Equipment

WIRE E JOU JOURNAL JULY 2014

速

INTERNATIONAL www.wirenet.org

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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CONTENTS

Volume 47 | Number 7 | July 2014

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

F EATURE

Calendar . . . . . . . . . . . . . . . . . 8 Industry News. . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People. . . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26 Fastener Update . . . . . . . . . . 28 WAI News . . . . . . . . . . . . . . . 30 Chapter Corner . . . . . . . . . . . 36 Products . . . . . . . . . . . . . . . . 54

Equipment . . . . . . . . . . . . . . . . . . 32 If you weren’t able to attend wire Düsseldorf, this feature presents a range of the equipment that was showcased there by more than a thousand exhibitors.

Of note, the Products section that follows presents more equipment from the show as well an assortment of products that were displayed at Wire Expo.

Technical Papers . . . . . . 66-84 Classified . . . . . . . . . . . . . . . 85 Career Opportunities . . . . . . 85 Ad Index . . . . . . . . . . . . . . . . 87 Advertisers’ Index . . . . . . . . 71

Next issue August 2014 • Industry Focus: Evolving industry standards • Preview: wire China

T ECHNICAL PAPERS Technology production and properties of high-strength, high-conductivity nanostructured copper-silver wires for a new type of overhead line conductors Tadeusz Knych, Eliza Sieja-Smaga, Andrzej Mamala, Paweł Kwaśniewski, Grzegorz Kiesiewicz, Beata Smyrak and Kinga Korzeń . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Effects of niobium additions to a vanadium microalloyed H-C wire steel Emmanuel De Moor and Stephanie L. Miller. . . . . . . . . . 74 Changes in mechanical parameters of stored patented cold-drawn steel wire Rüdiger Lux, Ulf Kletzin, Veronika Geinitz and Peter Beyer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Cover: New equipment displayed at wire Düsseldorf included a tilted rotary braider introduced by Niehoff GmbH.

JULY 2014 | 3

CONTENTS

INSIDE THIS ISSUE NEW STUFF AT WIRE DÜSSELDORF . . . . . 33

...

In April, the world’s largest event for the wire and cable industry, wire Düsseldorf, included a record display of technology and services to explore. The focus at the Fairgrounds in Germany, as ever, was on the equipment, with an impressive range of just about anything a plant could need. This feature presents a slice of what was on the show floor.

Attendees who traveled to Indianapolis, Indiana, in May for WAI’s traveling event found new and upgraded products at Wire Expo. The Products section, which follows the equipment feature, includes more equipment that was displayed at Düsseldorf equipment as well as new ideas, from reels and colorants and measuring equipment to bows that were presented at Wire Expo.

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AND ALSO AT

WIRE EXPO 2014 . . 38

EDITORIAL WIRE JOURNAL

EDITORIAL

®

Tech possibilities can blaze new trails ... until they come across bureacracy (and poles) If ever a company has blazed a technology trail for the ages, it is Google, a business that was founded on the Internet but has since gotten physical, bringing optical fiber to cities. It was among the consortium that built the 10,000 km Unity Trans-Pacific cable that links Japan and the U.S., and it recently announced that it is considering a new cable line that would connect data centers in Oregon and elsewhere with Japan.

But in Seattle, Washington, which Google had strongly considered for its first “fiber city,” the mammoth company encountered an obstacle it could not overcome: bureaucracy. In an interview with Crosscut, Bill Schrier, the now-retired Chief Technology Officer for the city, explained why Seattle, which had been on the “short list,” could not make the cut with Google. It took Kansas City one day to authorize a contract for Google, but Seattle’s city council and lawyers have a penchant for haggling over details and holding endless public hearings, said Schrier, who below describes what happened.

One key culprit was the 100,000+ utility poles the city co-owns. For Google to lease the poles would cost $28.12 a year. Per pole. Related permits could include ones for street use, land use and environmental. Further, as there already were lots of wires on the poles, they would have to be inspected and possibly replaced. At one point, the city’s backlog for such pole surveys was 18 months long.

Beyond the physical requirements, Seattle’s DOT requires that 60% of homeowners within 100 feet of a proposed new electrical cabinet must give written consent, this in areas that include many renters.

Also, requiring Google to offer service to all the city’s residents or none would be prohibitive.

In contrast, Kansas City officials, who really wanted to become a Google “fiber city,” okayed a 10-year deal in which they agreed to review all permits in five days; provide free access to all its poles, conduit, rack space, node, buildings and land; and not charge any permit or inspection fees. “Did Kansas City residents complain about these terms? You bet they did. According to the San Jose Mercury News, ‘they couldn’t get the service soon enough.’ ’’ Google, which had visited Seattle and later gave up on it, has since named 34 more potential fiber cities. Seattle was not on the list. In a way, one could personify Seattle as a customer stubbornly clinging to its established structure. Techology inevitably will drive the future, but human nature is not always quick to give up its ways.

Mark Marselli Editor-in-chief

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

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli Media Production Manager | Paul Streeto Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing & Corporate Communications | Janice E. Swindells Proofreader | Livia Jacobs Publications Committee Dane Armendariz | Chemetall Ferruccio Bellina | TKT Group/President ACIMAF, Italy Malcolm 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 editorial@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. © 2014 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: 313-761-4700.

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

6 | WIRE JOURNAL INTERNATIONAL

CALENDAR

CALENDAR Sept. 24-27, 2014: wire China 2014 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Oct. 28-30, 2014: Wire & Cable India Mumbai, India. To be held at the Bombay Convention & Exhibition Centre. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Nov. 9-12, 2014: 63rd IWCS ConferenceTM Providence, Rhode Island, USA. To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, www.iwcs.org.

Nov. 26-28, 2014: MFSH 2014 Shanghai, China. The China (Shanghai) International Exhibition on Platemetal, Bar, Wire, Steel Rope, Metal Processing and Setting Equipment 2014. Contact: Shanghai Aoya Exhibition Co., at 86-21-3351 8138, ayexpo@vip.163.com.

April 28-30, 2015: Interwire 2015 & WAI’s 85th Annual Convention Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its biennial trade show, technical programs and 85th Annual Convention.

Contact: WAI, USA. Tel. 001-203-453-2777; fax 001203-453-8384; www.wirenet.org.

April 4-8, 2016: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

June 8-9, 2016: WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. This WAI event, which will be held at the Mohegan Sun Resort Center, will include its trade show, technical programs and WAI’s 86th Annual Convention. WAI, USA. Tel. 001-203-4532777; fax 001-203-453-8384; www.wirenet.org.

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

Sept. 8, 2014: New England Chapter 20th Annual Golf Tournament Ellington, Connecticut, USA. The New England Chapter will return to the Ellington Ridge Country Club. Contact: WAI’s Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org.

Oct. 2, 2014. The Vannais Southeast Chapter’s 13th Annual Golf Tournament Conover, North Carolina, USA. The Southeast Chapter will return to the Rock Barn Golf and Spa. Contact: Art Deming, tel. 252-955-9451, art.deming@nexans.com.

8 | WIRE JOURNAL INTERNATIONAL

Oct. 20, 2014. Western Chapter’s 14th Annual Golf Tournament Fontana, California, USA. The Western Chapter will return to the Sierra Lakes Golf Course. Contact: John Stevens, tel. 905-851-5633, jstevens@emc-wire.com.

April 28-30, 2015: Interwire 2015 & WAI’s 85th Annual Convention Atlanta, Georgia, USA. See main listing.

