Industry Trends

WIRE JOURNAL DECEMBER 2011

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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

Industry Trends

wrapup: CabWire World Conference 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 44 | Number 12 | December 2011

F EATURE

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 20 People . . . . . . . . . . . . . . . . . 22 Fiber Watch . . . . . . . . . . . . . 24 Fastener Update . . . . . . . . . . 26 WAI News . . . . . . . . . . . . . . 28 Chapter Corner . . . . . . . . . . . 32

CabWire World Conference wrapup .34 The one-day conference on Nov. 7 drew 142 wire and cable professionals to the Messe Düsseldorf Congress Center, where the program offered a combination of 29 technical and general presentations balanced between ferrous and nonferrous subject areas as well as tabletops, plant tours and much networking.

Innovations . . . . . . . . . . . 42-43 Technical Papers . . . . . . . 52-69 Products. . . . . . . . . . . . . . . . 70 Classified . . . . . . . . . . . . . . . 76 Career Opportunities . . . . . . . 76 Advertisers’ Index . . . . . . . . . 78

Next issue

Industry Trends . . . . . . . . . . . . . . . .38 This feature provides a look by CRU’s Rob Daniels at a key industry force (the four BRIC nations); the return of an occasional WJI section, Innovations, where a new stranding method is proposed; a focus on marketing; and more.

T ECHNICAL P APERS Characterization of defects on Al-1350 rectangular wire produced by continuous extrusion process Sergio Gallegos, J. Angelica Ramos and Sergio Montes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

January 2012

Effect of extrusion temperature and speed on structure of CuAg15P5 alloy Rafał Włudzik, Jan W. Pilarczyk, Marcin Kwapisz and Łukasz Wierzbicki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

• Ferrous Wire Manufacturing • WAI officers for 2012

Effective use of infrared heating for wire and cable applications Richard E. Hoffman, Jr. and Eric P. Hummel . . . . . . . . .64

Cover: The words in the cover image capture the scope of industry activity as a whole, but one could also add some other aspects—the ones that are essential to making things happen—such as attention to customers, resilience and creativity. See p. 38.

DECEMBER 2011 | 3

INSIDE THIS ISSUE WITH DRIVE

. . . . . .32

CONTENTS

A ‘GREEN’ VENUE

The RDS Wire & Cable team (l-r) of Jon Stott, Danny Hoff, Bob Hoff, and Doug Stott claimed top honors in the Western Chapter’s golf tourney. Chapter President Michael Weiss of Whitmor/Wirenetics says their event may be last and it is not the biggest, but for other reasons he declares that it is still the best.

4 | WIRE JOURNAL INTERNATIONAL

AN

EVENT WITH SHOP FLOOR APPEAL

Wolfgang Schuh, managing director, welcomes attendees to the tour of Leoni Kerpen GmbH in Stolberg, Germany.

The tour, part of the CabWire World Conference that was held in November in Düsseldorf, was a group effort organized by five industry associations: ACIMAF, C.E.T., IWCEA, IWMA and WAI. A ferrous tour was held at Drahtwerk Köln in Cologne.

. .34

EDITORIAL WIRE JOURNAL

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EDITORIAL

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

Advancements keep the industry strong Last month, I joined WAI’s President Dominique Perroud at the CabWire Conference in Düsseldorf, Germany. I want to thank Dominique for his service as president of the Association during the past year. He was fully engaged in the WAI responsibilities as he seemed to expand his day to fit our business on top of his demanding role as the chief of SAMP’s growing Asia operations.

While never a “Spa Weekend” person, I understand the need to rejuvenate your body and mind. Whether we recognize it or not, we all need to break routines and introduce new thoughts, and I think the CabWire event was exactly that for those that attended last month’s event. The event wrapup starts on p. 34, but I wanted to share with you some of the message that I came away with, and frankly some of it contradicts the common characterization of the industry as being mature.

The program was full with 29 presentations that were just the right balance of practical and technical. There was plenty of good research being shared with interesting presentations from Ilmenau University, the Colorado School of Mines, the Institute of Spring Technology and Tata Steel. Product advancements were detailed by a number of suppliers, such as TKT’s borax-free lubricant, showing real progress on the environmental and safety front. And the Integer Research presentation gave everyone a global perspective on the continuously evolving cable industry.

The keynote paper, “New developments and trends in automotive wires,” by Leoni’s CEO Dr. Probst, revealed the kind of opportunities that exist for the wire and cable business. Probst detailed the reinvention of the wire harness business as the auto sector responds to demand for more comfort features as well as environmental interests influencing end products. Leoni has introduced miniaturized cables and lighter weight materials and focused on new products, such as charging connectors for electric vehicles and high tech applications for managing emissions.

Not all sectors are advancing as fast the automotive field, but the wire and cable industry ultimately is powered by research and innovation. Sure, some of it is connected to cost-cutting, but the industry is far from static or mature, and new ideas are needed.

One possible example of that may be found in the Innovations article on pp. 46-47. More importantly, I believe that progress as a whole will continue in response to the never-ending demand for new and better ways, because that’s the essence of the industry.

Steve Fetteroll WAI Executive Director

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Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli Senior Graphic Designer | Bill Branch Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing & Corporate Communications | Janice E. Swindells Graphic Artist | Adrienne E. Simpson Proofreader | Livia Jacobs Publications Advisory Board Dane G. Armendariz | Henkel Corporation, USA Ferruccio Bellina | TKT Group/President ACIMAF, Italy Peter A. Funk | Talley Metals Technology, USA Malcom Michael | AWIA Australia Don Schollin | Q-S Technologies, USA Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA 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. © 2011 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700.

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

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CALENDAR

CALENDAR March 26-30, 2012: wire Düsseldorf 2012 Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, info@mdna.com, tel. 312-781-5180.

April 18-19, 2012: Polymers in Cables 2012 Miami, Florida, USA. To be held at the Hyatt Regency Miami. Contact: Applied Market Information LLC (AMI), tel. 610-478-0800, mk@amiplastics-na.com, www.amiplastics-na.com.

May 9-10, 2012: 2012 National Electrical Wire Processing Technology Expo Milwaukee, Wisconsin, USA. To be held at the Frontier Airlines Center. Contact Expo Productions, Inc., tel. 800367-5520, www.expoproductionsinc.com/wire_home.htm.

May 21-22, 2012: AWPA 2012 Wire Rod Supply Chain Conference Dallas, Texas, USA. To be held at the Omni Dallas Hotel, this event, being put on by the American Wire Producers Association, is being held in conjunction with WAI’s Wire Operations Summit & Wire Expo 2012. Contact: AWPA, tel. 703-299-4434, www.awpa.org.

May 22-23, 2012: 2012 WAI Operations Summit & Wire Expo Dallas, Texas, USA. To be held at the Omni Dallas Hotel, this WAI event includes the Association’s 82nd Annual Convention, technical programs, trade show and more. www.wirenet.org.

June 11-13, 2012: CRU 6th Wire and Cable Conference Vienna, Austria. To be held at the Vienna Mariott hotel, this forum provides networking opportunities between cable manufacturers and their customers. Contact: CRU International, tel. 44-20-7903-2444, conferences@ crugroup.com, www.wireandcableconference.com.

Sept. 25-28, 2012: wire China 2012 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Oct. 3-5, 2012: SpringWorld 2012 Rosemont, Illinois, USA. To be held at the Donald E Stephens Convention Center. Contact: Tom Renk, The Chicago Association of Spring Manufacturers, Inc. (CASMI), tel. 630-369-3466, fax 630-369-3773, info@casmi-springworld.org, www.casmi-springworld.org.

Oct. 29-31, 2012: Wire & Cable India Mumbai, India. This event is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Nov. 11-14, 2012: 61st IWCS Conference™ Providence, Rhode Island, USA.To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990.

April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show, technical programs and the Association’s 83rd Annual Convention, www.wirenet.org.

May 2013: wire Russia 2013 Moscow, Russia. This event is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Sept. 17-19, 2013: wire Southeast Asia Bangkok, Thailand. This event is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. ■

W IRE ASSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org.

Jan. 26, 2011: New England Chapter Meeting Uncasville, Connecticut, USA. The chapter will hold its 18th annual meeting at the Mohegan Sun Resort Conference Center. Contact: Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org. See p. 32.

May 22-23, 2012: 2012 WAI Operations Summit & Wire Expo Dallas, Texas, USA. This WAI event at the Omni Dallas

8 | WIRE JOURNAL INTERNATIONAL

Hotel includes the Association’s 82nd Annual Convention, technical programs, trade show and more. www.wirenet.org.

April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show, technical programs and the Association’s 83rd Annual Convention, www.wirenet.org.

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INDUSTRY NEWS

INDUSTRY NEWS Prysmian Group reports further inroads in Brazil, North America The Prysmian Group announced that the company has made progress in Brazil, where it reported that the company’s new flexible pipes plant is now fully operational, and that its assimilation of the activities of Draka has broadened its product range to open up more opportunities in North America.

A press release said that the new plant in Brazil has seen “the first important commercial contracts,” marking a sharp acceleration in the Group’s expansion plans in the high-tech sector of flexible pipes for offshore oil production. It noted that the Group has received orders from

Draka’s entry into the Group created interesting crossselling opportunities, as in the case of the Petrobras contract for DHT cables, and accelerated this business’s expansion outside of Brazil, such as in the U.S. and other areas of the world where oil is produced offshore, including West Africa, Northern Europe and the ASEAN countries, the release said. “By the end of 2011 we expect to have made more than $150 million sales in this market, covering flexibles, umbilicals and DHT cables, confirming the importance of this high-tech business for the Group,” it said. Petrobras, it added, remains the main customer and technological partner, “but following the Draka integration, the Group has widened its customer base to prestigious oil industry names like Schlumberger, BakerHughes, BJ Services, GCDT and Roxar.”

The Brazilian plant, which cost about $150 million, has the capacity to produce more than 150 km of flexible pipes per year with a workforce of some 400 employees, the release said. It noted that the plant complements the production from the Group’s existing umbilical cables plant, opened in 2007 in Vila Velha, and Draka’s two U.S. DHT cable plants in Massachusetts and New Jersey.

Queins exits insolvency, reports that a new, stronger company has emerged

Demand for flexible pipes and cable for offshore applications has bolstered Prysmian’s order books.

Petrobras worth some $50 million to supply flexible pipes to connect platforms to wellheads thousands of meters below sea level, and special Downhole Technology (DHT) cables, including fiber optics, to control downhole instrumentation, power and hydraulic fluid cables. The order includes about 25 km of 2.5 in. and 4 in. flexible flow lines for the Sidon and Namorado oil fields that are worth approximately $20 million, it said, adding that a prior Petrobras order calls for Draka to supply DHT cables for various fields in the Campos Basin worth some $30 million over three years.

“This contract means not only further consolidation of the Petrobras relationship but also a first important benefit deriving from the integration,” the release said. “With Prysmian not previously present in this product category, the new Group has now a wider range of technologies and can capitalize on Draka’s already established presence in the American market.”

10 | WIRE JOURNAL INTERNATIONAL

The message from Hans Georg Queins, principal of Germany’s Queins & Co. GmbH, was brief and to the point: “The insolvency is over.”

It was on Aug. 31 that the company announced that it had been forced to declare insolvency because of a credit crunch created by a few large orders that were booked but later cancelled. It has returned under a new name, Queins Machines GmbH, and a firm base, a press release said. It said that Queins now belongs “to a financially very strong group of companies, and there are no problems anymore with deliveries, payments or guarantees of any kind.”

Asked by WJI what changes there may be in the company’s operations, Hans Georg Queins replied, “The manufacturing program remains the same and all staff has been taken over by the new owner. We continue business as usual and from the customer’s side there is no difference at all.” The Group, he said, consists of more than 60 companies with a total of 4,500 employees. He added that all company contact data, like mailing address, phone, e-mail and fax, will remain the same.

LS Cable & System reports contracts from Kazakhstan and Paraguay LS Cable & System reports that it won contracts for extra-high-voltage (EHV) transmission cables from Kazakhstan and gap conductors from Paraguay, made possible by its becoming the first cable company in South Korea to obtain business rights in the Commonwealth of

LS Cable & System was recognized as having technological capabilities and installation competencies superior to the competitors,” the release said. It noted that LS Cable & System “commenced vigorous overseas market entry (in) the early 1990s and now has around 100 operation sites in 24 countries.”

IWG reports operations expansion in southern U.S. and Eastern Europe International Wire Group Holdings, Inc. (IWG) announced that it has expanded its operations in the southwestern U.S. and in Eastern Europe.

A press releae said that IWG has completed its purchase of the machinery and equipment of Ffhoenix Cuivre, LLC, located in Santa Teresa, New Mexico, and assumed the related building lease. The purchase, it said, will expand the company’s manufacturing capacity in the southwestern U.S. It also reported that IWG has begun manufacturing product at its new plant in Dabrowa Gornicza, Poland.

This new plant, it said, will enable IWG to better serve its growing customer base located in Eastern Europe. Initial investment for these two expansions total approximately $14.5 million, it said.

“These two new plants will allow us to have additional

DECEMBER 2011 | 11

INDUSTRY NEWS

Independent States (CIS) and South American markets.

The power cable supply contracts, worth $24 million, are from Samruk Energy, a state-operated power company of Kazakhstan, and $9.1 million from the Administracion Nacional de Electricidad (ANDE) of Paraguay, a press release said. “Accordingly, the outlook for entry into the new markets of the CIS and South America has become bright,” as the company “has climbed to an advantageous position in terms of market entry into these areas of high growth potential.”

The Kazakhstani project, the release said, which requires 127 km of 220kV level extra-high-voltage transmission cables and joints as well as technical help, will resolve power deficiencies caused by expansive urban and industrial development in Almaty, the capital city.

The Paraguay order calls for LS Cable & System to provide 140 km of optical ground wire (OPGW) and 1,100 km of 220 kV level gap conductors, the latter of which are made from a super heat-resistant aluminum alloy and can provide twice the electricity transmission of the cables they replace without having to add transmission towers, the release said. They will be used in San Lorenzo and Guarambare for the country’s national backbone power and communication network, it said.

“Having won the contract after a series of two strict assessments against two market leaders, 3M and Nexans,

INDUSTRY NEWS

capacity closer to our customers and also provide for future growth,” IWG CEO Rodney D. Kent said. IWG notes that it manufactures and distributes its products at 19 facilities in the U.S., Belgium, France, Italy and Poland.

With latest news, Messe Düsseldorf now has events in all 4 BRIC nations Messe Düsseldorf reported that it and a partner, Grupo Cipa, have launched a trade show in Brazil. With the addition, the German-based trade show organizer now has trade shows for the wire and cable industry in each of the four BRIC countries (Brazil, Russia, India and China).

The new event, called wire South America, will run concurrently with a sister show for the tube industry when it is staged for the first time on Oct. 8-10, 2013, at the Imigrantes Exposicoes Exhibition Centre in São Paulo.

While wire South America is a new event, it had been previously held in a different form, most recently in São Paulo in Oct. 4-6 as one of multiple events that composed TUBOTECH. A press release said that the focus is on “developing wire South America as an independent trade fair customized to meet the local needs in the region. For our customers this is a gateway to give them access to the growth market of South America at an economically ideal time.”

“The difference is that the new trade fair will be an independent event which Messe Düsseldorf and its partner Grupo Cipa will establish in the Brazilian market,” said Jörg Dübelt, head of the department, International Exhibition Management, for Messe Düsseldorf. The event will be enhanced to offer more value to attendees, including new segments, such as spring making and machinery for fastener manufacturing, he said. “The goal of the new trade fair is to become the leading trade show in South America and the B2B event for this industry. The potential is there and so is the demand since the Brazilian market is booming. For example, in 2010, the Brazilian economy reached its strongest growth in the last 20 years with an impressive 7.7%. For 2011, economist forecast a growth rate of just under 4%.”

Grupo Cipa is responsible for South American customers, with Brazil’s Luis C. Carmo, the contact, available at tel. 55-11-5585-4357, lccippa@cipanet.com.br.

The U.S. contact for wire South America 2013 is Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

12 | WIRE JOURNAL INTERNATIONAL

Leggett & Platt plans to close its Adcom Wire plant in Nicholasville The Nicholasville, Kentucky, operation of Adcom Wire Co., a division of the Leggett & Platt Wire Group, is scheduled to close by year’s end, eliminating 68 positions there. A story in the Central Kentucky News, Jessamine County Economic Authority Director Wayne Foster said that he was told that the company, which manufacturers steel wire and steel alloy wire, was consolidating its operations.

Former CommScope executive is now serving industry in a new role Paul Bedder, a WAI member whose 30 years of industry experience includes serving as the vice president of CommScope BiMetals, is now offering a different range of services to the wire and cable industry.

Bedder, whose 12 years in the wire and cable industry includes his running two CommScope plants, said that he has joined Raindance Strategic Partners, a North Carolina-based firm that helps companies in transition.

“We provide business turnaround/renewal, debt restructuring, capital sourcing and merger & acquisition services to small- and medium-sized companies,” he said, noting that his background makes it possible for companies to get help and advice from a person who is well versed in the unique challenges of the industry.

Paul Bedder attended the 2011 staging of IWCS with a new company name tag.

Prior to running the BiMetals business, Bedder said that he led the operations and engineering functions in the start-up and maturing of the company’s wire and conduit businesses. That, he said, included systems development, with a focus on aspects such as lean manufacturing, Crosby Quality, Six-Sigma implementations and materialrecycling initiatives. “I believe that with my industry

TEC celebrates 25th anniversary U.S.-based Thermoplastics Engineering Corporation (TEC) this year celebrates its 25th year in business, noting that it has continued to provide a wide range of products and solutions for the wire and cable/fiber optic industries, driven by an experience base that has been there since “Day One.” “TEC’s business is and always has been market driven,” said Ernest Landry and Timothy Dacey, who co-founded

to the younger professionals coming into our industry,” he said, adding that the communication may be different but it does not really change their approach.

“We love what we do, so it’s easy for us to come to work every day,” Dacey said.

More details on the company can be found at www.thermopasticseng.com.

UL requires several cable types to come in boxes bearing holograms Underwriters Laboratiors (UL), which has been battling the inflow of non-compliant cables that improperly bear its mark, reports that as part of its Follow Up Service (FUS) program, all UL-listed communication and network cables must come in a box that has a holographic label with the UL mark.

“The enhanced FUS program will help minimize the risk associated with installing a noncompliant cable and allow end-users and specifiers to look for a UL Holographic label,” said Steve Galan. UL’s business development director for wire and cable. “The new security feature provides multiple levels of security and will help in specifying, verifying when ordering and/or installing cable.”

At Interwire 2011, TEC’s Tim Dacey, Ernie Landry, Sarah Landry and Pat Wilkins. the company in 1986. The business combines the mechanical engineering talents of Landry and electrical engineer skills of Dacey, who today serve as president and vice president, respectively. Both men had previously worked together for New England Wire Machinery, and over the years they said they have focused on evolving the business to be flexible to the needs of customers, to supply quality products and solutions and to have a knowledgeable staff that customers can depend on.

The company’s product range includes custom machinery for extrusion and cabling, as well as servicing the plastics market for tubing, profile and compounding machinery. Dacey said that one aspect of the business he enjoys is that many company relationships over the years have led to good friendships, including with some competitors. The company has changed over the years, and while it has always focused on better technology, it has evolved in ways that neither founder could have envisioned 25 years ago, he said. “We are in a phase of updating our web site, and we have a Facebook page to appeal

Holograms introduced by UL in 2009.

“CCCA applauds UL’s actions and initiatives to further strengthen programs and procedures in response to the non-complaint cable problem and its impact on public safety,” said Frank Peri, executive director of the Communications Cable and Connecticity Association (CCCA).

Sumitomo opens India subsidiary Japan’s Sumitomo Electric Industries, Ltd.. announced that it has has opened a subsidiary in India, SEI Trading India Private Limited, to reinforce its sales structure in the Indian market.

A press release said that since the mid-1980s,

DECEMBER 2011 | 13

INDUSTRY NEWS

expertise, Raindance can offer ideas to companies that will work because we understand what it takes to succeed in this industry, both in the front office and on the shop floor.”

Bedder can be contacted at tel. 828-455-0248, pbedder@raindance-sp.com or www.raindance-sp.com.

I joined WAI for the member discount on a technical conference and the investment paid off. No regrets!

Q: What are the three most valuable benefits you receive through WAI? A: Meeting the decision makers of the wire industries in a friendly context; getting to know the real social and economic situations of the countries beyond what newspapers report; and enjoying fantastic cocktails with extraordinary people.

Q: Why have you renewed your membership?

