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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

Ancillary Equipment

Ferrous view:

P. 48

The Chinese wire rod rollercoaster: how it impacts the rest of the world

2008 IWCS preview

P. 52


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Editorial . . . . . . . . . . . . . . . . 6


Volume 41 | Number 10 | October 2008


Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 12 Asian Focus . . . . . . . . . . . . . 24 People . . . . . . . . . . . . . . . . 28 Fiber Watch . . . . . . . . . . . . . 28

2008 IWCS preview . . . . . . . . . .52

Fastener Update . . . . . . . . . 34

IWCS™ returns to the Rhode Island Convention Center for its 57th annual Technical Symposium and Conference with a wider program scope.

WAI News . . . . . . . . . . . . . . 38

Ancillary Equipment . . . . . . . . .56

Chapter Corner . . . . . . . . . . 44 Ferrous View: the China effect . . . . . . . . . . . 48

This feature focuses on the less-heralded suppliers to the industry: those who provide the essentials, from air wipes and replacement bows to clutches/brakes to jacket strippers.

T ECHNICAL P APERS Technical Papers . . . . . . . 80-99 Products/Media . . . . . . . . . 102

Steel patenting technology in the manufacture of steel tire cord Thomas W. Tyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Classified . . . . . . . . . . . . . 107

Fabrication of shaped medical testing wire by drawing Kazunari Yoshida and Miki Matsunaga . . . . . . . . . . . .88

Career Opportunities . . . . . 107

FEM simulation of wire fracture phenomena during multi-pass drawing Andriej Milenin, B.P. Gautham, Sharad Goyal, Jan W. Pilarczyk and Zbigniew Muskalski . . . . . . . . . . . . . . . . . . 93

Advertisers’ Index . . . . . . . 110

Cover: A display of products that are part of the collective class of ancillary equipment/replacement parts that are essential to keeping the wire and cabe industry producing. See p. 56.

OCTOBER 2008 | 3

INSIDE THIS ISSUE F ERROUS V IEW . . . . . . . . . .48



. . . .44

Joe Snee, Amaral Automation Associates, was among the 156 golfers who enjoyed the New England Chapter’s annual golf tourney. For one player, “puttering around” proved to be especially rewarding.

With wire rod production 20 times that of the U.S., you might think wire companies in China have a relatively easy time sourcing rod. Murat Askin of SteelOrbis explains why everything is not as it seems and how the global wire rod market was singlehandedly affected by China in 2008.

Reels and packaging Axjo’s range of reels are made from environmentally friendly, recyclable materials and offer the best lifetime economy thanks to their versatility and efficient logistics. Our range includes reels with flange diameters from around 50 mm up to 1300 mm. We can offer over 500 different types of reels, for many different applications, such as storing cable, wire, tube, textile products, chain and sealing strip. AXJO Plastic AB is a Swedish company, founded in 1945. We manufacture and market products from polymers for industry and the consumer sector.

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Government intervention at Interwire 2009 a plus for exhibitors There’s no magic switch that one can flip to draw new attendees to a trade show, but the WAI has found what may be the next best thing: the U.S. Department of Commerce (DOC). The DOC is going to deploy its resources on behalf of U.S. exhibitors at Interwire 2009 that want to export or could use some help in exporting better. Better yet, the program is free to qualified U.S. exhibitors. What’s a qualified exhibitor? It is a U.S.-based company that exports products that are at least 51% of U.S. origin. The value of intangibles, such as R&D costs and marketing, can be factored in. The DOC’s International Buyer Program (IBP), offered through the International Trade Administration, is designed to attract international buyers to leading U.S. trade events and help them connect with U.S. exhibitors before, during and after the show, as well as providing export counseling. An IBP team will identify and directly contact potential international attendees and help smooth the process for them to be able to attend Interwire, which will be held April 25-30, 2009, in Cleveland, Ohio, USA. So, what’s the catch? There’s not one, other than there is a caveat. Applying for this program is not something that an exhibitor can put off until a month or so before the show. Companies interested in the program must send an e-mail to that effect to no later than Dec. 8 as the IBP program requires lead time to identify a company’s potential customers, to make contact and to follow-up. More details will follow about the IBP program in future issues, but the key is not to delay. The only cost for this program is your time and a sense of what countries you would like to target for your products. While the IBP program directly benefits the qualified U.S. exhibitors, it benefits the other exhibitors too as the net result of the program should be additional attendees on the show floor. Finally, it’s got to be a plus for everyone to see tax dollars working to support industry.

Mark Marselli Editor-in-chief

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 Graphic Artist | Adrienne E. Simpson 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; e-mail 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.






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CALENDAR 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; October 20-22, 2008: ITC Mexico Monterrey, Mexico. To be held at the Crowne 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,

November 9-12, 2008: 57th IWCS™ Conference and Symposium Providence, Rhode Island, USA. The IWCS returns to the Rhode Island Convention Center for its 57th annual event. See preview on p. 52. November 20-22, 2008: Wire & Cable India 2008 Mumbai, India. Contact: Cheryl Fernandes, Confederation of Indian Industry, tel. 91-22-24931790, ext. 470; fax 91-22-24939463; 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; ■ (continued on p. 10)

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W IRE ASSOCIATION I NT’L E VENTS For more information, contact the WAI, USA. Tel. 001-203453-2777; fax 001-203-453-8384; Internet October 14, 2008: Midwest Chapter Dinner Meeting Rosemont, Illinois, USA. Fed Reserve official William A. Strauss will speak at the WAI Midwest Chapter Dinner Meeting on Tuesday, October 14, 2008, at the Donald E Stephens Convention Center in Rosemont, Illinois. 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 Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, a wire museum tour and networking opportunities. 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 at the Rhode Island Convention Center. March 3-5, 2009: Modern technologies and modelling of drawing and manufacturing processes of metal products Zakapone, Poland, Members of the WAI’s Poland Chapter are among the organizers of this event, which will present theoretical and practical research results. Contact: Dr. Sylwia Wiewiórowska, wiewior@mim., 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;


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INDUSTRY NEWS SARK to open U.S. production plant, first such venture for Turkish business Sark Wire Corporation, which recently joined the Sarkuysan (SARK) Group of Companies, announced that it will begin manufacturing copper wire next year at operations it is establishing in Albany, New York, USA. Sark Wire represents SARK’s first international investment on the production side, said a press release from Sark-USA, Inc., a sales and marketing company for SARK. “SARK is pleased to join the U.S. manufacturing force and proud to become an American producer of copper wire.” The site, a former printing house that has about 50,000 sq ft of space on four acres, will be used by Sark Wire to annually process approximately 30 million pounds of copper, the release said. The plant will produce bare and tin-plated wire for the industrial, automotive, marine, aerospace, defense, communications and computer cabling sectors, among others, it said. The building, which had been closed, is being upgraded and production equipment will be installed, said SarkUSA Vice President Tolga Kaan, who added that the number of employees to be hired has not yet been finalized. She further explained the rationale for the venture. “Constantly rising transportation costs, the weak U.S. dollar against the Turkish lira, long lead times from Turkey to the U.S., a growing market share that started to be restricted by only imports and limited product range were some of the factors for us that led to this decision. Most importantly, it shows our commitment to our loyal customers and our ambition to serve the wire and cable industry in North America. This site will enable us to supply short lead times, competitive pricing and a broader range of products.”

Gerdau to build mill in Argentina Brazil’s Gerdau Group plans to invest US$524 million in a new steel mill in Pérez, Argentina, that will quadruple the steel production there by its Argentina business, Sipar Gerdau. Business News Americas reports that Gerdau CEO Gerdau Johannpeter made the announcement in a recent meeting with Argentine President Cristina Fernández. The new Sipar Gerdau plant will increase the group’s steel production in Argentina to 1.1 million metric tons, it said, adding that construction is set to begin in November with the first phase of the project scheduled for completion in 2011. At that point, it said, the Sipar plant should be annually producing some 650,000 mt of crude steel and 710,000 mt of long products, which includes shapes, wire

rod, wire, concrete reinforcing bar and more. Those investments are projected to cost US$310 million. The second project phase is scheduled for completion by 2016, it said. “Sipar Gerdau’s production is intended to meet the growing demand in the Argentinean market,” said Luis Pecora Nova, Sipar Gerdau. “These new investments will further prepare the company to respond especially to the needs of the construction and metal-mechanic industries.” The release described Sipar Gerdau as one of the major suppliers of finished long products for the construction and metal mechanic industries in Argentina. It noted that the company operates a mill in Pérez, in the province of Santa Fé, where it has 450 employees and an annual installed capacity to roll 260,000 mt.

Anixter International agrees to acquire World Class Wire & Cable Anixter International, Inc., announced that it has agreed to acquire World Class Wire & Cable, Inc., a distributor of electrical wire and cable, for approximately $62 million in cash and assumption of trade liabilities. From its single operating site in Waukesha, Wisconsin, World Class generates approximately $60 million per year in annualized sales, a press release said, noting that the deal was scheduled to be completed in early October. “We believe the World Class team will be an excellent fit with our existing presence in the wire and cable market in the Midwest,” Anixter CEO and President Bob Eck said in the release. “This acquisition positions us well to drive even stronger future organic growth.” Per the website at World Class Wire and Cable, the company was founded in 1994 by James M. Lindenberg in New Berlin, Wisconsin. It has expanded to serve a wider range of customers and made its most recent move in 2005, to Waukesha, Wisconsin, to a building twice the size of the last with double the production capability. A recipient of many business awards, World Class Wire and Cable notes that it has close ties with wire producers and offers services such as ink jet printing, hot stamping, drum packing, DRUMBOX®, UL & CSA respooling, coiling, striping, dyeing, topcoating, twisting, ring banding, ship to stock, repackaging, bar-coding, sourcing and just-in-time stocking programs.

Gauder Group demonstration of technology ends with welcome ‘twist’ A recent three-day demonstration of new LAN cable assembling technology at Gauder Group, Inc., the U.S. business of Belgium’s Gauder Group, ended with an order

Does your company have news that belongs here? E-mail it to the WJI at



U.S. Department of Commerce to be a key supporter of Interwire 2009 For the first time ever, Interwire will have the full backing of the U.S. Department of Commerce, which will provide global support and bolster marketing of the event, to be held in Cleveland, Ohio, in 2009, as well as provide programming at the event that will help U.S. exhibitors that want to export. See p. 6 and p. 38 for more.

for the Setic line that was displayed. The system from Setic, part of the Gauder Group, represents its latest technology for producing LAN cables, a press release said. It noted that representatives from major U.S. cable producers who attended the event got to see the “Quali2twist” process for UTP data cable in action (see p. 102 for details).

Attendees inspect a new Setic line at a recent demonstration at the U.S. headquarters of Gauder Group, Inc. During the event, several different type cables were assembled ranging from a standard solid PE Cat. 5e UTP to a FEP Cat. 7 FTP with mylar/Al tape, the release said. “Impressed by the speed and quality of the cables produced, the entire line was sold that same week and will soon be producing up to Cat. 6e UTP/FTP cables,” it said.

Nucor plans to restart Kingman mill U.S.-based Nucor Corporation announced that it plans to begin production of steel bar by the second quarter of 2009 at its previously idle rolling mill in Kingman, Arizona, a project that will cost an estimated $30 million in capital improvements.

OCTOBER 2008 | 13


Initial annual output of straight-length rebar, coiled rebar and wire rod should be about 250,000 tons, a press release said, adding that the mill “will have the capability to increase annual production to more than 500,000 tons.” The release noted the following. “Nucor acquired the idled plant from North Star Steel in 2003 for approximately $35 million. In 2004, it decided that Kingman’s melt shop would not be restarted and recorded a $13 million impairment charge for the melt shop assets. The rolling mill assets were held available for restart whenever market conditions warranted. The decision to start rolling rebar and wire rod products is driven by growing demand in the southwestern U.S. market from both Nucor’s outside customers and Nucor’s expanding downstream rebar fabrication business. Kingman’s very attractive capital cost for rolling steel will be leveraged by excess low-cost melting capacity at our existing bar mills.” “The restart of this facility expands our highly successful vertical integration business model,” said Nucor CEO and President Dan DiMicco.

American Kuhne reports sale of its 1000th extruder since 1997 U.S.-based American Kuhne reports that the company achieved a production milestone with a recent order for two extruders from a Nexans unit. Founded in 1997, American Kuhne sold its 1,000th extruder with an order for two systems from Nexans Electronics Cables, Elm City, North Carolina, for two high-temperature, corrosion-resistant extruders systems (one 1.5 in., the other 2.5 in.) for processing fluoropolymers and conventional resins, a press release said. Nexans Electronics Cables supplies communications solutions

Art Deming, a senior manufacturing engineer for Nexans, holds a plaque presented by American Kuhne Regional Sales Manager Doug Johnson, citing the sale of company’s 1,000th extruder.


and service to the aerospace/shipboard commercial and military markets. The extruders, it said, were bought to help meet consistent double-digit growth and to further improve quality. The milestone was recognized at a ceremony for American Kuhne and Nexans employees at American Kuhne’s new manufacturing facility in Ashaway, Rhode Island. Art Deming, a senior manufacturing engineer for Nexans, led the team that selected American Kuhne for the first time in their extruder buying history. He cited the supplier’s “unique willingness to customize the machine exactly as we wanted it” as one of the factors that led to the choice.

Electrical Manufacturing Expo to be held November 3-5 in Orlando The Electrical Manufacturing Expo (EME) will be held November 3-5, 2008, at the Gaylord Palms Convention Center in Orlando, Florida, USA. The event, whose organizers include the Electrical Manufacturing & Coil Winding Association, addresses magnetic and insulation materials and process equipment and is intended for those involved in the electrical manufacturing industry. It includes short courses, conference sessions, AiME courses, tutorials as well as exhibits. Contact: Chuck Thurman, tel. 619-435-3629; cthurman,

Draka to close Wales plant Draka Holding N.V. announced that as part of its Stop, Swap and Share program of maximizing resources, a decision has been made to cease production of copper wire at its U.K. plant in Llanelli, Wales, which employs about 135 people. A BBC News report cited management as saying that high transport costs were behind the decision, and that it was hoped that the employees would get job offers at other Draka plants, including the plant in Derby, which will take over a percentage of the Llanelli cable production. Draka Investor Relations Director Michael Bosman explained in the report that shipping costs proved to be too extreme. “We have to buy the rods from the continent, and ship it to the UK, draw wire from it, and then ship it back to our factories in Europe,” he was quoted as saying. “So that means the cost has increased quite tremendously in the last two years, and economically it is not wise to maintain this production site.” The BBC report said that Draka’s copper wire divisions produce more than 50,000 metric tons a year at locations in 15 European countries and Russia. Across Europe, the firm has a workforce of 9,000 people, with an annual turnover of about US$2.5 billion. Earlier this year, Draka announced the closure of its plant in Vigo, Spain, part of its Automotive & Aviation Division, with the loss of 100 jobs.


Prysmian reports winning submarine power link cable contract in Qatar Italy’s Prysmian announced that it has been awarded a contract valued at approximately US$250 million to develop the first-ever, high-voltage submarine power link in Qatar. The contract, from the Qatar General Electricity & Water Corporation (KAHRAMAA), is for a turnkey project serving Doha, the capital of Qatar, a press release said. The deal calls for Prysmian to supply a total of 63

km of 220 kV submarine and underground power cables and accessories, includes the engineering, marine and land surveys and procurement and cable construction, as well as submarine and land installation and commissioning services, it said. The installation will start in 2009 and is scheduled for completion by the end of 2010, it said, adding that the cable will be manufactured at Prysmian’s plant in Arco Felice, Italy. The latest deal follows a US$300 million contract recently secured with KAHRAMAA by a Prysmian-led consortium for the construction of a high-voltage underground cable system, the release said. It observed that Qatar, situated in the Arabic Gulf with its abundant petroleum and natural gas reserves, has posted double-digit growth rates and continues to invest in the country’s infrastructure. The Middle East region has been targeted as a strategic area of expansion for Prysmian, which has offices and facilities in Dubai and Abu Dhabi (UAE), Doha (Qatar), Manama (Bahrain) and Kuwait, the release said. It noted that Prysmian is currently involved in construction of the submarine power connection between Saudi Arabia and Bahrain, with the GCCIA (Gulf Cooperation Council Interconnection Authority); supply/installation of high-voltage cables and systems for an aluminum smelter facility in Abu Dhabi; power transmission projects in Fujairah (UAE) and Doha (QATAR); an oil and gas project in Qatar; cables for Burj Dubai, for the world’s highest tower; and the Palm Island Dubai/Logo Island interconnection (submarine medium voltage cables).

Company outlook still unclear, but not its cable production

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U.S.-based Delphi continues its struggles to escape Chapter 11, but those issues have not impacted the company production-wise. In August, the company noted that its yearly production of specialty auto cable topped one billion ft, and it is on schedule to manufacture 1.5 billion ft by the end of 2008. “Delphi’s leadership team is intensely focused on transformation initiatives and positioning the compa-

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ny for emergence ...,” a company spokesperson said. “The remainder of Delphi’s workforce, however, continues to focus on providing world-class products and services like our halogen-free cable to customers around the world.” A Delphi press release said that the company’s halogenfree, ultra-thin-wall cable, an environmentally friendly alternative to PVC and XLPE cables, is being used by three major auto makers. The insulation is half as thick as conventional coatings in North America (0.2 mm versus 0.4 mm), or about as thick as two sheets of paper, reducing weight by up to 27 percent and volume by up to 47 percent, it said. Those attributes result in improved fuel

efficiency and vehicle performance and free up space for automakers while meeting the chlorine- and lead-free parts requirement, it said, noting that the cables also offer “the best pinch and abrasion resistance in the industry.” The cable, which made its debut on the 2007 Toyota Tundra, is used in the wiring harness, which the company notes in the release “is one of the heaviest and most complex parts in a vehicle.” Use of the ultra-thin cable allows automakers “to fit more of the content consumers want in their vehicles,” it said.

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Brazil’s Madem Group, which notes that it is the world’s largest wooden cable reel producer in the world, reports that it has invested US$45 million the last five years as part of its expansion efforts. In a press release, the company outlined activity in four following regions. South America. Completion of a new US$8 million plywood plant in southern Brazil that will produce 70 containers a month of plywood reel flanges for Brazil Madem SA. The machinery was custom developed for Madem and a special plywood will be in the market by October 2008. Madem SA has three plants in Brazil, 800 employees, 30,000 acres of renewable pine forests, two sawmills and one recycling operation. United States. Madem Reels USA, Inc, located in Chattanooga, Tennessee, is aggressively launching a second shift as well as opening its first warehouse and recycling center in West Virginia. Another 10 warehouses will be opened by 2010. Madem Reels is already servicing eight customers from the Chattanoga plant operation. Middle East. Madem Gulf, WLL, which is located in Kingdom of Bahrain, has nearly completed construction of a new plant and production is expected to begin by January 2009. Madem is anticipating another new plant project for Middle East region in 2010. Europe. In Spain, Euromadem Spain SL, located in Calaf, Barcelona, has just launched a second shift. Already a leading seller in Spain and Portugal, Euromadem will soon penetrate markets in France, Belgium, Switzerland

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and Germany. In Eastern Europe, Madem Romania SRL located in Bistrita, Romania, has another production operation launch projected for this December. “With our new plants in Bahrain and Romania, Madem will be processing 750 trucks of lumber a month, selling to more than 150 customers in more than 40 countries, said Madem Group Sales Director Leandro Mazzoccato. He observed that over the last five years, the company has invested US$45 million in new plants, software, quality systems, machinery and warehouses. “We will continue our expansion strategy by servicing our local and worldwide customers,” he said, noting that the company is ISO 9000 and ISO 14000 compliant in Brazil and will begin ISO implementation in Spain and the U.S. in January 2009.

Italy’s Continuus-Properzi reports contract from Pakistan company Continuus-Properzi SpA, based in Milan, Italy, reports that the company, a global supplier of Properzi Continuous Casting and Rolling (CCR) rod lines, has received an order from Pakistan’s Universal Metals Ltd., for a CCR copper rod line, that will also use copper scrap and have capacity of 60 tons per day, the release said. With this latest deal, the release said, Continuus Properzi once again underlines its strong international presence. The company was founded in 1947 by Ilario Properzi.

ArcelorMittal unit in Germany orders steel wire rod mill from SMS Meer

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ArcelorMittal Hochfeld GmbH, Duisburg, Germany, has placed an order with SMS Meer for the supply of a complete high-capacity wire rod mill with FRS® technique for high grade steels. A report about the contract in SteelGuru said that the mill will have annual capacity of some 690,000 metric tons, the majority of which will be cold heading steel grades. The mill, characterized by its compactness and efficiency, will go into production in August 2010, it said. Spec-wise, it will enable production from 5.5 mm to 25.0 mm by means of temperature controlled rolling, with ultra-fine microstructure quality, especially for cold heading grades, by thermo mechanical rolling, at a maximum speed of 5.5 mm wire rod at 120 mps, it said. The deal includes a walking-beam furnace, the mechanical and electrical equipment of the mill train, all of the supply systems, the finishing facilities for the wire rod coils, the entire rolling and cooling equipment, and the erection and installation. The walking-beam furnace for billets of dimension 155 mm square will reach an output of 120 metric tons per hour. A four stand roughing train comprising HL stands with downstream free run out and an intermediate train consisting of 14 CL stands, each in horizontal and vertical arrangement. The wire rod outlet comprises a cooling and

Lincoln Electric notes completion of mill update for subsidiary


equalizing section in loop arrangement, a six-stand wire rod block and a four-stand FRS® block both in UHD arrangement. The wire-rod block and the FRS® block are each followed by a water cooling line. The core component of the mill is the FRS® block together with the proven cooling and equalizing section. The supply scope therefore also includes the 104-m long LCC® for forced and retarded cooling, a total of three water cooling lines and the CCT® system developed by SMS Meer. e-mail

The Lincoln Electric Company announced that the continuous cast aluminum rod mill at its Canadian subsidiary, Indalco Alloys Inc., has been modernized as part of a multi-million dollar upgrade by Continuus-Properzi SpA. A press release said that Continuus-Properzi upgraded the rod mill for Indalco, which it noted is the world’s only fully integrated aluminum welding wire producer. The modernization of the Indalco continuous cast rod mill by the Italian-based equipment supplier also included the upgrade of the electrical controls and user interface via continuous line data from the rod mill, it said. “This new generation rod mill demonstrates (our) commitment to continuous improvement in its processes and to serving our customers with the latest and best technology, while providing stability of supply which is so important these days with so many global supply chain issues,” said Joseph G. Doria, president and CEO of Lincoln Electric Company of Canada. Indalco, located in Mississauga, Ontario, is an ISO 9001 and ISO 14001 certified company, the release said.

OCTOBER 2008 | 21


Sonoco Products Company earns key certifications for stewardship U.S.-based Sonoco Products Company, a diversified global packaging business whose products include reels and spools, reported that it has earned several key certifications. A press release said that the company has received chain-of-custody certifications from the Forest Stewardship Council (FSC) as well as the Sustainable Forestry Initiative (SFI) and the Program for the Endorsement of Forest Certification (PEFC). The certifications, which recognize 13 Sonoco recycled paperboard mills and two recycled rigid paper container plants in the U.S. and Canada, “provide formal validation for the company’s sustainable fiber sourcing practices and its overall commitment to environmental stewardship,” it said. Chain-of-custody certification means a company has a tracking system in place that records the possession and transfer of wood fiber from its origin to its end use, including the manufacturing, production and processing stages. Sonoco now holds all three certifications recognized within the industry: the FSC (SW-COC-003307), SFI (Pwc-SFICOC-294) and PEFC (Pwc-PEFC-294). “Sonoco’s achievement of all three certifications reflects our continued leadership in the industry and provides assurances to consumers and to our customers that we’re doing things the right way,” said Jim Bowen, Sonoco’s senior vice president of global paper operations. The release noted that Sonoco annually uses some 1.9 million tons of reclaimed fiber, “thus saving millions of trees and extending the life of available landfill space by removing the materials from the waste stream.”

B&H Tool reports Brazilian contract U.S.-based B&H Tool reported that it has been chosen as the supplier of crossheads, in-line dies, and related tooling for MFX do Brasil, Salvador, Bahia, Brazil, a producer of high-pressure and high-resistance thermoplastic hose for marine, industrial and consumer applications. B&H will provide crossheads for one of the company’s umbilical extrusion lines, a press release said, noting that the umbilicals are complex hose and cable assemblies that provide electrical and hydraulic power to control and operate sub-sea installations from offshore oil and gas platforms. MFX do Brasil, it said, has some 30% of Brazil’s market for umbilicals.