June 8-9, 2016: WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. See main listing.

INDUSTRY NEWS

INDUSTRY NEWS Furukawa reports 1100-km cable order for power project in Canada

ITC imposes anti-dumping penalties on steel wire from China and Mexico

Suzhou Furukawa Power Optic Cable Co., Ltd., a subsidiary of Japan’s Furukawa Electric group, has won a contract to supply 1,100 km of optical ground wire (OPGW) with the company’s all-dielectric self-supporting (ADSS) fiber optic cable as well as fittings for what was called one of the largest power transmission projects in Newfoundland, Canada.

The U.S. International Trade Commission (ITC) will impose anti-dumping (AD) duties on steel wire from China and Mexico.

A press release said that the ITC six-member commission unanimously found that the U.S. industry is materially injured by imports of PC tie wire from China and Mexico.

It noted that the U.S. Department of Commerce previously determined that the products were sold at less than fair value.

Per the ITC decision, Chinese and Mexican producers and exporters that have sold the PC tie wire in the U.S. market face AD duties ranging from 31.40% to 35.31% ,and 9.99% respectively.

The release said that the Commerce Department launched the investigation last year in response to the petition filed by Insteel Wire Products Company and Davis Wire Corporation, which alleged that exporters and producers in China, Mexico and Thailand sold these products in the U.S. market at lower prices.

An OPGW cable from Suzhou Furukawa Power Optic Cable Co., Ltd. A press release said that the order is for a power transmission project from Nalcor Energy that links an 824-MW hydroelectric power plant in Labrador with a substation in Newfoundland. It said that the cables have to cope with frigid environments as severe as -50º below zero, as well as severe conditions of snow and icing. Per Nalcor Energy, the high-voltage, direct current (HVdc) system is the first of its kind in the province, and includes 400 km of transmission line in Labrador and 700 km on the island as well as 35 km of underwater cable that will cross the Strait of Belle Isle from Forteau, Labrador, to Shoal Cove, on the island.

The OPGW, it said, embeds an optical fiber inside the ground wire that is installed to protect the high-voltage overhead power transmission lines from a lightning strike.

Hiroyuki Otake, director and vice president of Furukawa Electric, said that the company’s OPGW business has also expanded in Brazil, where its subsidiary, Furukawa Industrial S.A. Produtos Electricos, has seen strong increases in sales for its OPGW with unique engineering technology. He added that Furukawa Electric is focusing on directly selling products made by their subsidiaries outside Japan without going through Japan (Outto-Out business).

The release said that there has been steady demand for OPGW in recent years due to power transmission infrastructure investment in emerging Asian and African countries. “Demand for renewable energy systems including wind, solar, hydro, and the like are expanding even in developed countries, primarily in the U.S., resulting in vigorous investment in power transmission lines,” it said.

U.S. company seeks relief from imported steel nails from 7 countries Mid Continent Steel & Wire, Inc., the parent company of Mid Continent Nail Corporation, has filed antidumping (AD) and countervailing (CV) duty cases against imports of steel nails from India, Korea, Malaysia, Oman, Taiwan, Turkey and Vietnam.

A U.S. wire company is seeking to penalize some imported steel nails that allegedly are being unfairly traded.

A press release said that Mid Continent, one of the largest U.S. producers of steel nails, requested that the U.S. Department of Commerce (Commerce) and the U.S. International Trade Commission (ITC) impose duties on the targeted steel nails, alleging that they are being unfairly traded. The petition, which cites dozens of foreign government programs that allegedly provided unfair subsidies, seeks dumping margins for India (543.25%), Korea (57.48%), Malaysia (35.49%), Oman (166.81%), Taiwan (106.45%), Turkey (99.09%) and Vietnam (115.29%). The petition covers certain steel nails up to 12 inches long that are produced from any type of steel.

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

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imports are being dumped and unfairly subsidized, and the ITC will determine whether the U.S. steel nail industry has been materially injured, or is threatened with injury, by reason of the imports. The ITC must reach its preliminary determination of material injury or threat of material injury no later than July 14, 2014. Commerce is required to announce preliminary CV duties in 85 days and preliminary AD duties in 160 days, though both deadlines may be extended. Once Commerce makes affirmative determinations, U.S. Customs and Border Protection will require importers to pay cash deposits or post bonds equal to the estimated amounts of dumping and unfair subsidies. The entire investigative process takes approximately one year. Final determinations of injury, dumping and unfair subsidies should occur in mid-2015.

Political twist to plans for submarine cable to link Finland and Germany The Finnish government has announced plans to fund a new submarine cable connecting Finland and Germany, bypassing Sweden, in what has been described as a snub related to alleged spying by the U.S. Expected to launch as early as 2015, the new cable will join up with Finland’s fiber network that runs along the nation’s railway lines. The new cable was announced late

JULY 2014 | 11

INDUSTRY NEWS

Per the release, “Dumped imports of steel nails from these countries constitute a large and increasing share of the U.S. market. Imports of nails from these countries surged nearly 90% from 2011 to 2013, growing from 134,821 short tons in 2011 to nearly 255,639 short tons in 2013. Shipments of steel nails from the countries identified in the Petition accounted for 51.2% of all nail imports in 2013, compared to 30.4% in 2011. This enormous increase far outstrips the improvements that have been made in the U.S. housing market in recent years.”

The release also noted that “this set of cases comes two years after (Commerce) imposed AD duties on imports of steel nails from the UAE, and six years after AD duties were imposed on imports of steel nails from China.”

Both those orders remain in place, and in January 2014, (Commerce) renewed the China order for at least another five years, it said.

“As this third set of cases in seven years should make clear, we will continue to vigorously defend our markets, our workers, and the bedrock principles of free and fair competition,” Mid Continent President David Libla said in the release. “We are and have always been ready and willing to compete with any producer in the world, so long as they abide by the trade laws their countries have agreed to follow. That will not change.”

Per the release, Commerce will determine whether

INDUSTRY NEWS

last year, shortly after Swedish TV reported that the country had helped the U.S. spy on Russia.

The report, based on documents leaked by NSA whistleblower Edward Snowden, quoted a document stating that Sweden’s National Defence Radio Establishment (FRA), the agency responsible for electronic surveillance, helped supply information on Russia to the U.S. Finland Communications Minister Krista Kiuru stressed the importance of Finland being a significant safe harbor of information, “where companies and countries can safely place their critical data.”

Per a report in zdnet.com, shortly after Finland announced its cable plan, it reportedly rejected a proposal

by Sweden’s TeliaSonera International Carrier to build a privately-owned fiber network from St Petersburg to Germany that would have passed through Finland and the Baltic countries. Finland’s Baltic Sea cable plan is being led by state-owned company Governia, which acquired Corenet Oy, a data cable company that owns a 7,100 km network fiber optic network in Finland, according to Finnish broadcaster YLE. However, not everyone is in accord with the above-cited project. A book by Petteri Järvinen presents a different perspective, one that is not quite so complimentary. Basically, he says that Finland’s much celebrated action to maintain its reputation is far from assured of achieving its goal.

Huawei subsidiary wins contract for a Russian submarine cable system Tehkompaniya Huawei, a subsidiary of China’s Huawei Technologies Co., Ltd., has won an order from Russian telecom provider Rostelecom for construction of a submarine cable system to connect the Sakhalin, Magadan, and Kamchatka regions in Russia.