A: WAI attracts the most eminent and influential persons in our business. This is a superb opportunity to meet with people who would otherwise be hard to reach. Every single WAI event combines professionalism and humanity of all participants and this enriches me both on a job-related and personal level. © Ph Emiliano Boga

Q: How did you get involved in the wire industry?

A: I took a master’s degree in theoretical philosophy. I explored different business sectors and found my dimension in the wire industry because as theoretical philosophy is the mother of all sciences, so heavy industry is the origin of any economic and productive process.

Paola D’Oria

Q: What would you be if you weren’t in the industry?

A: What I already am: an actress.

Executive Assistant | Continuus-Properzi SpA Member Since: 2001

Q: If you were to nominate yourself for an award, what would it be for?

A: Easy: the Academy Award for best female performance... what else?

Ciao Paola D’Oria.

One of WAI’s worldwide members.

One compelling story.

Skyscrapers. Bodyguards. Helicopters. Industrial relations and costume changes. It’s all in a day’s work for Paola.

She’s not a Bond agent but she is an actress.

Q: Who is the most famous person you’ve met?

A: Clint Eastwood. I interviewed him for three hours about the characteristics of a BMW while doing market research.

Categorically Magnetic | Expressive | Enthusiastic | Cerebral | Bella Vita | Organized | Captivating | Thoughtful She’s also at the right hand of one of the most prominent executives in the wire and cable industry. Concerned with legal affairs, and social and economic news, she relies on WAI to stay on cue.

Both authentic and theatrical, she takes balancing extremes in stride. She’s sure-footed, even in designer heels. She is prepared with an unscripted composure that allows her to dot the i’s while crossing the time zones.

Paola is absolutely effervescent. She’s bright, lighting everyone’s way with an unapologetic charisma that would make anyone’s day. That’s how she disarmed the toughest of Hollywood royalty. Behind her own glamorous spectacles she has an eye on an Oscar. Will she follow in Sophia Loren’s footsteps?

Her body language tells us she’s thinking about it.

Meet her on WAI’s international stage.

MNEMONIC TIP: PAOLA D’ORIA. PAOLA D’ORGANIZER.

Q: Who is your mentor?

A: Mr. Giulio Properzi taught me to be a professional executive assistant and a strong and determined person without forgetting the sensibility of a woman in a field dominated by men.

Q: What is your best wire industry related travel story?

A: To catch a flight from Mexico City to Hartford a client put a helicopter at our disposal, which landed on a skyscraper where six bodyguards were waiting for us. Amazing. I thought I was in a James Bond movie!

Q: Lifelong ambition?

A: Have no regrets.

Q: What is your greatest accomplishment?

A: Organization of the International Technical Conference in Stresa, Italy, in 2003.

Meet your peers. Achieve your goals. Join WAI’s community at www.wirenet.org.

The Wire Association International, Inc.

1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

pany’s specialized cable manufacturing facilities in Halden, Norway, will manufacture the power umbilical for the Jack and St. Malo fields in two separate lengths, together with the associated umbilical termination heads (UTHs). On completion, the power umbilicals will be delivered to the newly constructed carousel at the Theodore Industrial Port in Mobile, Alabama, in 2013, it

Baosteel subsidiary commissions rod line Shanghai-based Chinese steel giant Baosteel reports that one of its subsidiaries, inner Mongolia-based Baogang Wanteng Iron and Steel Co. (Baogang Wanteng Steel), has commissioned its new high-speed wire rod production line.

Steel Orbis reports that the new production line is part of the first phase of Baogang Wanteng Steel’s environmentally friendly project for the construction of an additional two million metric tons of annual steel output capacity. The first phase of the $485 million project, it said, included construction of a 1,166cubic-meter blast furnace, two sintering machines, a 120 mt converter and the wire rod production line.

Nexans wins U.S. umbilical contract Nexans reports that it has been awarded a contract by Chevron U.S.A., Inc., to supply 42 km of power umbilicals and terminations for the Jack and St. Malo fields in the Deepwater Gulf of Mexico.

A press release said that the comDECEMBER 2011 | 15

INDUSTRY NEWS

Sumitomo Electric and the Sumitomo Electric Group have engaged in the manufacture and sales of various products, including wiring harnesses and anti-vibration rubber parts for automobiles and cutting tools, through joint ventures with local companies. In 1996, it said, a liaison office was established to conduct market research and assist in market cultivation.

The Sumitomo subsidiary, to be headed by President Tatsuya Teramoto, has sales functions in Gurgaon, in the state of Haryana, the release said. It has opened with four employees in its initial stage, with capital of five million rupees, it said.

“Through the new company, the Sumitomo Electric Group will aggressively promote information and communications system, railroad and other social infrastructure businesses, in which robust demand is expected to continue, as well as the environment and renewable energy business, whose market is expected to also grow rapidly.”

INDUSTRY NEWS

said. The Jack and St. Malo fields are located within 40 km of each other, about 450 km south of New Orleans, Louisiana, in water as deep as 2,100 m.

The release described the power umbilical as a cable product pioneered by Nexans that integrates the functions of power cables and umbilicals in a single cable, enabling a high-voltage (HV) supply to be provided for deepwater projects. A power umbilical includes a number of steel tubes as well as fiber optic elements and signal cables for control and monitoring purposes, it said, noting that this eliminates the need to transport and install a separate power and control umbilical, which significantly reduces transportation and installation costs.

“Winning this major power umbilical contract for the Jack and St. Malo fields is an important development for Nexans since Chevron is one of the leading lease-holders in the Deepwater Gulf of Mexico, which is a region where we are establishing a significant reputation as a key supplier of subsea technology,” said Nexans Energy Division Sales & Marketing Director Ragnvald Graff, “This contract award is also a vital step forward in our strategic approach to this region with the introduction of the new long-term storage carousel that now improves the level of local logistical support we can provide.”

Preliminary ruling on galvanized steel wire goes against China and Mexico An Oct. 28 preliminary ruling by the U.S. Department of Commerce (DOC) sided with five U.S. wire companies that claimed suppliers from China and Mexico were dumping galvanized steel wire.

Wire reports said that the DOC determined that Chinese and Mexican exporters sold galvanized wire in the U.S. at margins ranging from 76.34 to 235% and 37.87 to 61.54%, respectively. The petitioners are: Davis Wire Corporation; Johnstown Wire Technologies, Inc.; Mid-South Wire Company, Inc.; National Standard, LLC; and Oklahoma Steel & Wire Company, Inc. In the China investigation, Tianjin Honbase Machinery Manufactory Co., Ltd. (Tianjin Honbase); and Shanghai Bao Zhang Industry Co., Ltd., Anhui Bao Zhang Metal Products Co., Ltd., and B&Z Galvanized Wire Industry (Baozhang) received preliminary dumping rates of 131.84 and 76.34%, respectively. Tianjin Huayuan Metal Wire Products Co., Ltd. received the China-wide rate of 235% because it did not receive a separate rate.

In the Mexico investigation, Deacero S.A. de C.V. received a preliminary dumping rate of 61.54% and Aceros Camesa, S.A. de C.V. received a preliminary dumping rate of 37.87%. All other Mexican exporters received a preliminary dumping rate of 59.37%.

16 | WIRE JOURNAL INTERNATIONAL

USITC to review wire rod from India The U.S. International Trade Commission (USITC) has voted to expedite its five-year “sunset” review concerning the existing antidumping duty order on stainless steel wire rod from India. As a result of this vote, the USITC will conduct an expedited review to determine whether revocation of the existing order would be likely to lead to continuation or recurrence of material injury within a reasonably foreseeable time.

Grupo Simex announces plans to build wire rod mill in São Paulo, Brazil Mexico’s Grupo Simec, a steel manufacturer for the construction and automotive industry, announced that it plans to invest over $500 million in a new rebar and wire rod mill in São Paulo, Brazil.

Steel Orbis reports that the steelmaker already has operations in Mexico, the U.S. and Canada. The mill will be built over the next 20 months and will begin operations in the latter half of 2013. In its first phase, the plant will have over 500,000 tons of annual production capacity.

Kobe Steel reports plan to expand the capacity of its joint venture in China Kobe Steel, Ltd., announces that it and its partners have decided to expand the production capacity of their Chinese joint venture, Kobe Special Steel Wire Products (Pinghu) Co., Ltd. (KSP).

A press release said that KSP plans to add two wiredrawing machines to the existing three units, which will increase drawing capacity from the current 2,100 metric tons per month to 3,350 metric tons per month. A second Short Time Cycle (STC) annealing furnace will also be installed, it said. The project requires additional space, and a 3,100-sq-m building will be constructed that in addition to the equipment will house three cranes, it said.

Start-up is anticipated to gradually begin in July 2012.

As of June 2011, the company had 58 employees.

Per the release, KSP began operations in 2009, and since that time, automobile production in China has continued to increase and consequently demand for cold heading (CH) steel wire has steadily grown. The CH wire, made from special steel wire rod, is manufactured into high-strength nuts and bolts for use in autos. Local procurement is anticipated to increase in the coming years, not only for CH steel wire, but also for bearing steel wire, for which demand is also rising.

Kobe Steel has a 50% share of the business. The other partners are Shinsho Corporation (30%), Osaka Seiko Co., Ltd. (10%) and Meihoku Kogyo Co., Ltd. (10%).

The plant is located in Pinghu in the Zhejiang Province of China.

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INDUSTRY NEWS

News in brief The U.S. business of Swiss-based Schleuniger, a global supplier of wire processing equipment, reports that the Manchester, New Hampshire, business was ranked 10th nationally in The Great Place to Work® Rankings: 2011 Best Small & Medium Workplaces from Entrepreneur®.

The annual list recognizes companies that have exceptional workplace cultures. “This is our third time being (thus) recognized…and I must give a big ‘thank you’ and congratulations to all the “Schleuni-ployees” who contribute and strengthen our special culture on a daily basis,” said company President Mike Rizzo. The company notes that

ne n-li ic i e l son lab vai ultra a O ow : N th GE W i ng w NE ani e l c

18 | WIRE JOURNAL INTERNATIONAL

Employees take part in the “Schleuni-Olympics.”

it encourages open communication and employee involvement in management decisions while fostering a “Have Fun and Get the Job Done” atmosphere. Employees work hard, but also take part in monthly activities that can include such things as ping-pong tournaments, summer BBQs, the “Schleuni-Olympics,” wiffle ball and flag football, and are encouraged to take breaks from the fast-paced customer-focused environment to have fun and release stress.… General Cable Corporation announced the appointment of Blomquist, Densley & Young as its authorized agent to represent its extensive line of cord, cordset, electronic, datacom, industrial and specialty wire and cable product lines to the U.S. electrical wholesale distribution market in the Utah, Southwest Wyoming, Northeast Nevada and Southern Idaho territories. … U.S.-based Huber Engineered Materials (HEM) reports that it has renamed its Alumina Trihydrate (ATH) business unit to Fire Retardant Additives. The new name, it said, more accurately reflects the company’s vast array of non-halogen fire retardant and smoke suppressant technologies, brands and products now offered for a variety of end-use applications. “With the recent acquisition of the Kemgard® flame retardant and smoke suppressant business from Sherwin-Williams and our agreement with Almatis to sell and market their specialty hydrates, the timing was right to create a name that encompasses the stronger brand and product line-up,” said Jerry Bertram,

INDUSTRY NEWS

vice president and general manager of HEM’s Industrial Minerals business, “so we updated the name to capture the essence of the business and where it’s going for future growth.” HEM’s Fire Retardant Additives business unit produces value-added ATH, MDH and molybdate-based products as well as thermoset composites for sectors that include wire and cable. … Earlier this year, Siemens VAI reported that it will upgrade a wire rod rolling line for Badische Stahlwerke GmbH (BSW) at its plant in Kehl, Germany.

Steel Orbis reports that Siemens will make an extensive upgrade, modernizing the automation system of the twostrand wire rod mill, as well as installing two new rod outlets, to increase production capacity and expand the spectrum of qualities and sizes. The project is scheduled to be carried out in three phases, from 2011 to 2014. …

RichardsApex Europe Ltd., the U.K. subsidiary of U.S.based RichardsApex, Inc., has appointed Diatech S.C., based in Warsaw, Poland, as its national agent for the company’s range of lubricants and compounds for the metal forming industry. Diatech, it said, is well known to the wire and cable industry in Poland as it represents technology suppliers such as Fort Wayne Wire Die, Inc., Eurotungstene Metal Powders Eramet Group and William Beckett Plastics Ltd. The contact is Andrzej Majewski, tel. 48-608-535-685, diatech@diatech.com.pl. … U.S.based SEA Wire and Cable, Inc., a provider of supply chain solutions for the mil-spec wire and cable industry, announced that the company achieved compliance with new, stringent AS9100 Rev C quality system requirements for aviation, space, and defense markets. …

Poland’s Tele-FONIKA Kable was one of 21 companies honored in September with the “INNOVATOR 2011” statuette, from “Wprost,” a Polish social-political weekly.

The nominees were selected from a list of the 500 most innovative companies in Poland as determined by the Institute of Economics of the Polish Academy of Sciences. “The company was assessed in terms of market innovation, process innovation, outlay of innovation, patents and European contracts and received a high C N B N N grade in the 5A system from the MSN Scientific network and the Institute of Economics PAN,” the The Tele-FONIKA’s award release said. ■ from Wprost.

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DECEMBER 2011 | 19

ASIAN FOCUS

ASIAN FOCUS Concerns of Intellectual Property (IP) theft are no small matter for industry The allure of heady revenues has drawn many manufacturers to China, which in 2009 drew total investments by U.S. multinationals worth $49 billion, up 66% from 2007, per a report from the U.S. Department of Commerce. The potential is great but it does not come without the possibility of a downside.

One company that has experienced both the highs and lows is U.S.-based American Superconductor Corporation (AMSC), which for years had struggled to turn a profit from sales of its superconductor technology but found instead stunning success from selling its technology for wind turbines to Sinovel, a major Chinese supplier of such turbines.

In a relatively short time, Sinovel became AMSC’s largest single customer, representing more than 70% of its 2010 revenues. AMSC was so confident that it reported early in 2011 that it expected to meet its goal of 2015 revenues of $1 billion a full year earlier.

The success story soured in a surprisingly short time when in April AMSC reported that Sinovel refused to accept shipment of ordered components. AMSC saw its stock price plummet from $25 a share by more than half in April, a trend that was fed by bad news about Sinovel and related earning report problems. AMSC filed a lawsuit in Beijing’s High Court against Sinovel.

“Based in part upon evidence obtained through the investigations, AMSC believes that Sinovel illegally obtained and used AMSC’s intellectual property to upgrade its 1.5 megawatt wind turbines in the field to meet proposed Chinese grid codes and to potentially allow for the use of core electrical components from other manufacturers,” a press release said. AMSC wants Sinovel to honor its IP, to pay for its past orders, its related economic losses and to accept all contracted but not yet delivered orders.

Sinovel filed a counterclaim to the Beijing Arbitration Commission basically saying that it was AMSC that was at fault. It claimed that AMSC’s electronic control components that Sinovel used to produce its SL1500 and SL3000 wind turbines were rejected “because they fail to meet contract requirements in technologies and quality.” It is asking for AMSC to pay Sinovel $12 million for economic losses from breach of eight contracts from May 2008 to January 2011. Sinovel reported that the arbitration tribunal has accepted the counterclaim and will try the case along with the AMSC arbitration application.

This case has drawn much interest because the issue of IP is a major concern to manufacturers. A report by the U.S. International Trade Commission (USITC) estimates that U.S. firms lost approximately $48 billion in 2009 due to infringement of IP rights by China, with some $36.6

billion, nearly 80%, from lost sales, the remainder from lost royalty and license payments as well as other unspecified losses.

Both parties claim the other violated the multi-year supply agreement, and an Austrian court ruled that an AMSC wind technician had illegally sold software codes to Sinovel, and American Superconductor Corporation sentenced him has experienced the highs and lows of to one year in marketing its technology in China. jail.

One person who has commented on the topic is Lou Schwartz, a lawyer and China specialist who focuses on the energy and metals sectors. In a piece published in Renewable Energy World, he put the case in context.

“So where does the truth reside? Is it a classic case of a Chinese company expropriating one of the quickly dwindling comparative advantages the U.S. continues to maintain? There certainly is precedent for Chinese companies not respecting and not paying for foreign intellectual property. And given the cutthroat nature of competition among Chinese turbine manufacturers, it is quite possible that Sinovel saw a ready place to reduce costs.

“Or is it, as Sinovel contends, that AMSC has failed to make the technological improvements to its products that were promised, forcing Sinovel to develop its own solutions? Is there anything to the charge by Sinovel that AMSC failed to develop a robust system to handle after-sales maintenance, repairs and equipment upgrades?

“Perhaps this is just another ordinary case of Chinese companies steadily occupying the manufacturing space of foreign companies. The Chinese regularly do trumpet their success with import substitution, developing industries that manufacture products previously only available through imports. Indeed, Sinovel has ‘localized’ production of a growing list of turbine parts (blades, gears, bearings, generators and frequency regulators), and is proud of how indigenous manufacturing of key wind turbine components has

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

20 | WIRE JOURNAL INTERNATIONAL

“We should be able to accept the results when the runs pile up from a well-executed series of singles, bunts and even stolen bases; but if the win comes from balks and stolen signs, it’s not surprising that we then question the score. The truth lies somewhere at the intersection of all these crosscurrents, which makes it more imperative than ever for both the Chinese and the U.S. to carry out honest assessments of what are the new rules of the road. The AMSC/Sinovel relationship would be as good a place as any to start.�

Lou Schwartz is a principal of China Strategies, LLC, Pittsburgh, Pennsylvania, USA. The company provides clients research and analysis, due diligence, merger and acquisition, private equity investment and other support for trade and investment in China. He holds degrees in East Asian Studies from the University of Michigan and Harvard University, where he studied Chinese language and literature, economics and law, among other disciplines. He also earned a J.D. from George Washington University Law School. He has taught at the University of Pittsburgh School of Law and its College of Arts and Sciences, and Carnegie-Mellon University, including law and development in China, Chinese for Lawyers and Technology and Development in India and China. He can be reached at lou@chinastrategiesllc.com. I

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ASIAN FOCUS

helped them reduce costs, increase profits and enhance the company’s competitiveness. “It was once said (in the context of the Japanese) that the Americans are like baseball sluggers who swing for the fences, as contrasted with the Japanese who score their runs through a combination of singles, bunts and the occasional stolen base. It’s an interesting analogy in part because baseball is a quintessential American game and the implication was that the Japanese were beating us at our own game by playing it differently. Similarly in the second decade of the 21st century, there is a prevailing view that the Chinese are beating us at our own game: the communists are outperforming the capitalists at capitalism. “As we lament losing out to the Chinese on our ‘home field,’ there also is that unsettling feeling that some of those losses are not a result of the Chinese simply outhustling us, but that they are playing by a different set of rules. Is it that the Chinese are more driven than us or because the Yuan doesn’t float freely? Do their much lower labor rates give them the flexibility to undersell the market or is the ‘China Price’ in part due to shortcuts that aren’t permitted according to our rulebook, e.g., lead in paint, melamine in milk or toxic waste from PV manufacturing dumped in rivers? Do the Chinese succeed because they are investing far more than us in infrastructure and human capital or because they beg, borrow and steal the intellectual property of innovation economies such as ours?

PEOPLE

PEOPLE U.S.-based Niehoff Endex North America, Inc. (NENA), announced that Hal Hattersley, vice president of engineering, has retired after 40 years of service in the wire and cable industry, including more than 25 with NENA. He began his career in 1971 as a mechanical design engineer NENA’s Hall Hattersley, l, and for General Fernando Pereira.

Cable Corporation, and during his time there he earned his second degree in electrical engineering. In 1978, he joined Syncro Machinery as a deputy engineering manager and in 1980 was promoted to engineering manager.

While there, he helped to develop Syncro’s first multiwire machine. In 1986, he went to work for Endex, which underwent several owners. It was acquired by Bekaert in 1995 and became Bekaert Engineering North America, and then in 1999 the operation was acquired by Niehoff GmbH & Co. KG., and became Niehoff Endex North America Inc. (NENA). In 1999, Hattersley was promoted to vice president of engineering, responsible for integrating Niehoff equipment built in Germany with the Endex product line. He holds patents on a rotational tape accumulator (1977), a high-speed, long-end system for a rod breakdown, dual spooler (1987) and an automated scrap removal method & apparatus (2010). His successor at NENA will be Fernando Pereira, who has served as an electrical engineer at NENA for more than eight years.

