Testing & Measuring Equipment

WIRE JOURNAL OCTOBER 2009

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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

Testing & Measuring Equipment

I W C S p r e v i ew OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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WIRE JOURNAL

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

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

CONTENTS

Volume 42 | Number 10 | October 2009

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 26 People . . . . . . . . . . . . . . . . 28 Fiber Watch . . . . . . . . . . . . . 30 Fastener Update . . . . . . . . . 32

Preview: 2009 IWCS

. . . . . . . . . . . .42

A look at the 58th Annual IWCS Conference, which will be held Nov. 8-11 at the Charlotte Convention Center.

Testing & Measuring Equipment . . . .46

WAI News . . . . . . . . . . . . . . 34 Chapter Corner . . . . . . . . . . 40

Suppliers of testing and measuring equipment present some of their technology in this feature, which also includes comments from manufacturers.

Technical Papers . . . . . . . 68-87

T ECHNICAL P APERS

Products/Media . . . . . . . . . . . 88 Classified . . . . . . . . . . . . . . 93 Career Opportunities . . . . . . 93 Advertisers’ Index . . . . . . . . 95

Formulation, analysis and measurement of fines Horace Pops and Gil Baker . . . . . . . . . . . . . . . . . . . . .68 Wear of dies, measured and calculated by the process control system in a drawing machine Magnus Jarl and Fredrik Axelsson . . . . . . . . . . . . . . . . .80 Stress development in 1350-H14 aluminum rod drawing Eva Cervantes, J. Angélica Ramos and Sergio A. Montes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Cover: Technology changes, and so does the need for manufacturers to deploy testing and measuring equipment that will help ensure that their products meet quality requirements. See p. 46.

OCTOBER 2009 | 3

INSIDE THIS ISSUE CONTENTS

I NDUSTRY N EWS : ‘ GREEN ’

IS IN

.11,12

News about alternative energy drives the Industry News section this issue. One story, about a unique U.K. project called “Wave Hub,” will permit developers of “wave energy” to tie into an underwater electrical “socket,” while a second is about a Leoni contract to provide the essential cabling for a major solar energy project. “Green” may be viewed by some as hype, but it can also make for good reading ... and business.

4 | WIRE JOURNAL INTERNATIONAL

WAI N EWS . . . . . . . . . . . . . . . .37 WAI historian Don Sayenga was the keynote speaker at a Sept. 19 Open House at the Roebling Museum in Roebling, New Jersey, USA. The site, which was once the Main Gate building of the operations of John A. Roebling’s Sons Company, is now operated by a separate board for The Roebling Museum, which is converting the structure to a 7,500-sq-ft museum.

The event allowed attendees to view the work done to date.

- Christian Guyot - 98185

EDITORIAL WIRE JOURNAL

®

EDITORIAL

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

The best direction starts with the basics

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli

Several months ago I wrote an editorial about our Board of Directors forming a Task Force to evaluate where we need to focus our efforts and resources as we move forward out of this economic downturn.

We rolled up our sleeves and began calling people: suppliers, exhibitors and WAI members and past presidents, anyone we knew who has a vested interest in the success of the industry. We asked for their opinions—and we listened. We read the reports from previous shows, and all the surveys that came back from the attendees and exhibitors at Interwire were read, and the suggestions tabulated. Then we sat back and thought about what we had been told and found that one of the keys was the need for the Association to be a true resource for the manufacturers, as everything else ultimately revolves around them. We then asked ourselves, “Are we meeting the needs of the ferrous, nonferrous and electrical manufacturing companies? And, more importantly, do we really know what those needs are?” So our director, Steve Fetteroll, packed his bag and hit the road to find out. No e-mail surveys, just good-old-fashioned, face-to-face discussions with top managers about what they want the WAI to be for them and how we can better serve the industry.

To date, Steve has visited 10 companies, accompanied by some board members for a few of those meetings. The manufacturers had a lot to say. The initial feedback has been very positive and while the current economic conditions remain difficult, it was clear that each company is focused on the future and the opportunities that lie ahead.

Steve’s meetings, which are ongoing, all help the WAI get a good feel for the pulse of the industry. In addition to the personal contact with manufacturers, the input comes from the hundred or so volunteers who serve on WAI committees, and our connections with the supplier community, whose support is vital to the organization.

Moving from suggestion to implementation in a relatively short time is a good start. I would like to thank Task Force members Mark Spencer, Don Schollin, Dominique Perroud, Nick Nickoletopoulos and José Ranc, who have put a tremendous amount of time and effort into this project. From here, we plan to determine what real-world steps will enable the WAI to best serve the industry in these tumultuous times. Look for more reports in future issues. And do feel free to send your suggestions to me at danearmendariz@wirenet.org.

Dane G. Armendariz WAI First Vice President

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 Malcom Michael | AWIA 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 R. M. Shemenski | RMS Consulting, Inc.

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel.

203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. 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. © 2009 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700.

POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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GERMANY • BRAZIL • CHINA • EGYPT • FRANCE • INDIA • ITALY • KOREA • RUSSIA • TURKEY • UKRAINE • USA

CALENDAR

CALENDAR Oct. 13-15, 2009: Wire Southeast Asia Bangkok, Thailand. To be held at the BITEC Exhibition Centre. Contact: Messe Düsseldorf North America, tel.

312-781-5180, info@mdna.com, www.mdna.com.

Nov. 2-3, 2009: Istanbul Cable & Wire 2009 Istanbul, Turkey. This biennial conference is jointly organized by IWMA, CET, ACIMAF and the WAI. Prior conferences were in Bologna, Italy (2007); Prague, The Czech Republic (2005); and Stresa, Italy (2003). Contact: WAI, tel. 203-453-2777, www.wirenet.org.

Nov. 8-11, 2009: 58th IWCS Conference™ Charlotte, North Carolina, USA. The 58th Annual IWCS Conference will be held at the Charlotte Convention Center. Contact: IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990.

Apr. 12-16, 2010: wire Düsseldorf Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com.

8 | WIRE JOURNAL INTERNATIONAL

May 12-13, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event includes the WAI’s 80th Annual Convention, trade show and technical program.

It will be co-located with The National Electrical Wire Processing Technology Expo. Contact: WAI, tel.

203-453-2777, www.wirenet.org.

Sept. 2010: wire China 2010 Shanghai, China. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Nov. 7-10, 2010: 59th IWCS Conference™ Providence, Rhode Island, USA. Contact: IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990.

Nov. 18-20, 2010: Wire & Cable India 2010 Mumbai, India. This event, organized by the Confederation of Indian Industry, will be held at the Bombay Exhibition Centre in Goregaon. Contact:

June 19-23, 2011: JI Cable Versailles, France. This multi-organizer international conference on insulated power cables, which has multiple organizers and was last held in 2007, will present a comprehensive forum about power cables as well as exhibits.

Contact: J1Cable 11, www.jicable.org.

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May 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show and the Association’s 81st Annual Convention. Exact dates to follow. ■

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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 www.wirenet.org.

Model BJS 1000* *Model BJS 1000 is bench-mounted.

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Oct. 15, 2009: 8th Annual Southeast Chapter Golf Tournament Conover, North Carolina, USA. Contact WAI’s Chip Marsh, cmarsh@wirenet.org, tel. 203-453-1748.

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Oct. 22, 2009: Ohio Valley dinner meeting Cleveland, Ohio, USA. Joe Downes, Senior Vice President of Leggett & Platt, Inc., will deliver a talk on “The State of the Steel Wire Industry” at this dinner meeting, to be held at the Cleveland Airport Marriott Hotel.

Oct. 22-23, 2009: Reconvene Cleveland, Ohio, USA. WAI will hold its second business meeting of the year at the Airport Marriott.

Oct. 26, 2009: 9th Annual Wild West Shootout Rancho Palos Verdes, California, USA. Contact WAI’s Chip Marsh, cmarsh@wirenet.org, tel. 203-453-1748.

Nov. 2-3, 2009: Istanbul Cable & Wire 2009 Istanbul, Turkey. This biennial conference is jointly organized by IWMA, CET, ACIMAF and the WAI. Prior conferences were in Bologna, Italy (2007); Prague, The Czech Republic (2005); and Stresa, Italy (2003). Contact: WAI, tel. 203-453-2777, www.wirenet.org.

May 12-13, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event includes the WAI’s 80th Annual Convention, trade show and technical program.

It will be co-located with The National Electrical Wire Processing Technology Expo. Contact: WAI, tel.

203-453-2777, www.wirenet.org.

May 2011: Interwire 2011 Atlanta, Georgia, USA. See main listing.

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CALENDAR

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INDUSTRY NEWS

INDUSTRY NEWS Draka and Prysmian end merger talks A Draka Holding N.V. press release reports that talks of a merger between it and Prysmian have ended as an agreement could not be reached. The deal would have combined two of the world’s largest cable companies, Prysmian being rated second in the world (after Nexans) and Draka eighth in a report on the world’s largest cable companies in WJI’s January 2009 issue. A Draka spokesman declined further comment.

LS Cable acquires Chinese company South Korea’s LS Cable announced that it has secured a base for power cable production in China by its acquisition of Hubei Yongding Hongqi Electricity (Hongqi) from China’s Yongding Group.

An announcement at its website said that the company bought 75% of the outstanding equity in the power cable manufacturer founded in 1968 by the Chinese government “with the aim of fostering key national industries.” Hongqi, it said, has about 1,000 employees who produce submarine cables, power cables (including 220kV extra-high voltage cables), and special industrial cables, in a plant in Yichang City, the second largest city in Hubei Province, it said. “As a leading cable maker in China, its main clients are staterun enterprises, and the company has good brand recognition in China thanks to its long history and technical knowhow,” it said, adding that it is the third largest manufacturer of submarine cables in China.

Yongding Group, which in 2003 acquired Hongqi Electricity, a state-run enterprise, managed the company until it sold it as part of the group’s restructuring strategy, and that move will greatly benefit LS Cable in China, the announcement said. “China’s power cable market is not easy to penetrate because of (its) preferential treatment to Chinese companies and high customs duties on foreign products. The strategic significance of LS Cable’s acquisition of Hongqi is that it has laid the foundation for breaking down an entry barrier to the Chinese market as well as secured a base in Hubei Province, a point of strategic importance for the development of Northwestern China.”

LS Cable notes that it owns several affiliates in China, one in Wuxi, Jiangsu Province, that produces power cable connectors, bus ducts, automotive cables, and device cables; one in Tianjin, Hubei Province, that produces winding wires; and one that produces winding wires for power transmission for US-based SPSX, a company that LS Cable acquired last year. “LS Cable is now planning to capitalize on the acquisition of Hongqi to complete its overall business portfolio in the Chinese market, and take advantage of its sales arm in Shanghai, LSIC, to extend market coverage across China.”

“The brand awareness and customers of Hongqi, the production technology and operating capabilities of LS Cable, and the synergies we have with existing businesses will allow us to turn the company into a major general cable maker in China,” said LS Cable President Jong-ho Sohn.

nkt cables buys high-voltage cable company to further China presence nkt cables reports that it has agreed to buy has a high-voltage cable factory in Hejian City, Hebei Province, from Xinhua Cables Group, as part of its strategy to expand its presence on the growing Chinese market.

“China is now the most rapidly expanding business area for nkt cables, driven by considerable investments in the infrastructure for power supply and transport,” the announcement said. It noted that the deal “should be seen in the context of nkt cables’ current presence in China, where they produce and sell medium voltage cables and overhead catenary systems for high speed trains.” Sales of those products in 2009 are expected to top US$145 million, it said.

The deal, expected to close in January 2010, bolsters the presence of nkt cables in China, where it has been active for nearly 15 years, the announcement said. The combination of the factory, which is fairly new, its high-voltage technology and nkt cables’ know-how, references and accessories assortment, “constitute a compelling offering to the market,” it said. The factory, which has three main production lines, can produce and test cables up to 500 kV. “Based on the expected expansion of the Chinese transmission grid and steadily growing urbanization, this acquisition is expected to provide support for growth in China of 50 percent in the coming years,” it said.

TURI gets some funding restored The Sept. WJI issue included a report that the Massachusetts Toxics Use Reduction Institute (TURI), which was operating through UMass Lowell, faced closing because its state funding had been cut off, even though it was generating enough industry-mandated fees to pay for its operations. TURI representatives report that UMass Lowell has reached an agreement with the MA Executive Office of Education for $1.3 million in additional stimulus money to fund TURI for the current fiscal year.

“This will provide funding for TURI’s remaining staff, as well as a modest amount of funding for administrative costs and programs, approximately one-third of last year’s program spending,” a TURI press release said. In it, the agency noted that its staff has had four positions transferred elsewhere in UMass Lowell, but that it now “looks forward to

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

10 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

getting back to the considerable work at hand: furthering the reduction of toxic (materials) in Massachusetts.”

Messe Düsseldorf organizers report: 2010 event looks surprisingly good The wire and cable industry may be operating in weakglobal economic conditions, but organizers of the world’s largest wire and cable event report that wire 2010 and its sister event, Tube 2010, are booking quite well and indicating that the fairgrounds will be busy next April.

“Eight months before the start of (wire 2010 and Tube 2010), one thing is certain: both industry fairs are defying the global economic situation and recording consistently good registration figures,” a press release said. “Even at this stage the international exhibitors already occupy more net exhibition space than was the case during the same period two years ago.” As of early September, wire 2010 had already booked 50,000 sq m, Tube 2010 around 40,000 sq m, it said.

“As a result, exhibition Halls 9 to 12 and 15 to 17 are quite full, but individual stands are still available,” the release said. For more details, go to www.mdna.com or www.messe-duesseldorf.de.

Leoni shines with its latest cable deal Leoni AG, best known as a major supplier to the automotive sector, announced that it has won a contract to supply more than 1,000 km of specialized installation cabling for Germany’s Lieberose solar farm, which it notes represents the world’s second largest photovoltaic plant.

A press release said that the cables will be used by the Lieberose operation in Brandenburg, which upon its scheduled completion at the end of this year will carry annual output of 53 megawatts generated from some 700,000 thinfilm solar modules. The venture, led by juwi solar GmbH, a project developer of solar, wind and bioenergy plants, is located across an area of 162 hectares, about the size of more than 210 football fields, and is designed to produce enough electricity to supply the needs of some 15,000 households, it said.

Leoni’s BETAflam solar cable will carry the electricity generated by the individual solar module panels to the system’s inverters, the release said. In it, juwi solar Purchasing Coordinator Marc Ziegler said that the cable “meets the heavy demands to which the solar modules (are subjected).”

The panel cables, each about three ft long, were described as being extremely weather resistant, with an expected use-

Leoni will supply more than 1,000 km of installation cables to the Lieberose solar farm in Brandenburg, Germany. ful life of more than 30 years. The cable, which is doubleinsulated and halogen-free, is flame retardant as well as resistant to UV, ozone, hydrolysis, heat and cold from –40 to +120°C, it said, adding that this is the first cable that can be universally used in both Europe and America for installation in photovoltaic systems because it is approved by both the TÜV (German Technical Inspection Association) and the American UL (Underwriters Laboratories).

“By equipping the Lieberose solar farm, Leoni is involved in a project that points the way to future,” the release said, noting that the company is expanding its capacity to produce such solar cables. “We are experiencing growing demand for our products and services in the area of renewable energy. There is call especially for our technological knowledge, global footprint and ability to supply cables and cable systems on a just-in-time basis,” said Leoni AG President and CEO Dr. Klaus Probst.

Rio Tinto sells majority interest in its Alcan Cable division to Platinum Equity Rio Tinto has sold a controlling interest in its Alcan Cable Division to Platinum Equity that includes cable plants in the U.S., Canada and China with some 1,200 employees.

An announcement at the Rio Tinto website said that the deal includes seven active production sites in the U.S., Canada and China, serving the utility transmission and distribution markets as well the residential and non-residential construction markets. It noted that while Rio Tinto is divesting its downstream Alcan Engineered Products business via its sale of 56% of its cable division to Platinum Equity, “Rio Tinto Alcan will remain a key supplier of aluminum rod and molten aluminum … in North America.”

Of note is that in June, Platinum Equity bought the Alcoa’s wire harness and electrical distribution business. It also had appeared to be the winning bidder for control of Delphi Corp., but lost to a late bid by a group of lenders to the company, which is still seeking to exit Chapter 11. A Platinum Equity spokesman declined comment.

OCTOBER 2009 | 11

INDUSTRY NEWS

Ground-breaking energy project calls for underwater cables The focus on renewable energy is often on solar and windmill technology, but a different niche has been a big plus for JDR Cables Systems, Ltd., a U.K. company that will be supplying the cabling for a project that creates power underwater. Not only does it allow the power of waves to be tapped, it will permit four developers to use their own methodology to harness water power that can then be converted to usable electricity that is distributed.

It will permit the developers to test their full-scale wave energy devices in a realistic, fully monitored marine environment.

The contract, from the South West RDA (Regional Development Agency), calls for JDR Cable Systems to supply subsea power cables for the U.K.’s Wave Hub project, said a press release that noted the following. The Wave Hub, which will be an integral element of the world’s largest offshore wave energy farm when completed, will create an electrical “socket” for the power to be plugged into. The Wave Hub will be placed on the seabed in some 50 meters of water around 10 miles off the coast of Cornwall in South West England that will be connected to the National Grid via a subsea cable. Four developers

12 | WIRE JOURNAL INTERNATIONAL

will each be able to tie their technology into a quarter of the 3 km by 1 km rectangle allocated to the Wave Hub, which will enable the transfer of power to the power grid for North An artist’s depiction of the view of the Cornwall.

U.K.’s Wave Hub energy project.

A press release explained the following: Wave Hub will have an initial maximum capacity of 20 MW (enough electricity to power approximately 7,000 homes) but has the potential to scale up to 50 MW in the future. The scope awarded to JDR includes 25 km of 33 kV three-phase power cables that will provide the essential link between the Wave Hub and the onshore control room. The Wave

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Energy Converters are connected back to the Wave Hub by four additional 300 m three-phase power cables and dry mate connector sets. All cables include fiber optics.

The release said that JDR will also supply the Wave Hub assembly, consisting of subsea terminations and a complete subsea protection structure. The equipment will be delivered in 2010 from JDR’s new deepwater quayside facility at Hartlepool Dock, and the first wave energy devices are expected to be deployed in 2011.

“The Wave Hub project draws on JDR’s wealth of experience in the design and manufacture of subsea cable and umbilical systems to produce a solution that will meet the demanding requirements of this innovative application,” said JDR Managing Director Patrick Phelan. “Our new quayside facility at Hartlepool dock is ideally sized for the manufacture and load-out of this 1,500 metric-ton cable system.”

Per Wikipedia, three of the confirmed developers include Fred Olsen Limited, a Norway-based ship business that has expanded into offshore wind. For this project, it has developed a multiple point-absorber system for energy extraction from the waves, using floating buoys attached to a light and stable floating platform that convert the wave energy to electricity. A second developer,

14 | WIRE JOURNAL INTERNATIONAL

WestWave, is a joint venture of E.ON and Ocean Prospect. It plans to install up to seven devices (Pelamis) that are semi-submerged, articulated structures composed of cylindrical sections linked by hinged joints that resist the wave-induced motion by hydraulic rams that drive electrical generators to produce electricity. A third developer, U.S.-based Ocean Power Technologies Limited, has a PowerBuoy system that extracts the natural energy in ocean waves based on the integration of patented technologies in hydrodynamics, electronics, energy conversion and computer control systems that respond to differing wave conditions.

The design of the project will enable each developer to link their technology via a cable riser that is connected to one of four 33kV 3core Wave Hub Tails tied back to the Wave Hub Chamber. JDR will provide a watertight connection between the Wave Hub Tails and the main cable.

Within the chamber, the main cable is terminated onto two isolated busbars and fiber optic cables split out to link with those running to each WEC via the integrated Tails and riser cables. JDR will also deliver the 25 km main subsea cable, which consists of twin 300 sq mm 33 kV triads and fiber optic cables, linking the Wave Hub system to the onshore grid network.

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16 | WIRE JOURNAL INTERNATIONAL

Cable project spec a ‘trenchant’ $1 million error The Port of Seattle has learned the hard way that a misunderstanding in a cable project can be very expensive as well as embarrassing. The project for the Washington, U.S. port called for the digging of a trench to fit a 2.50 in., 1,500ft-long electric cable that would be used to power cranes that lift containers from ships at the new cargo terminal on the Seattle waterfront.

Per reports in The Seattle Times, the project for Terminal 30 went fine until workers tried to fit the cable in the trench, which the contractors had constructed 2.52 in. wide: the 2.50 in. cable simply would not fit. At first there was some confusion and then as the news circulated there was much debate as to why the trench would have been made to such a tight tolerance. Eventually, it became apparent that the problem was not one of two thousandths: the trench should have been made about an inch wider than the cable. Port officials noted that similar trenches for other cables were three to four inches wide.

In a memo on the subject, Port CEO Tay Yoshitani said that about a dozen Port staff had reviewed the design plans multiple times and not caught the error.

“We took our best shot at catching many mistakes but this detail escaped us.

This particular error we should’ve caught.”

The Port had two choices: restructure the trench or find a smaller cable.

Building a larger trench, The Seattle Times reported, could cost $500,000 because the steel that lined the trench would have to be removed. Ultimately, the Port bought a second cable, from Italy, 2.28 in. wide, for about $111,000. It was a tight fit, but the cable was able to be secured in the trench. In the article,

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Port Commissioner John Creighton called the ordering of a new cable “the best course forward out of a bad situation.”

The project was completed, but with the lost revenue for its being held up for two months, the total extra costs were estimated to be as much as a $1 million. The Port, the contractor and the terminal tenant are negotiating how to resolve the losses.

Norwalk Innovation, Inc., a U.S.-based industry supplier of coil handling, material straightening and press feeding equipment, has been acquired by Press Room Equipment Co. (PRE), a division of American Products, LLC, from owner Bruce Malkin, who has retired.

A press release said that the company, which was founded in 1965 and located in Shelton, Connecticut, has been consolidated to an existing PRE site in Springfield, Missouri.

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OCTOBER 2009 | 17

INDUSTRY NEWS

Norwalk Innovation is acquired by PRE, now consolidated in Missouri

INDUSTRY NEWS

Nexans agrees to supply deep water umbilicals for Gulf of Mexico project France’s Nexans reports that it has entered into a frame agreement with BP Exploration & Production Inc. for deep water umbilical projects in the Gulf of Mexico. The deal is initially for one year, but BP has the right to extend the agreement for an additional four-year period and the overall project could be worth as much as US$300 million.

A press release said that the agreement calls for Nexans to design, manufacture and supply bespoke umbilicals that will carry fluid, power, control and telecom services for new subsea oil and gas projects or replacements in water depths of up to 1,980 meters. During the term of the agreement, Nexans could deliver more than 200 km of umbilical products to BP, it said.

The latest project follows the success of the previous umbilical frame agreement between BP Exploration & Production and Nexans for the Gulf of Mexico, which ran from 2002 to 2008, the release said. It noted that during that period, Nexans delivered several umbilical projects for BP

A view of umbillicals being deployed in a previous Nexans contract. Photo courtesy of Nexans. worth a total of US$130 million. Some of those projects, it said, presented significant technical challenges, such as implementation of a record breaking deep water dynamic umbilical incorporating high power cable.

“This new frame agreement … secures our position as a key strategic supplier of umbilicals for the Gulf of Mexico,” said Nexans Senior Corporate Executive Vice President Yvon Raak, “Nexans has demonstrated its outstanding project execution capability, not only in solving technical challenges but also in ensuring on-time delivery. With this new agreement, we have also demonstrated that we can provide a cost effective solution to the Gulf of Mexico.”

The umbilicals for the Gulf of Mexico will be designed and manufactured at Nexans’ specialized facility in Halden, Norway, the release said.

18 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

Rea Magnet Wire reports plans to invest in plant in Lafayette, Indiana U.S.-based Rea Magnet Wire Co. plans to invest $3.5 million in its plant in Lafayette, Indiana, to modernize the facility, add a new product line and install additional equipment for its existing product lines.

The modernization project includes installation of stateof-the-art wire production equipment and the addition of a new product line, a specialty wire used in magnetic resonance imaging and other medical equipment, a press release said.

