English, on the form below. Authors will be notified of acceptance.

Pa p e r s An “Author’s Guide” containing detailed instructions on how to prepare the paper and oral presentation will be e-mailed to accepted speakers. Only original papers not previously published will be accepted for Wire Association International paper awards and possible publication in Wire Journal International. Only papers received by the manuscript deadline will be included in the Conference Proceedings materials. Note: If your paper is received after the deadline

Log on to submit your abstract 1. Log on to www.wirenet.org. 2. Click on the horizontal tab called “technical” on the main page. 3. Select the “Call for Papers” tab from the drop-down menu. 4. Complete and submit the abstract form.

we cannot guarantee that your presentation will be scheduled in the technical program. Please complete the following information and e-mail, mail or fax to: Marc Murray, Director of Education, The Wire Association International, Inc., 1570 Boston Post Rd., P.O. Box 578, Guilford, CT 06437-0578 USA, Tel.: (001) 203-453-2777, Fax: (001) 203-453-8384, E-mail: mmurray@wirenet.org.

This form can also be completed on the WAI website: www.wirenet.org. (See log-on instructions above). Please indicate your are of interest: I would like to present a technical paper.

Tell me about Poster Paper Forums.

Author(s): _____________________________________________________________________________________________ Contact Author

(designate only one):

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(Affiliations for each author):

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Address: ______________________________________________________________________________________________ City: _________________________

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Please type your abstract in English on this form. If you need additional space, please use a separate page.

A b s t r a c t (75 word maximum)

IW 09

The Technical Papers Committee reserves the right to screen all abstracts and reject those abstracts deemed unsuitable or inappropriate for presentation or publication. Everyone who submits an abstract will be notified whether the abstract has been accepted.

Interwire 2009 is organized by The Wire Association International, Inc. 1570 Boston Post Road • P.O. Box 578 • Guilford, CT 06437-0578 USA Tel.: (001) 203-453-2777 • Fax: (001) 203-453-8384 • Web site: www.wirenet.org


7/18/2008

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Schleuniger acquires PAWO Systems Schleuniger Group, a supplier of wire-processing equipment, reports that it has acquired PAWO Systems AG, also Swiss-based, which specializes in machines for automatic assembly of loose parts to wires, especially automatic and semi automatic installation of weather seals. With a workforce of about 100 people, PAWO’s operations include its headquarters in Unterägeri, Switzerland, and its U.S. office, PAWO Inc., El Paso, Texas, as well as a representative office in Shanghai, China, a press release said. The price was not released. PAWO also offers shuttle and conventional transfermachines used to solve complex wire processing, assembly and quality testing, it said. “The Schleuniger Group, which recently was taken over by the Metall Zug Group in the context of a solution for succession, expands its market position with regard to the automotive industry and thus continues its strategy on which it embarked four years ago,” the release said. PAWO will retain and further develop its business at the same location and with the same company name, while distribution channels that are more or less identical with the ones that Schleuniger uses, will merge, it said. Schleuniger has production sites in Switzerland and Germany as well as sales companies in Germany, U.S., Canada, Mexico, Japan, Slovakia and China, and has a presence in 40 additional countries through long-term distribution partners.

supports the needs of the OEM and sub-assemblers located principally in Northern California and the Pacific Northwest Region of the U.S.

Sterlite seeks to buy ASARCO

Sterlite Industries (India) Limited has agreed to buy Asarco LLC, a U.S.-based mining, smelting and refining company, to acquire substantially all the operating assets of

IEWC acquires Control Master Products

U.S.-based Industrial Electric Wire and Cable (IEWC) reports that it has completed its acquisition of Control Master Products (CMP), a Concord, California, stocking distributor of wire, cable and wire management products. CMP, a UL and CSA certified business, also provides value-added services such as striping, dyeing and cutting of wire and cable. “Securing the assets of an existing distributor will help to accelerate Industrial Electric’s growth initiatives on the west coast,” a press release said, noting that CMP services and

AUGUST 2008 | 19

INDUSTRY NEWS

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the latter for $2.6 billion to be financed through a mix of debt and existing cash resources. Asarco, formerly known as American Smelting and Refining Company, produced 235,000 metric tons of refined copper in 2007. The integrated assets to be acquired include three open-pit copper mines and a copper smelter in Arizona and a copper refinery, rod and cake plant and precious metals plant in Texas. A key to the agreement was that it would not include legacy liabilities for asbestos and environmental claims for ceased operations. Asarco filed for bankruptcy protection in 2005 after it was sued for $1 billion over environmental cleanup and asbestos claims. Per Wikipedia, ASARCO has 20 superfund sites across the United States, and is subject to considerable litigation over pollution. Once the deal is completed, Sterlite notes that it would become the world’s third largest copper miner, with a combined capacity of 650,000 metric tons a year. However, The Times of India reported that Grupo Mexico, the current owner, claims that Asarco is not properly valued and hopes to block the sale.

American Kuhne moves to new location U.S.-based American Kuhne, a supplier of single screw extruders, feed screws, extrusion systems and extrusion process controllers for sectors that include the wire and cable industry, reports that it has completed the relocation of its sales, engineering, manufacturing and extrusion laboratory to its new location in Ashaway, Rhode Island. The new site is located on 12 acres the company bought at Exit 1 on Route 95 in Rhode Island, just over the Connecticut state border, a press release said. “We are very excited about the operating improvements that this new facility will bring, said company President Bill Kramer. Founded in 1997, American Kuhne supplies extruders that range from .5 in. through 12-in. Contact information is: American Kuhne, Inc., 401 Main Street, Ashaway, RI 02804, tel. 401-326-6200, www.americankuhne.com

Malaysia power cable project to continue despite loss of key company

Malaysia’s government will continue its plans to build undersea power cables linking Borneo to the mainland despite news that Malaysian conglomerate Sime Darby has pulled out from the project, AP reported. Sime, which was described as the world’s largest palm oil producer, announced that it would neither accept a government offer to lay two undersea 700-km cables to transmit power to mainland Malaysia nor take a 60% stake in the 2,400-megawatt Bakun dam project, the wire story said. Sime reported that the company had been discussing the deals with the government since November, but ultimately declared in a statement that they “do not fit in with our business strategy,” it said, adding that Sime would continue its role as contractor to complete the construction of the dam. The wire story cited Malaysian Second Finance Minister

20 | WIRE JOURNAL INTERNATIONAL

Nor Mohamed Yakcop as saying that the government “would seek new contractors to continue with plans to transport electricity from the Bakun hydroelectric dam in Sarawak state on Borneo.” Borneo and mainland Malaysia, it noted, are separated by the South China Sea, a gap that at its narrowest is 450 miles (725 kilometers) wide. “It is not derailed. The project will go on,” the AP article cited Nor Mohamed as saying. There were questions about the location for the undersea cables as the area is considered an earthquake-prone region and also because electricity transported from Borneo may not be cost effective due to the high cost of laying the cables, estimated to be at least US$2.8 billion, the article said.

Niehoff extends ties with Russian body

Germany’s Niehoff GmbH announced that it has furthered its alliance with the All-Russian Scientific Research and Development Cable Institute VNIIKP with the conclusion of a cooperation agreement. The Trade House of VNIIKP will act as an adviser for Niehoff for the markets of Russia, Belarus, Armenia and Uzbekistan, a press release said, noting that these countries represent “one of the most important markets” for the equipment maker. The goal is to achieve “further contact development and intensification between Niehoff and the companies in this economic area,” it said. The focus will be on making wire and cable companies aware of the potential advantages by modernization and extension of production programs by innovative high-quality machinery offering highest efficiency, the release said. It noted that a key to the effort is close cooperation and information exchange between VNIIKP and Niehoff of Russia, which was founded in 2005 in Moscow. That branch, which has nine Russian employees, can provide customer service, installation and commissioning of machinery, spare parts supply and after sales service, it said.

Mechel OAO subsidiary chooses Ernst Koch for plant expansion

A subsidiary of Mechel OAO, a Russian mining and metals business, announced that its subsidiary, Vyartsilya Metal Products Plant ZAO, and German’s Ernst Koch GmbH have agreed to a deal that will see Koch supply and install a new straight-thru KGT 25/47 type drawing mill for the company’s Vyartsilya Metal Products Plant (VMZ). The drawing machine will produce low-carbon wire (2.07.0 mm) in coils of up to three metric tons in weight, a press release said. The system offers high productivity through technology such as an intensive refrigerating system and computerization of the quality control system, it said. The new mill, once commissioned, will enable VMZ to increase its monthly average output volume by 1.5 thousand MT, the release said. The mill startup will increase both production capacity and product quality as well as improve working conditions for the equipment operators, it said. ■


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ASIAN FOCUS

ASIAN FOCUS Prysmian has ambitious plans for its presence and growth in China Hoping to continue with the success it has found in China, Italy’s Prysmian announced that its goal is to achieve growth there of 50 percent by 2010, a plan that will see the company investing approximately US$156 million via ongoing investments it has made there the last few years and more to come. “We have been present in China for more than 10 years, since the opening of the first production plant in 1997,” said Prysmian Group CEO Valerio Battista. “We have always believed in the huge potential of this country, which we consider one of the main areas for our group’s strategic growth. This confidence has been From l-r, Prysmian Group well rewarded as China was CEO Valerio Battista, among the countries where Italian Ambassador we achieved the best perRiccardo Sessa and formance of turnover in 2007, Prysmian China CEO with an increase of 16 percent Paolo Bazzoni at the from 2006.” opening of the Tianjin As noted above, the compa- plant. ny has been quite active already in China, with major projects including: the cabling of the Beijing 2008 Olympic Village; high voltage networks for the China State Grid in several cities and the cabling of the Beijing’s underground. Future growth The company notes that its growth strategy in China has led to a new organizational and company structure, including the creation of a holding company (Prysmian China Investment Co. Ltd.) as its China headquarters. That entity will link the group’s five main companies operating in the country, with five production facilities, which includes its new plant in Tianjin, and over 1,000 employees, the release said. The goal is to focus on development in higher addedvalue and technology content sectors that can benefit from strong economic growth and ongoing investments in infrastructures promoted in the country, the release said.

Sectors it highlighted include: Industrial cables. Prysmian’s strategy here is to leverage its new Tianjin plant, which has about 300 employees and an annual production capacity of approximately 10,000 tons. The Tianjin plant makes special cables for sectors such as oil and gas, railways, mining, wind farm and nuclear energy. Telecom cables. Prysmian plans to develop the Chinese domestic market (currently the most significant part of the Wuxi plant’s production is exported), in particular through the supply of fiber optic cables for the development of local telecom networks and Fiber to the Home. Power cables. The greatest Chinese cable growth is expected in the segments of high and higher voltage cables and

Prysmian’s new plant in Tianjin, China. systems with high transmission power (up to 500 kV) industrial cables, where an increase of 15 percent is expected in the next three years. Emphasis in China and outlook Prysmian is looking at the Chinese market as more than just a manufacturing or supply base. “In China we wish to grow as a company strongly rooted in the territory and not as foreign group,” said Prysmian China CEO Paolo Bazzoni. “That is why we are investing both in the development of production facilities and technological knowhow, as well as in further growth of local human resources, which represent our most important asset.” The Prysmian Group already ranks among the top Italian multinational groups in China, with a turnover of approximately US$235 million in 2007, the release said. Formerly Pirelli Cavi, Prysmian’s presence in China dates back to 1997 with the opening of its first joint venture manufacturing company, it said.

Have news that belongs here? If so, e-mail it to editorial@wirenet.org.

22 | WIRE JOURNAL INTERNATIONAL


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With regards to the structure, the new holding company will improve the activities’ management of the group of companies and plants in China, particularly in the purchase, commercial, finance and human resources department, to support the growth through a more efficient organization, the release said. Prysmian is also engaged in the improvement of high profile local resources through know-how development programs and training programs in technological and in commercial areas, it said. Prysmian is pursuing further development in the renewable energy sector, with investments in the special cables sector including the acquisition of the Angel Group’s assets in 2006. Major projects it is currently involved with include the supply of special cables for the new Chinese high-speed trains and supplying products for Beijing’s underground cabling. The investments made and to come are important for Prysmian to be able to serve the Chinese market, which represents about 20 percent of the global cables market, a percentage expected to grow, the release said. “Now, with the new organizational structure and new production facilities, we are ready to seize more significant increase opportunities, ensuring the development of new infrastructures for energy and telecommunications,” Battista said.

ASIAN NEWS BRIEF

Sterlite reports two major contracts

India’s Sterlite Technologies reports that it has won two contracts for fiber optic and copper telecom cable valued at more than US$26.7 million. The fiber optic contract from India telecoms giant BSNL (Bharat Sanchar Nigam Ltd.), is for Sterlite’s RIBBON-LITE™ 96F ribbon fiber optic cables, which BSNL will install in about 900 city sites across the country in the rapidly growing FTTx (fiber-to-the-”x”) applications sector, a press release said. The second contract is for a range of 10 to 2000-pair copper telecom cables, it said, adding that the cables will support the nation’s growing demand for ADSL broadband as well as basic telephony in rural and urban areas. The cable is to be delivered by the end of this year. The company also reported a third contract, from India’s Mahanagar Telephone Nigam Ltd (MTNL), that calls for the installation of an OSS / BSS (Operation / Business Support Systems) for the Metro Ethernet network Sterlite is installing for 200,000 broadband subscribers in Mumbai, India. ■

AUGUST 2008 | 23

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Based in Austria, Knill Technology Holding GmbH reported a number of key positions related to the company’s growth Siegfried Altmann has become general manager of Knill Technology Holding GmbH, and will serve as chairman of the board of Rosendahl, Nextrom and Silitec. He will work with their management to determine the strategic course of Knill Technology Group. He has more than 20 years of experience within Rosendahl, and has up to now served as managing director for Rosendahl and Nextrom. Management positions at Rosendahl Maschinen GmbH now include: Gerhard Jakopic, responsible for sales, marketing, financial management and quality management; Josef Altmayr, responsible for engineering, R&D and information technology; and Siegfried Tieber, responsible for production, supply chain, logistics and Rosendahl Industrial Services. The sales director position will be taken over by Johann Jäkel (sales and marketing) and Robert Trinkl (project engineering, project management and after sales service). Timo Id has been nominated as managing director for Nextrom Oy. Alain Giraud will remain in his role as the sales director for Nextrom. Frederic Sandoz is managing director for the Swiss company Silitec Fibers SA. Based in Austria, Knill Technology Holding GmbH has two divisions, Knill Energy and Knill Technology, the latter of which includes the companies of Rosendahl, Nextrom and Silitec. Sonoco Molded Plastics Division announced that Christine Matthias has joined the company, responsible for sales and customer account management in the MidWest and Mid-Atlantic for wire spools and other products.

She had been selling and supporting gauging and closed loop control systems in the wire and cable industry for the past ten years throughout North America. She holds a B.S. degree in business administration and a minor in computer science from Marist College. She served as the WAI’s Wire Link Scholar in 2004, Christine Matthias when she traveled to the U.K. to study the dynamics of its wire industry as well as attend the wire Dusseldorf show in Germany. Based in the U.S., Sonoco Crellin is one of the world’s largest manufacturers of plastics spools and reels. Johan Van Grootel, who had been president of Borealis Compounds LLC, has taken on the role of transformation manager at the parent company’s headquarters in Linz, Austria, where he is overseeing the integration of subsidiary AMI (Agrolinz Melamine Linz). On a day-to-day basis, Kenneth Wiecoreck, currently Rockport manufacturing manager, will act as Borealis Compounds pres- Johan Van Grootel ident pro tem until a successor is in place. Based in Port Murray, New Jersey, USA, Borealis Compounds LLC, supplies polyolefins to sectors that include wire and cable.

OBITUARY

Henry L. Hollingsworth, a long time wire industry veteran who held two patents, died June 17, 2008, in Fostoria, Ohio, USA, at age 89. He held several positions as an engineer, working for Fischer & Porter, Electric Auto-Lite, Phelps Dodge Magnet Wire, Rea Magnet Wire and Fostoria Corporation. A WAI member for more than 25 years, Hollingsworth received a B.S. degree in mechanical engineering from the University of Delaware in 1941 and during World War II served in the U.S. Merchant Marine as an engineer on the Atlantic run. He earned his Professional Engineer’s license in 1957 and was involved in starting up two companies: Mho Research and Filmtec, Inc. While at Mho Research he received two patents: one for a high speed wire take-up and spool changer and another on high-speed production of magnet wire. In 1969, in conjunction with local Henry L. investors, he started Filmtec, Inc., to develop and market a low pollution, efficient, fine wire Hollingsworth enameling system. Due to market challenges, the company focus changed to wire spooling equipment with an emphasis on layer-wind take-ups. He retired in 1999 and the company remains active in 2008 under the leadership of his two children. Survivors include his wife of nine years, Nancy Hollingsworth; his daughter, Jo; his son John; stepsons Jack, Gary, Ron and Lynn Kinser; and grandchildren, great-grandchildren, and nieces and nephews. He was predeceased by his first wife, Dorothy Paterson Hollingsworth.

24 | WIRE JOURNAL INTERNATIONAL


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Amphenol Corporation announced that, effective January 1, 2009, R. Adam orwitt, currently the company’s President and COO, will become its CEO and a member of the board of directors. Martin H. Loeffler, currently chairman and CEO, will be appointed to the newly created position of executive chairman, with specific emphasis on the company’s strategic direction and the continued development of the its leadership team. Norwitt has held a variety of management, business development and operating positions in Amphenol operations in Asia and the U.S. since joining it in 1998. He is a graduate of Georgetown University and has a law degree from the University of Michigan and an MBA from INSEAD. Based in Wallingford, Connecticut, USA, Amphenol Corp. manufactures markets electrical, electronic and fiber optic connectors, interconnect systems and coaxial and specialty cable. Liberty Wire & Cable has named David C. Traeger as territory manager for commercial products, covering the Southeastern U.S. and Puerto Rico. He has more than 20 years of experience in the professional and commercial A/V industries. Based in Colorado Springs, Colorado, USA, Liberty Wire & Cable supplies wire and cable products primarily for audio/video and security applications.

Pascal Rénevier has been named managing director for the marketing and sales division at Friedrich Kocks GmbH & Co KG. He succeeds Dr. Jürgen Ammerling, who has retired, having served in this position at Kocks since 1986. He will continue to actively support the company. Based in Hilden, Germany, Friedrich Kocks GmbH supplies mill construction worldwide.

Pascal Rénevier

ASTM International Committee D09 on Electrical and Electronic Insulating Materials has honored Lawrence B. Ingram, senior product development chemist at Alcan Cable, Williamsport, Pennsylvania, USA, with the Arnold H. Scott Award. The award is given for outstanding achievement in the science of electrical insulation. A WAI member since 1987, Ingram joined ASTM in 1991 and is the current vice chairman of Committee D09, active on various committees. He is also a member of the American Chemical Society, the SPE and the American Society for Quality. He holds a bachelor’s degree in chemistry from the Polytechnic Institute of New York. ■

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AUGUST 2008 | 25

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Fiber showing strong gains over copper More broadband subscribers chose fiber over copper in the first quarter of 2008, reports Point Topic, a U.K.-based company that provides information on broadband communications services Point Topic reported that some 4.2 million fiber users were added worldwide in the first three months of 2008, compared to 2.5 million copper users. “It’s a significant milestone for fiber optic broadband, where it is available consumers will take fiber over other broadband technologies,” said Point Topic CEO Oliver Johnson. A press release on the findings observed that prices are important. “If you look at the cost per megabit then DSL comes in at around $20 per megabit per month taking global averages. Cable does better at roughly $12 but they are both completely eclipsed by fibre where costs can get as low as 50 cents per megabit per month,” Johnson said. There are variations from country to country, region to region and operator to operator, “but a rule of thumb is that DSL can cost the consumer more than 15 times as much as fiber to get a megabit of bandwidth and cable is seven times as expensive given the current tariffs,” the release said. Fiber growth is being driven by China, Japan and South Korea, countries where cable and DSL are losing subscribers to the fiber technologies, it said, adding that in the

Total broadband subscribers Country

Q407

Q108

USA

73,206,858

75,742,120

China

66,564,400

71,034,820

Japan

28,425,700

28,826,100

Germany

20,001,616

21,184,450

UK

15,728,900

16,318,300

France

15,591,068

16,207,996

South Korea

14,709,998

14,869,370

Italy

10,860,650

11,232,077

Canada

8,658,689

8,859,868

Spain

7,988,990

8,290,507

Top ten broadband countries Q1 2008. Chart courtesy of Point Talk.

26 | WIRE JOURNAL INTERNATIONAL

U.S., U.K., France and Germany, “low availability means low adoption.” “There are problems in the de-regulated markets when it comes to major infrastructure investment,” said Johnson, citing the expense of deploying fiber and regulatory challenges in the U.S. and Europe. “It’s difficult to persuade operators to make the sort of commitment needed when they can’t guarantee their returns. In most western markets regulators frown on monopolies and it’s very difficult to sanction government expenditure given the self-imposed legal frameworks. Without some form of centralized funding however it will be a long time before consumers in these markets get access to cheaper bandwidth.” The report also noted that China continues to gain momentum in terms of broadband overall. It is second in the world in terms of total broadband subscribers to the USA but the gap continues to close, it said. For more about Point Topic, go to www.point-topic.com.

Cuba and Venezuela plan fiber link

Cuba and Venezuela plan to install an undersea optical fiber cable that will connect the two countries and greatly increase Cuba’s Internet and telephone capacity, Associated Press reported. The article cited Venezuela’s Julio Duran, president of state-run Telecom Venezuela, as saying that the new cable from should be finished within two years. Duran said the deal would provide a line with a capacity of 160 Gbit/sec, “well over 1,000 times the capacity of Cuba’s current satellite-based internet link, which was listed as 65 MBs per second on upload and 124 MB a second on download..” A second article pegged total capacity at 640 Gbit/sec for the two fibers, increasing by 3,000 times Cuba’s data, voice and video transmission capacity with other countries. Either way, the project would result in significant increase. Cuba, the article said, has one of the region’s lowest rates of internet usage, due to bandwidth and U.S. restrictions. As a result of the cooperation efforts by the Bolivarian Alternative for America (ALBA), the cable will connect Camuri of northern Venezuela with Siboney in east Cuba. Duran also said in the article that Venezuela’s decision to nationalize the country’s main telecom company, Compania Anonima Nacional Telefonos de Venezuela (CANTV) might lead to a merger with his own company. CANTV focuses on the heavily populated coastal regions while Telecom Venezuela has aimed at expanding service to more rural regions, he said. “We’re complementary companies. We can work in parallel and then be merged later on,” he said. The article noted that Venezuela’s government has signed a deal to buy the CANTV stake owned by U.S.-based Verizon Communications Inc. ■


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FASTENER UPDATE

FASTENER UPDATE NFDA to develop member reports The National Fastener Distributors Association announced that it will partner with the Institute for Trend Research (ITR) to develop a series of customized economic reports that will be produced exclusively for NFDA members. The FDA Economic Outlook Report, a quarterly publication, will “correlate macroeconomic data to specific product categories directly related to the fastener industry,” a press release said, noting that the first report will be issued this fall. The report, to be produced by an ITR Senior Economist, will “allow member companies to forecast what effect the economy has on their business and what they can reasonably expect for up to six quarters in the future.” The NFDA will also host an Economic Outlook Webinar so members can hear first-hand from ITR Executive Director Brian Beaulieu, who will review highlights of the report, provide additional analysis and answer questions from NFDA members, the release said. ITR will also provide a senior economist to speak at all future NFDA Annual Spring Meetings to discuss the reports and present a thorough look at what’s ahead for the fastener industry, it said The economic outlook reports provide NFDA members solid answers to such questions as when to increase overhead, when to add sales staff, when to cut inventory levels and when to increase or decrease sales and marketing allocations. Knowing when to act, and when not to, can often result in increased profits and costs savings for member companies. NFDA is a North American trade association with over 220 distributor and associate members. For more information go to www.nfda-fastener.org.