Per a report in Lighwave, “The project will create a highly reliable communication link for seismic areas with difficult climatic conditions, which will provide modern high-quality telecommunications services to residents of Kamchatka, Magadan, and Sakhalin regions, which cannot be achieved with the help of satellite communications,” said Rostelcom President Sergei Kalugin.

“Construction of a new undersea link will solve the issues of the digital divide in the Far East,” he said.

The contract, the story said, calls for the undersea cable system to have four fiber-optic cables reaching a distance of 1855 km, with maximum throughput of 8 Tbps. The contract includes supply of equipment, accessories, and materials, as well as execution of works and services, including all the necessary work on the list of underwater and terrestrial parts of the system.

The total cost of the “works and services” for the overall project was approximately $87 million, the story said.

Preparatory work to produce cables and equipment has begun,

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Southwire division reports startup of SCR system for customer in Taiwan

German wire and cable company plans to open a plant in Macedonia

Southwire’s SCR technology division announced that it has started up an SCR system for a company in Taiwan.

A press release said that a 2500 SCR system has undergone start-up in Kiaoshiung, Taiwan. The system, ordered

by Ruyu Metals Co. Ltd., is capable of hourly production of 20 metric tons, of 8 mm, 9.5 mm, 12.7 mm, 16 mm and 18 mm, utilizing a No-Twist® rolling mill from Seimens Industries Inc. (formerly Morgan).

Southwire’s SCR Technologies provides continuous rod system equipment and technology for the production of copper and aluminum rod. SCR Aluminum rod systems range in capacity from 2.5 to 15 metric tons per hour of EC aluminum and alloyed aluminum rod. SCR copper systems range in size from 7 to 54 metric tons per hour of ETP copper rod or other profiles such as flats. SCR shaft furnaces and furnace systems for rod, billet and anode casting are available with capacities ranging from 7 to 60 metric tons per hour.

ODW Elektrik, a German cable and wire manufacturer, is planning to set up a new production facility in Macedonia’s Ohrid-Struga free economic zone.

A story in European Plastics News said that Macedonian Prime Minister Nikola Gruevski announced the news at a press conference, noting that the government and company completed negotiations on April 11. The plan calls for ODW Elektrik to build its first plant in Macedonia on a 10,000-sq-m site, with the factory expected to become operational by the end of this year. The plant in southwestern Macedonia will eventually employ as many as a thousand people, the story said. It added that the project is estimated to be worth about €15 million.

Based in Steinau an der Straße, the manufacturer operates three production facilities in Germany, Ukraine and Hungary, the European Plastics News story said. Ludwig Bathon, chief executive of ODW Elektrik, was cited as saying that Macedonia’s labor force and the support provided by state institutions were among the reasons which convinced the manufacturer to launch its greenfield investment in Macedonia.

Philippine telecom company to further extend its fiber network by 15,000 km PDLT, a leading telecom service provider in the Philippines, plans to roll out an additional 15,000 km of

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INDUSTRY NEWS

and the submarine network will be technically ready in 2015, with an expected in-service date of June 2016, it said.

INDUSTRY NEWS

new fiber optic cable facilities this year.

A press release at the PDLT website said that the investment of more than US$311 million will “further fortify its already formidable fiber advantage,” extending the total length of the PLDT Group’s fiber network to nearly 100,000 km the end of 2014.

“We are further fortifying our fiber advantage which is critical to our ability to handle the expected explosion of data traffic in the coming years,” said PLDT President & CEO Napoleon L. Nazareno. “Our changing revenue mix underscores that our future clearly lies in data and fiber.”

The release said that PDLT had expanded its fiber optic network to 85,000 km by the end of the first quarter of 2014, an amount “that is five times more than its competition.” The aggressive expansion of PLDT’s fiber optic network will continue this year, he said, noting that another ongoing project is to fortify some 600 km of fiber in Northern Luzon.

To date this year, PLDT has completed the installation of over 150 km of submarine fiber optic cables that linked the island of Bohol to the major network centers in the Visayas and Mindanao areas, and rolled out 620 km of fiber optic inland and submarine cables connecting tourist-rich Palawan province in Western Philippines to the PLDT network and to the rest of the country and the world, the release said.

Molex Incorporated to acquire Flamar U.S.-based Molex Incorporated announced that it has agreed to acquire Flamar Cavi Elettrici Srl, an Italian designer and manufacturer of a broad range of custom cables for multiple markets and applications.

A press release said that Flamar’s “cable design strengths and European customer base in machine building and robotics align well with our global capacity to meet demand in these key markets.” Founded in 1976, Flamar provides cable solutions for industrial automation, robotics, broadcast audio/video, and telecommunications applications. It specializes in high-flex, multi-core cable for applications such as sensors, measurement, controls, robotics and machine drives.

The acquisition will “help expand Molex cabling product offerings for machine and process control in the industrial automation and robotic industries,” the release said. “Flamar has an outstanding reputation...Their cable design strengths and European customer base in machine building and robotics align well with our global capacity to meet demand in these key markets.”

The acquisition is expected to close this year.

Saarstahl plans to invest €46 million to modernize 2 company rolling mills Germany’s Saarstahl AG announced that it will spend 46 million euros to modernize rolling mills in Völklingen and Burbach, all part of a major investment plan.

“With these next phases of investment, we are aiming to strengthen strategically important products for the automotive industry and mechanical engineering branch-

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Sunset Review upholds most of orders for wire rod from 6 countries The U.S. International Trade Commission (ITC) made its final determination on two existing orders for six countries, upholding all but one of them for a single country.

A press release said that the second Sunset Review of the antidumping (AD) orders on carbon and certain alloy steel wire rod from Brazil, Indonesia, Mexico, Moldova, Trinidad & Tobago, and Ukraine, and a countervailing duty (CVD) order on wire rod from Brazil, upheld all the orders except for the AD order for the Ukraine.

“Accordingly, because the U.S. Department of Commerce had likewise made affirmative determinations in its sunset reviews of these orders, the AD and CVD orders on wire

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rod from Brazil, Indonesia, Mexico, Moldova, and Trinidad & Tobago will remain in force for a further period of five years. The AD order on wire rod from Ukraine will be revoked,” the release said.

U.S. company reportedly will locate automotive cable plant in Macedonia U.S.-based automotive company Amphenol plans to invest approximately $8.1 million in the first stage of a project for an automotive cable plant in eastern Macedonia. A report earlier this year in SeeNews.com, citing a government statement, said that the Amphenol’s brownfield investment in the eastern town of Kocani will open 1,500 jobs over a period of five years. The company will employ 250-350 at its Macedonian plant as soon as this year, it said.

Germany’s SMS reports that the steel industry continues to struggle In a recent report, Germany’s SMS Group, whose equipment for processing steel includes wire rod, observed that the steel industry remains in a difficult position because of overcapacity.

“As recently as the beginning of this year, we expected a boost to our business due to our customers’ hopes that the

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INDUSTRY NEWS

es and to be more flexible in reacting to the market,” said Saarstahl AG CEO Dr. Karlheinz Blessing. “From 2008 until today, Saarstahl (including Saarschmiede) will thus have invested around €1.1 billion.”

A press release said that €16 million will be spent for the company’s wire mill in Burbach, which will see it extend the existing four rolling stands on the one-strand roughing rolling mill by a further two stands and a shear. The electrical drive technology of the roughing rolling mill will also be completely renewed, it said. The work should be completed by the summer of 2016, it said.