Inside INdiana Business.com reported that Rea’s investment is being supported by up to $50,000 from the city of Lafayette for training, while the city is also providing $150,000 in Economic Development Income Tax funds for the project. The modernization project includes installation of state-of-the-art wire production equipment and the addition of a new product line, an insulated, round copper specialty wire used in magnetic resonance imaging and other medical equipment, it said. The product was described as similar to what the company produces for magnet wire.

Per the report from Inside INdiana Business.com, Plant Manager Eric Foster said that the MRI product line has allowed the company to hire four additional employees, boosting the work force at its 322,000-sq-ft facility to nearly 190. “We have a flexible, cross-trained workforce who are able to adapt to what’s required by the market,” he said.

“That ability to adapt played into the company’s decision to add a product line and install additional equipment in Lafayette. Rea Magnet Wire has a high level of confidence in our Lafayette employees.”

Earlier this year, Rea Magnet closed its Pontiac Street manufacturing plant in Fort Wayne, Indiana, noting that it was “no longer economically feasible to continue manufacturing operations (there).”

Layoffs announced at WireCo Citing harsh business conditions related to the economy, a WireCo WorldGroup official announced that 25 company employees have been laid off.

“We’re just continuing to react to business conditions,” said David Hornaday, WireCo senior vice president of administration, in multiple wire stories that carried the news. “Hopefully these conditions will improve and we’ll be able to call (the employees) all back.”

The layoffs, a press release said, follows previous costcutting efforts by the company, which include reducing the work week for some 200 employees from a 40-hour work week to a 32-hour work week.

WireCo officials said the hourly reductions were used as an alternative to layoffs at a time when the demand for wire rope had decreased worldwide. WireCo, a manufacturer of wire rope, wire rope assemblies, high-carbon wire and electromechanical cable, has manufacturing operations in St. Joseph and Chillicothe, Missouri.

OCTOBER 2009 | 19

INDUSTRY NEWS

Middle East company reports winning four cable contracts Middle East Specialised Cables Company reported winning four cable contracts for diverse projects valued at approximately US$36 million.

One project, worth more than US$25 million, is to supply cables to Sonatrach, an Algerian state-owned energy compa-

ny, AME Info reported. Per Wikipedia, Sonatrach is the largest Algerian company and the 11th largest oil consortium in the world. It employs approximately 120,000 workers and produces 30% of the GNP of Algeria.

The AME Info report said that the company also reported winning a US$11 million contract, through its Jordanian subsidiary MESC Fujikura Cable Company, to provide medium-voltage cables to the Princess Noura bint Abdulrahman University for Women project in Riyadh; a US$5.4 million contract on the UAE’s Ruwais green diesel project from South Korea’s GS Engineering and Construction; and a US$4 million contract from Italy’s Saipem to supply cables to the company’s fertilizer plant project at Mesaieed.

Russian company reports new wire line start-up Mechel, a Russian mining and metals company, announced that it has commissioned a new production line at its Beloretsk Metallurgical Plant (BMP) subsidiary.

A press release at the company’s website said that the new production line for cold-deformed reinforcement wire, which cost more than US$1.8 million, was heralded at a ceremony for its contribution to the region’s industrial and social development.

“Today’s new equipment commissioning is a bright example of Mechel Group’s commitment to its strategy of modernization and increase in production volume in spite of the world economic crisis consequences,” said Yury Pustovgarov, deputy prime minister of the Republic of Bashkortostan. He praised the Mechel Group’s “well thought-out production policy” of focusing on manufacturing high value-added products.

The new equipment, supplied by Italy’s GCR, will provide annual capacity of 36,000 metic tons and enable BMP to produce a new class of products, such as reinforcing wire from 4 mm to 12 mm for construction uses, the release said. The equipment includes an untwisting machine, mechanical descaler, lubricant-applying unit, coldrolling mill, twisting machine, pneumatic equipment for coil bundling, equipment for supply of compressed air and water-cooling station. A bridge

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INDUSTRY NEWS

crane with a lift capacity of five tons was mounted in the aisle to deliver and load the wire-rod feed. The need for such investment is a sound business approach, said Mechel OAO Senior Vice President Vladimir Polin. “We see (an) increase in demand for this new class of steel products and as early as this month we received an important order for reinforcing wire of BMP production,” he said.

Return to work outlook remains bleak for unionized Georgetown workers Unionized steel workers at Georgetown Steel voted down a contract proposal from the Arcelor Mittal-owned company, but a representative for their union said that she has not given up hope that a deal can be reached to save the South Carolina company.

“I plan to keep talking until the wrecking ball starts swinging,” union representative Deborah Hayes-Cook, who works with the International Steelworkers Union, told WJI. Workers had rejected the company’s last offer, which called for a 32-hour-work week and required a $3.65-an-hour pay cut if there were less than 50,000 tons of steel orders per quarter.

Nexans wins Chinese order to supply cables for India train fleet Nexans announced that it has won a contract from China’s Nanjing SR Puzhen Rail Transport (NPRT) to deliver 932 km of power, control and data cables that will be used for a fleet of 16 trains that are currently under construction for Mumbai Metro.

Over the next year, Nexans will supply NPRT with specialized rail cables for installation on 16 fourcar Mumbai Metro trains, a press release said. The cables, part of the company’s FLAMEX® range of special cables for the rolling stock industry, will be manufactured to the international NFF standard, and be used to distribute power throughout the new trains, it said.

The release noted that Nexans has worked closely with NPRT to develop the ideal cable solution for each application. “This collaboration has resulted in an important advance in cable technology for Nexans as it will be the first time that it has supplied twisted power cables for a rail customer,” it said.

The Mumbai Metro train power cables will be manufactured by Nexans (China) Wires & Cables

22 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

Co. Ltd., while the control and data cables will be produced

by Nexans Communications (Shanghai) Cables Co. Ltd. The new Mumbai Metro is designed to provide a high capacity transport system “to relieve the increasingly overstretched rail and road networks serving the world’s second most populous city, with a current population estimated at 18 million.” Phase 1, a new 11 km east-west route from Versova-Andheri-Ghatkopar, is designed to run on an ele-

vated track, cutting journey times on the east-west corridor from 90 minutes to just 21 minutes.

Arecelor Mittal subsidiary gets okay to close its wire rod mill in Mozambique ArcelorMittal South Africa Ltd., a unit of ArcelorMittal, has received regulatory approval to close down its Mozambique wire rod rerolling mill, resulting in the losses of 78 jobs there.

The plant, which had been mothballed since November 2008, has annual capacity of approximately 35,000 metric tons of wire rod a year, company spokesman Sven Lunsche said in an article that was posted at Morningstar.com. In it, he said that the decision to shut the plant down was made because it was no longer economically viable to keep it open in the weak construction market.

Per a report in Dow Jones Newswires, current orders for the Mozambique plant will be filled by the company’s plant in Newcastle, South Africa.

ArcelorMittal acquired the Mozambique plant in 2007 and opened it in May 2008 after completing refurbishment.

MMK completes repair of wire mill

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Russia’s Magnitogorsk Iron and Steel Works has completed repairs and restarted operations at its wire mill 170.

A report in Steel Guru, citing Steel Orbis, said that the repairs included the replacement of the internal lining of the mill’s reheating furnace and the repair and replacement of the mill’s mechanical equipment. The wire mill, supplied by Italy’s Danieli and commissioned in 2006, has annual production capacity of 765,000 mt of wire rod. ■

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ASIAN FOCUS

ASIAN FOCUS China’s focus on increasing wind power energy has been a big plus for AMSC Power is an essential element for any economy, and for China, a world leader in many manufacturing sectors, the need to access alternatives to fossil fuels and coal has led to its focus on wind power. That has also proved to be a plus for American Superconductor Technology (AMSC), a U.S. supplier of technology for superconducting cables as well as wind turbine components.

An article in People’s Daily Online, citing a report in the September issue of Science magazine, states that a team of environmental scientists from Harvard and Tsinghua universities believe that wind power may enable China to reduce emissions by 30% in 20 years. The article noted that China, which is second after the U.S. in its national power generating capacity, produces 792.5 gigawatts per year, a number that increases each year. As much as 80 percent of its power is produced through coal-making, making China and the U.S. the world’s two largest carbon emitters. Based on its future electricity needs, China would need to construct coal-fired power plants that produce the equivalent of 800 gigawatts of electricity, resulting in a potential increase of 3.5 gigatons of CO2 per year.

The article said that while wind-generated energy accounts for only 0.4 percent of China’s total current electricity supply, the country trails only the U.S., Germany and Spain in the capacity of existing wind farms. Further, projections are that the wind energy potential in China is as much as 24.7 petawatt-hours of electricity supply annually, more than seven times China’s current consumption. The research team, it said, evaluated the total potential for wind energy that could be realized at an affordable cost level, which would require installation of 640 GW of wind farms over the coming 20-year period.

The situation described in the article has been a boon to AMSC, which has become profitable and attracted a lot more attention from investors. Broadpoint Amtech analyst John Hardy was quoted as saying that AMSC will continue to benefit from the Chinese government’s increasing commitment towards wind energy and new customers in China Its biggest customer is China’s Sinovel Wind—the country’s largest manufacturer of wind turbines and one of the top 10 in the world—which accounts for nearly 70% of the its revenue, the article said. It noted that orders from Sinovel Wind have raised the value of its overall contract to $470 million.

“China, in particular the China wind industry, is the primary driver for our growth today,” AMSC CEO Greg Yurek said in a conference call with analysts. In a wire report, the company noted that China grew its installed based of wind turbines to about 12 GW in 2008 and earlier this year it announced plans to add another 10 GW or more in 2009, as

A wind farm in China composed of Sinovel wind turbines.

Photo courtesy of American Superconductor. it seeks to increase its wind power installed base to between 108 GW and 132 GW by 2020, he said.

AMSC spokesperson Jason Fredette was quoted as saying that China is the reason why the company has not been hurt by the worldwide recession. He said the country will continue to generate most of the company’s revenue in the next few quarters, although that is expected to gradually decline.

He added that AMSC was focusing on emerging economies like India. At this point, the orders are for the company’s windpower technology, but AMSC is pursuing commercial cable orders and has hopes of landing its first commercial order for superconductor wires in two to three years, he said.

To further that end, the company announced that it has formed AMSC India to serve India’s rapidly growing wind energy and power grid markets with AMSC’s power electronics and superconductor-based solutions.

“India is beginning to tap into its renewable energy resources and is making significant investments to vastly improve the throughput and reliability of its power grid,” Yurek said.

According to the World Bank, some 40% of residences in India are without electricity, and blackouts are a common occurrence throughout the country’s main cities. The Indian government wants to increase country’s installed generation capacity from 140,000 megawatts (MW) to nearly 225,000 MW by 2012, which will cost massive investment in India’s transmission and distribution infrastructure.

According to the Global Wind Energy Council’s Global Wind 2008 Report, India now ranks fifth in the world in terms of total installed wind power capacity, which grew by 22 percent in 2008 to 9,600 MW.

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

26 | WIRE JOURNAL INTERNATIONAL

Vietnam cable-stayed bridge opens 4 months early Ho Chi Minh City’s largest cable-stayed bridge across the Saigon River, the Phu My Bridge, was scheduled to open on September 9, four months before the four-year project’s deadline. A series of wire stories, most citing Thanh Nien News, reported the following. The 2,101-meter-long and 27.5-meter-wide, cable-stayed bridge was constructed by Australia’s New South Wales-based construction company Baulderstone in partnership with Germany’s Bilfinger Berger.

The bridge was built for approximately US$112 million under PPP (public-private partnerships) form. The bridge, designed by France’s ACARDIS and Australia’s CARDNO, is a joint effort by the city’s People’s Committee, is overseen by the Phu My Bridge Corporation, with Bilfinger Berger (BBBH) the general contractor. The cable-stayed bridge that is said to use the two largest cable planes ever used in Vietnam. The bridge is one of the first major structures crossing the Saigon River.

India’s Sterlite honored, fiber expansion continues Sterlite Technologies reports that it has once again won the V&D 100 2009 award for Top Telecom Cables Company in

Sterlite Technolgies plans to increase production of optical fiber at its plant in India.

India. The annual survey on the Indian telecom equipment industry conducted by Voice&Data Magazine, cited Sterlite as having a market share of over 30%, it said, adding that it is the only company to have won this award for six consecutive years from 2004-09. “Despite the current situation in the global marketplace, several global economies continue to build telecom infrastructures in preparation of economic revival,” said Sterlite COO (Telecom) K.S. Rao. The company also reported that that work continues to expand its annual production capacity of optical fiber at its India facility from 6 million-km (mkm) to 12 mkm, with plans to increase that level to 20 mkm in 2011. Other plans call for the company to increase its annual fiber optic cable capacity to 6 mkm. ■

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OCTOBER 2009 | 27

ASIAN FOCUS

ASIAN NEWS BRIEFS

PEOPLE

PEOPLE Allied Wire & Cable, which in April hired four sales representatives, has hired two more. Named as inside sales representatives are Michael Cresswell and Isaac Rose, both of whom will work out of the company’s location in Collegeville, Pennsylvania.

Cresswell, who graduated from Shippensburg University in 2007, most recently worked in outside sales, selling payroll accounts to small businesses. Rose, who graduated from Drexel Michael Cresswell University in 2008, with concentrations in international business and marketing, had been working in sales as a financial advisor. Based in Collegeville, Pennsylvania, Allied Wire & Cable is a privately owned value-added manufacturer Isaac Rose and distributor of electrical wire and cable products in the U.S. TELE-FONIKA has named Colin McKay as Deputy President of the Board (Sales) of TELE-FONIKA Kable Sp. z o. o., which is the general partner of TELE-FONIKA Kable Sp. z o. o. S.K.A. McKay replaces former 1st Deputy President of the Board Ryszard Pilch, who will remain on the board as a member for domestic market sales. Based in Poland, TELE-FONIKA was listed as the world’s 14th largest cable company in 2008.

SE Specialty Wire & Cable, LLC, recently announced the addition of Harry W. Fleming as sales & marketing manager, supporting the company’s manufacturing facility in Murrells Inlet, South Carolina, USA. He has more than 30 years of experience in the stranded wire and cable and wire rope industry, with previous positions, includng regional sales manager and director of sales for key manufacturers in the U.S. In his new position, he will be responsible for domestic and international sales and marketing operations, as well as the development of specific customers, products and industry segments. He holds a B.S. degree from Monmouth University and is a graduate of the Management Development Program at Rensselaer Polytechnic Institute. Based in Murrells Inlet, South Carolina, USA, SE Specialty Wire & Cable manufactures specialty stranded wire, wire rope and cable products for diverse commercial industry markets.

Cobra Wire & Cable, Inc., has named Thomas Stone as its national sales manager, responsible for the overall execution of the company’s field sales initiatives. The company also announced that Janice Bonk has been named director of marketing, with responsibilities that will include a focus on developing marketing solutions that leverage brand awareness. She has more than 30 years of experience in the wire and cable industry. She has been with Cobra since 1988, where she had served as operations manager and director of quality systems.

Denise Essick has been named assistant warehouse manager. She most recently had managed Cobra’s respooling department at its corporate headquarters. Based in Hatboro, Pennsylvania, USA, Cobra Wire & Cable, Inc., produces power cable and connectivity products for a wide range of markets. ■

OBITUARY Joseph J. Dellagala, a former vice president of operations and engineering for Mohawk, a division of Belden, died Sept. 8 after a long illness at age 63.

Dellagala began his career in 1967 at Phalo Corporation as a design engineer. During the following 19 years he held various technical positions, including manager of engineering for electronic cables, communications cables, cord sets and assemblies. In 1986, he joined Joseph Dellagala Hitachi Cable in Manchester, New

28 | WIRE JOURNAL INTERNATIONAL

Hampshire, as the product manager for telecommunications cables. He was promoted to director of sales and marketing in 1988. In 1991, he joined Mohawk/CDT as a technical support manager and held various positions including vice president engineering and quality and vice president operations for the facilities in Leominster, Massachusetts, and Manchester, Connecticut. He received the WCMA Distinguished Career Award in 2007.

The Massachusetts native served in the U.S. Army between 1965 and 1967. He leaves his wife, MaryJane; daughters, Stacey and Jennifer; five grandchildren; and parents, Esther and Joseph B. Dellagala.

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FIBERWATCH

FIBER WATCH Alcatel-Lucent lands contract for 3rd phase of Mozambique telecom project Alcatel-Lucent reports that it has furthered its work with Telecomunicacoes de Mocambique (TDM), the Mozambican state-owned telecommunications company, by entering a US$30 million contract to deploy the third phase of Mozambique’s national transmission network.

A press release said that Alcatel-Lucent has completed the first two phases of the project, which required 2,970 km of optical fiber to be laid across the country. The third phase calls for Alcatel-Lucent to lay 2,858 km of optical fiber and deploy its optical transmission solutions to connect any remaining geographic areas. Once completed in 2011, the backbone project will span some 5,500 km, connecting “Mozambican citizens and companies to the worldwide submarine network and bring high-speed connectivity to provincial capitals across the country.”

“This phase will conclude our nationwide project to build the Mozambican backbone transmission network, which is one of the most significant and largest telecommunications investments in our country,” TDM Board Chairman Joaquim de Carvalho was quoted as saying in a wire story. In it, he said, “The project’s final objective is to link all of our provincial capitals via an optical backbone network, bringing Mozambique into the information and communication community, and bridging the digital divide.”

Global broadband growth has slowed but fiber continues to displace DSL The economy has slowed global broadband growth rate as consumers are still reeling, but there are tentative signs of a recovery, according to Point Topic, a U.K.-based market research company.

The number of worldwide broadband subscribers grew by only 3% compared to the first and second quarters of 2009, said CEO Oliver Johnson in a wire report. In it, he said that 3% represents “the lowest growth Point Topic has seen since it began conducting research in 1999 and the number of broadband subscribers added between those quarters was the lowest since 2005.”

Still, the broadband subscriber base continues to grow, bolstered by better signs in markets such as Japan and Australia, Johnson said in the story. Eastern Europe and Latin America, which showed the biggest growth, still have a low broadband penetration rate, he said. In the report, he predicted that by the end of 2010 the total number of broadband subscribers will reach 500 million.

Fiber continues to be increasing competition for the market share of Digital Subscriber Line (DSL) and cable, Johnson said in the story. He noted that the number of fiber lines has grown by 24.5% in the last year, compared to about 15% for DSL and cable, he said.

While fiber gets a lot of attention, it remains the third most 30 | WIRE JOURNAL INTERNATIONAL

DSL use continues to grow, albeit at a slower rate.

popular in total numbers, he said, citing figures that showed DSL remains dominant, with a 64% share, compared to 21% for cable and 13% for fiber. At the same time, the number of homes with fiber access has grown along with Internet Protocol Television (IPTV), which grew by 56% between the second quarter in 2008 and 2009, he said.

Point Topic, founded in 1998, provides information on broadband communications services, including online databases and reports about broadband services around the world. Its website is at www.point-topic.com.

Glo-1 cable reaches Nigeria The Glo-1 undersea cable, which landed in Nigeria in September, is hoped to provide economic prosperity to the region by making efficient broadband Internet services available in West Africa.

A report in Ghana Business News quoted Globacom Group Executive Director (GED) Paddy Adenuga as saying that his company will stimulate a new era of prosperity in the continent by offering cheap, fast and reliable international calls, unprecedented fast access to the internet and revolutionary data transfer. Glo-1’s current and ultimate capacity is enough to cater to the required broadband capacity of Nigeria for at least the next 15 to 20 years, he said.

The cumulative effect of the huge bandwidth and cheaper rates Glo-1 would bring to the continent “will empower Africans in the field of communications, education, agriculture, banking and health,” Adenuga said in the report. The cable will help teleconferencing, distance learning, disaster recovery and telemedicine, among other benefits, he said.

The Globacom project calls for laying 9,800 km of fiber optic cables from Europe through West Africa, with its submarine cable connecting 16 countries to the rest of the world. The cable, the story said, has a current capacity of 640 gigabit per second and an ultimate capacity of 2.5 terabit per second.

The company has already begun laying cables in Ghana, the story said. The second phase of the submarine cable project will connect South Africa through Angola. ■

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FASTENER UPDATE

FASTENER UPDATE Study: industrial fasteners demand in China to be robust through 2013 Demand for industrial fasteners in China is projected to increase 10.7% annually to US$10.85 billion in 2013, predicts “Fasteners in China,” a new study from the Beijing office of The Freedonia Group, Inc., a U.S.-based industry research firm.

A press release about the 181-page study cites several factors for the high expectations, one of which is rapid growth in manufacturing production, especially industrial machinery and motor vehicles. Another key contributor it identifies is projected increases in electrical and electronic product manufacturing, although it noted that such growth will not match those achieved between 1998 and 2008. It also pointed to a rise in demand for higher-grade industrial fasteners that will boost overall market value. The projections might be even

Organizers report good registration numbers for November fastener show

INDUSTRIAL FASTENER DEMAND IN CHINA (billion yuan) % Annual Growth Item Industrial Fastener Demand Standard Externally Threaded Internally Threaded Nonthreaded Aerospace-Grade

2003

2008

2013 2003-

17.7 17.6 10.2 4.3 3.1 0.1

44.7 43.9 26.3 10.7 6.9 0.8

74.2 72.7 44.0 17.7 11.0 1.5

20082008 2013

20.3 20.1 20.9 19.9 17.5 46.1

10.7 10.6 10.8 10.5 9.9 13.4

Projections for the industrial fastener market in China through 2013. Chart courtesy of The Freedonia Group, Inc. more optimistic if it were not for expectations that increased use of new materials and manufacturing methods will reduce the number of fasteners required in the production of a variety of durable goods, it said.

Standard fasteners (externally threaded, internally threaded and nonthreaded) account for 98% of Chinese industrial fastener demand, said the release, which noted the following.

“Externally threaded fasteners are the dominant standard fastener type, accounting for three-fifths of standard fastener demand in China in 2008. They have resisted inroads made by alternative joining methods such as adhesives or welding and will grow at a slightly above-average rate. Internally threaded types will increase at a slightly below-average pace while nonthreaded types will post the slowest gains at 9.9% annually through 2013, affected by decelerating growth in construction activities. Sales of aerospace-grade fasteners will outpace advances for standard fasteners, rising 13.4% per year through 2013. Demand will be spurred by continued government investment in infrastructure, aerospace industries and national defense, all important markets for aerospace-grade fasteners.”

32 | WIRE JOURNAL INTERNATIONAL

The study covers a number of other areas as well. The release notes that new demand for fasteners in the OEM and construction markets will outpace that of maintenance/ repair/operation (MRO) markets through 2013. OEM, it said, will remain the largest market in China, accounting for more than three-fourths of total fastener demand, with new sales stimulated by rapid growth in the industrial machinery, motor vehicle, and electrical and electronic product markets.

It said that demand for fasteners used in construction applications will be driven by government funding for large-scale infrastructure construction and rising use of higher-performance fastener products in nonbuilding construction.

The study, published in September, is available for $5,200.

Contact: Corinne Gangloff, The Freedonia Group, Inc., tel.

440-684-9600, fax 440-646-0484, pr@freedoniagroup.com, www.freedoniagroup.com.

Advance registration has topped a thousand for the Las Vegas Fastener Expo/West, to be held November 16-18, 2009 at the Mandalay Bay Convention Center in Las Vegas, Nevada, USA, reports show management.

A press release posted at the organizer’s website said that advance registration was at 1,030 persons, with distributors the largest single contingent. It cited the following attendance breakdown: 329 distributors, 78 manufacturers, 46 manufacturers reps, 44 importers and 36 independent sales reps. The balance, it said consists of platers, rod and wire manufacturers, tooling component manufacturers and exhibitor personnel.

“We are delighted by these early numbers. It is very encouraging,” Show Manager Susan A. Hurley said in the release. In it, Assistant Show Manager Denise Hill encouraged potential attendees to register online at www.fastenershows.com. “It is easy, fast and secure,” she said.

The event is designed to bring together the manufacturers of fasteners, master distributors, fastener importers and providers of other related products and services with distributors in the distribution chain. The organizers note that they do not allow OEMs and other end users of fasteners from attending in an effort to preserve and protect the distributor’s role in the marketplace.