Fastener Fair Coventry draws well

The 12th Fastener Fair took place in Coventry on June 11-12, with more than 1,000 visitors attending the event designed for the fastener industry in U.K. and Ireland, the organizers reported. The event showcased technology and services from 140 exhibitors, a press release said. “Almost exactly the same number of visitors came as two years ago,” said organizer Jerry Ramsdale. “In fact, there were slightly more, which is a remarkable achievement for a mature event that’s been running since 1995. It shows that Fastener Fair Coventry is the industry’s key exhibition, and that with the help of our exhibitors we’ve managed to keep things fresh, lively and compelling for visitors.” “With the fastener industry preparing for less settled times, Fastener Fair Coventry provided new opportunities for a profitable future,” the release said, noting that 75 percent of attendees had purchasing responsibility for their companies. 28 | WIRE JOURNAL INTERNATIONAL

Exhibitors appear more than pleased at the 12th Fastener Fair Coventry. One of the key events that exemplifies Fastener Fair Coventry’s place at the heart of the UK and Ireland’s fastener and fixing industry is the ever-popular Gala Dinner. Comedian John Moloney entertained 230 guests at the industry’s famous networking event. Feedback from both exhibitors and visitors was that the venue, its facilities and location were all ideal for the show, so the next Fastener Fair Coventry will again take place at Coventry’s Ricoh Arena, the release said. Dates are to be confirmed, but are likely to be in June 2010, it noted.

Lombard invests in Taiwan company

U.S.-based Lombard Investments, Inc., reports that it has invested $15 million in Taiwan-based San Shing Fastech Corporation (San Shing), which it described as one of the world’s leading manufacturers of high-quality automotive fastener systems. San Shing will use the proceeds to expand its product line and enter new markets, a press release said, noting that Lombard Investments, an international private equity investment manager, will have a seat on the company’s board of directors. Lombard Managing Director Thomas J. Smith said that San Shing “is very well positioned for growth in the global automotive parts industry.” Per the release, San Shing was founded in Taiwan in 1965, and was listed on the Taiwan OTC in 1998. It has more than 1,100 employees at its manufacturing facilities in Tainan Hsein, Taiwan, where it operates as “as a fully integrated manufacturer, designing and producing tooling dies and production machinery, in addition to automotive fastener systems.” Lombard made its investment in San Shing through an affiliate of Lombard Asia III, the firm’s South East Asia and Greater China private equity fund, the release said. ■


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NEWS

Reconvene set for November 11 The WAI volunteers who serve on the bodies that direct the Association will meet on Tuesday, November 11, at the Providence Convention Center in Providence, Rhode Island, where they will address a range of matters. “This is an important meeting for us because the Association has to adjust to the needs of a constantly changing global business environment, and these committee meetings are the place where our volunteers thrash out what makes most sense,” said WAI Executive Director Steve Fetteroll. “I continue to be impressed at how these members are willing to commit their time to help the Association.” The WAI holds two business meetings a year, the first being held at either the Association’s Interwire or Wire Expo events. Bodies scheduled to meet this November include the WAI’s Board of Directors, Executive Committee, Member Relations Committee, Education Committee, Conference Programming Committee, Nominating Committee, Memorial Awards Committee and Exhibition Planning Committee.

From l-r at the board of director’s meeting are executive committee members WAI President Ron Reed, WAI First Vice President Antonio Ayala, WAI Second Vice President Dane Armendariz and Dominique Perroud. Some of the topics that are likely to be discussed include the location for Wire Expo 2010, an update on the WAI’s subsidiary in India, possible directions for the WAI’s technical programs as well as new editorial content for WJI, and more.

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S AV E T H E D A T E

WIRE, CABLE, AND FASTENERS The largest and longest-running wire industry trade show in the Americas.

SHOW: APRIL 25-30, 2009 EXHIBITS: APRIL 27-30, 2009 I-X CENTER, CLEVELAND, OHIO, USA

INQUIRE ABOUT AVAILABLE EXHIBIT SPACE TODAY! Interwire sales at WAI: 203-453-2777 or IFE sales at IFMSA: 203-794-0444

INK TO INDIA. BOLTS TO BANGLADESH. MACHINES TO MALAYASIA. If your selling wire and cable supplies, equipment, or manufactured products, meet Interwire, the gold standard in wire and cable trade events in the Americas and honored by Tradeshow Week as one of the top 200 Trades shows in the U.S. We’ll be back at Cleveland, Ohio’s I-X Center and backed by the U.S. Department of Commerce’s International Buyer Program putting special focus on U.S. exports around the world. Exports happen. And trade is in the air at Interwire 2009 where we expect delegates from more than 50 countries. So whether it’s wire to Wales or an order for fence in the outback, Interwire offers you a global marketplace on an international stage. And if it’s a new national account you’re looking for, join in. They may need tin in Tinseltown.

The Commercial Service logo is a Registered trademark of the U.S. Department of Commerce, used with permission.

To reserve exhibit space at Interwire—the largest wire and cable marketplace in the Americas in 2009—call now for availability or check online at: http://www.wirenet.org/events/interwire/index.htm

ORGANIZED BY: The Wire Association International, Inc.


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M EMBERSHIP A PPLICATION Send application and payment to: THE WIRE ASSOCIATION INTERNATIONAL, INC. 1570 Boston Post Road, P.O. Box 578 • Guilford, Connecticut 06437-0578 • USA • Telephone: (001) 203-453-2777 • Fax: (001) 203-453-8384

Individual Information LAST NAME

FIRST NAME

TITLE

M.I. .

COMPANY

❏ BUSINESS OR ❏ HOME

ADDRESS

CITY OR TOWN

STATE

ZIP/POSTAL CODE

PHONE (include area code — when applicable include country and city code) E-MAIL ADDRESS

COUNTRY

FAX (include area code — when applicable include country and city code)

[

] BIRTH DATE (MM/DD/YYYY)

Required to receive The WAI Connection member e-newsletter

Business Information (required)

GENDER (M/F)

REFERRED BY

:

A. Which ONE of the following best describes your company’s type of business? WIRE MANUFACTURING FASTENERS, WIRE FORMING, FABRICATING 10 ❏ Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) 61 ❏ Fastener Manufacture 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) 62 ❏ Four-Slide Forming 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) 64 ❏ Hot and/or Cold Forming and Heading 40 ❏ Other Metal (Rod/Bar, Bare Wire, Both) 66 ❏ Spring Manufacture 50 ❏ Electrical Wire & Cable (Insulated Wire) 68 ❏ Wire Cloth Mesh Screening 69 ❏ Other Forming and Fabricating (Please specify) 53 ❏ Communications Wire & Cable (Insulated Wire) 55 ❏ Fiber Optics SUPPLIER TO THE WIRE INDUSTRY

WIRE END-USER 11 ❏ Appliance 12 ❏ Communications (Voice/Data) 13 ❏ Computer 14 ❏ Construction/Building 15 ❏ Electrical (Equipment/Components/Power) 16 ❏ Transportation/Vehicular 17 ❏ Wire Formed Durable Goods OTHER 80 ❏ Service Centers, Distributors & Warehouses 90 ❏ Consultants 92 ❏ Government, Library and allied

72 ❏ Machinery 74 ❏ Process 76 ❏ Accessories B. Which ONE of the following best describes your primary job function? 10 ❏ General & Administrative Management 30 ❏ Technical, Research & Development, Quality Control 20 ❏ Engineering, Operations, Production 40 ❏ Purchasing

50 ❏ Sales & Marketing 90 ❏ Other (please specify)_________________________

C. As part of my membership, I wish to receive a free subscription to the Wire Journal International. SIGNATURE (REQUIRED)

DATE

Student Membership — Available to students enrolled full-time in an institution for advanced education and who have an interest in the processes, techniques, and methods for the manufacture of wire. Dues waived with proof of enrollment.

INSTITUTION

GRADUATION DATE

Chapter Membership WAI Chapters provide additional networking and educational opportunities on a regional level. Please select appropriate chapter and complete dues line below. ❏ New England US ❏ Mid-South US ❏ Midwest US ❏ Ohio Valley US ❏ Southeast US ❏ Western US ❏ Poland ❏ India

..

❏ Italy

Membership Dues Calculation Membership Dues:

❏ One year: $95

SAVE! ❏ Two years: $175

MORE SAVINGS ❏ Three years: $255

Chapter Dues (indicate chapter above):

❏ First year: free

❏ Two years: $15

❏ Three years: $30

INDICATE AMOUNT:

NOTE:

Total Amount Enclosed Payment options:

CARD NUMBER

❏ Check

❏ American Express

❏ Diner’s Club

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EXP. DATE

.

SIGNATURE

DATE

.

WIRE TRANSFER NUMBER

DATE

.

Your membership includes a free subscription to Wire Journal International. Please return this form by fax or mail for proper credit.

Reference Guide

NOTE: All checks must be in U.S. Dollars drawn on a U.S. bank. Credit card payments are preferred for members from outside the U.S. and Canada. If a check or credit card is not used, a wire transfer may be sent in U.S. dollars. For instructions, contact the WAI Membership Department at membership@wirenet.org or by phone at (001) 203-453-2777. Your membership dues may be deductible as an ordinary and necessary business expense, not as a charitable contribution. Membership in The Wire Association International, Inc. is held by the individual, not the company, and is continuous unless cancelled in writing. Membership is not transferable. Dues are non-refundable and are billed annually based upon the member’s anniversary date. Annual dues are set by the WAI Board of Directors, and are subject to change.

August 08

International Technical

Conference Proceedings


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The meeting will be held during the staging of the International Wire & Cable Symposium, which is being held November 9-12.

New team at work on program for ‘09 Before the technical sessions for Wire Expo 2008 were even finished, organizers were gearing up for next year’s show, Interwire 2009, through the “re-formation” of the Conference Programming Committee (CPC), which is now created anew each year. The 2008 CPC is tasked with organizing the technical program at WAI’s 79th Annual Convention, April 25-30, 2009, at the I-X Center in Cleveland. Changes have been made to make it easier for committee members to procure technical papers and other educational presentations for the WAI’s annual conference and trade show. The WAI’s Board of Directors is taking an active role in recruiting and advising committee members and meeting requirements have been reduced to lessen members’ time commitment, thus freeing them up to focus more on soliciting material. The committee, which continues to be headed by cochairmen Nick Nickoletopoulos, Ivaco Rolling Mills, and Masoud Garshasb, Freeport-McMoRan Copper & Gold, represents a cross-section of professionals from all seg-

ments of the industry, including suppliers. “We’re hoping to get folks involved who have never worked on the program before,” said WAI Director of Education Marc Murray. “The committee has been fortunate to have enthusiastic participation from a number of dedicated volunteers in recent years. But we have to remain sensitive to the energy it takes to track down good material and good speakers, and we don’t want members to feel obligated to repeat that kind of commitment year in, year out.” Regardless, Murray said the committee welcomes back any members eager to volunteer for another term. “Our members are always our best resource,” said WAI Executive Director Steve Fetteroll. “Their range of experiences, knowledge, and personal relationships is tremendous. We’re hoping the adjustments we’re making maximize our ability to tap into those resources for the benefit of the industry.” The committee will be accepting abstracts of proposed papers through the fall of this year. To submit an abstract for Interwire 2009, please use WAI’s online submission form at http://www.wirenet.org/technical/submit.htm, or call tel. 001-203-453-2777, ext. 121, or send an e-mail to mmurray@wirenet.org for more information. ■

AUGUST 2008 | 33

WAI NEWS

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CHAPTER CORNER

CHAPTER CORNER Midwest golf tourney a huge success The St Andrews Golf & Country Club in West Chicago, Illinois, host to the Sixth Annual WAI Midwest Chapter Golf Tournament on Monday, June 23, 2008, provided a picture-perfect setting for this year’s event. A record number of 74 golfers attacked the course and enjoyed the awards reception and dinner afterward. The winning team, with a score of 62, included A-1 Specialty Wire’s Tom Harmon and Steve Kendziorski, John Dabbelt of Fort Wayne Wire Die and Marty Muse of AXIS Computer Systems Inc. Also recognized was the team of Perry Koste and Joe Messina of D & S Wire along with John Makris of Roberts Swiss Inc. and Joe Dernbach of Tolerance Grinding, albeit for the day’s highest score. That score will be kept confidential out of respect. The skills contests were well contested. Gene Finley of JOMB Corp and Chris White of O & K American were the winners of the two closest-to-the-pin holes; Mike Malwitz of Metal-Matic Inc. out-hit everyone to win the long drive hole and Freeport McMoran’s Chris Klawitter showed off his precision by winning the accurate drive hole. One of the highlights of the event was a special award made to Bob Sears of North America OMCG, the tourna-

Bob Sears is honored for his longtime efforts as chair of the Midwest Chapter Golf Tournament. Flanking him are co-chair Kevin Sopczak (l) and Chapter President John Kukalis. Photo by Joanne Sears. ment’s chair since its inception. Chapter President John Kukalis and past president Kevin Sopczak presented Sears with a certificate honoring his years of service to the chapter tournament. Sears also served as chapter president in 2004. “It has been great co-chairing the tournament with Bob these past couple of years,” said Sopczak. “He has really worked hard over these past six years to make it an

34 | WIRE JOURNAL INTERNATIONAL

The team (l-r) of John Dabbelt, Tom Harmon, Marty Muse and Steve Kendziorski won the Midwest Chapter’s Sixth Annual Golf tournament. Photo by Joanne Sears. enjoyable event for all who have participated in it and has done a nice job helping it grow.” In addition to the largest field, the tournament benefited from the support of its largest number of sponsors to date as well. The $10,000 hole-in-one, which unfortunately went unclaimed, was sponsored by Freeport McMoran. Other major sponsors included Leggett & Platt Shaped Wire for the long drive hole, Schlatter, Inc., for the accurate drive, Henkel Corp for the putting contest, and Classic Die Services and O & K American for the two closest-to-the-pin holes. These companies were joined by corporate hole sponsors AXIS Comupter Systems Inc., Charter Steel, D & S Wire Inc,, Fort Wayne Metals Research, Fort Wayne Wire Die, Freeport McMoran, Krueger Steel & Wire, Numamerica, Premier Wire Die, RichardsApex Inc., W Gillies Technologies LLC, Wire & Plastic Machinery Corp, and Worth Steel. “The company support of this event is outstanding,” said Kukalis. “Now that we are drawing a larger number of golfers, the sponsorships are now filling the entire course for the first time.” Upcoming program Chapter President John Kukalis also announced that the chapter is putting together a dinner meeting for Tuesday, October 14, in Rosemont, Illinois, in advance of the Spring World show. A featured speaker will be economist William Strauss, of the Federal Reserve Bank of Chicago, who has expertise in the manufacturing sector. Details are being finalized and will be available soon. For more information, contact WAI’s Chip Marsh cmarsh@wirenet.org; 203-453-1748.


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CHAPTER CORNER

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Date set for New England tourney WAI’s New England Chapter will hold its 14th Annual Golf Tournament on Thursday, September 11, returning to the Kettle Brook Golf Club in Paxton, Massachusetts, for the fifth consecutive year. The popular scramble format tournament begins with a shotgun start at 9:15 am, with check-in and continental breakfast at 8:15. The day ends with the 19th hole reception and buffet awards dinner. The six teams with the lowest scores will earn prizes, and individual golfers will compete in multiple skills contests including the $10,000 hole-in-one on the par three 12th hole. Other challenges include: three closest-to-thepin holes, two long drive holes (both men’s and women’s winners), accurate drive, long putt and chipping contests. All golfers also will have a chance to qualify for the $2,500 putting contest, in which one golfer will earn the chance to sink a putt of at least 50 feet to win the money. Proceeds from the raffle, sports memorabilia auction and sale of the Chapter golf shirts will again go to support the New England Chapter Scholarship fund, which awards two scholarships each year to graduating high school seniors whose parent is a member of the Chapter. All raffle participants will have the opportunity to distribute their tickets among several prize packages, and the remaining tickets will be combined for the grand prize

36 | WIRE JOURNAL INTERNATIONAL

drawing of a set of irons. Donations are requested from all who are willing and interested in enhancing the options available for the raffle prize packages. “Last year’s tournament was our largest ever,” said cochair Mike Mathiasen, Mathiasen Machinery, Inc. “We’ve made a few changes this year, including adding refreshment tents at the 7th and 16th holes to help smooth the flow during the golf.” Sponsorship opportunities are available for companies looking for exposure. Most of the major options are already committed with 19th Hole Reception and $100 corporate hole sponsorships still available. All sponsors receive signage and recognition the day of the event as well as in the tournament wrap-up article in the WJI. “Knowing that we have virtually oversold this event the past two years, sponsoring companies really get excellent exposure,” said co-chair Mike McKee of Lloyd & Bouvier, Inc. The registration fee of $135 covers the greens fees, cart, continental breakfast and awards dinner. Non-golfers can attend the reception and dinner for $35. Deadline for registering is Wednesday, September 3.. For more information on the tournament or regarding raffle prize donation, contact WAI’s Chip Marsh at cmarsh@wirenet.org; tel. 203-453-1748. ■


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WIRE CHINA PREVIEW

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Wire China 2008: exhibitors remain optimistic The Shanghai New International Expo Center is expected to be a busy site when it again hosts Wire China, The All China - International Wire & Cable Industry Trade Fair, on September 23–26, 2008. Despite increasing headlines of economic worries, a sampling of exhibitors that starts on the next page generally indicates that they believe that China remains a good market. In 2006, the combined wire and tube events, both organized by Messe Düsseldorf China, a subsidiary of Germany’s Messe Düsseldorf, featured 923 exhibiting companies, a press release said. The majority of those were Chinese but also included exhibitors from dozens of other countries, with total exhibit space for the two shows accounting for approxi-

mately 40,000 sq m (430,500 sq ft) and drawing 32,000 trade visitors from 80 nations, it said. The wire event will again feature country group exhibits from Austria, France, Germany, Italy and the U.S. An organizer press release, which notes that the events will again feature country group exhibits from Austria, France, Germany, Italy and the U.S., projects that the outlook continues to be good in Asia. “The huge market demand for wire products is the basis for a successful wire 2008 staging. In 2006, China’s GDP reached $ 222.9 billion, surpassing Italy, France and Great Britain. Experts estimated that China’s economic development and GDP increase will continue in the next few years.” The organizers also noted that the

Opening ceremonies at the 2006 Wire China show. Photo courtesy of Messe Düsseldorf.

38 | WIRE JOURNAL INTERNATIONAL

Chinese government “forecasts predict continued and expanded growth in areas key to the wire and cable industry.” China’s wire and cable industry has developed rapidly over the past decade, and become one of the world’s major players in the field of wire and cable manufacturing, with monthly imports and exports of wire and cable products valued at around US $300 million. “In terms of manufacturing scale calculated in output of conductors, China has surpassed USA and Japan and become the biggest manufacturer of wire and cable, accounting for over 20% of the global total. … However, locally produced equipment hasn’t matched demand. For this very reason, wire China has been developed to tap into this market that is so essential for the future of China’s economic growth!” Exhibit categories at wire China 2008 will include wire, fastener and spring manufacturing and finishing machinery, process technology tools and auxiliary process technology equipment as well as special wires and cables, measuring and control technology and test engineering. Show hours are from 9 am to 4:30 pm each of the four days. In addition to Messe Düsseldorf, the show has direct support from the Shanghai Electric Cable Research Institution (SECRI), the only research institution in China that incorporates R&D, testing and inspection, information service and engineering design of wire and cable, and exhibitions/conferences for wire and cable. International supporters include IWCEA, VDKM, VÖDKMAWCMA, IWCEA and WCISA. For further information on visiting


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Attendees at Wire China 2006. Photo courtesy of Messe Düsseldorf.

or exhibiting at wire China 2008, contact Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Exhibitor comments

Why are you exhibiting at Wire China and what will you highlight? We will not be exhibiting a specific machine, but we will have information and videos on our respooling lines and drum packing lines. We have exhibited before, and in the past we have had our respooling lines exhibited. We are not new to the Chinese market, we have numerous customers in China and we are the major supplier of drum packing machinery for welding wire to the Chinese steel industry. Enrico Romagnolo, sales and marketing director, Gimax Group. China is a growing market for high-end products, so we expect a substantial growth in machine sales for rolling mills. We will display product samples of the final products manufactured on our machines, to show the wide range of applications possible on our rolling mills. Stefan Rettig, sales director, Bühler & Co GmbH.

We are exhibiting at Wire China to serve our Chinese customers and also the customers in neighbouring countries who frequently visit the Chinese exhibition.We have exhibited at this exhibition also before. The Chinese exhibition is not inviting to highlight latest technology as there are too many people interested only in knowing what it is and how to copy it. So our main interest is to inform about our solid and proven designs and show the difference to the Chinese copies. Queins & Co. GmbH. RichardsApex recognizes the need to exhibit their products in the most progressive manufacturing country in the world, China. We have exhibited in China twice before and have always obtained a wide variety of business and contacts throughout the Asian market. We will highlight our line of continuous cast copper rod rolling products that are known globally for their reliability and quality outcomes. RichardsApex has recently designed a new totally synthetic copper rod rolling lubricant that is providing superior results in these quality driven processes. Kyle Craft, managing director, RichardsApex AustralAsia.

Wire China in Shanghai has become the second largest exhibition of its kind in the world after Dusseldorf and it will continue to grow. Most wire and cable companies which are doing well, growing and expanding, are in or around China and they will visit Wire China. Wardwell exhibited at the first wire exhibition held in China in 1989 and every successive show since then. We will highlight a lower-cost version of the lever arm machine designed in Germany and built in China. We will also exhibit a lower-cost version of the bobbin winder and payoff designed in Italy and built in Shanghai. The design changes were commensurate with the requirements of the local market. David Farnum, Wardwell-Hamana (Shanghai) Machinery Co. Ltd. Gauder Group China, successfully established in Changzhou since 1999, contributes to strengthen the company’s position. It is a pioneer for manufacturing foreign rotating cable machinery in China with its SETIC machines for LAN cable as well as for bunching/cabling, keeping rigorously to European quality standards. The display will include a cost-effective SETIC triple twist line for Cat. 6/6e LAN cables, a Gauder Group double twist machine for bunching/stranding of 7, 19, 37 wires (Unilay construction) or multiwires, and posters/information on Pourtier equipment as well as second-hand equipment. Gauder Group. Niehoff GmbH and its Shanghai Representative Office will present an MMH101/RM141 multiwire drawing line and a D631 high speed bunching machine with two ARH type pay-off heads. Niehoff has successfully introduced the multiwire drawing technology to many wire and cable factories in China. For more than ten years, Niehoff has provided to its Chinese customers excellent technical services and spare parts support by the Niehoff Shanghai Rep. Office with experienced Chinese engineers. iehoff GmbH.

AUGUST 2008 | 39

WIRE CHINA PREVIEW

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Condat SA is exhibiting because Wire China is a major exhibition for the wire industry and we want to extend our business in China. We have been exhibiting since 2004, possibly before. CONDAT will display its range of lubricants covering all the industrial needs in the field of rod wire, cold rolling, wiredrawing, drawing of bars and tubes as well as cold heading with brand names: VICAFIL®: for all wiredrawing applications; STEELSKIN®, specific high tech dry lubricants; GALVASMOOTH®, for galvanizing wires for hot-dip processes; CONDACLEAN, cleaners for all applications; and EXTRUGLISS®, a dual purpose oil range for cold-heading applications. Condat SA. We are exhibiting because China is one of the biggest markets in the world and is a member of (Brasilia, Russia, India and China) nations. Development in China continues to be impressive and there is a lot of financial power as the country has very large cash reserves, while there are many concerns about U.S. debt. Different branches of FMS have had very successful exhibitions with its Chinese partners. China continues to advance and solve problems. It is on its way to becoming a superpower and has a good relationship with Russia, which is also a very interesting market after China and India. FMS plans to highlight its new RTM System at Wire China. Steffen Kaiser, director of sales and marketing, FMS - Force Measuring Systems AG. At Wire China, Medek & Schörner will present state-of-the-art cable marking machines that include: top quality gravure printers (LAN cables, control cables, etc.) for speeds up to 1200 m/min, embossing meter markers/ hot foil sequential meter markers for highest accuracy of length measurement (power cables, telecommunication cables, optical fiber cables, etc.); and high performance ring markers for speeds up to 2500 m/min (telephone wires, switchboard wires, automotive

40 | WIRE JOURNAL INTERNATIONAL

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cables, LAN cables). It also supplies optical fiber processing systems for color coding up to 3000 m/min, ring marking of optical fibers, tight buffering up to 1300 m/min and fiber ribbon production with excellent ribbon planarity and for speeds up to 1000 m/min. It covers virtually the entire spectrum of machines for marking cables and coding optical fibers; in particular for power, telecom and data cables. Medek & Schörner. China is a very important market for us as we have hundreds of cus-

50% of our turnover, so China is a very important market for us. We have exhibited in China for many years and have chosen Wire China as a new platform. Our machines and complete lines for the cable manufacturing and rubber processing industry is represented by Troester Machinery Shanghai (TMS), which is responsible for the sales, after sales service and production for the domestic market. At Wire China 2008, we will present information and new developments in the fields of: continuous vulcanization lines for XLPE and rubber cables (CCV and

Traffic at the German pavilion at Wire China 2006.

tomers in China, cable makers and cable making machinery makers alike. Our products are very well received in China and with the large number of U.S. and European multinational cable makers setting up or expanding in China, they are very appreciative of our technical backup and support located in Chengdu and Shanghai. We have exhibited in China for the past six years and we are looking forward to the show, wher we will show our complete range of measurement and control products. Grant Latimer, Proton Products International. Troester GmbH & Co. KG’s annual sales in China are between 30-

VCV lines); conductor postheating in the CV-tube splice box; sag control TRISAG for CCV lines; and TWINROT System for production of high-voltage cables on CCV lines. Dirk Schmidt, sales director cable, machinery division, Troester GmbH. We cooperate with all the major OFC producers. Most of these also have manufacturing in China and we wish to provide these branches with the best of service. There is also a growing number of local companies that focus on exports, and adopting fx European cable design. This is an opportunity for Roblon to cooperate with these manufacturers. Furthermore, we see a huge increase


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in production capacity (and demand) in China and believe China to be a key future market. At the show, we will highlight our various glass strength members. In many Asian countries cable designs are still based on aramide and we would like to promote the possibility to change to glass (especially for duct/buried cables) as has been done in many Western countries. Lasse ielsen, area sales manager, Roblon A/S, Industrial Fiber Division. Are you concerned that the current economic/raw material- and energyrelated woes may significantly affect business in emerging markets? We remain optimistic. As the price of raw materials increases interest in diameter control and non-contact length measurement increases, savings of 1% or 2% in raw materials

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have a very large impact on the bottom line for any cable company, and that’s where we can provide valuable help to cable manufacturers. Grant Latimer, Proton Products. Certainly this situation will affect business, but the important thing is to be aware of it and to adapt; in this way we can continue to offer our customers adequate solutions to their needs at a realistic cost that is competitive with the market situation. Enrico Romagnolo, sales and marketing director, Gimax Group. We are not concerned about that even with the current high material costs, the sales volume to the cable production industry has never been as high as today. Dirk Schmidt, sales director cable, machinery division, Troester GmbH.