His new position is engineering manager. Based in

NOTEWORTHY After an eight-decade long career, Max Fabian, an employee of A-Z Industries, a distributor of wire and cable products based in Northbrook, Illinois, has finally retired at age 102. The below story is from several reports, including one by Jeff Danna, TribLocal reporter.

At age 102, Max Fabian can still walk without a cane, and he likes to be active, including visiting the gym, where he still punches the bag. He is also still getting used to retirement, as he had worked through last month, capping off a working career that extended eight decades.

Even more remarkable, he spent most of those years working for four generations of the same family of business people, the Anixters.

While working as a detective for the Chicago Police Department in the 1930s, Fabian met Jules Anixter, who offered him a job working for the family as a chauffeur and security guard. In the 1940s, he joined the U.S. Army and spent four years in a counter-intelligence unit in the South Pacific.

Following the death of Jules Anixter, he was hired in 1956 by his two sons, Alan and Bill, when they started Anixter Bros. Wire & Cable. He completed a 30-year career as an administrative assistant and warehouse traffic and security manager at the business, which was sold to Sam Zell in 1986. Two years later, Jim Anixter co-founded A-Z Industries and brought Fabian with him.

Fabian, who drove himself to work in Northbrook from his home in Niles, Illinois, said he served as a “jack of all

22 | WIRE JOURNAL INTERNATIONAL

trades” at A-Z Industries, but his involvement went beyond the work duties.

“I consider Max part of the Anixter family,” said Jim Anixter, Max Fabian with Hall of Famer Billy who recalled Williams at Wrigley Field, where he that one of threw out the first pitch at age 101.

Max’s jobs was to drive his grandmother to and from the office. He described Fabian as “a phenomenal human being and a very dear friend.”

Jim Anixter says the company will be hosting a small retirement luncheon in the Northbrook area in late November for Max Fabian. Most of the guests will be from the company. “After all how all how many contemporaries are still around to help celebrate when a 102-year old legend retires?”

NOTEWORTHY is an occasional section that will highlight folks in the industry. Know someone who has done something special? Send the details and a good photo (JPG, 150 kB to 2 MB) to editorial@wirenet.org.

Earlier this year, Flynn~Garretson Associated Companies, LLC, was officially created, formed by industry veteran/WAI member Mark Garretson as managing director, responsible for day-to-day operations, joined by his wife, Debbie Garretson, who serves as president and CFO. He began his career at Great American Chemical Corp. and has worked in production, technical, sales Mark Garretson and management positions in PVC compound/resin manufacturing. A WAI member, he serves on the Association’s Education Committee. Based in Kathleen Florida, USA, the company’s primary services (www.flynngarretson.com) include sales, marketing, new product development and business consulting to sectors, such as wire and cable, that extrude plastic compounds, as well as supplying copper and filler and cross-web shapes.

Mohammad Haroon has been promoted to head of manufacturing for Exeed Electrocab LLC. A WAI member, he has more than 28 years of experience in power cables, and his current responsibilities include establishing a cable factory of 26,000 mt/annum in the MENA region. His focus there includes engineering, capacity analysis, technical discussions with equipment Mohammad suppliers, layout modifications and an Haroon updated market study to determine the optimum required for the country and region. Based in the UAE, Exeed Electrocab LLC is a business of the Exeed Group, which is part of the Abu Dhabi-based Holding Company, whose diversified portfolio includes wire and cable. ■

DECEMBER 2011 | 23

PEOPLE

Swedesboro, New Jersey, USA, Niehoff Endex North America is part of Germany’s Niehoff GmbH & Co. KG, a global supplier of wire and cable equipment.

FIBER WATCH

FIBER WATCH Fujitsu-Furukawa co-alliance reports fiber interconnect technology advance Fujitsu Laboratories Limited and Furukawa Electric Co., Ltd., announced that they have jointly developed optical interconnect technology for the high-speed, large-bandwidth internal data transmissions that will be needed for the next generation of high-performance servers.

A press release observed that deployment of next generation, high-performance servers is limited by copper wire in terms of speed and bandwidth. Optical transmission over fiber-optic lines, it notes, is a solution but there are issues about the amount of required space. “Now Fujitsu Laboratories and Furukawa Electric have developed optical interconnect technology that increases the density of fiberoptic lines while enabling high-bandwidth internal communications at speeds of 50 terabits per second (Tbps), ten times faster than is possible with today’s copper lines.”

The release said that the new technology (see Fig. 1.) “promises to enable high-bandwidth, high-performance servers capable of a wide range of services involving realtime analysis of huge amounts of data from sensors, such as forecasts of traffic congestion and of electric-power demand.”

Conventional interconnects pass electrical signals over copper wires, making it difficult to generate transmission speeds of 10-25 Gbps because simply increasing the number of copper lines leads to problems of waveform degradation and signal interference, the release said. While optical fiber has excellent characteristics in terms of high speed, large bandwidth and transmission distance, and it has long been used on long-haul telecommunications and subscriber networks, it has recently begun to be used in servers for data transmission, but the limited space inside servers has made it difficult to accommodate a large number of fiberoptic lines in this application, it said.

The solution from Fujitsu Laboratories and Furukawa Electric has been built on technologies held by the two companies to develop high-bandwidth interconnect technology that can be used inside servers. Using thin, highly flexible optic fibers, along with high-density optical connectors made possible with multiple lanes, allows for line capacity to be increased from the existing figure of 500 lines to 2,000 lines, it said.

These technologies were used to build a prototype with an optical midplane with optical fiber lines packaged densely together, the release said. An evaluation of transmission characteristics was performed using this midplane, which showed that, with 2,000 lines, each capable of 25 Gbps, together they could carry a total of 50 Tbps, it said.

“This technology can be used to compactly accommodate 2,000 optical lines for a tenfold increase in bandwidth, to 50 Tbps,” it said. “The two companies are moving ahead in converting the core technologies that they have developed into actual products, and are also exploring a variety of applications, with the aim of commercializing these technologies within the next few years.”

DuPont dedicates Kevlar plant

Fig.1. Prototype optical midplane and configuration of server used for research.

The key, the release said, is that ongoing improvements to CPU performance have led to an astonishing increase in the data-processing capacity of servers. Further, virtualization technology that consolidates multiple processes in a single CPU is advancing and the volume of data exchanged between CPUs and required memory capacity is rapidly increasing, it said. “Accordingly, several terabits per second of input/output signal-bandwidth capacity will become necessary. This creates a need for interconnects between multiple signal sources that can handle transmission speeds of tens of terabits per second in total.”

24 | WIRE JOURNAL INTERNATIONAL

DuPont recently dedicated a $500 million expansion of a South Carolina plant that will boost its production of Kevlar, which is used in a wide range of products that include fiber optic cable.

A press release said that the new plant, about 30 miles from Charleston, combined with a recent $50 million expansion of a plant in Richmond, Virginia, will increase production by about 25%. The $500 million investment was described as being one of the largest single industrial investments in state history. With other improvements planned for the next two years, total Kevlar production will increase by about 40%, it said.

The DuPont plant had 60 workers when the expansion was announced and is adding about 135 new employees, the release said. The investment was made despite tough economic times because the company takes a long-term view, it said. With the growth of broadband connections, the fiber optic cable industry is growing 10% a year in the U.S. and 15% a year in Asia, it said. ■

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FASTENER UPDATE

FASTENER UPDATE Las Vegas proves to be a winner for National Fastener & Mill Supply Expo Organizers of the National Industrial Fastener & Mill Supply Expo, held October 19-21, 2011, at the Sands Expo & Convention Center in Las Vegas, Nevada, declared the event “a huge success from every standpoint.”

The three-day fastener event, described as “North America’s Largest Fastener Expo,” drew 4,238 visitors and exhibitor personnel from the U.S. and 32 other nations, reported event management, who said that distributors accounted for 1,253 registrants, followed by suppliers (240), independent sales reps (173) and cold forming manufacturers and various other industry-related people (172). The organizers said that there were nearly 600 companies spread over 757 booths (75,700 sq. ft.). Outside the U.S., exhibiting companies came from Belgium, Canada, China, Germany, India, Israel, Italy, Korea, Mexico, Saudi Arabia, Singapore, Spain, Taiwan, U.K. and Vietnam, and showcased their latest lines of products and services including fasteners, inspection & testing equipment, fastener machinery & tooling, packaging equipment, mill supplies and a variety of industry-related services.

Activity at the National Fastener & Mill Supply Expo.

The first-day conference featured a variety of programs, workshops and meetings presented by Expo Management and a number of industry associations including the Fastener Training Institute (FTI), National Fastener Distributors Association (NFDA), Pacific-West Fastener Association (Pac-West), Fastener Industry Financial Group Network & the Business Credit Management Association and Women in the Fastener Industry (WIFI).

The Welcome Reception sponsored by expo management on Wednesday evening at Harrah’s Hotel & Casino saw “upwards of 1,600 persons buzzing with excitement and furiously networking while enjoying a great assortment of complementary food and drink,” and was followed by the two-day expo that saw the aisles “jammed with thousands of eager buyers,” organizers reported.

The Machinery & Tooling World area featured 43 companies, including many members of the International Fastener Machinery & Suppliers Association (IFMSA).

26 | WIRE JOURNAL INTERNATIONAL

“Over 70 of the exhibiting companies were either new to the Expo or returning after a three year absence and we are very encouraged by this,” said Susan Hurley, the Expo’s general manager.

“This year’s Expo is the third largest in our 30-year history and we are delighted with the results. We received numerous compliments from exhibitors and there are many signs that the industry is recovering,” said Jim Bannister and Mike McGuire, general partners.

The Traveling Salesman, a well-known fastener industry blogger, gave the event a thumbs-up in his write-up. “The show was excellent. Good attendance. Good location. The Venetian is a beautiful hotel and there are plenty of other less expensive hotels in the vicinity for those who spend less time in their room. ... The show layout was very good.

It seemed like a really simple layout but for some reason I found it a lot easier to navigate than in past years.”

The next staging of the event returns to the Sands on Oct. 10-12, 2012. For more details, contact Susan Hurley at tel. 614-895-1279, info@fastenershows.com or go to www.fastenershows.com.

Field Fastener to make acquisition U.S.-based Field Fastener announced that it plans to acquire Fastening Solutions LLC, a subsidiary of Duncan Bolt, a deal that it had said was scheduled for completion by the end of November.

A press release said that the deal will extend Field Fastener’s global footprint and provide customers with expanded products and service offerings as well as increase its supply base with over 30 new suppliers, “resulting in a broader product offering for its customers as well as the ability to purchase directly from selected suppliers.”

In North America, Field Fastener will gain a stronger presence in the southwestern United States, further establish its presence in Canada, increase the localization of service in Mexico, and enable the company to increase its customer base in China and India, the release said.

Würth Group buys Cardinal Fastener Dokka Fasteners, Inc., a provider of large-diameter fasteners to wind turbine manufacturers and their suppliers, announced that its German parent company, The Würth Group, has acquired the assets of Cardinal Fastener & Specialty Co., Inc. Wire reports said that the $3.9 million deal was okayed Oct. 27 in U.S. Bankruptcy Court, and that Marc Strandquist, CEO of Würth 's Michigan-based Dokka Fasteners unit, who represented the parent company in the proceedings, will oversee Cardinal as it continues to operate locally under its current president, John Grabner. Plans call for Cardinal, a manufacturer of bolts and other fasteners, to be resupplied, more staff is to be hired, including sales reps, relations with customers stabilized and new equipment installed, it said. ■

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WAI NEWS

WAI

NEWS

Prof. Paul Van Houtte chosen as the 2012 Mordical Memorial Award winner Paul Van Houtte, a full professor at Belgium’s Katholieke Universiteit Leuven whose published work is so extensive that it may be unparalleled in the wire and cable industry, has been named the winner of the Mordica Memorial Award for 2012.

Van Houtte, who joined Katholieke Universiteit Leuven in 1995, has been cited as a contributor to more than 400

publications, including as either author or co-author of more than 190 papers in reviewed journals and more than 180 in international conference proceedings as well as nine books. Beyond his history of publishing for topics related to mechanical properties, textures, computer modeling, and other aspects of both ferrous and nonferrous wire, he has studied, among other focuses, the

Van Houtte

WAI Q&A This occasional section will provide readers a better idea of the activities of WAI’s committees and boards.

WAI’s Conference Programming Committee The Conference Programming Committee has been tasked with a very different challenge for 2012—building from scratch a whole new program and format for WAI’s first-ever Operations Summit.

Taking the place of the traditional technical program at WAI trade shows, the Operations Summit will feature a program focused entirely on practical topics vital to the day-to-day functioning of a wire operation.

“With more panels and forums to share best practices, we’re hoping to stimulate a lot of back-and-forth and create an atmosphere that feels more like a two-day open discussion than a classroom,” said Chairman Thomas Maxwell, Jr. While past Conference Programming Committees have been concerned with organizing themes and procuring abstracts for paper presentations to match, this year’s group is zeroing in on subjects intended to appeal to personnel with job descriptions like production supervisor, quality control, plant manager, and maintenance manager.

The 14-member committee represents a cross-section of ferrous, nonferrous, and electrical manufacturers, as well as suppliers. Maxwell said the hope is to create a new model for WAI’s annual events that allows Interwire to continue to focus on the technical side of the business in odd-numbered years, while the Summit will appeal to the operations side in even years.

The committee began discussions earlier this year and has been working through numerous topic and format ideas. The members are dedicated to addressing topics not typically covered in past conferences.

While the program is still being planned, the committee

28 | WIRE JOURNAL INTERNATIONAL

has identified a number of major topics, each of which will be addressed in multiple sessions from different perspectives. Some of these include energy efficiency and sustainability, regulation issues, safety, training and hiring, patents and standards, commodities, risk mitigation, and material handling.

“Some folks may be wary when they Maxwell hear us use words like ‘new’ and ‘different’ to describe a WAI conference,” said WAI’s Director of Education and Member Services Marc Murray. “While we do always try to do something different every year, I think you can tell already that the newness of this one isn’t up for debate. From the new name (Operations Summit) to the variety of practical topics we’ve never covered before, we know it will truly feel like a whole new event, the first of many to come, we hope.”

Conference Programming Committee Members William Avise, Leggett & Platt, Inc. Richard Baker, Alcan Cable Anthony De Rosa, Cortinovis Machinery America, Inc. Thomas Maxwell Jr., Die Quip Corp. (Chairman) Patricio Murga, Viakable S.A de C.V. Nicholas Nickoletopoulos, Sivaco Wire Group Dale Olp, North American Steel & Wire LLC José Ranc, Whitney Blake Co. Donald Schollin, Q-S Technologies, Inc. Jan Sorige, Enkotec Co., Inc. Gary Spence, Encore Wire Corp.

Mark Spencer, W. Gillies Technologies LLC Mark Thackeray, General Cable Corp.

Bhaskar Yalamanchili, Gerdau Long Steel North America Liaison: Marc Murray, WAI staff

Ron Reed named winner of WAI’s 2012 Donnellan Memorial Award Ron Reed, the 2012 winner of the WAI’s Donnellan Memorial Award, has served the Asssociation in a wide range of positions since he joined it 1988.

The industry veteran served as WAI president in 2008, and spent two terms on the Board of Directors. He was co-chairman of the Conference Programming Committee that planned the educational content for Interwire 2011. He was a member and chairman of the Electrical Management Ron Reed Committee, on which he served from 1995-2005. He also served as a member of the Finance Committee and Memorial Awards Committee. As a charter member of the WAI’s New England Chapter, he held positions as both chapter director and treasurer, and he has moderated numerous technical programs for the Associaiton.

Reed began his career in the wire industry in 1983 as controller for Helix Wire Corporation in Leominster, Massachusetts, USA. In 1993 he became division manager for Horizon Wire & Cable, also in Leominster. In 2011, he became a principal in Lloyd & Bouvier, Inc. He holds a

B.S. degree in business administration from Fitchburg State College.

Wrote one person who supported the nomination of Reed, “I fully support (Ron) for the 2011 Donnellan Award. I have known Ron on both a personal and professional level for over 25 years. In that period of time I have admired his work ethic and devotion to the Wire Association. ... It is very fitting that Ron has been nominated for the Donnellan Award and I offer my full support and vote of confidence.”

Wrote a second person, “I do not know of many individuals that have provided as much support for the Wire Association and to the industry as a whole as Ron Reed.

Ron was one of the founding fathers of the New England Chapter, has been a past WAI President, has served on many boards and has been the chairperson on many committees. Ron has a long list of accomplishments and his tireless devotion to the industry should be recognized.”

Reed will be honored next May at WAI’s Operations Summit & Wire Expo in Dallas, Texas, USA.

Environmental webinar presented ‘green‘ ideas, options and advantages The appetite remains strong for details on making an operation green from top to bottom, as results from the Wire Association International’s recent webinar indicate.

More than 20 people tuned in (and chimed in) during the webinar “The Road to Being Recognized as a Business Environmental Leader.” The Oct. 27 presentation featured a flurry of questions ranging from practical day-to-day tips to strategic thinking.

“It was one of our most active webinars yet,” said Marc Murray, WAI Director of Education and Member Services.

“The number and variety of questions shows there is a strong demand in the industry for peers to share information on environmental strategies. It’s still uncharted territory for a lot of people, and the best way to learn is from the experience of others.”

Presenter Roberta Rocheleau, environmental coordinator for Champlain Cable Corp., described her company’s efforts to improve its operations’ effects on the environment. The presentation traced the steps taken at the cable manufacturer’s plant in Colchester, Vermont, USA. Some of the questions raised by the audience included how to measure success against goals; cost management; recycling of packaging; putting together an environmental team; impact on customer relationships; and applying for grant money to support environmental initiatives.

WAI, which had a Dec. 6 webinar planned recounting one wire company’s experience with its ISO 9001/AS9100 quality management system, also has one scheduled for Jan. 19, 2012, that will address spark testing.

Webinars are free to WAI members and $55 for nonmembers. Members also have free access to the online archives of past webinars. For more details, go to www.wirenet.org/events/webinars.

DECEMBER 2011 | 29

WAI NEWS

theory of quantitative texture analysis. He developed ODF software that is now used by many companies and universities for analysis of drawing processes and deep drawing of metals and alloys.

In cooperation with Bekaert and other universities, Van Houtte elaborated the process parameters for avoiding a delamination of high-carbon steel wire. He developed the method of residual stresses measurement in textured materials with application of X-ray and neutron diffraction. This method has been recently extended to thin coatings and thin wires. He and a colleague, Dr.Van Bael, elaborated finite element code for the metal forming processes for metals with texture-induced anisotropy which is implemented in the industry, such as for the calculation of the forming limits in sheet metal forming.

Van Houtte has won numerous awards, including an Honorary Doctoral Degree awarded by University of Metz, France in 1998 and the “De Leeuw-Damry-Bourlat Prize” awarded by Flemish National Science Foundation 2000.

Wrote one person supporting Van Houtte’s nomination, “Perhaps many of us in the wire industry are unaware of the significance that his technical contributions have made because they lean towards a more fundamental nature and were therefore not submitted to the Wire Journal. Nevertheless, they are extremely beneficial and help to enhance the foundation and principles of wiredrawing. I feel very humble in recommending Prof. Van Houtte for this very prestigious award.”

Prof. Van Houtte will be honored next May at WAI’s Operations Summit & Wire Expo in Dallas, Texas, USA.

Operations Summit and Wire Expo 2012 update: 140 units sold so far WAI NEWS

The trade show at WAI’s Operations Summit & Wire Expo in Dallas, Texas, USA, is about a half year away, but at this point a total of 140 units have been sold for the event, to be held May 22-23, 2012.

WAI Sales Director Robert Xeller said that a total of 126 booths were allocated at the Points Meeting on Oct. 6, and that since then the sales department has been contacted by a slow yet steady stream of companies seeking a booth.

Xeller said that companies interested in exhibiting can go on-line to www.wirenet.org, click on “EXPOCAD,” and see the layout of the show floor, the booths that have been allocated to date and by which companies, and more.

To reserve a booth, an exhibitor must submit a license and make the appropriate deposit. WAI’s sales staff can help make the arrangements. For more details, call Robert Xeller or Anna Bzowski at 203-453-2777, ext. 119/ext.

126, or e-mail sales@wirenet.org.

December is last chance to renew WAI membership dues before rate increase The first WAI dues increase since 1999 will go into effect as of Jan. 1, 2012, but individuals can either sign up for or renew a membership—for one, two or three years—at the lower rates through the end of December.

At its Oct. 12 meeting, WAI’s Board of Directors approved a membership dues increase of $15 per year.