INDUSTRY NEWS

steel market had bottomed out,” said Burkhard Dahmen, spokesman of the Managing Board of SMS Holding GmbH. “However, due to full capacity utilization, the global industry is still struggling with over-capacities, and the situation has only improved slightly. This in turn depresses the willingness of our customers to invest. Moreover, political uncertainty in our major sales markets Russia, Ukraine, and Venezuela is also disrupting our activities there.”

The result of the above factors was a slight decrease in orders, and the company noted that it has maintained an overall good position, bolstered by its acquisition of Paul Wurth. Its year-average number of employees (including apprentices) for 2013 was 13,856, up from 11,822 in 2012.

The company has responded to conditions by adjusting capacity, Dahmen said. That includes implementing an extensive cost-cutting program with even more process improvements, but the company will continue to expand the growth fields of modernization, electrics and automation, service, and energy and green technology, he said.

S&E Polymers has expanded its capacity with a new compound line

A press release said that the company, a supplier of specialty plastic compounds, has commissioned a new ENTEK 53 mm co-rotating twin-screw extruder with specialty feeders and other auxiliary equipment. It added that the company also bought three additional sets of customized twin screws to support faster change-outs when running different materials. “We invested in the new screw sets to run an expanded portfolio of products and increase our processing flexibility, said company President Duane Shooltz.

The new compounding line will allow S&E to significantly increase line capacity, and in some cases, more than double its throughput rate for some materials, the release said. It noted that with the purchase, S&E has expanded its current annual tolling capabilities to 15 million lb a year for polymers such as PVC, PVC alloys, Low Smoke Zero Halogen, TPOs, TPRs and flame retardant and UV-based concentrates.

Superior Essex first to offer EPDs that can contribute to LEED points/credits U.S.-based Superior Essex reports that it is the first company in the telecom cable manufacturing industry to offer Environmental Product Declarations (EPDs) that can contribute to obtaining points in the Leadership in Energy and Environmental Design (LEED) certification process for building projects.

U.S.-based S&E Specialty Polymers LLC reports that it has expanded its processing capabilities by adding a new materials compounding line at its headquarters in Lunenburg, Massachusetts.

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INDUSTRY NEWS

A press release said that EPDs have been published for 25 Superior Essex premises copper data cable products, including multiple designs of plenum-rated and riser-rated Cat. 5e, 6 and 6A cables. The LEED program, it noted, has become the de facto standard in the U.S. for rating and certifying the environmental impact of building projects, including new construction and existing structures.

The EPDs attributed to Superior Essex copper data cable products can be used towards the receipt of a Material and Resource Credit under LEED version 4, the release said. An EPD is a comprehensive report that examines the environmental impact of a product or product family through its lifecycle, which provides the transparency necessary to assess the environmental standing of the products. EPDs for Superior Essex have been certified and published by Underwriters’ Laboratories (UL), it said.

“Publishing an industry-first set of EPDs for 25 of their products not only demonstrates an important step towards greater transparency by Superior Essex, but also a willingness to take on a leadership position in the communications industry sector,” said Lisa Meier, vice president and general manager for UL Environment.

“Additionally, as green building continues to grow in relevance, it’s key for manufacturers to keep moving the marketplace towards products that are easily recognized

18 | WIRE JOURNAL INTERNATIONAL

in green rating systems such as LEED.” “Superior Essex has made it a top priority to lead the way in environmental sustainability within our industry, especially in terms of landfill waste diversion, recycling, energy conservation, and reduced material usage,” said Steve Born, senior One of 25 Superior Essex 4-pair applications engi- copper data cable products that neer and LEED can contribute to LEED credits.

AP for Superior Essex. “Up until now, organizations seeking LEED green building certification would not receive any credit for selecting cable products from companies who share their goal of exceptional environmental sustainability. Today’s announcement changes that.”

The LEED program is administered by the U.S. Green

Building Council (USGBC) and is applicable for new construction and existing structures ranging from data centers to government to educational and healthcare facilities.

Allied Wire and Cable a winner of President’s E Award for Exports U.S.-based Allied Wire & Cable (AWC) was one of 66 companies in the U.S. that were honored May 28th in Washington, DC, with the President’s “E” Award for exports, a recognition based on significant contribution to the expansion of U.S. exports.

U.S. Secretary of Commerce Penny Pritzker presented the award to the company, which had been cited in a letter for its export performance. “Congratulations to Allied Wire & Cable for its export achievement, which helps the local community, Pennsylvania, and the nation remain competitive in the global marketplace,” she said.

AWC President and CEO Tim Flynn, who accepted the award, said that it meant a lot to him “to see how our company has grown from its start in my family basement in the Philadelphia suburbs, to now, when we’re going to Washington to receive Presidential recognition for doing business around the world, and doing it well. It makes us extremely proud, not only as business owners, but also as Americans, to know that we are able to help grow the economy and provide more job opportunities in the US by increasing exports.”

Per an AWC spokeswoman, the company, a distributor and specialty manufacturer of wire and cable, shipped to 25 countries in 2006. Today, it exports to 68 countries and plans to expand that number. “We continue to research new markets for our services and work closely with various government entities to increase our export capabilities. Over the past five years, we have participated in trade missions to Canada, Mexico, South Africa, and Turkey to further explore our opportunities in each country.”

Increased exports stemmed from the efforts of an Export Committee AWC created with members repre-

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INDUSTRY NEWS

senting all operation elements (marketing, IT, production, shipping, finance, and sales), the spokeswoman said.

“Together, we found creative ways to increase international sales and overcome hurdles related to international expansion.”

“We’ve been able to increase foreign sales through our website and internal sales representatives,” the spokeswoman said. “About 20% of our incoming leads are from outside the U.S. Those are assigned to internal reps specializing in international sales. We have several bilingual sales representatives on staff. We also work with outside reps in several countries overseas.” She added that the company has to constantly reevaluate and increase its inventory. “We do not currently have warehouses outside the U.S., but that is something we are considering.”

News in brief The Scunthorpe Telegraph reported that five employees of the Long Products division of TATA Steel were fired for making comments on social networks. The specific comments were never disclosed, and the union employees may not have known that the activity could

20 | WIRE JOURNAL INTERNATIONAL

Holding the check are Gem Gravure President Dave Gemelli, r, and Executive V.P. Paul Gemelli, who were among the company’s particpants in a recent fundraiser. result in losing their jobs. ... 17 employees from Gem Gravure Company, Inc., were among the thousands in Boston taking part in a May 4 “Walk for Hunger” fundraiser for Project Bread. The GEM walkers raised $2,750. n

ASIAN FOCUS

ASIAN FOCUS Indian automotive company finds success by aquisitions; latest in U.S.

focus and resources on our other business segments, which are technology-driven with global applications and offer greater opportunities to provide higher value Motherson Sumi Systems Limited (MSSL), India’s to our shareholders,” largest automotive component maker and a leader in The acquisition of Stoneridge, which has been makwiring harnesses, has found ways to succeed even while ing wiring harnesses for 48 years and is well known in the Indian market is weak. Below are excerpted commajor markets like the U.S., will complement MSSL’s ments from published reports, including an interview business, Sehgal said. “Stoneridge’s current customers with Economic Times’ reporter Chanchal Pal Chauhan. are in segments like commercial vehicles, agricultural Samvardhana Motherson Group Chairman Vivek equipment, material handling equipment and off-highChaand Sehgal reports that the Indian auto market is way vehicles, which would help us leverage our capacifacing a temporary cyclical slowdown, but the company ties on a global scale.” is in a good position because of its approach. “We are a MSSL has done 10 acquisitions on its own, the first global company now with over 85% of (our) consolidatbeing a wiring harness company, in 2002, Sehgal said. ed revenue generated outside India. Our string of sucIt saw it latest annual cessful acquisitions revenues of $5 billion, and turnaround of where MSSL outperthese companies has formed the market made that possible. with a 40% growth in We have presence in volume. “Despite one 25 countries across of toughest years for six continents, includthe automobile indusing Europe and the try, our net profit for U.S., which are very the fiscal year was up competitive markets by 72%, while conand our strategies are solidated sales grew more attuned towards 20%. We also have a global markets rather strong order book in A wiring harness made by Stoneridge, a U.S. company aquired by than concentrating excess of 4 billion for a subsidiary of India’s Motherson Sumi Systems Limited (MSSL). only in India.” our various entities.”