This remains to be seen, however, despite the economic slowdown there seems to be a strong demand for FTTH and optical fiber cables in general and this leaves us with an optimistic view. Roblon’s half-year results showed a 17.7% increase in turnover over the same time last year. We have experienced increasing raw material prices and combined with an even tougher competitive environment, I am convinced that a number of manufacturers will merge, be acquired by larger groups or maybe even terminated. Lasse ielsen, area sales manager, Roblon A/S, Industrial Fiber Division. RichardsApex, like many others, is extremely concerned with the ongoing global energy and erratic base oil pricing. The unpredictable outcomes of these events significantly reduce

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AUGUST 2008 | 41

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Keir Manufacturing, Inc.

1-800-992-2402 (1-828-885-8444) www.keirmfg.com email: mwalters@keirmfg.com

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the stability of global manufacturing producers and economies. Kyle Craft, managing director, RichardsApex AustralAsia.

be used for business development and expansion. David Farnum, Wardwell-Hamana (Shanghai) Machinery Co. Ltd.

We do not expect that business will be significantly affected by the raw material shortage, but there will be some temporary disturbances, however, as presently the majority of machine manufacturers are overbooked we do not expect any major consequences. Queins & Co. GmbH.

Who is not affected from this in the business worldwide? The question is: who has the financial power for further development despite worse-case situations in terms of material- and energy-related problems? The answer is the BRIC nations! Steffen Kaiser, director of sales and marketing, FMS AG.

The situation in emerging markets is especially favorable for Maillefer in two regards. Power distribution with new infrastructure is on the rise. Also, there is rising concern for tight management of energy consumption through use of high technology. This is creating the strong demand for Maillefer’s energy cable manufacturing solutions. The other factor that plays an important role for supplying several of these regions is that they have ready access to important energy reserves and therefore, they have the financial resources to make smart investments for the future.

Yes, we are. We are indeed less competitive due to raw material and transport increases; moreover the euro rate is not in our favor. Condat SA. China is a growing market for high-end products, so we expect a substantial growth in machine sales for rolling mills. We will display product samples of the final products manufactured on our machines, to show the wide range of applications possible on our rolling mills. Stefan Rettig, sales director, Bühler & Co GmbH.

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The current market and global conditions can indeed affect business in all areas but especially in emerging markets where infrastructure is not yet fully developed. They may also use up capital that would otherwise

Exhibitors are listed on p. 46.


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Production programme • Wire rod surface preparation lines (mechanical descalers and/or descalers with brushes, electrolytic pickling, steam pickling, boraxing, lime-coating, phosphating, etc.) • Surface treatment lines (pre-cleaning, degreasing and/or electrolytic pickling) • Heat treatment lines • Mono- and multi-wire electrolytic plating lines • Units for hot-dip galvanizing lines • Straight-through dry drawing machines • Vertical and horizontal wet drawing machines equipped with cones or single capstans, combined with

Visit Us at Wire in-line dry drafts • Double-twist and four-twist stranding machines • Double-twist bunching and cabling machines • Spiral wrapping machines • Skip stranders • Tubular stranders • Single and multiple spool pay-offs and spoolers with random or precision layer rewinding take-up systems • Single and multiple coil pay-offs and coilers with random or pattern lay take-up systems • Single or multiple-head rewinding lines • Cold rolling lines • Complete processing lines • Complete production plants

Cold rolling lines for plain and indented wire Wire rod descaling and preparation units Single or multiple cold rolling machines Spoolers Spool tilting units

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Alpha list of exhibitors

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DuPont Performance Coatings/U.S.

Miltec UV Corporate Office/U.S.

Dussek Campbell (H&R ChemPharm/U.K.

Nexans GmbH/Germany

DYM Co., Ltd./South Korea

Niehoff GmbH/Germany

EB Tech Co., Ltd./South Korea

Nova Werke AG/Switzerland

EBNER Industrieofenbau GmbH/Austria

OHMIYA SEIKI Co., Ltd/Japan

Eder Engineering GmbH/Austria

Petrofer Chemie GmbH/Germany

Elantas Electrical Insulation/Germany

Polyone - Shanghai China/U.S.

Emerson Nerwork Power Co., Ltd/U.S.

Pourtier/France

Ernst Kock GmbH/Germany

Proton Products International/U.K.

Esteves China (Shanghai)/U.S.

PWT Limited/New Zealand

ETD Drives Technology (Yantai) Co., Ltd/U.S.

QED Wire Lines/Canada

A&E-Dongguan Dongmei Co. Ltd/U.S.

Eurolls S.p.A./Italy

Queins GmbH/Germany

A.L.M.T. Corp/Japan

EVG/Austria

Radyne IHWT/U.K.

AIM, Inc./U.S.

FIB/Belgium

Reber Systematic GmbH/Germany

AKSH Optifibre Limited/India

FMS Force Measuring/U.S.

Reynolds Flexible Packaging/U.S.

Alphagary Corporation/U.S.

Fort Wayne Wire Die, Inc./U.S.

RichardsApex/Australia

AMBICA Steels Limited/India

Fortuna-Federn GmbH

Rosendahl GmbH/Austria

August Strecker GmbH/Germany

Friedr. Krollman/Germany

RSD Technik GmbH/Germany

Aumann GmbH/Germany

FSP-one SAS/France

Saarstahl AG/Switzerland

Automat Industrial, S.L./Spain

H.A. Schlatter AG/Switzerland

Schnell SpA/Italy

Bekaert Mgt. (Shanghai) Co., Ltd/Belgium

Hae Dong Industries Co., Ltd./South Korea

Shanghai Hamana Machinery Co., Ltd/Japan

Besel Basim/Turkey

Haefely Test AG /Switzerland

Shinko Machinery Co., Ltd/Japan

Beta LaserMike Inc/U.S.

Hanil Machinery/South Korea

Sictra Srl/Italy

Bongard Trading GmbH/Germany

Hankuk Steel Wire Co., Ltd./South Korea

Siderex/Spain

Borouge Pte Ltd./Singapore

Henrich GmbH/Germany

Siebe Engineering GmbH/Germany

Bridon International Ltd./U.K.

Highvolt Pruftechnik GmbH/Germany

Sikora AG/Germany

Buhler & Co KG/Germany

Huntsman GmbH/Germany

SKET GmbH/Germany

Caballe/Spain

Ideal-Werk GmbH/Germany

Solvay (Shanghai) Co., Ltd/Italy

Candor Sweden A/B

India Steel Works Ltd/India

Southern Speciality Wire Sdn. Bhd/Malaysia

Carl Bechem GmbH/Germany

Indore Composite Pvt Ltd/India

Steuler GmbH/Germany

Ceeco Bartell Products/U.S.

Intras/U.K.

CERSA-MCI S.A.R.L./France

Isovolta AG/Austria

Sumitomo Electric Hardmetal Trading (Shanghai) Co., Ltd/Japan

COGNE ACCIAI SPECIALI S.p.A./Italy

JC Com Co., Ltd/South Korea

SWECO Inc./South Korea

Colorant Chromatics Trading/Switzerland

Joachim Uhing GmbH/Germany

T. Fukase & Co., Ltd/Japan

Condat Lubrifiants/France

Kalmark Integrated Systems/Canada

Team Meccanica SpA/Italy

Conductix Delachaux/France

Kieselstein GmbH/Germany

Teknor Apex Company/U.S.

Conoptica A.S./Norway

Kiswire Ltd./South Korea

Teuema/Spain

Construcciones Mecanicas/Spain

Kolon Industries Inc./South Korea

Tokyo Flat Wire Co., Ltd/Japan

Continuus-Properzi S.p.A./Italy

KOS Limited/South Korea

Vikas Spool Pvt Ltd/India

Cortinovis Machinery SpA/Italy

Kun Shan San Chi Engineering & Machinery Co., Ltd/Japan

VIRAJ Profiles Ltd/India

Corus/U.K. Computer Process Automation/Austria

Kyodo Engineering Co., Ltd/Japan

Wardwell-Hamana Shanghai Machinery Co./U.S.

Danielli/Italy.

Kyoeisha Chemical Co,, Ltd/Japan

Weber & Scher Mfg. Co./U.S.

Deuk Young Co., Ltd/South Korea

Lamnea Bruk AB/Sweden

Wire & Plastic Machinery Corp./U.S.

Deutsche Nickel GmbH/Germany

Lear Engineering Corporation/U.S.

Wire Association International/U.S.

DNSSHA/Japan

Leoni GmbH/Germany

Wire Journal International/U.S.

Domino Coding Limited/U.K.

Mali GmbH/Austria

World B.C. Co., Ltd/South Korea

Dong Guan Cogne Steel Products Co., Ltd/Italy

Mallifer SA/Switzerland

Zumbach Electronic (Shanghai) Co., Ltd

Dow Wire & Cable/U.S.

Medek & Schorner GmbH/Austria

DSM (China) Ltd./Netherlands

Messe Dusseldorf North America/U.S.

DSR Wire Corp./South Korea

Menam Stainless Wire Public Co., Ltd./Thailand

Below is an alpha listing for exhibitors outside China that was provided by the organizers. For a complete list of exhibitors, go to http://www.mdna.com/shows/wirechi na.html and click on “Wire China Homepage.” The list of exhibitors, including Chinese companies, will scroll on the right. Booth numbers can be found in the show program.

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Mario Frigerio S.p.A./Italy

VODKM-AWCMA/Austria


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M O N

INTERNATIONAL

TECHNIC

AL

CONFERENCE

T E R

R E Y

Photos courtesy of the Monterrey Department of Tourism.

ITC 2008 PREVIEW

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Wire and Cable Technical Program • Tabletop Exhibits • Museum Tour • Networking

20–22 O CTOBER 2008 • M ONTERREY, N.L. M EXICO • C ROWNE P L AZA H OTEL

WAI RETURNS TO MEXICO FOR 2008 ITC The WAI will return to Mexico this year for its International Technical Conference, which will be held October 20-22 at the Crowne Plaza Hotel in Monterrey, Mexico. The event will include a technical program with more than two dozen papers (abstracts start on p. 54), an opening reception to be held at a local brewery, a tour to a unique wire museum, tabletop displays as well as an opportunity to make contacts, and more. “Attendees will find this ITC to be very informative as well as entertaining,” said WAI First Vice President Antonio Ayala, who has headed the planning efforts for the event, which is organized by the Asociación Nacional

48 | WIRE JOURNAL INTERNATIONAL

de Transformadores de Acero A.C. (ANTAAC), the Departamento de Turismo de Nuevo León (OCVMTY), the Instituto Tecnológico de Estudios Superiores de Monterrey (ITESM) and WAI. Assisting Ayala was fellow WAI Board member Eduardo Anaya. The general session will feature 24 technical papers presented from 9:30 am to 1 pm and from 3 pm to 5 pm on Monday, October 20, and from 9 am to 1 pm and 2 pm to 6 pm on Tuesday, October 21. The program begins on Monday, October 20, with scheduled speeches by Grupo Condumex Director of Cable Sales Hugo Gomez and DeAcero President Raul Gutierrez Mugursa. That night, the ITC’s reception will be held at the Brewery


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Cuauhtemoc Moctezuma, where attendees will tour the site, enjoy the view from the outside patio then have dinner inside, with music provided by Mariachi players. Hours for the Suppliers Market (tabletop displays) will be held simultaneously with the technical papers. As of press time, the following companies have reserved space: American Kuhne, U.S.; ANTAAC, Mexico; Bartell Machinery, U.S.; Base Ten Consulting Inc., U.S.; Cemanco, U.S.; Condat, Brazil; Die Quip, U.S.; Esteves Group, Mexico; Euroalpha, Italy; Fine International Corporation, U.S.; Fort Wayne Wire Die, U.S., GCR Eurodraw SpA, Italy; Gem Gravure, U.S.; W. Gillies Technologies, U.S.; Grupo Condumex, Mexico; Guill Tool, U.S.; Ideal Welding Systems, U.S.; Interquip, Mexico; Lloyd & Bouvier, U.S.; William McCaskie, Inc., U.S.; Micro Products, U.S.; Neue Gesellschaft, Mexico; Pan Chemicals Spa, Italy; Paramount Die, U.S.; Parkway Kew Corporation, U.S.; Pittsfield Plastics, U.S.; Properzi/Continuus Properzi, U.S.; RichardsApex Inc., U.S.; Sikora International Corporation, U.S.; Simpacks, U.S.; Tulsa Products, U.S.; Vollmer America, U.S.; Windak USA, U.S.; WAI/WJI, U.S.; and Woodburn Diamnond Die, U.S. Companies who want a tabletop can contact Robert Xeller at tel. 203-453-2777, ext. 119, xeller@wirenet.org. On Wednesday, October 22, attendees will go on a tour of a unique steel museum, and the city itself offers many sites of interest, from the shopping center in the Macro Plaza to the Cathedral of Monterrey.

ITC SCHEDULE Monday, October 20, 2008 8:30 a.m. - 5:00 pm Registration 9:30 a.m. - 1:00 pm Technical papers 9:30 a.m. - 1:00 pm Suppliers Market 1:00 p.m. - 2:00 pm Lunch 2:00 p.m. - 5:00 pm Technical papers 2:00 p.m. - 5:00 pm Suppliers Market 5:30 p.m. Bus departs for Reception Tuesday, October 21, 2008 8:30 am - 5:00 pm 9:00 am - 1:00 pm 9:00 am - 1:00 pm 1:00 pm - 2:00 pm 2:00 pm - 6:00 pm 2:00 pm - 6:00 pm

Registration Technical papers Suppliers Market Lunch Technical papers Suppliers Market

Wednesday, October 22, 2008 9:30 am 1:00 pm

Depart for museum tour Bus returns to hotel

Schedule is subject to change.

MUSEUM BORN OUT OF A BLAST FURNACE ITC attendees will be able to explore a unique museum in Monterrey that once was the site for the country’s first integrated steel mill. The museum, Museo Del Acero Horno, is built in and around a decommissioned blast furnace that stands 230-ft tall, dominating the site, which itself is part of a 275-acre industrial campus that is a public park called Parque Fundidora. Blast Furnace No. 3, the third and newest component of the park, was operated from 1968–86 when foundry owners, Compañia Fundidora de Fierro y Acero de Monterrey, went bankrupt. Responding to a request by Patronato Museo del Acero, a government/nonprofit organization formed to turn the crumbling structure into a museum, local architects Oficina de Arquitectura partnered with U.K.-based Grimshaw Architects in 2005, The architects adapted the cast hall, furnace, its workings and surrounding infrastructure, and added 34,000 sq ft of new space for exhibitions, workshops, education, and archives. The first phase focused on stabilizing, cleaning, and treating the existing structure. It was “almost unsurveyable,” said Grimshaw’s William Horgan. “There was so much existing ironwork and not a single level surface.” Minimal intervention was needed for the steel structure, say the architects, since the load demand as a museum would be much less than it had been as a working foundry. Elements that were retained, such as the furnace itself, catwalks, and much of the original steel structure, were treated for surface corrosion: Oxidization was removed and the steel was encapsulated in an epoxy-based sealant and then coated with a clear, matte polyurethane. Though freshened up, these artifacts help preserve the A blast furnace is part of the gritty aesthetic from the Museo Del Acero Horno. building’s former life. The design team of AldrichPears Associates, in collaboration with museum staff, created an engaging experience that highlights the science and importance of steelmaking in Mexico. With the furnace as the central hub, the museum has a new entry wing, a new circular Steel Gallery, the massive Cast Hall and offices and a café in the former hoist room and control room, respectively. Soaring into the sky is an ironore elevator, retrofitted with an funicular-like cab, which rises 140 feet up to a network of original exterior catwalks that weave around the furnace, its pipes and its stoves, offering visitors a stunning views. Photo courtesy of: AldrichPears Associates (Vancouver, BC, Canada). Photographer: Roberto Ortiz.

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MEXICO VS. CHINA Below is an edited article written by Bob Cook, President, and Luis Ruiz, Marketing and Research Associate, El Paso Regional Economic Development Corporation. Mexico’s standing as a leader in the global manufacturing market has been long established, even amidst increased global competition. Many Fortune 500 companies and other multi-national companies have turned to Mexico in an attempt to cut costs while maintaining U.S. standards of quality and efficiency. Since the inception of the twin plant or maquila industry in the Cook 1960s, global companies have established labor intensive assembly operations in Mexico while paying substantially less for labor, components and real estate compared to the United States and many parts of Europe. In the early 1990s, the North American Free Trade Agreement (NAFTA) was established, making Mexico even more attractive for foreign direct investment by reducing and often eliminating existing tariffs, resulting in larger volumes of trade between North American countries. In 2007, trade between the United States and its NATFA partners (Mexico and Canada) stood at $908.9 billion, growing from $613.6 billion in 2001, a 48 percent increase. For more than 30 years following the creation of the maquila industry, Mexico enjoyed an environment that was relatively free of global competition in the race to make products for consumption in North America. But in 2001, the competitive landscape changed. After 15 years of aggressive negotiation, China was granted membership in the World Trade Organization (WTO). Since then, manufacturing operations have grown exponentially in China, catapulting it to a globally significant player in the exportation of manufactured goods, placing it in direct competition with Mexico. In 2001, U.S.-Mexico trade stood at $232.9 billion, almost double that of U.S.-China trade. In 2006, China surpassed Mexico in total trade with the U.S. for the first time, and in 2007, U.S. trade with China ($386.7 B) was approximately 13 percent higher than trade with Mexico. A closer look at the data, however, shows that U.S. exports to Mexico are still more than double the level of U.S. exports to China, which shows the close manufacturing relationship that continues to exist between the U.S. and Mexico. A recent survey by Deloitte Research indicates that China and Mexico are the top two potential destinations for foreign direct investment by U.S. manufacturers, with 38% of respondents contemplating China for manu-

50 | WIRE JOURNAL INTERNATIONAL

facturing operations and an additional 25% considering Mexico. As a result, a high level comparison of Mexico versus China is merited. Wages tend to attract the attention of most multi-national corporations. Direct labor wages in China currently stand at $0.90 per hour, which in most cases includes room and board. Mexico’s direct labor wage is $2.50 per hour, including taxes, meals, transportation and medical benefits as well as potential productivity and punctuality bonuses. A closer look reveals a substantial difference in productivity: per capita GDP in Mexico stands at $7,467, more than six times greater than China’s per capita GDP of $1,240. Research also shows that Mexico’s labor force may be more technologically savvy. There are only 62 computers and 220 cell phones per 1,000 people in China, while there are 228 computers and 600 cell phones per 1,000 people in Mexico. Mexico’s strengths tend to favor companies that manufacture highly customized products that are particularly sensitive to shipping costs and lead times. Production in Mexico will also tend to favor bulkier, heavier products that are destined for consumption in North America.

“No matter the industry, U.S. and Canadian companies that operate in Mexico have a significant advantage over operating in China ...” Because of its considerably lower labor costs, China typically favors labor-intensive, commodity-type products. While China’s labor assets are enormous (the population is almost 13 times larger than Mexico’s), their skills are typically less developed. As a result, China is typically better suited for high-volume, low-mix manufacturing operations. No matter the industry, U.S. and Canadian companies that operate in Mexico have a significant advantage over operating in China in terms of efficiently addressing engineering changes and other quality control issues, especially when those issues necessitate the direct attention of North American management. Geographic proximity and a more than 40-year track record of the maquiladora industry allow Mexican operations to consistently perform at U.S. levels of quality and safety. Intellectual Property protection is another advantage of operating in Mexico. The Office of the United States Trade Representative’s 2008 “Special 301” Report of intellectual property rights protection and enforcement placed China on the “Priority Watch List” designating it as the worst offender of IP protection among the 78


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countries surveyed. While Mexico was also listed, it was designated on the lower level “Watch List.” Industrial rental rates are comparable in the two countries, averaging $4.50 per square foot NNN in China and $5.00 per square foot NNN in Mexico. Mexico provides the option to own land and buildings, while only renting is possible in China. Industrial sites in Mexico (land and building) typically range between $30-32 per square foot. Mexico boasts numerous high quality manufacturing locations. For instance the Borderplex, a metropolitan area that includes the cities of El Paso, Texas; Ciudad Juarez, Mexico; and Las Cruces, New Mexico, comprises one of the top five manufacturing employment centers in North America, with over 260,000 production workers. Located at the midpoint of the 2,000-mile U.S./Mexico border, the Borderplex offers a world-class manufacturing environment with robust international logistics and communications infrastructure. Three commercial ports of entry in the Borderplex clear more than 2,000 commercial trucks per day and more than $50 billion in annual trade between Mexico and the U.S.

A border crossing station in El Paso, Texas. As the birthplace of the maquiladora industry in the 1960s, Juarez employs one in five of all maquila industry workers in Mexico. This regional manufacturing environment includes international rail service with multiple U.S. carriers, international airports in both cities, and the largest (over 300,000 sq ft) and most modern air cargo facility on the U.S./Mexico border. Some 3,400 people make the daily commute from El Paso to Juarez to work as plant managers, engineers and other positions, often within a 30-minute time period. ■ Bob Cook can be contacted at bcook@elpasoredco.org. More information on the El Paso Regional Economic Development Corporation, a non-profit corporation dedicated to recruiting business and industry and military missions to the El Paso region, can be found at www.elpasoredco.org.

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INTERNATIONAL TECHNIC AL CONFERENCE

M O N

CONFERENCE REGISTRATION FORM

T E R

M O N T E R R E Y, N . L . M E X I C O 20–22 OCTOBER 2008 CROWNE PLAZA HOTEL

R E Y

and

Sponsored by:

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First Name

Middle

Job Title

Guest Name (if attending)

Company Address City

State

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Phone (Include Country Code)

Fax (Include Country Code)

E-mail:

[

]

MEMBERSHIP: I am a member of the following organization. (Check all that apply) ❑ ANTAAC ❑ WAI Early Registration Fee Before October 1 USD$ Only

First Full Registration

$250 ❑

Includes: Technical Program, luncheons, reception, and breaks

$210 ❑

Additional Full Registration Single Day Registration

Includes: Monday OR Tuesday technical Program, luncheons, reception, and breaks

Museum Tour Wednesday 22 October

Space is limited - preference will be given to full registrants

Tabletop & Full Registration

Includes: One full registration (see above), table, table drape, two chairs, and table tent sign

Total USD $

MAIL FAX

$135 ❑

Regular Registration Fee After October 1 USD$ Only

$280 ❑ $240 ❑ $150 ❑ N/A

$40 ❑ $700 ❑

$700 ❑

FORM TO: The Wire Association International, Inc.