As a result, the annual dues will rise from $95 to $110 per year.

WAI Executiver Director Steve Fetteroll said that all members will be given the opportunity to pay for their next renewal before the end of this year, which will be at today's lower rate, he said. “As always, you will be given the option to renew for one, two, or three years, which means that some of you could delay the increase until 2015.” More than 30% of the membership, he said, takes advantage of the multi-year discount.

The decision to increase the cost of membership was presented by the Member Relations Committee, which had previously considered the matter and voted to recommend the increase to the board. Appropriately, the proposed dues increase was presented at same meeting where the Board reviewed the 2012 budgets.

Fetteroll said that, in evaluating the matter, the Board 30 | WIRE JOURNAL INTERNATIONAL

WAI NEWS

and Member Relations Committee also reviewed the dues rates from other similar organizations. Worth noting is that the last dues increase occurred in 1999, when it went from $75 to $95.

Any sparks that may fly during WAI’s Jan. 19 webinar will be well detected WAI’s series of webinars is getting off to a quick start in 2012 with a program sponsored by WAI’s Southeast Chapter that will focus on spark testing and related safety issues. The hour-long program on Jan. 19 will be presented from 11 am to noon (EST) by David Carroll, applications engineer, Clinton Instrument Co., with support from Nexans Inc. “The Southeast Chapter believes that there is no better topic than safety and hopes that companies will take this opportunity to share best practices,” said chapter President Art Deming of Nexans Inc. Spark testers are classified by the type of test voltage applied to the product. Available types include Alternating Current (AC), Direct Current (DC) and Impulse. The AC testers perform spark tests specified by NEMA, BS 5099, IPCEA, CSA, UL 1581, and others, and are recommended for solid insulations. Clinton Instrument supplies two types of AC spark testers: those that operate at power main frequencies, generally 50 or 60 Hertz, and those that operate at high frequency, such as 3kHz. Its DC spark testers are typically used for testing telecom and foam-insulated wire to the UL444 test. The Impulse is an old test not used widely except in military and commercial aerospace testing.

The webinar is not going to focus on specific models but instead will look closely at the safety aspects of grounding and the problems that can arise from ungrounded products. The testing technology, as long as it is adjusted to the correct setting, will work well, in part because of electricity’s inherent desire to resolve from high potential to ground.

Electricity wants to leave a high-voltage state but is kept from doing so by the insulation. If the insulation is made to spec and in good shape, the electricity cannot penetrate the insulation. That condition can change if the insulation is damaged, which can happen a lot of different ways during the production process, from pinholes caused by water vapor and cooling system problems to line vibration and mechanical process damage, and more.

“We plan to cover problems that can occur due to ungrounded center conductors, wet wire testing, the use of too low test voltage, and operator safety while using any high voltage spark test unit. Our goal for the webinar is to explain how to safely meet the required norms and assure the ultimate customer that they are getting the best possible quality wire or cable.”

The webinar is free to WAI members. ■

DECEMBER 2011 | 31

CHAPTER CORNER

CHAPTER CORNER Wild West Shootout ends peacefully The Western Chapter Board of Directors believes that the best golf tournament on the WAI “Chapter Tour” is the last: the Wild West Shootout, which just happens to be theirs. There could be some personal bias with that claim, but it’s not surprising as many of the original organizers are still involved 11 years later.

The outing was held Oct. 24 at Los Verdes Golf Course in Ranchos Palos Verdes, California, just south of Malibu.

For those of you that have never been there, the course, designed by Billy Bell, arguably offers the best ocean views in the entire state of California.

Western Chapter President Michael Weiss of Whitmor/ Wirenetics admits that his chapter’s outing may not be the largest but he still believes that it is the best. One reason for that, he said, is that “the chapter’s smaller field translates to a quick round, with the only delays resulting from the players enjoying the beautiful views.” Further, “through the generosity of the sponsors, many players won multiple prizes in the raffle, with some people needing a shopping cart to get their winnings to their car.”

Members of other chapters may not be so quick to agree, but Weiss speaks from experience as he has supported and played in most the other outings on the WAI Tour Even for the best of golfers, the Pacific Ocean makes putting a real challenge on almost every hole. However, the winning RDS Wire & Cable team of Jon Stott, Danny Hoff, Bob Hoff and Doug Stott, was not intimidated by the course and finished at nine under for the day.

“It was a great day,” said RDS CEO Doug Stott, who credited longtime friend Danny Hoff, the long drive contest winner, for powering his team to victory.

“It was a wonderful day for golf along the Pacific Ocean with Catalina Island off in the backdrop,” said Michael Howard of Coast Wire & Plastic Tech, who is the chairman of the outing.

Event sponsors included B&H Tool, Benefit Plan Coordinator, Beta LaserMike, Brent-wood Products, Champlain Cable, Chromatics, Engineered Machinery, Gem Gravure, Helistrand, James Monroe Wire & Cable, Leoni Wire, Lloyd & Bouvier, Silver State Wire & Cable, Thermax, Q-S Technologies and Whitmor/Wirenetics.

Howard reported that the date is firm for the 12th annual golf tourney, which is set for Monday, Oct. 22, 2012.

Golf outing makes a contribution to Southeast Chapter’s former leader In the days and weeks after Steve Vannais’ died in a plane crash in January 2011, Tim McElhany of Tulsa Power wasn’t sure if the Southeast Chapter Golf Outing should continue. After all, McElhany had worked as cochairman of the event with Vannais and he knew that the project would be a painful reminder of a task that he had

32 | WIRE JOURNAL INTERNATIONAL

shared with his good friend since the first outing in 2002.

McElhany wasn’t alone as fellow chapter board members Woody Holland of Clinton Instruments and Mike Kos of CNA Technologies felt the same. However, the sentiment was directed to honoring Vannais through the outing, to be named “The Vannais” as a permanent reminder of his contributions to the chapter. The board also voted to donate the proceeds to the Eric Vannais Scholarship Fund.

On Nov. 18, the chapter’s Board of Directors met and approved the donation of $5,000 to the scholarship fund.

Members of the Board are President Art Deming of Nexans, Vice President Tim McElhany, Treasurer Mike Kos, members Peter Funk of Talley Metals, Woody Holland, Tom Sanchez of Okonite, and Mike Sears of Superior Essex Communications.

The October WJI had a report on the event, which was held on Oct. 13, and included 89 golfers event. It was made possible by the generous support of the following 32 companies: Amaral Automation, AmerCable, American Kuhne, Beta LaserMike, Chase Corporation, Chromatics, Clinton Instrument, Commission Brokers, Davis-Standard, Fushi Copperweld, Gateway Recovery, Guill Tool, J.J. Lowe Associates, Lloyd & Bouvier, Microdia, Moorecraft Reels, Nexans Electronics Cables, Okonite, Process Control, Rosendahl Nextrom Technologies, SAMP USA, Sikora, T&T Marketing, Technical Development Corporation, Tensor, TSM, Tulsa Power, W. Gillies Technologies, Weber & Scher Manufacturing Company, Windak Inc., Wire & Plastic Machinery, and Zumbach.

New England Chapter meeting to be held Jan. 26 at the Mohegan Sun Final details are being set for the New England Chapter’s 18th Annual Dinner Meeting, to be held Thursday, Jan. 26, 2012, at the Mohegan Sun Casino.

The January WJI issue will have the complete details, including the speaker, but for more information, including the cost and the registration form, go to the chapter’s webpage at wirenet.org. Just click on “Members,” then “Chapters,” then “New England” to access it.

The WAI contact, Anna Bzowski, can be reached at tel.

203-453-2777, ext. 126, abzowski@wirenet.org. ■

EVENT WRAPUP

C ABWIRE

familiar surroundings for tech conference

While the venue was the same, it was clear from the leaves on the ground and the sun setting before the Altstadt came alive, that the wire and cable industry had gathered for something other than the biennial wire trade show produced by Messe Düsseldorf.

The CabWire World Conference 2011 brought 142 wire and cable professionals to the Messe Düsseldorf Congress Center on Nov. 7. The one-day conference was promoted as the “latest process and market developments” and the program delivered, providing a wide range of technical and general business topics. In total, there were 29 presentations that were nearly evenly balanced between ferrous and nonferrous subject areas.

Colin Dawson, chairman of IWMA, which served as the primary organizer of the conference, said that “the objective was to provide an event for the exchange of information that would be both practical and technical, that provided terrific value but was sensitive to cost and schedule demands.” Nearly all of the attendees were from Europe, and many arrived by car the night before and were able to return home right after the conference.

A total of 45 participants elected to stay a second day for the tours of Drahtwerk Köln in Cologne and Leoni Kerpen in Stolberg. The Drahtwerk plant manufactures a wide range of steel wire products. The Leoni tour provided a full review of its plant, which was acquired in 2005

Niehoff GmbH’s Heinz Rockenhauser (l) prepares to open the nonferrous session with Interlink Import-Export’s Peter Large.

The technical program featured 29 presentations.

34 | WIRE JOURNAL INTERNATIONAL

EVENT WRAPUP Conference participants, l-r, Dr. Andrew Stacey of Stonepark Consultancy, Walther Van Raemdonck of Bekaert and Glenn Rika-Rayne of Bar Products and Services at the Suppliers Forum.

TKT Group’s Giancarlo Arrighetti and Ferruccio Bellina talk about a new borax-free product with Ignacio Perez of Trenzas y Cable de Acero PCS, SL.

as part of the company’s diversification strategy. The plant manufactures a range of products, from instrumentation cable and fiber optics to data cable. The plant is located in the Stolberg countryside, where it employs 600 individuals.

Paulo Ribeiro, executive director of Grupo Cabelte, was one of the two dozen attendees who toured the Leoni Kerpen facility. When asked why he participated in the event, Ribeiro responded that “his objectives were to stay current on the issues and opportunities facing today’s cable sector.” Ribeiro, who attended along with his materials and industrial processes development manager, Guilherme Caldeira, said that there were two presenta-

tions that he found most interesting: the Market Overview

by Integer Research and the New Development and Trends in the Automotive Industry by Leoni.

In the Market Overview presentation, Integer Research Director Philip Radbourne provided a clear picture of the depths of the economic downturn. He observed that the resulting impact saw global cable production decline by more than 4% in 2009, its largest drop in 30 years. He reported that the industry has rebounded, and that much of the recovery is based on production from Asia and the former USSR.

One of the topics covered by Integer Research Director Philip Radbourne’s presentation was which regions were showing the greatest growth.

Keynote Paper Presenter Dr. Klaus Probst, CEO, Leoni AG, opened eyes with his insights on the automotive sector.

DECEMBER 2011 | 35

EVENT WRAPUP Attendees at the Leoni Kerpen GmbH tour.

Dr. Klaus Probst, CEO of Leoni, provided a keynote session to start the afternoon program in the nonferrous track with insights of the “mega trends” that Leoni sees impacting the automotive industry. He explained that four factors are influencing business for Leoni and their customers: urbanization, mobility, environmental awareness and demographic changes.

Probst described opportunities that are emerging from an upcoming European Union emission reduction program as well as customers’ demand for more “comfort” auto features, such as driver-assist and rearview. He also detailed Leoni’s miniaturization and weight reduction initiatives as being critical to its position as a market leader.

In the ferrous track, the program involved a mix of practical and research-based papers. IWMA’s Geoff Church said that “the presentations were excellent and the questions were marvelous.” He said that the Ilmenau University presentation, “Determining of parameters characterizing the functional behavior of spring steel wire in helical springs” by Veronika Geinitz, was very interesting

IWMA Chairman Colin Dawson of Whitelegg Machines, l, and Phillip Radbourne of Integer Research at the post conference reception.

36 | WIRE JOURNAL INTERNATIONAL

for its in-depth research and conclusions.

Her presentation detailed the changes to wire characteristics caused by manufacturing steps in spring production, using tensile and torsional stress testing. Based on the results, the characteristics established permit considerably more exact dimensioning of helical springs.

Beyond the presentations and tours, the event provided multiple opportunities for making new business contacts and networking, always an asset to industry professionals. Attendees were able to talk to representatives of the 25 supplier companies that participated in the Suppliers Forum and all participants networked further at the post show reception that of course included Düsseldorf’s famous Alt beer.

Event sponsors included Associazione Costruttori Italiani Macchine per Filo (ACIMAF), the International Wire & Cable Exhibitors Association (IWCEA), the International Wire & Machinery Association (IWMA) Educational Trust, Locton, Messe Düsseldorf, Niehoff Maschinenfabrik, Rosendahl Maschinen, Spring Tooling, Wire Association International (WAI) and XL Technologies.

The event organizers were ACIMAF, Comité Européen de la Tréfilerie (C.E.T), IWCEA, IWMA and WAI. While IWCEA is new to the group, the other organizations have previously sponsored Conference’s in Istanbul Turkey (2009), Bologna Italy (2007), Prague Czech Republic (2005) and Stresa Italy (2003).

Report and photos by WAI Executive Director Steve Fetteroll. ■

WAI President Dominique Perroud, l, with SAMP colleagues Joachim Schlicht and Giorgio Albertazzi, at the company’s tabletop display at the Suppliers Forum.

FEATURE

Industry Trends his feature—to be continued in future issues—includes a BRIC outlook from CRU,

T

the timely return of Innovations (a proposal for a new kind of strander), a glimpse

of a far, far-away possible product trend, a focus on reaching customers, and more.

The 4 BRIC nations will continue to serve as the global building block CRU Principal Consultant Rob Daniels believes that the BRIC nations of Brazil, Russia, India and China will not see even across-the-board future growth, but collectively the four countries will continue to be important con-

The four BRIC nations Chart courtesy of CRU. 38 | WIRE JOURNAL INTERNATIONAL

sumers and producers in the wire and cable industry.

As the below CRU chart shows, this is far from recent news, but it is a trend that has become more and more defined since 1998, at which time the four countries represented less than 20% of world market demand for metallic conductors. Speaking at the recent staging of IWCS, Daniels said that as of 2010, that market share topped 41%. He also noted the following.

What is interesting is how the growth has come to the different countries. China has seen the strongest growth, but that is slowing some, while India has quietly become the world’s third largest producer of wire and cable.

The Russian market had a hard time in 2008-09, due in part to the country’s decision to not pursue a stimulus package, but it rebounded 27% in 2010 and the latest CRU estimates peg its growth to date in 2011 at about 15%. Brazil

CRU Principal Consultant Rob Daniels speaking at IWCS.

A serious need (for suppliers) to be green The “green” influence has been seen in industry, but some companies are taking it quite seriously, especially when it comes to their suppliers.

One company that stands out in its approach is Japan’s Yazaki, which not only asks that its suppliers be good stewards of the environment, it requires them to show exactly what has been done in eight categories: environmental management, global warming prevention, legal/industry compliance, green products, continuous improvements, accolades and best practices. Would-be suppliers are graded and need to score at least 75% to be considered.

The company’s “Green Supplier Assessment” allows little wiggle room for suppliers through its requirements, two of which are shown below.

Section 3 - Waste Reduction a) Supplier tracks the amount of recyclable and nonrecyclable waste generated by their manufacturing practices b) Supplier tracks the amount of recyclable and nonrecyclable waste generated by their non-manufacturing practices c) Supplier takes active steps to reduce the amount of non-recyclable waste generated d) Supplier tracks the amount of resource consumed during operations e) Supplier takes active steps to reduce the amount of resources consumed in operations Note: Waste incudes any and all air, water, soil, or energy pollutant and can be generated at any stage of the process: mining, raw material production, finished goods production, logistics, use and disposal.

Section 5 - Green Products a) Supplier complies with all customer Substance of Concern requirements b) Supplier can show evidence that prohibited substances (as specified by GADSL) are not part of their products or processes

was still down 30% from 2005. “That’s quite a different picture than the BRIC countries,” he observed. All the BRIC countries outperformed the Rest of World (ROW) in 2010. CRU expects the BRIC countries to continue to outperform the ROW in 2011, but at a slower rate. The BRIC countries will continue to have a major impact on the global industry in terms of production and consumption. “In terms of growth, that’s what driving the world,” he said.

CRU provides market analysis and management consultancy as well as putting on conferences for the wire and cable industry. For more information, go to www.crugroup.com. Or contact Rob Daniels at robert.daniels@crugroup.com.

c) Supplier considers recyclability when designing new products and processes d) Life Cycle Management (LCM) as defined by the United Nations, has been voluntarily adopted by supplier e) Supplier has completed a Life Cycle Assessment f) LCM aspects have been incorporated into the supplies processes (Design, Distribution, Management, Marketing, Production, Procurement) At the same time,Yazaki, whose U.S.-based business is Yazaki North America, rewards companies that excel at environmental stewardship, with the potential of bonus points toward preferred supplier status.

A company statement said, “Yazaki’s global policy is that we are ‘A corporation in step with the world.’ We are committed to being environmentally friendly in every aspect of our business and encourage our supply base to share in our comYazaki staffers Elizabeth Cochranmitment.”

Romer and Jamila Darby display The company the company’s Green Supplier of noted that it in the Year plaque.

2008, Yazaki North America launched its voluntary Green Supplier of the Year program to recognize suppliers for their outstanding contributions to the environment. “As the program has grown and evolved, we have seen a significant increase in participation and a competitive spirit among our suppliers. Together with our suppliers, we look forward to a better, greener world.”

DECEMBER 2011 | 39

FEATURE

was hit by the recession in 2009 but also regained ground in 2010 to where it is now the world’s number 10 producer.

In contrast, Daniels said, North American production has been on a downward trend, and although it made a modest rebound in 2010, it

FEATURE

Steel and copper prices: a perennial ‘raw’ concern for manufacturers Raw materials can represent a significant percentage of the overall costs to produce finished wire and cable, and the need to react—or at least not be punished by those costs—is a trend (need) that never ends. It can also make for some stomach-churning times for manufacturers.

Below, Katie Memmel, content manager/editor-in-chief, SteelOrbis-Americas, and John E. Gross, the president of J.E. Gross & Co., Inc, a metals management and consultancy firm and the publisher of The Copper Journal, share their thoughts on the markets.

Like sand through their fingers U.S. wire rod mills made an impressive effort in late Q3/early Q4 to hold onto spot prices that were under pressure. Demand was unbearably weak; construction activity remained tepid, the manufacturing sector’s growth throughout 2011 slowed a bit, and other, well-performing enduse sectors did not take up enough pieces of the end-use pie to make much of a difference.

But after an ill-advised $30/net ton price increase announced in late summer was met with shrugs at best and hysterical Katie Memmel laughter at worst, mills found it harder to hold onto ever-softening spot prices, even as the scrap market chugged along at an unusually steady pace.

From mid-July to mid-November, domestic wire rod spot prices dipped an average of $15/net ton a month. But a $5/net ton dip here and $10/net ton dip there belied market conditions. Sources across the supply chain spectrum (except mills, of course) lamented the slow demand and lack of orders, but in October when shredded scrap prices had a modest $10 decline, U.S. mills tried to stand firm with current offers. It would have been mind boggling if not for the continuous, erratic chipping away of the spot price range, which mills never officially acknowledged but nevertheless added to the market unease.

Then, in November, shredded scrap prices took a dive far deeper than many had predicted. For well over a week, not a peep was heard from U.S. mills, and no one really knew if they were going to absorb the lower raw material costs and still try to keep prices level, or finally wake up to reality and adjust prices to match the market.

In the meantime, spot price deterioration continued, bit by bit, until the pressure finally became too much. In mid-November, rumors started floating throughout the market that mills were going to drop prices to reflect the full scrap decrease. While other long product markets such as rebar, merchant bar and wide flange beams were able to get away with a partial decrease, wire rod did not seem to be as lucky. Just before the U.S. market closed for the Thanksgiving holiday, U.S. mills remained cagey 40 | WIRE JOURNAL INTERNATIONAL

on the subject of a decrease, but new orders became fewer and farther between once rumors turned into solid speculation that not long after the holiday, mills would quietly acquiesce to a $30/net ton decrease in transaction prices, which would drag spot prices down to $670/net ton ($33.50 cwt.)—the lowest level in over a year.

Will spot prices continue to slip through mills’ fingers?

It’s hard to tell. But if last year was any indication, mills shouldn’t fret for long: Q1 2012 may very well bring a spike in wire rod prices as it did in 2011, considering that demand is not that different. But the market is rather apathetic to forecasting, so maybe that should be a New Year’s resolution for wire buyers: don’t even try to guess how mills will respond to market forces, because chances are, you’ll probably be wrong.

Contact Katie Memmel, SteelOrbis-Americas, at kmemmel@steelorbis.com, www.steelorbis.com.