Most recently, the Sehgal said in the company acquired U.S.-based Stoneridge, a wiring harness interview that the company’s revenue stream is mostly supplier with some 4,700 employees at six manufacturing concentrated in overseas markets. “Around 85% (comes) facilities in the U.S. and Mexico and an engineering and from our major foreign subsidiaries across 25 counadministrative center in Warren, Ohio. The $65.7 million tries, with India contributing the rest. But as things are investment was part of the company’s efforts to expand its moving in diverse directions and the Indian auto market customer reach. is expected to perform better in the next few years, I The Stoneridge division designs and manufactures wiring believe the domestic contribution could go up 25-30%. harness products for sale principally to the commercial, This could happen if we get the right policy support and agricultural and off-highway vehicle markets, as well as the market expands as expected.” assembling entire instrument panels that are configured The chairman said that he was hopeful that the results specifically to an OEM customer’s specifications in the of the recent election will be positive for the country commercial vehicle market. The deal, structured by way and the auto industry. “Like others (component manuof asset purchase, is subject to completion of regulatory facturers), we are also keeping our fingers crossed. It all approvals and is expected to be completed by the third depends on the new government, how it performs in due quarter of 2014. course and if that could turnaround the sluggish domesThe deal was described as “win-win” for both buyer tic automotive industry. The Indian market is facing a and seller. “The combination of Stoneridge’s Wiring temporary cyclical slowdown, but it would recover and Business with Motherson will increase the vertical and sales should pick up in the next few months.” global integration of the business, providing greater MSSL, the flagship company of the Samvardhana size, scale and additional global capabilities to service Motherson Group, was established in 1986. It is a joint customers’ requirements,” said John C. Corey, President venture between Samvardhana Motherson Group and and Chief Executive Officer of Stoneridge. “With the Sumitomo Wiring Systems (Japan). sale of our wiring business, we can now increase our

22 | WIRE JOURNAL INTERNATIONAL

this year, the city plans to re-arrange overhead wires in four areas in the inner city and clear up the communications lines. The committee’s Deputy Chairman, Nguyen Ha Noi authorities plan to remove Quoc Hung, said he had assigned the Department of snarled overhead cables by 2015 Construction to work on the problem.

Authorities in Ha Noi, Vietnam, are seeking to remove Burying the cables was one of three options that was the enormous tangle of overhead electric lines, phone and considered for the project. The first was to re-arrange television cables as part of the wires and tie into efforts to meet the deadbundles, which was line called for in the city’s estimated to cost 100 2011 plan to bury all wires million VND (US$4,700) by 2015. per km. The second was Per the municipal to add more poles and People’s Committee, beams to support the tangled wires are making wires, which would have the city ugly and posing cost about US$95,200 a threat to people’s lives, per km. The third option, said an online report by replacing all wires, Thai PBS. It said that would be very costly. the Lighting and Urban Of note, funding of Equipment Company will nearly US$367 milEfforts are planned to cure the tangled cables in Ha Noi. work with the Ha Noi lion is to be provided Power Corporation to to improve the infraremove all wires that are no longer in use, which could be as structure via the Ha Noi, Ho Chi Minh City Power much as 120 km of low-voltage lines. One problem, it noted, Grid Development Sector Project, financed by Asian was determining which lines were still in use.

Development Bank (ADB), ASEAN Infrastructure Fund As part of the project, the report said, the municipal (AIF) and the Ha Noi Power Corporation and Ho Chi DOT will also replace 784 electric and light poles. Within Minh City Power Corporation. 

JULY 2014 | 23

ASIAN FOCUS

ASIAN NEWS BRIEF

PEOPLE

PEOPLE P & R Specialty, Inc., reported two company hires. Craig Stiefel recently became business development manager, responsible for driving new customer growth with a focus on the U.S. Midwest and Northeast areas. He has more than 20 years of B2B development experience using a focused solutions approach to meet customer packaging and supply chain Craig Stiefel requirements. Travis Plunkett has become a customer service representative responsible for support of all customer order management activities. He has more than 15 years of customer service experience in the information technology industry. Based in Piqua, Ohio, USA, P & R Specialty, Inc., manufactures fiberboard spools, plastic spools, and plywood reels for multiple industries, including weldTravis Plunkett ing wire, building wire, fine wire, magnet wire, hose and cordage.

24 | WIRE JOURNAL INTERNATIONAL

Metro Wire and Cable reported two recent hires. Mark McCormick was named a sales consultant, with a territory that includes Georgia, South Carolina, Mississippi, Alabama, Florida, Texas, Louisiana, Arkansas, and Tennessee. He has more than 25 years of industry experience. Robert Wilhout has joined Metro Wire and Cable as sales consultant, responsible for cultivating new business in and around the southeastern portion of the U.S. He has experience in direct marketing and sales roles across multiple industries, and has a very strong customer service background. Based in Sterling Heights, Michigan, USA, Metro Wire & Cable notes that it is a leading electrical distributor.

Greg Fackler

Greg Fackler has joined Laboratory Testing, Inc., as a metallurgical engineer at the company’s Metallography Lab, where he will be responsible for performing the full-range of metallography services including microstructure examinations, macrostructure examinations and microhardness testing in accordance with AMS, ASTM, ASME

obituary WAI past president dies at age 98 WAI Past President John A. Bell, who was widely regarded in the wire industry for his integrity, expertise and innovative spirit, died March 21 at age 98.

The Indiana native grew up in East Moline, Illinois, then attended Augustana College in Rock Island, Illinois, and the University of Illinois in Champaign-Urbana, John A. Bell receiving a B.S. degree in metallurgical engineering and a B.A. degree in chemistry. He began his career in metallurgical

engineering in 1943, having been recruited by AT&T and its subsidiary, Western Electric, to be a development engineer at the Hawthorne Works in Chicago.

He remained there for 38 years, retiring in 1981. He became the principal technical expert on copper for AT&T, which at the time was the world’s largest purchaser of copper.

In the early 1960s, he helped develop a process for melting, casting and rolling copper into a continuous rod. An experimental line was installed, and he was the project’s metallurgical engineer for a year until the feasibility of the process was proved.

Bell, who lived for many years in Illinois before moving to New Jersey, led many in the industry to seek his advice and counsel. He served as president of the Wire Association in 1973-74, and authored a number of award-winning technical articles. He won the Association’s Mordica Memorial Award in 1970 and the J. Edward Donnellan Award in 1980 for his contributions to the betterment of the industry and the Association.