IWMA seeks both applicants and contributions for scholarship fund U.K.-based International Wire & Machinery Association (IWMA) has issued a call for both supporters and candidates for a worthy industry program. The IWMA is seeking both applicants and contributors for The Walter Niehoff Scholarship, named for a past


IWMA president. The scholarship provides a financial award every two years of up to $24,000 to be paid to an institute, training organization, university, college or similar establishment for the benefit of an individual trainee, student or apprentice engaged in study, research or training activities related to the wire, cable or wire product industries. Awards can also be made to industry institutions or establishments that offer training in the wire and cable sector. Applicants for the 2009/2010 scholarship may be employed by a company or be students, apprentices, individuals at colleges, institutions, universities or other places of research and learning who are introduced by an IWMA member and are committed to the study and future employment in the field of engineering applicable to the wire, cable or wire product industries, a press release said. A recent IWMA Educational Trust Scholar, Scott Kazur, sponsored by Reelex Packaging Systems in the U.S., said the experience was very good for him. “In the time I have attended Rensselaer Polytechnic Institute, I have learned a monumental amount of material that I feel will result in significant advancements in the wire industry. I sincerely thank the Association for future avenues and opportunities that will be presented to me as a result of this award. The generous contributions of the IWMA will prove to be incredibly beneficial.” One of the IWMA’s primary functions is to promote new technology, education and growth in the industry. The Educational Trust offers another very important educational route. Through both the IWMA’s Educational Trust Fund and its Travel Award program, the association actively encourages the gaining of new skills and experience for future rising stars in the industry. For more details, contact: International Wire & Machinery Association, tel. 44-1926-834680,,

ITC determines imports from China threaten U.S. wire garment industry At press time, the U.S. International Trade Commission (ITC) determined that a U.S. industry is materially injured or threatened with material injury by imports of steel wire garment hangers from China. A press release, noted that the U.S. Department of Commerce (DOC) had previously determined that the hangers are sold in the U.S. at less than fair value. Because the ITC has now issued its affirmative determination, the DOC will issue an antidumping duty order on imports of this product from China, it said. According to the release, seven U.S. firms employing about 140 people were involved in production of steel wire garment hangers in 2007, with production worth $12.4 million. It cited apparent U.S. consumption of those products in 2007 at some 2.7 billion hangers worth over $107 million. The imports in question were valued at $83.6 million, it said. ■


ASIAN FOCUS Wire and cable a part of Chinese show to be held this November

Land use thwarts some development in India, but one idea shows promise

Organizers of the 8th Shenzhen International Connectors, Inserters, Wires & Cables Industry Exhibition 2008 (AEE2008) report that the event, to be held November 2628, 2008, will draw attendees from more than 60 percent of the 500 top international enterprises. The Expo, organized by Shanghai Kuozhan Exhibition Service Co., Ltd., will cover a wide range of products, a press release said. In addition to connectors and inserters, the event will include a wide range of cables as well as ssociated materials and testing equipment. The exhibition will include an academic seminar and tech-

As India seeks to continue expanding its industrial base, one problem has little to do with finding companies to take part in the growth and everything to do with being a democracy. Yet for at least one case, a solution has been found. POSCO and Mittal have both reported that they will miss production schedules for two of the country’s largest steel projects, POSCO in Orissa and ArcelorMittal in Jharkhand, wire services report. Both companies had hoped to start production before 2010, but will not because of the difficulty they have had in acquiring the necessary land for their plants and mining operations. The use of the land has reportedly been subject to protests raised at public hearings. One report said that even if the company was able to start constructing their plants today, it would be mid 2012 before production could start. That same problem has created a roadblock for the Tata Group’s plans to produce the world’s cheapest car (about US$2,500), the Nano. That concept has been welcomed by some, but some 40,000 protestors gathered recently at Tata Motors plant in Singur, northwest of Calcutta, the state capital, to protest the use of the site, which they claimed had been taken unfairly from local farmers. According to one wire report, the Communist-run government of West Bengal State had invited the Tata Group to set up its plant in Singur, and acquired 1,000 acres from farmers on the company’s behalf. The farmers, the report said, had agreed to sell their land, but have since reconsidered, demanding it back. In one wire report, Ratan Tata, whose Tata Motors is India’s top vehicle maker, was quoted as saying that he

The Shenzhen Convention & Exhibition Center will host the 8th Shenzhen International Connectors, Inserters, Wires & Cables Industry Exhibition. nology promotion meeting, “gathering high-level people from inside and outside academia and the business community,” the release said. The forum will be used to summarize and exchange new theory, technology and products for the field to provide a top level exchange and cooperation platform, it said. The location of Shenzhen, one of China’s richest and fastest growing cities, is a plus for the event as it is a key to China’s foreign trade, “the best and most important window of foreign trade and technological exchanges,” the release said. It notes that, linked with Hong Kong, Shenzhen “possesses a high degree of business synergies.” In terms of foreign trade, Shenzhen has ranked first for 12 consecutive years and has the China mainland’s highest per capita GDP. For more details, contact: Sea Tang, AEE 2008 office, tel. 86-21-64753707 or mobile 13402053613, fax 86-2164755056,, or

Tata Motor’s development of its Nano car has run into delays because of protests in India.

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ASIAN NEWS BRIEFS ArcelorMittal expects big profits, but plans overall program designed to save US$4 billion ArcelorMittal is projecting that profits will rise by 47% for the first nine months of 2008, for more than $21 billion in profits before interest, tax, depreciation and amortization, but the world’s largest steel maker also plans to launch a program to save $4.0 billion over five year by productivity gains and job cuts via redundancy packages, voluntary retirement, normal departures and rationalization. The company said the cuts will raise productivity, reduce energy consumption and lower production costs, the company announced in a report by Agence France-Presse. In it, the company said the changes would provide $30 dollars per ton of steel. The report said that ArcelorMittal has saved $1.6 billion since the June 2006 acquisition of Arcelor, which made the combined companies the biggest world steel group, three times the size of the next biggest, Nippon Steel of Japan. In the first half of 2008, net profit was expected to have risen 31% to $8.2 billion, the report said. The group employs 320,000 people in about 60 countries. ■

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would move the plant if the demonstrations kept up, even though some $350 million has been invested in the project. Mr. Tata was quoted as saying that he thought the farmers would welcome a different way of life, one where they could acquire new skills in new jobs. “As each generation develops, the children of the rural economy must decide whether they want to continue to work on the farms,” he said in the report. He added that he would like to continue if possible. “We’ve made a huge investment. We’d like to stay.” A company official later said in another wire report that Tata Motors would go forward producing the car in other plants. Protests are common in India, but in one instance, a different approach was used to pacify local citizens. One wire report said that when farmers opposed a Special Economic Zone, Gurgaon based-Raheja Developers Ltd. gave the farmers, whose land it is acquiring, an option to own a certain amount of land for every acre of land given to the project. The developer acquired 255 acres in Gurgaon and the SEZ while the farmers got property that they are renting out. The developer reported that the project got local support and that about 40% of the farmers have chosen the lease-rental model, which includes the promise of jobs for two persons from each family of farmers whose land has been acquired.


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


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 MALAYSIA. If you’re 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 trade 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.

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ABP Induction Ace Metal Inc. ACM AB - KSM AEB International Inc. AIM Inc. All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates Ametek Specialty Metal Products A. Appiani Srl Arcelor Mittal AW Machinery LLC AWPA American Wire Producers Association AXIS Computer Systems Inc. Aztech Lubricants LLC B & H Tool Co. Inc. Balloffet Die Corp. Bao Zhang Galvanized Iron Wire Co., Ltd. Bartell Machinery Systems LLC Base Ten Consulting Inc. BCS Industries LLC Besel Basim San Tic Ltd. Sti Beta LaserMike Beta Systems Srl Blachford Corp. Bongard Machines USA LLC Boockmann GmbH/The Slover Group Boxy SpA Breen Color Concentrates Inc. Butt Welders USA Caballe SA Cable Consultants Corp. Canterbury Engineering Co. Carpenter Technology Corp. Carris Reels Inc. Cemanco LC CeramTec AG CERSA-MCI Chin Pu Jir Enterprise Co. Ltd. Clifford Welding Systems (Pty.) Ltd. Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. CN Wire Corp. Coats North America. Cometo Snc Commission Brokers Inc. CommScope

Condat Corp. Conductix Wampfler-Delachaux Conneaut Industries Inc. Continuus-Properzi SpA CoorsTek Cortinovis Machinery America Inc. CRU North America Inc. Davis-Standard LLC Design & Engineering LLC Die Quip Corp. Domeks Makine Ltd. Sti Donnelly Reels E-Beam Services Inc. Ebner Furnaces Inc. Ebner Industrieofenbau ECD Inc. Engineered Control Systems Inc. Engineered Machinery Group Enkotec Co. Inc. ERA Wire Inc. Er-Bakir Elektrolitik Bakir Esteves Group Etna-Bechem Lubricants Ltd. Etna Products Inc. Eurodraw Energy SpA Eurolls Group Eurowire Magazine George Evans Corp. EVG Inc. Fabritex Inc. Fenn Technologies FIB Belgium SA Fil-Tec Inc. Filtertech Inc. Fine International Corp. Fisk Alloy Wire Inc. FMS Force Measuring Systems AG FMS USA Inc. Fort Wayne Wire Die Inc. Frey Group LLC Frigeco Srl Frontier Composites & Castings Inc. FSP-One T. Fukase & Co. Ltd. Garg Sales Inc. Gauder SA Gavlick Machinery Corp. Gem Gravure Co. Inc. GEMCO Electrical

GENCA Corp. W. Gillies Technologies LLC Gimax Srl GMP-Slovakia Rudolf Grauer AG Guill Tool & Engineering Co. Hafner & Krullmann GmbH Vom Hagen & Funke GmbH Heacock Metal & Machine Co. Inc. Heany Industries Inc. Hearl Heaton Heatbath Corp. Henkel Corp. Heritage Wire Die Inc. Hezel GmbH & Co. KG Gebruder Hilgeland-Nutap GmbH Hofmann Ceramic GmbH Houghton International Inc. Howar Equipment Inc. Huestis Industrial Huettner Maschineenfabrik GmbH IDEAL Welding Systems Ideal-Werk India Steel Works Ltd. Industrial Steel & Wire Co. Industrial Heating Magazine Inosym Ltd. InterWire Products Intras Ltd. Iowa Steel & Wire Italian Trade Commission IWE Spools & Handling GmbH IWG High Performance Conductors Inc. IWMA International Wire & Machinery Association Kemaite Optic & Electric Products Co. Ltd. Kinrei of America Klaus Jakob Messlechnik AG KMK GmbH Ernst Koch GmbH & Co. KG Albert Krenn Friedr Krollmann GmbH Kuhar Metallizing Co. Inc. Lamnea Bruk AB Lamnea Bruk USA LaserLinc Inc. Laurel Wire Co. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. J.J. Lowe Associates Inc. M + E Macchine + Engineering Srl MacDermid Inc. Madem Reels USA Inc. Madem SA Magnetic Technologies Ltd. Magnus Equipment MAGPOWR Maillefer SA Mapre Belgium SA Mario Frigerio SpA Markem-Imaje USA Maschinenfabrik Niehoff Mathiasen Machinery Inc. William McCaskie Inc. Merritt Davis Metavan NV

ORGANIZED BY: The Wire Association International, Inc.

MFL USA Service Corp - Frigerio The MGS Group (MGS-Hall-Northampton) MGS Manufacturing - The MGS Group Micro Products Co. Microdia Mikrotek Machines Ltd. Morgan-Koch Corp. Mossberg Reel LLC /Boxy Group NEPTCO Inc. Nextrom Oy Niagara Composites Industries Inc. Niehoff Endex North America Inc. Northampton Machinery Co. The MGS Group Northeast Steel Corp. Norwalk Innovation Inc. NUMAMERICA/NUMALLIANCE Oklahoma Steel & Wire OM Frigerio OM Lesmo OMA USA Inc. OMCG North America Inc. OMCG SpA Panchmahal Steel Ltd. Paramount Die Co. Inc. Parkway-Kew Corp. Pave Automation Design PEKUtech GmbH Phifer Wire Inc. Pioneer Machinery Co. Ltd. Pittsfield Plastics Eng. Inc. Plasmait GmbH Plasticolor/Woywod GmbH Polyone Pourtier SAS Power Sonics LLC PrintSafe Process Control Corp. Properzi International Inc. Proton Products Ltd. PWT Ltd. QED Wire Lines Inc. Qinhuangdao Yanda-Guohai Stainless Steel Co. Ltd. Qual-Fab Inc. Queins & Co. GmbH Rad-Con Inc. Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Reelex Packaging Solutions Inc. RichardsApex Inc. Rizzardi Rohmann LP Rosendahl Maschinen GmbH Rosendahl Nextrom Technologies Roteq Machinery Inc. Saarsteel Inc. SAMP SpA (SAMPSISTEMI) SAMP USA Inc. Sanxin Wire Die Inc. SARK-USA Inc. Sarkuysan SA H A Schlatter AG Schlatter Inc. Schnell (Wire System) SpA Schunk Graphite Technology Sealeze

Setic SAS Shanghai Nanyang Shanghai Yingong Wire Products Equipment Co. Ltd. Shijiazhuang Kingway Metal Products Co. Shuster-Mettler Corp. Sictra Srl SIKORA International Corp. Simpacks Singleton Reels Sirio Wire Srl Sjogren Industries Inc. Skaltek Inc. SKET Verseilmaschinenbau GmbH Sonoco Crellin Inc. Sonoco Products South Fence Machinery Ltd. SPE Society of Plastics Engineers Staku-Anlagenbau GmbH Steuler Anlagenbau GmbH & Co. KG August Strecker GmbH & Co. KG Summit City Enterprises T & T Marketing Inc. TAK Enterprises Inc. Talladega Machinery & Supply Taymer Industries Inc. Team Meccanica Srl Technical Marketing Services Teknor Apex Co. Tensor Machinery Ltd. Teurema Thermcraft Inc. Timco Inc. Troester GmbH & Co. KG Tubular Products Co. Tulsa Power LLC Unitek North America Inc. Uniwire International Ltd. Urbano Associates US Synthetic Wire Die Vandor Corporation Vitari SpA Vollmer America Inc. Wafios AG Wafios Machinery Corp. Wardwell Braiding Machine Co. Wardwell Italy SRL Watson Parts & Service Weber & Scher Mfg. Co. Inc. Wire & Cable Asia Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp. wire 2008/Messe D端sseldorf North America The Wire Association International Inc. Wire Journal International Wire Lab Co. Wire Machine Systems Inc. WireCo WorldGroup WireWorld Witels Albert USA Ltd. Woodburn Diamond Die Inc. World B.C. Co. Ltd. Worth Steel & Machinery Inc. Woywod Kunststoff Maschinen GmbH Wyrepak Industries Inc. Zhejiang Minmetals Zumbach Electronics Corp.


PEOPLE Jeff Kohler, a co-founder and member of the board of directors of LaserLinc, Inc., has been named director of global sales and marketing. He has more than 22 years of experience in non-contact measurement, including in both outside sales and product development. Before co-founding LaserLinc, he worked for Techmet (now Beta LaserMike), which he joined in 1986. Kohler had held many of the responsibilities in the new position, which appointment formalizes. He is a graduate of Worcester Polytechnic Institute, where he earned a degree in computer science. Based in Fairborn, Jeff Kohler Ohio, USA, Laser Linc, Inc., supplies a range of testing and measuring equipment to the wire and cable industry. Process Control Corporation (PCC) announced the addition of Dana G. Darley as its new vice president/general manager. His career began at PCC in 1981 as a product development engineer and then as a senior product manager.


He is credited with a redesign of high efficiency dehumidifying dryers and developing a new line of gravimetric |blending and control systems for PCC. He worked for LCI Corporation/Maag Pump Systems Textron, where he designed and developed the Smarthopper gravimetric control system, and from 2001 to 2004 he served as president of Kreyenborg Industries, before launching Extrusion Auxiliary Services, Inc., a technical services and consulting company for extrusion equipment and systems. He holds a B.S. degree in mechanical engineering from Clemson University, has authored numerous technical papers on auxiliary equipment and holds a U.S. Patent for gravimetric control of gear pump systems. The company also reported the hiring of Thomas Kegley as a new sales engineer, Dana G. Darley responsible for technical blending and systems solutions in Ohio, Indiana, Michigan, Kentucky, West Virginia, western Pennsylvania and western New York. He has nearly two decades of experience in the plastics

industry, including as process engineer, sales engineer and sales management. He studied mechanical engineering at Youngstown State. Based in Atlanta, Georgia, USA, Process Control Corporation supplies a range of process control technology. Britt Johnson, who formerly worked as the western regional manager for Berk-Tek, a Nexans Company, will represent the company again through his manufacturer’s rep firm, JTech Systems. His agency will be responsible for the customer base in Northern California, Reno (NV) and Hawaii. Johnson has more than 16 years of sales experience in structured cabling. Prior to his seven years at Berk-Tek, he spent five years at Ortronics, where he served as a regional manager and then as national sales manager. Other sales personnel for the new firm include: Allison Allstott, Chris Rogers and Greg Olson, who were previously with West Cal Technologies. The agency, based in San Francisco, California, USA, can be contacted at Robert C. Rugh, who has served as executive vice president of DeWind, Inc., has been promoted to president of the company, which is a business of Composite Technology Corporation (CTC). He has extensive knowledge and experience in the wind turbine business, including commercial, engineering, supply chain, manufacturing and site operations. Prior to joining DeWind, he served as vice president, Wind Turbine Group, for Mitsubishi Power Systems

Americas (MPSA), where he led MPSA’s marketing, sales, engineering, projects and operations for wind turbines in the Americas. He replaces Marvin Sepe, who will remain CTC’s COO and will oversee both the DeWind and CTC Cable business subsidiaries. Based in Irvine, California, USA, DeWind, Inc., is a subsidiary of CTC, which provides transmission and distribution cable products. The Society of the Plastics Industry, Inc. (SPI) has appointed Al Damico as executive vice president. He has more than 20 years of experience in the business management and marketing of plastics manufacturing operations. He will oversee the work of SPI staff and leadership in managing SPI’s three councils formed last year to meet the specialized needs of the industry sectors represented by its membership: equipment manufacturers, material suppliers and processors as well as SPI’s four regional offices and membership activities. He has previously worked for global companies that include Ausimont Inc., Clorox Company, Pfizer Ind., Allied Chemical and Daiken America. He holds a B.S. in chemical engineering from Drexel University and has served as chairman of SPI’s Fluoropolymer Division. He replaces Catherine Randazzo, who left to lead The Sulfur Institute. The Society of the Plastics Industry, Inc., serves members who work throughout the entire plastics industry supply chain. ■

OCTOBER 2008 | 29

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FIBERWATCH Greece to invest in its fiber network, catch up to other European countries The government of Greece plans to invest in a new fiber optic network that will drastically upgrade its broadband and cable television capabilities, reported. In a statement to reporters, Communications Minister Costis Hadzidakis was cited as saying that, “Greece has decided to make a strategic leap. From where it is now, rather than adopt the intermediate technologies of today, we have decided to adopt future technologies that are already available”. The plan calls for a seven-year, US$3 billion program to build a national fiber-optic network connecting some two

The government of Greece seeks to expand Internet access and usage. million households around the country, the report said. The goal, the release said, was for the country to tender three separate concessions to private companies to build and operate fiber-optic networks with speeds of at least 100 megabytes per second (Mbps) in three separate regions of the country. The report said that Greece has been slow to transition to fiber optics, with only 0.1% Internet penetration as of four years ago. Since then, however, the country “has been quickly catching up with fellow European Union member states” in opening its telecom market and promoting use of broadband Internet, it said, noting that the usage figure is now 12%. “We have decided to invest as a country in a modern fiber optic network that will change the daily life of Greek citizens,” Economy Minister George Alogoskoufis was quoted as saying in the report.

Cable launch set for June 2009 Laying of shore-end cables was scheduled to have begun as of press time for landing stations that will serve as a part of a fiber optic undersea cable linking east Africa to Europe and Asia would be launched in June 2009.


A press release said that the majority of the 15,000 km of fiber optics undersea cable for the SEACOM undersea cable has been made. The shore-end cables include the stretches at shallow depths ranging from 15 m to 50 m, it said, adding that the first of three reliance class vessels were scheduled to start laying the actual cable in October. The final splicing, which involves connecting all cable sections, will take place in April 2009, allowing enough time for the testing of the system before the commercial launch in June, it said. The cable, which has a design capacity of 1.28 terabits a second, is being made in the U.S. and Japan, the release said. Project contractor Tyco Communications was in charge of shipping terrestrial equipment, which was to have been loaded in September. The SEACOM cable has been structured to meet the policy objectives of governments and the New Partnership for Africa’s Development, the release said, noting that it will help meet telecom demands as well as lower prices for the service. The cable, including repeaters needed to amplify the signal, will be stored in large tanks onboard the ships. The branching units necessary to divert the cable to the planned landing stations will be connected to the cable path on the ship shortly before deployment into the sea, the release said. The cable will then be buried under the ocean bed with the help of a plow along the best possible route as shown by the marine survey, it said. The cable is planned for service before the 2010 FIFA World Cup kick-off and SEACOM has been working with key broadcasters to meet their broadband requirements. The team is also trying to speed up construction in an attempt to assist with the broadcasting requirements of the FIFA Confederations Cup scheduled for June 2009.

Alcatel-Lucent wins defense contract LGS, a subsidiary of Alcatel-Lucent dedicated to serving the U.S. government community, announced that it has been awarded a $6.45 million contract with the United States Department of the Army to provide infrastructure and optical fiber upgrades to Fort Polk in Leesville, Louisiana, as well as for several range areas. LGS will also be installing two new communications shelters, consolidating communications nodes and upgrading the core hardware solution to 10 Gigabits providing one Gigabit to each end user building, a press release said. Fort Polk is home to the Joint Readiness Training Center (JRTC), the Warrior Brigade, and medical, dental and military police commands that support the installation. LGS was described as one of 10 prime contractors selected for an overall project, with a total ceiling of $4 billion dollars, that will create integrated, secure communications systems for Army installations, relying heavily on network transformation and migration to newer technologies. ■



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FASTENER UPDATE Anixter buys 2 European fastener firms U.S.-based Anixter International, Inc., announced that it has acquired two European fastener companies, one French and the other German. A press release said that the company will pay about $40 million in cash and assume about $19 million in debt to acquire the two overseas fastener distributors: France’s Sofrasar SA and Germany’s Camille Gergen. The two businesses are projected to have combined 2008 annual sales of more than $110 million, it said. “Through the addition of numerous important customers, primarily in France and Germany, we have added another key building block that will drive future organic growth in this important global end market,” said Bob Eck, Anixter president and chief executive. “Consistent with the strategy we have articulated, the acquisitions of Sofrasar and Gergen represent important steps in the geographic expansion of our OEM Supply business in Europe,” he said. Eck further observed that, “when combined with our existing OEM Supply businesses in Europe, we anticipate annual revenues of approximately $800 million in this market over the next year.” The addition of the two businesses will signif-

icantly enhance Anixter’s OEM Supply business in Europe and add considerable depth to its footprint in the area as the company will now be serving customers in 11 countries throughout the continent, he said.

ITW is named an American beauty Keep America Beautiful, Inc., described as the nation’s largest nonprofit community improvement organization, has chosen Illinois Tool Works (ITW) as its 2008 Vision for America Award honoree. ITW was cited for its leadership in environmental issues and its outstanding efforts to promote and sustain volunteerism in America, a press release said, noting that the company “provides a wonderful example of corporate citizenship and social responsibility that we are proud to honor.” A FORTUNE 200 company, ITW is comprised of over 825 business units in 52 countries and employs approximate-

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ly 60,000 women and men around the world, the release said. The multi-billion company, which designs and manufactures fasteners and components, equipment and consumable systems and a variety of specialty products and equipment for customers around the world, was praised for its corporation’s belief “that while you're never more than a few feet away from a product of ITW, you're also never more

than a few feet away from the positive impact the company has in its local communities.” Keep America Beautiful also praised the ITW Foundation, which in 2007 alone gave $14 million in financial support to organizations in the communities where its companies operate. Since 1996, ITW has contributed more than $75 million to over 100 different organizations.

Software aids process of fastener production Plexus Systems, providers of Plexus Online on-demand software for the manufacturing enterprise, announced that it has won a contract to help ContMid Group (Continental/Midland, Jacobson Mfg., Jacobson Mfg.-Tiffin, MSD Stamping and Minuteman Distribution) manage its production of fasteners throughout its geographically dispersed locations. A press release said that ContMid Group required a complete system to run all aspects of its manufacturing business at six different facilities in four states. Plexus Systems will consolidate three separate systems and provide the software, hardware and services to support the company’s production of specialty fasteners for automotive and industrial fasteners worldwide, it said. “The Plexus Online system will allow us to integrate our business functions and streamline our enterprise so we can maintain tighter control on our processes and our costs,” said Brent Hunter, IT manager for ContMid Group. Plexus will provide a fully integrated, total enterprise solution using modules that support engineering, sales, purchasing, inventory control, program management, accounting, tool tracking, human resources and other vital functions. Plexus Online was described as an on-demand enterprise resource planning (ERP) solution that builds on the “software as a service” (SaaS) model pioneered by and NetSuite. It provides companies instant access to vital information and management functions using a simple web browser from anywhere in the world. ■




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U.S. Department of Commerce to be a key supporter of Interwire 2009 For the first time ever, Interwire 2009 in Cleveland, Ohio, USA, will have the full backing of the U.S. Department of Commerce (DOC), which will provide global support and marketing as well as programming to help U.S. exhibitors that want to export. “We’re pleased to announce that Interwire was chosen to be part of DOC’s 2009 International Buyer Program (IBP),” said WAI Executive Director Steve Fetteroll. “We’re constantly looking for ways to attract more quality attendees to Interwire and this program will do just that. It will also help U.S. companies, both manufacturers and suppliers, looking to export.” Offered through the International Trade Administration, the U.S. Commercial Service IBP program offers free services for qualified U.S. exhibitors, attracting international buyers to leading U.S. trade events and helping them connect with U.S. exhibitors before, during and after the show as well as providing export counseling to

exhibitors who sign up for the program. The IBP will use the government’s resources to find international attendees to meet with participating U.S. exhibitors at Interwire. “We believe that once U.S. exhibitors understand the opportuniThe Commercial Service logo is a ties that this proregistered trademark of the U.S. gram will open up to Department of Commerce. Used some of them, they with permission. are going to be thrilled,” said WAI President Ron Reed. “It’s a program that has been around for a long time and we’re going to make sure that people

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Interwire will have the backing of the U.S. Department of Commerce when the event is held next year in Cleveland. Nofsinger noted that the 2009 staging of PROMAT will mark the 11th time it has been part of the IBP program. “The IBP designation has clearly served to enhance the awareness, recognition and credibility of PROMAT as well as MHIA as its sponsor,” he said.