Copper: the risk is rising (again) The global copper market is no stranger to excessive bouts of volatility, whether it’s driven by fundamental factors, speculative bubbles and subsequent bursts, or far reaching financial events. Over the past five years, however, we have experienced two periods of extreme volatility, and we now may be facing a third.

2006 will long be remembered by purchasers and users of copper. Prices skyrocketed as deeppocketed speculative traders took control of the marketplace: the Comex spot price for copper went from $2.20 in March to $4.08 in less than two months, an increase of 85%. There were John Gross there record highs, but there were also erratic swings from gains to losses and back, with some weekly changes topping 60 cents a pound. By year’s end, the price was at $2.85, and those wild fluctuations had led to the crippling of some companies.

In 2007 and 2008, copper was driven by easy credit and a falling dollar, but offset by growing losses in the housing sector. Still, copper’s global fundamentals were still seen as strong, and inventories were declining. During the first half of 2008, just as in 2006, commodity prices for copper and crude oil moved to record highs, driven by speculative trading. The dollar saw new lows and there was a sense that demand from developing economies would keep prices rising. Crude oil traded at $110 a barrel in March 2008 and many expected to see it top $200.

We were blind to the hidden dangers that lie ahead.

Copper prices began to plunge in July 2008. The dollar rallied, fell back, but held its prior low. Copper and oil had both topped out at their highs, and soon after they joined a full-fledged rout of many commodities as the (continued on p. 44)

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INNOVATIONS

INNOVATIONS A new stranding idea seeks a partner The subject of the below article was presented by Tom Clerkin in a technical paper at Wire Expo 2010. Such papers that are graded for publication appear in the technical paper section of WJI—but not this time. Instead, edited elements and further thoughts from the author are showcased here, not because the concept it presents is definitively the next great invention—it is still in the R&D stage—but that it exemplifies the “what if we were to” type of spirit that may lead there.

is much room for improvement, Clerkin declares. A lot of time and money go into labor, equipment and tooling to make smaller strands that would be wound back together into a cable capable of carrying a desired amount of current. “It seemed counterproductive that most of the manufacturing costs that went into making cable was simply to make the copper flexible enough for everyday use,” he said.

Ironically, Clerkin said that he had to leave the industry to find a path that led him to a different view. “My ‘aha!’ moment is the result of cross-pollination between industries. During my work in the orthopedic industry, I happened upon a device used for implanting replacement hips that was a solid piece of titanium that was literally as flexible as a slinky.

I thought, ‘If we can do this with titanium we certainly should be able to do this with copper.’”

Wire has evolved to what it looks like now mainly because of the available technology, Clerkin said. “If you decide that you can change what wire looks like, and concentrate on the fact that our desired product is actually just a round, flexible conductor of electricity, then you can reinvent the whole process and achieve true breakthroughs in technology,” he said, explaining why today’s technology has come to be.

Tom Clerkin, a former wire industry veteran, believes that he has found a better way to process wire in a continuous process, and has a tabletop prototype to demonstrate it. He even presented a technical paper on the methodology at Wire Expo 2010. Only he says that he is caught in a classic squeeze: there is lots of interest in his concept, which he calls a “form strander,” only people want to see it once it has been commercialized, but without a partner he can’t afford to do that.

Clerkin, who notes that early in his career he worked at Camden Wire as manager of product and process engineering for about five years, and was part of the SAE and ISO working groups, said that he has worked in other fields, like consumer goods, automotive and How we got here now medical devices for the past Stranded wire and bunched wire eight years. “One thing that I’ve have long been staple products. Both never lost sight of, however, is Inventor Tom Clerkin with his prototpye of are produced by drawing wire down how to solve the age-old problem a new strander. to small strands and then twisting of making wire in a continuous those strands back up to produce the process. I believe that I’ve finally finished product. Each has its own strengths and weakcracked the code and patented a process that works, but nesses. Each has served industry well for their simplicity the commercialization phase is a little more than I barand ease of manufacturability. Both, however, are limited, gained for. Not having cash puts a serious dent in new as neither product can be made in a continuous operation product development.” in-line with their upstream and downstream processes.

If one looks at the big picture of wire processing, there

Innovations is an occasional section where new technology can be presented. Companies that would like to be considered for future submissions in this section can send an e-mail to editorial@wirenet.org.

42 | WIRE JOURNAL INTERNATIONAL

INNOVATIONS

Why not? The answer lies in simple physics. You just can’t twist parallel strands without them either entangling themselves into a knot or twisting and then untwisting back into parallel strands. Imagine a group of parallel strands traveling from payoff reels, threaded through an imaginary in-line strander made up solely of multi-hole nose plates just like those commonly used on stranders around the world, and then taken up onto a reel. Now, suppose you want to create stranded wire by spinning the nose plate along its center axis. What happens? It twists the strands together but they knot up on both sides of the plate. You have to stop and production comes to a halt.

Now, imagine a similar group of parallel strands traveling from payoff reels into an imaginary in-line buncher made solely of a flyer found commonly on bunchers.

What happens? The strands twist going into the flyer, but promptly un-twist themselves into parallel strands upon leaving the flyer. The value added = zero. Stranders twist the strands around their payoff packages Ironically, Clerkin said before the stranding die while that he had to leave bunchers essenthe industry to find tially twist the a path that led him strands around their take-up to a different view. packages after “My ‘aha!’ moment the stranding die.

Both methods is the result of crosswork, but since pollination between neither is an inindustries.” line process there are manufacturing constraints and high equipment, labor and tooling costs.

Clerkin said that his system for stranding flexible copper cable wire in-line processes a single-strand copper wire along the x-axis into the machine. The wire, which can come from either a machine or a reel, then travels along the arm of a spinning flyer, double-twisting the single strand of copper wire around the longitudinal axis.

Unlike the external twist from a buncher or strander, the twist in this device is actually internal to the copper strand. Grooves are then cut into the single-strand wire along the longitudinal axis, and then run through a closing die.

The next step is where the true innovation takes place, Clerkin said. As the strand leaves the center of the device, it once again enters the spinning flyer and travels along, “untwisting” itself to form a round twisted and flexible copper stranding. By untwisting, the construct is now in its final form: a straight cylindrical copper wire with a continuous and uninterrupted helical groove(s) along its outer.

The number of grooves and strands is dependent upon the application. By forming only one groove, however,

A diagram showing in-line form stranding with an inset of the resulting wire the process produces.

you create a unique single end product that is as flexible as stranded wire but has all of the characteristics you might want to see in single end applications.

Further, this methods makes it possible to increase the processing speed by increasing the number of twists input into the copper before the forming operation. The net result of adding more twists before forming is that, while the line speed is increased, the total RPM of the machine can be minimized. Also, because of how it is used, the form strander can be much smaller in diameter and length, which reduces the rotating mass and translates directly into higher manufacturing speeds and consequently into greater profitability.

The process could require a post stranding anneal, which could be done via in-line annealers that actually provide a benefit to the finished product design as strand elongations would actually be higher than conventional stranding.

“My vision for the lean wire factory of the future includes wiredrawing, form stranding and extrusion all in one continuous process. Two other obvious benefits include a much smaller factory footprint and the elimination of work-in-process inventories. I have multiple patents pending and I don’t want to paint too rosy of a picture. The fact is, what I’ve invented is certainly possible, but it would take time and money to bring to fruition.

Like any other process there are the inevitable technical issues to overcome and I’d be seen as completely crazy if I didn’t acknowledge the amount of work ahead.”

The technology described here by inventor Thomas Clerkin is still in the initial R&D phase. A PDF that more completely presents the information, along with more diagrams, is available. Companies can contact Tom Clerkin at thomas.m.clerkin@gmail.com. ■

DECEMBER 2011 | 43

FEATURE

enormity of the financial crisis became apparent.

Today, we are seeing an extension of the crisis that began in 2008, this one based in Greece but with a widening ripple effect spreading throughout Europe.

Recently, commodity, financial and equity markets have all had wide swings as efforts were made to bail out Greece and the existing euro structure. The volatility in the markets draws an eerie parallel to 2006 and 2008.

To state the obvious, this is not the fundamentals alone at work. Instead, it seems to represent a tense and fragile environment, torn between the optimists who believe the European situation will be resolved with the global economy getting back on track, as opposed to the pessimists

who see the debt crisis only deepening and weighing further on the future of the European Union.

Given the erratic nature of the market today, it’s just not possible to predict where copper or other metal prices are headed as copper has as much opportunity to move significantly higher as it does to fall sharply. What you can do, however, is avoid the pitfalls of the last five years by adopting a strategy to manage price risk exposure to neutralize market fluctuations, and protect profit margins as well as inventory valuations.

Nanotubes: a future copper wire alternative?

could even replace traditional wiring in homes,” he said.

Cables made of carbon nanotubes “are inching toward electrical conductivities seen in metal wires, and that may light up interest among a range of industries.”

The release noted the following: The test cables spun from the nanotubes were able to be tied together without losing their conductivity. The iodine-doping increased the conductivity without any signs of instability. Zhao built the demo rig that let him toggle power through the nanocable and replace conventional copper wire in the light-bulb circuit. He left the bulb burning for days on end, with no sign of degradation in the nanotube cable.

He is also reasonably sure the cable is mechanically robust; tests showed the nanocable to be just as strong and tough as metals it would replace, and it worked in a wide range of temperatures. Zhao also found that tying two pieces of the cable together did not hinder their ability to conduct electricity.

The few centimeters of cable demonstrated in the present study seems short, but spinning billions of nanotubes (supplied by research partner Tsinghua University) into a cable at all is quite a feat, Barrera said. The chemical processes used to grow and then align nanotubes will ultimately be part of a larger process that begins with raw materials and ends with a steady stream of nanocable, he said. The next stage would be to make longer, thicker cables that carry higher current while keeping the wire lightweight. “We really want to go (further) than what copper or other metals can offer overall,” he said.

The project was supported by the Research Partnership to Secure Energy for America, the Department of Energy and Air Force Research Laboratory.

Barrera told WJI that the technology is being furthered by a U.S.-based company he co-founded, NanoRidge Materials (www.nanoridge.com) of Houston, Texas, which “is seeking motivated partners to commercialize the conductor into wires and cables.” The near-term opportunity depends “on having highly motived participants since the technology is at a stage to move to commercial products,” he said, adding that persons interested in knowing more can contact Chris Lundberg at clundberg@nanoridge.com.

It could be decades away from posing competition to electric cables, but nano-technology continues to make advances, most recently at Rice University, where researchers report that they have made a cable from double-walled carbon nanotubes that was able to power a fluorescent light bulb.

A press release said that the conductive cable was created by Rice University researchers Robert Vajtai, Enrique Barrera and Yao Zhao, using iodine-doped nanotubes capable of carrying household current. Powering the fluorescent light bulb at standard line voltage was “a true test of the novel material’s ability to stake a claim in energy systems of the future,” it said.

Barrera, a Rice professor of mechanical engineering and materials science, said in a report that the highly conductive nanotube-based cables could be just as efficient as traditional metals at a sixth of the weight. “They may find wide use first in applications where weight is a critical factor, such as airplanes and automobiles, and in the future

From l-r, Rice University researchers Robert Vajtai, Enrique Barrera and Yao Zhao have created a conductive cable from iodine-doped nanotubes capable of carrying household current. Photo by Jeff Fitlow/Rice University.

44 | WIRE JOURNAL INTERNATIONAL

Contact John Gross, J.E. Gross & Co./The Copper Journal, at john.gross@jegross.com/www.jegross.com.

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★

E X P R E S S

L E A R N I N G

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Learn more at www.wirenet.org.

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The Wire Association International, Inc.

FEATURE

The web ‘minimum has gone up There are no rules requiring a business to have a web presence, but even in the wire and cable industry, it is a rare company that does not have at least a home page with contact info and a few product photos. But what could/should a company have? A full-fledged marketing campaign largely based on the Internet takes time and resources, and using social media is a learning curve.

Social media may not seem to be a good fit for the wire and cable industry, but EMarketer notes that four out of five U.S. businesses with 100 or more employees will use social media marketing in 2011, up 42% from 2008.

The following primer from consultant Robert Davis, who previously worked for Loos & Co., and spearheaded its all-out internet marketing campaign, is followed by a company assessment on the results. At the same time, the internet is a tool, and face-to-face meetings, be they at trade shows or at focused forums, such as the one described below, can also be very effective.

Sharing information face-to-face still works

Beyond the web basics Wire and cable is a mature industry, but it’s not immune to the communications revolution affecting us all. To be viable in the future you’ll need to have more than just a few web pages with pictures and an “e-mail us” link. Your current and future customers expect your website and social media presence to provide more than your traditional sales and customer service activities.

Below are some considerations for designing or updating your web operations for the future.

Robert Davis

Any company can do this. If you think you’re too small to need or be able to create a meaningful site, it’s a self-fulfilling prophecy. A web presence provides a faster

and Cable Vice President Michael Bjorn. “We want to increase awareness of the performance and reliability of the existing power delivery infrastructure and gain a better appreciation of the opportunities and challenges that result from developing a more reliable network.”

“We had a very successful event and in the future we should collaborate further with Borealis and Borouge.” says Prof Fan, Chairman of the Wire & Cable Committee of China Electrotechnical Society.

Borealis is a global chemical supplier owned 64% by the International Petroleum Investment Company (IPIC) of Abu Dhabi and 36% by OMV, the leading energy group in the European growth belt. Borouge is a joint venture between Borealis and the Abu Dhabi National Oil Company (ADNOC).

The internet may hold much potential for finding new customers, but one other growth area for meeting customers has been through specialized forums, such as the Borealis and Borouge Wire & Cable Academy, which in November was staged for the first time in China. It was done in partnership with the Shanghai Electric Cable Research Institute (SECRI) as part of the 2011 Annual Technical Conference puton by the China Electrotechnical Society’s Wire and Cable Committee.

The Wire and Cable Academy, which includes presentations by company experts tailored to specific regions— such as power transmission from a cable maker’s perspective, performance and reliability of the current power infrastructure, the challenges of undergrounding highvoltage and extra-highvoltage cables as well as HVDC cable technology, specification and experience in installation and testing in China—has been held now for three years, with venues including Brazil, the U.S. and Russia.

“Our global Wire and Cable Academy provides a unique platform for experts to share knowledge and strengthen business relationships across the industry and we are pleased to initiate it in China,” said Borouge Wire Attendees at the Nov. 10 Borealis and Borouge Wire & Cable Academy event in China.

48 | WIRE JOURNAL INTERNATIONAL

by locating general web development firms, but make sure to interview several potential candidates as experience and costs can vary widely. Most importantly, do not try to go it alone. Building an effective web presence is a detail oriented process that needs to be done correctly in order to attract and retain customers.

A top-down commitment. Management plays a big role in a game-changing strategy shift like this. Success will hinge on how you support implementation and continued use of the web and social media. Show that you believe in the process and the outcome, and your employees with get you there. Take a lukewarm approach and be ready for quiet phones and empty inboxes.

Managing the process. Once you’ve determined your direction, appoint a lead person to organize and manage the creation of your web presence. But don’t go it alone!

Professional support is available to determine the level of commitment you need to make, in both time and money, and to help develop your site. Take the time to develop the site that meets your needs by proceeding in small steps, developing and testing sections of the site as you go. The goal isn’t just to get it done, but to build a presence that will help your company do business going forward.

Any employee can contribute. Traditional selling

DECEMBER 2011 | 49

FEATURE

response to customers at lower costs, which will help you grow, and in times of tight budgets, help maintain your profits. And that’s what ultimately drives your strategy, whether you’re a 10-person rigging shop or a multinational distributor.

Where to start. You’re not expected to have all the answers going in, but you need to think about your overall marketing strategy. If your company thrives on personal relationships and word of mouth advertising, a simple site may be just fine. If you focus heavily on the technical side to attract customers, you’ll need a complex site. And distributors will want to focus on e-commerce. Then consider your experience and comfort level with projects like this. If you have a person on staff that is comfortable with web marketing, put him or her in charge. Have them find a reputable web development firm to guide you in the building of your web presence. If you don't have such a person, you'll need to hire a marketing consultant to guide you through the process. How do you find such help?

Solicit recommendations from others in the industry that you trust and who have gone through the process. Finding a consultant and web developer with experience in the wire and cable business is a big plus, because they have background on the industry. You can also search directly

FEATURE

involved a lot of personal interactions and sales contact, while a web-based sales and marketing model allows employees to provide customers the choice of calling you or searching out their answers online. It’s the whole system that makes each part work so well, and the key is that you do not have to be an internet savvy person to contribute. With a minimum of instruction, the process should be easy, far easier than traditional cold-calling visits that have become less welcome in this age of lean staffing. The web and social media follow the same rules as traditional marketing communications: pick a message and begin a conversation with your market. Use all customer touch points to reinforce that message. With the web, you can increase these touches for a fraction of the cost of traditional methods.

Content to include? When a potential customer is looking for information, the first place he or she goes is the internet. Make sure that everything you want a customer to know, including your products, services, and experience, are front and center. That first impression can make or break your chances, but it doesn’t end there.

Companies are now expected to have information and a feedback channel available 24/7. Do your customers need certifications? You’ll need a portal to allow them to download. Technical support? You’ll need a YouTube Channel to show swaging techniques and surface inspection methods. Comments? You’ll be reading your customers thoughts on your Facebook or LinkedIn profile.

Fresh content is good content. The web doesn’t need to be a daily exercise, but content must remain current.

News must be maintained, product information must be updated. If your customers know that you have the latest market and product information on your website, they’ll continue to turn to you as their source in the industry.

Beyond the expected. Product catalogs and technical information are both givens, but your website presence must show that you are a credible business with real people. Pictures of employees at work, your latest function, or a recent charity event posted on Facebook will put a face to your business and create a more personal connection with your customers. And this connection helps create loyalty and ultimately a more successful business.

Be patient, this takes time. It likely will take three to six months for even a very well run web marketing program to have a noticeable impact. Build the critical mass of activity on your pages. Blog about technical information and increase your search engine response. Cultivate followers on Twitter and Facebook and give it time to grow. Ultimately, you’ll have a tighter connection with dedicated customers and the word of mouth advertising we all crave.

Customers will contact you. Purchasers and engineers, both young and old, are getting harder to reach through the traditional methods of trade shows and sales calls.

Meanwhile, potential customers are searching for you online. Make absolutely certain you are designing your web presence for Search Engine Optimization (SEO). An

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optimized web presence supports this change to the start of the sales cycle. You know you’ve got it right when customer phone calls start: “I found you online and was reading about your products…”.

Measure, measure, measure. Everything online is geared toward monitoring and optimizing activities that your customers value. Relate those activities to your business objectives, such as growing customers or increasing margins, and promote them. For example, if reading your specifications drives engineers to select your products, then you should be driving visitors to your specification pages. Set goals and monitor them on a monthly basis to make sure you’re on target and reaching your business objectives.

Robert Davis can be reached at rcdavis3rd@gmail.com

Beyond the web basics: U.S.-based Loos & Co. has made the internet a key to its marketing efforts. WJI asked Sales Director Michael Wallace about the company’s assessment of its efforts.

WJI: When did Loos & Co. make the decision to employ a full-fledged internet marketing program, what were your expectations at the time, and how would you judge what has been achieved?

Wallace: Loos made the decision to have a web site back in late 1997. It seemed to be the right thing to do at the time. Loos had always been a huge believer in printed advertising especially with the Thomas Register. At one point we had both a cover ad on one of the books as well as a spine ad.

Expectations were very low back in 1997. The internet was unchartMike Wallace ed territory and nobody knew what to expect.

Today, the Thomas Register no longer prints a set of books. Everything is on the internet. We average approximately 250 new visitors to our web site daily. It has become our major focus of advertising and self-promotion. In today’s competitive internet world, you are always trying to stay ahead of the rest of the pack in your respective industry. The need to constantly “leapfrog” the competition in search engine placement creates a full time job in many companies. Everybody is always trying to stay ahead but it’s nearly impossible to do. The key is to be at the top of the list when the search results come back from Google or any of the other major search engines. If you’re out of the top 10 you might as well not have a web site!

WJI: What advice would you have for a company that has a website but has not gone much beyond that?

WJI: Considering the resources that Loos & Co. invested, can you determine whether the direct and/or indirect payback has made it worthwhile?

Wallace: Yes, we certainly can! When we get orders from new customers or offer quotations to new prospects one of the questions we always ask is “How did you learn about Loos & Co.?” For the past four or five years the overwhelming majority have said the internet. Prior to that, the responses would have been equally split between The Thomas Register, print ads, word of mouth or sales reps. Due to this we have been able to reduce our spending on the more traditional forms of advertising.