The release reminded show exhibitors and visitors to reserve their rooms at Mandalay Bay at the special Fastener Show rate of only $149/night by calling the hotel’s toll-free number 877-632-7000 and mentioning the National Industrial Fastener Show.

For more details, contact Susan Hurley or Denise Hill at tel. 614-895-1279, info@fastenershows.com or visit the web site at www.fastenershows.com. ■

WAI NEWS

WAI

NEWS

Last call for Wire Link applications Applicants have until Tuesday, December 1, to file an application for the Wire Link Traveling Scholarship, a program that sends a wire professional to Europe where the winner can see how different companies operate as well as attend the wire Düsseldorf show.

The WAI is looking for ambitious wire professionals who have been employed for at least three years in the wire and cable (or related) industries, including manufacturers and suppliers. The program alternates between a U.S. representative going to the U.K., and a U.K. representative going to the U.S. through the program’s

co-sponsor, the Worshipful Company of Tin Plate Workers alias Wire Workers of England and the Wire Foundation. All expenses will be met by the sponsors during the trip to the U.K. Candidates must be: involved in the wire and cable or related industries; employed full-time in the U.S. for at least three years with a U.S.-based company; and a Wire Association International member in good standing at the time of application and travel. Applications must be sent to the WAI by December 1.

For more details, along with rules, regulations and an application form, visit WAI’s website at: http://www.wirenet.org/technical/wirelink.htm.

(WAI News continued on p. 37.)

Volunteer Sp✹tlight This occasional section will provide readers a better idea of what WAI’s committees/board of directors do.

Volunteer spotlight: WAI’s Exhibition Planning Committee The Exhibition Planning Committee (EPC) was formed to provide strategic planning and to recommend specific actions to improve the value of both Interwire and Wire Expo trade shows for both exhibitors and attendees. Its 22 members visit potential locations, often when a show is being held; recommend new formats and industry venues; and respond to the industry’s changing needs. They also look closely at comments from exhibitors in post-show surveys.

“We work on several levels, one being to make sure that we are providing a good venue for both attendees and exhibitors,” said EPC Chairman Tony DeRosa, Cortinovis Machinery America, Inc. “That means looking at ways to improve the process for the companies to bring in their displays and equipment and control costs, but that’s only part of the equation. We have to make sure the word is getting out to the industry as to why it should be there.

How can we publicize the event? We spend a lot of time looking at future sites, and that’s a challenging area because there are really only so many that can be used, and even then, you’re not going to find everyone in agreement as to where to go.”

DeRosa notes that the EPC’s members represent a good cross-section of exhibitors, which helps the committee as a whole take into account the needs of both large and small exhibitors, and those who are suppliers versus manufacturers. “It’s important for people to understand that we are not some chosen company representatives laying down 34 | WIRE JOURNAL INTERNATIONAL

a decree of what will happen,” he said. ”I see our mandate as getting the best information possible in terms of locations, services and expenses, and getting our exhibitors the best possible deal.”

WAI Sales Director Bob Xeller said that the EPC has been an effective body. “Making changes is often diffiTony DeRosa cult to do within a trade show organization, but each year the committee has helped determine changes that are made to improve both shows in response to the comments/surveys made,” he said.

Exhibition Planning Committee members Lou Arcuri, Pinnacle Metals Dane Armendariz, Henkel Surface Technologies Tom Copp, REELEX Packaging Solutions, Inc. John Dabbelt, Fort Wayne Wire Die Anthony DeRosa, Cortinovis Machinery America, Inc. Carolyn Edwards, Zumbach Electronics Corp.

Larry Fitzgerald, Davis-Standard Corp.

Rob Fulop, Wire Lab Company Sue Lynch, Sikora USA Steve Marcum, Esteves Group Tom Maxwell Jr., Die Quip Corp.

Richard Pechie, Vollmer America Inc. Dominique Perroud, SAMP/USA Inc. Bob Sears, North America OMCG Inc. Terry Sieger, Woodburn Diamond Die Inc. Joe Snee, Amaral Automation Jan Sorige, Enkotec Company Inc. Mark Spencer, W. Gillies Technologies LLC Bob Stockholm, Beta LaserMike Terri Terry, CommScope

panoramic view of

MILWAUKEE

Wis.

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In 100 sq. ft. and a third less time

EXHIBITORS CAN COVER MORE TERRITORY at Wire Expo 2010 CONVENTION & EXHIBITION:

MAY 12-13

2010 MILWAUKEE, WISCONSIN, USA MIDWEST AIRLINES CENTER

E-mail bxeller@wirenet.org or abzowski@wirenet.org for exhibiting information or find show details online at: www.wirenet.org.

Nobody knows your product better than you and your customers do. But that’s about to change.

Because the 2010 Wire Expo expands your territory by colocating with The National Electrical Wire Processing Technology Expo in Milwaukee, Wisconsin, USA. For the first time the shows will run side by side giving exhibitors and visitors the benefit of crossover participation.

The schedule is compact. Just two days. And the audience is specific so you’ll spend less time qualifying leads and more time engaging valuable prospects.

Considering the cost of international travel to some of the larger scale shows, the new Wire Expo format offers a friendly, affordable, and efficient option for exhibitors who want both a panoramic view of the wire making and wire processing industries and direct access to these viable manufacturing sectors.

Zone in on Milwaukee. Home in on prospects. And begin building new business relationships in an established show setting.

Wire Expo 2010. Low cost. Expanded value. A wise marketing decision.

co-located with The National Electrical Wire Processing Technology Expo

The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

MEMBERSHIP APPLICATION Send application and payment to: The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

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Required to receive The WAI Connection member e-newsletter

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Business Information (required) A. Which ONE of the following best describes your company’s type of business?

WIRE & CABLE MANUFACTURING 10 ❏ Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) 40 ❏ Other Metal (Rod/Bar, Bare Wire, Both) 50 ❏ Electrical Wire & Cable (Insulated Wire) 53 ❏ Communications Wire & Cable (Insulated Wire) 55 ❏ Fiber Optics

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

FASTENERS, WIRE FORMING, FABRICATING 61 ❏ Fastener Manufacture 62 ❏ Four-Slide Forming 64 ❏ Hot and/or Cold Forming and Heading 66 ❏ Spring Manufacture 68 ❏ Wire Cloth Mesh Screening 69 ❏ Other Forming and Fabricating (Please specify) SUPPLIER TO THE WIRE & CABLE INDUSTRY 72 ❏ Machinery 74 ❏ Process, Accessories, Materials

OTHER 80 ❏ Service Centers, Distributors & Warehouses 90 ❏ Consultants 92 ❏ Government, Library and allied

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10 ❏ General & Administrative Management 20 ❏ Engineering, Operations, Production

30 ❏ Technical, Research & Development, Quality Control 40 ❏ Purchasing

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

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

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For instructions, contact the WAI Membership Department at membership@wirenet.org or by phone at (001) 203-453-2777.

Your membership dues may be deductible as an ordinary and necessary business expense, not as a charitable contribution.

Membership in The Wire Association International, Inc. is held by the individual, not the company, and is continuous unless cancelled in writing. Membership is not transferable.

Dues are non-refundable and are billed annually based upon the member’s anniversary date. Annual dues are set by the WAI Board of Directors, and are subject to change.

October 09 International Technical

Conference Proceedings

WAI historian presents speech at Roebling Museum Open House

WAI historian Don Sayenga after his speech at the Roebling Museum in Roebling, New Jersey, USA.

I firmly believe we can achieve more in the future by having a better understanding of the past. Dr. Robert Shemenski has contrived a term “technovation� to explain how a new technique, or a new technical device, is always something that has been innovated, like the fruit on a tree, from an earlier technique or device. Neither can suddenly appear in a vacuum. Each depends upon a previous state of affairs.

Our ability to comprehend how that happens requires a close study of historical facts surrounding the attainment.

Those two aspects of technovation are similar but not exactly identical. Innovative devices emerge as answers or solutions in response to pre-existing questions. Innovative techniques are evolved from questions that arise in connection with the application of pre-existing solutions. I

GEM inks are economical and eco-friendly

WAI NEWS

WAI historian Don Sayenga, whose focus has included bridges and the contributions of industry pioneer John A. Roebling (1806-1869), made a fitting presenter at the Sept.

19 Open House at the Roebling Museum in Roebling, New Jersey, USA. The site, built by Charles Roebling to accommodate workers of the John A. Roebling’s Sons Company manufacturing plant, closed for good in 1974, the location later becoming a 240-acre EPA Superfund site. The Main Gate building, now operated by a separate board for The Roebling Museum, is being converted to a 7,500-sq-ft museum. The event recognized the progress to date, with attendees including WAI Executive Director Steve Fetteroll.

Below are excerpts from Sayenga’s speech.

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FAMILY OWNED & OPERATED SINCE 1952

See us at IWCS Focus Booth #607

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OCTOBER 2009 | 37

WAI NEWS

like to call the person who has devised an innovative device or new technique a technovator.

In 2009, we are celebrating the 175th anniversary of wire ropes because in 1834, Wilhelm Albert, a mining official in the Harz Mountains, performed experiments and documented his results, leading to the general adoption of wire ropes for mine hoists, ship rigging, and telegraph cables. Albert’s technovations, however, must be placed into the context of 500 years of wire drawing history that was launched earlier, in the 14th century at Nürmberg, where water power was first used in a wire mill.

During five centuries of technovation, the use of waterpower spread from Germany to France and England. In France, Marc Seguin and his brothers adapted iron wire to the construction of suspension bridges. In England, Andrew Smith and Robert Newall created steam powered machinery for ropemaking. James Horsfall’s patented heat-treating method yielded high strength steel wire, and ultimately in America, better constructions for wire ropes were devised by Thomas Seale and James Stone.

John A. Roebling was by far the most prolific American wire cable pioneer of the 19th century. He was the founder of the U.S. wire rope industry, from which his family

38 | WIRE JOURNAL INTERNATIONAL

accrued a great family fortune. Roebling also had a personal infatuation with wire cable suspension bridges, working as designer, architect, engineer, and builder.

When involved with bridge building, he tested a series of theoretical ideas, some of which were brilliant. No two of his structures were exactly alike. The Ohio River suspension bridge at Cincinnati is named for him, and two of his original cables, (made with iron wire from Manchester, U.K.) are still in place in the structure.

Roebling’s three sons each contributed to the success of the family company in a special way. Washington designed and built the Brooklyn Bridge, which became a company symbol, and provided corporate leadership. Ferdinand managed the sales of many newly-technovated products including cable car ropes, oil well drill lines and passenger elevator cables. Charles created an entire greenfield steel wire mill from scratch including a town for his workmen.

It is appropriate to have the former site of that mill as a location for the new Roebling Museum.

The Roebling Museum is seeking donations to complete the conversion. Further details about the museum and how to donate can be found at www.roeblingmuseum.org. ■

CHAPTER CORNER

CHAPTER CORNER Registration deadline nears for Western Chapter golf tournament this month Itâ&#x20AC;&#x2122;s last call for the WAIâ&#x20AC;&#x2122;s Western Chapterâ&#x20AC;&#x2122;s 9th Annual Shootout, which will be held Oct. 26 at the Los Verdes Golf

Course (www.losverdes.americangolf.com) in Rancho Palos Verdes, California.

The event begins with a 9:30 am check-in and warm-up, with tee off starting at 10 am, followed by the reception and a Western BBQ dinner and awards presentation. Players can sign up as teams of two or four or individually for the bestball scramble format event. The $90 fee covers the full day, including greens fees, range balls, cart and awards dinner.

Some event sponsorships, including premium sponsorships, are still available. For more details about availability, contact Chairman Michael Howard. tel. 310-639-9473, michael.howard@coastwire.com, or WAIâ&#x20AC;&#x2122;s Chip Marsh at cmarsh@wirenet.org, tel. 203-453-1748.

Downes to speak about steel industry at Ohio Valley dinner this month

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Joe Downes, Senior Vice President of Leggett & Platt, Inc., will be the featured speaker this month when the Ohio Valley holds its dinner meeting on Thursday, October 22, at the Cleveland Airport Marriott Hotel.

A well-known industry veteran, Downesâ&#x20AC;&#x2122;s talk will be â&#x20AC;&#x153;The State of the Steel Wire Industry.â&#x20AC;? He will share his

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http://www.wirenet.org/members/chapters/ohioval.htm.

For more details, contact WAI’s Chip Marsh at cmarsh@wirenet.org.

Last call for Southeast Chapter tourney The official registration deadline has passed for WAI’s Southeast Chapter, which will hold its 8th Annual Golf Tournament on Thursday, Oct. 15, but it may still be possible to secure a position for the event, to be held at Rock Barn Golf and Spa in Conover, North Carolina, the site of the PGA Tour’s Champions Tour Greater Hickory Classic.

One reason golfers may want to try to call for a last-minute reservation is that the field will face a new challenge: the Robert Trent Jones, Jr.-designed course, a hard-to-pass-up attraction.

The day begins with check-in and box lunch at 11 am, followed by the high noon shotgun start. After the golf concludes, there will be an awards reception and dinner where prizes will be presented to the winning teams and contest winners. The registration fee is $130, with non-golfers encouraged to join in on the reception and dinner for $35.

For more details, contact Steve Vannais, tel. 704-799-2258, svannais@davis-standard.com; Tim McElhany, tel. 864223-6146, tmcelhany@tulsapower.com; and WAI’s Chip Marsh, cmarsh@wirenet.org. ■

OCTOBER 2009 | 41

CHAPTER CORNER

impressions about the steel wire industry, including thoughts on how the recent economic downturn has changed the industry. Topics he will touch on include the rod segment, competitive forces on the industry, and thoughts on global trade and the direction of actions taking place in Washington.

Downes was appointed Senior Vice Joe Downes President in 2005 and President of the Industrial Materials Segment in 2004. He previously served the company as president of the Wire Group from 1999 to 2004 and in various other capacities since 1976. Before joining the company in 1976, he held positions with Atlantic Steel Company and Adcom Wire Company.

“The Ohio Valley Chapter is excited to have industry veteran Joe Downes as our program’s featured speaker,” said chapter President Dane Armendariz of Henkel Corp. “We look forward to Joe’s insights on the steel wire industry and what thoughts he has for the future.”

There is still time to sign up for the dinner meeting.

The cost is $40, discounted to $35 for chapter members.

Electronic registration forms can be found at

EVENT PREVIEW

IWCS to be held Nov. 8-11 at Charlotte Convention Center The Charlotte Convention Center in Charlotte, North Carolina, USA, will host the 58th IWCS Conference on Nov. 8-11, with the organizers noting that this year’s event will feature a solid technical program and a redesigned format.

IWCS CEO/Director John Barteld said that he believed the event was shaping up well despite the overall weak economy. “We have more presentations than last year, which is a function of our expansion into connectivity technologies. Those papers are new to the IWCS Symposium.

Our traditional paper sources have not disappointed either, the result being the increase of some 20 to 25% in papers to be presented.”

On the exhibit front, Barteld said that numbers were down some from 2008, which saw a record of 152 exhibit spaces taken. At press time, he said that about 115 booths had been taken, with a total of approximately 125 to 130 expected.

“We have suffered some cancellations, blamed on economic conditions, but also are hosting some companies that are new to the IWCS. Overall, we are not being surprised by anything so far.”

One area that is harder to predict is attendance, Barteld acknowledged. “Attendance is a question mark, as it is for all conferences this year,” he said. One positive aspect, he said, is that Charlotte is expected to attract a lot of drive-in traffic as there is an industry concentration within a 90- to 120-minute drive of the city.

Several program changes have been made for 2009, Barteld said. One move is that the Executive Forum has been folded into a “track,” eliminating the separate registration. “The program is excellent in terms of general industry

IWCS CEO/Director John Barteld at the 2008 event in Providence.

interest, and the market and economic data content has been moved to the plenary session. This was done as a result of our observations in past years of the very high interest in these components of the program,” he said. The schedule for the Professional Development Courses was amended for 2009, with the courses commencing with a session on Sunday afternoon and another session on Wednesday afternoon. “This will enable attendees to participate in all other scheduled events without conflict, and not have to arrive on Saturday for Sunday morning courses,” he said. “All in all, we have a very strong program this year.”

While the technical papers are the heart of IWCS, the single best-attended event continues to be the Plenary Session, which this year has four keynote presentations scheduled for the luncheon on Monday, Nov. 9. The talks include “Economic Outlook,”

by Dr. Robert Fry, Senior Economist, DuPont; “Introduction to Market Dynamics,” John Segal, Executive VP, CRU Research; “The Global Metallic Cable Industry: Where Does it Go from Here?” Rob Daniels, Principal Consultant, CRU Research; and “And the Last Shall be First: How the Emerging Markets are Reshaping the Fiber and Cable Industry,” Patrick Fay, Senior Consultant, KMI Research, CRU Activity at the 2008 IWCS event, which organizers said had a record 152 Group. booths.

42 | WIRE JOURNAL INTERNATIONAL

OCTOBER 2009 | 43

EVENT PREVIEW

A second program highlight, also on Monday, is the Executive Session, which starts at 8 am. Chaired by Robert Canny, Nexans, Inc., it will include the following presentations. “Outlasting the downturn: value creation strategies for the wire & cable industry,” D. Polansky, The Dow Chemical Corp.; “Intelligent buildings: the Duke energy headquarters,” R. Murchison/T. Shircliff, Intelligent Buildings; “Optical fiber industry update,” M. Curran, Corning, Inc.; “Trends in optical fiber Organizers expect approximately 125 to 130 booths this year at Charlotte. technologies,” A. Sarkar, Advanced Fiber Optic Solutions; “Smart gridinsensitive fiber–single mode; Cable design FTTH; Fiber impact on cable industry,” D. Houseman, Capgemini; and optic aerial & special applications; Connector component “Smart grid: a utility perspective,” R. Manning, Tennessee innovations in metallurgy; Bend insensitive fiber multiValley Authority. At 11 am, the Executive Panel Discussion mode; FTTH deployment in multi dwelling units (MDUs); will be held, with scheduled panelists including Clark Copper data cables & connectors; and Flame retardant mateKinlin, CEO, Corning Cable Systems; Brian Garrett, COO, rials. The Poster Papers session, which has 20 exhibits, will CommScope; Martin Hanchard, CEO, Prysmian Cables and be viewable on Tuesday, Nov. 10, from 4 pm to 6 pm.

Systems NA; Mike Amicone, CEO, Draka Communications Technical Symposium registrants will be offered their Americas; and Neil Wilkin, President and CEO, Optical choice of printed and bound proceedings or a CD. To see the Cable Corporation. dates and times for the papers, go to the IWCS website.

The Professional Development courses/instructors, on An alpha list of exhibitors is on the next page. Show hours Sunday, Nov. 8, include: “Fundamentals of copper conducfor the technical papers are as follows: exhibits are as foltors & metallic cable design & applications,” Trent Hayes, lows: Monday, Nov 9, 2 pm to 7 pm; Tuesday, Nov 10, 10 CommScope Inc., and Larry Bleich, CommScope; am to 6 pm; and Wednesday, Nov 11, 9 am to noon.

“Fundamentals of optical fibers & FO cable design & appliFor more information and to register, contact: Pat Hudak, cation,” David A. Seddon, Corning Cable Systems LLC; IWCS, Inc., tel. 732-389-0990, phudak@iwcs.org, “Selection & use of materials in wire & cable,” Dr. James S. www.iwcs.org.

Tyler, and Christopher McNutt, both of Superior Essex; “Intelligent building infrastructure design,” Thomas Boucino, CommScope Inc./Enterprise Solutions, and John Cowley, CommScope Inc.; and “GPON-fiber measurements,” Douglas Parker, WL Gore & Associates.

Courses on Wednesday, Nov. 11, include: “Electrical/electronic connector fundamentals,” Dr. Robert Mroczkowski, connNtext Associates; “Bend resistant fibers,” Scott Bickham, corning optical Fiber; “Fundamentals of polymer flame retardancy & testing,” Eduardo Redondo, Prysmian SpA; and “Extrusion technology and equipment for wire and cable,” Dagmar Glatz, Rosendahl GmbH. The technical symposium includes 16 sessions. The schedule for Tuesday, Nov. 10, includes: Fiber measurement & GPON; Cable design for multi dwelling unit (MDU); the Executive Track; Materials for optical fiber cable; FTTH deployment; Alternative energy & specialty cabling technologies; Connectors and interconnect technology, enabling Rob Daniels, CRU International, discusses wire and wire & cable solutions; and Polymer materials. cable markets at the 2008 IWCS. The schedule for Wednesday, Nov. 11, includes: Bend

CALL

FOR PAPERS

If wire processing is right up your alley

WAI WANTS TO HARNESS YOUR EXPERTISE for Wire Expo 2010

CONVENTION & EXHIBITION:

MAY 12-13

2010 MILWAUKEE, WISCONSIN, USA MIDWEST AIRLINES CENTER

ABSTRACT DEADLINE: DECEMBER 7, 2009 AUTHOR NOTIFICATION: JANUARY 4, 2010 MANUSCRIPT DEADLINE: MARCH 1, 2010

CALLING ALL EXPERTS Do you crimp, solder, or form wire? Do you mark, treat, test, assemble, package, or analyze it? Whatever your wire or cable discipline is, WAI wants your article ideas as it develops the technical program for Wire Expo in Milwaukee, Wisconsin, USA, May 12-13, 2010. Qualified experts in these areas and the topics listed below are invited to submit an article abstract. Accepted papers will be scheduled for presentation at Wire Expo and will be automatically considered for publication in Wire Journal International after the conference.

WAI welcomes articles in the electrical, ferrous, nonferrous, and general sectors. And because Wire Expo will co-locate with The National Electricl Wire Processing Technology Expo, special focus will be on submissions defined by the electrical processing technology topics that you know so well.

DESIRABLE TOPICS INCLUDE: • Application of non-traditional metals • Quality (statistics and testing) • Approval agencies • Surface treatment and powder • Environmental regulations coating • Failure analysis • Terminal technology • “Green” processes • Workplace safety • Laser marking Submit a 50-word abstract online at http://www.wirenet.org/technical/submit.htm or contact Marc Murray at mmurray@wirenet.org or Tel.: 203-453-2777, ext. 121 for more details.