Full program slated for Mexico ITC The WAI’s International Technical Conference in Mexico is just a month away, the programs and events are being finalized, led by strong demand for tabletops and

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in the wire and cable industry can discover whether this opportunity is for them.” The IBP program works in multiple ways. It will help identify qualified attendees from other countries; invite them to attend Interwire, both singly and in large groups; make sure travel arrangements run smoothly; and set up appointments for them at the show to meet with exhibitors who are part of the programs. Staff around the world in U.S. embassies and consulates will make official contact with prospective attendees on behalf of Interwire. The IBP program will not be hard to find at Interwire: its location, the International Business Center, will be on the main entryway. There will be meeting rooms for attendees to meet with exhibitors and translators and DOC staffers will present sessions on how they can help U.S. companies export, or export better. The head of one association that has been part of the IBP program for more than a decade said that for his group, the program has been a major boon. “With each cycle, we have seen progressive growth in both international attendance and exhibits,” said John Nofsinger, CEO of Material Handling Industry of America (MHIA), the organizer of PROMAT, a trade event for material handling and logistics providers.


the addition of two more presentations. The event, to be held October 20-22 at the Crowne Plaza Hotel in Monterrey, Mexico, will include a technical program, an opening reception to be held at a local brewery, a tour to a unique wire museum, tabletop displays, as an opportunity to make contacts, and more. The schedule for the technical program has been set, with 10 presentations set for Monday, October 20, five in the morning and five in the afternoon, and 13 presentations on Tuesday, October 21, seven in the morning and six in the afternoon. The event will be inaugurated by Raul Gutierrez, managing director of the group DeAcero. For a list of paper topics, names of authors and abstracts, go to and click on the Mexico ITC icon at the top right of the page, then “View Technical Program.” WAI Sales Director Robert Xeller reports that all the tabletop positions have been filled. Companies to be represented include: American Kuhne, ANTAAC, Bartell Machinery, Base Ten Consulting Inc., Beta LaserMike, Cemanco, Condat, Die Quip, Esteves Group, Fine International Corporation, Fort Wayne Wire Die, GCR Eurodraw SpA, Gem Gravure, W. Gillies Technologies LLC, Grupo Condumex and Guill Tool. Also, Hearl Heaton/Pentre Group, Ideal Welding Systems,


Interquip, Lloyd & Bouvier, J.J. Lowe Associates, Madem Reels USA, William McCaskie, Inc., Micro Products, Neue Gesellschaft, Niehoff Endex North America, Pan Chemicals Spa, Paramount Die, Parkway Kew Corporation, Pittsfield Plastics, Precision Die Technologies, Properzi/Continuus Properzi, Queins & Co. GmbH, RichardsApex Inc., SAMP USA, Sikora International Corporation, Simpacks, Tulsa Power LLC, Vollmer America, Windak USA, Wire & Plastic Machinery, WAI/WJI, Woodburn Diamond Die, Yield Management Corp. and Zumbach Electronics. Information on registration, tabletops and other program elements can be found by clicking on the Mexico icon at Each year, WAI organizes an international technical event, most recently in Bologna, Italy (2007), New Delhi, India (2006), The Czech Republic (2005), Mexico (2004), Italy (2003), Canada (2002) and the U.K. (2001).

WJI Reference Guide: it’s time to update your company listing for 2009 WJI will be updating entries and making additions for its 2009 Reference Guide publication within the next few months. E-mail reminders will be sent to the contacts list-



it’s really all about: who you know what you know where you go being in the right place at the right time leading the way finding a mentor professional growth personal development a global economy saving money sharing ideas putting words into action the destination the journey education experience working hard playing smart finding an edge staying sharp


If you answered “true” to any of these statements WAI membership is for you. Learn what thousands of wire industry professionals from 70 countries already know about WAI. During our last 77 years of program development, we’ve learned that all of the above are true. So, we think you’ll find that our benefits are as individual as your goals. If you’re already a member, why not be true to a colleague? See for details or pass along the application form on the reverse side.

At WAI, it’s really all about you! 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:


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

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A. Which ONE of the following best describes your company’s type of business? WIRE & CABLE 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 & CABLE 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, Accessories, Materials

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

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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.



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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 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.

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Reconvene: business of doing WAI business continues next month WAI staff carries out the business of the association, but it is the WAI volunteers who serve on its boards and committees that provide the direction at meetings held twice a year. That essential activity will take place Tuesday, November 11, at the Providence Convention Center in Providence, Rhode Island, where volunteers will address a range of matters. Bodies to meet include the WAI’s Board of Directors, Executive Committee, Member Relations Committee, Education Committee, Conference Programming Committee, Memorial Awards

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Committee and Exhibition Planning Committee. ed within our database during October. New entries are Some of the topics that are likely to be discussed also being accepted and will be published free of charge. include the location for Wire Expo 2010, an update on Published annually, the guide includes a directory of the WAI’s subsidiary in India, possible directions for the WAI members. The data in the international wire and WAI’s technical programs as well as new editorial content cable industry buyer’s guide is used to power WAI’s for WJI, and more. ■ Virtual Trade Show (VTS), an online marketplace. Each company profile—which details product, service, and contact information—is published in print and online at WAI’s Virtual Trade Show, ensuring the company’s visibility exactly at the customers’ point of interest. VTS records are updated daily. Search results are delivered instantly. Product categories are broken down into very specific niches. Each supplier profile includes representatives, websites, other product offerings and more. Display advertising is also offered in both media. To be listed, simply update your existing listing (no need to send duplicate information) or, if your company has not been listed in the High Performance Conductors is the recognized industry leader past, complete a company profile in lightweight conductor engineering and technology for the online. Just go to vts/admin/search.cfm and type in aerospace industry. Our Tensile Flex® Alloy 135 has been imitated, your company name. If it is not but never duplicated, and is specified by virtually every listed, a page will appear with a link that enables you to provide the major manufacturer in the industry. information for a new listing. E-mail any questions to Janice In response to global concerns, Swindells,


CHAPTER CORNER Six teams and 10 other golfers earned prizes during the best ball scramble format event. The top two teams both shot 61, a tie breaker giving the victory to the team of The largest-ever field of 156 golfers enjoyed near-perKen Deremiah, Mark Daniels, Chris Johnson and Rick fect weather at the 14th Annual WAI New England Stannard, all of Davis-Standard. The second place team Chapter Golf Tournament, held Thursday, September 11, was Vincent Griffin and Mike Swift of Premier Wire Die at the Kettle Brook Golf Club in Paxton, Massachusetts. along with Okham Keovanpheng of Loos & Co. and The highlight of the day, for one player at least, took Aaron Nolan of Sumitomo Electric Carbide Inc. In third place when John Netta of DuPont calmly stroked the winplace, with a 62, was the team of Ralph Marcario of ning 50-foot putt to claim the $2,500 prize. He earned the Chromatics Inc., Ken Berube of PMC Wire, Dimitri Maistrellis of Comtran Corp. and Ken Tober of Daikin America. There was a two-way tie for fourth place at 64 with the tie-breaker going to Ron and Scott Reed of Horizon Wire & Cable along with Al DiVencenzo and Dick Palmer. Taking fifth was Phil DuPuis and Pat Staffiere of The Kerite Co. along with Mark Mathiasen of Mathiasen Machinery Inc. and Nate Schilberg of Prime Metal Recovery Inc. In the sixth and final paying position was the team of T & T Marketing’s Ken Strandberg, Carl Beyor of Cable Technology, Mark Denne of Draka and Sam Friedman of General From l-r, Tournament Co-Chairman Mike Mathiasen and the winning team from Cable. Davis-Standard of Chris Johnson, Ken Deremiah, Rick Stannard and Mark In the other skill contests, Mike Daniels. Kos of Rosendahl Nextrom Technologies won the chipping conright to attempt the putt by being one of the 26 golfers test, Michael Weiss of Whitmor/Wirenetics won the long who qualified at the putting green, then being the only putt hole and Nate Schilberg hit the most accurate drive. one to sink a 25-footer in the second round. The chapter The three closest-to-the-pin shots were won by Vince added the putting contest three years ago and Netta is the Griffin, Sam Friedman and Dimitri Maistrellis. Men’s first to win. long drive winners were Jim Craig of Siri Wire Co. and

New England Chapter Golf tourney: a great day for a record field of players




NOVEMBER 2008: SPRING & FASTENER EQUIPMENT Bolted, nailed, pinned, screwed, tacked, stapled or hooked. Your product message will be securely delivered in WJI’s November issue. Don’t wait for the rust to set in. Place an ad in front of your prospects and customers while they’re riveted to spring and fastener coverage. Contact WJI’s Bob Xeller or Anna Bzowski today at Tel.: 001-203-453-2777 | E-mail: or



Mark Daniels. The women’s long drive winners were Leoni Wire’s Cathy Deloria and Deb Diiorio of Heat Trace Products LLC. “This was a superb day,” said Tournament Co-Chairman Mike Mathiasen of Mathiasen Machinery Inc. “The course was in great shape, and it really speaks well of the event when the top teams finish with such close scores. The day moved at a good pace considering the number of golfers we had, and it was a bonus to have John sink that 50 footer for the $2,500!” Company sponsors continue to make the tournament shine. Nobody aced the par three 12th hole to win the $10,000 prize, but the sponsorship by Commission Brokers/Martin Kenner gave the golfers a great goal on a picturesque hole. The Snack Shack was sponsored by Amacoil/Uhing and the Tee Off Breakfast by Dyneon – a 3M Company. New this year were the two refreshment stations on the course that were sponsored by Mossberg Reel LLC and Zumbach Electronics Corp. in conjunction with Amaral Automation Associates. The putting contest was sponsored by Wire & Plastic Machinery Corp., the chipping contest by NEPTCO; the two long-drive holes by Lloyd & Bouvier Inc., and Mathiasen Machinery Inc.; and the accurate drive hole by

A few golfers, including Bill Bliven, Tyco Madison, were not above begging for divine intervention prior to a putt.

Electronic Drives & Controls. Whitmor/Wirenetics sponsored the long-putt hole and the three closest-to-the-pin holes were sponsored by Breen Color Concentrates, Chromatics Inc. and W. Gillies Technologies LLC. Amaral Automation Associates, Cable Components


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OCTOBER 2008 | 45


Group, Champlain Cable Corp., Fluoropolymer Resources Inc. and IWG High Performance Conductors Inc. were the co-sponsors of the 19th Hole Reception. Corporate hole sponsors included: Amacoil/Uhing, Amaral Automation Associates, Bayshore Vinyl Compounds, C & M Corp, Carris Reels, Davis-Standard Corp., Fluoropolymer Resources Inc,, Gem Gravure Co., Horizon Wire & Cable, Huestis Industrial, Leoni Wire Inc., MacDermid Inc., Mantec, PLASTICOLOR, Premier Wire Die, Q-S Technologies Inc., Quirk Wire Co., Rosendahl Nextrom Technologies, SARK-USA Inc., Sikora International Corp., Siri Wire Co., T & T Marketing, W. Gillies Technologies LLC and WCMA. “The Chapter Scholarship Fund was the big winner of the day,” said Chapter President Paul McDermott of Q-S Technologies Inc. “Several people provided some great raffle prizes which resulted in more than $2,100 being raised for the fund.”

Midwest Chapter meeting speaker to assess economy, manufacturing The recent turmoil in the stock markets makes the “Economic Assessment” presentation by Federal Reserve official William A. Strauss that much more noteworthy


when he presents it at the WAI Midwest Chapter Dinner Meeting on Tuesday, October 14, at the Donald E Stephens Convention Center in Rosemont, Illinois. As the economy enters its seventh year of expansion there are concerns about its sustainability. The struggling housing market, the pull-back in manufacturing, and higher energy and commodity prices are just some of those factors. Strauss, who is senior economist and economic advisor in the economic research department at the Federal Reserve Bank of Chicago. will look at the performance of the overall U.S. macro economy with specific attention paid to key economic sectors and indicators. Strauss holds a B.A. degree in economics and geography from SUNY and an MBA degree in economics from Northwestern University. “We keep hearing how some companies are doing very well, while others are really struggling,” said Midwest Chapter President John Kukalis of Henkel Corp. “We thought that bringing in an economist like Bill Strauss, especially with his expertise in the manufacturing sector, would be interesting to a lot of people in the industry.” Strauss’s talk will cover the overall U.S. economy and focus on the manufacturing sector, looking at the performance of the overall U.S. macro economy with specific attention paid to key economic sectors and indicators. The conference website is

Abstracts sought for Poland technical conference to be held in 2009

The 7th Annual WAI Southeast Chapter Golf Tournament is set for Thursday, October 30, returning to the Rock Barn Golf and Spa in Conover, North Carolina. Team and individual prizes will be available, including a shot at $10,000 by acing a designated hole. “This tournament really brings a great group of people together from the industry,” said tournament co-chair and chapter President Steve Vannais, Davis-Standard. He noted that raffle prizes proceeds will support the Southeast Chapter’s Scholarship Fund. “We already have a driver and putter committed as raffle prizes and the course is a great setup for a scramble tournament,” said tournament Chairman Michael Weiss of Whitmor/Wirenetics. Check-in is 10 am with the shotgun start at 11 am. Registration is $135 and non-golfers can also enjoy the event by attending the dinner for $40. Registration and sponsorship forms can be downloaded at the chapter’s webpage. Contact: WAI’s Chip Marsh, tel. 203-453-1748, ■

Abstracts must be turned in as soon as possible for consideration for an international technical conference, “Modern Technologies and Modelling of Drawing and Manufacturing Processes of Metal Products,” that will be held March 5-8, 2009, in Zakopane, Poland. Czestochowa University of Technology (CUT) Prof. Jan W. Pilarczyk, the president of WAI’s Poland Chapter, is among those involved in the planning of the conference. He is a member of the conference scientific committee, which is led by a fellow CUT professor, Zbigniew Muskalski. The Organizing Committee is headed by Sylwia Wiewiórowska, also a professor at CUT. Conference topics include: steel wire and wire products; nonferrous wire and wire products; electrical wires and special products; and poster papers. Contact: Sylwia Wiewiórowska, tel. 48-34-3250-745,

Southeast Chapter Golf Tourney is the next one up for golfers

OCTOBER 2008 | 47


The dinner meeting will begin with a networking reception at 6 pm, followed by dinner and the speaker at 7 pm. Registration for the event is $65, $55 for members. For more details, contact WAI’s Chip Marsh at tel. 203-4531748;


FERROUS VIEW The Chinese wire rod roller coaster: how it impacts the rest of the world By Murat Askin

companies had to work hard to make up for the lost time. This flurry of pre-Olympic activity put China on overdrive in the winter and spring of 2008, resulting in an explosion of steel demand, with China pulling the rest the world steel markets along with it. Many wire companies in China are small- to mediumsized enterprises, if not the mom-and-pop type of extremely low-tech, extremely inefficient shops. These companies lack capital for inventory and rely on local traders and distributors to deliver rod shipments just-intime. When prices started to go up in September 2007, many wire companies were caught with low stocks. No one believed that prices would go up that much, so most companies refrained from buying steel. As a result, their inventories were further drawn down as the months went by and the price increases continued. Unlike the North

Everything seems small compared to China. Take the US wire rod industry – China’s annual wire rod production exceeds 80 million metric tons, more than 20 times the U.S. rod production. In a country where the raw materials for wiredrawing are so vast, you would think that sourcing would be a breeze. But you would think wrong. Chinese wire drawers, too, experienced significant challenges this year, and many did not survive. First, China wasn’t immune to the rapid increases in rod prices that have been taking place since September 2007. And the Chinese wire market’s challenges actually started even before the rapid rod price hikes, when, a few years back, Chinese USD/mt SteelOrbis Wire Rod Prices - U.S. vs China authorities finally succumbed to international pressure to reduce their steel exports. China started to lower its highly contentious but fully WTO-compliant VAT (Value Added Tax) rebates. Value Added Tax is a sort of sales tax. When a wire rod plant buys scrap or iron ore, they pay a VAT to their supplier. If the wire rod is exported, the company is entitled to get back the VAT that they paid. This is, at least in theory, how the VAT rebate works. China lowered the VAT rebate for wire rod down to 0% in April 2007, and what’s more, they further discouraged exportation of wire rod by adding an export tax of 15% in July 2007. Date With the export restrictions, you would think that all 80 million tons of rod This chart reflects the divergent paths of U.S. and Chinese wire rod prices. would stay in China and depress the Chart courtesy of SteelOrbis. Figures based on its historical data. local market, but again, you would think wrong. True, due to export restrictions and massive rod production, China’s domestic wire rod American wire industry, which deals with the mills directprices are still the world’s lowest. We will get to current ly, Chinese traders and distributors are in between the numbers later, but first, let’s review what has happened in mills and end-users that hold most of the wire rod stocks. the Chinese wire market since the beginning of the year. The local traders that hold most of the mill inventories Even though the wire industry in China enjoys some of refrained from selling their stocks, as they anticipated the lowest wire rod prices, it has been significantly affectmaking large sums of money with the increasing prices. ed by the price increases of 2008. Faced with skyrocketWith the traders holding onto their stocks, rod shortages ing iron ore and coke prices, wire rod mills had no choice developed and spot prices rose even more rapidly than the but to increase their prices rapidly. In the meantime, steel mill prices. consumption increased significantly in preparation of the China’s wire industry is a low-margin business, and proOlympic games in August 2008. China spent a lot of ducers have a hard time passing increases in raw material money for infrastructure, which provided a huge boost to costs along to their customers. The industry is not wellthe economy. What’s more, the industry around Beijing funded enough to go through a rough time like this for was going to be idled in the months leading up to the even a few consecutive quarters. Consequently, many games due to pollution control measures, and that meant 48 | WIRE JOURNAL INTERNATIONAL

Still, everything is relative when we talk about China. A slowing economy still means an amazing 9% annual growth, and therefore, demand will be plentiful in 2009 and beyond. Nothing will bring the dragon to its knees. The massive population still needs many luxury goods for the growing middle class, infrastructure and cars. In immediate terms, the tight market conditions and shortage of wire rod are now gone, and prices are softening. But no matter how fast and furious this correction has been, it is not expected to last too long, and long term prospects are still very good. Let’s talk about the numbers now. In early September ‘08 the difference between the U.S. local price and Chinese domestic price reached an astonishing $500/mt, with the U.S. market at close to its peak of $1225/mt and China’s average rod prices softening to $725/mt. With the price gap opening in this spectacular fashion, it is no wonder that there are, once again, cheap offers for wire rod from China. But there is one catch: Offers are for boron-added wire rod, which escapes the Chinese customs as “alloy steel.” Instead of paying the 15% export tax Murat Askin for carbon wire rod, mills enjoy a 5% VAT rebate for these so-called alloy rods. For minimally adding an element which should not change the physical properties of wire rod, mills get away with an almost 20% advantage. There is talk that this loophole may close imminently. If it does, this will be a shot in the arm for the wire rod markets, and export prices may start heading in other direction again. It has been quite a ride for both wire rod and wire market this year. If there is one benefit of the ‘08 roller coaster ride for the Chinese wire industry, it would be the cleaning out of some of the inefficient wire mills from production. These wire mills should be gone for good. And that’s a good thing for both China and for the rest of the world. Xu Fei of the SteelOrbis Shanghai office, also contributed to this article. SteelOrbis provides steel news, sector analysis, trade statistics on steel, market pricing and more as well as a secure e-trade platform for steel buyers and sellers. Murat Askin is SteelOrbis’ general manager in the Americas region. Prior to working for SteelOrbis, he had a lengthy commercial career in the North American wire rod market. Mr. Askin can be contacted at tel, 713589-6049. ■

OCTOBER 2008 | 49


wire drawers fell short on raw materials and had to reduce production or just close up shop during the raw materials shortage this year. Exporters of wire were further squeezed when the government reduced the VAT rebate for drawn and galvanized wire and subsequently added an export tax of 5%. In the meantime, appreciation of the Chinese currency, RMB, against the U.S. dollar made Chinese exports less competitive. Because of these market dynamics and government export tax regulations as well as increasing container and transportation costs, most first-tier Chinese wire products, such as bright basic wire and galvanized wire, are no longer being exported in a big way. In the spring of 2008, A slowing (Chinese) China’s wire offer prices for economy still means the U.S. were an amazing 9% annual significantly higher compared growth, and therefore, to the previous demand will be year, and most offers dried up plentiful in 2009 and completely. beyond. Nothing will What was left of the competitive bring the dragon to Chinese wire its knees. products were blocked by antidumping investigations such as those brought on by the nail, hanger and threaded rod filings in the U.S. Circumventing both Chinese export taxes and U.S. antidumping duties, Chinese wire is now finding its way to export markets for more value-added, downstream products like widgets, gadgets and tools, in which it still enjoys VAT rebates and higher margins. Coming back to the outlook for the balance of 2008 and beyond in China: When the Olympics started in August, inventories were high and consumption came to a halt. It was as though all of China was on vacation and watching the games. But despite the high inventories of end products and low consumption, the wire rod mills outside the Beijing area kept on rolling. In August, a major oversupply of steel products was apparent and prices started to cave. There are also other reasons why the demand started to drop off significantly. The public construction sector is cooling off as the central government is trying to suppress investments for various projects. China’s other robust industries, such as housing, appliances and automotive, are all showing signs of slowing down. And what about the reconstruction work for the earthquake area, you may ask? According to best estimates, about 20 million tons, only a small portion of overall steel production, are needed for reconstruction efforts. Therefore, it will only have a minor effect on demand.




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IWCS returns to Providence for 2008 event papers; Session 4: Materials 1, seven papers; Session 5: The International Wire & Cable Symposium, Inc., (IWCS), Poster Papers, 19 presentations; Session 6: FTTH returns November 9-12 to the Rhode Island Convention Distribution, eight papers; Session 7: Coatings & Processing, Center in Providence, Rhode Island, USA, where it will eight papers; Session 8: Invited Papers on stage its 57th annual IWCS™ Technical Connectivity, four papers; Session 9: Bendable Symposium and Conference. Fiber, six papers; Session 10: Data Centers, six This year, the organizers note that the papers; Session 11: Materials II, six papers; event will be a first step in emphasizing Session 12: FTTH For MultiIWCS “as a new and differentiated SCS Dwelling Unit (MDU) Applications, and I.T. infrastructure venue.” six papers; Session 13: Special Bolstered by stronger links with the Applications, six papers; and Session Communications Cable and 14: Copper Communication Connectivity Association, Inc. Cable Design, four papers. (CCCA), the event will include The Executive Forum, on Tuesday, technical papers and information on November 11, structured cabling systems will include reports by Rob (SCS) and applications used Daniels, CRU, on World in the Information Wire and Cable Markets; Technology (I.T.) infrastrucPatrick Fay, KMI Research, ture for commercial buildFiber Optic Markets and ings and critical facilities. Prospects; and Bob “Hotel bookings have Shrouds, DuPont, The been strong,” said IWCS Economic Environment for CEO/Director John Barteld. Wire & Cable. Speakers “Normally, we will be Marty Curran, get a lot of day traffic at Corning Inc., Perspective on Providence, but hotel bookGlobal Optical Fiber ings have been strong and Market; Brian Monks, the exhibits are doing well Underwriters Laboratories too.” Inc., Counterfeit Products; The IWCS Conference, Dale Reed, Emerson, organized by the IWCS, has Bandwidth Demand; four major components: the The Plenary Session program at IWCS in 2007 drew a Vincent DeGiorgio, Factory Executive Forum, the very good audience. Photo by Mike DeLucia. Mutual, Increased Safety in IWCS™ Technical Cables and Transit Systems Symposium, a Suppliers in Data Centers; and Cary Eskow, Avnet Electronics Exhibition and Professional Development Courses. The sinMarketing, High Brightness. The Executive Forum will be gle most noteworthy presentation is the keynote speech, prehosted by Bob Willis, President of ECA and Frank Peri, sented during the Plenary Session Luncheon on Monday, Executive Director of CCCA. November 10. This year, the speaker will be Ray Rapuano, The program begins on Sunday, October 9, with eight Cisco, Inc., whose presentation will be, “How Will professional development courses. Morning sessions Intelligent Buildings Impact Our Industry?” (8 am to noon) include: Fundamentals of Copper Conductors The technical papers that compose the technical sympo& Metallic Cable Design & Applications; Polymer sium will be presented Monday, November 10, to Degradation, Stabilization and Failure Mechanisms; BendWednesday, November 12. As of press time, a total of 79 Resistant Fibers; and The Art & Science of Extrusion for papers were scheduled in 13 Sessions, plus 19 more presenWire and Cable. Afternoon sessions (1 pm to 5 pm) include: tations that are part of the Poster Paper forum. The Sessions Fundamentals of Optical Fibers & FO Cable Design & include: Session 1: FTTH Distribution Network: Connection Application; Selection & Use of Materials in Wire & Cable; & Maintenance, seven papers; Session 2; Aerial The Art & Science of Extrusion for Wire and Cable II; and Applications, five papers; Session 3: 10GB Twisted Pair; six 52 | WIRE JOURNAL INTERNATIONAL

Visit our booth # 424 at IWCS Show

OCTOBER 2008 | 53


IWCS officials have been Fundamentals of Broadband working closer with CCCA, and FTT(x). a non-profit corporation The offerings include basic formed in 2007, that serves as concepts in core courses relata resource for the technologies ed to copper, fiber and materiand products of structured als. For the fifth year, IWCS cabling media to support curwill present the core courses of rent and future needs of the Copper 101, Fiber 101 and networking, IT and communiMaterials 101. Over time, stucations industries. dents completing those cours“We’re laying the framework es, along with two electives, for the future,” Bartel said, will be presented with an noting there are four or five IWCS Professional invited papers in one track for Development plaque. IWCS had more than a hundred technical presenta2008. The goal will be to step As of press time, 150 exhibtions in 2007. Photo by Mike DeLucia. forward from this beginning it spaces have been reserved. and make connectors a more The show hours were also substantive element, including adjusted so that on Tuesday, a complete technical paper track for 2009, he said. the exhibits would close at 6 pm instead of 7 pm, to make it “With this new relationship with CCCA, the IWCS easier for suppliers to have dedicated time with customers. Conference will expand its focus to include new and emergOne exhibitor, Teknor Apex Company, reported that each ing applications and best practices in communications and of its three divisions will be introducing new products at the data infrastructure,” said John Sicotte, Chairman of the event. See the Products section that begins on p. 102 for IWCS Board of Directors and a senior vice president of more details. Corning Cable Systems. Barteld said that it may not be noticeable to attendees, but


“Our relationship with IWCS gives CCCA a superb opportunity to extend our reach through technology and science-based research papers to help guide I.T. infrastructure planning and decision making,” said Kevin St. Cyr, CCCA

Chairman and President of Berk-Tek, a Nexans Company. For more information, contact John Barteld at IWCS, ■