FORM TO:

1570 Boston Post Road • P.O. Box 578 Guilford, CT 06437-0578 USA

REGISTRATION FEE IS PAID BY: ❑ Check enclosed in US dollars payable to The Wire Association International, Inc. ❑ Visa ❑ MasterCard ❑ American Express Fax registrations must use credit cards for payments of ALL meeting fees. Fax No.: (001) 203-453-8384 Name on Card (Please Print) Card Number Expiration Date (mm/dd/yy) Signature

Cancellation Policy: Refund requests must be received in writing by October 6, 2008 to receive a full refund. No refunds after October 6, 2008.

VISIT

THE

WAI

(001) 203-453-8384

The Wire Association International, Inc.

SITE:

www.wirenet.org for conference updates as they become available.


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INTERNATIONAL TECHNIC AL CONFERENCE

M O N

HOTEL RESERVATION FORM

T E R

M O N T E R R E Y, N . L . M E X I C O 20–22 OCTOBER 2008 CROWNE PLAZA HOTEL

R E Y

and

Sponsored by:

Reserve your room(s) at the special convention rate using any of the following methods: • Complete this reservation form and fax to (52) 81-8319-6141 • Or mail to: Crowne Plaza Monterrey Attn: Reservations Av. Constitucion Oriente 300 Monterrey, NL 64000 Mexico

ROOM RATE

(PER

:

PERSON)

U.S. $, plus tax, currently 17%

Standard Single Occupancy – $99.00 Standard Double Occupancy – $49.50

• Or call the hotel directly: In Mexico: 01 800 839 9300/01 800 000 4000 In USA: 800-637-3885 All Other Locations: (52) 01 818 319 6000 • Or e-mail: karina.gamez@hotelesmilenium.com

Superior Single Occupancy – $109.00 Superior Double Occupancy – $54.50

* Executive room rate includes continental breakfast

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Executive Single Occupancy – $129.00* Executive Double Occupancy – $64.50*

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PAYMENT: Reservations MUST be guaranteed by one of the following credit cards. ❑ Visa

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1) _________________________________________________ 2) _________________________________________________ Cancellation Policy: No charge if room is cancelled 72 hours prior to arrival. Cancellations within 72 hours will be charged for one night’s stay.

The Wire Association International, Inc.


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TECHNICAL PAPER PRESENTATIONS “Performance of boron grades versus carbon grades to produce cold heading parts class 8.8 for building and industry applications,” by B. Resiak, C. Bobadilla, M.T. Perrot-Simonetta, and M. Confente, Mittal Steel Europe Research Center, France. In Europe, highstrength screws and bolts class 8.8 or higher, obtained after heat treatment type quenching tempering, are produced from boron grades. Recently, there has been more competition from imported carbon grade parts coming from countries with low labor costs. This paper compares the potential of carbon steel grades versus boron steel grades for the production of bolts class 8.8 as defined by standard ISO 898.1. This study uses metallurgical investigations, mechanical tests, and modelling. “Analysis of different equations for calculations of wire tensile strength after patenting and drawing,” by Bogdan Golis and Jan W. Pilarczyk, Czestochowa University of Technology; Danuta Jama, the Silesian University of Technology; and Rafał Włudzik and Michał Kobyliski, Czestochowa University of Technology, Poland. This paper analyzes the work of various authors to select equations which provide the highest accuracy compared with values determined experimentally. A computer program was used which allows for tensile strength calculation after patenting and drawing. Equations from the following authors were considered: Faust, Schipley, Tulenkow, Potemkin, Manker, Baca, Pungel, and Robonyi. It was found that the tensile strength calculations after patenting using these equations was less than 2% different from values determined in the tensile test. “Influence of surface texture and residual stresses on fatigue strength of wire rope,” by Jan W. Pilarczyk, Bogdan Golis, Ryszard Budzik, Robert Kruzel, and Marek Gała, Czestochowa University of Technology, Poland. This paper presents the results of investigations into the fatigue strength of wire rope (zinc-coated and uncoated) for three steel grades: D55, D65, and D80. Residual stress and some parameters of the surface texture in longitudinal and circumferential direction were also determined. It has been proven that the hot zinc coating process lowers the fatigue strength of wire rope. This paper proposes a quantitative method for the estimation of the residual stresses, surface roughness, and material properties on the fatigue strength of the tested wire. “New approach for estimation of fatigue strength of wire rope,” by Bogdan Golis and Ryszard Budzik, Czestochowa University of Technology; Wieslaw Waszkielewicz, AGH University of Science and Technology; Honorata Howaniec, AGH University of Bielsko-Biala; and Jan W. Pilarczyk, Czestochowa University of Technology, Poland. This paper proposes a new approach to calculation of the fatigue strength of uncoated and zinc-coated wire rope. The proposed method offers the advantage of estimating fatigue properties on the basis of other wire properties. Indicators used 54 | WIRE JOURNAL INTERNATIONAL

in previous studies defined as the ratios of tensile strength to number of bends and number of twists has allowed calculation of the sum indicator Wd, which has been used for calculation of the coefficient K as a ratio of the fatigue strength to the aforementioned sum indicator. “Software tool for network reliability and availability analysis,” by Gerardo Castañón and Ana Maria Sarmiento, Instituto Tecnológico y de Estudios Superiores de Monterrey, Mexico. This paper presents an easy-to-use software tool designed to simplify the planning, design, and optimization processes for fiber access networks, and save valuable time preparing network configurations that provide a desired level of reliability, availability, and fiber length. It presents a comparative analysis of fiber network topologies—in particular, topologies such as star, ring, multilevel stars, multilevel rings, hybrid multilevel star-rings, and hybrid multilevel ring-stars.

Attendees at one of the technical presentations from the 2004 ITC in Queretaro, Mexico. “Gear pumps for the rubber industry,” by Bill Murphy, Maag Pump Systems Textron, USA. This paper reviews the benefits of gear pumps as used in the rubber industry. The gear pump is a positive displacement device that “meters” rubber at a very consistent flow. The pump generates pressure at higher efficiency versus the extruder or mixer, thus relieving the extruder from pressure building. Key benefits will be: reduced product temperature, consistent die pressure, and increased throughputs. Many of the first successes with the pumps have been in the wire and cable industry, specifically power cable running in continuous vulcanization processes. “The latest challenges in multiwire processing: drawing, annealing, and bunching,” by Niehoff. Increased metal prices and reduced metal weights in conductors are pushing wire manufacturers to find alternative and more costeffective solutions to existing applications and products. These new demands are adding complexity and challenges to wire processes and forcing equipment manufacturers to develop and refine their equipment designs to meet


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these new requirements. This paper describes the added challenges to the process and presents potential equipment solutions. “Wear of dies, measured and calculated by the process control system in a drawing machine,” by Magnus Jarl, Örebro University, and Fredrik Axelsson, Ovako Hjulsbro AB, Sweden. This paper discusses an industrial trial in a drawing machine. The final dimensions have been measured and calculated from wire weight and length, yielding calculations of dimensions within ±0.01 mm. The dimension measurements in different drafts were compared to the dimensions given by the process control system. It was found that accuracy was not satisfactory, and the wear of the dies was correlated to the wire length. “Block maintenance and coatings – what you need to know,” by Robert Galperin and Mark Patrizzia, Parkway-Kew Corporation, USA. This paper highlights the importance of proper coating selection and precise finished contours for wiredrawing equipment parts such as capstans (i.e., blocks or drums), stepcones, pulleys, sheaves, and guide rollers. It describes the available types of coatings (i.e., carbides, ceramics, and alloys), and the specific applications for which each is best suited. Emphasis is placed on the need to establish and accurately reproduce appropriate tapers along with other maintenance processes and practices. “Effect of B and Si on the formation of graphite particles in medium-carbon steels,” by Lee Hyong-Jik, POSCO, South Korea. Machining is inevitable in most cases for obtaining complicated shapes, even though advanced forming technology has been developed. Graphite particles are known to improve machinability of steels that demand high strength and high toughness as structural materials. This paper investigates the formation of graphite particles that could be accelerated by adding boron and silicon in medium-carbon steels using thermodynamic and kinetic calculations as well as dilatometric analyses.

“61-wire single-twist stranding,” by Andy Blackmore, Roteq Machinery Inc., Canada. The productivity of the single-twist machine for stranding is higher than the rigid strander. The strand quality is significantly better than that of a double-twist machine. The set-up time and setup scrap rate for this process is lower than both alternatives. Combining this performance with a stem input and the use of the Single Input Wire (SIW) strand technology makes this option an attractive alternative to traditional stranding processes. This presentation documents the performance and details the merits of this alternative stranding process. “Cumulative strain theory for simulation and development of wire rolling,” by Vladimir Bitkov, Russian Academy of Science, Russia. Specific drawing and rolling practices are required to achieve specific mechanical properties in finished wire. In choosing the diameter of initial rolled wire, it is necessary to know initial parameters of plasticity and strength. In the absence of a generalized parameter of metal plasticity, it is not possible to make a critical examination of wire reduction routes in terms of parameters of plasticity. This paper attempts to provide a mathematical apparatus based on a phenomenological model of fracture. “Dynamic preventative maintenance systems (DPMS) for purchasing in the manufacture of steel tire cord,” by Thomas W. Tyl, Tire Wire Technology, LLC, USA. Steel tire cord plants rely on PM programs to address inevitable equipment wear. Reducing PM programs in times of tight budgets jeopardizes profitability by loss of efficiency, increased operating costs, and poor in-process and final product quality. The objective is to manage PM programs through efficiencies in labor and materials resulting in the lowest cost and the highest operating levels. This paper discusses differences between traditional PM programs and Dynamic PM Systems (DPMS). “Improving wire drawing efficiency with Upcast® Cu-OF rod,” by Matti Nordman and Juan Carlos Bodington, Upcast Oy, Finland. The main copper

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grades used in electrical applications are Cu-ETP and Cu-OF. Most Cu-OF rod producers cast rod for their own use and just occasionally sell out small lots. Thus many wire and cable companies lack knowledge of, let alone experience with, Cu-OF. Fundamental differences between Cu-OF and Cu-ETP set the former in the pole position as far as drawability. However, to realize this built-in potential, the casting process must fulfill certain important requirements. “Test and evaluation of tempered bead wire in the cold-drawing process,” by Chu Shaojun, Zhang Wei, and Zhai Dan, University of Science and Technology Beijing; and Zeng Guozhen and Cao Xiaofeng, Shandong Tianlun Steel Wire Co., Ltd., China. During cold drawing, resistivity curves as a function of percent reduction for bead wire samples demonstrated a two-step behavior: resistivity decreased with an increase in the reduction per pass in the initial period until a minimal value was reached, and then increased with continued drawing. Results indicate that optimum conditions for rod bundles are lower nominal resistivity in pass reductions and/or higher total percent reduction at which the nominal resistivity reaches a minimal value. “Stress development in 1350-H14 aluminum rod drawing,” by E. Cervantes, Universidad Autónoma de Nuevo León, and J. Angelica Ramos and Sergio A. Montes, Viakable, Mexico. This paper examines coldwork hardening, as it occurs within a rod breakdown machine, in detail for aluminum rod from various sources in order to explain observed differences in processability in a wire and cable facility. Studies were performed by means of surface quality, mechanical testing, and chemical and microstructural analysis. Significant differences were found in microstructure and surface quality. The paper attempts to correlate these findings with observed behavior on the factory floor.

lower tensile stress did not have enough silicon precipitation due to lower iron and silicon content. “Estimation of thermal diffusivity of crosslinkable cable insulations,” by Sergio A. Montes, Viakable, and C.A. Alejo, Universidad Autónoma de Nuevo León, Mexico. Temperature-averaged thermal diffusivity of crosslinkable materials used as cable insulations were measured by means of heating experiments on slabs. A single value of thermal diffusivity explains the thermal response of amorphous and semi-crystalline materials, both jackets and insulations. However, crystalline materials show a thermal response that is affected by melting. Two mathematical treatments based on a finite difference scheme were used to calculate an average diffusivity value. “Screw selection and extruder considerations for wire and cable coating,” by Edward Steward, American Kuhne Corp., USA. Wire coating extruders are often asked to handle several polymers and/or a wide range of operating conditions in production. Selecting the proper screw to optimally handle the requirements set forth is important to maximizing performance and profitability. Screws over the years have evolved and today’s barrier screws are widely used, but the simpler screws of the past still fit well in some applications. This paper will cover screw and extruder performance features for many of today’s wire and cable applications.

“Effect of iron and silicon content and previous cold work on 1350 aluminum alloy,” by Jesus O. González and J.L. Cavazos, Universidad Autónoma de Nuevo León, and Sergio A. Montes and J. Angelica Ramos, Viakable, Mexico. Properties of two different aluminum rod lots were studied in this paper. Differences in ultimate tensile stress were observed after wiredrawing, even though both samples complied with the standard chemical composition. A microstructural analysis was carried out by means of optical and scanning electronic microscopy. Results showed that the aluminum rod sample with the

AUGUST 2008 | 57

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“Effect of active screen plasma nitriding parameters on the behavior of a low-alloy steel,” by Farrokh Taherkhani, Amirkabir University of Technology, and Elham Taherkhani, Iran. This paper considers the effects of plasma nitriding process parameters such as: temperature and composition of the treatment gas; and active screen set up parameters—including the type of the

Antonio Ayala, co-chairman of the local organizing committee, and Steve Fetteroll, WAI executive director at the 2004 ITC in Queretaro, Mexico.

58 | WIRE JOURNAL INTERNATIONAL

top lid (screen or simple) and the screen hole size—on low alloy steel DIN 1.6580 in the active screen plasma nitriding method. The nitriding process was carried out at 550 and 580°C for five hours in a nitrogen and hydrogen atmosphere with a volume ratio (N2/H2) of 1/3 and 3/1. All of the treated samples were characterized using metallographic techniques, XRD, SEM and micro-hardness methods. X-ray diffraction analysis showed the formation of the phases and confirmed the development of phases during the nitriding process. The results show that an increase in the compound layer thickness, with increased treatment temperature and screen hole size at the same temperature, have no effect on the layer thickness when a screen top lid is used; and when the iron plate is used (simple condition) the layer thickness increases with the increases in the screen hole size at the same temperature. The micro-hardness profiles show that surface hardness increases with increasing nitriding temperature as well as %Vol. nitrogen in the treatment gas mixture. It was also indicated that hardness values obtained using a screen top lid are only incrementally more than those obtained with using a simple top lid. It was found that the steel top lid has little effect on the micro-hardness of samples. “Rapid tensile test elongation study for measuring the annealability of copper rod,” by José Luis Magaña Leon and Elias Fernández G., Conticon, S.A. de C.V.,


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México. A mathematical model, based upon precise elongation testing of annealed copper rod and its relationship to element (chemical analysis) content was obtained to predict the annealability elongation of copper rod.

tion with PVC type THW-LS/THHW-LS, cables with thermofixed insulation with XLP type XHHW-2 LS and cables with armor steel or aluminum with conductors of copper or aluminium alloy of AA 8000 series. ■

Check www.wirenet.org for the most current technical “Performance based lubrication: What does it mean?,” paper schedule. by Roy Warner, Envirotec, New Zealand. Experienced contributors to the wire industry know that, in broad terms, the three fundamental materials required are: rod, lubricant, and dies. It is contended that any manufacturer of a wire product must have direct performance-based systems in place for each of these three materials in order to: optimize their control of a quality product; maximize their bottom-line; and establish themselves as a leader in their given industry. “Envirotec Purification System” is fast becoming associated with quality performance within the industry. Various controlled tests have been conducted to demonstrate the benefits of applying measures, controls, and purification to the lubrication aspect of the three fundamental aspects of wiredrawing. High Performance Conductors is the recognized industry leader Reduced friction, reduced cost, reduced waste generation, and in lightweight conductor engineering and technology for the improved quality are the demonstrated results of a ‘performance based aerospace industry. Our Tensile Flex® Alloy 135 has been imitated, lubrication’ system.

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“Utilizing the high productivity of double-twist machines in the manufacture of power cables,” by Sean Harrington, Ceeco Bartell, Canada. The production of power cable incorporating double twist machines is a rapidly expanding area. This is due in no small part to the economic advantages and product flexibility of using this type of machine, especially when coupled with Ceeco Bartell’s parented roll form technology. “New cable requirements for the building industry in Mexico,” by Jesús Martín Ricárdez Barberá; Conductores Mexicanos Eléctricos y de Telecomunicaciones S.A. de C.V., Mexico. This paper will show the types of electrical conductors required to meet the Mexican official norm (specs) of electrical systems (NOM-001-SEDE-2005) and electrical conductors (NOM-063-2001SCFI) for the construction market. It will show the requirements of construction, test, electrical installations and fulfillment of the RoHS directive for cables with thermoplastic insula-

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Wire Expo 2008:

tech, exhibits and a site for business

Pittsburgh proved to be a good host for Wire Expo 2008, which was held June 7-10 at the David L. Lawrence Convention Center, Pittsburgh, Pennsylvania, USA. The event, which included the Wire Association International’s 78th Annual Convention, drew a total participation of 1,957 people. Participants came from 38 states, including a healthy amount of drive-in traffic from wire plants in the surrounding regions of Pennsylvania, Ohio, New York, Indiana and Michigan. The event also had an international element, with representatives from

31 countries who were there for the exhibits or technical programs or business meetings. A sampling of comments about Wire Expo from attendees who were not exhibitors or active WAI volunteers, starts on the opposite page. “As chairman of the local planning committee for the Wire Expo show in Boston in 2006, we expected and saw strong support from the New England contingent of wire professionals,” said WAI President Ronald Reed. “This year we were pleased with the turnout for the individual elements of the event, and although overall attendance

Keynote speaker General Cable’s Mark Thackeray explains General Cable pursuit of lean manufacturing.

Activity at the Condat Corporation booth, where Neil Lowdon later made a Production Solutions presentation.

60 | WIRE JOURNAL INTERNATIONAL


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Comments from Wire Expo 2008 attendees It was very nice to get back to the show after many years of absence. I have always enjoyed the interaction and camaraderie of the show attendees. It is also a very good way of seeing what is happening in the industry around the world, providing you make the effort to meet with others. Terry Bartel, Charter Steel.

Not a lot of exhibits, even for an off-year show. Henry Jarboe, AFL Telecommunications.

It was very important to meet suppliers and success the steel market. The show was OK but everyone in the steel industry was there. Derek Burghardt, ITW Paslode. WAI President Ron Reed welcomes attendees at the Kickoff Awards ceremony.

This year’s circumstances in the market made the meeting less valuable than other years. Mills are sold out, material is on allocation and rehashing tough market conditions was not pleasant. Brad Martin, Metal Solutions LLC.

At the Esteves Group booth, Gary Kantz explains die fine points, part of the Product Solutions show floor program. . It provided the opportunity to meet with people who you have dealt with for years and share ideas and also meet new wire business personnel. Steve Bungo, Delphi Packard. Very informative regarding new products and machinery and as always it is great to meet people face to face when in conversation. John Ray, orth American Wire LC.

Anand Bhagwat, who heads the WAI’s India subsidiary, discusses operations there during the board meeting.

It is sad to watch the continuing decline of U.S. manufacturing. I walked the entire show in an hour, saw everyone I needed to see and flew back to New York. Is it harder and harder for the small manufacturer to find parts, affordable manufacturing alternatives and resources to compete against Asian competitors. James Larkin, Reinforcing Supply.

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Comments ... (cont’d.) Very informative. Work booths were very well done. Due to the steel markets globally, this is one way to stay in touch and also witness the new technology regarding equipment relating to operational efficiencies. Wayne Scott, Emerson. Well thought out, well organized, good venue, well advertised. Derek Saxby, Ivaco Rolling Mills.

Wire Expo was very informative and educational. Paul Duval, Venus Stainless. Just seems the off-year shows have less value and participation as the main. George Yura, Bridon American Corp. It’s been many years since I attended a Wire Expo. I was surprised that there were not as many vendors as there used to be. John Sorenson, First Capitol Wire & Cable. It is easy in manufacturing to get locked into “everyday” mode. It was good to get away and speak with people and see presentations on different ways of doing things. It helps me to have a fresh look at things. Tracy Gooding, Mar-Mac Wire Company. The show is more orientated towards ferrous people. I am a non-ferrous person. Robert Delp, First Capitol Wire and Cable. Overall, the show was just what I was looking for, with the exception of no actual wiredrawing machine companies being represented. Terry Battaglia, Buffalo Wire Works.

FMS was one of more than 250 exhibiting companies ready to offer solutions to attendees.

was 18% shy of the 2006 figures, Wire Expo continues to provide a productive forum for the North American wire and cable industry to exchange information and better understand the trends in today’s quickly changing environment. As a wire manufacturer, I welcome the chance to learn from my peers on key subjects including raw material sourcing, energy management, and productivity advancements as well as lean and green manufacturing.” The WAI Awards ceremony was a noteworthy event. It featured an excellent presentation by Mark A. Thackeray, Senior Vice President, North American Operations, General Cable, whose keynote address, “Pursuit of Manufacturing Excellence – A Journey,” gave an insider’s view of what the company has been able to achieve from its focus on lean manufacturing. WJI plans to have more on this in the September issue.

As a first-time attendee, I would have thought that there would have been better participation by machine manufacturers. I realize that this is an off-year show, but even just having a booth to discuss with representatives would have been helpful. Gary Morykwas, Brush Wellman. It´s an extremely useful way of contacting colleagues and to follow up “state of the art” technologies. It´s even very useful to know which problems are not still solved in the wire world. Leandro Rey, Acindar Group ArcelorMittal. While the show was relatively small, it gave us a great opportunity to visit with other vendors and potential vendors of interest. This opportunity is of significant value since it is not always cost effective for all U.S. vendors to make special trips into Canada to visit potential customers. Dennis Olexiuk, Leoni Eloxiuk Limited.

62 | WIRE JOURNAL INTERNATIONAL

Al Clement and Don Fisher spread the good word about what Wafios can offer manufacturers.


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The Awards ceremony also saw the presentation of the Mordica Memorial Award to Dr. Bhaskar Yalamanchili. Accompanied by his wife, Radha, and son, Rajeev, and a table of co-workers and colleagues, he explained why the award meant so much to him. For that and more, turn to p. 74 to read the Mordica Lecture that he presented later that morning. The Donnellan Memorial Award was presented to two individuals: Italy’s Giulio Properzi, a unique man who in addition to serving as WAI president and helping the formation of the WAI’s Italy Chapter, serving as its president, was a key driver in the Association’s ability to put on International Technical Conferences in Italy. The other Donnellan winner was the late Barry Loudon, the former president of the Australasian Wire Industry Association, who received the award posthumously. A very active member of the WAI’s Board of Directors Loudon died in 2006 at age 53. Accepting the award on his behalf were his three daughters, Catherine, Alexandra and Kirrilee. The speech by Catherine was a moving tribute, one that resulted in a standing ovation from the crowd. See p. 65. During the awards ceremony, the WAI honored its new 25-year and Life members as well as award-winning authors. Those include: Ferrous Division: the Allan B.

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Winners of the WAI’s Mordica and Donnellan awards. Representing the late Barry Loudon, a posthumous co-winner of the Donnellan Memorial Award, are his daughters Catherine, Alexandra and Kirrilee; Mordica Memorial Award winner Dr. Bhaskar Yalamachili; and Giulio Properzi, co-winner of the Donnellan Memorial Award.

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ACKNOWLEDGES THE FOLLOWING CONTRIBUTORS TO THE

WIRE EXPO 2008 TECHNICAL PROGRAM The educational program at Wire Expo 2008 was the result of the combined efforts of dozens of experts, volunteers, and special guests. This year’s successful program would not have been possible without their dedication to the Wire Association International’s educational mission.

AUTHORS/PRESENTERS

D. Kashiyama

Ian Winfield

GUEST SPEAKERS

Motoo Asakawa

Ryosuke Komami

Rafal Wludzik

Gary Hoover

Jose Miguel Atienza

Jan Krnac

Roger N. Wright

Mark A. Thackeray

Gil Baker

Hiroaki Kubota

Shingo Yamasaki

Sonia Benesova

Neil Lowdon

E. M. Yokley

ORGANIZERS

Gerhard Boockmann

Joe Memmott

Kazunari Yoshida

Dane Armendariz

Michaela Boockmann

Seiki Nishida

Robert T. Young

Michael Caranna

Iain Brooks

Christine Pallin

Ryszard Budzik

G. Palumbo

MODERATORS

Tom Maxwell, Jr.