Bell is survived by Dorothy, his wife of 70 years; sons John W. Bell and his wife Melissa, James E. Bell and his wife Yvonne, and Richard S. Bell and his wife Meredith; a brother, Kenneth Bell and his wife Dodie; and many nieces, nephews and grandchildren. 

JULY 2014 | 25

PEOPLE

and MIL specifications. He will also handle SEM analysis and other testing and evaluation required for conducting failure analyses. He holds a degree in metallurgical engineering from the University of MissouriRolla (now called Missouri University of Science and Technology). Based in Hatfield, Pennsylvania, USA, Laboratory Testing, Inc., has been an independent, accredited testing and metrology laboratory in business since 1984.

FIBER WATCH

FIBER WATCH U.S. Navy awards contract to lay fiber cable to Guantánamo base

U.S. agency orders a protected fiber optic system for Air Force

The U.S. Navy has awarded a $31 million contract to a Texas firm, Xtera Communications Inc., to lay an undersea fiber-optic cable connecting the remote U.S. Navy base in southeast Cuba with South Florida.

A story in the Miami Herald said that the project will upgrade services at the U.S. base, which has about 6,000 residents, including about 2,200 soldiers and other temporary staff at the prison camps currently holding 154 captives. The work, it said, should be completed by the end of 2015.

The story cited a spokesman for Secretary of Defense Chuck Hagel as saying that the cable would be robust enough to someday provide fiber-optic services to the entire island of Cuba, although a separate spokesman said that “there is no vision of expanding the fiber optic cable beyond the minefield that separates the outpost in southeast Cuba from the rest of the island.”

The Miami Herald first disclosed plans for a $40 million undersea cable more than a year ago, quoting sources as saying it would go from the base in southeast Cuba through the Windward Passage to an undisclosed link in South Florida.

CenturyLink reported that it has won a contract from the Defense Information Systems Agency (DISA) to provide a fiber-optic system that will be buried in concrete and steel.

A press release said that the contract calls for CenturyLink to run a fiber optic cable will run in a steep pipe encased in concrete conduit to protect it from the effects of high altitude electromagnetic pulses to ensure continuity of service and survivability. The system, it said, will support the Colorado Springs Survivable Communications Network, helping to deliver uninterrupted connectivity among Schriever Air Force Base, Peterson Air Force Base and Cheyenne Mountain Air Force Station.

Last year, CenturyLink was chosen to provide a fiberbased network that will connect DISA’s supercomputers and researchers at speeds ranging from 50 Mbps to 100 Gbps. That calls for a mix of Ethernet, IP and optical wavelength services through a Virtual Private Local Area Network Service (VPLS) that will connect defense scientists and engineers at various research entities, laboratories and test facilities at more than 150 U.S.-based defense department locations. 

26 | WIRE JOURNAL INTERNATIONAL

FASTENER UPDATE

FASTENER UPDATE Bossard expands its presence in Southeast Asia, lands Tesla contract Earlier this year, Switzerland-based Bossard, a multinational supplier of fasteners, announced that it has expanded its presence in Malaysia and won a contract from Tesla.

At its website, the company reported that it has expanded its presence in Southeast Asia with the opening in Malaysia with a new distribution and administrative center in the Penang Science Park in Bukit Minyak.

The site, it said, is located in the highly industrialized Federal State of Penang, in the northwest of the country.

The new 9,000-sq-m facility of Bossard Malaysia will have a storage capacity of 800 metric tons and some 80 employees, it said, adding that, “Malaysia forms a focal point of investment activity in this region of the world.”

“Our new center in Malaysia provides the basis for continued growth in this region of the world. We can use it to approach more directly our customers and serve them even more efficiently,” said Bossard Group CEO David Dean. He explained that the investment was made because of “the market potential in this economically

28 | WIRE JOURNAL INTERNATIONAL

developed region, where many multinational industrial groups have settled.”

The company also reported that it has strengthened its ties with American electric vehicle manufacturer, Tesla Motors, which has awarded Bossard with a three-year contract worth an estimated US$140 million for production fasteners, engineering and logistical services. That activity has prompted Bossard to open a new distribution center near the Tesla factory in Fremont, California, USA, it said.

In its announcement, Bossard said that the two companies have collaborated for more than four years in the design and development of Tesla’s cutting-edge Model S, including engineering, prototyping and ultimate delivery of production fasteners, using Bossard’s SmartBin®inventory management system.

“Bossard considers it an honor that the existing successful collaboration is now solidified with a three-year contract with an estimated value of US$140 million for this period,” Dean said. He noted that “Bossard has steadily expanded its market share in the past few years in the United States, in part due to the intensified collaboration with Tesla.” 

WAI NEWS

July 2014

WAI MEMBERSHIP

SPOTLIGHT This section introduces a new WAI member each issue.

Sparky Christakos President Gladding Braided Products, Inc.

Q: What does your company do?

A: We braid shielding over customer-supplied cables with copper, bronze, aluminum, stainless steel and textile fibers like Kevlar, Nomex, fiberglass, ceramics, etc.

Q: What is your role there?

A: President and owner. We are a small company (75 people, 120,000 sq ft), but have a very diverse mixture of capital assets (1,500 braiding machines).

Q: What do you like best about your position?

A: Developing products and processes (and sometimes machinery) to meet a customer’s need(s). We have partnerships where we not only do the customer’s braided shielding work in our facility, but for some long-distance cases we design, build and sell the braiding machines so customers can do the work themselves.

Q: How has the industry most changed?

A: Over time, as people retire and companies grow, we find many cable companies are crammed for space and lack the braiding expertise. That is a void we fill, and we have seen more companies choosing to send their cables to us for shielding with a quick turn-around.

Q: How does your company remain competitive?

A: By a mixture of constantly reducing and keeping low overhead costs, along with a committed in-house fabrication shop that provides us (and often our customers) with custom-built, efficient braiding equipment. Raw materials are fixed by the markets, so our above-cited advantages allow us to offer cost savings options to those that need overbraiding/shielding.

Q: Why did you recently join WAI? A: With our recent acquisition of Belgium’s Eaton Braiding plant machinery (arrived at our plant in May 2014), we have added capacity and equipment to put to work. We thought that joining was another way to network to cable companies who may not know of us, and may need braiding and shielding work provided.