The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

3N International, Inc. . . . . . . . . . . .219 AESA Cortaillod . . . . . . . . . . . . . . .116 AKSH Optifibre Ltd. . . . . . . . . . . . .402 AlphaGary Corp. . . . . . . . . . . . . . .104 Amaral Automation . . . . . . . . . . . .300 American & Efird, Inc. (A&E) . . . .206 ASI/Silica Machinery, LLC . . . . . . .205 B&H Tool Company . . . . . . . . . . . .521 Beta LaserMike . . . . . . . . . . . . . . .319 Boockmann GmbH/Slover Group .406 Borealis Compounds Inc . . . . . . . .321 Boxy Group/Mossberg Assoc.Inc. 320 Breen Color Concentrates . . . . . .504 Caballe . . . . . . . . . . . . . . . . . . . . . .114 Cable Components Group . . . . . .213 Carris Reels . . . . . . . . . . . . . . . . . .312

Cary Compounds, LLC . . . . . . . . .123 CERSA-MCI . . . . . . . . . . . . . . . . .301 Chengdu Centran Industrial Co. . .305 Cincinnati Thermal Spray . . . . . . .129 Coats North America . . . . . . . . . .322 Commission Brokers, Inc. . . . . . . .212 Conneaut Industries, Inc. . . . . . . .214 Corning Optical Fiber . . . . . . . . . .309 CRU North America, Inc. . . . . . . .117 Daikin America, Inc. . . . . . . . . . . .515 DeWal Industries, Inc. . . . . . . . . . .204 Dow Wire & Cable . . . . . . . . . . . . .113 Draka Comteq Optical Fibre . . . . .509 DSM Desotech, Inc. . . . . . . . . . . .101 EuroWire . . . . . . . . . . . . . . . . . . . .324 Fiber-Line, Inc. . . . . . . . . . . . . . . . .119 Fil-Tec, Inc. . . . . . . . . . . . . . . . . . . .518 FSP-one . . . . . . . . . . . . . . . . . . . . .220 Fusion UV Systems, Inc. . . . . . . .404 Gauder Group, Inc. . . . . . . . . . . . .517 Gem Gravure . . . . . . . . . . . . . . . . .607 Guill Tool & Engineering Co, Inc. .408 Indore Composite Pvt Ltd . . . . . . .422 Inhol BV . . . . . . . . . . . . . . . . . . . . .318 International Wire & Cable Symposium (IWCS), Inc. . . . . . . .327 Intertek . . . . . . . . . . . . . . . . . . . . . .600

j-fiber GmbH . . . . . . . . . . . . . . . . .505 J.M. Huber Engineered Materials .520 Kinrei of America, LLC . . . . . . . . .208 KOLON Industries, Inc. . . . . . . . . .603 Lantor BV . . . . . . . . . . . . . . . . . . . .513 LaserLinc, Inc. . . . . . . . . . . . . . . .606 Lloyd & Bouvier, Inc . . . . . . . . . . .216 Longvision (Shanghai) Cable Materials Co Ltd . . . . . . . . . . . . . .512 Madem Reels USA, Inc. . . . . . . . .519 Maillefer S.A. . . . . . . . . . . . . . . . . .307 MGS Manufacturing Inc. . . . . . . . .120 Miltec UV . . . . . . . . . . . . . . . . . . . .409 Nabaltec AG . . . . . . . . . . . . . . . . .207 NEPTCO . . . . . . . . . . . . . . . . . . . .100 OFS . . . . . . . . . . . . . . . . . . . . . . . .105 OptEM Engineering, Inc. . . . . . . . .209 Photon Kinetics, Inc. . . . . . . . . . . .221 Pittsfield Plastics Engineering, Inc.128 Plumettaz S.A. . . . . . . . . . . . . . . . .608 PolyOne Corporation . . . . . . . . . . .106 Printsafe, Inc. . . . . . . . . . . . . . . . . .107 REELEX Packaging Solutions, Inc500 Rio Tinto Minerals . . . . . . . . . . . . .400 Rosendahl Nextrom Technologies 407 S&E Specialty Polymers Toner Plastics . . . . . . . . . . . . . . . . . . . . . .602 Saint-Gobain Perf. Plastics Corp. .601 Shanghai Wangxun New Material Co Ltd . . . . . . . . . . . . . . .503 Shenzhen Delifeng Trading Co Ltd507 Shenzhen Unigel Telecom Co. . . .403 Sikora International Corp. . . . . . . .110 SMEETS SA . . . . . . . . . . . . . . . . .223 Solvay Solexis . . . . . . . . . . . . . . . .401 Sonoco Products . . . . . . . . . . . . . .200 SSCP USA . . . . . . . . . . . . . . . . . .304 Stewart Group, The . . . . . . . . . . . .418 T & T Marketing, Inc. . . . . . . . . . . .122 Teijin Aramid USA . . . . . . . . . . . . .419 Teknor Apex Co. . . . . . . . . . . . . . .412 Tekstilna Tovarna Okroglica . . . . .405 Tensor Machinery, Ltd. . . . . . . . . .508 W. Gillies Technologies, LLC . . . . .302 Weber & Scher Mfg. Co., Inc. . . . .501 Wire & Cable Technology Int’l . . .222 Wire & Cable Industry Suppliers Association (WCISA) . . . . . . . . . . .222 Wire & Cable Asia . . . . . . . . . . . . .324 Wire & Plastic Machinery Corp. . .306 Wire Association International . . .218 Wire World Internet . . . . . . . . . . . .424 Wyrepak Industries . . . . . . . . . . . .323 Yangtze Optical Fibre & Cable Co.502 Yield Management Corporation . .118 Zumbach Electronics Corp. . . . . .201

EVENT PREVIEW

List of exhibitors (as of 9/14/09)

A stronger weld that doesn't cost the earth Clean, green and easy to operate, PWM cold welders produce strong reliable permanent welds without heat, flux or filler, reducing material wastage and power consumption.

No set up time is required, no fumes are generated and the weld cycle is completed in minutes.

Manual and energy efficient powered models available, with capacities from .003145" (0.08mm) to 1.181" (30mm).

Call for details or visit www.pwmltd.co.uk.

MADE IN THE UK

Booth 300 IWCS Conference ‘09 Amaral Automation Associates 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: joe@amaralautomation.com www.amaralautomation.com

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

OCTOBER 2009 | 45

FEATURE

Testing & Measuring Equipment

T

his feature presents a range of testing and measuring equipment as well as commentary on the technology by both some of the suppliers as well as three

manufacturers.

ACM AB/Howar Equipment The KSM off-line measuring, database and evaluation systems from ACM AB, represented in North America by Howar Equipment Inc., are extensively used around the world, saving its users significant amounts of insulation and jacketing compound due to its unprecedented accuracy and statistical controls. Nearly 200 of the KSM systems for cross-sectional measuring unit for cables, tubes

A chart showing potential savings by reduction of unecessary raw materials by use of technology from ACM AB, represented in N. America by Howar Equipment. and profiles are now in full operation. The KSM unit offers dramatically higher repeat measuring speed and accuracy than manual methods and is replacing pin gauges, measuring microscopes and shadow graphs where the human influence can result in a 5-7% spread of the

46 | WIRE JOURNAL INTERNATIONAL

measuring values. The KSM system displays the result within 0.2–2 seconds, depending on the complexity of the slice, with practical experience showing a repeat accuracy of 0.2%. Through the summary protocols, manager trend curves the KSM evaluation program and images of the measured products can be displayed. Other data, typically hot-set values, can also be added, and a date range filter has been integrated. Beyond the standard min/max product dimensions and specifications, the values of many other parameters, such as stripping force and resistance, can be integrated in this module. One North-American customer initially rented a KSM unit, rather that outright purchasing it, to evaluate the savings potential. After six months of using the KSM unit to measure their 12 and 14 AWG, PVC-insulated bunched conductor, he projected annual savings of $240,000. He ended up buying four KSM systems. Reducing the 5-7% of the insulation material costs from “over-insulating” a cable can result in dramatic savings, although to do this the wealth of information created by the KSM system needs to be converted into a practical approach and its conclusions consistently implemented in the extrusion process. The returns, however, are definitely worth it.

Benz Testing Instruments Benz Testing Instruments has changed its R&D focus in the past year to cut the instrumentation costs. It has been a challenge as we have been designing instruments with instrument accuracy and operator convenience as the foremost design concerns. The soft economy and its effect on laboratory budgets have changed the focus of lab managers. Labs are now more concerned with initial costs, not total cost of operation as the primary factor in the purchasing decision. This has forced us to minimize the

FEATURE

bells and whistles we include in the design. Our model DIN2200 abrader for abrasion resistance of plastics and elastomers used in wire insulation is an example. Some customers have requested output to a computer and sample weighing integrated into the system. The standard instrument has speed and distance adjustment and monitoring, as well as automated start and stop programming.

It has been designed as an international machine, meaning the machine automatically adjusts to different voltage and frequency requirements. Our latest design is a response to a customer’s question: “How much will it cost me for just an on/off switch?” It does cut the instrument cost in half, but it makes more work for the operator. Our “Cost per Test” focus has changed to “Cost to Test.”

The DIN2200 DIN abrader from Benz Testing Instruments.

Upgrade of T&M equipment driven by customer needs Condumex, a major industrial group in Mexico that started operations in 1954, is the country’s largest electrical conductor manufacturer. It has representation in over 40 countries, and is a two-time winner (2002, 2007) of the National Award of Technology. It reports the following.

One of the largest Condumex factories, Cometel Vallejo, which manufactures power cable, has some 1,000 testing and measuring devices (T&M) in six laboratories and on the manufacturing floor. Calibration and maintenance schedules for T&M equipment are tracked by proprietary software and new equipment may be purchased if it is determined that it will provide a significant improvement in features, precision, accuracy and usability.

In 2007, Cometel started a strategic T&M project named SIAD (Spanish acronym for Remote Inspection System) to automate the T&M process by integrating digital test equipment and a graphical user interface using controlling software. The $4.36 million upgrade includes a shielded room that is unique in Latin America, laboratory adaptation and software development.

Prior to SIAD, tests were done by analog equipment and the results manually recorded in Excel files, both steps having the potential for mistakes. Further, customers had to be present during the execution of the acceptance tests to release the material.

SIAD increases the reliability of the tests applied to the finished product by recording the data automatically from the equipment and without direct intervention of the lab technician, thereby reducing the possibility of human error. The customer can monitor the execution of the

acceptance tests either in real-time or at any time later in a web page. We can execute tests without depending on the customer’s auditing schedule. The audit can be done at any time. This capability has improved the costumer’s confidence in the tests results, and productivity has increased by getting release of the final product from the customer automatically.

This approach has been demonstrated to be reliable and the plan is to extend it to other Condumex factories in the near future.

Yamil De León and Sergio A. Gómez, Cometel Vallejo/Condumex

Quality Manager Junior Amezquita at the lab at the Condumex Vallejo Plant (Power Plant).

OCTOBER 2009 | 47

FEATURE

Beta LaserMike The LaserSpeed速 system by Beta LaserMike has proven its value to the cable industry by improving quality and increasing profits for manufacturers. In just a short time, 750 LaserSpeed units have been sold to the cable industry alone. Manufacturers are looking for ways to improve processes and the LaserSpeed does just that in a very simple-to-use, cost-effective package. Many manufacturers understand that current methods for measuring length are problematic and expensive. Due to slippage alone, contact encoders can costs manufacturers >$60,000 per line per year, a conservative number considering as wheel encoders tend to be inaccurate to 1-2% and the cost of producing cable is continually increasing. Over-shipping expensive cable can lead to hundreds of thousands of dollars, if not more, in lost profits. This does not even include down time for maintenance and calibration. The LaserSpeed helps manufacturers by drastically improving length accuracy and uptime. With +/- 0.05% (about 20 to 40 times more accurate than contact methods) accuracy and permanent calibration, the LaserSpeed eliminates over-shipment of

A Beta LaserMike LaserSpeed速 system. profits out the door and increases uptime. It has all the same interfaces as existing contact encoders so integrating into existing systems is very simple. For new installations, the LaserSpeed also offers more advanced connectivity to meet the demands of more modern equipment.

Remote capability of T&M equipment a customer plus Viakable, a Mexican wire and cable group whose products range from power cables up to 230 kv and building wire to magnet wire and coax/data, with operations in Mexico and Brazil that include Conductores Monterrey, Magnekon and Sao Marco, reported the following.

We use about 10 different types of equipment for measuring mass, temperature, force, flux, electricity, length, and pressure. Decisions on updating or renewal are based on either the condition of the equipment determined by our own metrology lab, or by needs coming from new products. For instance, in 2006 a major utility company that was a very important customer wanted to be able to examine all electrical testing results and reports on finished cables on a real-time basis from their headquarters.

This forced us to reconfigure and design an Internet port, and some equipment had to be replaced because the model and configuration could not work. Now we can offer access to results and reports in a transparent way to both customer and supplier.

Some testing and measuring equipment we acquired years ago has a more robust construction and very good accuracy, but its operation is more complex. We find that the newer equipment is simpler to operate, has excellent accuracy and better resolution, but it demands better care in its operation.

In our opinion, the durability of testing and measuring equipment depends on the proper and correct operation and maintenance as per the vendor recommendations, and the proper selection of the vendor and model in the buying

48 | WIRE JOURNAL INTERNATIONAL

process. If we follow the calibration and maintenance recommendations and properly operate the equipment, it should last more than a decade with a high degree of reliability.

Our preference for equipment over the years has been to have different brands and models, depending on the technical characteristics and commercial conditions.

However, we have had specific cases where we have one-supplier equipment because their performance is far better than the others. In general, we consider testing and measuring equipment to be a Conductores Monterrey QA fairly problem-free Manager Walter Reeker, l, and operation, based Viakable Director of Technology upon our strong & Development Patricio G. Murga and close superviwith a reel of Extra High Voltage sion from our (EVH) cable that requires extensive metrology laborause of testing and measuring equiptory. ment.

Our Laser Diffraction Sensors (LDS) instruments, for fine wire diameter measurement, are used worldwide and recognized for their high measurement accuracy and stability. Featuring robust technology and temperaturecompensated, these instruments were initially made for in-line measurement because of their ability to keep accurate measurements despite the wire vibrations. But their metrological performances have resulted in customers also widely using them in the laboratory for the allimportant final check and certification of the product characteristics. In the laboratory, the LDS instruments are highly regarded because of the low measurement uncertainty (±0.03%) in the percentage of the diameter. The measurements are very reproducible with high accuracy, resulting in very high measurement stability and accuracy in time. The models have a long lifetime, typically 10 to 20 years, and are entirely static as there are no moving parts. The LDS, which provides metrological characteristics for each individual measure instead of averaging, can be used for metallic wires, fibers, capillaries, filaments,

bonding wires, enameled wires and drawing dies.

Complementary accessories make it possible to check ovalities or shapes and average diameters, a include a

FEATURE

Cersa-MCI

An array of Cersa-MCI equipment.

Manufacturers of both

‘HUSH’ & ‘LOCK ON’ PULLING IN DOGS T: +44 (0)1527 570977 F: 882423 E: sales@locton.co.uk www.locton.co.uk

OCTOBER 2009 | 49

FEATURE

label printer and software for data logging and a display that are time-proven. An optional portable instrument can be used in a production line to measure a series of diameters in line to get a sample of statistics (average, max./ min. and standard deviation) with associated advanced PC software for data transfer, recording and automatic graph display, which allows the tracking of different machines (127 max.) with only one single instrument.

Clinton Instrument Company The FL-20A cable fault locator is Clinton’s newest quality tool for the wire and cable industry. Cable rejected during the hi-pot test has always been an expensive problem for the manufacturer. Until now, finding opens and shorts with an analog cable fault locator took expertise and patience, since the procedure required tedious meter and sensitivity adjustments as well as mathematical calculation once the test was completed. The digital FL-20A automates cable fault detection, greatly reducing the time

and training required to find these problems. Opens, metallic shorts, or high voltage shorts between conductors or between conductor and shield are pinpointed quickly and with ease. The operator simply connects the FL-20A test probes to each The FL-20A cable fault locator. end of the cable from Clinton Instruments. under test, enters the cable length and gauge size on the digital front panel display, and selects “Shorts” or “Opens” to begin the test. Within a few seconds, the unit calculates the distance of the fault site

Ability to verify accuracy of T&M equipment is essential Founded in 1941, TE Wire & Cable, a Marmon Wire & Cable/Berkshire Hathaway company, manufactures thermocouple wire and extension cable along with instrumentation and control cables. Its thermocouple products are used to measure temperatures from as low as -400°F to as high as 2350°F. It reports the following.

The testing & measuring equipment we use is very important to us as well as our customers, especially as those whose products end up in airplanes themselves need to show that they are using the highest quality product.

For us to ensure customers get what they need, we maintain an internal in-house temperature calibration laboratory that has to be accredited and be able to pass regular, independent auditing. Our lab has been accredited by A2LA to the latest international standard ISO 17025 for laboratory calibration.

(ISO 17025 is separate and additional to ISO 9001-2008 which TE Wire is separately accredited to by Lloyds Registry.) A2LA, as an independent accrediting agency, reviews and corrects lab procedures, equipment, training, and accuracy budgets. A2LA’s thorough and detailed threeday, on-site audits verify our temperature accuracy.

Our primary laboratory equipment includes: Hewlett Packard Data Acquisition units, NIST-calibrated SPRT reference RTDs, triple point (water-ice-vapor) cells, metal-freeze point cells, 10 atmosphere furnaces, two high-temperature furnaces, four reference junction ice baths, oil baths and fluidized bath units. We perform biannual review of our equipment to ensure it is meeting our needs, and whether it is time for upgrading.

Dante Bediones, an NIST-trained lab manager, and Ed Kohler, QA manager, work closely with A2LA to keep our lab procedures, equipment, and training at an industry-lead-

50 | WIRE JOURNAL INTERNATIONAL

ing level. Dante, along with two highly experienced employees, programs the lab computers with temperatures, dwell time, drift tests and more. Then the computers take over. The computers control the 10 test furnaces, raising or lowering to the proper programmed temperatures and times. Readings are taken and recorded electronically. After converting the accuracy measurement taken in micro-volts, the results are recorded along with other information to meet ISO 17025 requirements. Having the computer control the temperatures, take the readings and do the math eliminates the possibility of human error. We archive the data and supply it to customers for reference.

“Testing and measuring equipment is vital because our customers must have confidence that our products are accurate and dependable,” said TE Wire & Cable President Greg Smith. “That hasn’t changed in 68 years.”

TE Wire & Cable Lab Manager Dante Bediones, l, with QA Manager Ed Kohler.

DCM Industries DCM’s model ES-2G, which provides compliance testing of high performance twisted-pair cables, includes the automatic switching and baluns needed to interface a test cable to an external vector network analyzer (VNA). The ES-2G software includes a simple, easy-to-use test program that fully automates the testing of Return Loss, Insertion Loss, Impedance, NEXT, FEXT and more. It includes specialized ISTP (CAT 7) test heads providing an easy means for connecting the cable under test to the test system, minimizing external influences and providing >90 dB system isolation up to 1.2 GHz. The ES-2G is also available with interchangeable UTP test heads for testing Cat. 5 and 6 cables, providing a highly flexible system geared to manufacturers’ specific needs. The ES-

2G includes many innovative features that provide tremendous value for cable manufacturers whether in the development labThe ES-2G model from DCM Industries. oratory or on the production floor. The ES-2G was the first of its kind to store VNA error corrections in the computer rather than in the VNA, and allows the calibration plane to be moved from the VNA up to the cable connection point. Each calibration standard is independently modeled to the maximum frequency range. This not only provides more accuracy, but reduces overall test time by enabling one calibration routine to cover a wide variety of frequency ranges. DCM offers a complete line of LAN, telecom and RF/coaxial cable testing solutions.

Lamnea Bruk AB 610 10 Ljusfallshammar Sweden Tel. +46 122 23200 Fax + 46 122 232 99 info@lamnea.se www.lamnea.se

Lämneå Bruk, your reliable supplier of semi- and fully automatic Precision Layer Winders for Co2, Flux Cored, Sub-ARC and Stainless Steel

Lamnea Bruk USA PO Box 216 Codorus, PA 17311 Tel. 717 229 8755 Fax 717 229 8785

OCTOBER 2009 | 51

FEATURE

from each test probe and displays the location in feet or meters. The failure can then be cut out or repaired and the remaining good product salvaged, resulting in great savings to the producer. The FL-20A Cable Fault Locator, a compact 15 in. w x 14 in. d by 10 in. h weighing only 30 lb, is significantly smaller and lighter than its predecessors. It promises a great return on investment by salvaging expensive cable assemblies and lowering the costs associated with salvage.

Die Quip specializes in measuring products for draw dies, tooling and quality control labs. The problems with inspecting small diameter dies is the difficulty in getting enough light into the die. Die Quip has solved this with

Plug gauges offered in the U.S. by Die Quip Corp.

our fiber optic light pads for new or existing microscopes.

The light pads provide an abundance of adjustable bright white light to be able to find defects and prevent them from going into production. Die Quip’s other new product for measuring dies are plug gauges treated with black oxide to show you exactly when gauges are wearing out of tolerance. No more guess work or tedious measuring of gauges to determine if still in specification. Simply use a gauge till the treatment wears off and then replace.

These gauges are available in ZZ Class (.0002 in.) in plus or minus tolerance, have a 10 micro-inch surface finish and are hardened to 60-62 Rockwell C. They are available individually or in sets from .011-.500 in. (0.25-12.0 mm).

EddyTech Systems Inc. Wire and bar end users are demanding that their suppliers provide high quality material and even insist on zero

NOVEMBER 2009

FEATURE

Die Quip Corp.

52 | WIRE JOURNAL INTERNATIONAL

defects in some cases. Although this may be impractical, most suppliers have discovered that eddy current inspection potentially offers a real solution. The latest all-digital EddyChek 5® “Advanced” is an eddy current instrument that forms the foundation of a state-of-the-art inspection system. With its ease of use, versatility and robust design, it includes features, such as Windows XP ‘Embedded’ for hack-proof operation, a large LCD display and a simple touchscreen operation.

Contextsensitive help screens in a variety of languages guide even An EddyChek 5® “Advanced” model. the most novice user through setup and calibration of the system. The EddyChek 5 is easy to install on most production lines and can be used to inspect both ferrous and nonferrous material. An autofilter option is available, which continuously compensates for line speed variations to reduce false positives, generally caused by vibration or electrical noise. Extensive reporting capabilities, including the ability to record and play back defect signals, provide valuable real time data throughout the production process. Housed in its own environmentally sealed cabinet, the system is ideal for the harsh environments in many facilities. For more than 30 years the EddyChek name has been synonymous with high quality, German-engineered equipment. The EddyChek 5 “Advanced” continues this tradition of providing superior instruments for process monitoring, quality control and scrap reduction.

L UBRIC ANTS & F ILTRATION

Force Measuring Systems (FMS)

Product-specific solutions from Foerster Instruments Inc.

Foerster Instruments Inc. For years eddy current testing of round valve spring wire has been a world standard for leading manufacturers who can use a combination of Foerster’s CIRCOGRAPH (rotating sensors) and DEFECTOMAT (encircling through type coil) technology. Today, Foerster’s CIRCOGRAPH/DEFECTOMAT DS model with the Ro 20 and M 40 or H 40 is the state-of-the-art equipment for longitudinal and transverse defects in spring wire applications, both round and ovate (non-round sections).

For round wire, longitudinal cracks with a depth of 40 µm can be detected with rotating sensors with an excellent S/N ratio. Modern designs use ovate or egg-shaped sections for improving spring characteristics and weight reduction. For ovate/non-round wire with special clearance compensation, longitudinal cracks with a depth of 60 µm can be detected when the maximum diameter is not larger than the minimum diameter by 1 mm. Equal sensitivity and detectability is ensured throughout the circumference with this feature. Similarly, for transverse defects, Foerster’s shaped coils adapt to the wire shape to ensure uniform sensitivity between the minimum

FMS launches its newest RTM (Radio Transmitted Tension Monitoring) system. Through continuous development work on the RTM System, wire and cable manufacturers now have an affordable way to monitor and control tension of individual wires on most planetary or tube stranders, bunchers, twisters, or other rotating machinery.

The system monitors tension in real time for up to 32 individual strands, and can be configured to handle nearly any tension measurement or control task. Actual tension values are displayed graphically on a PC monitor and also logged for possible quality assurance reference. The monitoring system is comprised of tension sensors, tension measuring amplifiers, a bus system with radio transceivers, a control unit, and software. For applications where closed loop tension control is desired, digital tension controllers are integrated into the system. Controller parameters, including tension set points, can be adjusted during machine operation. Possible configurations include the capability to provide a high/low tension alarm signal, or an output to stop the machine immediately in case of a

RTM technology from Force Measuring Systems (FMS).

WIRE JOURNAL

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INTERNATIONAL

GO WITH THE FLOW Want to catch prospects streaming in your direction? WJI is your answer.

Thousands of readers pore over each issue of WJI looking for manufacturing solutions.

Place a product ad the November issue on lubricants and filtration and increase your current prospects before they’re enmeshed with a competitor.

Call WJI’s sales team today before this marketing opportunity slides by. We’ll help you keep business running smoothly.

Contact WJI’s Sales Team: Tel.: 001-203-453-2777 Bob Xeller E-mail: bxeller@wirenet.org Anna Bzowski E-mail: abzowski@wirenet.org

OCTOBER 2009 | 53

FEATURE

and maximum diameters. Both the CIRCOGRAPH and DEFECTOMAT eddy current systems offer features and functions to improve the testing quality for non round valve spring wire. This is another real step for improving product quality.

LEIBINGER Inkjet printer Camera systems

wire break. The FMS tension sensors are specially designed for rotating applications, and are compensated for both centrifugal and Coriolis forces to very high accelerations. A wide range of tension sensors are available to suit most any application. With the standard data logging feature, the RTM system will record the tension value of each strand correlated to the product running length. The RTM System is reliable, accurate, economical, easy to operate and virtually maintenance-free.