IWCS Alphabetical list of exhibitors/booths (as of 9/10/08) 3N International, Inc. . . . . . . . . . . . . . .305 AGC Chemicals Americas, Inc. . . . . . .310 AKSH Optifibre Ltd . . . . . . . . . . . . . . . .329 AlphaGary Corp. . . . . . . . . . . . . . . . . . .417 Amaral Automation . . . . . . . . . . . . . . . .112 American & Efird, Inc. . . . . . . . . . . . . . .335 American Electronic Components . . . .130 Arkema, Inc. . . . . . . . . . . . . . . . . . . . . .230 Ashland Distribution . . . . . . . . . . . . . . .438 ASI/Silica Machinery, LLC . . . . . . . . . .201 B&H Tool Company, Inc. . . . . . . . . . . . .307 BASF SE . . . . . . . . . . . . . . . . . . . . . . .418 Beta Lasermike . . . . . . . . . . . . . . . . . . .128 Boockmann GmbH / Slover Group . . . .236 Borealis Compounds, LLC . . . . . . . . . .400 Breen Color Concentrates, Inc. . . . . . .415 Buss, Inc. – USA . . . . . . . . . . . . . . . . .327 Caballe . . . . . . . . . . . . . . . . . . . . . . . . .114 Cable Components Group, LLC . . . . . .324 Carris Reels . . . . . . . . . . . . . . . . . . . . .216 Cary Compounds . . . . . . . . . . . . . . . . .302 Cersa-MCI . . . . . . . . . . . . . . . . . . . . . .210 Chengdu Centran Industrial Co.,Ltd. . .300 Chromatics Inc. . . . . . . . . . . . . . . . . . . .303 Commission Brokers . . . . . . . . . . . . .401A Composite & Wire Machinery Inc. . . . .403 Conductix Wampfler-Delachaux . . . . . .425 Conneaut Industries . . . . . . . . . . . . . . .213 Copperweld Bimetallic Products . . . . . .100 Corning Optical Fiber . . . . . . . . . . . . . .233 Cortinovis America, LLC . . . . . . . . . . . .212 CRU North America, Inc. . . . . . . . . . . .414 CWB Electronics . . . . . . . . . . . . . . . . . .603 Daikin America, Inc. . . . . . . . . . . . . . . .229 Davis-Standard, LLC . . . . . . . . . . . . . .206 Delta Ulbrich Precision Metals . . . . . . .504 DeWal Industires, Inc. . . . . . . . . . . . . .113 Dow Wire & Cable . . . . . . . . . . . . . . . .119 Draka Comteq Optical Fibre . . . . . . . . .125 DSM Desotech, Inc. . . . . . . . . . . . . . . .101 Dyneon, LLC, A 3M Company . . . . . . .413


E-BEAM Services, Inc. . . . . . . . . . . . . .306 ECA Electronic Components, Assemblies & Materials Association . . . . . . . . . . . . . .606 Equistar Chemicals/Lyondell . . . . . . . .429 Estane® Engineered Polymers . . . . . .406 EuroWire/Wire & Cable Asia Magazine 605 Fiber-Line, Inc. . . . . . . . . . . . . . . . . . . .223 Fil-Tec, Inc. . . . . . . . . . . . . . . . . . . . . . .134 Fisk Alloy Conductors . . . . . . . . . . . . . .137 FSP-one . . . . . . . . . . . . . . . . . . . . . . . .204 Fusion UV Systems, Inc. . . . . . . . . . . .409 Gauder Group, Inc. . . . . . . . . . . . . . . . .120 Gem Gravure Company, Inc. . . . . . . . .319 Gotex S.A. . . . . . . . . . . . . . . . . . . . . . .501 Guill Tool & Engineering Co, Inc . . . . . .219 Halopolymer . . . . . . . . . . . . . . . . . . . . .234 Heraeus Quarzglas GmbH & Co KG . .600 Huber Engineered Materials . . . . . . . . .131 Huestis Machine Corporation . . . . . . . .336 Indore Composite Pvt Ltd. . . . . . . . . . .423 Inhol BV/ PTL . . . . . . . . . . . . . . . . . . . .124 Intertek . . . . . . . . . . . . . . . . . . . . . . . . .507 j-fiber GmbH . . . . . . . . . . . . . . . . . . . . .207 Jiangsu Zhongtian Technologies Co. . .313 King Industries, Inc. . . . . . . . . . . . . . . .404 Kinrei of America, LLC . . . . . . . . . . . . .326 Lantor . . . . . . . . . . . . . . . . . . . . . . . . . .419 LaserLinc, Inc. . . . . . . . . . . . . . . . . . . .314 Leoni Wire, Inc. . . . . . . . . . . . . . . . . . . .424 Lloyd & Bouvier, Inc. . . . . . . . . . . . . . . .407 Madem Reels USA, Inc. . . . . . . . . . . . .411 Maillefer Extrusion . . . . . . . . . . . . . . . .205 Mathiasen Machinery, Inc. . . . . . . . . . .139 MGS Group (MGS-Hall-Northampton) .115 Miltec UV . . . . . . . . . . . . . . . . . . . . . . .601 Mossberg Reel LLC/ Boxy Group . . . . .126 MYTecSoft, Inc. . . . . . . . . . . . . .Booth 338 Nabaltec AG . . . . . . . . . . . . . . . . . . . . .607 NEPTCO . . . . . . . . . . . . . . . . . . . . . . . .104 Niehoff Endex North America Inc. . . . .339 OFS . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Okroglica Tekstilna Tovarna . . . . . . . . .436 OptEM Engineering, Inc. . . . . . . . . . . .311 PE.fiberoptics Ltd. . . . . . . . . . . . . . . . .428 Photon Kinetics, Inc. . . . . . . . . . . . . . . .211 Photonium Oy . . . . . . . . . . . . . . . . . . . .203 Pittsfield Plastics Engineering, Inc. . . .135 Plymouth Wire Reels & Dies . . . . . . . .401 PrintSafe, Inc. . . . . . . . . . . . . . . . . . . . .110 PVC Compounders, LLC . . . . . . . . . . .228 REELEX Packaging Solutions, Inc. . . .410 Rio Tinto Minerals . . . . . . . . . . . . . . . . .138 ROBLON A/S . . . . . . . . . . . . . . . . . . . .325 Rosendahl Nextrom Technologies . . . .315 S&E Specialty Polymers, LLC . . . . . . .337 Saint-Gobain Performance Plastics . . .328 SAMP USA, Inc. . . . . . . . . . . . . . . . . . .421 Shang Hai Wang Xun New Material . .434 Shenzhen Delifeng Trading Co Ltd . . . .412 Shenzhen Unigel Telecom. Co. Ltd. . . .312 Sikora International Corp . . . . . . . . . . .116 SMEETS S.A. . . . . . . . . . . . . . . . . . . . .231 Solvay Solexis . . . . . . . . . . . . . . . . . . .301 Sonoco Products . . . . . . . . . . . . . . . . .200 SSCP USA . . . . . . . . . . . . . . . . . . . . . .304 Stewart Group, The . . . . . . . . . . . . . . .127 T & T Marketing, Inc. . . . . . . . . . . . . . .331 Teijin Aramid USA, Inc. . . . . . . . . . . . . .224 Teknor Apex Company . . . . . . . . . . . . .215 Tensor Machinery . . . . . . . . . . . . . . . . .426 Thermoplastics Engineering Corp . . . .238 Wardwell Braiding Machine Co. . . . . . .334 W. Gillies Technologies, LLC . . . . . . . .136 Weber & Scher Mfg. Co., Inc. . . . . . . . .402 Windak Inc. . . . . . . . . . . . . . . . . . . . . . .506 Wire & Cable Technology Int’l/WCISA .503 Wire & Plastic Machinery Corp. . . . . . .214 Wire Association/Wire Journal Int’l . . . .405 Wire World Internet . . . . . . . . . . . . . . . .604 Wyrepak Industries Inc. . . . . . . . . . . . .330 Yangtze Optical Fibre & Cable Co Ltd .430 Zumbach Electronics Corp. . . . . . . . . .105


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It’s been 25 years since the first installation of underground power cable with tree retardant crosslinkable insulation material from Dow Wire & Cable. Samples of underground cable installed in 1983 show little wear today. EPRI* says about our Dow 4202 family of products, “Based on research results and field data, it appears that the service life…will be greater than 40 years.”

Our patented technology provides an extra-clean, cost-effective material system, and gives your customer proven

performance. That’s what you need to satisfy the rapidly growing demand for underground cable. From competitive initial cost and ease of installation to long, dependable service life. Dow 4202 materials are consistent and easy to extrude. And they’re sold and supported from locations around the world. The secret to supplying power companies with the best value in underground cable is materials from Dow Wire & Cable. Please visit us at IWCS – Booth #119.

Contact Dow Wire & Cable: w w w . d o w w i r e a n d c a b l e . c o m In Europe: 00800 3 694 6367 (800 783 825 from Italy, 990 3 694 6367 from Finland) / In USA and Canada: 1-800-441-4DOW / In Asia Pacific + 800-7776-7776 / Use reference #1-2GN70V ®Trademark of The Dow Chemical Company Dow Wire & Cable is a global business unit of The Dow Chemical Company and its subsidiaries. *Electric Power Research Institute

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Ancillary Equipment


any features in WJI present capital machinery and commodities such as dies, lubes and reels, but the industry depends on a myriad of other

products to keep the processes working. This feature is for these less-heralded suppliers, those who provide ancillary equipment, from air wipes and replacement bows to clutches/brakes and cable strippers.

Amacoil, Inc./U.S. In take-up systems, the Uhing traverse guides materials onto spools in smooth, even layers. Mechanical control over linear pitch and travel direction eliminates the need for electronics and programming. A fine adjustment option for stroke length improves accuracy, particularly at the reversal points. Driven via a belt and pulley linked to the spool drive motor, the Uhing traverse speed remains synchronized with take-up spool rotation speed without A Uhing traverse guide from requiring clutches Amacoil, Inc. or gears. The pitch


control lever on the Uhing traverse affords a 10:1 turndown ratio on the pitch permitting the use of a single traverse assembly for a wide range of material diameters. The traverse is also available with sensors for improved winding accuracy.

Ameritherm/U.S. Brazing, annealing, preheating and patenting are common wire industry processes that require precision heating during manufacturing. Ameritherm, an Ambrell company, provides a broad range of induction heating solutions for these processes, delivering cost savings and production efficiency. Induction heating is an efficient, rapid, non-contact and flameless method to heat electrically conductive material. Users find that induction heating systems, while easy-to-use, provide many manufacturing benefits: repeatability, dependability and energy savings. Energy savings is achieved by eliminating wasted heat; heat is directed strictly to where it is needed. Rapid heating of the part eliminates wasting heat on surrounding air and other materials. With a compact footprint, Ameritherm equipment easily integrates into production lines and robotic manufacturing strategies. Systems

At Wire Expo 2008, Ameritherm’s Chip Laskowski with the EKOHEAT induction heating system. optimal equipment required for applications. Drawing upon more than 20 years’ application experience, Ameritherm experts recommend the most efficient solutions to meet quality and production goals.

B&H Tool/U.S. B&H Tool Wedge Ring Removers and Core Tube Removers (left and center on photo) provide fast, zerodamage extrusion change-overs. These advanced disassembly tools are compatible with all adjustable center

B&H Tool President Peter Neville at Wire Expo 2008, with an inset of some company products.

crossheads. Wedge rings and core tubes have historically been the most difficult pieces to remove for clean-up and change-over. Heat, pressure and tenacious plastic residue often mean that substantial force must be applied. These two B&H disassembly tools greatly shorten the time and

force that is needed, and diminish the risk of damage and additional downtime. The B&H Wedge Ring Remover enables operators to instantly pop-out the wedge ring after each extrusion run. The wedge ring “floats” so that the die adjustment is made against hydraulic pressure, rather than mechanical force. The B&H Core Tube Remover is a simple, inexpensive tool to remove the core tube from the front end of the crosshead without damaging the front end of the core tube or compromising the threads on the back end. Also from B&H Tool: a costeffective striping attachment that allows the co-extrusion of a single, dual, triple or “quad” stripe. The attachment installs quickly between the die holder and barrel body. It is compatible with all adjustable center crossheads and inline spider dies used for insulating wire and jacketing cable. The attachment allows the stripe to be embedded in a tube or jacket or extruded on the outside. Attachments are available for low-temperature and high-temperature insulated wire and jacketed cable applications. Customers can choose a “stand-alone” striping attachment or a new assembly that includes the attachment. An extended range core tube can be supplied where added length is needed.

Boockmann GmbH/Germany Slover Group/U.S. At Wire Expo 2008, Germany’s Boockmann GmbH, represented in the U.S. by The Slover Group, displayed its Helicord technology for cleaning and surface preparation of wire, cable and welding consumables. Using a tension and speed-controlled string or cord wrapped around a wire, strand or cable, its systems provide multiple 360°

Michaela Boockmann, Boockmann GmbH, by the company's Helicord system at Wire Expo 2008. contact under controlled friction with constantly renewed cord that guarantees reliable surface preparation without use of harsh chemicals and expensive filtering of liquids. Controlled friction and the speed difference of the string and wire permit prediction of parameters and calculation of results. The process can wipe off metal fines, spikes and particles of wire and strands to avoid pollution of the following production steps, achieve pinhole-free thin

OCTOBER 2008 | 57


from Ameritherm range in power from 1 kW to 350 kW with output frequencies from 1.5 to 400 kHz. The geometry, material and size of the parts to be heated dictate the


extruded insulation, avoid blow-ups after the extruder, increase average breakdown and partial discharge inception voltage and reduce bit faults and improve adhesion of the insulation to the conductor. Cleaning can be supported by the use of solvents or other liquids on the surface of bare single wire, insulated conductors or metal jackets. Helicord can modify the surface structure mechanically by grinding or polishing to remove residual drawing lubricant powders, and influence the depth of roughness to either improve adherence or make an appearance more shiny or dull. It can also apply liquids or meltable agents to replace talcum powder, control adherence, protect against oxidation, improve sliding or stripping and improve windability of magnet wires and to replace use of solvents for lubricant application (Helilub). During the last three years, actual operating experience has shown that Helicord can replace inefficient or costand energy-intense processes like ultrasonic cleaning or air wipes.,, or

Cemanco LC/U.S. For over 20 years, U.S.-based Cemanco has provided the wire industry with high quality ceramic drawing cones, capstans and rings in zirconium oxide and aluminum oxide. To reach and maintain top quality of the finished product during wet drawing of non-ferrous materials, the choice of the right supplier for drawing tools is essential. The right quality of ceramic drawing tools will guarantee a smooth and controlled drawing process as well as longevity of the material. Cemancoâ&#x20AC;&#x2122;s ceramics are manufactured to the highest standards regarding raw materials, density and surface finish, with each finished part subjected to two levels of end control. Customers can choose from over 2,000 drawings for standard machines of manufacturers like Niehoff, SAMP, Herborn, Henrich, Syncro or Vaughn. The company also offers conversions from steel to ceramic/steel composite cones as well re-finishing and polishing services that will allow extended usage of valuable drawing tools. Also available


Cemancoâ&#x20AC;&#x2122;s Ranier Lashofer and Beliza Bermudez at Wire Expo 2008. are consumable ceramics like flanged eyelets, rods, bow guides in a variety of qualities and surface finishes. Pulleys and sheaves can be provided in standard stock sizes or customized to customer specifications with materials ranging from ceramic coated aluminum to ceramic/steel composites and plastic materials.

Cosmos North America/U.S. Cosmos created Harsh Environment Guide Pulleys in response to an industry need for them. In the course of manufacturing, wire is subjected to a harsh environment from elevated temperatures, corrosive baths and corrosive baths at elevated temperature. Prior to the present innovation, the choice of wire guides available for high temperature and submerged applications was limited to stationary ceramic wire guides. Revolving ceramic guide pulleys could not be considered in view of the heat-sensitive and corrosion-prone metallic ball bearings indispensable to imparting the rotational guidance. Cosmos offers a range of its special guide pulleys, including units that are

Pulleys offered by Cosmos North America.

Die Quip Corp./U.S. fitted with full ceramic ball bearings, which were innovated by Cosmos to withstand both high temperatures and corrosive baths. These can be tailored to customer requirements by specifying the following parameters: temperature range; bath composition, if submerged; material and diameter of shaft; wire diameter, tension and speed; and groove diameter of pulley. For applications where only the wire is at elevated temperature, such as immediately after emerging from an annealing oven, Cosmos’s aluminum flanged pulleys are the optimum

Die Quip’s line of Krenn wire cutters includes manual, battery, electro-hydraulic and air powered cutters. The electro-hydraulic cutters (pictured) are designed for cutting tough materials from 1/8” up to 1 1/8”. Compared to hydraulic cutters these self contained units are portable, smaller in size and just as powerful. They use a 110 or 220V electric motor to drive a self-contained hydraulic cylinder to shear cut the wire. Six different size shear cut units fit any application and size of wire along with a number of specialty units for cutting PC Strand, spring

Stay cool under pressure Clean, 'green' and easy to operate, PWM cold welders join non-ferrous wire and rod quickly and economically to create a permanent bond stronger than the parent material. No set up time is required and the weld cycle is completed in minutes. Our range of high performance, low maintenance machines includes both manual and powered models with capacities from .003145" to 1.181" (0.08mm to 30.00mm). All inquiries within North America for machines, spares and dies, contact: AMARAL AUTOMATION ASSOCIATES PO Box 7816, Cumberland, RI 02864 Tel: 401 405 0755 / 774 991 0504 Fax: 401 405 0757 E-mail:

Pressure Welding Machines Ltd, Bethersden, Kent England TN26 3DY Tel: +44 (0) 1233 820847 Fax: +44 (0) 1233 820591 E-mail:

OCTOBER 2008 | 59


choice. The company’s Diamond-Polished Harsh Environment Pulleys were submerged in tin baths to replace stationary wire guides without diamond polish. Not only was the wire tension reduced, but the pulleys were free of tin contamination, which substantially reduced down time. Cosmos also offers sprayed pulleys. Its thermal spray-coated aluminum pulleys, when fitted with full ceramic bearings, are equally versatile in high temperature environment. The coating material can be alumina (white), chromium oxide (black) and tungsten carbide cobalt (WC12Co).,


steels, chain and others. In conjunction with the electrohydraulic cutters Die Quip offers four battery-powered cutters capable of cutting wires from 1/8-3/4” without the need for electricity. This makes them perfect for cutting samples from the yard or moving the cutter from one machine to another. To cut small diameter wires Die Quip provides Knipex pliers Die Quip Corp. President Tom and hand-held Maxwell with a Krenn wire cutter cutting tools. at Wire Expo. Knipex uses the best quality steels to manufacture their pliers, allowing them to harden the cutting and wear surfaces to the highest Rockwell C scale without sacrificing the pliers’ toughness. Knipex pliers are engineered to perform better and last longer than other pliers. One example is the company’s diagonal cutters that use only two pieces instead of three, allowing the cutter to make more cuts without losing its ability to make precise cuts.

The Eraser Company, Inc./U.S. The Eraser Company, Inc., celebrating its 96th anniversary in business, manufactures a wide range of industrial products including wire, cable and tubing cutters, wire and cable strippers, wire twisters, wire brush wheels, dereelers, infrared heating equipment, measuring The model C300 Twin Blade Rotary tools, and Wire Stripper and Twister from The fybRglass® Eraser Company. erasers. Designed for production, its Model C300 Twin Blade Rotary Wire Stripper and Twister will strip insulations from solid and stranded wires. The unit is capable of processing Teflon, P.T.F.E., PVC, nylon, rubber, KEL-F, miniature coax, coaxial cables, shielded wires and cables. The slug may be left on the wire and removed later when terminated.


The stripping head incorporates a pair of accurately adjustable tungsten carbide stripping blades. The blades are easily adjusted and remain on center. By reversing the belt, the unit may be operated with either clockwise or counterclockwise rotation. The company, ISO 9001:2000 certified, offers a free E.S.P. (Eraser Sample Program). Send a 10-20 foot sample of material and Eraser will recommend the best solution for your processing needs from its line of more than 200 products.

Fine International Corporation/U.S. While Fine International concentrates its main activities on the extrusion capital equipment market, several ancillary products are offered. Gas injection systems for coaxial cable production require the use of specialized injector nozzles which dictate the flow rate of nitrogen gas into the molten polymer. Standard injector nozzles (typ. 4-50 micron) and special low flow rate assemblies are available from Fine and are typically suitable for Cast aluminum sheaves (24 in.) all models of from Fine International Corp. injection systems. Threaded ends are based on standard industry pressure transducer configuration. Fine International also offers specialty large cast aluminum sheaves from 20 in.–72 in. (500 mm–1800 mm). All sheaves include precision bearings and can be custom designed per application.

Force Measuring Systems AG/Switzerland FMS USA, Inc./U.S. Wire and cable makers now have an affordable way to monitor and control tension in individual wires on rotating machines. The new technology by FMS, called Radio Transmitted Tension Monitoring (RTM), can be easily applied on most planetary or tube stranders, bunchers, twisters, or any rotating machinery. It digitally monitors tension in real time on up to 32 individual positions and displays the values on a PC screen. RTM pays for itself typically in one to two years by reducing material breaks and eliminating overstressing and excessive slack in wires and cables. The radio-transmitted system avoids the many drawbacks of mechanisms such as slip rings (cost, wear, signal noise, installation issues, etc.) and telemetry systems (unidirectional analog data transmission, multi-positional prohibitive cost, etc.). The technology can be configured in various ways to handle nearly any tension measurement or control task. The monitoring system is comprised of tension sensors, tension measuring amplifiers, a bus system with radio transceiver, and software. A


wide range of tension sensors is available for any tension requirement, and if closedloop conRadio Transmitted Tension Monitoring trol is technology offered by FMS. required, digital controllers are used instead of measuring amplifiers. The RTM System is powered by 24VDC and is reliable, accurate, economical, easy to operate and virtually maintenance-free. An optional RTM rechargeable Battery Power Pack (BPP) that comes in three different sizes (and power duration) includes a power monitoring system, and is easily combined with the signal transmitter on one plate for easy mounting. Battery life depends on the number of sensor positions on the machine but the BPPs are designed to produce a minimum of one shift of power (eight hours). The batteries are completely rechargeable, reusable and changeable in only a few seconds. The RTM system can easily be used with existing equipment as it bolts down in a small footprint, utilizes standard FMS load cells and amplifiers, and runs on PC software so a new PLC installation is not required to utilize the system.

OM Frigerio/Italy Howar Equipment/Canada OM Frigerio, represented in North America by Howar Equipment, offers the FASO SCLO heavy duty mechanical 12 mm wire descaler with subsequent wire brusher, which excels for customers seeking an environmentally friendly alternative to acid pickling their steel wire. The system features an eightroller, tungsten carbide-fused, reverse-bending roller descaler at The FASO SCLO mechanical wire the entrance of descaler system from Italyâ&#x20AC;&#x2122;s OM the unit. The Frigerio, represented in North reverse bending Ameria by Howar Equipment. . section has its own enclosure

OCTOBER 2008 | 61


with complete safety doors and wire entry guides. The descaler collects the wireâ&#x20AC;&#x2122;s scales/oxide debris in a removable tray underneath the reverse bending rollers. The wire then enters the orbital+ rotating wire brushing unit. The 6 in. wide brushes are mounted on a special orbital head that rotates around the wire being drawn to efficiently cleans the entire circumference. The combination of reverse bending rollers and the wire brushing unit allows the unit to be installed in front of wire drawing and forming machines to provide exceptional cleaning capabilities at speeds up to 5 m/sec (1000 ft/min). The units are used for various grades of carbon steel and stainless steels requiring cleaning prior to further processing. The wire is cleaned just before wiredrawing in an environmentally friendly manner, without the use of dangerous chemicals and pickling acids. Tests have proven the equal quality of mechanically descaled wire vs. chemically cleaned wire without all the negative environmental and health hazards. Following the 6 roller reverse bending roller descaler, the wire goes through a wire brushing head which operates with new 5.5 in. wide wire brushes that can be adjusted to maintain proper brushing pressure. The brushing head as well as the brushes rotate simultaneously to provide a clean surface around the entire circumference of the wire, and can be provided with a double head for drawing speeds at up to 5 m/sec (1000 ft/min). This descaler provides an economical means of cleaning the wire prior to wire drawing, and requires very little maintenance compared to chemical acid pickling. Howar Equipment represents a wide range of other ancillary and wear replacement products, such as wire straighteners, guides, rollers, feeders, traverses and rotating die units as well as payoffs and take-ups, tensioning and tension equalization equipment and more.; in North America,


Frontier Composites and Castings, Inc./U.S. A manufacturer of wire winding bows and flyer bows, Frontier Composites, in business since 1992, has become the best friend of many maintenance departments. Being the manufacturer of some 80 different model sizes makes Frontier a logical choice for anyone in a rush. Bows can be of carbon fiber or fiberglass with Kevlar used where desirable. Aluminum, steel or titanium bows Frontier Composites President Jim can also be supplied on a custom Howe by replacement bows at basis. Wire Expo 2008. Frontier's products are the result of a collaborative effort between the company and composites engineers of many years experience. The company keeps a wide range of hardware in stock at all times, sufficient to satisfy the individual requirements of most customers. This enables Frontier Composites to deliver to any plant in North America in from one to three days, with a few dimensional exceptions. This makes it possible for purchasing agents to respond to the rush demands of a maintenance department striving to maintain production schedules, with the knowledge that these demands will be met.