30 | WIRE JOURNAL INTERNATIONAL

Bukola Adubi Exec Dir MicCom Cables & Wires Ltd

Kevin Laporte Proj Eng Sivaco Wire Group

James Schraml Proc Met Ulbrich Shaped Wire Inc

Bryan Barnett Proc Eng Carlisle Interconnect Technologies

William Livingston General Cable Corp

Dave Seydel Dir of Quality & NPD Direct Manfacturing

Roger L Brown Sls Mgr Gauder Group Inc Dale Carroll VP of Ops Southern Imperial Inc Sparky Christakos Pres Gladding Braided Products Inc Patrick Churchill Eng General Cable Corp Dionne Dillon Corp Metall Eng Mgr WireCo WorldGroup Kimberly Dout Assoc Eng General Cable Corp John G Glendenning Proc Eng Mgr ABB

Victor Luciano Plt Mgr Ulbrich Shaped Wire Inc Ng Iat Man Gen Mgr MKT Fortune Mica Henry Mangaing Chmn London Industrial Products Inc Isabelle Martinez Reg Sls Mgr Esteves Group Thomas R Melichar Prod Mgr Charter Steel

Steven C Slagle Prod Mgr - Galv Mid-South Wire Co Inc Brad Slaughter Matl Eng Tech Delphi Packard Electric Systems Kyle Trewitz General Cable Corp Glen Vega Proc Eng Carlisle Interconnect Technologies Jan Vintrlik ALBAform Inc

Jared Mullinax Sls Gem Gravure Co Inc

David Walz Supv Southwire Co

Art Nelson Comdel Innovation

Leonard Weiner Mat/Cable Eng Delphi Packard Electric Systems

Jose Miguel Ortiz Ind Dir Inproel SA

Chad A Kauffman Proc Eng Materion Brush Performance Alloys

Charles Peet Prod Supv Harbour Industries Inc

Will Kent Dev Eng Southwire Co

Pawel J Pepera Proc Chem Eng Charter Steel

Brent Lalonde Dir - Sourc & Prcmt Shamrock International Fasteners

Duane Piewacki Bus Dev Mgr Saco Polymers Inc David M Sanderson Dir of Mfg Mar-Mac Wire Inc

WAI NEWS

The following individuals either recently joined WAI or became Platinum Members through their companies.

Jacob Weiss Proc Eng Southwire Co Ray Westerfield Supv Southwire Co Ryan York Maint Mgr Southwire Co Chunlei Zhang Dir of R&D Ctr Fasten Group

WAI Platinum Membership Companies Industry leaders can contact WAI Executive Director Steve Fetteroll at sfetteroll@wirenet. org or 203-453-2777, ext.

115, to learn more about this special membership program. Such organizations actively support the Association by participating as exhibitors, advertisers, sponsors or content providers for WAI-organized events, publications and educational programs.

JULY 2014 | 31

WIRE & CABLE MAKING MACHINERY PLANT OPERATIONS SESSIONS SPEAKING OPPORTUNITIES NEW TRENDS & PRODUCTS SUPPLIES & EQUIPMENT GLOBAL NETWORKING SPONSORSHIPS

INTERWIRE 2015 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS. GEORGIA WORLD CONGRESS CENTER | ATLANTA, GEORGIA, USA

SAVE THE DATE EXPOSITION: APRIL 28-30, 2015 CONVENTION: APRIL 27-30, 2015 ALSO WITH: WAI’s 2nd Global Continuous Casting Forum

www.interwire15.com 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

PARTICIPATING EXHIBITORS Ace Metal Inc. ADVARIS GmbH Agape Industry Inc. AIM Inc. All Forming Machinery Inc. Amacoil Inc. American & Efird Inc. Anbao Wire & Mesh Co. Ltd. Assomac Machines Ltd. AW Machinery LLC Aztech Lubricants LLC B & H Tool Co. Inc. B & Z Galvanized Wire Ind. Balloffet Die Corp.

Bechem Lubrication Technology LLC Beijing Orient PengSheng Tech Co. Ltd. Bergandi Machinery Co. Beta LaserMike Blachford Corp.

BLM Group USA Corp.

Breen Color Concentrates Inc. Brookfield Wire Co. Butt Welders USA Caballe SA Cable Consultants Corp.

Canterbury Engineering Co. Inc. Carris Reels Inc. Ceeco Bartell Products, Bartell Machinery Systems Cemanco LC CERSA-MCI Chase Wire & Cable Materials Chemetall Chengdu Centran Industrial Co. Ltd. China Ruijin Fairs International Cimteq Clinton Instrument Co. CM Furnaces Inc CMEC International Exhibition Ltd. CN Wire Corp.

Collins & Jewell Co. Inc. Commission Brokers Inc. Condat Conneaut Industries Inc. Davis-Standard LLC Die Quip Corp.

Domeks Makine Ltd. Sti Dynamex Corp.

Ebner Furnaces Inc. Electron Beam Technologies Inc. Enercon Industries Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Esteves Group USA Etna Products Inc. Eurobend SA Eurolls Group Srl George Evans Corp.

Fabritex Inc. Fil-Tec Inc. Filtertech Inc. Fine International Corp.

Fisk Alloy Wire Inc. FMS USA Inc.

Foerster Instruments Inc. Fort Wayne Wire Die Inc. Frigeco USA Inc./ MFL USA Service Corp.

Frontier Composites & Castings Inc. FSP-One Fuhr GmbH & Co. Kg Gavlick Machinery Corp.

GCR Eurodraw SpA Gem Gravure Co Inc. W. Gillies Technologies LLC GMP Slovakia s.r.o Guill Tool & Engineering Co. Hangzhou JR Exhibition Co. Ltd. Heany Industries Inc. Heatbath Corp.

Heritage Wire Die Inc. Holland Colours Americas Inc. Houghton International Inc. Howar Equipment Inc. Huestis Industrial ICE Wire Line Equipment Inc. IDEAL Welding Systems INHOL LLC InnoVites International Wire & Cable Machinery Association Isotek Corp.

IWG High Performance Conductors Inc. Joe Snee Associates, Inc. Joe-Tools Jouhsen-Bundgens Inc. Kablosan Turkey-FBC Yayincilik Ltd. sti KEIR Manufacturing Inc. Keystone Steel & Wire Co. Kinrei of America Lamnea Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. Madison Steel Inc. Magnetic Technologies Ltd. Maillefer Extrusion Oy Mathiasen Machinery Inc. Messe Düsseldorf North America Metal Resource Solutions Inc. MGS Manufacturing Inc. Micro Products Co. Microdia USA Mid-South Wire Morgan-Koch Corp.

Mossberg Industries Inc. Niagara Composites Int’l.Inc. Niehoff Endex North America Inc. Nimsco LLC / SB2C Numalliance North America Inc. Oklahoma Steel & Wire OMCG North America Inc. Ozyasar Tel Ve Galvanizleme P & R Specialty Inc. Paramount Die Co. Parkway-Kew Corp.

Troester Maschinenfabrik GmbH & Co. KG Pentre Group Ltd.-Hearl Heaton

Phifer Wire Inc. PKG Equipment Inc. Plas-Ties Co. PolyOne Polytec Inc. Pourtier & Setic of America Precision Die Technologies Inc. Premier Wire Die PrintSafe Progressive Machinery Inc. Properzi International Inc. QED Wire Lines Inc. Queins Machines GmbH Raajratna Stainless Wire Inc. Radyne Corp.

Rainbow Rubber & Plastics Refractron Technologies Corp.

RichardsApex Inc. Rosendahl Nextrom Technologies Roteq Machinery Inc. RSD Group USA S&E Specialty Polymers SAMP USA Inc. Sarkuysan SA Schlatter Inc. Shanghai Pudong International Exhibition Co. Sikora International Corp.

SIMPACKS Sjogren Industries Inc. Sonoco Reels Starrett-Bytewise Measurement Systems Stolberger Inc DBA Wardwell Braiding Subec AB T & T Marketing Inc. Tapeformers Ltd. Taubensee Steel & Wire Co. Taymer International Inc. Tecnofil SA Teknikor Teknor Apex Tensor Machinery Ltd. TMS-Specialties Manufacturing Co. Inc. Traxit North America LLC Tubular Products Co. Tulsa Power Inc. United Wire Co. Inc. Vandor Corp.

VINSTON US Corp.

Vollmer America Inc. WAFIOS Machinery Corp.