Frédéric Deschampt

Jan W. Pilarczyk

Robert Glodowski

Aaron Nolan

Manuel Elices

Horace Pops

Giuseppe Marcantoni

Ralph Noonan

Marek Gala

Jesus Ruiz-Hervias

Nicholas Nickoletopoulos

Mark Sitar

B.P. Gautham

Harishankar Shantharam

Don Schollin

Ernest Stricsek

Rosario A. Gerhardt

Robert M. Shemenski

Bo Vandromme

Bogdan Golis

Surya Kumar Singh

Sharad Goyal

B. Sriram

COURSE INSTRUCTORS

Gary N. Graham

Yea-Yang Su

Thomas Black

Dinesh Gudadhe

Tsuyoshi Sugiyama

Peter Blokker

David P. Gzesh

Michal Szota

Dieter Brandstätter

Ryota Hamada

Koichiro Tanabe

Marco Gerardo

R. Heard

Yuichi Tanaka

Rick Gordon

Daisuke Hirakami

Toshimi Tarui

Sean Harrington

Tom Horn

Thomas W. Tyl

Tom Maxwell, Jr.

Jozef Jasinski

Motohiko Urabe

Horace Pops

Satoshi Kajino

Grzegorz Walczak

Robert M. Shemenski

Gary Kantz

Wieslaw Waszkielewicz

Rob Fulop

SUPPORTING SPONSORS American Wire Producers Association (AWPA) Society of Plastics Engineers (SPE) EDUCATIONAL ALLIANCES Asociación Nacional de Transformadores de Acero, AC (ANTAAC) Australasian Wire Industry Association (AWIA)

Wire Expo 2008 is organized by The Wire Association International, Inc. 1570 Boston Post Road • P.O. Box 578 • Guilford, CT 06437-0578 USA Tel.: (001) 203-453-2777 • Fax: (001) 203-453-8384 • Web site: www.wirenet.org


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Acceptance speech a most fitting tribute Below are the remarks made by Catherine Loudon, 22, during the awards ceremony at Wire Expo 2008. With her on the stage were sisters Alexandra, 20, and Kirrilee, 18, all of whom came from Australia to accept the Donnellan Memorial Award on behalf of their late father, Barry Loudon, the former president of the Australasian Wire Industry Association. A very active member of the WAI’s Board of Directors, he died in 2006 at age 53. On behalf of my dad, my sisters and my family I would like to thank you for this prestigious award. At home we have so many photos of my dad making speeches at conferences just like this that it feels strange to be up here in his place but it is also a real honor. At his funeral Malcolm Michael described our dad as a champion of the wire industry and this award is testament to that. Barry put so much effort into this industry and still

With her father’s image on the screen, Catherine Loudon accepts the Donnellan Memorial Award. The awards ceremony audience gave her a standing ovation.

managed the time to be a full time dad to us, as well as to have a drink at the pub with his mates. It is only since he passed away and we have heard comments from his friends and colleagues that we have come to realize the commitment and love he had for what he did. He was incredibly dedicated to his work and went to extraordinary lengths to push the industry forward. I believe that the Australasian Wire Industry Association’s alliance with the WAI was made possible directly through his efforts. We would like to offer our congratulations to Mr. Properzi who, We were so excited to knowing the amount hear about this award of work our dad put and to be able to be in, must have shown the same dedication. here to accept it, yet We would also we were sad that dad like to thank you for never knew about it. giving us the opportunity to be here to accept the award. For us this is a once in a lifetime opportunity and it has been an absolutely unforgettable experience. We were so excited to hear about this award and to be able to be here to accept it, yet we are sad that dad never knew about it. Knowing the kind of person he was however, he probably would have felt that he hadn’t done anything extraordinary and that he didn’t deserve it. We would also like to thank Malcolm Michael for the nomination as this wouldn’t have happened without him. Malcolm was a good friend to dad and has done such a wonderful job of taking on the role of director secretary of the AWIA after his passing. We would also like to extend a personal thank you to Steve Fetteroll for his efforts in organizing the trip for us. He truly went above and beyond to make sure everything ran as smoothly as possible for us. Finally, to dad, we love you and miss you and we are so proud of you. Thank you.

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The Ferrous Wire Handbook is published by The Wire Association International, Inc. 1570 Boston Post Road • P.O. Box 578 • Guilford, CT 06437-0578 USA Tel.: (001) 203-453-2777 • Fax: (001) 203-453-8384 • Web site: www.wirenet.org


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Kamatics was willing to bend (its products) over backwards to show the value of its replacement bows.

SAMP USA’s Dominique Perroud talks to attendees.

Dove Memorial Award went to Lucas Franciga and Jorgelina Geisler, Acindar SA, Argentina; and Paulo Cetlin and Cristiano Cunha, Federal University of Minas Gerais, Brazil, for their paper, “Analysis of the forming of points in wire nails.” The Silver Certificate Award in the Ferrous Division went to Andrew Bell, Shaun Hobson, and John Wilkinson, Corus; and Chris O’Connor and Sara Sefton,

Bridon International Ltd., UK, for their paper: “Development of ultra high-strength wire for offshore applications.” Nonferrous Division: the Marshall V. Yokelson Memorial Medal Award went to Horace Pops, Horace Pops Consulting, Inc., USA, for his paper, “Processing of wire from antiquity to the future.” The Silver Certificate Award in the Nonferrous Division went to Kazunari

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AUGUST 2008 | 67


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The WAI’s Conference Programing Committee was among those that met at Pittsburgh.

Rick Gordon, Gerdau Ameristeel, discusses stainless steel technology as part of the WAI’s fundamentals course.

Yoshida and Miki Matsunaga, Tokai University, Japan, for their paper, “Fabrication of shaped medical testing wire by drawing.” Electrical Division: The Urbain J.H. Malo Memorial Medal Award went to Walt Ogrodnik, HazardGuard Safety Wire, Inc., USA, for his paper, “Use of colorchanging pigments to detect wire and cable hazards.”

The Silver Certificate Award in the Electrical Division went to Andrea Cavallini, Davide Fabiani, and Gian Carlo Montanari, University of Bologna, Italy, for their paper, “Evaluation of motor winding insulation performance under pulse waveforms through electrical measurements.” In the General Division, the Horace Pops Award went to Michel Hone and Nicholas Nickoletopoulos, Ivaco

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By the Continuus Properzi booth, instructor Horace Pops talks about wire breaks as part of Production Solutions.

WAI past presidents gather for a group shot outside the convention center.

Rolling Mills; and Darryl Seaman, CedarRidge Technologies, Inc., Canada, for their paper, “The Mobile Impact Tester for cold heading research at Ivaco Rolling Mills.” The Silver Certificate Award in the General Division went to Les Jenson and Mike Kordik, Beta LaserMike, for their paper, “The application of Laser Doppler Velocimetry for the non-contact speed/length

measurement and sequential printing of wire and cable products to decrease costs and improve productivity.” The education forums began over the weekend with the two-day “Fundamentals of Wire Manufacturing” course, which drew approximately 40 attendees. On Tuesday, the forum was the show floor, where three instructors (Horace Pops at the Continuus Properzi booth, Gary

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Kantz at the Esteves Group booth and Neil Lowdon at the Condat Corporation booth) made presentations that drew dozens of attendees. On Wednesday, 15 attendees were part of Tom Black’s extrusion workshop, which continues to get high ratings from the students. Some of the largest crowds were for the three Production Solutions presentations made on the show floor, but the technical papers continued to be the anchor, with some two dozen papers presented on Tuesday and Wednesday. The week’s social activities were tailored to the regional setting beginning with WAI’s 5K Road Race, sponsored by exhibiting company Leoni Wire, in support of the local Mario Lemieux Foundation. The event was held late Sunday afternoon under very hot, very humid conditions, with the winner Motohiko Urabe, age 22, a student at the Department of Mechanical Engineering, School of

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Moderator Don Schollin with tech authors (l-r): Yuichi Tanaka, Tsuyoshi Sugiyama, Koichiro Tanabe, Motohiko Urabe, Prof. Kazanuri Yoshida and Prof. Motoo Asakawa.


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As ever, the WAI’s Opening Reception made for a good opportunity to mingle.

Flanked by WAI’s Steve Fetteroll and WAI 1st V.P. Antonio Ayala, WAI President Ron Reed displays the new Ferrous Handbook at the board of directors meeting.

Science and Engineering, at Japan’s Waseda University. His win was especially impressive as he and fellow runner Yuichi Tanaka had just completed their long flight to the U.S. a few hours earlier. A total of 17 runners competed and all finished. The following day featured WAI’s traditional Opening

Reception, held this year on the third floor and veranda of the Convention Center, which gave visitors an appreciation for the cable work in Pittsburgh’s many bridge infrastructures. It also provided an exceptional view of the massive cable structures used in the Convention Center itself. On Tuesday, WAI’s Ohio Valley Chapter organized

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Motohiko Urabe, Waseda University, winner of the WAI’s fourth annual 5K Industry Run, accepts an award from eville Crabbe, Leoni Wire, the event sponsor.

a group outing to PNC Park that was sponsored by Gem Gravure Co. Inc., also an exhibiting company. It was a great evening for baseball, with pleasant weather and five home runs although the home team Pirates, just one strike away from a win, gave up two runs in the ninth inning and lost. And, of course, many attendees and guests found their own destinations to enjoy in Pittsburgh. Wire Expo 2008 was supported by sponsoring organizations including: The American Wire Producers Association (AWPA) and The Society of Plastics Engineers (SPE). WAI has educational alliances with the Australasian Wire Industry Association (AWIA) and the

Attendees at the baseball outing at PNC Park, sponsored by Gem Gravure, react to the first of five home runs.

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Gem Gravure President Dave Gemelli gets an award from WAI President Ron Reed for his long-time support. At left is WAI’s Chip Marsh and at right, wrestling legend Bruno Sammartino, who also donned Gem’s “green” look.

Asociación Nacional de Transformadores de Acero, A.C., (ANTAAC), which represents ferrous wire manufacturing operations in Mexico. Wire Expo is held biennially for the wire and cable manufacturing industry. Initiated in 1990 in Boston, Wire Expo offers global industry information in a regional setting and a timely meeting point for suppliers, manufacturers, buyers, researchers, and industry pioneers from around the globe. The date and location for Wire Expo 2010 will be announced later this year. ■

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The city of Pittsburgh got a “thumbs” up from this unofficial tour group.

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LECTURE

My professional career and experiences in the wire industry The below Mordica Lecture, presented at Wire Expo 2008, traces lessons learned and experiences gained by the recipient, including the value of setting and following through on goals, strong team work and management support. By Dr. Bhaskar Yalamanchili

Good morning ladies and gentleman. It is a great pleasure and honor to be here after receiving the Mordica Memorial Award and I want to give something back to you and the Wire Association. What I would like to do is review some basics of what I was able to achieve in this profession and how it was possible. First of all, you have to have a good education, and I am very fortunate to have parents who supported me all the way through my educational career. I would not be here today giving this lecture without having had their strong support. Because of it, I was fortunate enough in 1971 to attend the Indian Institute of Technology, where I obtained my B.Sc. degree in metallurgy. Next, after entering the work force, you have to decide whether you will try to do everything yourself or choose to be a team player. I chose the latter and have been fortunate to have worked with good people throughout my entire international career. I was also very blessed to have had

Fig. 1. Under-deoxidized steel.

Fig. 2. Fully deoxidized steel.

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several mentors. One of my earliest mentors was Dr. R.H.G. Rau, who guided me while I was starting to climb the ladder. Without having to stretch as a person to learn and meet his initial stringent quality requirements, I would not be here today. When I moved from one side of the globe to the other, I was very fortunate to work for a second superb mentor, Dr. Alan Gorton, chief metallurgist for Atlantic Steel Company in Atlanta, Georgia, who showed me the path to succeed in an entirely different world. Dr. Gorton’s coaching and guidance were also crucial to my achieving this award, and I owe my gratitude to him. What did I learn from these fine gentlemen? One thing is that you have to have goals: daily, weekly, monthly, yearly and lifelong. I can tell you that, without these, your potential will not be fully developed. It is easy to write down the goals but if you do not follow through and execute them, you will never achieve to your full potential. Success or

Fig. 3. Cracks initiated in sanding marks.

Fig. 4. Breakage of coat hanger.


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failure comes through execution! One of my friends and another close mentor, Peter Power, asked me how was I able to coauthor 26 technical papers apart from the normal day-to-day firefighting. I said to Pete, it is all vision, determination and execution. You will always find the time if you know what you really want to achieve, and plan accordingly.

“I would also like to stress one thing I have learned over the years in this industry: you need to have a passion for what you do, for that is what leads to results.” I would also like to thank my employer, Gerdau Ameristeel, for supporting me in my professional endeavors. I am very grateful that the company permitted me to do what I needed to do for my future growth. Last, but not least, I want to acknowledge the tremendous impact that the Wire Association has made. The conventions, committees, seminars, literature and friendships have all contributed immeasurably to the advancement of my career. I am very grateful for all that the WAI has done for me. I would also like to stress one thing I have learned over the years in this industry: you need to have a passion for what you do, for that is what leads to results. In my case, it led to recognition in the form of this Mordica Award. At this point, I would like to review some of the quality and metallurgical contributions that my teams and I have made to the wire rod industry. Some industrial experiences and contributions Resistivity measurements in telephone wire. During my first internship job in India, at Mukand Iron and Steel Company, I was asked to develop a low-carbon grade of steel to meet the restricted resistivity requirements for telephone wire. With the help of Dr. Rau and my colleagues,

Fig. 5. Tensile vs. % reduction for boron and non-boron.

we produced several different chemistries for testing trials of both rod and customers’ wire. Finally, we were successful in meeting all requirements specified by the leading International Standards governing this grade of wire. Introduction of oxygen probe to assist deoxidation practice. While producing steel by the newly installed continuous casting process at Atlantic Steel, we encountered a serious problem with under-deoxidation that resulted in pinholes and blow holes in the billets as shown in Fig. 1. With the help of Electro-Nite, we were able to measure the dissolved oxygen and thus optimize our deoxidation practice to produce the defect-free, fully deoxidized steel as shown in Fig. 2. This work, coupled with help from Dr. Gorton and the college facilities, enabled me to complete the thesis requirement for my M.S. degree in metallurgy from the Georgia Institute of Technology. This thesis formed the basis for the measurement of dissolved oxygen in liquid steel to assure complete deoxidation that is still being used. Use of a Scanning Electron Microscope (SEM). One interesting investigation using this modern metallurgical tool led to the conclusion that surface sanding striations were responsible for initiating the stress raiser cracks that caused the forming fractures. See Fig. 3. The technique clearly identified that the problem was not caused by the steel itself, but rather originated during the customer’s mechanical descaling operation. The saying goes that “The customer is always right,” but they will accept responsibility for their faults, if you have good metallurgical evidence to solve the case. The SEM did just that. Boron in low carbon (patent). One of our sales managers, Bill Swift, sent a memo asking if we could help reduce the breakage that was occurring during forming of coat hangers such as the example shown in Fig. 4. This led to the concept of controlling the boron-to-nitrogen ratio in order to reduce the work hardening effect. Our team, consisting of Thad Boudreaux, Frank Wisniewski and Pete Power, designed chemistry that reduced the work hardening during drawing as well as the subsequent aging. At the time, we faced some objections from the melt shop management who were reluctant to use boron due to its

Fig. 6. Resistance to plastic deformation of metals (presence of nitrogen). AUGUST 2008 | 75

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Fig. 7. Dislocation tangles.

Fig. 8. B particle.

Fig. 9. Surface damage, “As received.”

Fig. 10. Martensite formed by the damage in Fig. 9. 76 | WIRE JOURNAL INTERNATIONAL

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cost. However, we were able to convince management of the potential value of trying this and obtained permission to produce just one heat. The results were extremely interesting! Steve Filips, our plant manager at that time, agreed to proceed with making more heats in order to satisfy our quality goals. This work eventually led to filing and acceptance of a U.S. patent titled “Process for producing low carbon steel for cold drawing.” The reduction of tensile strength gain obtained during drawing that resulted from this practice is substantial as shown in Fig. 5. It was our understanding of the fundamental metallurgical principles involved that made it possible to solve this problem. The nitrogen solute atoms increase resistance to plastic deformation during wiredrawing (Fig. 6). This adds to the amount of strain hardening by increasing the dislocation density that results from tangling (Fig. 7). Boron combines with the nitrogen to form BN inclusions (Fig. 8), thus removing its effect on the dislocations. Concurrently, this work also served to satisfy the requirements for my thesis and doctoral degree obtained from Lamar University in 2002. The improvement in ductility resulting from the boron addition has become well recognized, and is now a normal practice in our industry. Rod coil rust guide. Our group thought this to be very subjective, and that we needed a more scientific measurement of the degree of rusting required. This would facilitate communication between customer and suppliers by having a “common language” for setting specifications. With this concept we developed a Rust Guide of photographs showing various rust levels on the rod coil (see Appendix 1). This tool is now being utilized regularly by many of our customers. Mechanical damage. After making good quality steel wire rod, if proper care is not taken, it is very easy to damage its surface (Fig. 9). It is also very common to produce surface martensite in high-carbon grades when a coil is scraped mechanically (Fig. 10). Extreme care, therefore, is needed to protect the surface in order to avoid costly mistakes and increase the cost of quality. Vigorous training and explanations have been able to solve/reduce these kinds of quality problems. Chevron cracking analysis. Chevron cracking is an all too common problem for wire drawers. In our experience it was mainly due to the segregation of elements at the center of the continuously cast high-carbon billets. Our groups worked on this problem for many years to improve billet casting practices that were designed to minimize segregation. Much work was also done with the controlled cooling practices in the rod mill in order to minimize the formation of hard, non-deformable microstructures at the centerline. Since there are many causes for this phenomenon, we finally developed a Cause Analysis Chart as shown in Appendix 2, to guide us through the identification of the various causes for chevron cracking. Utilizing this technique, along with identifying some of the metallurgical phenomena involved, we were able to solve one of our


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customer’s unique problems relating to chevron cracking. Publication of this case, which highlighted the steelmaking practices used to control nitrogen, ultimately led us to winning the WAI Silver Certificate Award for best ferrous paper in 2004. Tensile gain rate reduction. In response to the WAI theme

“You have to have a quality leader at the top who believes in quality and supports your corrective action decisions.”

several obstacles to quality before qualifying as a reliable supplier of rod for prestressed concrete strand. During this period, we needed much support from plant management and were fortunate to get that from our plant manager John Harrell, to whom I owe much thanks. Having reached this plateau, the next challenge was to develop rod for cable stay wire. One day, while we were at the 2004 Cleveland wire show, we received news that the wire rod trial we had produced for cable stay had failed our stringent testing. This message was passed on to our then-plant manager, Greg Bott, who quickly responded and gave directions to make another trial heat in the attempt to meet customer requirements. You have to have a quality leader at the top who believes in quality and supports your corrective action decisions. Well, I can proudly report that this support enabled us to produce the required cable stay quality rod

session on this topic we reviewed the literature, and our experiences, to write a paper that described and explained the available methods. Our objective was to assist wire drawers and rod producers to combine their practices for optimum results. This work was summarized in chart form for easy reference as in Appendix 3. Cable stay wire. We required several years to overcome

Fig. 11. The Charleston cable stay bridge, whose early patrons include the Mordica Memorial Award winner.

Fig. 12. Life cycle graph.

Appendix 1. Rod coil rust guide.

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Appendix 2. Chevron cracking cause analysis chart.

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Appendix 3. Methods to reduce tensile gain rate.

for Sumiden, which included it in their material that was supplied to build the new Charleston Bridge (Fig. 11). I am very pleased to say I drove over that bridge with great pride. Thank you, Greg, for your bold decision in support of quality development. Mentoring Over the years we have had several rewarding experiences in mentoring. I am particularly proud to have been able to succeed in having two department members – Thad Boudreaux and Huey Hampton – work for several years during their spare time in order to receive their degrees from Lamar University and Lamar Institute of Technology some 25 years after high school graduation. They are now working for us at much higher level jobs. Planning for the future by mentoring associates and professionals new to the industry is a powerful way to contribute to the success of both your organization and the individuals involved.

Contributing to the Wire Association Five of the nine examples given above were taken from our “regular work” that eventually served as the basis for papers that were published in Wire Journal International. We also work with several universities and their students to provide them the opportunity to do industrial-based projects that fulfill the requirements for their master’s and doctoral theses (11 and 2, respectively). Two of these projects have resulted in WAI papers that we co-authored with the students. While preparing the work for publication does add significant work, I can truthfully say that this has greatly contributed to the learning and professionalism of all involved. This, in turn, prepared us all to meet even greater challenges for our company. There are many other ways in which to contribute to the Wire Association. There are currently 13 WAI committees whose work depends on members with expertise to volunteer the necessary time and effort for action. There are ongoing

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educational seminars that are prepared and presented by member volunteers, and the list goes on and on. Having served on several of these committees, I can say from experience that they have all greatly helped me in return. Some Lessons Learned Continuous improvement is necessary. Considering the standard life-cycle graph as shown in Fig. 12, all technical professionals should look for ways to lead their organizations to the achievement of continuous quality improvement. You need to think always that you are on the left side – “Good” – of this curve and need to continually strive for “Great.” If you think you are already on top at “Great” and ignore improvement, the next step soon will be the “Gone” of obsolescence. So, always think at the bottom and keep aiming for the top. Seek excellence and you will not only achieve your goals but also be able to make valuable and necessary contributions to your companies and to our Wire Association International. Working as a team. We have all heard it said, in very many ways and from very many sources, that we should work “as a team.” Based on my experience, I emphatically add my voice to this chorus! Being part of a group that competently, objectively works together definitely leads synergistically to the achievement of better results than any individual could ever do alone. In bringing technical service to the customer, it is paramount to have strong support from sales. We have been very fortunate to have had this from our sales team for several years under Ed Goettl’s leadership.

“We are all very fortunate to be working in such an industry. After all, wire in its myriad forms is the world’s most versatile engineering material.” Problem solving and innovative thinking. Long term success requires this kind of thinking so that process improvements can be made in order to achieve the necessary quality requirements at least cost and maximum yield. Achieving product quality should not be a needless expense. I learned this through one of our strongly supportive customers. When a customer is pushing for extreme higher quality levels at your expense, you should challenge that customer to prove that it is actually necessary to have such stringent quality requirements for that particular end use. Upper management support is a must. It is necessary that you win the support of upper management in order to achieve your quality goals. This requires credibility, objectivity, and an ongoing list of achievements.

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Mentoring is valuable. Be alert for opportunities to become actively involved in supporting the career development of others. Participation in industry and professional organizations. This is another valuable means to enhance the careers of all who become actively involved. Ongoing education. Always seek to improve your knowledge through continuing education and industry sponsored seminars. Advancement of technology. Recognize and implement opportunities for the advancement of technology in your work environment. In Conclusion By reviewing my experiences, I hope that I have revealed how diversified and stimulating our wire industry is, and really can be, for you. We are all very fortunate to be working in such an industry. After all, wire in its myriad forms is the world’s most versatile engineering material. It has tremendous scope for challenging all who are involved with it; most of its problems are solvable without requiring a genius; the opportunities to contribute are many, and the rewards from your efforts can be great. Remember, John Mordica was just as busy as we all are, but he made the time to establish, and nurture the Wire Association, which has become an invaluable asset to our industry and all our careers. So I end in a paraphrase by asking all of you to consider “What can you do for the Wire Association, rather than what can the Wire Association do for you.” Acknowledgement I especially want to thank the Wire Association for the honor of this award and humbly accept it on behalf of all my colleagues and myself. As you can see from this review, strong team work and management support is necessary in order to achieve your goals. Therefore, I want to thank, and am most grateful for, all the help I have received from those mentioned above as well as from all those too numerous to mention here. I want to thank Marc Murray for his referencing support in preparing this lecture. My sincere thanks also go to Lorna Warner for her excellent help in drafting and preparing this presentation as well as for other reports and publications she has done over the years. Last, but not least, I am extremely grateful to my family, Radha, Ranjit and Rajeev, without whose support and sacrifices, I could not have achieved this award. ■


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Baskar Yalamanchili speaking at the Awards Breakfast at Wire Expo 2008.