LaserLinc Inc.

2 1 0 V 2 . /E 4 0 74 44 .

14 T 4 960 LO 221 84

LaserLinc’s UltraGauge+ ultrasonic measurement system (laser and ultrasonic technology) provides incredible pairing of tools for non-contact monitoring and control of OD, ID and wall thickness. The system includes transducers, a digital signal processing unit (DSP), a laser micrometer, and, for even more precise measurement of length and speed, we now offer a non-contact encoder. Our ultrasonic device measures wall thickness at up to eight positions with 2000 measurements per second. The transducers sit in either the product’s cooling or vacuum tank, or a LaserLinc manufactured tank. A transducer emits an ultrasonic “ping” toward the product and the DSP computes the time difference between the ping echoes at each layer LaserLinc’s UltraGauge+ ultrasonic measureinterface, using the speed of sound in the ment system. product to build a picture of it. The DSP connects via Ethernet to a computer running Total Vu™ software, The measurement/data processing package, and the PC can be fairly distant from the production line, eliminating many cabling and distance limitations. The measurement devices combine with Total Vu software that runs on Windows-based PCs to create realtime charts, graphical cross-section displays, and measurements in configurable, easy-to-read panels. The software also provides in-process tolerance checking, trending, SPC, control, data logging and other features. These tools reduce scrap, increase production efficiency and improve quality. All LaserLinc micrometers and the UltraGauge+ DSP have a 4-year warranty, parts and labor (transducers a 1-year warranty).

Magnetic Analysis Corporation (MAC)

www.leibinger-group.com PAUL LEIBINGER GMBH & CO. KG Germany

The detection of the few flaws that may occur in large production runs of metal wire or bars at production line speeds is best accomplished using the NDT techniques that are most capable of detecting the specific unacceptable conditions that are anticipated in the product. For critical applications where the wire or bar must be free of surface, subsurface and internal defects of a variety of shapes and sizes, systems with multiple test stations at which dedicated techniques, based upon ultrasonic and eddy current methods, are often used. An example of this is shown in the photo of an automated MAC test system for cold drawn bar. Included are an encircling differential coil eddy current tester for detecting short surface and subsurface defects such as slivers and pits; a spinning probe eddy current system to find long, surface defects such

FEATURE

as seams; and a rotating transducer ultrasonic system for internal defects such as non metallic inclusions or stringers. Also, an absolute coil eddy current system for detecting grade or alloy mix and a demagnetizer to minimize residual magnetism generated by the eddy current system when inspecting magnetic material. These components are mounted on a constant center test bench with

wire

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join the best 12 – 16 April 2010

An automated MAC test system. triple roll drives which are adjusted and controlled automatically through conductor controls. This type of bench is especially useful for small diameter coil to bar installations, as small as 12 mm, where centering is critical. By using multiple test methods, there are less “false” rejects and fewer unacceptable defects will be missed than in a system using only one test method, which results in a quick investment payback.

Proton Products/Weber & Scher In today’s economic climate, process control is critical in preventing raw material waste which directly translates into cost. In response, Proton Products offers the NEXiS CS3G series of controllers to control cable diameter, shrinkage, average wall thickness and even width and thickness in flat product applications. The system uses a proprietary control board featuring advanced control algorithms and I/O such as RS232, USB, Technology from Proton analogue and relay Products, represented in the outputs. The Proton U.S. by Weber & Scher.

Products InteliSENS

Düsseldorf, Germany International Wire and Cable Trade Fair www.wire.de

Secure your advantage The innovation cycles are constantly getting shorter. New technologies and solutions offer new possibilities.

In order to maintain or to extend your lead, first hand information is necessary.

At wire 2010, the entire international wire and cable industry will meet to experience innovations live. Take part and discover the trends and markets for the future. Profit from the expertise of leading suppliers and secure your advantage.

Together with the concurrently held Tube trade fair, wire 2010 will open up new and profitable perspectives.

Order your wire 2010 entrance passes online in advance of the show at reduced rates!

Wire, Cable, Fibre Optic, Wire Products and Machinery

For show information: Messe Düsseldorf North America 150 North Michigan Avenue Suite 2920 Chicago, IL 60601 Tel. (312) 781-5180 Fax (312) 781-5188 E-mail: info@mdna.com http://www.mdna.com

Spring Making

Fastener Technology

For hotel and travel arrangements: TTI Travel, Inc. Tel. (866) 674-3476 Fax (212) 674-3477

Official Airline

OCTOBER 2009 | 55

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series of diameter gauges connects via a datasecure CANBUS network delivering fast, accurate data.

The NEXiS CS3G processes the data and adjusts the level of control provided to the extrusion line resulting in a smooth control of product dimensions.

Sikora AG/Sikora International The X-RAY 8000 NXT, which was realized from the concept stage by Sikora’s R&D team, best exemplifies the company’s technology and full resource capabilities. The X-RAY 8000 first appeared in the market in 1993, addressing a real need in power cable manufacturing to reduce startup scrap and production overconsumption on a reliable basis. Since its introduction, the device has been widely accepted and has been one of the most successful stories of measurement systems in history. The XRAY 8000 NXT, the latest system version, Sikora’s X-RAY 8000 NXT. presents technological advances as well as “Green”-oriented initiatives, one being the implementation of non-toxic windows. Other notable advances are ceramic windows that stay clean; multi-sensor technology for measurement reliability, even with vibrating cables; and a variety of hardware advancements. The software advances have introduced a new operating system making the operator’s environment the easiest interface while providing a host of new data logging and statistical tools to manage, analyze and control the application. Sikora’s R&D used the experience learned with the X-RAY 8000 NXT to bring to market the X-RAY 2000 in 2005. Since this device was introduced, it has revolutionized the measurement and control of jacketing and insulating lines in wire and cable applications as well as a number of other applications in other industries. The success of these systems and the technology could be the number of systems sold, but what is also quite noteworthy is the degree of acceptance it has achieved in the applications.

56 | WIRE JOURNAL INTERNATIONAL

Pinholes, neck-downs, bulges and blemishes can be detected using Taymer’s SI4200 inspection system, which can detect all jacket defects with a single system, minimizing floor space and cost. The system provides 360 degrees of coverage of the wire at line speeds up to 600 feet per minute. The Surface Defect Detection System (SI4200) consists of multiple cameras to capture highspeed, real-time images of cable surfaces. The system software can determine the size and types of a wide range of surface defects.

Even defects as small as 0.025 in., will be detected and the system will trigger an alarm. Taymer International’s SI4200 inspection The digital system.

images are enhanced, magnified and displayed on a remote monitor, enabling the operator to verify the defects. This allows operators to determine the type of defect, to distinguish between real and fake defects (e.g., a water droplet), and even to detect surface blemishes (e.g., surface discoloring, scratches). A record of the defect type and size can be saved to a database along with the defect location. Operators can pinpoint the defect locations after production is completed. The system easily integrates to your lines and works well for all types of cables (armored, jacketed, bare wires, and convoluted profiles). Taymer’s surface defect detection system ensures that any problems are discovered before the defective products are sent to customers, a great technology to assure product quality.

FEATURE

Taymer International Inc.

Zumbach Electronics AG/ Zumbach Electronics Corp.

A primary example of cross-over development of products is our series of laser- and camera-based PROFILEMASTER® systems. The PROFILEMASTER was developed with plastic profile (window, decking, automotive, furniture, etc.) applications in mind, but is quite well suit-

Payoff Flyers and Winders Payoff with dancer accumulator and double pivot to pre-load for spools dia 560 mm to dia 800 mm, tension adjustment by magnetic particle brake or hysteresis brake

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FEATURE

ed to many wire and cable applications, including category spacers, drop-cable (“figure-eight”), duplex cables, general flat cables, triangle (sector cables) and more. We recently introduced the SIMAC 63; our new highspeed, camerabased surface inspection system.

The SIMAC 63 offers full 100% coverage of a round product to detect and locate faults (such as gels, lumps and neckdowns), color Zumbach’s SIMAC 63 model. changes, inclusions, scratches, jacket tears, etc.

The SIMAC 63 has important applications in tube and pipe (medical, automotive, irrigation, gas, cold and hot water, fuel, etc.), but also any conventional round cable, including telephone, power, fiber, and more.

Supplier thoughts: WJI: Do cable manufacturers generally take advantage of their testing & measuring technology, or is the ability to generate comprehensive data seldom used (or to its full potential)?

It’s a mixed bag.

Many companies insist that their inspection equipment be capable of providing both real time and archived statistical data. However, they soon discover that collecting data is easy and that the real challenge is finding ways to use that data effectively. In

Rich Fisher, EddyTech Systems, Inc.

Visit our stand # 300 at IWCS

Distributor and Manufacturers Representative offering: • Cold Pressure Welders and Dies

• Diameter/Measurement Systems

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P.O. Box 7816, Cumberland, RI 02864 • Tel: 401-405-0755 • Fax: 401-405-0757 e-mail: insidesales@amaralautomation.com • www.amaralautomation.com 58 | WIRE JOURNAL INTERNATIONAL

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Williamsport, MD 21795 USA Tel.: 301 223 8584 Fax: 301 223 8542 info@sampinc.com www.sampsistemi.com

SAMP S.p.A. – Division Sampsistemi Via Saliceto No. 15 40010 Bentivoglio (Bologna) – Italy Tel.: +39 051 6319411 Fax: +39 051 370860 info@sampsistemi.com www.sampsistemi.com

FEATURE

our experience, those companies that actually develop methods to utilize collected data for process control and improvement generally wind up with the highest yields, lowest scrap rates and best overall quality. Others that merely use inspection equipment as a pass/fail sorting gauge rarely attain the same level of quality or efficiency.

Rich Fisher, president, EddyTech Systems, Inc. Cable manufacturers definitely take great advantage of test data.

The data is vitally important in two primary areas: 1) to establish, improve and perfect cable designs for existing and new applications. Without automated test systems like those offered by DCM, cable producers would spend considerably more

Perry Chattler, DCM.

time and money in their design process and still not have the amount of data needed to improve and perfect their cable designs; and, 2) to monitor the performance of the production process ensuring that only high quality cables are produced on a consistent basis. Testing tools like the DCM Margin Analysis allow producers to quickly monitor trends in the production process and to make the process and machinery adjustments needed before quality issues arise. Perry Chattler, president, DCM Industries, Inc. The wire and cable market has a very mature range of experience with measurement and control systems.

Therefore, most applications have viable product solutions today for basic applications, such as outer diameter measurement, wall thickness, capacitance, preheating, etc.

However, that does not mean that todayâ&#x20AC;&#x2122;s measurement systems will remain â&#x20AC;&#x153;good enough.â&#x20AC;? With our large customer base in all market segments for wire and cable, we are constantly being approached for opportunities to improve existing products or to expand our product line to offer a new solution. Keith Donahue, vice president of sales, Zumbach Electronics.

Cable manufactures are certainly not utilizing the degree of testing and measuring instruments which would provide them with the best control over the processes. Some of the instruments presently used are archaic and rely heavily on operator capabilities, which invariably results in rather inaccurate results. Willy Hauer, principal, Howar Equipment/ACM. WJI: How has your company most changed the focus of its R&D in recent years, and why?

In the past four years up to the end of 2008 and the start of the recession, Sikora had experienced double digit growth. During this growth phase Sikora invested heavily in R&D to continue the tradition of innovation, which the company is known for. With this growth we have 23 people involved in R&D efforts today.

This number has remained constant even through the recession as our management believes in keeping the team together to maintain our strength. This investment in R&D has allowed Sikora to bring new developments

60 | WIRE JOURNAL INTERNATIONAL

Our focus has been on advancing the state-of-the-art in core signal processing technologies such as Laser Doppler Velocimetry, noncontact eccentricity measurement, Structured Return Loss (SRL) measurement, as well as our patented UltraScan “Snap” Technology which automates the configuration of ultrasonics measurement devices. Additionally, we Ken Wright, Beta have invested heavily in the interLaserMike. connectivity of our equipment with third-party vendors through technologies such as Ethernet IP. We have focused significant engineering resources into developing customized, “ondemand” solutions to provide manufacturers products tailored to their specific manufacturing needs, enabling them to remain competitive technologically. Ken Wright, president, Beta LaserMike.

Equipment is available to meet most needs. To address ever-tightening specifications and cost saving requirements, diameter measurement has moved to 3, 4, even 6-axis laser microscopes, and at much higher speeds (4000/axis) for better coverage along the length of wire and cable but also around its circumference. Coupled with technology such as ultrasonics for centering and wall measurement, thorough inspection is possible. Throw in the most accurate solution for length (and speed)—a noncontact encoder—and the most critical aspects of product measurement are covered. With software such as trending, high-speed logging, SPC, FFT/SRL, the tools for process improvement are more powerful than ever. Jeff Kohler, vice president and sales director, LaserLinc.

The global economic recession started in 2008, balanced by the optical fiber activity progress, pushed us to change our R&D priorities. Restarting complementary works on coating, postponed for years now, we succeed in accurate and fast diameter measurement early this year. Our coming new laser Interferometric instrument for coating will complete our line of high performance instruments for production draw towers. The LIS-coating will include in one instrument, accurate and fast diameter measurement along with internal defect check. The new

Sjogren Tensile Testing Wedge Grips WHEN IT COMES TO TROUBLE-FREE

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OCTOBER 2009 | 61

FEATURE

to address challenges our customers face in their daily quest of manufacturing excellence. Jeff Swinchatt, president, Sikora International.

FEATURE

software will include this instrument in order to offer a “full package” for a “full in line quality certification,” that make most of off line tests obsolete. Rossitsa Spilkova, marketing & sales, Cersa-MCI. Recent and current R&D efforts have resulted in the development of ultrasonic and eddy current instruments which are actually computers with special software that enables the establishment of criteria that differentiates between signals from a wide Don Bugden, MAC. variety of small defects, and signals from production variations which are not detrimental. The bottom line is fast changeovers and high yields. These improvements are in response to tighter specifications by wire and bar producers reflected in industry standards sources such as the ASTM. MAC has worked for many years on ASTM E-07 Committee applying developing technologies to new requirements that are constantly evolving. Don Bugden, marketing vice president, Magnetic Analysis Corp.

ACM/KSM has been able to enlarge its research focus onto the elaboration and evaluation of the measuring data obtained from the KMS system, allowing their customers

to get a more complete accurate and faster picture of the actual situation of compound usage. A number of customers are using the system directly with their computerized production facilities. Willy Hauer, principal, Howar Equipment/ACM. Zumbach traditionally has focused on wire and cable, plastic tubing and steel rod applications but its R&D has expanded in recent years to include other markets that involve steel, glass, rubber and plastic tube, pipe, profile and more. We have recognized opportunities to develop solutions which could also cross-over to our traditional markets, such as the PROFILEMASTER® systems we chose to highlight. Keith Donahue, vice president of sales, Zumbach Electronics.

WJI: Does your company primarily act to make changes in industry standards based on equipment capability or does it respond to changes from the manufacturers and standards’ organizations?

It is difficult to say like that. It comes from the experience of the industry, the technology progress and the search for the whole process improvement. This “mixture” generates ideas and suggestions to the industry that leads to developments plans. This is the mission of machine manufacturers to check permanently how to improve the processes and best answer the manufacturer needs. It cannot be done without close customer cooperation. Rossitsa Spilkova, marketing & sales, Cersa-MCI. ■

Contact list Benz Testing Instruments, U.S., Ted Benz, tel. 401-331-5650, ted@benztesters.com, www.benztesters.com

LaserLinc, U.S., Robert Wexler, tel. 937-318-2440, rwexler@laserlinc.com, www.laserlinc.com

Beta LaserMike, U.S., Ken Wright, tel. 937-233-9935, sales@betalasermike.com, www.betalasermike.com

Magnetic Analysis Corporation (MAC). U.S., Robert Bugden, tel. 914-699-9450, info@mac-ndt.com, www.mac-ndt.com

CERSA-MCI, France, Rossitsa Spilkova, tel. 33-4-4202-0873, r.spilkova@cersa-mci.com, www.cersa-mci.com

Proton Products International/Weber & Scher, U.K./U.S., Gregory K. Scher, tel. 908-236–8484, webscher@webscher.com, www.protonproducts.com, www.webscher.com.

DCM Industries, U.S., Perry Chattler, tel. 510-670-7200, pchattler@dcmindustries.com, www.dcmindustries.com Die Quip Corp., U.S., Tom Maxwell Jr., tel. 412-833-1662, diequip@diequip.com, www.diequip.com EddyTech Systems, Inc., U.S., Rich Fisher, tel. 440-234-4809, ext. 102, rfisher@eddytech.com, www.eddytech.com FMS Force Measuring Systems AG/FMS USA, Inc., Switzerland/U.S., Steve Leibold, tel. 847-519-4400, steven.leibold@fms-technology.com, www.fms-technology.com

62 | WIRE JOURNAL INTERNATIONAL

Sikora AG/Sikora International, Germany/U.S., Jeff Swinchatt, tel. 770-486-1233, sales@sikora-usa.com, www.sikora.com.

Taymer International Inc., U.S., tel. 905-479-2614, info@taymer.com, www.taymer.com Zumbach Electronics AG/Zumbach Electronics Corp., Switzerland/U.S., Carolyn Edwards, tel. 914-241-7080, ext. 303, cedwards@zumbach.com, www.zumbach.com.

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New Technology for Global Markets TWO DAYS. TWO CONTINENTS. ONE STOP. Take a look at developing industries in the wire and cable sectors as you join colleagues, presenters, and exhibitors at this educational conference and marketplace 2-3 November 2009.

SAVE THE DATE: 2-3 NOVEMBER 2009 | ISTANBUL, TURKEY

Set in Istanbul, Turkey—one of the largest cities in Europe, which is also the only metropolis situated on two continents—the event is next in the series of anticipated conferences by the WAI, ACIMAF, CET, and IWMA sponsors designed to surface big ideas and relevant dialogue.

EXHIBITORS NOTE: TABLETOP SPACE AVAILABLE FROM € 630.

Details and registration information available online at: www.wirenet.org or www.iwma.org.

For more information contact: Marc Murray, Director of Education, The Wire Association International, Inc., 1570 Boston Post Rd., P.O. Box 578, Guilford, CT 06437-0578 USA, Tel.: (001) 203-453-2777 ext. 121, Fax: (001) 203-453-8384, E-mail: mmurray@wirenet.org.

Conference organized by: Associazione Costruttori Italiani Macchine Per Filo

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Comité Européen de la Tréfilerie

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The Wire Association International, Inc.

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Formulation, analysis, and measurement of fines

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TECHNICAL PAPERS

TECHNICAL PAPER

This paper presents an overview of fines, a new method to quantitatively determine the fines-potential of rod samples and discusses several methods to reduce the generation of fines.

By Horace Pops and Gil Baker

Introduction According to Webster’s dictionary, fines are defined as “a finely powdered material or very small particles in a mixture of various sizes.” They are a very well known nuisance in the wire and cable industry and can create such problems as die wear, wire breaks, poor lubrication, and surface damage.

Overall, the presence of this undesirable substance leads to poor productivity, lowered quality, and increased manufacturing costs. Although there are numerous references in the technical literature to the treatment and characterization of fines, almost all of these articles deal with the extraction of fines and the disposal of spent lubricant. For example, the subjects of filter media selection for wiredrawing fluids1, lubricant filtration and disposal2, and heat generation and cooling3 are adequately summarized in the Wire Association Nonferrous Wire

Handbook, Vol. 3. Since high surface quality is one of the most important requirements for magnet wire, the presence of fines can lead to surface damage and poor enamel films4.

Likewise, fine particulates of copper-copper oxide flakes can spall from copper rod during subsequent torsional twisting or wiredrawing5. It is not surprising that fines can result in packed or plugged drawing dies, and ultimately lead to more wire breaks6. Typical sizes and distribution of metallic fines have been reported7 for particles that were generated using both carbide dies and polycrystalline diamonds. Finally, it should be noted that excessive formation of fines can lead to rapid wear and failure of drawing dies8.

In spite of these references, there is very little information in the published literature concerning the origin of fines and how they are formed. Consequently, this paper was written in part

Fig. 1. Surface oxides on copper rod. a) a copper-copper oxide flake that was separated from the surface of a twisted rod, X250; b) cross-section of rod showing outer layer of reduced copper and residual subsurface oxide scale from alcohol-pickled rod.

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TECHNICAL PAPERS Fig. 2. Plowing shown on a wire surface due to the die asperities. Indicative of abrasive wear.

Fig. 3. Fines that were created due to abrasive wear by poorly blended draw die.

to provide a detailed description of the various formation mechanisms, and to discuss various factors that may accelerate these mechanisms. In addition, a new method has been developed to determine quantitatively the amount of fines that may be generated from the surface of copper rod. A final objective was to quantify some properties of fines, such as their shapes and size distributions and to assess means to prevent or reduce their formation.

Mechanisms of fines generation

Nature of fines Surface flakes on copper rod are a mixture of copper and copper oxide, as may be seen from the microstructures in Fig. 1a and 1b. The disbursed oxides are considerably harder than the much softer copper matrix, and therefore have a greater negative effect upon die wear. As will be described later in this paper, the oxide constituent originates from the as-cast bar but it is not removed completely during the rod cleaning stage, which normally employs either acid pickling or oxide reduction in an aqueous alcohol solution. In contrast, fines that are formed on wire tend to be primarily copper. There are five different wear mechanisms for the generation of these fines during wire drawing, and each of these classifications, along with typical photomicrographs, will be described in detail in a later section of this paper. The presence of slivers and reaction compounds are two other sources of fines.

Once fines are formed during wiredrawing, they either remain on the outer surface of the wire or are washed into the surrounding liquid lubricant. Although ultrasonic cleaning can be used commercially9, oftentimes there is insufficient residence time, and therefore the metallic fines tend to cling to the bare wire surface. When the fines do wash into the drawing solution, however, they react with the lubricant to form soaps and sludge, which again interfere with the wiredrawing process. Oftentimes these fines promote unstable chemistries that adversely affect lubricity. To prevent this problem from accelerating, adequate settling and/or filtration are needed to limit contact of fines with the lubricant and dies1-3.

Fines generation is the process by which a particle of metal is liberated from the wire. In this section various fines generation mechanisms are discussed, but the next section will describe a related activity that is termed â&#x20AC;&#x153;Acceleration of Fines Generation.â&#x20AC;? Phenomena that are discussed in these two sections are very different. The present section discusses mechanisms by which fines are liberated without considering outside factors that might increase their frequency of formation. For example, if lubricant were denied to a die, the generation of fines would greatly increase and cause an inevitable wire break. Although bad lubrication accelerates the generation of fines, it is not a formation mechanism in the true sense.

This section will discuss eight key fines generation mechanisms. The first five are attributed to wear and are well documented in metal forming operations, namely: abrasive wear; third body abrasive wear; surface deformation wear; adhesive wear; and delamination wear.

Three additional causes of fines generation are surface oxides on rod, drawing and rod related slivers, and chemical compounds. A brief description of all eight mechanisms is as follows: Abrasive wear. The typical use of sandpaper employs abrasive wear to remove material. Tiny hard particles on the sand paper remove material from the softer material. Each hard particle acts like a tiny cutting tool that plows through the surface of the softer material. These tiny cutting tools can liberate slivers of the softer material on each pass. In a less abrasive case the hard particles create ridges in the soft material in one pass and in subsequent passes those ridges are further abraded until the material is liberated. In wiredrawing, die surface asperities act in a similar way to the sand paper. Fig. 2 shows the surface of a wire with clear striation marks indicative of abrasive wear and plowing of asperities. Fig. 3 shows elongated fines that are created by the abrasive wear mechanism. While all dies have harder asperities than the wire, abrasive wear is most severe with polycrystalline diamond dies,

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TECHNICAL PAPERS Fig. 4. Image of a fine-grained polycrystalline diamond die surface, displaying sharp grain boundaries. Photo courtesy of Fort Wayne Wire Die.

which have both much harder and sharper asperities than other die materials. The grain size of polycrystalline dies plays a big role in determining the severity of abrasive wear. Often as the polycrystalline diamond grain size becomes finer, the abrasiveness becomes more severe, as was noted by Patel and Chia7. Fig. 4 shows the surface of a PCD die.