T. Fukase & Co., Ltd., represented in the U.S. by Urbano Associates, offers three types of air wipes with efficient wiping ability to remove unwanted water or other low viscosity liquids from wires or cable. The Type

T. Fukase’s Tohru Fukase (l) and Naota Fukase with Anthony Urbano, Urbano Associates at Wire Expo 2008. FAS air wipe features top and bottom air inlets with bottom drain and absence of misting at the entering or exiting wire. The FAS series allows both right-to-left and left-to-right wire line directions, and easy threading because of the split, hinged PVC body structure. It is available in throughput wire sizes from 0.15 mm to 9.0 mm at speeds up to 400 m/min. Other sizes and hole profiles are available on specific request. The Type FA line of air wipe features a solid PVC body structure with top air inlet nozzle, bottom drain, and nonmarking ceramic guides. Both right-to-left and left-to-

right wire line directions are also possible with this model, which is available to process throughput wire sizes from 0.15 mm to 7.0 mm. Type TBM air wipes are designed for compact and efficient air wiping up to 400 m/min. They feature top and bottom air inlets and “blow back” of water mist along the inlet wire line, and are available in throughput wire sizes from 0.5 mm to 45 mm. Mounting brackets are available for all the above types. The company also offers rolling ring traverse units and assemblies from the U.K.’s Marldon Group for converting rotary motion into linear motion with both efficiency and longevity of service. They are available in four shaft sizes: 15 mm, 20 mm, 30 mm and 40 mm (60 mm available on special request). The traverse units feature a solid one-piece housing with fixed, load-carrying bushings fitted onto the shaft and a driving system that is independent of the housing. These features separate the functions of the traverse unit for consistent load bearing and driving performance for longer, reliable service., U.S.:

Gem Gravure Company Inc./U.S. Gem Gravure Company Inc., Hanover, Massachusetts, introduces the latest in combined contact and ink jet printing: the AMMIP (AM Motorized Ink Pick Up) printer. This model provides a clean, high speed way to mark wire with high quality contact printing and sequential code via ink jet in a single pass. This unique system uses a motorized transfer wheel to deliver an even film of ink to the laser-engraved printing wheel, drastically reducing ink splash. An ink jet printer head is easily mounted to the unit, allowing variable, sequential printing during the contact printing process. An X-Y attachment is used to fine-tune the distance between the ink jet print head and




NOVEMBER 2008: SPRING & FASTENER EQUIPMENT Bolted, nailed, pinned, screwed, tacked, stapled or hooked. Your product message will be securely delivered in WJI’s November issue. Don’t wait for the rust to set in. Place an ad in front of your prospects and customers while they’re riveted to spring and fastener coverage. Contact WJI’s Bob Xeller or Anna Bzowski today at Tel.: 001-203-453-2777 | E-mail: or

OCTOBER 2008 | 63


T. Fukase & Co. Ltd./Japan Urbano Associates/U.S.


the wire surface. Ink viscosity is maintained with the use of a solvent delivery system that can be adjusted to customer requirements and production conditions. All Gem printers (contact and ink jet) are supported by a full line of high quality inks. Pigmented inks providing bright, opaque codes on dark surfaces have been a specialty at Gem Gem Gravure’s new AMMIP for over 50 years. printer. Contact inks are available in a rainbow of colors, formulated for adhesion on a wide variety of surfaces. Ink jet fluids are available for use in all major brands of ink jet printers.

Heany Industries, Inc./U.S. What is so special about Heanium™? Maybe nothing more than that it is a dependable product made by a dependable company. Heany Industries is a U.S.-based, family owned business, staffed with dedicated employees

Charles Alridge, Heany Industries, with a range of replacement parts at Wire Expo 2008.

who are wire industry veterans. Its commitment to the wire industry spans 50 years and is represented by the full line of ceramic and coated components it supplies to all facets of wire manufacturing. Heanium Industrial Wear Ceramic is the recognized industry leader for ceramic wire guides. Its patented pink material optimizes the combination of hardness and toughness, which has made its


components so popular. The products are utilized in all areas of all wire and fiber optic manufacture. Decades of experience have resulted in the accumulation of specifications and tooling for thousands of wire guides and related components. Hundreds of these standard retro-fit ceramic components are available in stock. Heany’s experienced engineers and sales staff also design new and custom parts for both new and existing wire equipment. The company maintains full machine shop capabilities that include diamond grinding and polishing for all high-tolerance and high polish requirements. It also supplies ceramic, carbide and metallic thermal spray coatings which are applied to pulleys, capstans, rings and rollers. This unique level of experience and familiarity with the wire industry allows Heany to provide one stop shopping for wear resistant components for wire processing. Where there is a wear problem, there is a Heanium wear solution. The company’s business model is based on standing behind its products and being a customer friendly supplier: nothing more, nothing less. It is, and has always been, proud to be a small but important part of the wire industry.

Huestis Industrial/U.S. The marketplace today features many homemade cable stripping units that use fixed knives or blades to cut the jacket or insulation as it is pulled by a cater puller or take-up. One problem with such systems is that they do not follow the variations in jacket thickness because the blade height is fixed. Thus, the core is not protected from the cutting surface and, when variations occur, the conductor surface is scored, cut or damaged. The A close-up of the Huestis cable jacket Huestis cable stripper in action. jacket stripper allows for such variations and protects the core product by means of a stripping shoe that separates the core from the material as it is being cut or stripped. This machine, which is versatile and solid in design, has a proven history of performance, including being customized for specific applications. When used in conjunction with a payoff and a take-up, it will handle a variety of size ranges. It has had many successful applications on single and stranded (bare metal or cable core) as well flat, shielded or fiber optics to name a few. It is available in bench or floor models and can be set up in a cell along with various custom operations such as wash and reprint, strip and print (THHN for

Kamatics Corp./U.S. In 1990, Kamatics introduced a unique high-performance composite flyer bow by combining aerospace proven technology and a revolutionary tri-axial braiding process.

Since 2005, it has been offering a new innovative solution for wire processing, called the BackBoneÂŽ Bow, which is designed to incorporate all the positive features of an enclosed bow without any of the negatives associated with operating a totally enclosed flyer bow. The semienclosed BackBone bow gives the customer the increased reliability and performance needed in todayâ&#x20AC;&#x2122;s competitive environment. The hex-shaped A close up of a composite bow wear bushing can offered by Kamatics Corp. be made of different material types for bare copper, aluminum, steel, plated and insulated wire processing. This opens up the problem solving options not available with the standard wear strip and ceramic or carbide guide combination. Features of the BackBone Bow include: improved bow strength; I-beam


example) and braiders. Some reclamation systems use a granulator as the jacket is stripped and the jacket material is reintroduced as a percentage of the extrusion process. The Huestis stripper system begins with the sizing of the stripping shoe to the diameter of the core or conductor to be salvaged. The core is the guiding surface as the product is drawn through the process. There are adjustable rollers that press and hold the product against the shoe. Pressure is adjustable to accommodate a variety of materials both soft and hard. The top of the shoe has a groove cut into it where a high-speed, cutting blade spins at 3,600 rpm. Setting up the machine involves inserting the tip of the shoe between the core to be salvaged and the jacketing material that is to be stripped. The core is strung up to the take-up and processed in this fashion. Huestis models can process most cable jackets .030 in. to 4.00 in. core diameters.


construction for significantly improved bow stiffness; wire positioned out of the air stream; and an aerodynamic shape for improved speeds with lower amperage draw. The wear bushings can made from ceramic, steel (5860Rc) and many other materials or coatings. This design offers improved support of difficult to make products and prevents the wire from pinching between the guide and the wear strip. Benefits include: improved wire quality, higher tpm, less bow breakage, lower power (AMPS) consumption, a dimpled wear surface which reduces friction, reduced downtime and maintenance, quick and easy assembly and change-out of wear bushings.,

Friedr. Krollmann GmbH & Co./Germany Morgan Koch Corporation/U.S. Friedr. Krollmann GmbH & Co. KG, represented in the U.S. by Morgan Koch, produces a full line of roll pointing machines, including pointing/stringing/welding combinations for a wide range of wire sizes. Its products include swaging machines, point milling machines and tube pointing presses. Roll pointing machines are used to

Keir Manufacturing/U.S. Finally, an air wipe that really works. Just when the industry has given up on finding an air wipe that would dry wire completely with compressed air, Keir has developed a dependable, simple and cost-effective new design. Boldly independent by design, reliable yet thrifty, the FRONTIERSMAN air wipe makes the most of any situation. What makes it so unique? The FRONTIERSMAN air wipe from Keir’s design Keir Manufacturing. relies on the controlled use of compressed air that is allowed to decompress to atmospheric pressure within a carefully sized chamber. The air accelerates to nearly the speed of sound in a thin layer surrounding the wire. This release of kinetic energy, stored when the air was compressed, does far more work than other systems that rely on high volumes of air. The wire path is lined with high-density ceramic material for long life. The configuration of the ceramic keeps the wire centered within the airflow. Keir offers two designs that incorporate the same proprietary concept. One, primarily for bare wire, consists of a polymer mounting block with a high-density, wear-resistant ceramic insert that is handpressed into the mount and seals with O-rings. The other, a split design for jacketed wire or cable, opens to allow welds or extrusion bulges to pass through without damage. It can be used to thread the wire through an air wipe when setting up the line. Keir also offers a full line of 99.8% Alumina products of the highest quality made to your specifications.


Krollmann GmbH’s DWU-3-D pointing machine.

produce drawing points on round, square, flat and other profiles. The model DWU-3-D machine, used for pointing wires up to 15 mm in diameter, offers a unique operating feature where the part of the machine containing the forming rolls continuously swings between the two positions shown in the photograph. The distinct advantage for pointing large diameter wires is that between each step of the pointing cycle, the operator must only transfer the end of the wire to the next smaller groove. Also, because the rotating portion is in continuous movement, the wire is rolled on several planes resulting in a neat and round point as compared to machines with a horizontal and a vertical roll pair. The machines can be equipped with a shear and an option is available for a portable base. or, U.S., darryl@,

Lloyd & Bouvier, Inc./U.S. Lloyd & Bouvier, Inc. offers many replacement parts for several popular brands of wire and cable equipment. For example, brake drum and brake shoe assembly parts for Davis Standard 36” drag style payoffs, and traverse nuts for Davis Standard and Clipper DR-30 and DR-36 dual reel take-ups are fabricated new and are usually available from stock. A state-of-the-art machine shop provides customers with a source for those common wear parts or sometimes hard-to-find parts that need fast deliv-

pany has accredited machinery appraisers able to evaluate small lots or full plants anywhere in North America, can review extruders, takeups, payoffs, cablers, braiders, preheaters, bunchers and more.

Magnetic Technologies Ltd./U.S. Magnetic Technologies recently added a line of “pancake” style magnetic brakes that are just right for those hard-to-fit places like tubular stranders. Two of the most popular “pancake style” brakes will retrofit Bartell’s B-62 and B-64 tubular stranders. The name of the brake stems from its description. Most magnetic brakes are two to five inches thick and house the bearings, magnets and a rotor. The problem, however, is the lack of space. To retrofit a tubular strander, one needs to shrink the brake to a halfinch thick. The O.D. is not as important as tensioning a spool that can be 5-12 inches in diameter, but the width is critical. What Magnetic Technologies did was redesign its brake with many planetary magnets surrounding the rotor to reduce the width by half. It then designed the bearing structure specifically to fit tubular stranders. Typically, the spool in a tubular strander is supported on either end by seating in the outside rails of the strander. Magnetic Technologies made its bearing structure do the same. The

Payoff Flyers and Winders Payoff with dancer accumulator...

Flyer Payoff with dancer accumulator

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for spools dia 100 mm

Driven Tangential Payoff

to dia 300 mm

... and double pivot to pre-load for spools dia 560 mm to dia 800 mm, tension adjustment by magnetic particle brake or hysteresis brake

with tension and rpm control by sensor and frequency inverter for single wire, multiwire and flat wire sections for spools up to dia 800 mm

Flyer Payoff to put in bobbin hole Take Up

for spools dia 500 mm to dia 1250 mm Phone +49 (0)431- 65 02 77

for spools dia 560 mm to dia 800 mm Fax +49 (0)431- 65 05 11

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OCTOBER 2008 | 67


ery when equipment is down. These in-house capabilities allow Lloyd & Bouvier to proReplacement brake parts for a Davisvide Standard payoff from Lloyd & Bouvier. innovative solutions to customers’ unique requirements when designing new or rebuilt wire and cable equipment, from replacement parts to individual items such as payoffs, take-ups, capstans, cablers, stripers, and Wardwell braiders, to complete lines for extrusion, cabling, respooling, taping, wire drawing, and specialty applications. Each new or rebuilt machine or system is designed to the customer’s specific requirement and tested in-house before shipment to ensure conformance to customer requirements. The com-


result is a very accurate magnetic tensioning system to replace the old “rope brake.” Companies today have found tubular stranders to be very good for stranding hard alloy wire, and Magnetic Technologies President Jonathan Ely with a “pancake” style this brake gives them the ability magnetic brake at Wire Expo 2008. to tension fine and very fine wire. Magnetic Technologies has also added a series of accessories and niche products to complement its basic line of brakes and clutches. These accessories include: universal drive plates that clamp on the payoff shaft instead of using set screws; cones, plugs and adaptors to help “bush up” shafts to fit various reels on payoff shaft; and a quality line of stainless steel FastLocks® that clamp better and last longer than competitive designs.

Niagara Composites/U.S. Building on a background in composites manufacturing stretching almost four decades, Niagara Composites has been manufacturing and supplying composite wire twisting bows to the wire and cable industry since 1980. The

with some of the best companies in bow development as well as end users who really know the challenges present in a wire or cable production environment. Manufacturing bows to specification, whether supplied as blanks or fully fitted and balanced sets as each installation requires, is what sets the company apart. Some of Niagra Composites’ bows have been on machines for eight years or more. Indeed, with proper maintenance, operator care, and a clean environment, the bows should perform this well or better. Among the products and services the company offer is its "Bow Repair" service for those bows that may do in an emergency, but sit for years because everyone is scared to use them. If they are repairable, Niagara Composites will provide only what is needed. If they are beyond safe usage, the hardware will be used to produce a set at a fraction of the cost of a new set. Companies the world over appreciate Niagara Composites’ willingness to listen, its dedication to solving problem situations and rely on it to provide exactly what they need, when they need it.

Pannier Corporation/U.S. Designed for high volume, high speed tag requirements; Pannier’s Automatic Embossing System (AES) enables the creation of embossed tags, with little or no operator intervention. Pannier’s embossed tags are especially suited for tracking products that require pickling, annealing, painting and other coatings during the manufacturing

Michale Leard, Pannier Corporation, with a company marking system at Wire Expo 2008.

Ross Jordan, Niagara Composites, with a replacement bow at Wire Expo 2008. first company to dedicate its efforts on these products in North America, it introduced new materials and processes before other companies began. Bows using fiberglass, carbon fiber, and Kevlar as base materials are being manufactured in various combinations. Sizes range from fifteen inches to a recent monster bow that is over 22 feet long. Niagara Composites has had the privilege to work


process. An embossed tag can still be read after these processes because the characters are elevated from the tag surface. The characters are part of the tag material, not an ink or paper that can be stripped away or painted over, rendering the part unidentifiable. The AES is computer controlled and can be easily integrated into the manufacturer’s ERP environment, interfaced with MS Excel spreadsheets, or manual keyboard data entry. Manufactures no longer need to dedicate an operator for producing embossed tags, the system can be networked and remotely started similar to a standard printer. The AES is designed for ultimate flexibility in producing


embossed tags including variable height characters, automatic serial number and date code generation as well as embossed 2D Data Matrix barcodes. The system utilizes Pannier’s own coiled stock tags, either in 7/8”, 2” or 3” width. The length of the tag is designed based on the amount of information needed. The advanced tag drive mechanism ensures smooth, reliable and jam-free tag production. Pannier’s AES and coiled tag offers reduced labor, low maintenance and ultimately lower tag production costs than comparable single-feed embossing systems. or

PowerHandling/U.S. PowerHandling reports that its newest compact materials handling system, the H40/H50S model, represents the company’s most powerful unit, able to move heavy rolling material up to 50 tons. The system is offered in compressed air-powered units (J and A types) or electrical devices (the B and H series). The H40/H50S model was developed especially to move very heavy paper reels and cable drums. The batteries last for eight hours, when the machine is being used with normal interval time, with a recharge time of only 60 to 70 minutes. The model is rated for medium duty-cycle and high load applications. It has the patented PowerHandlin’s direct drive system and uses a fan-cooled and sealed electric motor with a heavy

PowerHandling’s H40/H50S model material mover. duty, three-stage planetary gearbox. The machine incorporates an all-welded and chrome-plated main chassis that features large diameter rear wheels for faster and easier maneuvering. It has a battery-in-base design resulting in a lighter handle assembly providing the operator an effortless swivel action. This machine can transport cable drums up to 50 tons and paper reels up to 14 tons on a flat concrete floor. The true value of the company’s systems is in their ease-of-use, as they are not just incredibly powerful and (despite their compact size) very heavy-

OCTOBER 2008 | 69


duty, they are also highly maneuverable and easy to use. Powerhandlers are sold all over the world, at an average of 750 to 800 machines annually.

Rainbow Rubber & Plastics, Inc./U.S. Rainbow Rubber & Plastics, Inc., has been a supplier to the wire and cable market for over a decade, solving the problems with caterpuller, capstan and haul-off belts. The company’s single-piece construction has no seams or splices, which eliminates common belt failures that have plagued manufacturers for years. Short belt life, cover separation and tracking issues can be reduced by using the proper belt structure and rubber compound. All of Rainbow Rubber & Plastics’s belts are designed specifically for the wire and cable industry. It has developed compounds that address problems with oil on the armoring lines and wear issues on CV lines as well as a belt

Patrick Fitzgerald (l), Sealeze national sales manager, and Michael Jordon, sales representative, display some of the company’s wire cleaning brushes at Wire Expo 2008.

A Rainbow Rubber & Plastic belt in action.

structure with a breaker fabric that eliminates lengthwise splitting issues. Breaker fabric is a ply of fabric inserted in the middle of the belt that dissipates the down pressure across the entire width of the belt. This reduces centerline pressure that cause belts to wear and split. Combined with Rainbow Rubber & Plastics’s technical experience, manufacturers can be assured that they have the proper belt the first time, a basis that has helped the company gain customers such as Southwire, Okonite, Nexans, General Cable and Tyco, to name a few. Rainbow Rubber & Plastics, a leader in belting for the wire and cable industry, also offers on-site surveys and technical assistances to help reduce belt expenditures and increase machine up time.,

Sealeze, a unit of Jason Inc./U.S. Sealeze manufactures a range of brushes in Richmond, Virginia, that are used in a variety of areas in wiredrawing and forming operations to increase process effectiveness and efficiency. By removing excess scale or lubricants, the brushes improve drawing and bending machine


performance and reliability, extend die life, improve uniform lubricant adhesion, and optimize surface finish and brightness. Additionally, when used in conjunction with chemical descaling, they can speed processes and lower costs by extending the life of the bath. Sealeze has been manufacturing brush solutions for industrial applications for over 30 years. The company’s brush products are found in applications ranging from shielding on machine tools to guides on conveyor systems. The customforming capabilities enable them to make shapes and designs specific to the needs of the application.

Sjogren Industries, Inc./U.S. For over 80 years, Sjogren Industries, has been a leading provider of quality machinery, tooling and accessories for the wire and cable industry, offering the most respected quality precision wire tools in the market for the handling and preparation of wire, rod or bar. Wedge grips, assemblies and replacement parts. Sjogren offers three main styles of puller assemblies for setup up wiredrawing machines: S&H-style, which uses a roller chain and a pin-type hook that fits into a radial hole in the drawing block; Vaughn-style, for wiredrawing machines with a leaf-style chain ; and Morgan-style, a heavy-duty construction grip for wiredrawing machines with a link chain. The S&H grip can come with a thumb-release version for easy loading of wire into the grip. All grips can be provided with/without chain and hooks for all drawing applications. Sjogren also offers a spring-loaded safety chain


designed to enhance an operator’s safety by tensioning the puller assembly during string-up, allowing for hands free operation, as well replacement jaws that are easily replaced without tools. Magnetic Tensioning Brakes and Clutches. Sjogren supplies unique solutions for managing torque or tension control problems in material payoff or windup applications. These devices operate using permanent magnets to deliver constant or variable torque resistance. Tensioning brakes A range of products offered by provide constant Sjogren Industries. torque independent of rotational speed, ideal for payoff applications. Tensioning brakes with a feedback arm can provide constant tension during payoff applications, using a follower arm that rides on the material and automatically reduces the torque as the spool diameter decreases. Tensioning clutches provide varying torque to a spool during a wind-up process resulting in a constant material tension throughout the wind-up process. A variety of mounting options and bolting configurations are available. Wire Roller Guides. Sjogren’s units for guiding wire in process lines are manufactured on-site at its Worcester plant, which makes it both convenient and cost-effective for customer’s “One Stop Shopping” to order everything at once, in one place. The company also offers a comprehensive line of modular roll straighteners along with replacement parts and precision grooved rolls.

TMS/U.S. Talladega Machinery & Supply Co, Inc.’s Wire Division (TMS) is well known for its Syncro replacement parts, and rebuilds. However, a quick glance at its web site,, will show all interested buyers that TMS has much more to offer than just Syncro parts and repairs. Its capabilities far exceed local machine and job shops. The TMS Wire Division can manufacture and supply replacements parts for virtually all brands and types of wire machinery. The company has an engineering

OCTOBER 2008 | 71


Greg Daniels and Gerry Runyan, Talladega Machinery & Supply Co. at Wire Expo 2008. department that can reconstruct AutoCAD and Solidworks drawings from worn customer samples. Its large fabrication facility can fabricate multiple level towers, mezzanines and safety guards for operators' protection. TMS has a machining and gear division that can turn and hob a gear 72 in. in diameter, or turn a shaft 20 feet long. Its plasma burn table is 12' x 60'. For mass production, TMS has a Mitsubishi laser table that is self-feeding and will run 24 hours a day. It even has a casting foundry to recreate castings or cast new designs. Whether the need is a replacement part, a totally refurbished machine or large accessory fabrications, TMS, which is ISO 9002certified, can handle the job.

but has applications in various wire manufacturing industries. It has numerous advantages over conventional technology, the most notable being toxicity and regulatory issues. The quenching media used in the Thermcraft process is basically 98% water, with the remainder being a proprietary mixture of non-toxic chemicals. Installation costs are also reduced since the requirements for fume removal, spill containment, and additional regulatory requirements for the lead systems are not needed. When compared to the sand bed operations, maintenance costs are greatly reduced. The system design allows for increased productivity as well as reduced down time. Another advantage is LQF’s ability to handle a wide range of wire sizes simultaneously. While a typical patenting system will allow a user to process wire in the range of 1.5 mm to 2.5 mm, due to its modular construction, the Thermcraft Liquid Quench unit is designed to allow users to process 0.2 mm to 2.5 mm wire simultaneously. Besides being a “green” process, this system has several operational advantages over the molten lead bath and fluidized sand bed processes traditional used in wire patenting.

Tulsa Power LLC/U.S. Tulsa Power LLC, a leading manufacturer and supplier of ancillary equipment to the wire and cable industry, offers a broad range of caterpuller capstans, dual wheel

Thermcraft Inc./U.S. Thermcraft Inc. offers an extensive range of heating elements as well as a wide range of both continuous and batch wire annealing furnaces and material handling systems. A new product the company showcased this year is

James Miller, Tulsa Power, at Wire Expo 2008.

Thermcraft Inc. President Thomas Crafton at Wire Expo 2008 with some company products. an environmentally friendly continuous wire patenting system known as the “Liquid Quench” (LQF) product line. The LQF is directed to the tire steel cord industry


capstans, vertical and horizontal configured accumulators, catenary and multi-sheave dancers, and measuring systems with capacities from 1/64” diameter thru 6” diameter. Tulsa’s caterpuller lines offer track lengths from 12” thru 110” with pulling capacities up to 8,000 lb. Dualwheel configured units offer multi-grooved sheaves with root diameters up to 60”. The company’s vertical accumulators consume minimal floor space requirements while offering a range of accumulation to 1,000 ft. Horizontal units are offered with up to 60” root diameter sheaves and accumulation sized to the application. Horizontal systems can be ceiling hung or offered with support stands and


string-up platform. Dancer systems for controlling speed/torque and line tension on payoffs and take-ups are offered as single-arm catenary style for low speed and multi-sheaved units for higher speed applications. Line tension can be controlled via mechanical weights or with pneumatic systems. Tulsa Power’s handling equipment for wire and cable includes a broad offering of shafted and shaftless payoffs and take-ups, capstans, accumulators, respoolers, coilers, tape wrappers and measuring systems as well as custom-designed equipment to meet and exceed customer specifications.

Videojet Technologies Inc./U.S. The Videojet® 1510 small character continuous ink jet printer from Videojet Technologies Inc. is the first in a new line of printers that sets a higher standard in marking and coding performance for maximum uptime. It is easy to operate through its intuitive user interface and a simplified fluid replacement system with the industry’s first microchip-enabled fluid bottle, called Smart Cartridge™, which is a fluid bottle with a microchip that identifies whether compatible fluid has been installed, to prevent errors in ink types or switching make-up and ink bottles. The Smart Cartridge design is uniquely shaped to A new printer from Videojet. drain completely, wasting no residual ink to further reduce costs. A needle-andseptum design eliminates the need for operators to pour ink, preventing fluid spillage and waste. A unique printhead automatically sets up and adjusts to environment changes, resulting in consistently sharp print quality in even the most challenging environments. Designed for medium-duty applications that involve printing codes roughly 16 to 20 hours per day six days per week, the model is the first release in the new Videojet 1000 Line of small character continuous ink jet printers. The integrated core, which consolidates the printer’s key ink system components into one part, requires preventive maintenance only every 9,000 hours, or 18 months, for mediumduty applications. A countdown meter on the user interface indicates time remaining until the core must be changed.


Warner Electric/Altra Industrial Motion/U.S. Altra Industrial Motion, a multinational designer, producer and marketer of a wide range of mechanical power transmission products, is better known to the wire industry for its Warner Electric and Wichita Clutch brands. These two brands offer multiple products that provide solutions to the challenges of tension control within wire processes, most of which take the form of brakes for controlling unwinds or nip rolls; or clutches for controlling rewind processes. Within these two brands are permanent magnet, electro-magnetic friction, magnetic particle and pneumatically engaged brakes and clutches. The product lines generally break down into two groupings: frictional products and non-frictional. While all control tension, non-frictional products are excellent for use where clean operation is beneficial. These products can be controlled either manually or via a feedback device

An assortment of tension-control products from Warner Electric. and control. The torque range is from 0.1 ounce inch to several thousand ft lb and heat dissipation capacity ranges from a few watts to nearly 20 Thermal HP. Altra provides solutions for a wide range of application challenges. Besides brakes and clutches, Warner Electric can provide controls that will enhance machine performance. These range from simple manually adjusted controls to fully closed-loop controls that will interact with a dancer or load cell system. The combined resources of the two divisions offer solutions ranging from simple components to complete systems to meet both OEM and retrofit applications.