Dr. Bhaskar Yalamanchili, the 2008 Mordica Memorial Award winner, is Director of Corporate Quality for Gerdau Ameristeel (Gerdau). He is responsible for coordinating process/product quality and quality assurance of Gerdau’s 18 plants. He had previously served as Manager Product Development & Technology for its plant in Beaumont, Texas, where he had served in quality assurance when it was the North Star Steel Beaumont plant. Prior to North Star Steel, he was a chief metallurgist for Iron & Steel Co. of Trinidad and Tobago (Mittal); developmental and melt shop metallurgist at Atlantic Steel Co. (Gerdau); rolling mill metallurgist at Super Alloys plant (MIDHANI) at Hyderabad; and quality control metallurgist at Mukand Iron and Steel, Bombay. He holds advanced degrees that include a Ph.D. in engineering from Lamar University, an M.S. degree in process metallurgy from Georgia Institute of Technology; an M.S. degree in physical metallurgy from Indian Institute of Technology; and a B.S. degree in metallurgy from Banaras Hindu University. He has published 26 technical papers, coauthoring a 2004 award-winner, and holds a patent in producing low carbon wire rod with boron. He is a past chairman of the West Indies Chapter of ASM, a past chairman for American Society for Quality Control, Beaumont, and a past president of the India Association of Southeast Texas. This presentation was made at WAI’s 78th Annual Convention, Pittsburgh, Pennsylvania, USA, June 2008.

Baskar Yalamanchili presenting his Mordica Lecture.

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E DA L ER W INN AWA R

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The Mobile Impact Tester for cold heading research at Ivaco Rolling Mills

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A new Universal Horizontal Impact Tester (UHIT) system designed to measure flow stress in materials has been found to be very useful in understanding and development of steels for cold heading processes. By Michel Hone, Nicholas Nickoletopoulos and Darryl Seaman

The Universal Horizontal Impact Tester (UHIT) at Ivaco Rolling Mills (IRM) is a multi-purpose apparatus for applying a well-defined quantity of mechanical energy to a specimen. The apparatus has two embodiments: the collision embodiment and the sweep embodiment. In the collision embodiment, the UHIT is a two-car impact tester used for: constitutive modeling of material flow stress; determination of material damage constants; and physical simulation of upsetting in the cold heading process. Two cars mounted on rollers are raised to the desired height at the ends of oppositely inclined rails, and are latched in the armed position. Fig. 1 shows one car carrying an accelerometer at the top of the track, the extra weights stored between the tracks, the jib crane for loading weights onto cars, and the bumper to prevent secondary impacts. Upon release, the cars are propelled by gravity down the rails. In this embodiment, the roller flanges of both cars are on the inside of the rails and the cars collide in the horizontal portion of the track. Kinetic energy stored in the cars is dissipated in a specimen carried by one of the cars. When flat dies are used, as in constitutive modeling of flow stress, the specimen falls into a calorimeter following the recoil of the cars. This enables the determination of the total energy absorbed by the specimen and hence the quasiadiabatic temperature attained by the specimen. In the sweep embodiment, the UHIT is a two-car fracture specimen tester. It may be used for: Charpy specimen impact energy determination; Izod specimen impact energy determination; fastener head impact testing; tensile specimen impact testing; and skelp V-Notch specimen impact testing. The wide rails of the UHIT allow the roller flanges of one

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car to be on the inside of the rails, and the roller flanges of the other car on the outside of the rails, as shown in Fig. 2. In the sweep embodiment, the design is such that cars can sweep by one another without touching. However, by inserting a fracture specimen in one car, and mounting a striker on the other car, the kinetic energy of the cars can be partly dissipated into the fracture specimen. The fracture energy is determined from the initial and final heights of the car centroids, taking into consideration parasitic losses. The device shown in Fig. 2 is actually a 500 J Charpy Impact Tester being developed by CedarRidge Technologies Inc. that uses the sweep embodiment principles of the UHIT but on a much smaller scale than that of the impact tester at IRM. The first four sweep embodiments are useful in the study of cold heading of long products, while the fifth pertains to testing flat products, for example, determining the ductile-to-brittle transition temperature of skelp products. The objective of this paper is to present the unique features of the UHIT that overcome difficulties that were encountered in the original cold heading work at IRM1 carried out on a Vertical Drop Weight Tester In the horizontal application of impact energy, the extensive foundation work found in conventional vertical drop weight impact testers and pendulum machines is not required. This allows the UHIT in both its collision and sweep embodiments to be implemented on the same frame, mounted in a mobile laboratory that may be hauled from location to location. The UHIT used at IRM is housed in a 48-ft, low-deck commercial trailer complete with control room and specimen preparation equipment. In vertical drop-weight testers, a collision occurs between a striker and a fixed specimen. These testers must


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be carefully designed to protect the instrumented striker and the test specimen. Some designs use shock absorbers that repel the crosshead after the test specimen fractures and catch the striker. The drop-weight system must be securely bolted to a rigid foundation to permit maximum utilization of these design features and prevent damage to critical components. The functions of the foundation are firstly, to provide a rigid mass through which the shock is absorbed and dissipated into the earth, and secondly, to provide a flat, level surface to which the drop-weight system can be affixed. If a rigid foundation is not provided, alterations in the test data, premature failure of the equipment and excessive vibration causing spring action can occur. Guidelines are provided by manufacturers of drop-weight testers to assist in the installation of their equipment. The mass of a rigid foundation must be 10 times greater than the crosshead mass impacting the test specimen and stop blocks. For example, a crosshead mass of 1000 kg calls for a foundation of 10,000 kg, which if constructed of steel-reinforced concrete equates to a block 2 m wide, 2m deep and 1.25 m high2. The static load-bearing capacity of the soil for the location of each impact tester must be determined by a soil engineer, taking into consideration that the dynamic impact loads should not exceed the static load of the soil. Moreover, the foundation should have sufficient contact

Fig. 1 The Universal Horizontal Impact Tester at IRM.

area with the soil to prevent undue settling. Manufacturers generally recommend that the slab be isolated from the surrounding floor to alleviate any potential vibration to equipment located in close proximity. In particular, it is very important that the drop-weight system be carefully secured to a steel mounting plate built into the foundation. The recommended procedure is to carefully level the mounting plate and use a very thin layer of epoxy filler between the mounting plate and drop-weight system base plate to secure a good integral fit between these two components. The crosshead must drop in a vertical path and thereby minimize friction caused by the interaction with the guide columns. Pendulum impact testers, where a striker impacts a fixed specimen and sweeps by, are analogous to the sweep embodiment of the UHIT. Again, foundations for pendulum impact testers must be carefully designed or the following problems can arise: alterations in the test data; premature failure of equipment; and excessive vibration causing spring action. A typical foundation for a commercially available 400 J pendulum impact tester3 consists of a block 1.5 m wide, 1 m deep and 0.5 m high, which amounts to 1500 kg. A 500 J C-type pendulum tester is documented by Yamaguchi, Takagi and Nakano4. The machine is fixed on a 1.5 m wide, 1m deep and 0.1 m thick steel block foundation that is embedded in a concrete floor to ensure rigid mounting of the machine. A block of steel of these dimensions weighs 1200 kg. As yet another example, Charpy5 describes a pendulum tester with a 50 kg striker plate. The anvil-bed weighs 1600 kg. It is driven into the ground and cemented

Fig. 2. A 500 J Charpy Impact Tester under development by CedarRidge Technologies Inc. AUGUST 2008 | 83

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into a masonry block of 5 m3 weighing 10,000 kg. It can now be appreciated that the foundation issues which are of tremendous concern in Vertical Drop Weight Testers are virtually non-existent in a UHIT. Energy balance considerations in a UHIT While the displacement of a free-falling cross-head in Vertical Drop Weight Testers is virtually friction-free, rolling friction is obviously present in the UHIT. So, one set of concerns has been exchanged for another. However, the authors believe that the parasitic losses are much better circumscribed in the case of the UHIT. Newtonian mechanics note that the potential energy, E, of an object in a gravitational field is: E = Mg (Hinitial –Hdatum)

Here, g is the gravitational constant, M is the mass of the object (a UHIT car in this case), Hinitial is the initial height of the car centroid, and Hdatum is the datum height, or height of the car centroid along the horizontal portion of the track. The datum height is normally taken as zero. In the UHIT, this energy is converted into kinetic energy EK equal to: EK = ½ MV2

Here, V is the velocity of the car at the datum level, or along the horizontal portion of the track. By equating potential and kinetic energies, one arrives at: V = [2g Hinitial]1/2 The initial impact velocity Vo seen by the impact speci-

men is set by adjusting the centroid heights of the two cars in the armed position on the inclined segments of the track. The cars are set at equal heights to minimize residual momentum. The relative initial impact velocity between the two cars is then twice the velocity of each car: Vo = 2 [2g Hinitial]1/2

The impact energy applied to the specimen is set by adjusting the initial heights of the two cars in the armed position on the inclined segments of the track and/or by changing the mass of the cars. Again the cars are set at equal height, and are allotted equal mass, to minimize residual momentum. The total energy available from both cars is then: E = 2 Mg Hinitial

An overwhelming fraction of the energy E is delivered to the specimen. The energy applied to the specimen can be calculated, net of energy dissipated in friction, by allowing one car to travel, unimpeded, down one incline and up the other. For each car, the intensive friction loss, eF, that is, the energy lost in friction per length of car travel, Sfree travel, is determined by measuring the difference between the initial height of the mass centroid of the car, Hinitial, and the final height of the mass centroid of the car at its apogee, Hapogee: eF = M g [Hinitial - Hapogee]/ Sfree travel

The total energy lost in friction, EF, lost during an impact test is: EF = eF Simpact

where Simpact is the centroid to centroid distance between a car in the armed position, and the car at the point of impact, measured along the track, respectively. The rotational energy absorbed by the 4 rollers of a car can also be accounted for by writing: ER = 4IgH/r2

where I and r are the moment of inertia and radius of a roller. Energy is also stored as elastic energy in the cars, dies, and specimen during impact, and thence dissipated in friction as the cars undergo a minor rebound or bounce. The elastic bounce energy of a car in the collision mode, EB, can be calculated using the following relation: EB = MgHbounce + eF Sbounce

Fig. 3 Macrograph of an impacted cold heading simulation specimen.

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Here, Hbounce is the height of the centroid of the car above the datum on the horizontal segment of track at the apogee of the bouncing car, and Sbounce is the distance


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travelled back along the track by the car. In a properly constructed horizontal impact tester, the cars are evenly matched, making it sufficient to determine EF, ER and EB for one car only. The plastic deformation energy delivered to a compression specimen, E, by the two cars is then: E = 2 [Mg Hinitial – (EF + ER + EB)]

In the case of the UHIT at IRM, the authors find that in the worst case, where the cars start out at 2 m and are fully loaded at 500 kg apiece, the three parasitic loss terms are, per car: EF = 1150 J EB = 250 J ER = 100 J

This energy amounts to 1500 J, or 3000 J for both cars, that is, 15% of the total potential energy that can be developed by the UHIT. Therefore the energy conversion efficiency of the apparatus is about 85%. Physical simulation of the cold heading process Cold heading is a cold forging process in which the force developed by a heading tool is employed to displace metal to form a section of different contour or of a different cross section. The process is widely used to produce a variety of small and medium sized hardware items, for example bolts, nuts and rivets. Although rules of thumb are still used in industry to successfully produce cold-headed parts, the imperatives of competition are bringing companies to employ physical and mathematical simulations of the process to arrive at optimal forging sequences. The heat of deformation ignites an explosive charge at the bottom of the die pocket, thereby propelling the specimen into a calorimeter set between the rails. This technique allows a straightforward calculation of the amount of energy absorbed by the specimen. Mathematical simulations using FEM require inputs such as data on friction between die and work piece, fracture criteria constants, and flow stress relationships to be applied successfully. It is an objective of the UHIT work at IRM to offer cold heading customers a means of rapidly and accurately generating this information. A cold heading specimen is mounted in a die pocket cavity. The cars are raised to the desired height, latched in the armed position and then released. During the collision event, the kinetic energy of the cars is dissipated in the specimen. Strains in excess of 3 and initial strain rates in excess of 1000/s are readily achieved. The specimen takes on the appearance, Fig. 3, of a mushroom. Apart from the portion extending into the die pocket, the cylinder diameter originally was 22 mm in diameter by 28 mm high. Cracking and shear bands emanating from the head/shank junction are clearly visible. The material is low carbon,

phosphorized, sulphurized and leaded bar stock. An FEM modeling software such as DEFORM2D or DEFORM3D can be used to calculate a damage criterion, for example, at the equatorial surface of the specimen. Specimens are repeatedly tested at increasing energy input until incipient cracking appears on the physical specimen, generally at the equatorial surface. FEM modeling of the simulated part is then used to calculate a material damage constant which is a property of the tested material. Modeling of material flow stress The compression test is the preferred method for determining flow stress data for materials at various temperatures, strains and strain rates. It is especially useful in view of its inherent capability for applying large strains, such as those experienced in most bulk metal forming processes. Other tests used for determining flow stress are the tensile test and the torsion test. Tensile tests are of limited use in bulk metal forming processes, because the results are valid only for relatively small amounts of plastic strain. The torsion test is typically used for finding flow stress data at higher true strains between 2 and 4, but the deformation is by definition non-homogeneous. Various types of machines can be used to perform a compression test. The hydraulic press can keep the strain rate constant by controlling the speed versus stroke of the press ram such that ram-velocity is a constant. In the mechanical press, with its regular crank or eccentric cam, the strain rate is not constant during the press stroke so average values of strain rate must be used. The latter two machines generally have a lower strain rate capability, and not within the range experienced in cold forging applications. The cam plastometer is the classic method of determining the flow stress. A ram rapidly strikes a specimen mounted on a platen. A hydraulic motor and a flywheel rotate a cam; in turn, a cam follower governs the motion of the ram to deform the specimen a given stroke distance. The cam is specifically configured to drive the ram at a constant strain rate. The main drawback with this machine is the compliance or bedding-in of the drive train components. The application of correction factors throws doubt on the data validity. In its collision embodiment, the Universal Horizontal Impact Tester can be used to obtain material flow stress data and to establish constitutive models of material flow stress. The procedure is straightforward. A cylindrical specimen is lightly attached by means of paraffin or similar lubricant to the finely polished platen of a die mounted on one car. The specimen must be upset without barreling to maintain a state of uniform stress. Barreling can be prevented or at least minimized by employing several techniques, two of which are described below. In one technique, maintaining adequate lubrication between the polished platens and the specimen during compression minimizes barreling. In this case, two types of cylindrical specimens are generally used: Spiral groove specimens have spiral grooves machined at both ends to a depth of about 0.25 mm while Rastegaev specimens6 have

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recesses machined at both ends. The grooves or recesses are filled with lubricant, and can provide nearly frictionless and uniform metal flow. For both types of specimens, the preferred height to diameter ratio is 1.5 to 1. Siebel and Pomp7 developed another technique. They suggested that a uniform distribution of stress be obtained by compressing the cylindrical test specimen, not between two plane platens, but between two cones. The generatrix of a cone makes an angle with the plane of compression, equal to the angle of friction. The resultant stress in the compression surfaces of the two cones is then parallel to the direction of compression. This favors the development of a pure axial compressive stress in the test specimen. Both techniques can be readily implemented using the UHIT operating in the collision mode. In the constitutive modeling of flow stress, an accelerometer attached to one of the cars is used to obtain the deceleration as a function of time. The cable attached to such an device mounted at the back of a car is visible in Fig. 1. The force history, F(t), is obtained by multiplying the deceleration a(t) by the total mass of the cars, and the specimen, M, according to the well-known law of Newtonian physics: F(t) = M a(t)

After obtaining the force history, the above equation can be integrated with respect to time to obtain the velocity history, v(t): 1/M ∫ F(t)dt = ∫ dv

from t = 0 to t = t in the LHS of the equation, and from v = vo to v = v in the RHS of the equation.

After obtaining the velocity history, the velocity can then be integrated with respect to time to obtain the deformation history, s(t): ∫ v(t)dt = ∫ ds

from v = vo to v = v in the LHS of the equation, and from s = so to s = s in the RHS of the equation.

The area of the compression specimen as a function of time, A(t), is known since the deformation is essentially homogeneous, and A(t) = Vs /s(t), by virtue of the fact that the volume of the specimen, Vs, is essentially constant during plastic deformation. Therefore, the flow stress of the material, σ (t), can be calculated as: σ (t) = F(t) / Vs s(t)

The strain can now be calculated from the definition of true strain: ε(t) = ln (so/s(t))

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while the strain rate, εdot, can be calculated from its defining equation: εdot(t) = dε(t) /dt

Thus, the three quantities essential in constitutive modeling of flow stress, namely, σ (t), ε(t), and εdot(t) are established as a function of a common parameter, t, enabling σ to be plotted or curve fitted as a function of ε and εdot. An additional extremely important parameter in the establishment of flow stress, namely the temperature history of the specimen, can be determined using the UHIT. Indeed, it exploits the slight rebound after impact to release the compression specimen from the grip of the platens. The specimen then drops and funnels into a calorimeter, located between the rails. The final heat content of the specimen may be ascertained using the simple and well-known thermodynamic relation: Q = m Cp ∆T

where Q is the heat content of the specimen determined by the calorimeter, m is the mass of the specimen, Cp is the heat capacity of the test material, and ∆T is the temperature elevation above ambient temperature, Tambient. Here, ∆T = Tfinal - Tambient

The final specimen temperature, Tfinal, can thus be calculated. Since the heat is rapidly generated in the specimen, the compression is essentially adiabatic, with little loss to the platens. The value of Q therefore approximates the energy input to the specimen. This enables the implementation of a Finite Element Model operating in the thermally-coupled adiabatic mode, and the derivation of a fit between experimental and calculated values of σ (t), ε(t) and εdot(t) and Tfinal . This technique, known as Inverse Analysis, has been used by Chenot8, Cho9 and others to determine the parameters of a constitutive model useful for FEM simulation where strain, strain rate and temperature are expressed as independent variables. In summary, the UHIT is a new approach to impact testing that the authors believe will further the understanding and development of steels for cold heading processes.1

1. The UHIT was commissioned in the spring of 2006, following four years of design and construction. Five prototypes were built to evaluate track configurations, car release mechanisms, rebound devices, and data acquisition systems. Developmental work is continuing to extend the energy range of the present UHIT from one hundred joules for undergraduate teaching purposes to over one hundred million joules in advanced hot forging applications.


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References 1. N. Nickoletopoulos, Physical and Numerical Modeling of Steel Wire Rod Fracture during Upsetting for Cold Heading Operations, Ph.D. Thesis, McGill University, 2001. 2. Instron Canada Inc., Private Communication, 2001. 3. INSTRON-SATEC Systems, SI-1 Series Impact Testing System, Document Number 000052-03-0700, p. 12. 4. Y. Yamaguchi, S. Takagi, and H. Nakano, Effects of Anvil Configuration on Absorbed Energy, p. 164, in Pendulum Impact Testing: A Century of Progress, T.A. Siewert and M. Manahan, editors, ASTM, 2000. 5. G. Charpy, Essay on the Metal Impact Bend Test of Notched Bars (Reprint from 1901), p46, in Pendulum Impact Testing: A Century of Progress, T.A. Siewert and M. Manahan, editors, ASTM, 2000. 6. M.V. Rastegaev, New Method of Homogeneous Upsetting of Specimens for the Determination of Flow Stress and the Coefficient of Internal Friction, Xavod Lab., p. 354, (1940). 7. E. Siebel and G. Pomp, Die Ermittlung der Formänderungsfestigkeit von Metallen durch den Stauchversuch, Mitt. Kaiser-Wilhelm Inst. Eisenforsch, vol 9, p. 157, Düsseldorf, 1927. 8. J.-L. Chenot, E. Massoni and L. Fourment, “Inverse Problems in Finite Element Simulation of Metal Forming Processes,” Engineering Computations, Vol. 13 No. 2/3/4, p. 190, 1996. 9. H. Cho, G. Ngaile and T. Altan, “Simultaneous Derivation of Flow Stress and Interface Friction By Finite Element Base Inverse Analysis Technique,” Annals of CIRP, Vol. 1, p. 221, 2003. ■

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Michel Hone is manager advanced technology at Ivaco Rolling Mills, l’Orignal, Quebec, Canada. He has been instrumental in the development of the UHIT and its application to the improvement of cold heading steels. In the last 10 years he has conducted innovative Hone research on the effect of continuous casting mold shape on billet quality, and on the manufacture of dual-phase steels for high-impact energy applications. He has worked in the steel industry for more than 35 years, mainly in research and development. icholas ickoletopoulos is manager quality and techniickoletopoulos cal services at Ivaco Rolling Mills. He has worked at Ivaco for more than 11 years, mainly in quality control, technical servicing, and research and development. Darryl Seaman is president of CedarRidge Technologies Inc., Hudson, Quebec, Canada. He designs and builds custom test equipment for the metals industry. He Seaman has 30 years of experience in mechanical and electrical maintenance. This paper, which was presented at the Wire Association International’s 77th Annual Convention, Cleveland, Ohio, USA, May 2007, won the WAI’s top award in the general paper category.

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TECHNICAL PAPER Fire refined copper rod production in a clean environment With more awareness of environmental demands, suppliers of copper rod lines that are offering environmentally friendly technology that better controls harmful emissions and encourages further recycling of scrap materials. By Giulio Properzi and Vladimir Djukic

Some 20 years ago, the old traditional technology of making copper rod starting from scrap made an important step forward toward the updated quality and efficiency that is mandatory today. The traditional methods could not match the quality of continuous rod quality standard and were not very economical either. Melting, refining via selected scrap oxidation and poling or fuel injection, and then casting wirebars for subsequent rod rolling, was a dying process in North America and Europe and limited – sporadically – in other parts of the world. The rod made by this process was of second and even third-rate quality and could not match the demands of high drawing speed and fine diameters of the modern times. That was the backdrop for La Farga Lacambra, a new company born on the ashes of an ancient copper foundry that launched a courageous business plan based on its experience in buying copper scrap. The company developed in a consistent manner, bolstered by its profitable use of FRHC (Fire

Photo 1. Batch process with tiltable furnace, 110 MT. 88 | WIRE JOURNAL INTERNATIONAL

Refined High Conductivity) wire, rod and billet produced from scrap. Supplied by Continuus-Properzi, a new rod line with a new tilting reverberatory furnace was installed in La Farga Lacambra’s old building. The operation had used a batch process with a scrap furnace for melting and refining 56 metric tons (MT) of scrap with 97-98% copper content during two shifts. The Properzi line could cast and roll the melt during the third shift at a rate of 7 MT/h. Total first year production was 12,000 MT of rod. The successful commissioning and subsequent continuous refining technology improvements have been described in several papers. With a constant and dedicated development of the process, the quality of the feeding scrap (and its price) was able to be lowered down to 92-93% copper content while the production, by increasing the furnace capacity and upgrading the CCR line, doubled to about 110 MT per day. See Photo 1. In 2000-2001, a continuous rod production process with CU content higher than 97% was developed and started. Named Cosmelt, the process saw one special shaft furnace, two continuous refining furnaces and one holding furnace feed the Properzi line, which now operated at 15 MT/hr for about two shifts per day. In 2006, this resulted in daily production of 330 MT net (more than 100,000 MT per year) working 320 days. Rod production was 72,500 MT: the drawing shop produced 46,600 MT with seven break-down lines and 15,700 MT with 80 multiwire lines. Approximately 20,000 MT were stranded in flexible and rigid bare cables. Billet production was over 24,000 MT. The nearby tube plant Tertube produced about 17,000 MT of sanitary/air conditioning tubes. In 2006, an after-taxes cash flow of 12.2 million euro (about US$17 million) was generated and a new project started at the beginning of 2007. This complete greenfield rod facility, called La Farga Rod, is based on a 25 MT/h Properzi line that will be fed by cathodes. At the time this paper was written, machine delivery was almost complete and the first rod production was projected for January 2008, an impressive schedule as it cuts the normal timeframe in half.


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Scrap recycling: good for the planet Transforming old copper, a precious metal, into new rod and wire a potentially unlimited number of times is very important to ensuring a sufficient supply of this commodity for the decades to come. Some 15 million MT of primary copper is annually produced worldwide from mines while 5 million of semis are generated from scrap. Energy savings is about 85% when using recycled copper. When producing rod, scrap is usually recycled via anodes production, followed by the electrolytic process, which transforms anodes into cathodes, and then melting cathodes, casting and rolling rod again. The La Farga–Properzi process is much shorter: scrap is melted, refined and continuously cast and rolled into rod. This process can save some two million kCAL per metric ton (MT) as well as the energy used for electrolysis. Nevertheless, scrap operations tend to be seen with suspicion and negativity by some environmentalists and/or those who belong to the “NIMBY” party. Considering that burying scrap causes pollution as well as wastes a fundamental but scanty resource, it is vital to remelt and refine scrap, using extreme caution and appropriate technology. Pollution control is relatively recent but not so young. In response to the Great Smog of 1952, when a mixture of coal smoke, sulfur dioxide, carbon dioxide, hydrochloric acid and other industrial pollutants took the lives of some 4,000 U.K. residents, the British Government introduced the first Clean Air Act in 1956. It was not until 1970, when the Clean Air Act was updated in the U.S. and Environmental Protection

Photo 2. View inside the La Farga Lacambra plant.