Third body abrasive wear. Third body abrasive wear is similar to abrasive wear, albeit it is not the die asperity that is plowing into the wire. In third body abrasive wear, a hard particle between the wire and the die causes abrasions to the wire.

Whereas abrasive wear can be demonstrated by sandpaper, third body abrasive wear is illustrated when an abrasive powder is rubbed onto a surface. Consequently, the abrasive particles are causing the wear. Third body abrasive wear can be more severe than abrasive wear because the abrasive particles roll into different positions and can expose multiple sharp points. In wire drawing, the vast majority of the abrasive particles are fines themselves. The material that forms these fines is sometimes already oxidized. On occasion, the fines can become oxidized after they are liberated from the wire due to the high temperatures experienced between the wire and die.

Since oxides are harder than the metal, oxidized fines are quite abrasive to the wire.

Surface deformation wear. In most wire drawing operations the wire undergoes intermediate anneals to either help reduce wire breaks or to obtain better final properties. Often the wire surface experiences more deformation and work hardening than the interior of the wire. The surface could also experience frictional heating so that the surface anneals and softening might occur. When the cumulative work hardening of the surface becomes excessive, however, the hard and brittle surface will begin to crack and break up. This phenomenon is called surface deformation wear, and an example is shown in Fig. 5.

Adhesive wear. When two solid bodies are brought into direct contact, their asperities adhere to one another at a microscopic level. Two solid bodies sliding with respect to 70 | WIRE JOURNAL INTERNATIONAL

each other is a continuous process of asperity adhesion and subsequent breaking of those adhesive bonds. Most often the bonds are not broken exactly at the interface between the two materials. Instead, part of the softer material is oftentimes sheared off, thereby forming wear particles. Gross adhesive wear is indicated by many characteristics, Fig. 6 for one example. Die inspection would probably be the best method to spot adhesive wear problems. In extreme cases, i.e., with high pressures and poor lubrication, galling occurs and a large amount of the softer material remains bonded to the die surface. While adhesive wear will occur mostly at the wire to die interface, it can also occur at the wire-to-capstan or wire-towire contacts.

Delamination wear. In delamination wear, which was originally proposed by Suh10-11, subsurface cracks nucleate and propagate parallel with the surface, as shown in Fig. 712.

Cracks occur at a depth of about 10 microns (10-5 meters) below the surface. At this location the tensile stresses are at a maximum value and are perpendicular to the outer surface. As these cracks grow the layer of material between the cracks and the surface experiences considerably greater deformation than the bulk of the wire due to fewer constraints. A typical deformed layer can be seen in Fig. 7. Ultimately, the crack growth coupled with the accelerated deformation causes this top layer to delaminate from the bulk of the wire. Fig. 8 shows a fine that was captured in the act of delaminating.

Resulting fines are usually thick and flake-like particles, and sometimes show the curvature of the wire. Fig. 9 shows typical delamination fines. Unlike all other fines generation mechanisms, which are always present to some degree, delamination wear can be completely absent, particularly if there are no copper oxide inclusions at nucleation sites. When delamination wear is present, however, the weight of fines that are generated will increase by an order of magnitude12. While this weight increase can be dramatic, delamination wear will probably have a minor impact on wire drawing problems compared with the other mechanisms because delamination wear particles are relatively large and easier to filter. Therefore, the lubricant degrades to a lesser extent. Bending the hard drawn wire around a small diameter will increase the generation of delaminated particles. In addition, they are more likely to occur in work-hardened materials.

Rod surface quality (oxides). The quality of the incoming rod, i.e., its surface oxide film thickness, such as that shown previously in Fig. 1b, has a great influence on the fines that are generated downstream in the rod breakdown machines. There may also be residual fines on the rod that are picked up from the hot rolling process. All of these particulates clog wire die entrances or become third body abrasive wear particles. Fines can originate from either subsurface oxides or from the alcohol reduced outer copper layer that lies between these oxides and the wire surface. Subsurface oxides may form when hot cracks occur in the cast bar or if fold-overs take place before the scale can be removed. Similar problems may occur if there is misalignment of the mill rolls leading to protrusions and fold-overs. It is important to note that these rod surface and subsurface defects can adversely affect the wiredrawing

TECHNICAL PAPERS Fig. 5. A micrograph showing the break up of a wire surface, which is indicative of surface deformation wear.

process by accelerating additional fines generation. This overall damage can be assessed quantitatively by a new test introduced later in this paper.

Drawing and rod-related slivers. Slivers are usually very long but thin pieces of metal that peel off from the drawn wire surface. They can be caused by residual oxides, mechanical damage, misalignment between the wire and the draw die, or poor lubrication. It can sometimes be difficult to distinguish visually between a rod-related defect or one with a wiredrawing origin. Metallographic examination of the wireâ&#x20AC;&#x2122;s crosssection is the sure way to make a proper distinction, because rod-related slivers always emanate from bulk material, often due to embedded oxides. Drawing related slivers, on the other hand, are due to drawing problems alone, and therefore, embedded oxides are usually not present. Fig. 10a through 10c show typical rod- and drawing-related slivers.

Chemical compounds. Interactions between copper wire and the drawing lubricant may lead to the formation of organic copper soaps in drawing machines. These compounds are much softer than metallic or oxide flakes, and are nearly spherical, as may be seen in Fig. 11. Additional compounds sometimes form when using acid pickled rod because of an interaction between the copper and the sulfuric acid pickling solution. It is also possible to have chemical reactions occurring in shaved rod between the copper and the shaving lubricants.

Acceleration of fines generation This section briefly discusses several factors that can exacerbate and accelerate all of the fines generation mechanisms that were discussed in the previous section. Seven major factors and their characteristics are as follows.

Applied lubrication. If proper lubrication is not applied to each die, fines generation may increase. High speed hydrodynamic lubrication is preferred for reducing fines because it

Fig. 6. Micrograph showing adhesive wear formation on a copper wire surface. Gross adhesive wear is indicated by many characteristics. Die inspection would probably be the best method to spot adhesive wear problems.

keeps the wire and die surfaces separated, but 100% attainment is never practical. Major lubrication problems include clogged nozzles or clogged die entrances, which starve the die of lubricant. The lubricant can also break down due to excessive drawing temperatures or excessive fines. Volumes of tiny fines can present a large surface area to the lubricant, thereby attracting polar molecules that are designed to protectively adhere to wire surfaces.

Filtration. It is imperative that fines are filtered from the drawing solution as efficiently as is practical. As noted above, fines remaining in the lubricant may clog nozzles and die entrances and will enable third body abraders in the die.

Drawing temperature. High drawing temperatures tend to increase fines when wire surface hardness is reduced and effectiveness of the lubricant is reduced. A greater percentage of abrasive oxide is produced within the fines, thus increasing third body abrasive wear. Viscosity of the lubricant is altered, possibly reducing the hydrodynamic lubrication film thickness.

Die quality and die alignment.As a polycrystalline diamond or carbide die wears it exposes sharper and more numerous asperities to the wire surface, particularly at the polycrystalline die grain boundaries. Furthermore, a worn die increases friction in the deformation zone. Dies with numerous recuts may become too shallow at the entrance and create additional sharp surfaces. Residual stresses in the wire can cause the wire to commence drawing outside of the die reduction zone and perhaps outside of its bell. Misorientation is discussed in more detail in the next section on residual stresses and can create a gross situation akin to shaving, as illustrated in Fig. 12. Grossly misaligned dies at the die entrance or die exit can create abrasive wear.

Inasmuch as die angle has a strong influence on the formation of fines there is an optimum die angle for lowest fines generation12. At high die angles there is high pressure

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TECHNICAL PAPERS Fig. 7. Longitudinal metallographic section of a copper wire that was plated with nickel to preserve the subsurface. A line of cracks is revealed below the surface that was created via delamination wear. The material between the wire surface and the crack-line experiences greater deformation than the rest of the wire.

Fig. 8. Longitudinal metallographic section of a copper wire that has been plated with nickel to preserve the subsurface. A delamination fine is captured here lifting off the wire surface.

at the wire-die interface, albeit the surface contact area and sliding distance are low. On the other hand, low-angled dies reverse this situation by lowering die pressure and increasing the contact area and sliding distance. An optimal total included die angle of 16 to 20 degrees balances these competing influences.

Residual stresses. Residual stresses are created in a wire during typical drawing processes due to several factors. If the residual stresses are created fairly uniformly around the circumference of the wire, then their influence on fines is negligible. One source of uniform residual stress is uniform wire surface heating during drawing and subsequent cooling prior to the next die pass. On the other hand, the residual stresses created within a wire are often highly non-uniform, which does accelerate fines generation. Baker and Pops have explained in detail how non-uniform internal stresses may develop13. These stresses cause the wire to shift off its die axis and result in asymmetric drawing. A realistic cross-section of such a wire and die is illustrated in Fig. 13. Asymmetric drawing causes the wire to experience extreme pressures on one point in its circumference which are higher than the pressure expected by the die design. In Fig. 13 the top of the wire has a longer contact length with the die, which would therefore increase fines generation via this increased sliding contact.

When the reduction zone is too small, the top of the wire might even hit the bell, again creating substantially more fines. On the other hand, the bottom of the wire can cause greater die pressures, which would also lead to increased fines.

It has been mentioned already that gross mis-alignment between the wire and the die can cause high fines generation.

Unfortunately, a perfectly aligned die is most often unachievable for two reasons. First, in cone-type machines the die changes the wire’s direction slightly to allow for proper contact with the capstans. Consequently, the wire entering or exit-

ing the die must be at an angle to the die axis. Second, residual stresses can cause the wire to move off the die axis in favor of its preferred cast. Consequently, attempting to align dies as if the wire were a “string” that could be strung along the die axis may not result in the optimal die alignment.

Wire vibrations. Since wires are typically unsupported between the capstan and the die, they may undergo severe vibrations as a result of stick-slip oscillations, impinging lubricant flow or machinery oscillations. Except for fine wire drawing, vibrations seem innocuous because the wire usually impacts nothing other than the capstan and the die. However, the influence of wire vibrations at the die entrance is, in fact, substantial. Wire vibrations cause oscillations in the wire near the die surface, and may create three problems, namely: 1) The hydrodynamic lubricant film is disturbed. As noted before, in high-speed drawing with liquid lubricants, it is best to have the thickest and most comprehensive hydrodynamic lubricant film possible. However, this lubricant film is fragile, and is most stable only with constant fluid flow. Vibrations of the wire disturb the hydrodynamic process and do not give the film enough stability to develop its full potential.

2) Die areas are subject to fatigue. Wire vibrations accelerate die wear by placing die areas under cyclic stresses, as illustrated in Fig. 14. Vibrations alter the location of worn areas in the reduction zone and create a wider wear ring. Basic fatigue theory dictates that materials under cyclic stresses will fail at much lower applied stresses than materials under static stress.

3) Higher die pressures are generated. As the wire oscillates with respect to the die, it increases the maximum die pressure and consequently increases die wear, as seen in Fig. 14.

Sometimes wire surfaces show evidence of transverse scratches that result from vibrations of the wire at the die exit, as shown in Fig. 15. Wire vibrations at the die exit may not have a significant influence on die wear or the lubricant film, but marks on the wire surface created at the die exit will accel-

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TECHNICAL PAPERS Fig. 9. SEM micrograph of collected fines, which are flake-like and indicative of delamination wear.

erate fines generation at the next die.

Wire-to-wire contact. It is quite common to have wire-towire contact, particularly in cone-type drawing machines.

Fines may develop due to adhesive wear when wires moving in different directions impact each other. If this cross-over contact is too severe the likelihood of torsional wire breaks, kinks or twisting is accelerated. The tendency for cross-over is magnified because of insufficient back tension or misalignment.

Techniques for analyzing fines There are numerous methods for analyzing fines, which can provide the needed insight on means to reduce their formation. The categories discussed herein are as follows.

Wire and rod surface examination. Wire and rod surfaces can be analyzed by optical microscopy, scanning electron microscopy (SEM) and metallography. The outer surface contains information on how fines have been liberated from the metal surface. Figs. 2, 5-8 and 15 show illustrations of the various fines generation mechanisms observed through wire surface and subsurface observations. Most dramatically, Fig. 8 shows a fine in the process of separation via delamination wear. Observing the fines generation mechanism process on the wire fosters an understanding of how to reduce fines. Rod surfaces can also be examined after twist testing, since twisting exposes existing subsurface damage. Replica technique has been used to observe wire surfaces in low-depth of field optical microscopes14-15. If the wires are not cleaned before making a replica, some of the fines that adhere to the wire will become embedded in the translucent replica material. This allows the viewing of the fines simultaneous with observation of the wire surface, as shown in Fig. 16.

Examination of fines collected from filtration systems. Large samples of fines can be readily obtained from the filtration systems. These fines should be ultrasonically cleaned in a sol-

Fig. 10. Slivers in copper caused by rod and drawing issues; a) Rod-related sliver; b) cross-section near sliver showing cracks forming due to embedded oxides; and c) Sliver in enameled copper wire caused by wire drawing. No oxides are present. X240.

vent, such as n-methyl pyrrolidone (NMP). After the fines are cleaned and dried, their particle size distribution can be determined. There are expensive instruments that determine particle-size distributions automatically on near spherical particles.

However, fines are more often flake-like or slivers, and cannot be diagnosed in the automated systems.

The best particle size determination method for fines is inexpensive but time-consuming. It employs a series of sieves, typically ranging from 2,000 to 38 microns pore size, which are used to collect fines of a specific size. The collected fines are then weighed. A particle size histogram is created by calculating the percentage of the total fines weight that remained in each sieve. The histogram reveals the predominant fines generation mechanism(s) in operation. For example, delamination wear particles will be, by far, the largest.

Through this method Patel and Chia7 found that fines from tungsten carbide dies were much coarser than particles from

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TECHNICAL PAPERS Fig. 11. Copper soap caused by chemical reaction between copper wire and drawing lubricant.

Fig. 12. A wire break exhibiting severe damage at the entrance of the die, caused by shaving and misalignment.

the same-gaged PCD dies. In the latter, over 57% of the fines were smaller than 38 microns, while for the tungsten carbide dies, only 26% were that small. Thus, the very tiny asperities on the polycrystalline dies tend to produce a large quantity of very fine and elongated particles.

The fines that have been separated into the sieves can also be examined with a microscope and/or the SEM to reveal more insight on the fines generation mechanisms. Fig. 17 shows images of such collected fines, while Fig. 18 is an example of a typical histogram for fines that were collected from a wiredrawing machine.

Monitoring of fines generation rate. As discussed previously, fines generation is attributed mostly to wear. The deformational aspect of this wear process differentiates it from other wear processes in many ways. Most notably, fines generation can increase dramatically based upon conditional changes.

Thus, a 5 to 10 times or more increase in fines generation rate at a particular die is not extraordinary7, 12. It is important to monitor the rate of fines generation in order to spot when dramatic increases occur so that the problem can be corrected.

Monitoring the total weight of fines collected by the filtration system is usually unspecific to date or machine. Thus, a more specific monitoring system must be used. One convenient method is to periodically sample the lubricant from an individual drawing machine. The same volume of liquid should be taken from the same location for each measurement. Each sample is vacuum filtered and the filter paper is weighed to yield the weight of fines. The filter pore size can be chosen to trap the predominant particle size typically generated by the system, and can be determined by the histogram discussed in the last subsection.

If the monitored fines data are placed in simple SPC software, personnel will be alerted to sharp increases in fines generation rate. When such an increase occurs, the system can be examined for readily observed problems, such as clogged die entrances, grossly mis-aligned dies or lubricant breakdown.

Each die should be examined for excessive accumulation of fines on its entrance or exit. Once the die where the offending

fines generation commences is determined, it should be thoroughly examined and replaced if necessary to alleviate the problem. Dies downstream of the offending die may have an increase in fines generation rate due to that suspect die.

Examination of the hot-rolling process. In rod breakdown machines the fines rate can be heavily dependent on the condition of the incoming rod such as the thickness of surface oxide scales. A powerful technique that will be presented later in the subsection, â&#x20AC;&#x153;Ultrasonic Collection of Fines from Wire and Rod Surfacesâ&#x20AC;? can be used to evaluate and grade rod for its potential fines generation rate. A mill constant analysis16 should also be used to optimize the hot-rolling process, thereby helping to reduce the formation of fines, protrusions, and overfills.

Examination of the wiredrawing process. The wiredrawing process can be examined to gain insights on fines generation.

Key drawing process indications include: gross die misalignment; detection of wear rings; lubricant deterioration, especially high wire-metal concentrations; excessive drawing temperature; and wire break analyses, such as impacted fines, crowâ&#x20AC;&#x2122;s feet and slivers.

Finally, one additional method will be introduced. As discussed in the subsection on residual stresses and as depicted in Fig. 13, wiredrawing is often asymmetric. To determine the degree of asymmetry for each die13, pull the wire out of a die and examine it in a microscope, especially noting whether the asymmetry has caused the wire to draw outside of the die cone. An asymmetry ratio can be calculated by:

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Asymmetry Ratio = 2 (L-S) / (L + S)

Eq. (1)

The longest and shortest lengths of the die contacts are measured and denoted as L and S respectively, as shown in Fig. 19. The method is convenient because most of the work is already performed when a wire break occurs, since the conditions at the dies upstream of the break are frozen in place.

TECHNICAL PAPERS Fig. 13. Illustrates that asymmetric drawing causes the wire to experience longer sliding distance on one portion of the die and higher die pressures on another portion.

Methods of reduction of fines The section entitled, â&#x20AC;&#x153;Accelration of fines generation,â&#x20AC;? listed seven causes that accelerate fines. To reduce fines, reduction of those causes is sought. Most of these methods, already common known, are presented briefly in Table 1. However, newer concepts will be discussed in more depth, namely, vibration reduction, increasing back-tension and removal of fines from wires. It must be emphasized that the monitoring of fines generation rate, as previously discussed will yield the greatest benefit overall as it identifies problems quickly so that they can be located and remedied.

Vibration reduction. The three ways that wire vibrations significantly influence fine generation has been discussed. Baker and Pops13 discovered that the application of a roll to a wire near the die entrance immediately decreased the average wiredie coefficient of friction by approximately ten percent. This is a clear indication that wire vibrations prevent the full establishment of the hydrodynamic lubricant film and that by reducing vibrations this film can immediately improve. Thus, the use of a simple vibration reduction method such as the idler roll will definitely reduce fines and also reduce die wear.

Olsen and Valberg17 discuss the reduction of vibrations in fine wiredrawing. They also propose the use of an idler roll and prove that such a roll does not have to be applied near the die entrance to be effective in reducing vibrations.

Increasing back tension. It has been shown that increasing back tension can significantly reduce fines12, because die pressures are reduced. Increasing back tension may not be practical at most dies but it is definitely practical at the most influential die for fines generation. Fines generated at the first die in a machine travel and influence dies downstream.

Furthermore, at the first die, the wire is often annealed and the much softer wire material creates more fines. At the same time back tension is often ignored, and thus low, at the first die.

Instead, some type of tensioning device should be employed to maintain high back tension going into the first die.

Removal of fines from wire. It has been shown that most

Fig. 14. Illustrates three ways that wire vibrations have a negative impact on the wire-die contact. The lubricant film is not shown in this illustration, but its disturbance by vibrations has the greatest consequences.

fines generated in one die move to the next die on the wire surface (12), where they accelerate fines via third body abrasive wear. Thus, it is beneficial to remove as much fines as possible from the wire before the next die. An application of lubricant spray designed especially to remove fines may help.

Otherwise cleaning methods are available and are especially practical as the wire moves from one machine to another.

Fines-potential test High-quality rod ought to have surface and subsurface qualities that will result in a very small amount of fines when drawn. Consequently, a laboratory test was developed to determine this parameter, called fines-potential, so that coils might be segregated according to the intended usage. Critical quality applications such as magnet wire or wire that will subsequently be plated will require rod having a very low finespotential. A suggested laboratory procedure for this finespotential test is as follows.

Step 1. Since there has proven to be a correlation between the fines-potential and the surface oxide test, oxide film thicknesses should be determined on at least one sample from each subject coil.

Step 2. Approximately three to six rod samples should be collected for testing and made as straight as is practicable.

Three samples at one time are then ultrasonically cleaned for 10 minutes using apparatus such as that shown in Fig. 20. A glass vessel (see Fig. 21) is filled with n-methyl pyrrolidone (NMP), which is safe to handle yet very effective in removing loose surface contaminants on the rods. This glass vessel is placed inside a two inch inner diameter stainless steel pipe that is filled with a soapy water solution into which ultrasonic vibrations are transmitted. The glass vessel sits on a vinyl gasket at the top of the pipe. For greater accuracy, another set of three samples can be fixtured and suspended inside the glass vessel, and also cleaned for 10 minutes. The NMP should be replaced after about nine samples have been run.

Step 3. If 8 mm copper rod is to be tested, each of the sam-

OCTOBER 2009 | 75

TECHNICAL PAPERS Fig. 15. Transverse score-marks shown on a wire surface that were produced due to wire vibrations as the wire exited the die.

Fig. 16. Replica of a wire surface showing details of the surface along with fines embedded in the replica.

In this replica technique the wire is not cleaned so the replica also exhibits discoloration from residual lubricant on the wire.

ples is subjected to a standard 10 x 10 twist test using a 10 inch gage length. This procedure loosens fines yet retains most on the rod surface. (An alternative method of loosening fines is to draw the rods through three standard B&S reductions.) A stand is needed so that the rod surface does not touch the table and alter the results via fines transfer.

Step 4. Fines are collected from the rod samples using a procedure similar to that described in Step 2, but with fresh NMP. After the group of three (or six) twisted rod samples is treated ultrasonically for 10 minutes, they are removed and placed on a stand to dry. A glass cap holding a one micron pore size Teflon filter, which has been tared, is then screwed onto the top of the glass vessel. The vessel is next inverted and placed on a glass vacuum filtration flask. The NMP is then drawn through the Teflon filter using a vacuum pump, leaving the fines on the filter. The filter containing the fines is then dried in a low temperature oven (~ 65oC) and weighed until a con-

stant weight is achieved. Thus, the increase in filter weight is considered to be the weight of the fines. It should be noted that the fines are mostly a mixture of wire metal and their oxides.

For acid pickled rod, however, other compounds may be obtained.

Step 5. Rod weights are determined on the dry samples after the twisted ends are cut off from the gage length. If desired, the dried fines can be examined microscopically or metallographically. In general, the amount of copper fines generated from rod via this fines-potential test was found to increase with increasing surface oxide (Step #1), as may be seen in Fig. 22. A linear relationship could be expressed by the following equation (Wf/Wr) x 10-6 = 8.733 + 0.0492 x SO

Eq. (2)

where Wf is the weight of fines, Wr is the weight of the rods,

Table 2. Copper contents of fines for various rod sources.

Table 1. Common fines reduction methods.

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TECHNICAL PAPERS Fig. 18. Typical histogram of fines collected from a drawing machine.

Fig. 17. Fines caused by abrasive wear and drawing slivers that were collected from a filtering system.

and SO is the surface oxide thickness in angstroms (1 Angstrom = 10-8 cm). The correlation coefficient for this relationship was ~ 0.77 for all sources of rod that were subjected to the 10 x 10 twist test. In contrast, results using the three-die test were not quite as reliable, and the correlation coefficient was only 0.45.

Data were obtained for more than one dozen different rod sources, and included samples that were acid pickled, shaved, or alcohol cleaned. As might be expected, shaved rod had the smallest quantity of recovered fines. The fines produced from hot-rolled rod were flake-like and had an average width of ~ 50 microns. Although particles from shaved rods were 10 to 20 microns in diameter, there were also many needles, which undoubtedly were produced by the shaver dies. Acid pickled

Fig. 19. Optical micrograph of a wire that has been removed from a die, revealing the asymmetry in the drawing process. The longest and shortest die contacts lengths are measured and denoted as L and S, respectively.

rod contained small light brown spherical particles that were only a couple of microns in diameter, and also some dark green crystals that were 10 to 20 microns in size.