Wyrepak Industries, Inc./U.S. With a legacy of 50 years in business, Wyrepak Industries’ rotating cap and brush continues to offer controlled payoff of wire and textile products from reels ranging in size from 3 in. to 48 in. The cap has a bearing at its center. This allows it to turn as the wire rubs against it and in so doing, provides the wire with a slip surface to help it leave the reel. The brush puts back tension on the wire while still on the reel. This tension helps prevent the wire from getting loose and cascading down or tangling.





wire • cable • supplies • equipment

Be seen in PRINT or ONLINE See and be seen among more than 3,000 wire and cable industry companies in WJI’s 2009 Reference Guide and companion online “Virtual Trade Show” (VTS) pages. Published annually and updated daily online, this is the place for your customers to find sources for wire, cable, supplies, and equipment. A basic listing is free. One company profile is seen in print and online. And, with the many search options offered it is easier than ever for your prospects to find you. In fact, more than 130 visitors actively search the VTS each day. If you don’t like cold calls, this hot reference source can help keep you face to face with the people who buy your products. Really looking for the attention you deserve? Boldface listings, display advertisements, and online banner ads are a proven way to boost your visibility. Space reservation deadline: November 12, 2008. Call the WJI sales team at: (001) 203-453-2777 to outline an advertising plan that will work for you. Why HIDE when your customers SEEK?

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Wire Journal International is the official publication of 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:


to lessen uneven tension and neck down. The cap and brush remains the simplest and most economical way to pay off wire under controlled tension. An added benefit is the ability to payoff continuously, thus eliminating down time. Wyrepak also offers other products to assist the movement of wire. Its full line of sheaves have root diameters from 5/8 in. up to 22 in. Many feature replaceable contact surfaces. In addition, if constant tension is needed on wire as it feeds a process, Wyrepak can design a tension capstan to meet specific company needs.,

Yield Management Corp./U.S.

David Monighetti, Wyrepak Industries, displays his companyâ&#x20AC;&#x2122;s cap and brush technology at wire 2008. When the wire line stops, the nylon bristles hold the wire and prevent run on. When the line restarts, so does the wire, but with minimum inertia to overcome. This helps

System Solutions Preformers VR Straighteners Rolls Guides Drives

Preformers for standard and customized final products. Do you have to manufacture strands and ropes in small batch sizes? By using our standard VR or customized preformers you are able to manufacture your strands and ropes efficiently.

WITELS-ALBERT USA Ltd. Phone: 410 228 8383, FAX: 410 228 1813,


Yield Management Corporation (YMC) manufactures and installs accessory products that reduce defects and increase productivity in wire and cable operations. It recently introduced a line of products specifically designed for stranding and cabling machinery. The new BW700 series product, introduced at wire 2008, is a spool monitoring system for tubular and bow stranding machinery and planetary and rigid frame cabling machinery. If any one of the payoff spools stops rotating because of material run out or broken wire, the detection system immediately shuts the machine down, reducing defects and eliminating waste. The addition of this

Genca Wire & Cable Extrusion. From Pellet To Product.

No matter what type of wire or cable you may be extruding, Genca designs and manufactures everything you need for your extrusion process. From Crossheads and In-line Heads to Tips, Dies, Screws, Barrels, Breakerplates and more, Genca leads the industry with a complete line of innovative and highly productive extrusion products for your business. For more information, contact Genca at 1-800-237-5448 or online at


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supervisory monitoring system enables “lights out” operation and offers the opportunity to increase productivity and efficiency. The new BW701 series product for cabling machinery, a strand counting device, was introduced at Wire Expo 2008. This newest product counts the number of strands at the die point and stops the machine within four machine revolutions after a strand is missing. The operator sets the number of expected strands from 0-99 via a thumbwheel switch. A digital display provides feedback with the actual strands counted each revolution. If the actual count is less than the expected set-point, the system stops the machine, eliminating defective product and finished goods scrap. Yield Management Corporation also supplies its awardwinning Low Bobbin Detector for braiding machinery. By stopping the braiding machine before the bobbins is completely empty, reduces defects and increases productivity. ■ Yield Management Corp. President Bob Brown with the BW701 model introduced at Wire Expo 2008.

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

New machines and lines upon request

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



TECHNICAL PAPER Steel patenting technology in the manufacture of steel tire cord Use of patent-pending Liquid Quenchant Fluidized Bed Technology can overcome common problems encountered with processing higher strength cables, such as tire cord used by the auto industry. By Thomas W. Tyl

The tire industry’s desire to decrease conversion costs by replacing low strength Normal Tensile (NT) and High Tensile (HT) cable with higher strength cables like Super Tensile (ST), Ultra Tensile (UT) and Mega Tensile (MT) are forcing more advanced technologies to emerge for steel tire cord manufacture. Gains for tire manufacturers lie not only in higher strength, lower weight cord, but also in reductions in rubber top-coat compound related to ST, UT and MT cable reduced diameter. For steel tire cord manufacturers, diameter and chemistry concurrencies limit conventional strand heat treating processes like molten lead and sand fluidized beds that consume relatively large quantities of energy. Newer technologies like Bekaert’s (U.S. Patent 6228188) “Near Water” process consume a fraction of the operating energy but do not address concurrencies. Liquid Quenchant

Fluidized Bed Technology (LQF, U.S. and Other Patents Pending) overcomes concurrency constraints and significantly reduces energy and maintenance requirements by using a liquid to alter the forced convective heat transfer coefficient; quenching and soaking temperature of the media are relatively unimportant. Current old technologies and even the “Near Water” process differ in degree; LQF offers a difference in kind. LQF is based on the Thermodynamic Wire Transformation (TWT) theory stating multiple forced convective heat transfer coefficients are advantageous to dissipate heat after austenitizing. Heat extracted during the roughly 0.7 seconds of quenching from the austenitizing temperature is almost 13 times greater than that extracted during the 5.2 seconds kinetics allots to transformation to pearlite. In addition, heat dissipation during quenching is linear while

Fig. 1. Convection and radiation.

Fig. 2. Early patenting 1070 Steel.


Austenitizing. Strand annealing or patenting for the manufacture of steel tire cord consists of two steps: heating transformation for austenization and cooling transformation for controlling microstructure. Austenization can be completed using various techniques like direct-fired gas furnaces, induction, the joule effect, indirect heating via tube or muffle furnaces (with or without protective atmospheres) and various combinations thereof. By far the most prevalent austenization method utilizes a direct-fired gas furnace requiring sophisticated atmosphere control schemes to maximize heat transfer rates while avoiding excessive oxidation, reduction and decarburization. Although the driving force for heat transfer is the difference in temperature between furnace atmosphere and wire, two competing types of heat transfer (convection and radiation) impact the rate at which heat is transferred. Below a

wire temperature of about 700oC, convection is dominant while above this wire temperature radiation is much more important. Oxygen-rich atmospheres high in di-atomic molecules are beneficial to convection, but also increase the rate of scale formation. Hence, oxygen-rich atmospheres normally extend about 20% into the furnace to control scale formation. Tri-atomic and other more complex molecules like unburned methane (CH4) dominate gasrich atmospheres to promote radiation by providing radiation emitters in the form of soot particles that glow at furnace temperatures. Austenization atmospheres are set to maximize a particular heat transfer rate while minimizing propensity for scaling, decarburization and other reactions that are deleterious to material properties. Shifts in furnace atmosphere can result in wire temperature changes, decarburization, oxidization and reduction. A schematic of convective and radiant heat transfer rates is depicted in Fig. 1. Regardless of the particular method used to reach the appropriate austenitizing temperature, the goal is identical: to exceed a wire temperature of about 700°C as quickly as possible to take advantage of quick radiant heat transfer rates while avoiding deleterious reactions. Steel Technology. Controlled cooling should produce a microstructure suitable for subsequent drawing, namely purely fine pearlite lacking proeutectoid microconstituents and without upper bainite and minimal “degenerative pearlite,” where this term refers to an amalgam of microconstituents with morphology related to fine pearlite and upper bainite. Since the 1970s, when steel-belted radial tires were introduced in mass, steel cord manufacturing technology has evolved into a sophisticated process. In the mid 1980s a shift was made from Normal Tensile product to High Tensile. At the time, this meant converting from 1070 grade steel to 1080 grade steel, complicating the

Fig. 3. Lead patenting 1070 steel.

Fig. 4. Air fluidized sand patenting 1070 steel.


OCTOBER 2008 | 81


that of transformation is nearly parabolic. The TWT theory concludes that roughly 97 units of energy per second are extracted during quenching for every 1 unit extracted during transformation. This means that high quenching rates are required to cool austenite to near the TTT nose and very small heat transfer rates are required to hold the transforming product at temperature. The resulting fine pearlitic microstructure is desirable for drawing to high strength, torsional and fatigue properties. Cementite plates are very thin and less fracture prone during texturing. They yield stronger, more ductile filament with elevated torsional and fatigue properties. For hypoand hyper-eutectoid steels rapid quenching precludes proeutectoid microconstituents “trapping” these, further increasing internal energy, making filament stronger and more fatigue resistant.


patenting process. In the late 1980s, Super Tensile steel tire cord was introduced. It was initially manufactured using an array of micro-alloyed steels (e.g. 1080 SiCr, 1092 Cr, etc.). As the patenting process became more controllable, micro-alloyed steels were replaced by plain-carbon steels like 1090. Further refinements in patenting technology and wet drawing lubrication eventually allowed some Super Tensile products to be manufactured from 1080 grade steel. In the early 1990s, Ultra Tensile product was manufactured from the micro-alloyed steels previously mentioned while currently it is common to manufacture small diameter Ultra Tensile product from 1080 or 1090 grade steel while larger diameter Ultra Tensile product is made from 1090 grade plain carbon or micro-alloyed steel. Beginning in the late 1990s and continuing today, Mega Tensile steel is being developed. Mega Tensile steel is currently manufactured from high carbon micro-alloyed steel.

Controlled cooling Super Tensile and Ultra Tensile products utilize hypereutectoid steels where suppression of the proeutectoid cementite reaction is essential for control of drawability, high strength, delamination free filament torsion and high filament and subsequent cable fatigue. Controlled cooling for higher carbon and microalloyed steels is more critical than when patenting lower strength products. Mechanisms of conventional and new controlled cooling technologies rely on “conductive cooling,” with a vapor barrier based on Newton’s Law of Convective Cooling (or Newton’s Law of Forced Convective Cooling): Q = A * h * ΔT, where Q is the heat transfer rate to the surrounding media, A is the wire’s surface area, h is the forced convective heat transfer coefficient, and ΔT is the temperature difference between wire (Tw) and media (Tm).

Fig. 5. Fluidized sand patenting 1070 steel overheated quench.


Air and water patenting Very early strand annealing utilized austenization followed by air, water or a combination of air and water for controlled cooling. See Fig. 2. These processes resulted in coarse pearlite unsuitable for drawing to small diameters and high total strains. Exothermic transformation of unstable austenite to coarse pearlite increased wire temperature further, coarsening the resulting product. As the process evolved, a limited amount of water was used to increase the initial cooling rate and absorb limited heat of transformation. This technique also proved unsuccessful for small diameters since heat transfer rate was crudely controlled.

Lead Patenting The next successful patenting advancement, still in wide use today utilized molten lead as a quenching media. See Fig. 3. Liquid lead has a high heat transfer rate due to lead’s relatively low vapor pressure. A liquid’s vapor pressure, particularly in a still bath, can dramatically affect the resulting heat transfer rate. Materials with low vapor pressure like lead, limits vapor formation at the surface of the strand product effectively increasing the forced convective heat transfer rate. It is commonly accepted that lead bath and wire temperature equilibrate near the TTT “beginning” line close to the TTT “nose.” However, it is difficult to exactly measure this temperature since the product is submerged in a liquid bath. The most common technique is to weld a small diameter thermocouple to the wire’s surface, but this technique actually returns an average of the wire’s surface and bath temperature. Additionally, since the lead bath technique relies on the ΔT = (Tm-Tw) term from Newton’s Law of Forced Convective Cooling, the lead bath can be set to only one temperature meaning that compromises are made between quenching and soaking. If molten lead tempera-

Fig. 6. Fluidized sand patenting 1070 steel undercooling.

Sand Patenting The theory of sand patenting is that cool air-fluidized sand that comes in contact with hot wire will force heat to move from the hot wire to the cooler sand. Air used to fluidize sand, in turn, provides a vehicle to transport heat from the sand and into the surroundings via a stack or chimney. Although the vapor pressure of sand can be ignored, temperature, particle size and fluidization pressure play major roles in the heat transfer rate. Heat is effectively removed from wire only while in contact with sand. The time duration that the sand is in contact with wire is a function of wire and sand velocity. In turn, sand velocity is proportional to sand depth, fluidization pressure, airflow rate and sand granule size. However, once equipment is designed, sand velocity is only a function of fluidization pressure and sand granule size. The heat energy that a granule of sand absorbs is a function of ΔT = (Tm-Tw) as well as the granule’s mass. Some air-fluidized sand beds rely on one patenting temperature for the entire bed. This leads to the same limitation as lead baths, namely that it is not possible to optimize both quenching and soaking with a single bath temperature as the wire will not be optimized for strength, torsion and

Fig. 7. Pearlite transformation.

fatigue properties. The further limitation that only steels of similar (the same) chemistry can be processed concurrently applies since different chemistries require different quenching and soaking conditions. An attractive alternative to air-fluidized sand beds adds a fixed-length sand quenching zone; the sand temperature can be lowered to increase apparent heat transfer rate. See Fig. 4. Although this modification addresses the quenching and soaking limitation of a one-temperature bed, the operation is still limited to processing similar (the same) chemistries since different steel chemistries can require significantly different quenching and soaking temperatures. A further limitation is that wires of the same chemistry must also be of similar diameter since the quenching length is set once the equipment is designed. The quench is designed to remove a maximum amount of heat energy per unit of time. Concurrently processing wires of dramatically different diameters can result in one of two outcomes: • The quench may be too short to remove heat from the larger diameter product, resulting in wire entering the soaking section at unexpectedly high temperatures. See Fig. 5. • The quench may be too long for the smaller diameter product, resulting in wire entering the soaking section at unexpectedly low temperatures. See Fig 6.

New steel patenting process A new process used and patented by Bekaert relies on a large “ΔT” and two “h”s, from Newton’s Law of Forced Convective Cooling. • A heat-transfer coefficient similar to liquid close in temperature to boiling water; and • A heat-transfer coefficient similar to a gas close to still air. Per the patent description, the cooling process is alternately completed by “film boiling” in water followed by

Fig. 8. Exemplary LQF cooling curves.

OCTOBER 2008 | 83


ture is set low transformation can occur below the TTT nose while if lead temperature is set high the resulting microstructure will be coarsened pearlite. It is not possible to optimize both the quenching and soaking operations with a single bath temperature and the wire will not be optimized for strength, torsion and fatigue properties. Further, only steels of similar (the same) chemistry can be processed concurrently in the same molten lead bath; different chemistries require different quenching and soaking conditions. For example 1070 grade steel may be lead patented at 535°C while 1090 grade steel may require a molten lead temperature closer to 560°C.


cooling in still air. The term “film boiling” or “film water cooling” refers to the stage where wire is surrounded by a continuous stable vapor film and resulting in regular and relatively slow cooling. This stage differs from the nucleation stage of boiling where the vapor film is irregular and cooling is rapid and the convective cooling stage where water and wire are in direct contact. Quenching additives are mixed with the “water” to help promote the film boiling stage, hence the name “Near Water.” This two-step process may be alternated several times to achieve the proper microstructure. The number and length of film water cooling and still air cooling periods are chosen to produce a fine pearlitic microstructure. The number and length of these periods also limits wire heating due to exothermic recalescence to a maximum of 30–75°C above the transformation temperature. This helps to avoid the formation of coarse pearlite. The transformation to pearlite begins at a temperature near the nose of the TTT curve, between 550°C and 650°C, depending upon the steel alloy being processed. To reduce operating costs, energy does not need to be supplied to the water baths except for start-up since energy provided by the hot wires sufficiently heats the water to the desired temperature. Other advantages of Bekaert’s Near Water process are its relatively low investment, operating (water and chemicals) and maintenance costs. The patent claims that wires as small as 0.80 mm can be patented using this process. Thus far only Bekaert operates the Near Water process (U.S. Patent 6228188), and it has made no data available. However, extrapolating from information in the U.S. patent it appears that the process may be relatively unwieldy to control and may suffer the same limitations as lead and air fluidized sand patenting; it may be difficult or impossible to concurrently patent wires of differing chem-

istry and diameter. These issues are directly related to the limitation of having only two available forced-convective, heat transfer rates, not imaginatively different from air-fluidized sand patenting.

Fig. 9. X bar average LQF bench scale tensile strength.

Fig. 10. X bar average LQF bench scale cross sectional area.


Liquid Quenchant Fluidized bed technology Liquid Quenchant Fluidized (LQF) bed technology was developed to address limitations related to productivity and waste associated with the manufacture of steel tire cord. Production manufacturing and engineering experts in the steel tire cord industry overwhelmingly assert that code changes, maintenance and stability issues related to the patenting process are the largest contributors to plant waste and process upsets. LQF at once addresses maintenance, energy, stability and concurrency limitations of other patenting processes. LQF approaches the issue of heat transfer in a way different from all other patenting techniques. Maintenance issues related to air-fluidized sand beds are eliminated when a low temperature liquid is substituted for the heat transferring media. Except for start-up, no energy is required to heat the transfer media and up to 95 percent of the evaporate can be returned to the bath depending upon the specifics of the system used to condense the evaporate. Once the proper quenching and soaking settings are determined for a given chemistry and diameter, the same settings can be used again to reach similar plated and filament properties. Concurrencies can be addressed by dividing patenting lines into groups of wires that travel the same speed and setting the quenching and soaking parameters for the particular group of material. In this way any diameter can be run with any chemistry that can be supported by the range of take-up speeds necessary to properly austenitize the steel. LQF heat transfer relies on the Thermodynamic Wire Transformation (TWT) Process to achieve these goals.

Fig. 11. X bar average for LQF reduction of area.

that below about 725°C and after about 0.7 seconds for eutectoid steel quenched to the TTT “nose,” the wire gives off heat, which changes the curve’s shape. The amount of exothermic heat generated during this process is a small fraction of heat absorbed to reduce wire temperature from the austenitizing temperature to the soaking temperature. A realistic curve shape accounting for recalescence after the wire passes the TTT “nose” is shown in Fig 7.

Mechanical properties Continuous samples ranging in size from a few meters to a thousand kilograms have been successfully processed on a bench scale LQF in the U.S. The bench scale is limited to diameters in the range of 2.0 mm and speeds of 15 m/min due to take-up speed and bath length equipment limitations. In addition, bench scale equipment is limited by the ability to control tension at the payoff, resulting in diameter changes during austenization. However, hand samples as small as 0.76 mm have been successfully produced by manually paying off wire into the austenitizing furnace. Chemistries ranging from 1070 to 1092 Cr have been used resulting in filament meeting mechanical properties (strength, torsion, fatigue) ranging in strength from Normal Tensile through Ultra Tensile tire cord requirements. Many cooling curves have been measured for the LQF process. Experience has shown that different steel tire cord manufacturers require different cooling rates for their particular processes. Cooling curves for the LQF process are relatively easy to generate and are fairly accurate since the wire temperature can be measured fairly accurately at almost any point in the patenting process. Two exemplary curves for nominal 1.95 mm 1090 grade steel are shown in Fig. 8. A major advantage of LQF is process stability, seen even

Fig. 12. True stress strain curves.

OCTOBER 2008 | 85


Simply stated, the Thermodynamic Wire Transformation Process asserts that an alternative to constant media temperature that effectively controls Newton’s Forced Convective Heat Transfer Rate “Q” during cooling is to manipulate the forced convective heat transfer coefficient “h” in Newton’s Law of Cooling: Q = A * h * ΔT. Conventional processes control “Tm” from ΔT = (TwTm) and the Near Water process is limited to two “h” values: • “Tm” is controlled to one value for molten lead or air fluidized sand beds without a quench. • “Tm” is controlled to two values for air fluidized sand beds with a quench • “h” is controlled to two values (still air and “film water cooling”) for the Near Water process. The TWT process controls “h” to an infinite number of values at any point. This newly developed quenching and soaking technique can precisely quench and soak steel during strand patenting. The TWT Process allows an infinite number of heat transfer coefficients by changing media composition depending upon thermodynamic wire requirements at any specific time. To remain competitive in emerging and future Super Tensile, Ultra Tensile and Mega Tensile tire cord markets, shortcomings of molten lead, sand fluidized beds and the Near Water process have been addressed using the TWT Process’s innately efficient quenching to near the appropriate TTT curve nose and precise thermodynamic soaking by altering the quenchant chemistry. The resulting fine pearlitic microstructure with a lack of microconstituents at grain boundaries is desirable for drawing to high strength and true strains while maintaining torsional stability and high fatigue properties. The transformation from austenite to pearlite (recalescence) is exothermic and skewed parabolic. This means


with limitations listed above. For example, an X bar Average chart for patented tensile strength is shown in Fig. 9. This chart is not dissimilar to charts generated using conventional commercial equipment like lead, air-fluidized sand and Near Water processes. However, nearly half of the variation in strength can be attributed to differences in patented diameter due to payoff limitations. Fig. 10 shows variation in patented cross sectional area for the same samples. An indication of variation can be determined by comparing the difference between the upper control limit (UCL) and lower control limit (LCL) as a percentage of the average (using this crude but easily understood method, if the UCL and LCL coincide with the average, variation is 0%). For data in the previous figures, the indication of variation for tensile strength is 2.2% and that for cross sectional area is 1.3%. This is an expected number for tensile strength variation and an unexpected large number for cross sectional area variation for the length of samples tested. It is also noted that wires with larger diameters had higher breaking loads and corresponding lower tensile strengths. This indicates that a commercial LQF unit with proper ancillary equipment will have significantly less variation in patented tensile strength than conventional patenting units. The same study produced reduction of area data for LQF product. These are representative of normal variation indicating relatively uniform heating during austenization and similar microstructure along the sample length. Data are represented graphically in Fig. 11. As-drawn wire from one heat of steel was purchased, divided into lots and supplied to tire cord-manufacturing participants for comparison of LQF, lead, and fluidized bed patenting. The wire, nominally 1.95 mm, was drawn to nominally 0.35 mm after patenting and plating using the

various techniques. True stress strain curves were generated by determining the tensile strength and true strain at each position in the die practice. The curves were similar and in each case the LQF product resulted in a higher final strength. Torsional properties for LQF and lead patented product were stable, air fluidized sand filament samples were not stable in torsion. Fig. 12 shows the true stress strain curves for the study. Microstructural analysis was completed on lead patented (STD) and LQF patented product. The nominal diameter was about 2.0 mm and various chemistries were examined. To complete the study estimates were made of the percentages of fine pearlite, degenerative pearlite and bainite and fragmented pearlite. In no instance were proeutectoid microconstituents observed. Results indicated that LQF product generally had a higher percentage of fine pearlite and similar amounts of degenerative pearlite and bainite and slightly less fragmented pearlite. However, the goal of LQF patenting is to increase the amount of fine pearlite at the expense of degenerative pearlite and bainite. Results of the study are shown graphically in Fig. 13. A further study was conducted using LQF technology to generate samples in 10 different patenting conditions, including changes to quenching and soaking temperature as well as austenitizing temperature. To date results of the continuing study have not been completed.

Summary The Thermodynamic Wire Transformation (TWT) Process applies the thermodynamics and kinetics of heat transfer during controlled vigorous cooling from the austenitizing temperature to the appropriate transformation temperature. The TWT Process also utilizes an infinite choice of forced convective heat transfer coefficients, “h” in Newton’s Law of Convective Cooling, to help ensure that the wire remains at the appropriate temperature during the entire transformation. Some advantages of the TWT Process utilizing the in Liquid Quenchant Fluidized Bed Technology (LQF – U.S. Patent Pending) are: • Low product variability; • Ability to patent very small wire sizes (<0.50 mm); • High control ability of exothermic transformation; • Very low energy consumption; • No diameter concurrency limitations; • No chemistry concurrency limitations; • Non-toxic heat transfer medium; and • Low maintenance requirements.


Fig. 13. Microstructural analysis, nominal 2.0 mm.


Tire Wire Technology, LLC, Siler City, North Carolina, USA, would like to thank RichardsApex, Incorporated, Philadelphia, Pennsylvania, USA, for leading the development of a quenchant suitable for the Thermodynamic Wire Transformation (TWT) Process. Also, Thermcraft, Incorporated, Winston-Salem, North Carolina, USA, for technical support developing the tech-


nology for a bench scale model to develop the data to confirm and understand the Thermodynamics of Liquid Quenchant Fluidized Bed Technology (LQF).