Whatever we’ve spent on developing and maintaining an effective web site has been more than covered by spending reductions in the other areas. Additionally we now reach a much broader audience on the internet and it’s a global one.

The social media outlets like Twitter and Facebook haven’t really spilled over into the industrial sales arena yet. But I’m sure they will, given time. As young people enter the workforce who have grown up using the social media outlets, they will transition to using them in the workplaces for thing like purchasing or sourcing vendors.

It’s coming so the earlier you are a part of it the better off you will be.

Loos & Co.’s website can seen at www.loosco.com. ■

675$,*+7(1(56 *8,'(6 )(('ERS &/2 7)2% s #!",%3 s 45"%3 s 342)03

WITELS-ALBERT USA Ltd. Phone 410 228 8383 info@witels-albert-usa.com

Fax: 410 228 1813

www.witels-albert-usa.com

DECEMBER 2011 | 51

FEATURE

Wallace: In real estate it “location, location, location.”

In today’s internet world its “placement, placement, placement.” It’s very much the same concept. If you’re a restaurant you want to be on that perfect corner with plenty of parking. If you’re in the wire and cable business you want to be at the top of the search engine results. One of the keys to getting there is content on your website.

The more content you have on your website the better the chance you have of getting close to the top of the search engine results. There are companies out there who profess to be able to optimize your search engine placement.

They are called Search Engine Optimization (SEO) specialists. If you don’t have your own in house specialist this might be the way to go. For smaller companies it’s a way to get higher up in the search results without hiring a full time employee. One tip, whatever you do it requires full time attention. Web sites must be kept fresh to continue to have people visit. Online catalogs, technical data and industry/product news all turn your site into an information resource for the whole world.

TECHNICAL PAPERS

TECHNICAL PAPER Characterization of defects on Al-1350 rectangular wire produced by continuous extrusion process Metallographical analysis of rectangular wires found that rod defects often can be traced to oxide inclusions related to rod quality or process conditions, and that cleanliness was a very imortant factor for blisters.

By Sergio Gallegos, J. Angelica Ramos and Sergio Montes

Rectangular wire is typically produced by continuous extrusion as follows. An aluminum rod is inserted in the groove of a wheel and then drawn by friction against the same. The drawn material is dammed by an abutment insert-

ed in the groove, and the extrusion pressure is generated as the shoe covers the groove. The material flows into the die chamber and can be extruded from the die in any form including complex shapes1. See Fig. 1. Since the material generates frictional heat, temperatures up to 500°C or more can be reached (without using a heater), this temperature exceeds the aluminum recrystallization point (~315°C) obtaining rectangular wire in O-temper1-2.

The defects found on rectangular wire may appear due to defects on the rod as well as the conditions to which the rod is subjected during the process3-4. As has been widely observed, the internal defects on the rectangular wire may arise from the processing as every different process condition havs a particular defect associated with it5-6. On the other hand, failures from the production of the raw materials (i.e. the rod) lead to different defects for the final product, including imperfections such as metallic and non-metallic inclusions, oxides and macroporosity, among others7-13. The goal of this paper is to contribute to the development of classification and interpretation criteria for common defects on rectan-

Fig. 1. Schematic of a continuous extrusion machine.

Fig. 2. Comparison of stress – strain curves in aluminum 1350 rods.

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Fig. 3. Comparison of stress–strain curves in aluminum 1350 rectangular wires.

TECHNICAL PAPERS Fig. 4. Macrostructure of the aluminium 1350 rods, 10% (vol.) hydrofluoric acid.

Fig. 5. Microstructure of the rectangular wires, polarized light. 10 % (vol.) hydrofluoric acid.

gular wire Al-1350 (heat treated to a fully annealed state) produced by continuous extrusion, as well as determining the optimal rod properties for the manufacture of said wire.

in order to find the difference between them.

Mechanical properties. Mechanical properties of the four batches, as well as two rectangular wire batch samples (A’ and B’), were analyzed by means of tensile test15-16.

Grain structure analysis by optical microscopy.

Microstructural analysis was performed on rod and rectangular wire batches. The samples were prepared for metallo-

Experimental Procedure Chemical composition. Four rod batches (A, B, C and D) were characterized through optical emission spectroscopy14,

Fig. 6. Macrographs of a ductile tensile failure in rectangular wire.

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The defects were studied by stereoscopic microscopy, however, the defects that could not be classified by this technique were taken to a metallographic analysis in transversal and longitudinal directions, and finally scanning electron microscopy (SEM) when required in order to analyze the chemical composition on the failure zone.

Results and discussion

Fig. 7. Parallel marks on rectangular wire.

graphic examination in transversal and longitudinal direction, the etchant used for revealing grain structure was HF 10% vol. diluted in distilled water17.

Optical and scanning electron microscopy defect analysis.

Chemical composition. Table 1 shows the chemical composition of the batches. There is a difference in the titanium and boron content of batch D; these two elements together form TiB2 particles, which act as grain refiners in aluminum17.

Mechanical properties. Figs. 2 and 3 show the stress–strain curves on rods and rectangular wire, respectively. Batches A and B for rod condition had the lowest tensile stress, conditions that reflect a better processability. The tensile stress of rectangular wires (batches A’ and B’) was lower than rods, this occurs because of the recrystallization phenomenon occurred during the processing18.

Grain structure analysis by optical microscopy. Fig. 4 shows the grain structures on a macro level of the rods in transversal and longitudinal directions. Batches A, B and C have a columnar grain structure, which might be caused due to a recovery of the metal during the rolling process18.

Batch D exhibits an equiaxial grain structure derived from the grain refiners as should be inferred from Table 117.

Fig. 5 shows the micrographs of rectangular wires in transversal and longitudinal directions. In the micro-

Fig. 8. A and B. Macrographs of the incrustation defect, the ferrous particles arise from machine tooling.

Table 1. Chemical composition of test batches.

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Fig. 9. Longitudinal micrograph of incrustation defect, with ferrous particles seen at surface.

TECHNICAL PAPERS Fig. 11. Macrographs of sliver defects on rectangular wire surface.

Fig. 10. A) SEM image of a incrustated particles, B) EDAX results indicates the presence of iron in the aluminium matrix.

Fig. 12. Sliver defect micrographs in longitudinal direction, the internal rupture alignment is parallel to the wire surface indicating a processing defect. 50Ă—, as-polished condition.

Fig. 13. A) SEM image of a sliver defect; B) EDAX results indicates the presence of oxygen due to aluminium exposure to high temperatures. Other elements such as Cl, S, K, Ca may arise from the solution cooling.

graphs, severe microstructural changes of batches A, B and C are observed; the grain structure was modified from columnar to equiaxial due to recrystallization effect that occurs during continuous extrusion of rectangular wires18. The recrystallization effect in continuous extrusion occurs due to a rise of temperature during the plastic deformation, frictional heat generated in the extrusion zone cause that working temperature fluctuates around 500°C. Characterization of typical rectangular wire defects.

Continuous extrusion defects that typically occur during aluminum rod processing include: tension, parallel marks, blisters, slivers, incrustations and inclusions as casting oxides.

The defects are described below.

Tensile failure. This defect is produced when the tension exceeds the UTS (ultimate tensile strength) of the aluminum rectangular wire. In addition, imperfections on the wire surface such as cracks and scratches may lead to a fragile tensile rupture since they act as stress concentrators4. Fig. 6 shows an example of this defect.

Parallel marks. Optical inspection revealed parallel marks on the surface of a rectangular wire. Those marks may be caused by a non-uniform tension on rectangular wire associated with oscillations during the coiling, Fig. 7 exhibits an image of this defect19.

Incrustated particles. Figs. 8 and 9 show macrographs of an incrustated particles defect. The sample was subjected to a scanning electron analysis and it was determined that the foreign particles correspond to low-carbon steel due to the lack of elements like chrome, titanium or vanadium, and it is unlikely that the ferrous particles were added to the surface during rod manufacturing. These particles could have adhered to the rectangular wire by contact with the machine tooling. See Fig. 10.

Sliver. This failure is present as periodical ruptures on the surface of rectangular wires. Fig. 11 shows an example of this defect. Fig. 12 exhibits two micrographs of the ruptures zone: a) a sliver formation on the wire surface in longitudinal

DECEMBER 2011 | 55

TECHNICAL PAPERS Fig. 14. Macrographs of casting oxide in rectangular wire.

direction; and b) internal rupture parallel to the surface along the rectangular wire. It should be noted that the slivers occur periodically and only on one side of the rectangular wire.

This aligned morphology of the internal rupture, as well as its equidistant location along the wire surface, indicates that this defect is caused by an incorrect adjustment of continuous extrusion process parameters. An EDAX analysis was performed in the failure zone by scanning electron microscopy, and results are shown in Fig. 13; oxygen content was found inside the sliver, which can be explained by a prolongated

Fig. 15. A) SEM image of casting oxide defect; B) EDAX results indicates the presence of oxygen due to inefficient cleaning during rod manufacturing.

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exposure time of the aluminum to high temperatures on the extrusion zone.

Casting oxide. Aluminum oxide that forms on liquid metal in the tundish is eventually introduced to the cast bar during continuous casting process. Oxide films or particles can cause defects during further processing of the rod. It was observed that this defect has an undefined morphology in rectangular wire. See Fig. 14. Oxygen presence was observed in the EDAX analysis of the defect area, as seen in Fig. 1520.

Blister. It has been reported that a blister defect is produced by the presence of contaminants on rod surface, such as lubricant, oils and humidity, but a high hydrogen content could cause similar damage to the wire20. Fig. 16 shows a blister defect on wire surface. A metallographic analysis of a blister sample was performed to study transversal and longitudinal sections of this defect. Fig. 17 shows the typical cavities caused by moisture, organic material or existing pores in the rod. Fig. 18 shows EDAX analysis results of a blister defect.

Fig. 16. Macrograph of blister defect.

Aluminum rods with tensile stress of ~85 MPa performed better than higher tensile stress rods while processing by continuous extrusion (batches A and D).

Rectangular wires have an equiaxial grain structure due to recrystallization that occurs when rods are subjected to high temperatures (around 500°C).

Tensile failures and paralFig. 17. A) Transversal; and B) longitudinal micrographs of a blister, in the aslel marks defects are caused polished condition. by an improper tension force during rectangular wire coiling, and are not 6. J. Cho and H. Jeong, Parametric investigation on the surrelated to material quality. face defect occurrence in conform process by the finite eleDamage and misalignment in tools used for the extrusion ment method, J. Materials Processing Technology, 1999. machine can result in wire contact with them, leading to fer7. J. Campbell, Castings, Butterworth Heinemann, Oxford, rous particles adhered on the wire’s surface.

U.K., 1991.

Oxide formation can be produced by exposure of the alu8. R. Menezes and J. Adams, ASM Handbook, Vol. 2, minum to high temperatures for long periods of time on the extrusion wheel.

Sliver defects are produced by continuous extrusion process; they have a defined periodic morphology and appear aligned on wire surface.

Casting oxide inclusions do not show a specific morphology or location in the wire because they are related to the continuous casting process.

Rod surface cleanliness is a very important factor. It was confirmed that humidity or organic materials (i.e. lubricants, oils or grease) on a rod’s surface, can produce blister or slivers defects.

Acknowledgments The author thanks Viakable S.A. de C.V., for the permission to conduct this project and use its equipment. Thanks also to Javier Solis and Julio Costilla for their valuable collaboration in this work.

References 1. T. Tonogi, K. Okazoto and S. Tsukada, Precise Extrusion Technology by Conform Process for irregular Sectional Copper, Hitachi Cable Review, No. 2, 2002.

2. S. Avner, Introducción a la Metalurgia Física, McGraw Hill, México, 1988.

3. A. Das, Metallurgy of Failure Analysis, Michigan University, 1997.

4. S. Schmid, Manufactura, Ingeniería y Tecnología, Edición 4, México, 2002.

5. J. Cho and H. Jeong, Conform process: surface separation, curling and process characteristics to the wheel diameter, J. Materials Processing Technology, 2003.

Fig. 18. A) SEM image of a blister in transversal section; B) EDAX results indicates the absence of oxygen or other impurities in aluminium (foreign particles).

DECEMBER 2011 | 57

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Conclusions

TECHNICAL PAPERS

Properties and Selection Nonferrous Alloys, USA, 1992.

9. G. Totten and S. Mackenzie, Handbook of Aluminum, Vol. 1: Physical Metallurgy and Processes, USA, 2003.

10. W. Hufnagel, Manual del Aluminio, Edición 2, España, 1992.

11. E. Król and J. Tamminen, Solidification Characteristics of Aluminum Alloys Vol.1: Wrought Alloys, Oslo, Norway, 1986.

12. Phelps Dodge Corporation, Manual de Estirado de Alambre.

13. H. Pops and J. Steininger, Wire breaks and failure analysis, USA, 2003.

14. ASTM Standard E 227-67, Optical Emission Spectrometric Analysis of Aluminum and Aluminum Alloys by the Point-to-Plane Technique, ASTM International, Philadelphia, Pa, 1985.

15. ASTM Standard B 557-84, Tension Testing Wrought and Cast Aluminum – and Magnesium – Alloy, ASTM International, Philadelphia, Pa, 1985.

16. ASTM Standard B233, Standard Specification for Aluminum 1350 Drawing Stock for Electrical Purposes, ASTM International, West Conshohocken, Pa, 1997.

17. A. Brent and A Debbie, ASM Handbook, Vol. 9: Metallography and Microstructure, USA, 2004.

18. W. Callister, Introducción a la Ciencia e Ingeniería de los Materiales, Vol. 1, España, 1998.

19. H. Pops, Metallurgy and technology of Comercial Copper Electrical Conductor Wire, Essex Group Inc. 20. R. Menezes and G. Abbaschian, ASM Handbook Vol. 15, Castings, USA, 1988. ■

Sergio Gallegos has finished course work in the Materials Engineering Department of the Facultad de Ingeniería Mecánica y Eléctrica (FIME) of the Universidad Autónoma de Nuevo León (UANL), Monterrey, Mexico.

This work is part of his B.Sc. thesis. He is studying for an M.Sc. degree in materials engineering at FIME-UANL. He has previous experience in the nickel and titanium aerospace industry. Angélica Ramos heads the Gallegos Ramos Montes metals laboratory of Viakable—a group of wire and cable companies that includes Conductores Monterrey—San Nicolas de los Garza, Mexico. She earned a Ph.D. degree in materials Previous academic experience includes graduate studies engineering from FIME-UANL, where she worked on the at the University of Tennessee at Knoxville, USA, and at development of aluminum alloys. Previous academic the Universidad Autónoma de Coahuila at Saltillo, work includes research in steelmaking processes and Mexico. He has been author or co-author of more than 17 materials characterization. Sergio A. Montes is currently publications in the polymer research area, especially in manager of the R&D materials laboratory of Viakable. the field of rheology and processing of polymeric materiHe graduated from the University of Akron, Ohio, USA, als. This paper was presented at WAI’s International techas a student in the polymer engineering department. nical Conference, Monterrey, Mexico, October 2010.

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Effect of extrusion temperature and speed on structure of CuAg15P5 alloy Reducing the deformation rate and adding phosphorous was found to make a big difference in the resulting plastic properties of wire drawn from CuAg15P5 alloy, which were able to be further drawn.

By Rafał Włudzik, Jan W. Pilarczyk, Marcin Kwapisz and Łukasz Wierzbicki

CuAg15P5 is a copper-phosphorous alloy. These alloys, with the addition of silver, are hard brazing materials that are used for difficult cold-deformation applications. They are commonly used for hard brazing of copper, bronze, brass and other alloys of the copper and silver and also tungsten and molybdenum. The alloy CuAg15P5 contains 14.5-15.5% Ag and 4.7-5.3% P, the rest copper.

Temperatures (solidus-liquidus) are in the range between

645°C and 800°C according to EN1044:1999/ ANSI/AWS A5.8-:20042,3. The copper-phosphorous brazes with silver addition have replaced commonly used silver alloys, mainly due to the lower price. A high phosphorous content increases the wettability of the alloy in brazing temperature, which makes it possible for joining without flux.

Adding phosphorous to copper forms Cu3P, which hardens the alloy and increases its resistance to wear.

Fig. 1. Sample microstructure after casting process.

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TECHNICAL PAPERS

TECHNICAL PAPER

TECHNICAL PAPERS

Results of mechanical property investigations published in works1,4 confirm that the alloy CuAg15P5 is plastic at higher temperatures. However, those investigations have not allowed for determination of temperatures of phase transformations during alloy deformation at different temperatures during heating and cooling processes.

Also, the effect of deformation at different temperatures with different strain rates on microstructure of the considered alloy has been determined in this work.

Materials and experimental procedures Samples from an ingot (90 mm in diameter and 190 mm long) made from the CuAg15P5 alloy were cast on a Wertli horizontal continuous casting line. The alloy underwent structural investigations, microstructure by an optical microscope, Axiovert 25, and dilatometric investigations on a Dilatometer DIL 805A/D. Physical simulation of the process was performed by a Gleeble 3800 with strain rates 0.154 s-1, 0.62 s-1 at deformation temperature of 450°C and with strain rate 0.01 s-1, 0.04 s-1, 0.154 s-1, 0.62 s-1 at deformation temperatures of 500°C and 550°C. X-ray microanalysis was performed with the diffractometer X-ray XRD.

Research results Observations of the microstructure of CuAg15P5 alloy after the casting process were conducted by the Axiovert optical microscope to find differences in the morphology of the alloy structure. Fig. 1 shows the microstructure of the sample at magnifications of 100x, 500x and 1000x.

The microstructure of the ingot made from the CuP5Ag15 alloy mainly consists of fine dendrites of the Cu phase. Fine dendrites of the Ag phase are also visible, particularly in the areas where solidification proceeded slower. Moreover, the areas with ternary eutectics ((Cu) + (Ag) + Cu3P) have been found, which were very fine-

Fig. 5. Dilatogram of CuAg15P5 alloy during heating.

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Fig. 2. X-ray diffraction from the surface of sample after the process of casting.

grained character, whereas the Ag phase grains were almost invisible.

Analyzing the microstructure of the alloy after the casting process confirmed the existence of three phases with different dispersion. X-ray investigations were conducted for their identification with a Seifert diffractometer, X-ray XRD 3003 T-T. A DHN Powder Diffraction System (PDS) software was used for analysis of the experimental data. It contains a catalogue of data for more than 50,000 crystallographic phase. Filtered radiation of cobalt cathode was applied during the taking of the measurements. The parameters of the diffractometer work were as follows: U = 0 KV, I =40 mA, 2Θ = 20-100°, counting time = 15 s.

Fig. 2 shows the results of the X-ray analysis, from which it can be certified that the solutions of copper and silver are the main components of the alloy structure. The intermetallic phase Cu3P, which is fragile, also was found in the alloy microstructure.

Simulator investigations were done to examine the influence of temperature and the rate of deformation on changes

Fig. 6. Dilatogram of CuAg15P5 alloy during cooling.

TECHNICAL PAPERS Fig. 9. Measurement points for calculation of temperatures in the axis of the extruded material and at its surface.

Fig. 7. Scheme of eight-hole dies (2.4 mm diameter) for extrusion of copper-silver phosphorous alloys.

Fig. 8. Schedule of the temperature of squeezed-out wire on the section of die near the temperature of the squeezed-out batch 500°C and speed of the stamp: a) 20 mm/min, and b) 40 mm/min.

in the microstructure of the CuAg15P5 alloy. The investigations included the deformation of the alloy on the Gleeble simulator at temperatures of 450°C, 500°C and 550°C at deformation rates of 0.01 s-1, 0.04 s-1, 0.154 s-1 and 0.62 s-1, then freezing the structure in water and final observations of the microstructure of the alloy. The average speed of the cooling was about 600°C/s.

Fig. 3 shows the microstructures of the alloy after the simulator deforming at a rate of 0.154 s-1 at temperatures of 450°C, 500°C and 550°C. It can be stated from the research that the deformation temperature has a remarkable influence on the structure of the deformed alloy. A temperature increase during the deforming process resulted in the formation of a finegrained and more homogeneous structure. At the 550°C deformation temperature, the enlargement of the areas con-

taining threefold eutectic—(Cu)+(Ag)+Cu3P—has been observed, in comparison to the structure after deforming at temperatures of 450°C and 500°C. Such structure advantageously influences the plasticity of the material.

Fig. 4 shows the alloy structures after simulator deforming at a temperature of 550°C at rates of 0.01 s-1, 0.04 s-1 and 0.62 s-1. It can also be stated that the rate of the deformation influences the structure of the CuAg15P5 alloy. A decrease of the deformation rate results in considerable crumbling and homogenization of the material, which has a profitable influence on plasticity.