Copper contents of fines were determined by first dissolving them in a heated nitric acid solution, and then performing tests using a direct-coupled plasma unit. Typical results are shown in Table 2.

Since none of the samples consisted of 100% copper, the difference is probably a combination of oxides, copper salts, soaps, or extraneous debris. Light brown particles in the acid pickled rods are probably a by-product of the sulfuric acid

Fig. 20. Potential test apparatus for fines.

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TECHNICAL PAPERS Fig. 21. Schematic of glass vessel used to house samples and NMP.

Fig. 22. Results of fines-potential test for copper rod samples that were acid pickled, alcohol cleaned, and shaved.

pickle. On the other hand, shaved rod fines undoubtedly contain a by-product of a lubricant interaction with copper in the shaver die. It should be noted, however, that the influence of the rod source will decrease after each draw die.

Although this test has been used primarily on rods, it has also been used to measure fines on wire surfaces. With wires, Steps #2 and #3 are skipped so that fines adhering to the asdrawn wire surface are collected. Due to this difference, it is important that the wires are handled very cautiously while removing them from the drawing machine to the test site. At least six wires from each lot should be tested. The apparatus used in this test method has been incroporated into a convenient kit with more detailed instructions and is currently available (see www.confident-instruments.com/fines-pot.htm).

Summary and conclusions This paper describes eight different mechanisms in nonferrous metals but particularly copper conductors that are likely to create fines during wire drawing. In addition to slivers and copper oxides, fines may have a component consisting of organic or inorganic compounds resulting from chemical interactions between copper and either the wire drawing lubricant, the acid pickle solution, or the shaving lubricant.

Five different wear mechanisms are discussed in detail, namely, abrasion, third body abrasive wear, adhesion, delamination, and surface deformation. Seven different parameters were discussed that can accelerate or aggravate the formation of fines and include inadequate cooling and lubrication, inefficient fines removal, misalignment, improper die blending

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and geometry, wire vibrations, and residual stresses.

Finally, a new method has been developed to collect and measure fines from the surface of copper rod or wire, and is termed a “Fines-Potential Test.” It employs ultrasonic vibrations and gravimetric analysis on particles that are removed and collected in special glass apparatus. The results have shown a direct linear relationship between the weight of fines and the surface oxide thickness.

Acknowledgments Thanks are extended to two colleagues who worked with us at Essex, namely, Terry Wiedemann for performing the chemical analyses and Julie Steininger for conducting many of the fines measurements. The authors also wish to thank Irv Adler for reviewing and critiquing this paper. Thanks are also extended to Fort Wayne Wire Die for Fig. 4. Finally, appreciation is extended to the Copper Development Association and Prof. Roger Wright for sponsoring and supervising a research project respectively at RPI on a few of the items in this paper.

References 1. C. Sorrick, “Filter media selection for wiredrawing fluids,” WAI Nonferrous Wire Handbook, Volume 3, 1995, pp.

434-442.

2. J. Scalise, “Lubricant filtration and disposal,” WAI Nonferrous Wire Handbook, Volume 3, 1995, pp. 443-466.

3. J. Scalise, “Heat generation, lubrication, and cooling,” WAI Nonferrous Wire Handbook, Volume 3, 1995, pp. 467475.

13. G. Baker and H. Pops, “Some New Concepts in Drawing Analysis of Copper Wire,” Metallurgy, Processing and Applications of Metal Wires, the Minerals, Metals & Materials Society, 1996, pp. 29-42.

14. G. Baker and R. Wright, “Correlation of Surface Quality, Subsurface Quality, and Fine Generation Analysis,” Wire Journal International, October 1996, pp. 76-85.

15. G. Baker and R. Wright, “Evaluation of Wire Surface Topography,” WAI Nonferrous Wire Handbook, Volume 3, 1995, pp. 546-563.

16. D. Gould, “Roll-pass Design,” WAI Nonferrous Wire Handbook, Volume 1, 1977, pp. 369-382.

17. H. Olsen and H. Valberg, “Controlling wire vibrations during fine wire processing,” Wire Journal International, January 1984, pp. 80-83. ■

Horace Pops is president of Horace Pops Consulting, Inc., Ft. Wayne, Indiana, USA. He previously was director, metals laboratory at Superior Essex in Ft. Wayne. He joined Superior Essex in 1972 and founded the company’s corporate metals laboratory. He holds an Sc.D. degree from the University of Pittsburgh and M.Met.E. degree from Lehigh University, and a B.Met.E. degree from Rensselaer Polytechnic Institute.

He is the sole or co-holder of 10 patents. Many of his papers have been published in leading technical journals, and this paper represents his 16th such paper to win an award. Gil Baker formed an instrument development firm called Confident Instruments that combines mechanical design, electronics, and software skills. He was previously senior metallurgical engineer at Superior Essex. He holds Ph.D. and M.S. degrees in mechanical engineering from Rensselaer and a B.S. degree in mechanical engineering from Cornell University. He won the WAI’s 1999 award for best general paper and the 1993 award for best nonferrous paper, as well as a 1998 Essex Technology Award. This paper, which was presented at WAI’s 78th Annual Convention, Pittsburgh, Pennsylvania, USA, June 2008, won the medal award in the Nonferrous Division.

Pops and Baker

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TECHNICAL PAPERS

4. H. Pops, “Importance of the conductor and control of its properties for magnet wire applications,” Wire Journal International, April 1993, pp. 62-72.

5. H. Pops, “Copper rod requirements for magnet wire,” Wire Journal International, May 1987, pp. 59-70.

6. H. Pops and J. Walker, “Wire breaks and failure analysis,” Wire Association International, 2003, pp. 1-49.

7. G. Patel and H. Chia, “Characterization of copper fines and its impact on filtration,” Wire Journal International, April 1992, pp. 49-56.

8. L. Corbin, “Analysis of wear and failure in wiredrawing dies,” WAI Nonferrous Wire Handbook, Volume 3, 1995, pp.

490-498.

9. J. Line, “Using sound waves to clean wire,” WAI Nonferrous Wire Handbook, Volume 3, 1995, pp 388-397.

10. N.P. Suh, “The Delamination Theory of Wear,” Wear, Vol. 25, 1973, pp. 111-124.

11. N.P. Suh, “An overview of the Delamination Theory of Wear,” Wear, Vol. 44, 1977, pp. 1-16.

12. G. Baker, “Work piece Wear Mechanisms in the Drawing of Copper Wire,” Ph.D. Thesis, Rensselaer Polytechnic Institute, Troy, New York, August 1994.

TECHNICAL PAPERS

TECHNICAL PAPER Wear of dies, measured and calculated by the process control system in a drawing machine Industrial tests found that, because of variables inherent in the methodology, a process control system is not accurate enough to properly monitor die wear.

By Magnus Jarl and Fredrik Axelsson

During wiredrawing, dies become worn and have to be replaced after a certain length of wire has been produced. Die wear may be divided into two parts: a wear ring at the point where the wire hits the die; and an increase in dimension in the latter part of the drawing cone and the bearing1.

Modern wiredrawing machines have an advanced process control system. One feature is monitoring of wire dimensions in each draft. The dimensions in the drafts are calculated by the laser gauge dimension in the final draft and the wire velocity in the different drafts. This method may make it possible to follow the wear of the dies, but the accuracy is not known. The objective of this present work is to evaluate the possibility of monitoring die wear by the process control system.

Fig. 1. Reductions in different drafts and wire velocities after different drafts.

Experimental A high-carbon wire rod was used during the experiment. The 11 mm rod was drawn to a 4.26 mm wire in nine drafts. The dies used for the first four drafts had a diameter of 75 mm and a height of 28 mm. The die nibs had a diameter of 25 mm and a height of 28 mm. For the next five drafts, conical nibs with a diameter of 17-18 mm and a height of 18 mm were used. These nibs were held by pressure die casings with a diameter of 75 mm.

The dies were immersed in cooling water. The geometry of the drawing dies was measured before the experiments by an optical measuring device from Conoptica AS. The drawing machine had a capstan diameter of 1200 mm. The machine was equipped with a laser diameter gauge and radiation pyrometers. The length of the wire was measured by a pulse counter at the last capstan.

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Fig. 2. Final wire dimensions before and after change of last die calculated from length and weight with the density 7820 kg/m3, laser and micrometer measurements.

TECHNICAL PAPERS

The process control system calculated the die diameters from the laser gauge measurement of the finished wire and the revolutions of the motors. The wire was collected on spools that were weighed with and without wire. The plan was to weigh spools before and after the change of the last die. At the same time, the wire diameters after each draft were measured by a micrometer. The wear rings were measured by a needle profile recorder with the die tilted to eliminate the drawing cone angle. Die wear was evaluated from the measurements. The reductions and wire velocities in the experiment are given in Fig. 1.

Density of specimens was measured according to Swedish standard.

Results Final dimensions. Some of the changes in the last die were caused by die breakage and no measurements were done before these die changes. Fig. 2 compares different methods of measurements. The density of the actual steel, 7820 kg/m3, was estimated2.

The calculated dimensions are smaller compared to the measured. Thus the density was used as a correction parameter and reduced 1% to 7750 kg/m3. The results are shown in Fig. 3. This density gives a good agreement between the calculated dimensions and the micrometer measurements.

The difference between micrometer measurements compared to laser measurements and calculated dimensions are shown in Fig. 4.

The laser measurements are about 0.01 mm larger compared to the micrometer measurements. The variation in the calculated dimensions is about + 0.01 mm.

The difference between the laser measurements compared to micrometer and calculations are given in Fig. 5. The laser measurements are about 0.01 mm larger than the micrometer measurements. There is some correlation between calculations and micrometer measurements, indicating some random scattering of the laser measurements.

Dimensions in different drafts. The different draft dimensions were measured by micrometer before and after the last die change. The difference between the measurements after the last die change and those calculated by the process control system are shown in Figs. 6 and 7. The calculated dimensions show somewhat better agreement with the measurements for the later drafts (5-8) compared to the previous drafts (5-9).

Die wear. Die wear was evaluated as measured wire dimensions minus the die dimensions measured before the experiment. The wire lengths

Fig. 3. Final wire dimensions before and after change of last die calculated from length and weight with the density 7750 kg/m3, laser and micrometer measurements.

Fig. 4. Difference between calculated dimensions and laser measurements compared to micrometer measurements.

Fig. 5. Difference between calculated dimensions and micrometer measurements compared to laser measurements.

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TECHNICAL PAPERS Fig. 6. Difference between dimensions given by the process control system and the micrometer measurements, drafts 1-4.

were calculated as ingoing lengths to the dies.

The results are shown in Figs. 8 and 9. The wire dimensions seem to be about 0.02 mm larger compared to the die dimensions in the beginning of the drawing. Die measurements after the experiment confirmed this observation.

The wear is larger in the first four drafts compared to the later drafts (5-8) The wear in draft nine may be a little larger compared to draft 5-8.

The dimensions increased with 0.08 mm after about 700 km in the first four drafts and after about 1200 km in the latter drafts (5-8). Pressure dies were used in the latter drafts, but not in the first four drafts.

Wear rings. Wear rings were evaluated as the maximum deviation from tangent to the unused part of the drawing cone. The results are shown in Fig. 10. The die in the first draft had been worn in the whole cone and the wear ring in this draft is underestimated. The die from draft seven was lost. The die in draft eight was replaced earlier than the dies in drafts one to seven. The ring formation seems to be somewhat faster in draft nine than in drafts eight, six and five, also done with pressure dies.

The depth of the wear rings in the first drafts (1-4) seem to be the same regardless of the different wire lengths. This indicates that the ring formation in draft one is faster compared to drafts (4-8).

Discussion and conclusions

Fig. 7. Difference between dimensions given by the process control system and the micrometer measurements, drafts 5-8.

Fig. 8. Wear of dies in drafts 1-4. Wire length into the dies.

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The accuracy of micrometer measurements are at best + 0.005 mm. The laser measurements are 0.01 mm thicker compared to the micrometer measurements. A calculation of dimensions from weight and length measurements needed a reduction in density. This gave calculated final dimensions within +0.01 mm compared to the micrometer. An estimation of the errors may be

where d is the diameter, l the length, Ď the density and W the weight. Assume no variation in the density and the weight errors Î&#x201D;W/W equal to 0.002. The errors in final dimension were 0.01/4.25 = 0.0024. The measurements of the final length were thus very stable. At the start of the drawing process, the dimension was 9.66 mm. The expected error should be +0.02 mm, but the dimensions given by the process control system deviate from the measurements up to 0.1 mm. The process control system uses the motor revolutions, and the capstans are driven by belts

TECHNICAL PAPERS

that may slip. The ratio between capstan revolution and motor revolution may thus fluctuate.

The results indicate that direct measurement of the capstan revolution should increase the accuracy of the dimensions calculated by the process control system.

As noted earlier, die wear may be separated into wear ring and dimension increase. Both wear types are mainly functions of the wire length into the die, and pressure dies reduce such wear.

Acknowledgement The experiments were done at OVAKO Hjulsbro AB free of charge and OVAKO permitted the publication of the results. This work was funded by The Swedish Agency for Innovation Systems. The work was carried out in cooperation with the Swedish Steel Producers’ Association.

Fig. 9. Wear of dies in draft 5-9. Wire length into the dies.

References 1. P. Gillström and M. Jarl, “Wear of Die after Drawing of Pickled or Reverse Bent Wire Rod,” Wear, 262 2007, pp. 858-867.

2. F. Richter, “Die wichtigsten physikalischen Eigenschaften von 52 Eisenwerkstoffen,” Mitteilung aus dem Forschungsinstitut der Mannesman AG, Stahleisen Sonderberichte Heft 8, Verlag Stahleisen, Düsseldorf, 1973. ■

Fig. 10. Wear rings in dies. Wire length into the dies.

Magnus Jarl is a professor of mechanical engineering at Örebro University, Örebro, Sweden. He joined the university in 2001. He was previously a senior researcher at MEFOS, Luleå, Sweden. He holds a Ph.D. degree in physical metallurgy from the Royal Institute of Technology in Stockholm, Sweden.

Fredrik Axelsson is an engineer at Ovako Hjulsbro AB, Sweden. He holds a master’s degree in mechanical engineering from Örebro. This paper was presented at WAI’s International Technical Conference, Monterrey, Mexico, October 2008.

Jarl

Axelsson

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TECHNICAL PAPER Stress development in 1350-H14 aluminum rod drawing The growth of tensile strain rate in commercial 1350-H14 aluminum rod is due to slight differences in chemical composition as well as differences in rod production process parameters.

By Eva Cervantes, J. AngĂŠlica Ramos and Sergio A. Montes

The relationship among the many variables that affect wiredrawing performance on the factory floor is certainly a complicated one. Composition, morphology, surface quality and processing all play a role in determining the key quality parameters of an aluminum wire. In particular, how cold work within a factory rod breakdown machine affects tensile stress is an important issue, since this behavior is related both to the intensity of cold work and to rod temper in a manner that is not clearly understood for rods coming from various sources.

This work studies the factors that determine how the tensile stress of aluminum 1350 H14 behaves within a factory rod breakdown machine. In particular, an attempt will be made to understand why rods from different sources behave quite differently in actual wiredrawing operations. Surface roughness of the rods will be also considered.

(CMSA) from three suppliers (A, B and C). The samples are ASTM B230 commercial products used in the wire and cable industry today.

Sample preparation. Wire samples having various levels of cold work were prepared by an FX-13 breakdown machine in operation at CMSA and provided with a five-die reduction series, typical of a wire and cable operation.

Samples having reductions of 26, 37, 54, 61 and 66% were selected for further testing. All samples were drawn under the same processing conditions at standard production rates.

Testing. A Spectro atomic emission spectrometer model Spectrolab was used for chemical composition analysis

Experimental Materials. Six 1350-H14 aluminum rod samples, whose tensile properties are shown in Table 1, were used. For this study, two production samples were taken from regular shipments to a Conductores Monterrey power cable plant

Table 1. Tensile properties of 1350-H14 rod samples used in this study.

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Table 2. Chemical composition data.

Fig. 1. Macrostructure of cross-sectional area of rod samples.

Results Composition. Table 2 shows compositional data for the rod samples. No significant differences in the iron and silicon contents can be noted.

Fig. 3. Phase distribution in rod samples (500x).

Fig 2. Morphological features of the rods observed at 50x.

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according to ASTM E1251. Calibration standards were used for each of the elements tested. Tensile properties were determined according to ASTM B-557. Original rod samples and the wires obtained from the reductions were subjected to metallographical analysis that consisted of mounting, grinding, polishing with 1Îź alumina powder, alcohol washing and air drying. Etching was performed by a 0.5 % HF solution for six minutes, as previously reported1. Optical microscopy was used to observe the obtained microstructure. The type and distribution of the phases for these materials were determined by means of a Spectroplus SEM. Surface quality. Surface roughness of rod samples was determined by means of a laser profilometer. The rod surface was scanned and local roughness readings were taken every 200Îź in the length direction. Five scans of 250 mm in length were performed for each sample. A roughness index (in micron units) was defined as the standard deviation of readings in the radial direction normalized with a local rod diameter, such that roughness in the micron size range was determined without the interference of long range diameter fluctuations.

TECHNICAL PAPERS Fig. 4. Tensile strength as a function of cold work within a rod breakdown machine.

Fig. 5. Strain-hardening exponent versus cold work within a rod breakdown machine.

Fig. 6. Surface quality characteristics of aluminum rods as measured by profilometry.

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Microstructural analysis. Fig. 1 shows the cross sectional area of the as-received rods. The main microstructural feature observed is that sample A1 shows an out-of-center structure, as opposed to those of samples B1 and C1, which are radially symmetrical. However, as Fig. 2 shows, there are significant differences among the samples when they are observed at 50x. A and B samples show a radially columnar grain type while C samples exhibit equiaxed structures. It is possible that in case of the C samples, the as-cast structure (columnar grains) is broken when the cast bar is subjected to further rolling operations during the manufacture of the rod 2.

With regard to phases, a homogeneous distribution was observed as shown in Fig. 3.

However, their size is different, since the B samples have smaller and more abundant particles than do the A samples. In the case of the C samples, the phases are generally fine but some larger ones are also found. It has been reported in the literature that these phases correspond to iron-content particles (Al3Fe)3.

Tensile properties. Tensile stress as a function of cold work deformation is shown in Fig. 4 for the six materials considered in this study. As expected, linear relationships are observed for all materials. It can be observed that although initial stress is nearly the same, the slopes are different. Fig. 5 shows the average strain hardening exponent as a function of cold work where it can be observed that very significant differences are found. The exponent can be almost independent of cold work or it can grow, either linearly or exponentially, depending upon the source of the rod. It is apparent that there is a relationship between the observed morphologies shown in Fig. 2 and their strain hardening behavior. Those rods having a radially columnar structure (A and B) show a much more pronounced strain hardening tendency as opposed to the C samples, where a equiaxed grain structure is associated with a nearly constant strain hardening exponent.

With regard to the possible effects of chemical composition, according to the literature, Fe+Si content causes an increase in mechanical properties above 0.2% in annealed condition4.

In this work, it is very difficult to establish a direct correlation between % (Fe+Si) and mechanical properties because when the rods under study are made, a certain amount of cold work (H14) is applied to them in order to comply with the appropriate tensile requirements of aluminum rod for wire applications.

Surface quality. Surface roughness results for

Conclusions It has been shown that for aluminum 1350-H14 drawn within a rod breakdown machine, tensile stress increases linearly with cold work, expressed as area reduction. The tensile stress growth rate is dependent on the source of the rod and is not correlated with the strain hardening exponent n. However, this n index can be constant, increase linearly or exponentially with area reduction, depending upon the source of the rod.

No direct correlation was found between tensile stress behavior and the chemical composition of the rods, except for a very slight difference in Fe+Si content. Rods with a slightly major content of Fe+Si shown an increased tensile strength.

Since chemical composition was almost similar for all samples, it is concluded that differences found in processability are directly attributed to differences in rod production

process parameters of different sources. Surface quality is dependent on morphology and grain size; best surface quality was observed on fine equiaxial grain rods.

References 1. ASM Metals HandBook, Volume 9, Metallography and Microstructures.

2. S. Avner, Introducción a la Metalurgia Física, McGraw Hill, 1964.

3. ASM Metals Handbook, Vol. 2, Properties and selection of nonferrous alloys, American Society for Metals.

4. J. Hatch, Aluminum Handbook, Properties and Physical Metallurgy, American Society for Metals.

5. M.R. Stoudt and R.E. Ricker, Metallurgical and Materials Transactions, Sept. 2002, 33A, 9, pg. 2883. ■

Eva Cervantes works at the metals laboratory of Viakable, a group of wire and cable companies that includes Conductores Monterrey, San Nicolas de los Garza, Mexico. She is now studying a Master of Science in Materials Engineering at the Facultad de Ingeniería Mecánica y Eléctrica (FIME) of the Universidad Autónoma de Nuevo León, Monterrey, Mexico.

This work was part of her B.Sc. thesis.

Cervantes Ramos Montes She has previous experience in the aluminum foundry industry.

J. Angélica Ramos heads the metals Ohio, USA, as a student in the polymer laboratory of Viakable. She earned a Ph.D. degree in engineering department. Previous academic experience materials engineering from the Facultad de Ingeniería includes graduate studies at the University of Tennessee Mecánica y Eléctrica (FIME) of the Universidad at Knoxville, Tennessee, USA, and at the Universidad Autónoma de Nuevo León where she worked on the Autónoma de Coahuila at Saltillo, Mexico. He has development of aluminum alloys. Previous academic authored or co-authored more than 17 publications in work includes research in steelmaking processes and the polymer research area, specifically in the field of materials characterization. Sergio A. Montes is current- rheology and processing of polymeric materials. This ly manager of the R&D materials laboratory of paper was presented at WAI’s International Technical Viakable. He graduated from the University of Akron, Conference, Monterrey, Mexico, October 2008.

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the rod samples are shown in Fig. 6, where boxplots of the roughness index described above demonstrate that commercial aluminum rods have significantly different micron-scale roughness values. These results are comparable to those in the literature of surface characteristics of aluminum alloys5.

The relationship between this index and other parameters related to surface quality is not known at this time but certainly will be the matter of further work. Surface quality is directly related to different parameters of rod production process (such as casting control and rolling mills for example).

PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS CNC wire-rebar bending system offers manufacturers the latest technology U.S.-based AIM Inc., recently introduced a range of new and upgraded technology for producing wire and rebar products, from small wire anchors to large rebar stirrups, that provide fast and cost-effective manufacturing.

One of the upgraded models is the AFT line, the simplest programmable CNC machine available in the market that is capable of bending wire, tube or rebar, a press release said. Programming is quick and easy, as all that is needed is someone to enter the lengths and angles of a product, view the design, edit if necessary and then begin production, it said, citing the following specs. Standard feeding speeds exceed 15 meters per minute; bending speeds exceed 600 degrees per second; smallest resolution of the wire/tube feeder is 273 pulses per millimeter; bender resolution is 1450 pulses per degree; servo controller acuracy is ±1 pulse, length accuracy is ±0.1 millimeter; and angle accuracy is ±0.05 degrees. The model, which can take pre-cut material that is loaded either manually or from an optional hopper, uses XYZ, LRA or CAD file programming. The CNC system is available in models with one, two or three axes, with prices starting from US$25,000 for the single axis version, it said.

The AFT line is available in three sizes machine: AFT-8, 2.7 to 8.0 mm; AFT 12, 2.7 to 12.0 mm; and the AFT 16, 4.0 to 16 mm. Other recent models include the Compact 3D machine, part of the company’s AFC series, and the AccuForm Rebar (AFR) system, an accurate, all-electric CNC rebar bender with capacities up to 22 mm (#7) or two 16 mm (#5) rebar. All models employ the latest technology from solid modeling file translation (CAD file importation) to capabilities for secondary operations and robot communications for hands-free operation. For more details, go to the company’s website.

Contact: Constantine Grapsas, AIM, Inc., tel. 630-4580008, ext. 111, cg@AIMmachines.com, www.aimmachines.com.

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These ‘green‘ reels come in blue The R-2 Systems Division of U.S.-based Mossberg Industries Incorporated reports that it has developed a truly sustainable cable reel package, one that is a plus for both the environment and company budgets as well as the people who need to assemble/disassemble as well as store the units.