Agency (EPA) was founded that “Pollution Control” became a big issue. In recent years, greater industry consciousness has led to more environmental options. Recycling copper scrap is neither too difficult nor too expensive. The LaFarga experience has shown that means do exist to reduce pollution. La Farga Lacambra’s long experience and achievements are important. The Spanish company runs the most complicated and difficult system with one 110 MT reverberatory furnace, one 15 MT/h shaft melting Cosmelt furnace, two 40 MT each refining furnaces, one holding furnace for the Properzi line and one holding furnace for the billet caster. Rather than describe the current La Farga abatement system, this paper focuses on a different technique that can be used in a BAT (Best Available Technology) system and the results. See Photo 2. Fumes filtration The authors are going to make a distinction between the fumes relevant to the Batch Process and those ones relevant the Cosmelt Process due to their substantial differences and because the two technologies are presently in operation only in La Farga. Batch Fumes High Exit Temperature Variable Flow Rate Variable Composition

Cosmelt Fumes Low Exit Temperature Constant Flow Rate Constant Composition

All the gases shown in Table 1 contain dust, metals and acid components and the formation of dioxin and VOCs (Volatile Organic Components) is possible due to the presence of small amounts of chlorine (oil and plastic) in the scrap. Scrap charged into the reverberatory furnace produces very limited dioxin and VOCs because of the high temperature of the furnace chamber and the high exhaust gas temperature (900°C). On the contrary, at the top of the shaft furnace where scrap is charged in the Cosmelt process the temperature is very low and off-gases must be heated and maintained for 3 seconds at high temperature to reduce dioxin and VOCs in simple non-toxic components; a subsequent cooling is suggested to avoid any recombination. Because every plant using the La Farga – Properzi technology (a dozen have been already sold worldwide) is different in size and uses different scrap sources, it is not possible to discuss a precise, unique recipe on the perfect means for the more environment-friendly operation. Each installation has its own requirements and must also cope with local authority regulations. The pollution control science is a mix of Chemistry – Medicine – Biology – Politics and Bureaucracy and is always committed to a constant improvement of the results. For instance, the European Commission is continuously updating the Reference Document on

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others can be treated with alkali like lime, magnesium hydroxide, sodium hydroxide, sodium or aluminum sulphate in both dry and wet system.

Table 1. Limits of gases in Italy for nonferrous industry production. (2006).

Best Available Techniques in the Non Ferrous Metals Industries – Integrated Pollution Prevention and Control (IPPC). Pollution control devices and means Bag house. This consists of a series of cloth filters (bags) up to 10 m long made in different materials like Polyester, Teflon, Glass or sintered metal for up to 900°C. Available bag houses today are fully automatic and can provide filtration efficiencies to 99.9 % plus of dust. Candle filters. In recent years, these have proven to be a very effective form of air filtration. The candles work by having contaminated gas forced through a mesh of silicon carbide, a very porous, chemical neutral and heat resistant material, which acts as a filter. Wet scrubber. These remove dust particles by capturing them in water droplets and remove pollutant gases by dissolving or absorbing them into the water. To obtain high efficiency removal of 1 micrometer (or less) particles, high energy devices such as Venturi scrubbers are used. Additionally, a properly designed mist eliminator is important to achieve high removal efficiency. Wet scrubbers require the disposal of contaminated waters. Afterburner. Abatement of Co, VOCs and dioxin is based on pyrolysis, meaning that high temperature of fumes provide the transformation of CO into CO2 and of VOCs, and dioxin becomes simple elements like HCL – CO2 – H2O. An immediate cooling is needed to avoid a recombination of harmful components. One afterburner is very simple but sometimes costly. Regenerative thermal oxidizer. This can replace the After Burner Process. Process gas with VOCs, Co and dioxin contaminants enters one stoneware chamber, which pre-heats the process stream. The flow is heated in the combustion chamber. Contaminants are then oxidized, releasing energy in the second stoneware chamber, thereby reducing any auxiliary fuel requirement. The flow control valve switches and alternates the stoneware bed. If the process gas contains enough VOCs and Co, the energy released from their combustion allows almost self-sustained operation. The device installation is more expensive than the after burner but fuel consumption is heavily reduced. Additives. Corrosive gases such as SO2 – HCL – H2S and

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Results The previously discussed technology can help copper scrap recycling operations meet the requirements of the Italian normative for nonferrous production industries (2006) that are shown in Table 1. Italian (European) limits, which are nearly identical to global standards, are increasingly able to be met by development of the Best Available Technology. Table 2. shows a very important document for analysis of pollutant emissions and techniques for prevention/reduction of pollution is the “European Commission. BREF - Reference Document on Best Available Techniques in the Non Ferrous Metals Industries - December 2001 - Integrated Pollution Prevention and Control (IPPC)”. Summary of the abatement methods for components in off-gases produced in different process stages is (European Commission “Reference Document on Best Available Techniques in the Non Ferrous Metals Industries, 2001). Table 3 shows a summary of the possible emission levels associated with abatement systems that are considered to be Best Available Technologies for the non-ferrous metal processes is reported. Possible emissions to air from secondary smelting and converting, primary and secondary fire refining, electric slag cleaning and melting associated with the use of BAT in the copper sector (European Commission “Reference Document on Best Available Techniques in the Non Ferrous Metals Industries, 2001). Examples Cosmelt process. The Cosmelt process in La Farga is composed of three different furnaces: one melting furnace, with constant fumes emission of 11,500 Nm3/h; two refining furnaces, with 12,000 Nm3/h emission during refining process; and a holding furnace that is considered as non-pollutant. The pollutants measured in the flue gas are: PM10, CO, NOx, SO2, VOC, HCl, Cu. Fig. 1 shows a simplified scheme of the possible emission treatment plant. With this setup, the cyclone provides pre de-dust treatment of the flue gas and the ceramic candle filter provides a dry scrubbing. Ceramic filters are an appropriate treatment for cleaning hot gases due to their resistance to attacks by aggressive gases and high temperatures. In addition to particulate removal, acid gases such as

Fig. 1. Scheme of possible flue gas treatment for the Cosmelt process.


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SO2 and HCl can be removed by reaction with powder solid sorbents injected upstream of the filter (Duo et al, 1997). Sodiumbased reagents such as sodium bicarbonate (instead of lime-based materials) have the following advantages: high efficiency; easy handling; requires a lower stechiometric ratio; is efficient at higher temperatures; and the Regenerative Thermal Oxidator removes organic carbon compounds. This technical approach is similar to the one described in HalĂ sz (1996), in which a treatment line for preventing formation of dioxins and other toxic organic micropollutants (in that case, from a waste incinerator) was presented. Table 2. Summary of the abatement methods for components in off-gases Batch refining process, 100 MT. produced in different stages per European Commission document. The refining process has three different steps: the charging + melting process, which is the most important in terms of polluting emissions, having a fume emission scrubbing reagent such as lime or sodium hydroxide. of about 20.000 Nm3/h; oxidation + reduction process, with a Wet scrubbers offer the following advantages: they have the fume emission of about 15.000 Nm3/h; and a casting process, ability to handle high temperatures and moisture; the inlet 3 with a fume emission of about 10.000 Nm /h (practically nongases are cooled, resulting in smaller overall size equipment; polluting). The pollutants in the flues are: particles, CO, NOx, SO2, H2S, Cl-, Zn, Al, Sr, As, Sb, Cu, Fe, Pb. Fig. 2 shows a simplified scheme of the possible emission treatment plant. If the gas stream contains both particle matter and gases, wet scrubbers are generally the only single air pollution control device that can remove both pollutants. Wet scrubbers can achieve high removal efficiencies for either particles or gases and, in some instances, can achieve a high removal efficiency for both pollutants in the same system. However the best operating conditions for particles collection are often the poorest for gas removal. In general, obtaining high simultaneous gas and particulate removal efficiencies requires one of them to be easily collected (i.e., gases are very soluble in the liquid or the particles are large and readily captured) or by the use of a

Fig. 2. Scheme of possible fine gas treatment for the batch refining process.

Table 3. Possible emissions to air from secondary smelting and converting, primary and secondary fire refining, electric slag cleaning and melting associated with using BAT in the copper sector. AUGUST 2008 | 91

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they can remove both gases and particulate matter; and they can neutralize corrosive gases. Disadvantages include: corrosion; the need for entrainment separation or mist removal to obtain high efficiencies; and the need for treatment of spent liquid to match normative standard limits. When air wet cleaning techniques are applied, the contaminated liquid effluent requires further treatment, such as precipitation and/or sedimentation for solid-liquid separation. Sometimes specific treatment measures like ion exchange are used to remove very harmful or valuable metal compounds. To reduce the concentration of water pollutants, one can use end-of-pipe techniques as reported in the BREF-Non Ferrous Metals Industries (2001) and briefly described as follows: Chemical precipitation. This is primarily used to remove soluble metal ions from liquid effluent. The soluble metals can be precipitated from wastewater by adjustment of the pHvalue. A reagent, such as lime, sodium hydroxide, sodium sulphide or a combination of reagents is added to the effluent and forms an insoluble compound with the metal to form a precipitate. Sedimentation. This solid/liquid separation technique uses gravity to separate the insoluble metal complexes and solid particles from liquid effluent. Sedimentation can take place in a variety of different settling vessels like sedimentation basins, lagoons or specialized sedimentation tanks (thickeners, clarifiers) with a sludge removal device on the bottom of the tank. Filtration. These techniques are normally used for solid/liquid separation and as a final clarification step in a wastewater treatment process. Filtration can take place in a variety of different filter systems depending on the solid particles that have to be removed: normal filters, sand filters, hyper-filtration or reverse osmosis, ultra-filtration. Conclusion Today the available technology can assure a clean operation when recycling copper scrap. Cost of pollution control can be maintained at a reasonable level, even when recycling less precious scrap; for instance, in Italy, some 20 million metric tons of steel scrap are recycled each year. References 1. Italian decree of April 3, 2006, p. 152 “Norme in materia ambientaleâ€? published in Gazzetta Ufficiale n. 88 of April 14, 2006, Ordinary Supplement, p. 96. 2. European Commission, “Reference Document on Best Available Techniques in the Non Ferrous Metals Industries December 2001 - Integrated Pollution Prevention and Control (IPPC).â€? 3. A. Esparducer, M.A.Fernandez, M. Segarra, J.M. Chimenos and F. Espiell, “Characterization of fire-refined copper recycled from scrap,â€? Kluver Academic Publishers, 1999. 4. O. Guixa and R.C. Reuter, “High quality copper wires directly from 100% scrap,â€? Annual meeting of GDMB in Alpach, Austria, 1998. 5. W. Duo, J.P.K. Seville, N.F. Kirkby, H. BĂźchele and C.K. Cheung, “Parchy cleaning of rigid gas filters – II. 92 | WIRE JOURNAL INTERNATIONAL

Experiments and model validation,â€? Chemical Engineering Science, 1997, 52 (1) pp. 153-164. 6. O. Guixa and M. Garcia, “Further steps in copper scrap refining and subsequent CCR Copper Rod Production,â€? 1997. 7. A. HalĂ sz, “PCDD/F emission control by intermediate dust removal at medical waste incinerators,â€? Waste Management & Research, 1996, 14, 3–14. 8. G. Properzi and O. Guixa, “Continuous copper rod production from 100 percent scrap,â€? Wire Journal International March 1996, p. 60. â– 

Giulio Properzi is president and CEO of ContinuusProperzi SpA, Milan, Italy. He became head of his familyowned business in 1971 and in 1979 co-founded Properzi International, Inc., Davenport, Iowa, USA, which has been part of Continuus since 1988. He has more than 40 years of Properzi experience in the wire industry. He is responsible for numerous technical advances and holds about 100 worldwide patents in different fields, mostly related to continuous casting and rolling of nonferrous rod. He holds a master’s degree in mechanical engineering from Milan Polytechnic. He is a former president of the Wire Association International, its Djukic first from outside orth America. Vladimir Djukic is the sales director at Continuus-Properzi SpA. He holds a master’s degree in mechanical engineering from the Moscow Power Institute. This paper was presented at Wire Bologna 2007, Bologna, Italy, ovember 2007.


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PRODUCTS & MEDIA PRODUCTS

Automatic 3D wire bender is very compact and cost-effective to run U.S.-based Aim, Inc., has introduced a compact 3D machine that it said sets new benchmarks for cost-effective, automatic wire-bending operations for processing wire up to 8 mm. Part of the company’s AFC series (AccuForm Compact), the new model comes complete with AIM’s unique programming package of Industrial PC running Windows XP Pro and SmartEditor® as well as a host of features previously available only on much more expensive machines, a press release said. The AccuForm Compact model comes with a two-plane straightener, maintenance-free servo quad-roller feeder and precision bender axes, it said. The release noted that SmartEditor features the world’s most flexible programming language with intuitive commands and simple to use, conversational step-by-step programs. All a manufacturer needs to know to make parts is the length and bend angle, it said. The language will allow programming of sophisticated shapes, with near unlimited program storage and the ability to compensate each program with simple commands, it said. Contact: Aim, Inc., tel. 630-458-0008, sales@aimmachines.com, www.aimmachines.com.

Shielded Category 6A cable can support 10 G/bit applications

Nexans reports that its new shielded Cat 6A technology is immune from alien crosswalk and optimizes cabling for short distance applications, removing the need for overlength cabling in data centers Citing projections that more than 80 percent of modern data centers predict that they will be employing 10 G/bit technology within the next five years, Nexans said in a press release that its Cat 6A Zero Risk Solution can provide the cabling to meet center requirements for more bandwidth, higher capacity and higher density. The new LANmark-6A range, supported by a newly developed connector with excellent electrical performance, offers up to three connection points within 10 meters, it said, adding that “this makes it an ideal solution for modern data centers that are already facing severe space problems

with cables that are too long and heavy.” This technology was not achievable with most 10G compliant copper cabling solutions, the release said. “Now, this flexibility is available for data centers in a lower-cost copper solution that also addresses the critical space and storage problems presented by over-length cabling. Because Nexans’ 10G cables have a smaller diameter and tighter bend radius than most UTP solutions, screened 10G systems are easier to install than 10G UTP solutions and therefore also more cost efficient.” Contact: exans, www.nexans.com.

Industry software offered for free

Base Ten Consulting, Inc., a U.S. provider of ERP/MRP software and services, announced at Wire Expo 2008 that it will provide a full feature-based software package to the wire and cable industry at no charge to customers who sign up for a support contract. Base Ten’s Praetor Manufacturing Software may now be used by any organization without software charges, said company President Byron Ball. “Over the past 10 years Base Ten has developed and provided a well received ERP/MRP software system designed with maximum set up flexibility for the wire industry. Looking to the future of software provision and distribution, Base Ten has joined the effort to provide advanced software at pricing available to all sizes of organizations by eliminating the normal price and user fee structure.” Clients using the software gain the right to use by agreeing to a minimum of a three-year support contract, Ball said. Contact: Base Ten Consulting, Inc., tel. 716-608-8293, info@baseten.com, www.baseten.com.

Respooler offers innovation, accuracy

U.S.-based Independent Machine Company reports that its latest innovation in computerized spooling equipment is an offline, single-position respooler traverse that winds a composite string from a previously wound spool. The mode, a press release said, offers adjustable constant unwind tension that is controlled by an electronic brake through ultrasonic diameter measurement feedback. The driven capstan is the main speed reference of the machine and provides tension isolation between the unwind and rewind, it said.

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IFE Ap CLEV RE ril EL TUR 2 7- AND NS The only show in the 30 IN TO • Americas exclusively focused I-X 200 Ce 9 on machinery and tooling for the nt er From Patagonia to Prudhoe Bay...

design and manufacture of fasteners and precision formed parts.

Following the successful 2007 event, IFE returns to Cleveland in 2009 and will again co-locate with INTERWIRE to present the widest array of resources...anywhere in the Americas...for manufacturing fasteners and precisioned formed parts. See the latest advances in:

• Machinery • Materials • Tooling • Components • Accessories • Supplies • Manufacturing Systems, Controls and Support Services

For suppliers to the international fastener industry, IFE is your most efficient and cost-effective opportunity to meet the active buying market in a key region of fastener manufacturing activity. Show attendees come from every industry group, including automotive, aviation/aerospace, appliance, building and construction, electronics, industrial and heavy equipment and many other core fastener segments. All are ready and eager to discuss their product specifications and application requirements. You’ll meet the key personnel from design engineering, product development, production, manufacturing IT, QA/QC, facilities management, distribution and other authoritative decision makers—representing captive, OEM, and contract manufacturing operations. Whether actively involved in developing next-generation smart fasteners, or meeting the requirements of their customers’ application-specific designs, IFE attendees are prime customers and prospects for your products, equipment and systems. Contact us now to discuss your participation and exhibit space requirements at IFE ‘09. If you’re a manufacturer, there’s no better place than IFE ‘09 to see and explore the full range of information and product and equipment resources for bringing innovative fastening solutions and precision formed parts from concept to your customers. Plan now to attend. Visit our Web site for updated show information: www.IFEtradeshow.com

INTERNATIONAL FASTENER & PRECISION FORMED PARTS MANUFACTURING Exposition and Conference Ap ril 27-30, 2009 • I-X Center Cleveland, Ohio USA Co-located with

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Sponsored by the International Fastener Machinery and Suppliers Association Tel: 203.794.0444 • 800.688.1698 • Fax: 203.743.4810 www.IFEtradeshow.com • info@IFEtradeshow.com


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The rewind, the release said, can accommodate a range of spool sizes while entry of the material onto the spool is controlled by an interchangeable guide roll sized to product width. Programmable rewind tension, accurate to within 7 grams throughout the speed range, is controlled by exclusive IMC dancer tension controller and diameter measurement, it said. Programmable traverse adjustments that include pitch, stroke length, end dwell and winding pattern are entered through an operator keypad and controlled by a computerized servo drive and IMC Smartwinders® software, it said. Contact: Independent Machine Company, tel. 973882-0060, imco@aol.com, www.independentusa.com.

Innovative wiredrawing system offers both performance and ease of use Italy’s Team Meccanica, part of the Eurolls Group and represented in North America by Cortinovis Machinery America, reports that its wiredrawing line, model DSD

610/8, offers innovative patented technological solutions that makes it simpler to use and maintain. The steel wire drawing line, which has a production range of 6.50–1.50 mm at 25 m/s, SAE 1004 - 1060, employs innovative patented solutions such as “plug & play” technology, a press release said. The eight-block system has direct synchro drive with 45 KW synchronous motors directly connected to the capstans while a patented high-efficiency wire cooling system uses closedcircuit water recirculation for the forming cassettes and motors, it said. There is no need for gearboxes, belts, transmission means and lubrication oil, it said, noting that the drawing is done by roller forming cassettes or die boxes. The line has a pre-wired on-board electric board, can be installed without foundation bolts and comes with a fiveyear guarantee, extension up to seven years, it said. Contact: Tony DeRosa, Cortinovis Machinery America, tel. 908-479-9818, cortonivois@cortinovisamerica.com.

On-line Continuous PD Monitoring for power transformers, generators and motors

The PD Guard!

Call or visit our website today! Solutions for Electric Power Safety and Reliability HV TECHNOLOGIES, Inc. hvsales@hvtechnologies.com

Tel: 703-365-2330 www.hvtechnologies.com

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Company demonstrates the use of intermingled Cat 6/6a UTP cables Earlier this year, Berk-Tek, a Nexans Company, demonstrated a dual usage of cabling where Cat. 6 and Cat. 6a UTP cables were intermingled in the same pathway, sending simultaneous Gigabit and 10Gigabit Ethernet signals. A press release said that the demonstration at Data Center World included a continuous live 10GBASE-T network transmission over a 100-meter NetClear GTX channel consisting of Berk-Tek’s LANmark-10G2 Augmented Category 6 cable. At the same time, a demonstration of 1 Gigabit transmission over a NetClear GT2 channel is being shown utilizing the Berk-Tek LANmark1000 Category 6, which is interwoven on the same reel, it said. The live three-minute exhibit visually contrasted a 10GBASE-T network operating on a NetClear GTX Category 6A channel sending the equivalent of 200 CDs worth of data with a parallel 1000BASE-T 1 Gigabit Ethernet system operating over a NetClear GT3, Category 6+ UTP channel, that sends the equivalent of 28 CDs in the same amount of time, the release said. The test, it said, included the worst case configuration where a NetClear GTX (10-Gigabit UTP solution) was inserted into the center of the bundle that included seven NetClear GT2 (Category 6 UTP) channels around the outside. “Even 4-connector NetClear GTX channels tested in this configuration passed the Augmented Category 6 channel specifications for both internal parameters, as well as all Alien Crosstalk parameters,” it said. Contact: Berktek, www.berktek.com or www.nexans.com.

High-flex, shielded flat cables are designed for motion control uses

The Cicoil Corp., a U.S. manufacturer of flat, flexible cabling, is offering new Motion Series PLUS (MS+) flat power/signal cables for high-performance motion control applications that the company notes integrates six power conductors and 20 signal wires in a compact flat cable measuring just 0.80 in. x 0.2 in. Motion Series Plus cables feature ultra-high-

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flex shielded wires and Cicoil’s exclusive “glass-clear” silicone encapsulation for unsurpassed flexibility, durability and environmental resistance, a press release said. For multi-axis applications, the new configuration allows designers to place the cables side-by-side for maximum flexibility, or stack them for a very condensed and compact cable bundle, it said. The cable is available in a single axis design that may be ganged for 1, 2 or 3 axes of servo motion. Their silicone encapsulation provides a solid, one-piece construction that creates a highly durable cable package. The cable will not deform, break or wear during a lifetime of more than 10 million cycles, even under high flex conditions, it said. Two options are available, the first an integrated Teflon® tubing for transmission of fluids or gases and a second for the company’s patent pending StripMount™ integrated mounting aid, the release said. StripMount is reinforced strip embedded in the cable that allows for quick and easy cable mounting, eliminating the need for bulky, expensive cable management systems, it said. Contact: The Cicoil Corporation, tel. 661-295-1295, www.cicoil.com.

Industrial wire cutter/stripper can easily handle 10 to 26 AWG sizes

U.S.-based Xuron Corporation has introduced a compact, industrial-duty wire cutter and stripper that it said can process a wide range of wire sizes. A press release said that the Xuron Model 501 Wire Cutter & Stripper, which is made from alloyed steel, features a full by-pass cutter and thumb-adjustable cam wheel that enables the unit to eight different wire sizes from 10 to 26 AWG. Replacing the need for several tools, this combination wire cutter and stripper locks shut to pack away into a tool kit, drawer, or pocket, it said. Ergonomically designed to provide optimum leverage and performance, the Xuron Model 501 Wire Cutter & Stripper has Xuro-Rubber™ cushioned grips, a Light-Touch™ return spring, and fits comfortably into large or small hands, the release said. It is suitable for manufacturers, tradesman, homeowners and hobbyists. Contact: Xuron Corporation, tel. 207-283-1401, arobey@xuron.com, www.xuron.com.

Extrusion technology is part of company’s ‘earth-friendly’ portfolio U.S.-based Milacron, Inc., announced that it has expanded its “Earth Friendly” product line with


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SERVTEK TCS technology that was introduced at the ANTEC/PLASTECS Encounter Show. A press release said that SERVTEK TCS, which provides barrel heating and cooling technology for injection molding machines, blow molding machines and extruders to plastics processors in the Americas, has addressed the critical area of heating and cooling, a high-energy cost area of injection molding, long deserving of the application of advanced technology solutions. “Energy savings of up to 30-50% have been documented with as little as 18 months pay back time,” it said. The SERVTEK TCS injection unit and extruder barrel heaters provide a high radiant energy release from an element which directs 100% of the heat directly into the barrel, the release said. “The encapsulated barrel keeps all the heat inside, allowing a fast heat up cycle. The technology is of a simple and easy to install design and is quite different from old-fashioned ceramic heater bands, insulated heater bands and water-cooled systems that all must heat themselves up prior to delivering heat to the barrel.” The release added that the SERVTEK TCS technology is easily retrofittable on installed equipment and now can be ordered with new machinery offered by Milacron.

Contact: Rich Waterfield, SERVTEK TCS, tel. 513-536-2289, rich_waterfield@servtek.com, www.servtek.com.