The microstructure of samples after the deformation process in laboratory conditions has shown the presence in the alloy of the earlier mentioned phases with different dispersion. However, considerable homogenization of the structure at higher temperatures and a smaller rate of the

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been observed.

The fading of fragile phase Cu3P shows that the temperature range between 528°C587°C would be best for wire extrusion from the CuAg15P5 alloy due to the good plastic properties of the alloy in that temperature range. It can further allow for subsequent realization of the drawing process.

The results show that the alloy possesses very good plastic properties in the phase transformation and this offers the possibility of using larger Fig. 10. Distribution of temperatures in measuring points on the wire surface for reductions. extrusion speeds (20 and 40 mm/min) for different billet heating temperatures.

The simulation the extrusion process for 2.4 mm wire was done on an eight-orifice die (Fig. 7) at temperatures of 500°C, 550°C, 570°C and 600°C at a speed of 20 and 40 mm/min. See Fig. 7.

Fig. 8 shows the temperature distribution before the wire enters the die, in the die and after exiting the die at a batch temperature of 500°C and extrusion speed of 20 and 40 mm/min. It has been found that the temperature increases in the deformation zone as there is an increase in the extrusion speed.

The values of calculated temFig. 11. Distributions of temperatures in the axis of the wire for extrusion peratures were taken from the speeds (20 and 40 mm/min) for different temperatures of billet heating. simulation files in the deformation zone of the wire in the axis and on the surface according to points introduced in Fig. 9. deformation has also been observed. This is profitable, From this basis, Figs. 10 and 11 were drawn. because it represents an improvement of the plastic properThe analysis of the results of the temperature distributies of the alloy. tions on the section of the deformed material certify that Figs. 5 and 6 show dilatogram graphs in which the temthe essential temperature increase can be observed during peratures of phase transformation are marked during the the passing of the material along the zone of the deformaheating and the cooling of tested specimens. Samples were tion, both in the axis of the material as well as on the surheated at a constant rate to 630°C and subsequently were face of the contact of the material with the die. However, cooled. there are not considerable differences between the values From Fig. 5, two critical points confirming transformaof the temperatures on the surface of the wire in relation to tions in the alloy structure on the dilatogram curve during the temperatures in the axis. This can be explained by the heating can be seen. First, the temperature of 528°C is convery large deformation energy generated in the extrusion nected with the beginning of the dissolution of the fragile processes and the small diameters of the extruded wire. phase Cu3P, and second, the upper temperature of the transformation 587°C, corresponds to the end of this Summary process.

Analysis of the microstructure of the CuAg15P5 alloy Fig. 6 shows that during the cooling stage, a shift of the after the casting process confirmed that there was formarange of critical temperatures from 395.6°C - 504.1°C has tion of three phases with different dispersions. It was found

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Włudzik

This scientific research is supported by Polish Ministry of Science in the frame of the project No. N N508 438536 granted in the years 2009/2010.

References 1. Ł. Marchewka, J. Stobrawa, B. Cwolek and E. H adasik, “Badania wpływu temperatury, pr dko ci i stopnia odkształcenia na struktur i własno ci trudnoodkształcalnych stopów CuPAg, Rudy i metale nie elazne,” Nr. 6, SIGMANOT, 2007, Poland.

2. ANSI/AWS A5.8-2004: Specification for filler metals for brazing and braze welding.

3. Polish Standard PN- EN1044:1999, Lutowanie twarde, Spoiwa.

4. R. Włudzik, M. Knapinski, J.W. Pilarczyk, S. Ksiearek and Z. Smolarczyk, “Effect of parameters of extrusion on strain and stress states in the manufacturing process of wire from alloy CuAg15P5,” Proceedings of WAI’s 79th Annual Convention (Interwire) in Cleveland, April, 2009, p. 201-219. ■

Editor’s Note: due to space limitations, Figs. 3 and 4 were not included. For a PDF of the two figures, please e-mail editorial@wirenet.org

Pilarczyk

Rafał Włudzik works at Yawal S.A., a manufacturer of aluminium profiles system for windows, doors and curtain walls in Poland. He holds a Ph.D. degree in specialty plastic working of metals obtained in the Department of Materials Processing Technology and Applied Physics at Czestochowa University of Technology in Poland. He specializes in the wiredrawing, silver brazing and extrusion of aluminum profiles.

A WAI member, he is the author or co-author of more than 25 technical papers. Jan W. Pilarczyk is a professor at Czestochowa University of Technology.. He is the author or co-author of more than 200 papers, including 50 published in Wire Journal International. The coauthor of 15 books and holder of 10 patents, he won the Wire Association International’s Mordica Memorial Award in 2004 and since 1999 has served as president of

Kwapisz

the Poland Chapter of WAI. Kwapisz is an assistant professor at Czestochowa University of Technology. He is authored and co-authored over 50 publications. He was the supervisor of 10 works of engineering and master thesis. Łukasz J. Wierzbicki is a researcher at the Department of Processing of Metals and Alloys at the Institute of Non-Ferrous Metals, Gliwce, Poland, where he has been working since 2002. He has been involved in studies into such processes as casting, working of copper and silver alloys, brazing materials, also in powder metallurgy and metallography. He obtained his degree from the University of Science and Technology, Kraków, Poland. This paper was presented at WAI’s 80th Annual Convention, Milwaukee, Wisconsin, USA, May 2010.

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on the base of diffractometric analysis that solid solutions of copper and silver were the main components in the structure. It also confirmed the formation during the intermetallic phase of Cu3P, which is very brittle and can limit the ability of the alloy for plastic deformation.

Research of the microstructures of samples after the deformation process on the Gleeble 3800 simulator confirmed the influence of temperature and the rate of deformation on the structure in the studied alloy. The reduction in the deformation rate from 0.62 to s-1 to 0.01 s-1 resulted in considerable refinement and the homogenization of the structure of the alloy.

The addition of phosphorus to the Cu-Ag alloy improves its hardness. The hardness increase is caused mainly by formation of the Cu3P phase. The hot extrusion of the alloy in the 530°C to 590°C range of temperatures and application of slower extrusion speeds resulted in wires with good plastic properties that can be further subjected to subsequent drawing process.

Conducted simulations were made to choose the optimum variant of the wire extrusion process from the CuAg15P5 alloy. Warming the batch above 570°C and extruding the wire at speed greater than 20 mm/min can cause an increase the alloy temperature beyond its melting point at the exit of the wire from the die.

TECHNICAL PAPERS

TECHNICAL PAPER Effective use of infrared heating for wire and cable applications The three primary methods for heating, drying or curing wire and cable products (convection, conduction or radiation) all have pluses and minuses. This paper reviews the different methods and focuses on the use of infrared technology.

By Richard E. Hoffman, Jr. and Eric P. Hummel

Infrared technology has been used in industrial heating applications for many decades. As infrared heaters and control of the heaters have improved, wider use and acceptance of this technology has resulted. It is now a commonly used means of heating webs and three-dimensional objects in hundreds of manufacturing applications.

Specific to the topic at hand, infrared heating is used to heat process wire and cable products.

Heating, drying or curing of wire and cable products (or any object) is accomplished through at least one of three modes of heat transfer: convection, conduction or radiation. Each mode has advantages and disadvantages for a given process heating requirement. Sometimes the choice is quite clear where one method of heat transfer is plainly superior; however, usually two or more methods of heat transfer can satisfy the process criteria and a judgment needs to be made as to the advantages and disadvantages of each approach. Infrared heat transfer is a non-mechanical (quiet) and noncontact means of transferring large quantities of heat energy to a target at the speed of light.

The intent of this paper is to flush out the last statement

as it relates to practical heating, drying and curing applications that are encountered every day in wire and cable processing. This paper will briefly examine how infrared technology works, look at the types of infrared equipment available for industrial heat-processing applications and illustrate some infrared applications in wire and cable processing.

Infrared technology: how it works All objects above absolute zero (-60째F) emit infrared radiation. The infrared portion of the electromagnetic spectrum is found between visible light and short radio waves.

Infrared radiation is emitted at wavelengths between 0.72 and 1000 microns. However, only the 1 to 10 micron wavelength band is utilized in the vast majority of industrial heating applications (1% of the range). See Fig. 1.

Why is such a narrow slice of the infrared energy utilized to dry, cure or heat wire and cable products? Because this range of wavelengths represents an infrared source temperature range that is readily available and commercially viable for continuous product manufacturers requiring heat

Fig. 1. Useful infrared spectrum for industrial heating applications.

Fig. 2. Conservation of radiation energy.

64 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Fig. 4. Useful infrared source temperature range.

Fig. 3. Absorption and emission curves.

energy to help form their products. It also represents energy sources that are transferring energy at watt densities that the wire and cable products can tolerate. Below is an equation that can better help one understand the role of temperature. σ (T s4 - Tt4) Stefan-Boltzmann Law: W = Eσ E = Emissivity Factor (1 for Black Body) Ts = Absolute Temperature of Source Tt = Absolute Temperature of Target σ = Stefan – Boltzmann Constant = 3.5 x 10-12 (° F + 460)4 W = Watts/in2 Energy Density or Flux Transferred The above equation shows how small changes in source temperature relate to much larger increases in energy transferred. The implication of this law reveals that a practical limit is quickly reached with respect to industrial heating

applications for the kinds of products and materials under consideration for this presentation.

As an example, if the source temperature is increased 10% from 1500° F to 1650° F, the energy transferred or flux increases from 51 W/in2 to 69 W/in2 or 35%. Below is an equation that provides further key information.

Wein’s Displacement Law: μm = C/T μm = Wavelength of most energetic radiation T = Absolute Source Temperature C = 5200 when applied to absolute temp. in Fahrenheit (°F + 460) C = 2900 when applied to absolute temperature in Centigrade (°C = 273) The above equation will calculate the most energetic or peak operating wavelength of the radiant source when operated at a specific temperature. For example, at 1500° F, the peak wavelength equals 2.7 μm.

Conservation of Energy: α + ρ + T = 1 α = absorptivity or coefficient of absorptance ρ = reflectivity or coefficient of reflectance T = transmissvity or coefficient transmittance

Fig. 5. Infrared heater characteristics.

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The physical characteristics of any material or product (target) to be heated dictate what happens when radiant energy strikes it. Part of the energy is absorbed, other parts are reflected and transmitted.

The absorbed energy heats the target and generally speaking, the reflected and transmitted energy is lost unless these components are “returned” to the heating source. Therefore, it is important to know as much about the absorption characteristics of the target as possible. See Fig. 2.

Practical overview of infrared theory Trick or treat? Most products are made up of more than one material, and whether one is or is not, almost all products are heat sensitive. Tuning a heater to operate at the peak absorption wavelength of one component could be detrimental to another and lead to overheating. What hap-

pens if you start to overheat? Turn the heater down. Well, the heater is now operating at a lower temperature and longer wavelength and has become “tone deaf.”

Industrial infrared heaters are not perfect black body radiators. They are constructed of several different materials. They cannot operate at just one wavelength. What happens to the rest of the energy being emitted? Will the product absorb the leftover energy or will it just be lost? See Fig. 3.

What you should know. Infrared energy delivered to a product by an industrial heater encompasses a range of wavelengths and temperatures. The physical characteristics of a product will determine the rate at which infrared energy is effectively absorbed. Almost all products are highly absorptive at more than one wavelength.

Fig. 6. Short-wave infrared heater characteristics.

Fig. 7. Medium-wave quartz cylinder infrared heater characteristics.

Fig. 8. Medium-wave panel infrared heater characteristics.

66 | WIRE JOURNAL INTERNATIONAL

The key to successfully incorporating infrared energy on a product manufacturing line relates more to watt density and dwell time and less to whether the infrared heater is operating at the peak absorption wavelength of the product.

How aggressively can a product be heated before something bad happens?

How much time is required to transfer the energy needed to get the work done?

Answering those questions will ultimately help a company produce an acceptable product, and the authors believe that the following information can provide a good starting point.

In order to transfer a useful level of heat energy that most

wire and cable products require, the infrared source temperatures need to be relatively high, at least 750°F. Though this temperature seems high relative to the desired product temperature for many applications, an IR heater operating at 750°F is considered a very “gentle” heating condition with a fairly low operating flux (7.23 Watts/in2). See Fig. 4.

So, by inference, infrared sources operating between 750°F and 1800°F are most widely used for wire and cable heating and drying applications. There are also applications in which short-wave infrared, having a much higher source temperature, is effective. Induction heating coils are another approach for preheating conductors when process line speeds are high and/or available space is limited.

Why? The heat transferred in this temperature range is at a level that many processes can accept without undesirable

Fig. 9. Semi-open loop temperature control.

Fig. 10. Closed-loop temperature control.

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The right approach: solve for watt density and dwell time

TECHNICAL PAPERS

System applications for wire and cable

Fig. 11. Preheat fine gauge and braided wire prior to Teflon速 extrusion.

Fig. 13. Cure-extruded jacket on wire/cable.

Fig. 12. Dry PTFE release agent on bare stranded tin/copper wire in line with extruder.

Fig. 14. Cure solvent-based resin impregnated braid on flat copper (magnetic) wire.

Fig. 16. Horizontal multiple-end or multiple pass heat tunnel system.

Fig. 15. Vertical multiple-end or multiple pass heat tunnel system.

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What makes it work: infrared equipment Infrared heater designs and control of IR heaters. One of IR heating’s biggest advantages over other methods of heat transfer is its ability to transfer significant heat energy in a relative small space. This concentrated energy needs to be accurately controlled for repeatable process results. A radiant heater realizes its full potential for a given application only when the proper controls are utilized. The method of control relates the heater to the application. See Figs. 6-8.

The requirements of the application will determine the selection of such items as the type of switching mechanism or voltage control (electro-mechanical, solid state contactor, phase shift or zero cross SCR, etc.) the temperaturesensing device (thermocouple imbedded in the heater or radiation pyrometer) and the type of control circuit (open loop, semi-open loop or closed loop).

For electric IR heaters, solid-state control has replaced outdated on/off contactor controls with percentage timers.

For precise control with negligible temperature swings, the silicon controlled rectifier (SCR) is most suitable.

Heater element versus product temperature control.

Where the temperature of the heater or of the work (prod-

uct) must be the controlling factor, a temperature sensing device must be used. To control by heater temperature, an embedded thermocouple is mounted in a fixed position relative to the heating element. To control by work (product) temperature, a radiation pyrometer or optical pyrometer is used. Each of these devices can be connected in a control loop.

Open-loop control. These circuits do not use heater or work (product) temperature as a control factor. Instead, control is done by manually varying the heater supply voltage. Since there is no corrective feedback from heater temperature or work temperature, open-loop control cannot be used where close control of the process is important.

Semi-open loop control. These circuits use heater temperature as a control factor. A thermocouple is embedded in the heater in a fixed position near the heating element that senses the heater temperature. The closed part of the loop includes the thermocouple, the controller and the heater. The loop is open between the heater and the work.

See Fig. 9.

Closed-loop control. These circuits use the work (product) temperature as it passes out of the radiant heater as a control factor. An optical pyrometer measures this temperature and feeds the information back to temperature controller. The temperature controller compares the actual product temperature signal to the desired set point and sends a proportional signal to the SCR power controller, which varies the voltage to the radiant heater. The radiant output will vary to maintain the preset temperature of the work (product). The system is practical with fast response heaters and requires accurate sensing of the work (product) temperature.

Figs. 10-16 show system uses for wire and cable applications. The above information provides basic information about effective use of infrared heating technology. More specific information can be found by going to www.glenro.com. â–

Richard E. Hoffmann, Jr. is the director of sales for Glenro Inc., Paterson, New Jersey, USA, and is also responsible for recruiting and training the regional sales engineers for the company. He joined the company in 1986, after graduating from The Pennsylvania State University with a B.S. degree in mechanical engineering. Eric P. Hummel is a regional sales engineer for Glenro, and has more than 20 years of experience in the field of industrial heating applications. He joined the company in 1988, after graduating from The Pennsylvania State University with a B.S. degree in mechanical engineering. This paper was presented at WAI’s 80th Annual Convention, Milwaukee, Wisconsin, USA, May 2010.

Hoffmann

Hummel

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effects, such as surface overheating or coating blistering.

The wavelength range of the energy emitted by the IR sources in this temperature range corresponds well with the infrared absorption characteristics of most wire and cable products, coatings, extruded covers and water, thereby resulting in high energy transfer efficiencies.

The use of short-wave infrared can be effective if the total exposure time is very limited because of high process line speeds or if the material to be heated is highly reflective.

Induction coils establish a rapid heat up of a bare conductor which, in turn, transfers heat energy by conduction to other product components.

For the purpose of this discussion, the following review will focus on short-wave and medium- to long-wave infrared heat sources and their practical application for several wire and cable applications. See Fig. 5.

PRODUCTS & MEDIA

PRODUCTS & MEDIA PROD DUCTS New charging system more efficient for copper scrap refining furnace Italy’s ContinuusProperzi SpA reports that it has developed a new charging system for a copper scrap refining furnace with a capacity of 250 metric tons (mt) that can be used with the company’s CCR line, which is able to produce 30 tons of Fire Refined High Conductivity (FRHC) copper rod per hour.

Represented in North America by Properzi International Inc., the company reports that the furnace represents a major step forward as its prior largest size furnace was 150 mt. The daily cycle of such furnaces traditionally follows a schedule of eight hours for charging and melting, eight hours for refining and eight hours for casting and rod rolling. When designing a new furnace of 250 mt, the challenge was to design a system (loading device and charging door) able to contain the charging and melting time of loose scrap within eight hours.

The company said that many concepts were considered but none worked until a new idea came to light: change the geometrical configuration of the furnace by placing a very large door in an elevated position served by a skipcharging machine (pictured). “It worked. Not only is loading of the loose scrap easier and faster, we are able to achieve significantly improved thermal efficiency due to the enormous quantity of scrap inside the fire room.”

The new approach did not change the footprint of the furnace but it is about 3 m taller, the release said, adding that the concept has been used in an order for a 250-ton furnace/30-ton-per-hour rod line that will soon be in operation.

The full advantages of the system are still being determined, but they are believed to include an increase of the system’s thermal efficiency as well as some time savings in the loading and melting cycle, the company said.

Contact: Properzi International Inc., tel. 443-2124320, info@properzi.us; Continuus-Properzi SpA, tel.

39-02-98-84-92-1, sales@properzi.it, www.properzi.com.

Acid purification technology offers multiple advantages U.S.-based PRO-pHx, Inc., supplies Pro-pHx acid purification technology that it reports offers multiple 70 | WIRE JOURNAL INTERNATIONAL

advantages for wire companies that use hydrochloric acid for pickling wire. A press release said that the technology, commercialized 11 years ago, produces a catalytic reaction that causes heavy metals and organics to become insoluble in any type of acid. The insoluble particles, it said, are removed with a Siebec filtration system that can remove up to 10-12 kg of solids per L-TECH cartridge, it said, adding that the cartridges are washable and reusable.

The high solids retention means longer filter runs, requiring less time devoted to changing the cartridges, it said.

Previously, acid concentrations were maintained at 160 g/l and the pickle tanks were purged periodically to control the iron at 80 g/l, the release said. Now, the acid levels are maintained at 80-100 g/l and the iron concentration maintained at 70-75 g/l with no “blowdown,” it said.

Further, lower iron and acid concentrations are drug out into the rinses because the iron is removed in the acid tank and the acid concentration in the pickle tank is 80 g/l instead of 160 g/l. Process savings are due to reduced virgin acid purchases, reduced caustic purchases for neutralization and reduced volumes of filter cake from the wastewater treatment system, it said.

Contact: PRO-pHx, Inc., tel. 501-609-9808 or cell 501282-3699, prophxinc@aol.com, www.pro-phx.com.

New dosing unit can process multiple free-flowing materials Germany’s Woywod GmbH & Co. KG has launched a new model, the PLASTICOLOR 2500 Dosing Unit, that has a capacity up to 150 kg/h and can process all freeflowing materials such as powders, granules, regrinds, flakes and agglomerates.

A press release said that the 2500 model has a redesigned material inlet that results in a more precise and constant dosing. The quick discharge from the larger diameter and easy action slide offers clear advantages in the unit’s handling capabilities, it said, adding that an option allows the discharge to be upgraded to a pneumatic-operated version. The neckpiece slide’s larger diameter allows materials that are more coarse to flow without any problems while there is also more dust content control from a modification of the sealing at the screw shaft, it said. The motor and gearbox have been installed with newly designed backpressure protection and a three-claw coupling was used for better centering, it said. Finally, an optional automatic screw identification could be installed to prevent dosing error by using the wrong screws, it said.