References 1. T.W. Tyl, “Control of Strengthening Mechanisms in the Manufacture of Steel Tire Cord,” Wire Journal International, February 2006, pp 122-128. 2. R. P. Schenk and T.W. Tyl, “Control of Wet Drawing Lubricant in the Manufacture of Steel Tire Cord,” WAI’s International Technical Conference, Prague, Czech Republic, October 2005. 3. T.W. Tyl, “Control of Cable Twist in the Manufacture of Steel Tire Cord,” Presented at the 2006 WAI 76st Annual Convention, Boston, Massachusetts, USA. 4. T.W. Tyl, “Liquid Quenchant Fluidized Bed Technology in the Manufacture of Steel Tire Cord,” WAI’s International Technical Conference, New Delhi, India, October 2006. 5. T.W. Tyl, “Thermodynamic Wire Transformation Process in the Manufacture of Steel Tire Cord,” WAI’s 77th Annual Convention, Cleveland, OH USA, May 2007. 6. Private Conversations, Stanislav Antolin, “Thermodynamic and kinetic properties of steel during pearlitic transformation,” April 2007. 7. “The Making Shaping and Treating of Steel,” edited by Harold E. McGannon, United States Steel, 9th Edition, 1971. 8. T. Hamada, et al., “Development of a Numerical Model for Predicting the Temperature of a Steel Wire Threaded Through a Fluidized Bed for Patenting Treatment,” Wire Journal International, June 2001, pg. 74. 9. M. Murahashi, et al., “The Influence of Material and Process Factors on the Drawability of Mechanically Descaled High Carbon Steel Wire Rod,” Wire Journal International, November 1993, pg. 50. 10. I. Ochiai, et al., “Effects of Metallurgical Factors on Strengthening of Steel Tire Cord,” Wire Journal International, December 1993, pg. 50. 11. M. Zelin, “Microstructure Evolution in Pearlitic Steels During Wire Drawing,” Acta Materialia, 50-2002, 4431. ■

Thomas W. Tyl is the principal for Tire Wire Technology (TWT), LLC, Siler City, North Carolina, USA. He has 22 years of experience in the field of steel reinforcement, previously working for the Goodyear Tire & Rubber Company. He is the inventor of the Liquid Quenchant Tyl Fluidized Bed Technology (patent pending); Torsional Wire Treatment (patent pending), a unique die design that improves the torsional properties of drawn wire; and the Tempering & Wire Trioxide Improvement Process (patent pending) that allows patenting in a direct fired gas furnace without formation of iron oxide. He holds a M.E. degree in metallurgical engineering and materials science from Carnegie Mellon University, an M.B.A. degree in manufacturing management from the University of Pittsburgh, and a B.S. degree in materials science from North Carolina State University. This paper was presented at WAI’s 77th Annual Convention, May 2007, Cleveland, Ohio, USA.

OCTOBER 2008 | 87


Fabrication of shaped medical testing wire by drawing





One finding from a series of tests performed to clarify optimal drawing conditions showed that a rectangular wire can effectively be made by using a larger single reduction. By Kazunari Yoshida and Miki Matsunaga

Superfine wires with a cross sections of various shapes have been attracting attention as structural materials used in the medical and dental fields and in micro machines, as well as machine elements used in small motors. For example, wires with a round cross section have conventionally been used as orthodontic wires; however, the use of rectangular wires enables more efficient orthodontic treatment because rectangular wires are easier to handle and orthodontic strength is sustainable1. Wires used in the medical and dental fields require biocompatibility, less allergic reaction induced in human bodies and high corrosion-resistance. Therefore, the metals used for these purposes are limited to a few materials, such as titanium. There have been some reports on microshaped wires made of common materials, such as copper and stainless steel2-3; however, the number of reports on

micro-shaped wires made of special steels, such as titanium and shape memory alloy, is limited. There are various methods for fabricating shaped wires. These include: drawing with a shaped die after the wire is subjected to flattening by a flat roller; drawing with a cassette roller die4; and rolling with a Turks-head roller5-6. However, these methods are not appropriate for fabricating shaped fine wires requiring high dimensional accuracy. In this study, micro wires with a rectangular cross section used in medical fields were obtained by drawing round titanium and round Ni-Ti shape memory alloy wires, and the improvements in the wire quality and dimensional accuracy were examined both experimentally and by Finite Element Method (FEM). Optimal drawing conditions for fabricating shaped wires with a rectangular cross section were clarified by FEM. Then, dimensional accuracy and

Table 1. Reductions per pass by drawing.

Fig. 2. Round to shape drawing.

Fig. 1. Profiles of die. 88 | WIRE JOURNAL INTERNATIONAL

Materials and methods The materials used in this study were pure titanium and shape memory alloy. For comparison, stainless steel (JIS SUS304), currently used in the dental field, was also used. Round wires with diameter d0 in the range of 0.6-0.8 mm in steps of 0.05 mm were prepared. After the wire samples were annealed, the wires were drawn using a cemented carbide rectangular die, as shown in Fig. 1. The die half angle was set to be ι= 13°, on the basis of the results obtained by Y. C. Kim7 as well as the authors8. Because the obtained wires are assumed to be used as orthodontic wires, the dimensions were width W = 0.63 mm, height h = 0.43 mm and corner R = 0.1 mm. Table 1 summarizes the reduction per pass values applied for sample wires. Fig. 3 shows the stress-strain diagram for annealed pure titanium, Ni-Ti shape memory alloy and stainless steel wires, obtained during the tensile test. The stress-strain curve for Ni-Ti shape memory alloy wire is complicated and indicates a two-step yield. Breaking strain is one factor that makes it possible to judge the level of plastic workability. The breaking strain of Ni-Ti shape memory alloy wire, 1.3, is the highest among the three; however, processing this wire is difficult because the amount of work hardening is significant. The breaking strains of pure titanium and stainless steel wires were 0.3 and 0.6, respectively. As a method of obtaining shaped wires with high dimensional accuracy, multipass drawing is one option. However, in this study, a wire with a rectangular cross section was obtained from a wire with a round cross section

by one-pass drawing to reduce the processing cost. Because the drawing of a wire with a round cross section into a wire with a differently shaped cross section involves a complicated deformation, the drawing process was analyzed by FEM. The FEM code used in this study was commercially available MSC.Marc2005.

Experimental results and discussion FEM examination of characteristics of drawn shaped wires. Knowing the dimensional accuracy, processing strain and residual stress before drawing is extremely effective in controlling shaped drawing. The cross-sectional shape, equivalent strain distributions and drawing limit of the wires, which were obtained by drawing under various reductions per pass (R/P), were calculated by FEM. See Fig. 4. It was found (see Fig. 4) that strain in the height direction is high, while strain in the width direction is negligible when the reduction per pass is small. When a round wire is shape-drawn into a rectangular wire, the material in the height direction is flattened in the width direction to form a rectangular cross section. Therefore, the magnitude of reduction per pass has an effect on the dimensional accuracy. On the basis of the analysis results, it was confirmed that the drawing limit of the pure titanium wire is 48% when the reduction per pass is 32%. With increasing reduction per pass, both dimensional accuracy and equivalent strain increase. Effect of reduction per pass on dimensional accuracy wires. Test wires with a diameter d0 of 0.6-0.8 mm and composed of one of the three materials were drawn using the rectangular die shown in Fig. 1. The drawing limit and cross-sectional shape of the drawn wires were evaluated. The drawing limits for Ni-Ti shape memory alloy, pure

Fig. 3. Mechanical properties of annealed wire in tensile test. Fig. 4. Profiles and equivalent strain distributions of drawn shaped wire by FEM. OCTOBER 2008 | 89


mechanical properties of the shaped wires were examined by conducting tensile tests after wires were drawn under various cross-sectional reduction per pass conditions.

TECHNICAL PAPERS Table 2. Cross-sectional shapes of drawn wires under various reduction per pass conditions.

titanium and stainless steel wires were 33%, 41% and 48%, respectively. Table 2 summarizes the cross-sectional shapes of the drawn wires for the three materials obtained under various reduction per pass conditions. As is expected from the FEM analysis results, dimensional accuracy is improved with increasing reduction per pass. To quantitatively compare the above results, the effect of the reduction per pass on the dimensional accuracy of the shaped wires ((cross-sectional area of the drawn wire, A’)/(area of the die used for shaped drawing, A)) and on drawing stress was examined. The results are shown in Figs. 5 and 6. As the dimensional accuracy A’/A value approaches 1.0, wires with better shape can be obtained. In this study, the goal was aimed at obtaining drawn wires with A’/A values of 3% or less from 1.0. Similar to the results obtained by FEM analysis, when the reduction per pass is large, A’/A values increase for the wires of the three materials. The trends of A’/A value as a

function of reduction per pass for stainless steel wire and pure titanium wire are similar. However, the A’/A value for Ni-Ti shape memory alloy wire is small; the inferior dimensional accuracy is considered to be due to the shapememory characteristic or super elastic effect of the material. The targeted dimensional accuracy can be obtained when the reduction per pass is either 32% or 41% for stainless steel wire and 32% for titanium wire. However, when the reduction per pass exceeds 32%, drawing stress becomes too large, and the wire material itself is subjected to tension, leading to inferior dimensional accuracy. Therefore, the shaped wires with the best dimensional accuracy can be obtained when the reduction per pass is 32%. Mechanical properties of shaped wires. The mechanical characteristics of wires used for orthodontic purposes are very important. Tensile tests were carried out using such drawn shaped wires.

Fig. 5. Relationship between reduction per pass and dimensional accuracy A’/A.

Fig. 6. Relationship between reduction per pass and drawing stress.


TECHNICAL PAPERS Fig. 7. Mechanical properties of three drawn shaped wire.

When the reduction per pass, a parameter indicating the degree of drawing, is increased, the tensile strength greatly increases and breaks elongation decreases for wires of the three materials. The Ni-Ti shape memory alloy wire shows higher breaking strain and tensile strength than those of stainless steel and pure titanium wires; however, sufficiently accurate cross-sectional shape is not obtained. For stainless steel and pure titanium wires, tensile strength is high and breaking strain does not decrease to the minimum value up to the reduction per pass of 32%.

Furthermore, as explained above, an accurate cross-sectional shape can be obtained even when wires are subjected to only one-pass drawing. Therefore, stainless steel and pure titanium wires subjected to one-pass drawing are promising for use in actual industrial applications. Dimples are observed in the fracture surface in the width direction (Fig.8(c)) but not in the height direction (Fig. 8(a)), indicating that the wire was subjected to brittle fracture. In shaped drawing, the shape of the fracture surface is known to differ with the degree of drawing in the height

Fig. 8. SEM images of fracture surface of drawn pure titanium wire in tensile test.

Fig. 9. Final products of orthodontic wire. OCTOBER 2008 | 91


and width directions. Therefore, wires having a diameter that can endure general reduction per pass conditions during conventional drawing may break during shaped drawing. Possibility of fabricating wires with rectangular cross section by one-pass drawing. The possibility of fabricating wires with a rectangular cross section by only one-pass drawing was examined using pure-titanium, Ni-Ti shape memory alloy and stainless steel wires. It is possible to obtain wires with rectangular cross sections of high dimensional accuracy by increasing the reduction per pass in the one-pass drawing. However, a reduction per pass that is too high may cause overly thin drawn wires and wire breakage. Also, it was found that shaped wires with high dimensional accuracy are obtained by only one-pass drawing of stainless steel and pure titanium wires. Fig. 9 shows the cross sections of the final products obtained in this experiment. It is not possible to obtain NiTi shape memory alloy wire with high dimensional accuracy by one-pass drawing because of the shape-memory characteristic or super-elastic effect of the material. It is necessary to examine the possibility of processing such wires by two-pass drawing; this will be clarified in a future study.

“Drawing of stainless shaped steel microwire of 400-600 µm size,” Wire Journal Int’l, March 2004, pp. 56-61. 3) K. Yoshida and S. Imai, “Improvement in Dimensional Accuracy of Drawn Micro Shaped Wire,” Japanese spring conference for the technology of plasticity, 2002, Vol. 53, pp. 329-330. 4) K. Yoshida, T. Shima and M. Takano, “Drawing of NiTi shape memory alloy wire using cassette roller dies,” The Proceedings of the 1989 Japanese spring conference for the technology of plasticity, 1989, Vol. 1989, pp. 163-166. 5) H. Suzuki, Plastic Working, 1980, p. 178, Shokado. 6) J. Araki and H. Suzuki, Journal of the Japan Society for Technology of Plasticity, 1971, 12-127. 7) Y.C. Kim and B.M. Kim, “A study on the corner filling in the drawing of a rectangular rod from a round bar,” Machine Tools & Manufacture, 2000, pp 2099-2117. 8) K. Yoshida and M. Maejima, “Optimum drawing conditions for shaped micro wire of 100-400 μm side,” Advanced Technology of plasticity, pp. 449-450, 200. ■

Conclusions Using pure titanium, Ni-Ti shape memory alloy and stainless steel wires, the shaped drawing of wires used mainly in the medical field was studied. The possibility of fabricating wires with a rectangular cross section and increased dimensional accuracy was examined by FEM analysis and conducting experiments. The following results were obtained: • upon increasing the reduction per pass, the dimensional accuracy of the shaped drawn wires increases; • the drawing limits and equivalent strain distributions of the three wires were examined by FEM analysis and conducting experiments; • the cross section of the Ni-Ti shape memory alloy wire subjected to one-pass drawing is roundish and its dimensional accuracy is poor because of the shape-memory characteristic and super elastic effect of the material itself; and • the dimensional accuracy and mechanical properties of the stainless steel and pure titanium shape-drawn wires are good even when they are subjected to one-pass drawing at a reduction per pass of approximately 32%.

Acknowledgments The authors thank Shinko Wire Co., Ltd. and Furukawa Techno Material Co., Ltd., for their valuable suggestions.

References 1) M. Miyagi, “Medical application and biocompatibility of TiNi alloy,” J. Japan Inst. Metals, Vol. 24, No. 1, pp. 6974, 1985. 2) K. Yoshida, D. Sriprapai, T. Shinohara and T. Imai,


Kazunari Yoshida is a professor of precision mechanics at the school of engineering at Tokai University, Japan. He researches wiredrawing, extrusion and forging processes and has served as a member of the steering committee for Japanese Wire Drawing. He holds a Ph.D. degree in engineering. He authored a prizewinning paper for the Japan Society for Technology of Plasticity in 1984 and won medal awards from the Wire Association International, for the best nonferrous paper in 1999, 2001, 2003 and 2004. Miki Matsunaga is a graduate student in mechanical engineering at Tokai University. This paper, which was presented at WAI’s 77th Annual Convention, May 2007, Cleveland, Ohio, USA, won the Silver Certificate Award in the nonferrous division.




TECHNICAL PAPERS FEM simulation of wire fracture phenomena during multi-pass drawing An analysis of two different software packages for analyzing the fracture processes during a wiredrawing test run have found that both show similar results for the influence of die angle and friction coefficient.

By Andriej Milenin, B.P. Gautham, Sharad Goyal, Jan W. Pilarczyk and Zbigniew Muskalski

Prediction of wire fracture in a drawing process of steel wires is very important from theoretical and practical point of views. Criteria proposed by Avitzur1, Wright and Yoshida2 allow for a prediction of the possibility of central bursts. However, these take into account only a few parameters of drawing, such as the die angle and reduction ratio. These criteria do not consider the estimation of a risk of fracture in other locations in a deformation zone during

drawing. It is also not possible with the above-mentioned equations to determine a risk of central bursts formation in multi-pass situations and also when drawing with different drawing directions. Muskalski3 found that altering a drawing direction has a negative effect on the fatigue strength of wire and significantly influences the state of stress and strain. It is interesting to study whether the risk of fracture in the outer layers is higher than it is near the central axis of the wire and if altering the drawing direction influences this risk. A recent work by Gautham, et al4 predicted wire breakage through a triaxiality parameter defined as the ratio of pressure (hydrostatic component of the stress state) to a flow stress of the drawn material, which can be assumed as a good indicator for the wire breakage in a deformation zone. They computed the triaxiality factor using an FEM based code they developed. Milenin5 used the fracture phenomena derived using the theory of fracture by Kolmogorov6 and Bogatow7. This approach uses a parameter called â&#x20AC;&#x153;resource of plasticity.â&#x20AC;? In this paper, FEM analysis has been performed of a drawing process with two FEM codes, one developed by Milenin5 and the other by TRDDC, Pune8. The risk of fracture in a deformation zone has been esti-

Fig. 1. Dependence between critical deformation and triaxiality factor.

Table 1. Chemical composition of steel GD76A.

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Table. 2. Schedule of reductions drawing a 4.00 mm wire down to 1.70 mm

Fig. 2. Geometrical parameters of drawing process.

mated using a distribution of the above-mentioned indicator for two high-carbon steel drawing processes: conventional and hydrodynamic. A 4 mm steel wire (GD76A grade) was drawn to 1.70 mm in six passes. Values of friction coefficient were assumed to be equal to 0.006 for hydrodynamic drawing and 0.07 for conventional drawing. The draw speed was equal to 1.6 m/s in all passes. This work compares the two above-mentioned fracture criteria using different FEM based codes during multi-pass drawing. Drawing2d software The FEM code Drawing2d was developed by Milenin5. In this FEM model a boundary value problem has been solved considering other phenomena: plastic deformation, heat transfer and wire heating due to deformation and friction. In the model, the strain tensor distribution obtained in the previous pass is transferred to the next one. A change of the drawing direction is also possible in the elaborated software. For obtaining the solution of the boundary problem, the variation principle of rigid-plastic theory is used:

Table 3. Parameters of drawing and parameters of fracture model prediction in 6th pass (ψ6, K6)

Eq. (1) where: σs = yield stress, ξi = the intensity of strain rate, V = volume, σ0 = mean stress, ξ0 = volumetric strain rate, F = the metal contact area with the die, στ = the stress of the friction and vτ = the metal slip velocity along the surface of the die. The components of the deformation tensor εij are calculated through integration of each component of the strain rate tensor along the flow line: Eq. (2) where: Δτ(k) = the current time increment and ξij(k) = the values of the components of the strain rate tensor determined according to the follow equation:

Eq. (3) Fig. 3. The flow curves of a steel GD76A and it approximation by equation12.


where: N = the finite element shape functions, ξijn = the nodal values of the components of the strain rate tensor for

TECHNICAL PAPERS Fig. 4. Comparison of center line triaxiality for Pass 4.

Fig. 5. Comparison of different criteria for maximum failure in Pass 6.

the current finite element and nnd = the number of nodes in element. A determination of the next points of the flow line is based on the calculation of the components of metal velocity for current point k per the follow equation:

ty ψ is > 1, the material will experience fracture. The function εp (k, μσ) is obtained through experiments. Bogatow proposed the following form for this function:

Eq. (7) Eq. (4)

and the integration of coordinates:

where α1 = empirical coefficients for steel. If the deformation process is multistep, then Eq. (6) is describe by the following:

Eq. (5) Eq. (8) The flow lines are estimated as described above, which allows easy visual analysis of the deformation state during the drawing processes. The boundary problem was solved as non-isothermal. Fracture theory: Kolmogorov and Bogatow This theory was developed especially for metal working processes such as drawing. A detailed description of this theory can be found in literature6-7. The main concept of the fracture theory described above is as follows. The key parameter representing fracture is called “resource of plasticity” given by the following equation: Eq. (6) where ψ = the resource of plasticity, εi = the intensity of deformation in metal working processes and εp = the critical deformation before fracture of metal as a function of the triaxity factor

and the Lode coefficient where σ = mean stress and σ1, σ2, σ3 = the principle stress components of the stress tensor. If the resource of plastici-

where ξi = the strain rate and τ = the time of deformation. The FEM code Drawing2d uses integration procedure along the flow line (2) to evaluate the above integral. This results in:

Eq. (9) where: Δτ(k) = the current time increment, ξi(k) = the values of the strain rate in the current time and k = is a time step during integration along the flow line. For axisymmetric deformation (as drawing of wire) the Lode coefficient is equal to zero. Therefore, one can propose a more simple equation for calculating the resource of plasticity: Eq. (10) and and an equation for the εp (k, μσ) function: Eq. (11)

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TECHNICAL PAPERS Fig. 6. Result of calculated recourse of plasticity (a) and triaxity factor (b) for 1th pass case 1 in Table 3.

Fig. 7. Result of calculate the recourse of plasticity (a) and triaxity factor (b) for 6th pass variant 1 in Table 3.


TECHNICAL PAPERS Fig. 8. Result of calculated recourse of plasticity (a) and triaxity factor (b) for 6th pass case 2 in Table 3.

The empirical coefficients of Eq. (11) were determined by fitting the experimental results presented in the literature6. See Fig. 1. TRDDC model. The model developed by TRDDC8 is based on an updated Lagrangian formulation and uses an elasto-plastic material model that takes into account the thermal effects due to plastic deformation, frictional heat and loss to die and interpass equipment. The incompressibility and hydrostatic component of the stress is handled through selective reduced integration. The fracture criteria used is the triaxiality factor.

Numericals Simulation. Here, a steel wire, grade GD 76 A according to Polish standards, used for mining hoisting ropes (first class) has been considered. The chemical composition and the schedule of total and single reductions are shown in Tables 1 and 2. Two cases of friction coefficient 0.006 (hydrodynamic drawing) and 0.07 (conventional drawing) are considered in the analysis. With two cases of semi-cone angle of the die (4° and 9°) the complete list of cases considered is given in Table 3. The die angle and other geometrical parameters of model are shown in Fig. 2. The flow curves of a steel GD76A are shown in Fig. 3. These data were approximated by the following equation:

Eq. (12) where t = the temperature in Celsius. Verification of triaxiality factor calculation. The comparison of the triaxiality factor obtained by the Drawing2d code and the TRDDC code for the above four cases at Passes four and six are discussed in this section. The center line triaxiality factor (k) for the fourth pass is shown in Fig. 4. It can be seen that both models show a similar trend with lower “k” values for lower die angles and lower friction. The trend is as expected. However, the quantitative difference is significant. A comparison of maximum triaxiality factor and “resource of plasticity” for Pass six is shown in Fig. 5. As in the case of center line triaxiality, here too the models predict similar trends, but the magnitudes are different. The match of trends between the triaxiality predicted by the TRDDC model and the resource of plasticity predicted by Milenin are in better agreement. Contours of recourse of plasticity and the triaxiality factor for the first and sixth passes for cases one to four per Table 3, calculated by Drawing2d, are shown in Figs. 6-10. Both models show significantly varied magnitudes of triaxiality, but predict similar trends on the effect of die angle and friction. The triaxiality differences could be due to the ways the models predict hydrostatic components under near incompressible plasticity conditions.

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TECHNICAL PAPERS Fig. 9. Result of calculated recourse of plasticity (a) and triaxity factor (b) for 6th pass case 3 in Table 3.

Fig. 10. Result of calculated recourse of plasticity (a) and triaxity factor (b) for 6th pass case 4 in Table 3.


Conclusions The theory of damage, implemented into FEM code Drawing2d, makes it possible to analyze the fracture processes during wiredrawing. The model predictions of Drawing2d and TRDDC model have similar trends, though different in magnitudes. The increase the angle of die significantly increased the value of factor ψ. Friction coefficient has similar effects. References 1. B. Avitzur, “Handbook of Metal Forming Processes,” 1983, John Wiley & Sons, Inc., New York. 2. Krnac J., Kruzel R., Pilarczyk J.W., Golis B.: Criteria of central bursting- experimental verification. Wire Journal International, December 2006, pp. 59-64.

Andriej Milenin is a professor in the Department of Applied Computer Science and Modeling at AGH University of Science and Technology, Krakow, Poland. He is the author or co-author of more than 200 papers. B.P. Gautham leads the deformation processing activities at Tata Research Development and Design Centre, a division of Tata Consultancy Services Ltd., Pune, India. His interests include deformation analysis in metal forming and solidification. He has worked closely with various industries in enhancing manufacturing processes including quality, productivity, and energy. He holds a Ph.D. degree in applied mechanics from the Indian Institute of Technology – Chennai. Sharad Goyal, who has been a scientist at Tata Research Development and Design Centre since 1998, researches deformation processing and finite element analysis. He holds an MS degree from the Indian Institute of Technology, Kanpur. Jan W. Pilarczyk is a professor in the Department of Materials Processing Technology and Applied Physics at the Czestochowa University of Technology, Poland. He works on the development of new technology for wiredrawing and metal products. He is the author or co-author of more than 170 papers. He is president of Poland Chapter of WAI. Zbigniew Muskalski is an associate professor and vice dean in the Department of Materials Processing Technology at the Czestochowa University of Technology.ce, Poland. He is the author or co-author of more than 120 papers. This paper was presented at the WAI’s International Technical Conference, Bologna, Italy, November 2007.

3. Z. Muskalski, “The influence of drawing direction of fatigue durability of high carbon rope wires,” Wire Journal International, December 2003, pp. 61-63. 4. S.K. Singh, B.P. Gautham, S. Goyal, A. Joshi and D. Gudadhe, “Development of a virtual wire drawing tool for process analysis and optimization,” International Technical Conference, November 2006, New Delhi, India, Wire Association International. 5. A. Milenin, “Program komputerowy Drawing2d – narzędzie do analizy procesów technologicznych ciągnienia wielostopniowego,” Hutnik, No. 2, 2005, pp. 100104 (in Polish). 6. V. Kolmogorov, “Mechanika obrabotki metallow dawleniem,” Moscow, Metallurgy, 1986 (in Russian). 7. A. Bogatow, “Osobennosti reologiczeskogo povedenija i razruszenija metalla pri monotonnoj i znakoperemennojdeformaciji.” Plasticzeskaja deformacja stalej i spławów, Moscow, 1996, pp.. 90-98 (in Russian). 8. B.P. Gautham and S. Goyal, “Optimization of wire drawing operation,” TRDDC Report 2005. ■






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An analysis of the results shows that the last (fourth) variant in Table 3 has the maximum probability to damage. The increased die angle significantly increased the possibility of failure. The friction coefficient has similar effects.

View exhibits. Find a company. Look for supplies. Consult. Buy wire. Visit early. All available. All Discover: More than reels.

Build a booth. List your business. Market products. Consultants. Sell cable. Visit often. All of the time. online. Real.

A VIRTUAL TRADE SHOW is the official web site of 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:


PRODUCTS & MEDIA PRODUCTS Spooler can process 6 spools a minute Windak announced that its new generation, high-speed fully automatic spooler, model SW6, has shown it can process cable at speeds of up to six 100 m spools per minute. The spooler, designed for a maximum output of six spools/min (100 m), has a guarantee of at least five spools per/min (100 m), notes Windak Sweden Managing Director Urban Bollo. “To the best of our knowledge, the SW6 is the fastest 100 m cable spooler in the world,” he said. A press release explained that one obstacle to achieving 6 x 100 m spools/minute had been the loading/unloading cycle time. “Windak’s new dual lift system, it said, allows for cycle times of less than 10 seconds. With short cycle times and a stop time of less than one second, the SW6 is truly optimized for in-line production of spools 165 mm (6.5”) OD x 90 – 200 mm (3.5”- 8”) wide,” it said. Contact: Windak AB, tel. 46-8-580-38930, or Windak Inc. (U.S.), tel. 828-3222292,

Interconnect cables can support the latest kinds of HD technologies U.S.-based Coleman Cable. Inc., has introduced SignalPlus™ high performance interconnect cables, a series of cables constructed to support the latest HD technologies including component and composite video, HDMI, HD audio and Toslink®. A press release said that the UL-listed cables, available in lengths of 1, 2, 3, 5, 10 and 15 meters, feature 24k gold-plated connectors, extra flexible jacketing, durable strain relief and oxygen-free copper conductors for superior connectivity and signal transfer.