Rotating bulletin tower can display range of information to workforce Noting that sharing information in common areas encourages collaboration, innovation and productivity, U.S.-based Magnatag® Visible Systems reports that its RotoCube® Rotating Bulletin Tower is a good way of keeping shop floor employees informed about production goals, results and more. “With the touch of a finger, the RotoCube® Tower turns quietly in either direction, so several people can view and share information at the same time,” a press release said. The system was developed for customization and a variety of uses, offering over 25 panel styles such as calendars, photos, charts, grids, columns, cork, fabric and plain or custom printed whiteboards.

®

WIRE JOURNAL

SEPTEMBER 2008: WIRE & CABLE MACHINERY—PART 2 I N T E R N A T I O N A L

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A second model, the RotoCubeŽ Big Island Tower, “offers an amazing 42 square feet of display without taking up an inch of wall space,� the release said. Side panel options make a variety of information display methods available right at the center of the action, in high traffic areas, manufacturing settings and more, it said. Contact: MagnatagŽ Visible Systems, tel. 800-6244154, www.magnatag.com/rotocube.

MEDIA

Guide presents company’s fiber optic products intended for A/V pros U.S.-based Liberty Wire & Cable notes that it has published its first-ever guide to fiber optic products and solutions, which was introduced at INFOCOMM International 2008, the annual convention of the International Communications Industries Association. Designed for A/V and custom installation professionals, Fiber Optic Solutions is a full-color, easy to read guide to products, solutions and services, a press release said. It provides vital information about bulk fiber and bulk fiber connectors, virtually unbreakable durable fiber, field termination kits, molded and custom fiber assemblies, and electronics using fiber connections — making it a convenient literature reference for busy professionals, it said. Products covered in its pages include Liberty’s bulk break-out fiber cables, bulk distribution cables, plenumrated cables, Organizer Packs of 25 connectors in reusable carrying-cases, a DigitaLinx Fiber Optic Extender, stock and custom wall plates, and Corning’s UniCam Pretium Tool Kit, which is a portable field termination kit that can be used with single-mode or multimode connectors, the release said. The guide also includes the company’s “extensive manufacturing capabilities for custom cable assemblies in any length, with simplex or duplex jumpers, and many additional options.� Contact: Liberty Wire & Cable, libertycable.com.

New series of product brochures covers company’s machinery range

Germany’s Niehoff GmbH has created a completely new set of product brochures that display the range of the company, a leading manufacturers of machinery for the wire and cable industry. A press release said that Niehoff, which is continuously

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modifying, enhancing and expanding its product range, felt it was appropriate to present the whole range of products and services in a more appropriate format. “As a result the entire collection of Niehoff product materials was given a total make-over and updated through much creative effort and technical input.� The new, clearly arranged leaflets have a standardized structure inclusive of product pictures accompanied by detailed technical data, with the essential characteristics of each product highlighted, the release said. The new brochures are printed in English, German, and Russian. Copies are available at the Niehoff headquarters, through its website as well as its subsidiaries and the sales and service companies. Contact: iehoff GmbH, www.niehoff.de or iehoff Endex orth America, Inc., www.niehoff-usa.com.

Research report assesses steel wire market, has key company profiles

Reportlinker.com reports that its catalog now includes a new market research report from Global Industry Analysts, Inc., on the global steel wire market that looks at various challenges as well as includes profiles of more than 200 key companies. World Steel Wire Market analyzes the worldwide markets for steel wire, including the following product segments: carbon steel wire (plain, plated/coated with zinc and other coated); alloy steel wire (plain and coated); and stainless steel wire (round and others), a press release said. The $4,450 report, the release noted, provides separate comprehensive analytics for the U.S., Canada, Japan, Europe, AsiaPacific, Middle East and Latin America. Annual forecasts are provided for each region for the period of 2001 through 2015 as well as a 10-year historic analysis for these markets with annual market analysis, it said. The report profiles 214 companies including notables such as ArcelorMittal, Bridon International, Carrington Wire Ltd., Davis Wire Corporation, Insteel Industries, Inc., Ivaco, Inc., Kobe Steel Ltd., Leggett & Platt, NV Bekaert SA, Pohang Iron & Steel Co., Ltd., Steel Authority of India Ltd., Tata SSL Ltd., Tree Island Industries Ltd., and Wire Rope Industries. Market data and analytics are derived from primary and secondary research, the release said, adding that company profiles are mostly extracted from URL research and reported select online sources. Contact: Reportlinker.com, tel. 718-473-0872 (U.S.), us-team@reportlinker.com or eu-team@reportlinker.com, www.reportlinker.com. â–


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CLASSIFIEDS

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking employment positions are entitled to FREE “Position Wanted” classified ads. Limit: one ad per issue, maximum three ads per year. This WAI membership benefit is not transferable to nonmembers or to companies.

days after receipt. Responses to Blind Box ads should be addressed to: Wire Journal International, Box number (as it appears in print or on-line), P.O. Box 578, Guilford, CT 06437-0578 USA.

CLASSIFIED AD RATES: • $1.30 per word for Wire Journal International and on-line classifieds at wirenet.org (20 word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category.

DEADLINES: Copy is due a full month in advance, i.e., it must be received by March 1 for publication in the April issue. Classifieds booked on-line, run for at least one-month on-line, from the date of booking. Wire Journal International “Print classifieds” booked on-line as an “add-on” to an “online classified” booking will run in the next available issue of the WJI.

BLIND BOX INFO: Blind box numbers assure the confidentiality of the advertiser in both the WJI and the on-line publication. Responses are mailed out within two business

PAYMENT POLICY: All ads must be pre-paid.

CAREER OPPORTUNITIES

DIES

SALES AGENTS. Midwest Wire & Cable manufacturer is seeking for commission-based agents. Previous experience in insulated and bare copper required. Please send resume to sales@abcwire.com.

APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural & PCD DIAMOND DIES. Fair prices & excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@wmconnect.com.

PERSONNEL SERVICES

MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904-388-3654.

“LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors, managers and executives. For corporations we provide recruitment, outplacement, and salary assessment functions. For the professional exploring a new opportunity, we provide career evaluation and guidance. Our services are performed in absolute confidence.

DIAMOND & CARBIDE DIES: PRICED TO MOVE! Take advantage of discounted pricing on new, used and recut diamond and carbide dies in standard case sizes: 2, 5, and 6. For quality

dies with competitive pricing, contact Ida Pardo at info@knottco.com or by phone at 617-519-3303. MACHINERY WWW.URBANOASSOCIATES. COM. For New & Used Wire & Cable Equipment. Tel. 727-863-4700; fax 727-863-4711; or by e-mail at urbassoc@verizon.net. BEST WARRANTY-LOWEST PRICES on high quality Rolling Ring Traverses. YR Products phone/fax: 708672-5007 or e-mail kamoline@ comcast.net. CAST MACHINE PARTS. Specializing in Arbor Dies. Dutile iron & Bronze. Excellent price, delivery &

E-mail Peter Carino or Jack Cutler pcarino@wireresources.com or jcutler@wireresources.com www.wireresources.com. Wire Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-6223000 or 800-394-WIRE.

Serving the non-ferrous and ferrous industries since 1983

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WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION

NAME _________________________________________________________________________TITLE _________________________________________________ COMPANY ____________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________

CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail

NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

WAI MEMBER? YES____ NO ____ WAI MEMBERSHIP # ______________________ (Applies only to “Position Wanted”)

Engineering help. JESTREITMAN LLC. Phone & Fax 704-882-2167. E-mail-jes1930@aol.com.

hensive hard-cover book is a new, definitive industry resource for ferrous wire written by members of the Association and edited by former WAI President Robert M. Shemenski. It is a modern-day reference tool for those working directly in the steel wire or manufacturing, engineering, or opera-

MEDIA FERROUS WIRE HANDBOOK. The most recent in a series of handbooks published by WAI, this compre-

COMMISSION BROKERS, INC. EQUIPMENT SPECIALISTS TO THE ELECTRICAL WIRE & CABLE INDUSTRY APPRAISERS • COMMISSION BROKERS • INDIVIDUAL PIECES OR ENTIRE PLANTS

FOR SALE

1 - WMCA 37-Wire, 6+12+18, 16” Planetary Line 1 - NEW ENGLAND BUTT 12-Head 16” Planetary Cabler 1 - WATSON 6-Head 16” Planetary Cabler 1 - WATSON 36” Rotating Cabler Line 1 - NORTHAMPTON ST1000 Cabler, 1999 1 - NIEHOFF M15 Wire Drawer, Annealer, SG45 Spooler 1 - D/S 2.5” 24:1 L/D Nylon Extruder 1 - D/S 2” 30:1 L/D Hi-Temp Extrusion Line 1 - D/S 1.25” 30:1 L/D Hi-Temp Extruder 1 - D/S 2” 24:1 L/D Extruder 4 - DAVIS STANDARD, ENTWISTLE 50” Shaftless Payoffs 1 - DAVIS ELECTRIC 36” Shaftless, Model POS18-36 1 - TULSA 30” Payoff, Model PSPO-1, 1000lb cap, 8/90 1 - 30” Core Neutralizer Payoff

1 - NEB 61-Wire 22” Rigid Strander Line 1 - D/S 36” H.S. Dual Reel Take-up, twin Motors 1 - ENTWISTLE 36” Dual Reel Take-up, Model THE 24/36 4 - D/S 30” Dual Reel Take-ups 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 7 - CLIPPER Model SP16 Dual Spoolers 2 - BARTELL 72” Shaftless Take-ups 1 - DAVIS ELECTRIC 36” Shaftless, Model TUS36 3 - TULSA/KENRAKE Model WTR-656 Respoolers 1 - ADVANTAGE Chiller, Model MK-25AM41HBX, 9/98 1 - IMAJE Model Jaime 1000 S4 Ink Jet Printer, 10/96 41 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels

Contact: Martin Kenner

COMMISSION BROKERS, INC.

P.O. Box 8456 • Cranston, RI 02920-0456 • Tel. (401) 943-3777 • Fax: (401) 943-3670 WEB: www.commissionbrokers.com • E-MAIL: marty137@aol.com

100 | WIRE JOURNAL INTERNATIONAL

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org. For more details, you can call her at 203-453-2777, ext. 116.

tions sectors of the industry. At 1,168 pages, the publication’s comprehensive 36 chapters cover a broad range of topics including many of the equipment types, processes, and specialty applications of steel wire manufacturing. The book begins with a history of the steel industry and includes the evolution of ferrous steel manufacture, appendices and a complete index. List Price is $235, $195 for WAI members. To purchase, go to wirenet.org and click on The WAI Bookstore. WIRE BREAKS, by Horace Pops and Julie Steininger, 2003, 49 pages. Breakage of copper, steel, or aluminum wire is one of the most common and costly problems facing the wire industry today. To help minimize the number of breaks, drawing personnel must first be able to recognize and identify the type and cause of material failure. With this need in mind, the following reference manual was prepared. It contains pictures of the most frequent examples of broken wires found in the wire mill and at the customer’s facility. In addition, many pictures of cross-sections are included that were obtained in the laboratory using metallographic techniques The photomicrographs do provide useful supplemental information that helps to confirm and explain the nature of the wire breaks. List Price: $15, WAI Member Price: $10. To purchase, go to wirenet.org and click on The WAI Bookstore.


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ELECTRICAL WIRE HANDBOOK. This three soft-cover book set examines materials, equipment and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire and more. Part 1 is Wire and Cable Production Materials, Part 2 is Wire and Cable Production Processes and Part 3 is Types of Cables. The new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. The handbooks, produced by the WAI’s Electrical Management Committee, are a valuable reference tool for members of the industry to help keep up with today’s rapidly changing technology. List Price: $99, WAI Member Price: $59. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

GAVLICK MACHINERY CORPORATION 100 Franklin St., Bristol, CT 06010 USA Phone: 860-589-2900 Fax: 860-589-0863 email: sales@gavlick.com www.gavlick.com

Buying & Selling Used Ferrous & Non-Ferrous Wire & Cable Machinery JUST PURCHASED: • Vaughn #18 Bullblock; 30"x125hp; 1"start; late model controls-excellent • Vaughn #19 Bullblock; 30"x65/75hp; start .625" • (8) Taiwan Cheng model MDC-10L Descalers; 5.5-10mm, scale breaking, brush, coating-heating • (16) Drawing Deadblocks; Morgans, Macbees, Whitacre; all sizes; 16"-28"; 30-75HP • (9) Wire Lab Model 310 Descalers, reverse bend WIRE DRAWERS: • Vaughn model 5HRM w/30" Deadblock; (5) 40/50/69HP motors; (4) 26" blocks; start: .280" S.S.; PLC controls; excellent • Vaughn model 6/7 HIVXX; (1) 20/30HP motor 1st block; (5) 15/22.5HP motors; start block dia 20"; intermediate 14"; finish 16" + 22"; start wire .220"; 2400 FPM; PLC controls • Morgan 5BW; 5x22" blocks; start .218", finish .086", 300HP AC • Morgan 6BW; 4x26"/2 x 22" blocks; start .218", finish .076"; 300HP AC STRAIGHT & CUT MACHINES: • Shuster Model 4AV; .375"-.625"; 3' runout; new 9' track in crate; 1991 • (5) Lewis Model 1SHV-HS; .031"-.062" to .135"; 4' runout; 250-400 FPM BUTT WELDERS: • (5) Micro J6-S • Micro T-HD; .125"-.500" • (2) Strecker Model 2B Butt Welders; 5-16mm, new 1997

• Micro J5S, .060"-.250" BAG-BAR TIE MACHINES: • (1) 3-head Bar Tie Spooling Machine • (4) Bag-Bar Tie Machines; 16 ga.; 5"-12" lgths. • (4) Bar Tie Wire Spooling Machines; 3- 3-1/2 lbs.; 16 ga. TURKHEADS: • Fenn Model 5U + 5P tandem, 28" shedding drum, 25/30HP • Fenn 6U Turkshead • Fenn 5TH Turkshead; max. sq. .437" MESH WELDERS: • Hurricane Hinge Joint Fence Machine model HJL55"; 11 line wires, 6"-12" stay; completely rebuilt • Jager NS200; 102"wide, .019"-.098" wire; shear; coiler • EVG GZN/85; 90"max. width; 85"max weld width; 1,2,3,4,6,8 line spacing; cross wire 1/2" up to 4"; wire dia. 1.4-3.8mm; slitter; nibbler; coiler for rolls; excellent NAIL MACHINES: • (3) Wafios N-4 • (2) Wafios N-5 • (2) Waterbury #10 Roll Threaders-nail threading SPOOLERS: • Hall; 20"-30"; traverse, 1000 lb. cap; 5002500FPM • (2) 30" traverse base; 16" traverse; (4) 280FPM, 5HP EC motors

WE WANT TO BUY YOUR GOOD SURPLUS EQUIPMENT. SEND US YOUR LIST.

VISIT WWW.GAVLICK.COM TO SEE OUR COMPLETE LISTINGS

Machines USA More than 1200 second-hand machines for the wire-, cable- and rolling mill industry www.bongard.us

New machines and lines upon request

e-mail Dave.Evans@george-evans.com

reconditioned 6 block double capstan drawing machine

Contact us: Bongard Machines USA LLC Suite 160 6920 Pointe Inverness Way Fort Wayne, IN 46804 Phone +1 260 225 4510 Fax +1 260 225 4513 E-Mail chris.z@bongard.us www.bongard.us

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ADVERTISERS’ INDEX ADVERTISER . . . . . . . . . . . . . .PAGE

ADVERTISER . . . . . . . . . . . . . .PAGE

AIM Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4

Dow Wire & Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Amacoil Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

Esteves Group USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Amaral Automation Associates . . . . . . . . . . . . . . . . . . . . .25

Eurolls Group/Vitari Spa . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Ametek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .63

Mario Frigerio SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Arkema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Balloffet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Gavlick Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . . .101

Beneke Wire Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Gem Gravure Co Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Guill Tool & Engineering Co . . . . . . . . . . . . . . . . . . . . . . . .44

Bomco Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

HV Technologies Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . .101

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .51

IWG High Performance Conductors Inc . . . . . . . . . . . . . .59

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

International Fastener Machinery & Suppliers Association (IFMSA) . . . . . . . . . . . . . . . . . . .94

Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . .100 Conneaut Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Cortinovis Machinery America/Vitari Spa . . . . . . . . . . . . .37 Die Quip Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

WIRE JOURNAL I N T E R N A T I O N A L

ORTH AMERICA Robert J. Xeller Anna Bzowski Wire Journal International 1570 Boston Post Road P.O. Box 578 Guilford, CT 06437-0578 USA Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

EUROPE

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. 63 St. Andrew’s Road Cambridge CB4 1DH, England Tel/Fax: 44-1223-360472 franksco@btopenworld.com

102 | WIRE JOURNAL INTERNATIONAL

J&D Associates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Joe-Tools Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Kinrei of America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

SALES OFFICES Germany, Austria, & Switzerland Dagmar Melcher Media Service International P.O. Box 103 D-82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

ASIA/WAI IDIA OFFICE

Anand Bhagwat Wire & Cable Services Pvt. Ltd. (WCS) Mobile 91-98-508-38467 abhagwat@wirenet.org


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ADVERTISER . . . . . . . . . . . . . .PAGE

ADVERTISER . . . . . . . . . . . . . .PAGE

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Sealeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Madem Reels USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Shanti Metal Supply Corp . . . . . . . . . . . . . . . . . . . . . . . . .97

Maillefer SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Mario Frigerio SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Sikora International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . .99

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Skaltek AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Sonoco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .73

Sweed Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . .42-43

Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . .68

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Reel-O-Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Troester GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Sanxin Wire Die, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Vandor Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

RECENT PURCHASES — INVENTORY HIGHLIGHTS

EXPL304 - ROSENDAHL Skin-Foam-Skin Insulation Line, 2000. Henrich Annealer, Preheater, 60/45/30mm extruders w/gas injection, Multi capstan, Rosendahl DIN500 Dual Take up. EXP858/859 - (2) 4 1/2” D.STD. Therm V. 24:1, EXP834/835 (2) 2” D.STD. 24:1. EXP864/864 (2) 3” D.STD. 24:1. CBR708 - 60” CEECO Planetary Cabler, 1+6, Type DC-3/60, 24” Dual ECC Taper. 72” Belt Cat, 96” Portal Floor Trav Take up CBR833 - 96”/2.50m CEECO DrumTwister, 1998, Oscillator W/dual binder. CBR977 - ENTWISTLE COOK SC-48 S.T. Cabler (1983). CBR980 - (2) 760mm LESMO D.T. Buncher, DTO-760MB (1998). CBR981 760mm SAMP D.T. Buncher, BM-760D. (1995) CBR965 - 50 Pair 500mm CABALLE Group Twinning Line (1992), w/ 84” rot. take up 5 head OSC/binder. CBR967 - 52 PAIR 500mm CEECO Group Twinning Line, (1992), w/1.6m Pourtier rot. take up, 7 head OSC/binder, (2) SZ OSCbinder, (2) 1.6m Ceeco portal trav. T/U. CBR968 - 84” CEECO Cabling Line w/(29) 64” S/L payoffs, (2) conc binders. CBR966 - 50 Pair 500mm POURTIER Line with 1.6m Pourtier rotating take up, 10 head osc/binder. O.A. binder. CBR949 - NEXTROM 18 Bobbin (6+6+6) Ribbon Strander, 450mm bobbins CBR927 - (10) 560mm WATSON/KINREI D.T. Twinners, 20” Dual Driven payoffs, 1998. CBR923 - 1250mm POURTIER Drum Twister, 12-630mm Neutralizing

Payoffs, Rotating Caterpuller, 1.25m Rotating Payoff. CBR948 - 48” TEC Drum Twister w/(2) Conc. Tapers. NOKIA DUAL TAKEUPS - (2) EKP-5 2001, EKP-50 1998, EKP-100 1995. TKU1061 - (2) 60” BARTELL S/T take ups. TKU1043 -36” CLIPPER Dual Reel Take up, PS-36 Recently rebuilt. RWD445 - CLIPPER SP-16.Dual shaft rewinder, RWD359 - 2.6 m SKALTEK Rewind Line. A264K Payoff, S60/L100 line controls. Measuring mach. Guide roller assy. U26T Take up. WRD678 - SAMP 14 wire Drawing line, Model MLS/5.T.14 w/MT8 Drawer R12.14.14.550 annealer, (2) TE 65/M spoolers, 1993, 14 AWG-34/38 AWG finish. WRD722 - NEXTROM Multi Wire Drawing Line, 7 Wire w/Annealer, 630mm Spooler, Yr. 1999 WRD831 - SAMP 8 Wire Multiwire Line 996. Samp MT 8.2.4.Samp R16M8-1350 Annealer. Samp SS/1-630 Spooler, Dancer Assy. Control Panel?. Filtetech Filtration Sys Flyer Payoffs. Still Installed- Complete WRD818 VAUGHN - Tandem Rod Breakdown Machine, 10 dies, 18” Capstan, 400 HP DC Drive, 30” spooler. WRD835 ENDEX 18” Drop Coiler with Turntable. WRD837 (4) NIEHOFF M30 Intermediate Wire Drawing w/VG_30 annealer, 75 kw DC motor, controls. BIN131 (2) CABALLE 18 Position Kevlar servers, RKCR-250-18, 250 RPM, Year 2000, Siemens S7/300 PLC. LATE MODEL HIGH QUALITY (BRAND NAME US & EUROPEAN) WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY EX-STOCK FROM (6) USA WAREHOUSES

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ADVERTISER . . . . . . . . . . . . . .PAGE Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . .103

What’s your story? Messages from ads and articles that appear in Wire Journal International make great reprints and serve as another opportunity to tell your company’s story.

Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .72 Wyrepak Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . . . . . .15

Layouts can be customized to suit your promotional needs. So, why not brand your reprints by including your logo, plant location, or the corresponding Wire Journal International cover with your reprint?

WIRE ASSOCIATION INTERNATIONAL ADS

For more information about reprints be sure to have the WJI issue month, year, and page number handy when you contact The Reprint Department at: ckeener@reprintdept.com or Tel.: 800-259-0470.

Interwire 2009 Call for Papers . . . . . . . . . . . . . . . . . . .17-18 Inrterwire 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

When it comes to reprints, we’ll help you tell it like it is.

WAI 2008 ITC: Monterrey, Mexico . . . . . . . . . . . . . . . . .52-53

Kinrei is Kabling

Ferrous Wire Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . .66

In fact, Kinrei is your source for the latest technology in cabling, stranding and twinning solutions. Our double twist twinners and cablers produce today’s highest performance data and communications cables. Our complete Stranding Systems output levels are 15 – 40% higher than competitive machines. And that’s just the beginning — to learn more visit www.kinreiusa.com for product details!

Also representing: Donnelly High Performance ABS Reels

Watson Parts and Service Company Featuring OEM Replacement Parts & Rebuilds The Kinrei HK560 Watson Machine Company • Wire Machinery Corporation of America, Inc. The Edmands Company • The New England Butt Company • Peachtree Fiber Optics

Call for a quote, 973-677-9500, ext. 143. Or e-mail shess@kinreiusa.com Donnelly Reels

KINREI OF AMERICA, L.L.C. | 26 NORTH CENTER STREET | ORANGE, NJ 07050 973-677-9500 | WWW.KINREIUSA.COM

104 | WIRE JOURNAL INTERNATIONAL


Amacoilbth.qxp

3/19/2007

8:05 AM

Page 7

Wind up with an Amacoil/Uhing assembly for perfect pitch every time Pitch is adjustable (10:1) without requiring gear changes or adjusting motor speed. A single Amacoil/Uhing assembly may be used for winding many different diameter materials. Automatic reversal of the traverse is mechanically controlled – without clutches, cams or gears. No electronics or programming needed. FEATURES • Zero backlash. • Automatically synchronizes pitch with take-up reel rotational speed. • Traverse drives with up to 800 lbs. axial thrust. • Smooth, unthreaded shaft won't clog or jam – no bellows assembly needed. • One inexpensive, unidirectional motor drives both the traverse and take-up reel. • Free movement lever – no need to "jog" system on and off to position linear drive. • Options and accessories for every winding situation. • Light, medium and heavy-duty systems.

For Brochure or CD-ROM Call toll free 800-252-2645

email: amacoil@amacoil.com

www.amacoil.com AMACOIL, INC. PO Box 2228 • Aston, PA 19014 • Phone: 610-485-8300 • Fax: 610-485-2357


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7/17/2008

11:01 AM

Page 7

2008 ITC Mexico preview  

Feature Stories: 2008 ITC Mexico preview, Wire China preview. Technical Papers: The Mobile Impact Tester for cold heading research at Ivaco...

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