Ultrasonic unit offers superior splicing U.S.-based Sonobond Ultrasonics reports that its Dual Head SpliceRite™ ultrasonic wire splicer represents a major breakthrough in fast, dependable wire splicing.

A press release said that the wire splicer can easily process wire bundles with cross-sectional areas of 48 to 100 sq mm as well as weld tinned wires up to 60 sq mm, a range that no other ultrasonic unit can equal “with just one hit.” The ultrasonic wire splicer, it said, is especially suited for assembling heavy cables used for cars, trucks and industrial machinery.

The unit has two welding heads, one on each side of the

weld area, and can accurately weld nonferrous, similar and dissimilar metals with repeated accuracy, the release said. The welds, it added, have excellent conductivity as the unit creates solid-state metallurgical bonds without the need for filler materials or for clipping, soldering, crimping or dipping. “It’s an environmentally-friendly, cost-effective process that produces no waste. And it consumes only minimal energy.”

Contact: Sonobond Ultrasonics, tel. 610-696-4710, info@sonobond.com, www.sonobondultrasonics.com.

Optical fiber cable technology has been further improved U.S.-based Corning Cable Systems LLC, part of Corning Incorporated’s Telecommunications segment, recently highlighted its latest innovations in data center and local area network (LAN) solutions at the 2011 BICSI Fall Conference & Exhibition in Orlando.

A press release said that the company’s interactive exhibit showcased a variety of optical fiber cabling solutions for enterprise applications, particularly recent userfocused improvements to its Pretium EDGE® Solutions

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Contact: Woywod GmbH & Co. KG, www.plasticolor.de.

PRODUCTS & MEDIA

for data center applications. Enabled by Corning® ClearCurve® bend-insensitive multimode fiber, Pretium EDGE Solutions address the needs of ease-of-use, scalability, termination density and technology future-proofing as well as allowing for up to 35% faster installation, it said, from new features such as snap-in routing guides, mounting brackets and a reduced cable leg outside diameter to make installations even more convenient.

The release said that Corning also showcased its highperformance UniCam® Connectors, which offer leading optical performance in a fast, easy field-termination solution; its OptiSplice® M90e Fusion Splicer, which offers the accuracy of a power-through splice measurement of Cornings’ core alignment LID-SYSTEM™ process, as well as the speed and versatility of the passive core-alignment technology, known as the Core Detection System (CDS); and more.

Contact: Corning Cable Systems, tel. 828-901-5000, www.corning.com/cablesystems.

High-temp cable line is expanded U.S.-based TPC Wire & Cable Corp. has added 500-K single and multi-conductor cable to the company’s current high-temperature cable line known as Thermo-Trex®.

A press release said that the addition of the 500-K product line fills a need for high temperature/high performance cables for use in abrasive environments. The 500-K products, it said, are jacketed with an aramid fiber to provide outstanding protection against abrasion, and have silicone insulation that performs extremely well in high temperature environments. Designed for industrial applications, the product is rated for 600 volts and carries a 200°C temperature rating, it said.

“The value-added proposition of the fluoropolymer layer in our 500-K (will reduce) … end-user costs and downtime” said TPC Product Manager David Sedivy.

Contact: TPC Wire & Cable Corp., tel. 216-525-4400, customerservice@tpcwire.com, www.tpcwire.com.

Lightweight wire stripper can process solid and stranded wire The Eraser Company describes its HTS1C Thermal Wire Stripper as a lightweight, hand-held unit for stripping solid and stranded wires.

The HTS Series from the U.S.based company, a press release said, is especially effective on insulations such as P.T.F.E. and Teflon, with the temperature at the stripping elements variable up to 1100°F (594°C).

The HTS1C has a cradle switch, and when the tool is placed in the cradle, heat to the elements is disconnected.

The handpiece is only 7.25 in., and a FybRglass® brush is provided with each unit to clean the elements periodically, it said.

The Eraser Company, Inc., which notes that it is celebrating its 100th anniversary in business, manufactures a wide range of industrial products including wire, cable, and tubing cutters, wire and cable strippers, wire twisters, wire brush wheels, dereelers, infrared heating equipment, measuring tools and FybRglass erasers.

Contact: The Eraser Company, tel. 315-454-3237, www.eraser.com.

Gas-fired box furnace designed to anneal aluminum wire spools

What makes the product unique, the release said, is the fluoropolymer layer under the aramid fiber jacket. In dynamic/flexing applications, this layer acts as a lubricant between the silicone and aramid layers, reducing internal abrasion, increasing cable performance and prolonging cable life to make this an ideal choice for high temperature dynamic applications such as festoon systems, it said.

It added that the fluoropolymer layer also provides an additional moisture barrier for added protection in harsh environments.

72 | WIRE JOURNAL INTERNATIONAL

U.S.-based Wisconsin Oven has designed and manufactured a gas-fired heavy box furnace to anneal spools of aluminum wire used in electrical cables.

A press release said that the heat-treating furnace has total chamber dimensions of 14 ft, 6 in. wide x 13 ft 9 in. long x 17 ft high and a maximum operating temperature of 800ºF. The furnace shell is constructed with Wisconsin Oven’s patented, high-efficiency Expandable Surface™ design, which includes six in. of semi-rigid, batt-type insulation and a segmented sheet metal interior, it said.

The outer shell is made of 3/16 in. carbon steel plate and the inner shell and ductwork are 20 gauge aluminized steel while the annealing furnace has one vertical lift, electrically operated door with counterweight, it said.

The furnace heating system consists of four tube-fired burners and a combustion blower, a recirculation system with a 39,000 CFM plug-style blower that uses a combi-

Extrusion mandrel can provide a better surface for faster production U.S.-based Applied Plastics Co., Inc., reports that its PTFE Natural® Extrusion Mandrel for manufacturing and forming catheter tubing provides a smooth, slippery surface to permit faster production.

A press release said that the extrusion mandrel is biocompatible and features a 0.5 dynamic coefficient of friction. Designed for extruding small diameter catheter tubing, this silverplated copper wire with the PTFE Natural coating is supplied in continuous lengths on spools, it said.

The extrusion mandrel, which allows more than 25% elongation without flaking and failure, is available in .010 in. to .080 in. sizes, meeting tolerances of up to +/-.0003 in., depending upon size, it said. The anti-stick extrusion and forming mandrel is chemically inert and capable of withstanding up to 315°C (600°F) service, it said.

Contact: David Ring, Applied Plastics Co., Inc., tel. 781-762-1881, davering@appliedplastics.com, www.appliedplastics.com.

Line of laser wire strippers expanded U.K.-based Spectrum Technologies PLC announced that it has expanded the range of its SIENNA line of laser wire strippers range with the introduction of the SIENNA 600 model, which targets high-volume, high-precision electronic manufacturing applications.

A press release said that the 600 series range of freestanding, fixed-beam laser systems features a high-speed moving stage that offer a strip area of 400 mm by 300 mm. The large process area means the system is particularly suited to large batch processing or for long strip requirements for wires with ODs of up to 6 mm, it said.

The unit can process to speeds of 300 mm per second, and has a PLC control system that ensures strip accura-

PRECISE…

When it comes to making cold welders and dies, we don't believe in short cuts. We don't skimp on design or manufacture and all our dies are precisionengineered by our own skilled craftsmen in the UK. With a PWM cold welder, you get precisely what you need: strong, consistent welds, plus the expert technical support you'd expect from a company with over 25 years' experience of cold weld technology and applications.

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

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

MADE IN THE UK

Welders and dies available from PWM or authorised distributors only.

DECEMBER 2011 | 73

PRODUCTS & MEDIA

nation airflow design to maximize heating rates and temperature uniformity.

Contact: Wisconsin Oven, tel. 262-642-3938, sales@wisoven.com, www.wisoven.com.

PRODUCTS & MEDIA

cies of +/-0.1 mm, it said. The system can incorporate different laser types depending on the end application, so it can be specified for standard cable stripping, metallic shield scribing or fine magnet wire stripping, it said, adding that it is especially well suited for processing small micro-coax cables used in electronic and medical devices.

Contact: Spectrum Technologies PLC, www.spectrumtech.com.

MEDIAA Updated website highlights scope, range and expertise of company U.S.-based Heatbath® Corporation, a supplier of cleaning and coating products for the ferrous wire industry, has updated its website to include newly engineered technologies for zinc phosphating, acid pickling and lubrication as well as a wide range of products for surface pretreatment and corrosion protection.

In addition to the newly updated design and easy navigation, one of the new features is a product search section that makes it simpler to find the most appropriate metal-finishing and heattreating products, a press release said. There’s also an instructional video page that provides practical information about topics such as: Shipping Freezable Products; Collection and Handling of Parts for Salt Spray Testing; Salt Spray Operation ASMT B-117; and Titrating Free and Total Acid Using A pH Meter.

Heatbath’s website also features industry news, current events, technical articles, customer testimonials and links to the company Facebook page. Visitors can also sign up for the company’s quarterly e-newsletter.

Contact: Cheryl Hickman, Heatbath Corporation, tel. 413-452-2000, ext. 336, cheryl@heatbath.com, www.heatbath.com.

Crosshead manual is downloadable at company website in 3 languages U.S.-based B&H Tool Company, a supplier of extrusion tooling technology, has made its operations manual for adjustable center crossheads available for instant download at its website.

A press release said that the new, updated document is available in a PDF format in English, Spanish and Chinese. The manual, it said, “is the most comprehensive of its kind, and provides a user-friendly way for workers

74 | WIRE JOURNAL INTERNATIONAL

to read and understand set-up, breakdown, tip and die adjustment and other critical tasks.” It described the manual as being highly detailed, and with instructions that are easy to read. “By making the manuals instantly available, at no cost, B&H shows its dedication to helping customers optimize the quality and consistency of extruded product, reduce set-up and scrap, and facilitate faster line speeds,” it said.

The B&H tool crosshead, the release said, “is used worldwide by manufacturers of insulated wire, jacketed cable, tubing, hose, pipe and profiles.” The manual as well as a crosshead extrusion cleaning manual, can be found at www.bhtool.com, using the links at the bottom of the home page.

Contact: Peter Neville, B&H Tool Company, tel. 800272-8878 or 760-471-8949, pneville@bhtool.com, www.bhtool.com.

New book on Toyota culture offers advice that applies to all fields A new book on the Toyota Culture written by Toyota team members, One Team on All Levels: Stories from Toyota Team Members, Second Edition, is described as “not another technical explanation” of the Toyota Production System (TPS).

A press release said that the book illustrates the culture it creates through stories by employees from various levels of the organization that show how Toyota’s presence in Kentucky has transformed the professional and personal lives of those who worked for the company. The book, it said, demonstrates the culture created by the Toyota Production System; examines how the TPS principles and precepts serve as models for servant leadership; presents valuable insights from a wide range of Toyota team members, from hourly to management-level; and shows how Toyota partnered with the city of Georgetown and its community Supplying a first-hand look at the principles that have transformed Toyota into one of the leading manufacturers in the world, the book includes chapters that address how this manufacturing giant was able to survive and improve in the midst of a down economy and recent recalls, the release said. “The real-life stories supply an unprecedented look at how the Toyota precepts and the 14 Toyota Way principles can help you improve morale, avoid layoffs, and create a culture of continuous improvement within your organization.”

The 322-page book, which was published in September, costs $29.95. It is offered by Productivity Press, a division of The Taylor and Francis Group.

Contact: Productivity Press, www.productivitypress.com. ■

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CAREER OPPORTUNITIES SALES & MARKETING MANAGER. Cable Components Group, LLC (CCG), an engineering driven extrusion company manufacturing a diverse range of profile extrusions; tubing; slit films and tapes; mono-filaments and multi-filaments; and non-wovens is looking for a Manager of Sales & Marketing.

appears in print or on-line), P.O. Box 578, Guilford, CT 06437-0578 USA. PAYMENT POLICY: All ads must be pre-paid.

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

The ideal candidate must have a technical competence with a B.S. in

Engineering and/or a B.A./B.S. in Business. An employment history and

sales/marketing exposure to diverse industries to include wire and cable, filtration, photovoltaic, and alternative energy is desirable. A knowledge of Fluoropolymers (FEP, MFA, PFA, ETFE, ECTFE, PVDF) and other engineered resins such as PPS, PES, and PEEK is a critical aspect of the marketing development role, which includes the positioning of the aforementioned materials in this entrepreneurial compa-

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

FOR SALE 7 1 1 5 1 3 3 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1

- WARDWELL 12-Carrier Braiders - SPIRKA 24-Carrier Braider, Model 24N4, 1990 - SPIRKA 16-Carrier Braider, 500mm Take-up and Payoff - NEB 12-C, 16-C, 24-C #2 Braiders, Long Legs, Motors - NEB 48-Carrier Harness Braider - TMW 24-Carrier Cable Braiders, 6” Horn Gears - COOK BH30 Bunchers - EDMANDS 18-Wire, 6+12, 16” Planetary Cabler Line - EDMANDS 36-Head 16” Rigid Strander - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 - CONAIR 39” Continuous Belt Caterpuller Capstan, Model 6-39 - Continuous Belt Caterpuller Capstan, 42” Belt Length x 8” Width - DAVIS STANDARD 4.5” 24:1 L/D Extruders - D/S 2.5” 24:1 L/D Hi-Temp Extrusion Line - D/S 2” 30:1 L/D Hi-Temp Extruder - ENTWISTLE 2” 24:1 L/D Extruder, Model TFII-2000-24 - WAYNE 1.5” 30:1 Extruder, 15HP Motor, Panel - SKALTEK 1600mm Motorized Payoff , Model A16-4K - HALL 40” Motorized Payoff w/Dancer - CLIPPER DF6 Dual Cone Flyer Payoff (24” Reels) w/Reel Jacks - ROSENDAHL 630mm Parallel Axis Dual Reel Take-up, never used - NOKIA Model EKP100 Parallel Axis Dual Reel Take-up - NOKIA Model EKP50 Parallel Axis Dual Reel Take-up, 1997 - SPHEREX 18” Dual Reel Take-up, refurbished

1 1 2 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1

- CLIPPER Model SP16 Dual Spooler - TULSA Model WTR-2416 Respooler - AL-BE Model MS12 Respoolers, 12” Reels - REEL-O-MATIC Model PRR1 Rim Drive Powered Reel Roller - REEL-O-MATIC Model RD-5 Rim Drive Take-up w/Coiling Head - STANDARD MILL SUPPLY Bobbin Winders w/Payoffs - TEC Model DTC630 D.T. Twister - ENTWISTLE 4-Wire 24” D.T. Twisters, Model 4WDT24 - FINE Preheater, Model IP4000-180-1, 2007 - SCHLEUNIGER JS8300 Jacket Stripper - SCHLEUNIGER US2100 Stripper - SCHLEUNIGER CS9050 Cut & Strip Machine - KOMAX Model KAPPA 320 Cut & Strip Machine, 2009/10 - EUBANKS Model 4000-04 Cut and Strip Machine - EUBANKS Model 9800-03 Cut & Strip Machine - GETTIG Tape and Labeling System - ERASER Model TW-20 Wire Twister - IDEAL 940 Bench Stripper (now ARTOS 45-940) - CARPENTER 3-Head Stripper, Model 74-C - CARPENTER Strippers, Model 70-B - MICRODIA Crosshead, Model M9000/10XFL - TECHMET 183 LaserMike - BETA Lump Detector, Model LN1025XY-DL, 12/05 - BETA “Accuscan 3010”, 2006

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

DECEMBER 2011 | 75

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”)

ny. Extensive travel required to fulfill the company’s sales and marketing philosophy of personal selling and relationship building with key existing and new customers. Strong computer and analytical skills are a must to include Microsoft Office, i.e., Word, Excel, PowerPoint, Outlook, Project, etc.

More than 1,200 second-hand machines in stock Reconditioned 6 block double capstan drawing machine

New machines designed for your production New Bongard drawing line for trolley wire

Bongard Machines USA Bongard Machines USA LLCLLC 832160 Mill· 6920 LakePointe RoadInverness Way Suite Fort Wayne, IN. 46845 Fort Wayne, IN 46804, USA Phone 260-338-2634 Phone +1 260 225 4510 Fax 260-338-2635 Fax +1 260 225 4513 E-Mail chris.z@bongard.us E Mail jh@bongard.us www.bongard.us www.bongard.us

76 | WIRE JOURNAL INTERNATIONAL

The candidate’s metrics of success will embody meeting and exceeding customer demands for new and existing products and will include a passionate commitment to long range new product development to ensure the company’s sustainability as a competitive and viable manufacturing entity throughout this decade.

Please submit resume to: Cable Components Group, LLC, Human Resources Dept., 185 South Broad St., Pawcatuck, CT 06379. Email: CCGHR@cablecomponents.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 and managers.

Contact: E-mail Peter Carino at pcarino@wireresources.com or email Jack Cutler at jcutler@ wireresources.com, or visit the Wire Resources company website at www.wireresources.com.

Wire Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE.

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 WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, color-o-meters and pointers). Tel: 727863-4700 or by e-mail, please send to urbassoc@verizon.net.

DIES 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.

SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service.

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

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@ comcast.net. ■

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WIRE JOURNAL

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INTERNATIONAL

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LAST NAME

FIRST NAME

TITLE

M.I. .

COMPANY

ADDRESS

❏ BUSINESS OR ❏ PERSONAL

CITY OR TOWN

STATE

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

ZIP/POSTAL CODE

COUNTRY

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

A. Which ONE of the following best describes your company’s type of business?

WIRE & CABLE MANUFACTURING

FASTENERS, WIRE FORMING, FABRICATING

WIRE END-USER

10 ❏ 20 ❏ 30 ❏ 40 ❏ 50 ❏ 53 ❏ 55 ❏

61 ❏ 62 ❏ 64 ❏ 66 ❏ 68 ❏ 69 ❏

11 ❏ 12 ❏ 13 ❏ 14 ❏ 15 ❏ 16 ❏ 17 ❏

Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) Other Metal (Rod/Bar, Bare Wire, Both) Electrical Wire & Cable (Insulated Wire) Communications Wire & Cable (Insulated Wire) Fiber Optics

Fastener Manufacture Four-Slide Forming Hot and/or Cold Forming & Heading Spring Manufacture Wire Cloth Mesh Screening Other Forming and Fabricating (please specify): _________________________________

Appliance Communications (Voice/Data) Computer Construction/Building Electrical (Equipment/Components/Power) Transportation/Vehicular Wire Formed Durable Goods

SUPPLIER TO THE WIRE & CABLE INDUSTRY

OTHER

72 ❏ Machinery 74 ❏ Process, Accessories, Materials

80 ❏ Service Centers, Distributors & Warehouses 90 ❏ Consultants 92 ❏ Government, Library & Allied

B. Which ONE of the following best describes your primary job function?

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

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

50 ❏ Sales & Marketing 90 ❏ Other (please specify): ________________________

C. YES! I wish to receive a FREE subscription to the Wire Journal International.

SIGNATURE REQUIRED

DATE

Fax to: (001) 203-453-8384 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

ADVERTISERS’ INDEX

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

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

AEB International Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .75

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

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .51

GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

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

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11, 71

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .76

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

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

MIND THE GENERATION GAP

Great minds are developing. Engineers. Metallurgists.

Innovators. The future of the industry depends on them.

Find them online. Connect with them. Influence them.

And meet them halfway through WAI.

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

78 | WIRE JOURNAL INTERNATIONAL

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

Messe Düsseldorf GmbH . . . . . . . . . . . . . . . . . . . . . . . . . .19

Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Parkway-Kew Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Power Sonics LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Talladega Machinery & Supply Co . . . . . . . . . . . . . . . . . .23

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

Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . . . . .17

Unience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

Reel-O-Matic Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Rosendahl Maschinen GmbH . . . . . . . . . . . . . . . . . . . . . .45

Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .79

DECEMBER 2011 | 79

ADVERTISERS’ INDEX

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

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE Witels Albert USA Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

February 2012 WJI • Düsseldorf preview Advertising Deadline: Jan. 1, 2012

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

WIRE ASSOCIATION INTERNATIONAL ADS WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

WAI Webinar (spark testers) . . . . . . . . . . . . . . . . . . . . .30-31

WAI Operations Summit & Wire Expo 2012 . . . . . . . . .46-47

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

80 | 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

India Wire & Cable Services Pvt. Ltd. (WCS) 501, Rainbow Plaza, S. No. 7 Pimple-Saudeagar Vil. Rahatani, Pune - 411017, India Huned Contractor mobile - +91 988 1084 202 hcontractor@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