“We went all out to produce the highest quality cables in the market place,” said Coleman Cable National Accounts Manager Bob Bennish. “Our extra durable products are perfect for in-wall applications including 1080p over HDMI up to 65 feet.” Contact: Coleman Cable, Inc., tel. 847-672-2300,

Cabling assembling line offers quick means for producing UTP cables Gauder Group reports that the high-speed “Quali2Twist” assembling line for LAN cables, offered by its Setic business, is capable of production speeds two times the capacity of a conventional single twist laying-up line. During a recent demonstration (see p. xx), the system operated at speeds of up to 1600 tpm, a press release said. At the presentation, the system assembled several different types of cables, from a standard solid PE Cat. 5e UTP to a FEP Cat. 7 FTP with mylar/Al tape, it said. The release noted the following about the Setic system: The line produces cable with the quality and consistency of those made on a traditional single-twist machine, but at speeds closer to a double-twist system. However, unlike the standard double-twist process, there is no cable geometry modification after the assembling point. Impedance is very stable and NEXT level is an extremely low at 250H Mhz. This single-twist type quality is achieved by a very specific guiding system along the wire path inside the cabler, which enables the cable to move freely without friction, thus allowing final cable assembly to be done at the closing die (before the cabling machine itself). As a result, cross fillers, tapes and binders can easily be used at very high production speeds. Contact: Gauder Group,

Indoor/outdoor plenum compounds reduce need for fiber optic connections Teknor Apex Company plans to introduce an indoor/outdoor FIREGUARD® plenum compounds at IWCS that it said can eliminate many of the optical fiber connections in plant and campus installations. New formulation technology for FireGUARD low-flame, low-smoke plenum compounds makes it possible to have continuous indoor/outdoor (I/O) optical fiber cables, a press release said. The I/O RoHS-compliant formulations provide the UV resistance and anti-microbial properties

Technology represents new approach to controlling extrusion material usage Switzerland’s Maillefer SA reports that its new technology, called Cinegran, represents “a completely new approach in reliable control of extruder material consumption or that of a dosing unit.” Thanks to immediate optical measurements, feedback on material throughput is very reactive, even during start-up phases and speed transitions, a press release said. The system, which has a compact camera housing positioned just below the material feeding hopper, measures granular movement within the dedicated feeding column, it said. The Cinegran system foresees the unexpected, such as a break in material supply, a feeding blockage or throughput variations, the release said, noting that it “immediately detects the event and reports back with a descriptive alarm.” The system, which can be used with most polymers (PE, PA, PVC, TPU, FEP, etc.), is appropriate for all but very soft materials or fine polymer powders, the release said, adding that for mass throughput measurement, the Cinegran G model is recommended. From one to three apparatus can be integrated into the 12inch touch screen monitor provided, the release said. Cinegran is delivered with a standard configuration for any specified Maillefer MXC extruder, the release said. Throughput starts at 100 g/h up to 2,000 kg/h, depending on the model. Contact: Maillefer SA,

Improved strain relief helps make for better conductor termination points U.S.-based C&M Corporation reports that its engineers have designed a hard/soft strain relief that eliminates all stress and strain from the electrical conductors’ termination points. This new design, a press release said, is engineered with an anti-twist function as well as the elimination of the pistoning action of conductors inside the cable jacket at the termination point of an assembly. The hard/soft strain relief is designed to meet or exceed the straight pull test of its corresponding cable and connected assembly. The weighted 180° tick-tock flex tension testing has successfully achieved 750,000 cycles, it said. Through in-house molding technology capabilities, C&M matches the contours of the assembly attachment area, making the interface both secure and esthetically pleasing, the release said. It noted that the unique strain relief can be produced in PVC (and its alloys), polyurethane, TPR, and other materials as well. Contact: C&M Corporation, tel. 860-774-4812,,

Strander has multiple applications A planetary cage strander from Italy’s Cortinovis Machinery SpA, has multiple applications and can be used for a range of products. A press release said that the system, which can process steel wires or strands up to 8 mm in diameter, can be used for armoring energy and communication cable with steel wires, stranding steel wires to produce strand, and closing steel strands to produce ropes. The machine, which is supported on bearings, has a very modern design, with cages for bobbins up to 630 mm. An under roller design is used when the size of the cage requires a distributed system of supports. Different technical solutions are applied on the basic machine, with the target of robust, reliable and “operator friendly” construction, it said. The system provides: total back-twist, with a simple and reliable detorsion ring that makes it possible to work in

OCTOBER 2008 | 103


required for outdoor exposure without tradeoffs in the physical, electrical, and flame and smoke properties available with standard FireGUARD grades, said Mike Patel, industry manager for the Vinyl Division of Teknor Apex. The new formulations are available for all FireGUARD compounds used as jackets in optical fiber cable applications, he said. “In large corporate or institutional settings, FireGUARD I/O compounds for optical fiber cables withstand exposure to solar UV, fungus, and water while passing the rigorous tests for flame and smoke performance required to ensure indoor safety,” Patel said. “Continuous cabling enables installers to avoid the added time, hardware, and cost for connecting outdoor cable to indoor at the point where it enters a building. This translates into large savings in complex installations like university campuses.” Contact: Teknor Apex Company, Vinyl Division,


torsion, typical for armoring with steel flat wires; partial back-twist, given with a separate motor and transmission with pulleys and belts, for applications in the steel industry for production of strands and ropes; and a modular design that allows different sizes and number of bobbins. With one version, the under-roller cage can handle larger sized bobbins, from 710 up to 1000 mm in diameter, while a second version has a rigid rotor design, with reliable supports made with roll bearings, easy alignment and maintenance-free rollers. Contact: Cortinovis Machinery America, Inc., tel. 908-479-9818;,

TPEs meet stringent UL fire criteria The Thermoplastic Elastomer Division of U.S.-based Teknor Apex Company plans to introduce a new class of thermoplastic elastomer (TPE) compounds at IWCS that it reports meets stringent UL criteria for fire retardance while providing flexibility and toughness over a broad temperature range. Part of the company’s Elexar® product range, the new TPEs, available with hardnesses from Shore 56A to 90A are recommended for insulation, jackets and molded parts for flexible cords, coil cords, and cables in power tools, appliances, industrial robots, welding equipment, and entertainment audio and lighting systems, a press release said. “The breadth of applications for which the new Elexar compounds are well suited is unique among TPEs for wire and cable,” said Phil Scadding, market manager. “Besides providing enhanced flame retardance, these compounds deliver excellent performance at temperature extremes and in outdoor environments, exhibit rubber-like flexibility, are oil-resistant, and are available in a broad range of hardnesses.” Key characteristics cited by Scadding include that the RoHS-compliant TPEs: deliver excellent fire retardant performance without use of polybrominated diphenyl ether (PBDE) flame retardant; have enhanced flame retardance, meeting UL94 V-0 flame test requirements, among others; have a broad service-temperature range, able to be used from -50°C to 125°C; have good electrical properties, with a dielectric constant of 2.4 and minimal dissipation losses, making them good for low- to medium-voltage wire and cable applications; and have good oil-resistant resistance. Contact: Thermoplastic Elastomer Division, Teknor Apex Company,


Reel line expanded via investments Slovakia’s GMP-Slovakia, represented in North America by Canada’s Howar Equipment Inc., has expanded the range of reels that it offers. A press release said that GMP-Slovakia has invested in specialized machinery for the production of the corrugated flanges, using automated equipment. That, it said, has enabled the company to supply such reels in sizes from 1000 mm – 3600 mm (39 in. – 144 in.) in various material thicknesses up to 5 mm (0.196 in.). The reels are customized based on customer requirements, by adding smooth inside flange walls, and additional drum supports, the release said. It noted that the reels have lateral structural members for high rotational forces being applied by drum twister applications, with optional special replaceable arbor bushings to reduce maintenance on the reels. In North America, Howar Equipment reports that it is supplying these reels to numerous customers, in conjunction with its ability to assemble the reels locally for efficient costs and delivery times. Contact: Howar Equipment Inc., tel. 905-738-4010,,

Company introduces high performance line of flexible motor supply cables Alpha Wire Company announced that it has extended its high performance XTRA•GUARD™ product range with the addition of flexible motor supply cables. The new cable, which complements the company’s existing, high-performance, Variable Frequency Drive (VFD) product line, is ideally suited to motor and drive applications requiring small outer diameter, flexibility and ease of handling, a press release said. It added that the cable, designed to be more flexible, smaller and less expensive than the VFD cables, also offers as superior EMI/RFI shielding options using the company’s SUPRASHIELD® technology. The new motor supply range has a round geometry to facilitate environmental sealing, while the symmetrical design improves the electrical performance allowing the cable to exhibit uniform bending characteristics, the release said. The RoHS-compliant cables have PVC nylon tape, four symmetrical drain wires and a specially formulated oilresistant PVC jacket, making them extremely durable in the most demanding of envi-

Wire stripper can process film-type kinds of insulation from fine wires The Model RT2S magnet wire stripper from U.S.-based Eraser Company will strip most film type insulations including Formvar, ML, enamel, varnish, isonel and more, from fine wires. Multiple wires may be stripped in one operation. The conical brushes rotate at high speed to generate frictional heat which softens the insulation on the wire. The “nap” of the brush wipes this insulation away. Stripping is quick and safe

with no risk of contaminating the wire conductor. The stripping head is enclosed for operator safety. A strip length stop produces consistent strip lengths. Machine set-up is simple. A dust take off port is incorporated into the machine. Model RT2S also cleans and polishes leads of small electronic components and removes oxidation and other contaminants from leads as small as 0.0012” (.03 mm) diameter with no risk of deforming or nicking the lead. Contact: The Eraser Company, Inc., tel. 800-724-0594 or 315-454-3237,, www.eraser.jpg.

MEDIA On-line brochure describes software company’s vision, processes A brochure from Germany’s Simufact Engineering GmbH describes the range and vision of the software company’s vision for manufacturing. The on-line brochure, which can be found at, notes that the company’s software for manufacturing processes

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.

Tel: 703-365-2330

OCTOBER 2008 | 105


ronments, it said, noting that the cables are available in gauge sizes from 16 awg to 6 awg, with larger custom cables available on request. The new range meets a plethora of safety and installation ratings and has an ·operating temperature range of -20°C to +90°C for static applications. Contact: Alpha Wire Company,


is designed and optimized with the help of process simulation. It also notes that it cooperates “with all industrial sectors, from manufacturers of semi-finished products, tool designers and machine vendors up to the manufacturing shops. In these sectors we deal with a variety of problems, e.g. extrusion processes with integrated tool analysis, forging and rolling of defined and free shapes, deep drawing processes in all dimensions up to mechanical and thermal joining. Neither the dimensions of the workpiece nor the process parameters are a limitation for us.” The company notes that it handles “a variety of manufacturing technologies of metal forming as well as mechanical and thermal joining processes.” Contact: Simufact Engineering GmbH,


Increase Productivity! Improve Throughput! Optimize Product Quality! When you need expert solutions for your Wire & Cable Extrusion Processes, you need Canterbury Engineering. Canterbury’s vast design and manufacturing capabilities offer a complete line of custom designed Crossheads, In-line Heads, Screws, Barrels, Breaker Plates and more. Plus, Canterbury offers the best in Rebuilds, Relines, Repairs, and all OEM Replacements. For more information, contact Canterbury at 1-800-241-7650, or online at


Literature outlines compounds line U.S.-based Sylvin Technologies, Inc., a custom vinyl compound manufacturer, has published a new quick reference literature guide designed to enable customers to quickly find a specific compound for their application. The literature cites a list of the wide range of vinyl compounds available for wire and cable, injection molding, profile extrusion, electrical molding and FDA applications. The Sylvin compounds listed in the literature are all RoHS compliant and numerous compounds are UL and CSA listed, a press release said. All Sylvin compounds, it noted, are available in quantities as low as 50 pounds up to truckload quantities. The company notes that, with more than 30 years of meeting and exceeding customer’s expectations, Sylvin Technologies is a leading manufacturer of flexible to semi-rigid vinyl and vinyl alloy compounds. It offers a full line of standard and custom formulations for a variety of markets such as wire and cable, automotive, industrial, toys and building products. Contact: Sylvin Technologies Inc., tel. 717-336-2823, ■

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

POSITION SOUGHT ELECTRICAL/MECHANICAL ENGINEER with 22 years’ extensive manufacturing experience seeks a southern regional sales position with ability to work from home office. Excellent communication skills, above average computer skills including Cad and PLC programming. Experience includes: equipment design and fabrication; management of engineering department, quality department and programs; equipment manufacturing. installation and commissioning; and process engineering in various plastic industries, specializing in wire and cable processes. Contact: Resume7676

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. PAYMENT POLICY: All ads must be pre-paid. 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.

in the production of musical instrument strings. The position will require extensive knowledge and experience with the production, procedures and technology associated with wire production, coupled with a thorough understanding of machinery and equipment capabilities. The ideal candidate will possess excellent interpersonal and problem solving skills, along with the ability to succeed under limited supervision.

• Oversee the sourcing of high quality, economical raw materials.

This role also requires the ability to work effectively with others to accomplish defined production and quality goals on a timely basis.

• Directs all R&D projects related to raw material and finished wire quality and consistency.

Major Responsibilities: • Direct the scheduling and production of inventory for customer orders.

• Monitor and track daily production and quality reports. • Organize and maintain documentation of all procedures and work rules related to wire drawing, straightening and plating operations, as well as quality specifications.

• Oversee inventory management, bills of material, purchasing, customer service, accounts receivable/payable, etc.

CAREER OPPORTUNITIES GENERAL MANAGER. Renaissance Wire, a high-carbon steel wire manufacturer, located just outside of Worcester, MA, is seeking a General Manager. The position will be responsible for overseeing the day- to-day operation of a 15,000 square foot production facility, serving both domestic and international customers. The Manager will direct and coordinate the drawing, straightening and plating of round & hexagonally shaped high carbon steel wire predominantly used

Serving the non-ferrous and ferrous industries since 1983

OCTOBER 2008 | 107






























(Applies only to Position Wanted )

• Handle all personnel related issues

training preferred.

• Interface with ownership, regarding financial and management reporting requirements.

• 3-5 years experience in wire manufacturing and/or related Management.

Qualifications: • Lean Manufacturing background/

• BS in Mechanical and/or Metallurgical Engineering; or equivalent training and experience.


FOR SALE 1 1 1 3 1 2 1 1 1 1 1 1 1 1 1 1 1

NEB 64-Carrier CB-1 Cabler Braider WATSON 36” Rotating Cabler Line NORTHAMPTON ST1000 Cabler, 1999 NORTHAMPTON 630mm Cablers/Bunchers - CEECO 6-Bobbin 60” Closer - MGS Model LC50 Caterpuller Capstans - NIEHOFF M15 Wire Drawer, Annealer, SG45 Spooler - D/S 4.5” 24:1 L/D Extruder, 200HP Motor, 1999 - D/S 100mm 24:1 L/D Extrusion Line, 1998 – D/S 3” 24:1 L/D Extruder - D/S 2.5” 24:1 L/D Nylon Extruder - D/S 2” 30:1 L/D Hi-Temp Extrusion Line - D/S 1.25” 30:1 L/D Hi-Temp Extruder - D/S 2” 24:1 L/D Extruder - D/S 36” H.S. Dual Reel Take-up, twin Motors - CLIPPER PS36 Parallel Axis Dual Reel Take-up, 1999 - 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 1 - BARTELL 72” Shaftless Take-ups 1 - DAVIS ELECTRIC 36” Shaftless Take-up, Model TUS36 3 - TULSA/KENRAKE Model WTR-656 Respoolers 2 - TEC Model 24STC Hi-Speed Twisters, rated 1300rpm 1 - ADVANTAGE Chiller, Model MK-25AM41HBX, 9/98 1 - NEW ENGLAND BUTT 60” Dual Wheel Capstan Assembly 1 - SCHLEUNIGER OS9400 OmniStripper, 1999 1 - SCHLEUNIGER CPS1500 Coiler 1 - SCHLEUNIGER WS500 Wire Stacker 1 - RAYMOND 3000lb Stacker Forklift 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: • E-MAIL:



Please e-mail the re uested in ormation to: WAI s Cindy irmss at c irmss For more details, you can call her at 2 - -2 , ext. .

• Computer skills- Microsoft Word, Excel, Mapics MRP System We offer competitive compensation and benefits, including an excellent 401k and Pension Plan, along with the opportunity to build a career with one of the most highly regarded organizations in the industry. For immediate consideration, please email your resume and salary requirements to or apply online at EXTRUDER OPERATING TECHNICIAN: Individual will be tasked with the set up and operation of extrusion lines used in the insulation and jacketing of wire and cable. Additionally, this individual will have the benefit of being employed by a long established family owned company based in sunny southwest Florida. All interested candidates should submit resumes and cover letters inclusive of salary requirements by e-mail to S A L E S AG E N T: E s t a b l i s h e d Stainless Wire and Shaped Wire company looking for commission sales representatives in Ohio, Western PA and in Chicago region. Will be responsible for maintaining established accounts, as well as, generating new business. Please respond to Box 10-1. MANAGER. A very large cable Manufacturing multi-national company, is seeking a Manager MV/HV/EHV, having in-depth know-how of the or Wire Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-6223000 or 800-394-WIRE.



“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.

Interested to acquire a medium size company operating in USA/Europe in the non-ferrous conductor industry, essentially into copper/copper alloys/ nickels/nickel alloys/bimetallics/ compensating alloys/precious metals & the like. Will be interested in outright purchase or equity partnership with operating exposure .Currently we have two operating plants manufacturing copper & copper alloy products. Please contact Box 10-3.

E-mail Peter Carino or Jack Cutler


100 Franklin St., Bristol, CT 06010 USA Phone: 860-589-2900 Fax: 860-589-0863 email:

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 • (5) Wire Lab Model 310 Descalers, reverse bend WIRE DRAWERS: • Vaughn 6/7HIV, 6 block, 7 die; start .130"-.142"; finish .045"-.036"; 6x15HP motors • Frigerio 12- block, model Rt680/9-Rt600/3; 9x680x114.5kw ea blk; 3x600x58.5kw ea blk; start 8mm hi-l.c., finish 1.0-2.6mm; 18M/sec; year 2000; excellent • Tecno Impianti 8 block; model BTR560-8; inlet 7mm, outlet 2.1mm; 560mm block dia; 25M/sec.; air-water cooled blocks; twin payoffs; descaler; spooler; electrics; 1990 • Vaughn model 5HRM w/30" Deadblock; (5) 40/50/69HP motors; (4) 26" blocks; start: .280" S.S.; PLC controls; excellent • 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: • (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 Micro J5S, .060"-.250" BAG-BAR TIE MACHINES: (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 MESH WELDERS: Hurricane Hinge Joint Fence Machine model HJL55"; 11 line wires, 6"-12" stay; completely rebuilt 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: Vitari V-23; .150"-.251" wire dia.; 1-5/8" to 8" nail; 220NPM -Wafios DSC-29 Fence Staple Machine; .070"-.196" wire dia; 2" staples (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

DIES 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 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. MACHINERY NAIL PLANT FOR SALE. Wafios N3 (1) N4 (1) N5 (3) N6 (1) YT3 (2) YT4 (1). Collated Nails: Zeus high Frequency coil welder (1); Willy Heiff Plastic strip (3); Nail Threaders (3); 50 lbs packaging line with case erector; Wafios Tool Grinder (1); Nail Tumbling (1); Racking system 500 skids (1). Call: J-M or M-A Perron # 450-447-5000 ext: 24 or 23. WWW.URBANOASSOCIATES. COM. For New & Used Wire & Cable Equipment. Tel. 727-863-4700; fax 727-863-4711; or by e-mail at urbassoc@ BEST WARRANTY-LOWEST PRICES on high quality Rolling Ring Traverses. YR Products, phone/fax: 708-672-5007 or e-mail kamoline@ FOR SALE. A complete line for netting, WAFIOS VDF-80, in excellent mechanical condition and still working. Line includes: • electrical clutch; • table length of 2250 mm; • tools for mesh, 50 mm & 60 mm; and • electrical cabinet. Price - 35,000 Euro, exfactory packed in a container. Photographs emailed upon request. Chavmal Co Ltd., Tel: 972-4-8726161, Fax: 972-4-8492776, email: ■



OCTOBER 2008 | 109


product who can lead a team to reach the objective and goals. Engineers having experience from Scratch to the Managerial Level can apply to Box 10-2.


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

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

ACM/Howar Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

GMP Slovakia/Howar Equipment Inc . . . . . . . . . . . . . . . . .71

AIM Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

HV Technologies Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

AXIS Computer Systems Inc . . . . . . . . . . . . . . . . . . . . . . .28

Howar Equipment Inc/GMP Slovakia . . . . . . . . . . . . . . . . .71

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

Howar Equipment Inc/ACM . . . . . . . . . . . . . . . . . . . . . . . .21

Amaral Automation Associates . . . . . . . . . . . . . . . . . . . . .34

Howar Equipment Inc/Metavan . . . . . . . . . . . . . . . . . . . . .78

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . .106

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Axjo Plastic AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

IWG High Performance Conductors Inc . . . . . . . . . . . . . .43

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

International Fastener Machinery & Suppliers Association (IFMSA) . . . . . . . . . . . . . . . . . . . . .37

Bomco Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .78 Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Canterbury Eng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Cimteq Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 CommScope Bimetals . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . .108 Conneaut Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Dow Wire &Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Esteves Group USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Eurolls Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31, 33 George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Fine International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Fort Wayne Wire Die Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Mario Frigerio SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Gavlick Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . . .109 Gem Gravure Co Inc . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2 Genca . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76


Joe Tools Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Kinrei of America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Leoni Wire Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Madem Reels USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . .107 Messe Dusseldorf Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Metavan/Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . .78 Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Mobac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .36 Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .59 Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 REELEX Packaging Solutions Inc . . . . . . . . . . . . . . . . . . .73 SAMP USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Sanxin Wire Die, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Sikora International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

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

Sweed Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . .46 Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 US Synthetic Wire Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Wafios Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . .111 Witels Albert USA Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . .105 Wyrepak Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41-42 WAI 2008 ITC: Monterrey, Mexico . . . . . . . . . . . . . . . . .50-51 WJI Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Virtual Trade Show . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Ferrrous Wire Handbook . . . . . . . . . . . . . . . . . . . . . . . . .112

Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 4

RECENT PURCHASES — INVENTORY HIGHLIGHTS CAT434/CAT435 - 1.6m BCA-12 Belt Caterpullers, Yr. 1998. TKU1089 - 2.6m NOKIA BTU-6 Portal Trav. Take up, Yr. 1998. EXP893/EXP894 (2) 48” D.STD. 24:1 Therm. III W.C. Ext. 150 HP DC drive. EXP895 - 6” STERLING 24:1 Extruder, 200 DC air cooled. EXP896 - 3 1/2” D.STD 36:1 Therm II, air cooled, DC drive. WRD846 - SYNCRO D13 Int Dwg w/DFH 30” Spooler EXPL319 - (2) DEANGELI/SAMP 45mm Hi Temp Lines with Zumbach Preheater, SS multipass Capstan, 560mm Dual Parallel Axis Take ups. 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. CBR997 - 2” WATSON 24 Wire Planetary Cable with Conc. Taper, 36” Dual Capstan. CBR986 (2) - ENTWISTLE SC30 Single Twist Cablers CBR995/CBR989 - 630mm MGS & TEC D.T. Twinners, NMC 800mm D.T. CBR833 - 96”/2.50m CEECO Drum Twister, 1998, Oscillator W/dual Binder. CBR981 - 760mm SAMP D.T. Buncher, BM-760D. (1995) 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.

TKU1043 -36” CLIPPER Dual Reel Take up, PS-36 Recently rebuilt. TKU1077 36” CLIPPER DR-36 Take up with caliper disc brakes, motorized traverse, AB PanelView 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. RWD466 - 96” BARTELL Shaftless Rewind Line 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 Multi Wire Line 1996. Samp MT 8.2.4.Samp R16M-8-1350 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 Drawer w/VG_30 annealer, 75 kw DC motor, controls. LATE MODEL HIGH QUALITY (BRAND NAME US & EUROPEAN) WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY EX-STOCK FROM (6) USA WAREHOUSES

OCTOBER 2008 | 111


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



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Introducing the new definitive industry resource for ferrous wire—edited by Dr. Robert M. Shemenski—and offered exclusively through WAI. • New material • 1160+ pages strong • 36 chapters long


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:

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

Savings & Quality With the Right Measuring Solution Diameter

Wall Thickness



With ODAC Laser Gauges

With UMAC /WALLMASTER Ultrasonic Scanners

s Highest accuracy,

repeatability up to .0000001 in. / 0.05 μm

s Ultra high scan rate, up to 2000/s

s Worldwide, more than 60,000 gauges sold

s Up to 8 measuring points s Up to 15,000 measurements/s

Eccentricity With ODEX® Optical/ Magnetic Gauges

s Extremely fast

- 1200 readings/s - Fast data output for FFT

s Extremely compact and

s Novel concentric

transducer adjustment allows product diameter set in a few seconds

fully static, no moving mechanisms

s Automatic inductor

Material Savings and Process Optimization s Fast Return On Investment s Most efficient solution for specific application s Superior mechanical design, efficient protection = stability s Worldwide Zumbach Customer Service and Sales Offices Zumbach Electronic AG – SWITZERLAND (H.Q.) Zumbach Electrónica Argentina S.R.L. – ARGENTINA Zumbach Electronic S.A. – BELGIUM Zumbach do Brasil Ltda – BRAZIL Zumbach Electronic Co., Ltd. – CHINA P.R. Zumbach Bureau France – FRANCE Zumbach Electronic GmbH – GERMANY

Zumbach Electronic India Pvt. Ltd. – INDIA Zumbach Electronic Srl – ITALY Zumbach Electrónica S.L. – SPAIN Zumbach Electronics Far East – TAIWAN Zumbach Electronics Ltd. – UK Zumbach Electronics Corp. – USA

We Measure Quality

control allows for installation in tight areas

Ancillary Equipment