Designed to save on shipping costs, the break-down cable reels are returnable, reusable and recyclable, a press release said. It declared that the heavy-duty LLDPE plastic eliminates the possibly of nails, splinters, sharp burrs and rust that could damage the cable or create safety concerns.

Each 48 in. flange weighs 39 lb while the center barrel weighs 36.8 lb, yet it takes only one person, without tools, to assemble/ disassemble the pieces—which can be stored in a third the space of an assembled reel—in less than 30 seconds, it said. The reels, it added, have “flat” locations each 90° on the (flange) edges that provide a stationary work surface while longitudinal barrel grooves allow banding of partial coils for easy removal.

The reel is designed to last for approximately 200 uses, and individual reel components can be replaced, the release said. It noted that used reel components can be returned to R-2 Systems for credit against future orders, the plastic later ground up for use in other products. The basic color is blue, but custom flange colors are available for customer and product ID. Contact: June Hauer, R-2 Systems, Division of Mossberg Industries, Inc., tel. 260-357-5141, ext.128, jhauer@mossbergind.com. www.mossbergind.com.

Cords provide safe connections in disaster siutations, more U.S.-based Coleman Cable, Inc., has introduced a new line of disaster recovery and testoration cords that it notes can offer a safe, convenient electrical connection to convert dryer, range or generator outlets into usable power during disaster clean-up, rebuilds and restoration projects.

The need for the new product line stems from the conditions that can exist following fires, tornadoes,

New line of irradiation crosslinkable compounds is commercially available Inhol BV/PTL, based in The Netherlands, reports that it has delivered new irradiation crosslinkable compounds to wire and cable industry customers that have begun testing them.

A press release said that Inhol BV/PTL has developed compounds that include ones designed to cover specifications that include: EN 50264 and EN 50306 for rolling stock, TUV 2PfG 1169/08.2007 for photovoltaic-solar applications and UL 3680 for 150°C heat-resistant wires. The solar as well as the rolling stock compounds have been approved in Europe and the U.S., and are now commercially available, it said. Further, new compound developments have been initiated for specifications such as: VG 95218, Part 28, Type C + E, for defense applications; VG 95218, Part 29, for defense applications; and IEC 61892-4, Oil and MUD-resistant, for shipbuilding and off-shore. It added that samples of that latter group of compounds were scheduled to have been sent into the market as of press time.

The release said that company focuses on providing a consistent, quality product. To that end, it notes, all PTLbrand compounds are made at selected ISO certified compounding facilities in Europe and the U.S., and that once a compound has been approved by a customer, that specific compound will continue to be made by the same compounding company on the same machines, with the shipment to include a quality certificate.

Contact: Inhol BV/PTL, tel. 31-35-6033-234, office@inhol.com, www.inhol.com.

Descaling system is designed to process wire in coil form Canadian-based Wheelabrator Group notes that its coil-blast machine is used as a batch operation to remove surface contaminants such as mill and heat treat scale from the surfaces of wire in coil form.

A press release said that the bulk coil, shot-blast descaler does not require wire to be uncoiled for processing, is easy to load and unload, has short processing times and works on a ground-level operation, with no need for a pit or basement requirement. The model, it noted, is highlyproductive and sustainable; resulting in overall reduced maintenance costs for customers.

The totally enclosed system has a space-saving double or single swing-door configuration and a fold-in oscillating mandrel, while the EZEFIT® blast wheel technology permits the use of various wheel configurations that ensure long wheel life coupled with effective cleaning and low cycle times, the release said. The articulating mandrel arm with special lifters is designed to fold within the profile of the cabinet door, providing easy access for smooth material transfers, while clockwise and counter-clockwise rotation of the mandrel and lifters provide continuous separation of the wire coils, for maximum blast coverage, it said. Mandrels are available in 10 ft (3 m), 13 ft (4 m) and 15 ft (4.5 m) in length, each driven by a direct motor and controlled by a variable frequency inverter for oscillation control.

Contact: The Wheelabrator Group, www.wheelabratorgroup.com.

Module tops international standards Germany-based Corning Cable Systems LLC, part of Corning Incorporated’s Telecommunications segment, announced that its FutureCom™10TENe System exceeds international ISO/IEC 11801:2002, Amd 1:2008, and American ANSI/TIA/EIA-568-B.2-10-CAT6A system standards requirements.

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PRODUCTS & MEDIA

hurricanes, flood damage or other severe disasters that devastate structures and limit the readily available power for heavy equipment, said a press release, noting that, during such events, the only reliable sources of significant power are 250V range and dryer outlets, or portable generators.

The cords can help emergency response teams and contractors convert dryer, range or generator outlets into usable power for larger equipment or temporary power distribution boxes, the release said, citing the following.

The NEMA 14-30P (30A dryer outlet); NEMA 14-50P (50A range outlet) and NEMA L14-30P (30A generator) cords offer either a NEMA L14-30R (receptacle) or a 50A Twist receptacle to energize temporary power distribution boxes, while all cords complement Coleman Cable’s full-product offering of Temporary Power Distribution X-Treme™ Boxes; Polar-Solar®; Yellow Jacket®; Generator Power; Twist-To-Lock; “Y” and “W” extension cords and adapters.

“This new line of cords provides customers with a wider choice of power solutions in delivering ‘power where you need it,’” the release said.

Contact: Coleman Cable, Inc., www.colemancable.com.

PRODUCTS & MEDIA

The system is the newest addition to the highperformance FutureCom solutions and has been specifically developed to support 10 Gbit/s applications over 100 meters, a press release noted. The FutureCom10TENe System is fully compliant with the IEEE 802.3an and the recently released new EA class, it said, adding that the system is suitable for Power over Ethernet and PoE Plus applications.

The FutureCom S10TENe Module has received the GHMT Premium certification from the accredited test lab for cabling and connection components, GHMT, the release said. The insulation displacement connector (IDC) technology allows for fast and easy termination without special tooling or wire preparation, it noted.

Contact: Corning Cable Systems LLC, tel.

49-800-267-646-41, or in Europe, www.corning.com/cablesystems.

Tough technology excels for silicone cable manufacturing Swiss-based Maillefer SA reports that its EPL 25 extrusion lines excel at manufacturing highly resistant silicone cables for electrical wiring, a product that it noted has seen increased demand. A company representative noted that standards for safety and fire resistance, harsh end-use regions, such as the Arctic as well as increased exploration for resources have collectively increased the demand for cables that can resist severe mechanical and chemical aggressions, even in extreme conditions.

A press release notes that the company’s water-cooled extruder for silicone is designed to provide superior cables. Fed in bands or pellets, the crosshead is also watercooled to maintain the warmed silicone below its critical curing temperature as it is distributed around the conductor, it said. A series of curing tunnels follow, where temperature can reach up to 750°C, while the usual downstream equipment is positioned after curing and includes a multipass cooling trough, measurement gauges, powder application and continuous winding on reels, it said.

“The EPL 25 lines are built and tailored for the individual applications to provide high performance production for the best known types of silicone cables,” the release said. Manufacturers cite the details of their cable constructions and Maillifer designs the optimum package of extrusion, curing, cooling and wire reeling

90 | WIRE JOURNAL INTERNATIONAL

capacity to meet their requirements, it said.

Contact: Maillefer SA, tel. 41-21-694-4111, info@maillefer.net, www.mailleferextrusion.com.

MEDIA Redesigned company website enhances user experience U.S.-based Southwire has launched a completely redesigned web site that makes it easier for customers, distributors, contractors, engineers and other industry visitors to interact with the electrical wire and cable manufacturer.

“The site is designed to make the user experience with Southwire more satisfying and effective,” explained Southwire President and CEO Stu Thorn in a video introduction to the site. “We also wanted everyone to come away with a better understanding of our culture of collaboration, our commitment to innovation, and the many ways we are working to maintain the quality of life and the environment for our employees, customers and the communities where we do business.”

The website evolution was guided by user responses to a needs survey and managed by a cross-functional team representing all parts of the company, a press release said.

The focus was on making the site easier to navigate, more interactive and faster for the user to accomplish a wide range of practical tasks, from finding information about products and technical services to placing orders.

Enhanced features include Q-Service, a web-based ordering and self-service system, and SWIM, which incorporates EDI and Internet technology to enable vendor-managed inventory, it said. The site also includes information about Southwire’s ongoing sustainability efforts, an enhanced video library that features product demonstrations, training and instruction, and more, along with vignettes about the company’s community outreach programs.

Contact: Southwire Company, www.southwire.com.

Study shows that flat cable scores well for particulates A report available from U.S.-based W. L. Gore & Associates, Inc., presents the results of a cable particulation study that found the company’s GORE™ High Flex Flat Cables and GORE™ Trackless Cable registered zero particulates in a low-vibration chain test.

Based on ISO guidelines, Fraunhofer concluded that the GORE cables were superior because the design distributes the force placed on the cable jacketing, which resulted in less friction caused by movement.The results can be seen at www.gore.com/ particulation. The company notes that the cables also reduce the weight and stress of cable systems by eliminating the need for cable chains, dividers, and shelves, which ultimately improves cable performance and life.

Contact: W. L. Gore & Associates, Inc., tel. 3020-2925100, www.gore.com/electronics.

OCTOBER 2009 | 91

PRODUCTS & MEDIA

The test, performed by Germany’s Fraunhofer Institute for Manufacturing Engineering and Automation IPA, measured the particulation of four different cable systems for ISO cleanroom certification: two cable chains with GORE™ High Flex Flat Cables, one cable chain with round cables, and one GORE™ Trackless Cable, a press release said. To identify the source of potential particulation for the two chains with GORE™ Flat Cables, Gore selected two non-metal cable chains to use in the test, a low-vibration cable chain and a conventional chain design with links and pins, it said.

Using criteria set forth in Guideline VDI 2083 and ISO 14644-1, Fraunhofer calculated the amount of particles at three separate measuring points for each cable, the release said. The test registered zero particulates for both GORE cables in the low-vibration chain, while the conventional chain with GORE™ High Flex Flat Cables emitted particles at rates of 0.1 to 1.7 particles per cubic foot, depending on the velocity, and the conventional chain with round cables was also affected by velocity, emitting 0.0 to 2.5 particles per cubic foot. Testing identical flat cables in two different cable chains indicated that the particulation was caused by the cable chain and not the cable, it said.

PRODUCTS & MEDIA

Guide outlines lean principles uses A new book on lean principles for process industries focuses on how to assess an operation, identify weaknesses (bottlenecks) and improve them.

The book, Lean for the Process Industries: Dealing with Complexity, written by Peter L. King and published

by U.S.-based Productivity Press, provides “the first comprehensive resource written explicitly for change agents within the process industries.”

The author, who worked for Dow Chemical for 42 years and now is president of Lean Dynamics, LLC, a U.S. manufacturing improvement consulting firm, focuses on areas where the improvement needs of the process industry differ from parts assembly manufacturing, it said.

A press release said that the book presents: each of the eight wastes commonly described in “lean” literature, looking at how they manifest themselves in process operations; how to adapt value stream mapping for process operations; how to identify the root causes of bottlenecks, and systemically eliminate them; process-oriented modifications that will enhance the usefulness of cellular manufacturing, Heijunka production leveling, and pull replenishment systems; and the role of process operations management in a lean strategy Contact: Productivity Press, www.productivitypress.com. ■

Call Cemanco for

Drawing Cones and Capstans (by Ceramtec)

Parts available for all OEM equipment SYNCRO parts in stock 951 N.W. 31st Avenue • Pompano Beach, FL 33069 Phone: 954/970-3099 • Fax: 954/970-3056 e-mail: sales@cemanco.com Web page: cemanco.com

92 | WIRE JOURNAL INTERNATIONAL

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

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

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

PAYMENT POLICY: All ads must be pre-paid.

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

CAREER OPPORTUNITIES SALES POSITION: Midwest thermoplastic compounder has immediate sales position openings in the Midwest, Southeast and Southwest territories.

Ideal candidates should have a minimum of 3-5 years of technical selling experience in Flexible PVC’s, TPR’s (SBS & SEBS), TPE’s, TPO’s and/or color concentrates. Salary is commensurate with experience. Compensation also includes a full benefits package with auto/auto allowance, travel reimbursement, medical insurance and 401k with company match. Please forward all inquiries to: Box 10-1.

MANUFACTURER’S REP. Position wanted on East Coast to sell imported diamond wire drawing dies. Contact: Electronic Material Sales, 11 Algonquin Lane, Brunswick ME 04011. Phone: 207-373-0314, dwiredies@ gmail.com.

PERSONNEL SERVICES “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

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.

guidance. Our services are performed in absolute confidence.

Contact: E-mail Peter Carino at pcarino@wireresources.com or Jack Cutler at jcutler@wireresources.com, or visit the Wire Resources website at w w w. w i r e r e s o u r c e s . c o m . Wi re Resources, Inc., 522 E. Putnam Ave,

Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE. DIES SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service.

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

FOR SALE

1 - HALL Vertical Accumulator, 15” O.D. Sheaves, 500’ accum., ‘97 1 - NEB 64-Carrier CB-1 Cabler Braider 2 - WARDWELL 24-C Speedmaster Braiders 2 - STEEGER 16-C Braiders 3 - DeANGELI 760mm Bunchers 1 - REDAELLI 630mm D.T. Buncher 1 - WATSON 36” Rotating Cabler Line 1 - GODDERIDGE 800mm Cabler 3 - NORTHAMPTON 630mm D.T. Cablers 2 - NEW ENGLAND BUTT 12-Wire 8” Vertical Planetary Cablers 1 - CEECO 6-Bobbin 60” Closer w/Caterpuller, Take-up 2 - MGS Model LC50.4 Caterpuller Capstans 1 - DAVIS ELECTRIC Model CAT-TRAK 22 Caterpuller Capstan 1 - VITECK 24” Horizontal Belt Wrap Capstan 1 - NIEHOFF M15 Wire Drawer, Annealer, SG45 Spooler 4 - D/S 3.5” 24:1 L/D Extruders 1 - D/S 3” 24:1 L/D Mark V Extruder 1 - D/S 2.5” 24:1 L/D Nylon Extruder 1 - D/S 2” 30:1 L/D Hi-Temp Extrusion Line

2 - SKALTEK Rewind lines: A22-4K Payoffs; U20t Take-ups 2 - HALL 36” Motorized Payoffs 2 - TULSA 24” Motorized Shaftless Payoffs, Model HSPO-1, 12/02 3 - MGS 18-Bay 10” Tubular Stranders 1 - DAVIS STANDARD 36” Dual Reel Take-up, Model PS36 1 - ENTWISTLE 36” Dual Reel Take-up, Model THE 24/36 4 - D/S 30” Dual Reel Take-ups 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 4 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-ups 1 - CLIPPER Model SP16 Dual Spooler 1 - WATSON/AFA 96” Rewind Line 2 - TEC Model 24STC Hi-Speed Twisters, rated 1300rpm w/2-Wire Payoffs 1 - TEC 600mm Backtwister D.T. Twister 1 - TEC 600mm D.T. Twinner 41 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels 1 - D/S 3.5" 20:1 CV Line, complete

Contact: Martin Kenner

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

OCTOBER 2009 | 93

CLASSIFIEDS

CLASSIFIEDS

CLASSIFIEDS

WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME _________________________________________________________________________TITLE _________________________________________________ COMPANY ____________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

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

60+ years of quality products and service to the wire industry. Contact Bill Drumm at 1-800-332-0747, or E-Mail at sales@sancliff.com.

ajexturner@gmail.com. A-53, G.T. Karnal Road, Delhi-33 India. Ph: 00919811078882 (Ravi Bansal).

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.

REP OPPORTUNITY

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

AJEX & TURNER WIRE DIES CO. offers a wide range of PCD/nd/carbide dies, extrusion tools, die polishing machine, ceramic and diamond tools.

Please visit our company web site: www.ajexturner.com. Send inquiry to

COMMISSION OPPORTUNITY. An ISO CERTIFIED Co. mfg.

Crossheads, Inline Heads, Tips, Dies, Breaker Plates, Clamps, Injection Non Return Valves, Screw Tips, End Caps, Nozzles, etc, wishes to appoint partners in Sales on handsome Commission basis. Please contact: extrusion.tooling @gmail.com.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous and NonFerrous; Marldon Rolling Ring Traverses) and Used Wire and Cable Equipment. Please contact by tel. at 727-863-4700 or by e-mail at urbassoc@verizon.net.

Serving the non-ferrous and ferrous industries since 1983

94 | WIRE JOURNAL INTERNATIONAL

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org.

For more details, you can call her at 203-453-2777, ext. 116.

MACHINERY SERVICES INDEPENDENT SERVICE ENGINEER. Service your customers easily and efficiently with an independent service engineer. Only pay for the time working at your customer’s site.

Installations, warranty and service contracts. 25 years experience in W&C machinery, electronics, measurement and software systems. Contract or perdiem. Contact R. Paladini at 610 346 9020 or services@metrilogic.com.

WIRE FOR SALE FOR SALE. Titanium wire for sale. .125,” .144,” .160,” .187.” Grade 2, 4, 5. In coil and 12” length. Contact info@filochrome.com.

MEDIA ELECTRICAL WIRE HANDBOOK. Focusing on the special needs of the insulated wire and cable industry, this three softcover book set examines materials, equipment, and products.

The original version remains available while the revised Electrical Wire Handbook is divided into three separate handbooks: Part 1 - Wire and Cable Production Materials, Part 2 - Wire and Cable Production Processes, and Part 3 - Types of Cables. List Price: $99, WAI Member Price: $59. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

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

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

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

CERSA-MCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Amaral Automation Associates . . . . . . . . . . . . . . . . . . . . .58

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .93

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .38

CommScope Bimetals . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Arkema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Eurolls Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

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

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Bomco Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .49

Gem Gravure Co Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Caballe SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Gimax Srl . . . . . . . . . . . . . . . . . . . . . . .insert between 16-17

Cable Components Group . . . . . . . . . . . . . . . . . . . .Cover 2

Howar Equipment Inc/ACM . . . . . . . . . . . . . . . . . . . . . . . .16

Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Howar Equipment Inc/Metavan . . . . . . . . . . . . . . . . . . . . .38

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Howar Equipment Inc/Unitek Crossheads . . . . . . . . . . . .14

Cemanco LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

PLEASE VISIT US AT WIRE SOUTHEAST ASIA BOOTH #B02 WAREHOUSE SPACE AVAILABLE: PAWTUCKET, RI - ATTLEBORO, MA - MORVEN, NC - BONHAM TX

RECENT PURCHASES — INVENTORY HIGHLIGHTS CBR1038 60” WATSON Rotating T/U, 27” Dual Capstan.

CBR1036 WATSON 1+3 Bar/Tube Twister w/dual 36” capstan, DC drive.

CBR1039 AFA 12 Wire Planetary Cabler.

CBR998 (8) SETIC 630mm PA630i D.T. Twinners, 1998.

CBR1000 84” CABALLE/KALMAR/POURTIER Drum Twisting Line, 1990’s.

CBR995/CBR989 630mm MGS & TEC, 800mm NMC D.T. Twinners.

PAY1559/TKU1132 60” BARTELL Shaftless Payoff & Take up.

PAY1540 CLIPPER Driven Flyer Payoff Jacks, with 24” & 30” dual cone flyers.

PAY1546 (9) TEC 24” Dual Driven Payoffs w/MGS vertical dancers.

PAY1537 (6) 24” MGS Dual S/L driven payoffs w/ vert dancers.

MGS/BARTELL Payoffs 60”, 72”, 84”, 96” Take ups 60”, 84” 96” (some rebuilt) EXPL347 2 1/2” D.STD./SAMP Tandem Wire Dwg Insul Line w/2 1/2” & 1 1/4” extruders, 630mm Samp dual T/U, Yr. 2005.

EXPL325 4 1/2“ Jacketing Line w/2) 60” Belt Caterpullers, 96” Portal P/O, T/U, 30” multipass capstan.

EXPL319 (2) DEANGELI/SAMP 45mm Hi Temp Lines w/Zumbach Preheater, SS multipass capstan, 560mm dual parallel axis take ups.

EXPL304 ROSENDAHL Skin-Foam-Skin Ins Line, 2000, Henrich annealer, preheater, 60/45/30mm extruders w/gas inj., multi cap, Rosendahl DIN500 dual T/U. HI TEMP EXTRUDERS: (YR 1998): EXP740 1 1/2” D.STD. 30:1, EXP770 1 1/2” D.STD.24:1, EXP666 2” D.STD. 30:1.

EXRL38 3 1/2”/ 1 1/4” AMERICAN KUHNE XLPE, CV Line, 2001, Endex CC18 18” Drop Coiler, mutlipass capstan.

EXR172/171/168 4 1/2”, 3 1/2”, 6“ D.STD. 20:1 Rubber Extruders, roller feed water cooled.

BPK055 (2) 14” BONGARD TW470-KT Barrel Packers, 1999/2000 CLR214 SKALTEK MPS-260 Automatic Coilng Line for 250mm coils, CS260 pallet stackers.

RWD359 2.6m SKALTEK Rewind Line. A264K P/O, S60/L100 line controls., meas mach. Guide roller assy. U26T T/U. RWD445 (7) CLIPPER Dual S/T Rewinders, SP16, SP18 SP24, SP6.5

PREOWNED HIGH QUALITY WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY AVAILABLE EX-STOCK FROM SIX US WAREHOUSE LOCATIONS.

OCTOBER 2009 | 95

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

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

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

IDEAL Welding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .91

REELEX Packaging Solutions Inc . . . . . . . . . . . . . . . . . . .15

Inhol BV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Rosendahl Maschinen GmbH . . . . . . . . . . . . . . . . . . . . . .25

InterWire Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

SAMP USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Kamatics Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Sanxin Wire Die, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

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

Paul Leibinger GmbH & Co. KG . . . . . . . . . . . . . . . . . . . . .54

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Super Power Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . . . . .56

Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . . .4

Lloyd & Bouvier Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Teknor Apex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Windak AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . .94

Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .95

Messe Düsseldorf North America . . . . . . . . . . . . . . . . . . .55

Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .61

Mobac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

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

Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .22 Power Sonics LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Precision Die Technologies Inc . . . . . . . . . . . . . . . . . . . . .16 Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .45 Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . . . . .31

WIRE ASSOCIATION INTERNATIONAL ADS Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Wire Expo 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Wire Expo 2010 Call for Papers . . . . . . . . . . . . . . . . . . . . .44 WAI ITC: Turkey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63-65

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

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

NORTH AMERICA

EUROPE

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

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

96 | WIRE JOURNAL INTERNATIONAL

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

Wire & Cable Services Pvt. Ltd. (WCS) sales@wirenet.org

Wind up with an Amacoil/Uhing assembly for perfect pitch every time Pitch is adjustable (10:1) without requiring gear changes or adjusting motor speed. A single Amacoil/Uhing assembly may be used for winding many different diameter materials. Automatic reversal of the traverse is mechanically controlled – without clutches, cams or gears. No electronics or programming needed.

FEATURES • Zero backlash.

• Automatically synchronizes pitch with take-up reel rotational speed.

• Traverse drives with up to 800 lbs. axial thrust.

• Smooth, unthreaded shaft won't clog or jam – no bellows assembly needed.

• One inexpensive, unidirectional motor drives both the traverse and take-up reel.

• Free movement lever – no need to "jog" system on and off to position linear drive.

• Options and accessories for every winding situation.

• Light, medium and heavy-duty systems.

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

email: amacoil@amacoil.com

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

Innovation & Latest Technology For In-line Profile Measurement

Diameter / Ovality

X-Ray (3 layer)

Eccentricity

Capacitance

Wall Thickness

Spark Test

Faults

Temperature

In-line Full Cross Section Measurement s Maximize profits resulting from reduced production costs s Latest light-cut system s Measurement field .08 – 3.15 in. (2 – 80 mm) s Accuracy typically +/- .00008 in. (0.002 mm) s Rapid payback from optimizing process, quality control and material cost s Compact design adds greater flexibility into your systems

Worldwide Zumbach Customer Service and Sales Offices in 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

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Preheating

www.zumbach.com

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The Full Range of Measuring & Control Systems for the Wire & Cable Industry