Weber & Scher Mfg. Co. Inc. Welding Wire Machineries Windak Inc. Wire & Cable Technology International Wire & Plastic Machinery Corp.

Wire Association International, Inc. Wire Journal Interanational Wire Lab Co. Wire Machine Systems (WMS) Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Zumbach Electronics Corp.

WAI NEWS

Spence to spearhead expanded sequel to casting forum event at Interwire 2015 In 2011, Encore Wire’s Gary Spence staged the Global Continuous Casting Forum, a phenomenally successful event that was co-located at Interwire. A total of 205 participants from 25 countries attend the program, which is believed to be the most comprehensive such event ever presented for copper rod producers.

What made the 2011 program special was that it did not focus on one or two of the major technologies but all of them. Spence described the four-day program, which included rave reviews for the presentations by wellknown and highly regarded speakers, as “a blend of networking, education, value and fun.”

Now, the event (see p. 35) will once again co-locate at Interwire, but this time it will do so with an even wider scope as the program will include an aluminum track, which Spence said stemmed from requests by people in that field.

Staging the initial event in 2011 took a massive effort, and Spence stunned WAI staff by how he single-handedly was able to bring together the program. The general theme was innovation and process improvement, and the forum included operational and technical papers, workshops and panel discussions.

Spence said that one reason he initially wanted to hold

34 | WIRE JOURNAL INTERNATIONAL

A 2011 photo of forum attendees, all casting practitioners. the event was that it would bring together many people in a relatively small niche, regardless of the casting process they use. “I have worked on three different continuous casting processes, and have met really good practioners on all systems from different parts of the world. I feel our connection is people. People with similar visions, goals and objectives.”

More details will come in future issues. n

The best way to deliver an encore is to add to the cast.

Aluminum joins copper for WAI’s second Global Continuous Casting Forum April 27 - 30, 2015 | Atlanta, Georgia, USA | With Interwire 2015 Join a renowned ensemble of continuous casting practitioners, raw material suppliers, and equipment manufacturers on an educational journey from ore to more at WAI’s second Global Continuous Casting Forum.

Shared sessions. Independent technical tracks. Unalloyed networking. All focused on saving money through performance-based casting technologies. www.castingforum15.com.

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

CHAPTER CORNER

CHAPTER CORNER Winners of 7 college scholarships announced The below seven students have been named winners of college scholarships from WAI’s Midwest, Southeast and New England chapters.

Midwest Chapter • Nathan Palmer. The son of Mark T. Palmer, process engineer, 3M Company, Nathan will be attending North Dakota State University.

Southeast Chapter • Luan Dang Vo. The son of Loc Vo, process engineer, CommScope, Luan will be attending the University of North Carolina Charlotte.

Nathan Palmer

Luan Dang Vo

Amy Blew

Chiara Marcario

• Amy Blew. The daughter of Doug Blew, vice president of global manufacturing engineering, CommScope, Amy will be attending East Carolina University.

New England Chapter • Chiara Marcario. The daughter of Ralph Marcario, director of sales and marketing of Chromatics Inc., a division of PolyOne, Chiara will be attending Ithaca College.

• Nora Wurmbach. The daughter of Rolf Wurmbach, general manager, Niehoff Endex North America, Nora will be attending Drexel University.

Nora Wurmbach

Kyla Madden

• Kyla Madden. The granddaughter of David Thibodeau, president of Quirk Wire, Kyla will be attending the University of New Hampshire • Nolan Karsok. The son of William Karsok, engineer, W. Gillies Technologies, Nolan will be attending Bryant University.

36 | WIRE JOURNAL INTERNATIONAL

Nolan Karsok

Western Chapter to return to the Sierra Lakes Golf Course for annual tourney EMC Wire’s John Stevens reports that the Western Chapter will return to the Sierra Lakes Golf Course in Fontana, California, on Monday, Oct. 20, to stage its 14th annual “Wild West Shootout.”

The event includes the golf, cart, range practice, a western-style BBQ buffet and lots of comaradarie. For more details, contact John Stevens at tel. 909-851-5633 or jstevens@emcwire.com or WAI’s Steve Fetteroll at tel. 203-453-2777, ext. 115, or sfetteroll@wirenet.org.

The Midwest Chapter already held its golf event on June 20, and the August issue will include a wrapup. But two other chapter golf outings are scheduled to take place before the Western Chapter event.

The New England Chapter will return on Sept. 8 to the Ellington Ridge Country Club in Ellington, Connecticut, to hold its 20th Annual Golf Tournament. Contact: Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org.

The Southeast Chapter will return on Oct. 2 to the Rock Barn Golf and Spa in Conover, North Carolina, to hold the Vannais Southeast Chapter’s 13th Annual Golf Tournament. Contact Art Deming, tel. 252-955-9451, art.deming@nexans.com.

Each event offers multiple sponsorship opportunities and the chapters also welcome donations of items for raffles, held during the awards presentations.

The events offer an opportunity for bragging rights and come with a WAI snow-free guarantee. 

FEATURE

Equipment Below is a range of the equipment that was showcased at wire Düsseldorf.

More equipment is included in the Products section that follows this feature and includes technology that was presented at Wire Expo.

C.M. Caballé, S.A. A new “bullhead” strander from Caballé S.A. for 32 DIN 500 reels and one DIN 1600 reel for the core for the production of OPGW cables and armoring optical/special cables was displayed at wire Düsseldorf.

The system presents an alternative to traditional planetary or tubular stranders. The biggest difference between older versions of the bullhead strander and this new version is the improved wire paths and precise tension controls. The bullhead has a special feeder integrated at the end of the tubular strander that consists of a large payoff with bows that revolve around the reel and convey the wires coming from the tubular to the closing point. It has been designed to allow a wide range of working tensions, which makes it suitable for a single steel tube with fibers inside as well as for an armored cable with a first layer of steel wires. Wire tension is provided by a precise mechanical system or by an optional driven system that maintains payoff tensions fully constant throughout the complete process within the entire adjustable tension range.

Caballe Sales Manager Luis Morancho with the company’s new bullhead strander.

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With this system, the central core with the fiber optics inside is payed off completely straight. No twist occurs in the product, so the resulting quality is the same as with a planetary strander but with much higher stranding speeds.

The resulting productivity can be five times greater than a planetary strander.

Specifics for the bullhead tubular strander include: number of steel/aluminum wires (12 to 36); payoff bobbins (DIN 500 to 630); central tube reel size (DIN 1600 to 2500); special wire path for the aluminum coated steel wires (ACS); tension control by motor/dancer system; and maximum stranding speed (500 rpm). www.cmcaballe.es.

Euroalpha Srl At wire Düsseldorf, Euroalpha, a leading manufacturer of limited-slip drawing machines for nonferrous wire, displayed the company’s patented four-twist bunching machine, model B630-F. All of Euroalpha bunching machines are based on the revolutionary concept of having the main supply for electrics self-generated directly into the cradle. This Bonomini Massimiliano, sales manager patented for Euroalpha, by the company’s new advance B630-F bunching system.

At wire Düsseldorf, the focus at Maillefer’s booth was not so much on its equipment as it was on its new market concept: a tri-level range of technology production solutions. Below, Juha Hiltunen, Maillefer’s Director, Sales & Marketing, Wire & Cable Business, discusses the concept, which he noted was well received by attendees.

The global wire and cable industry has great variations in its needs and practices, so no one solution can be the best answer for all. Based on that premise, Maillefer’s nearly 20 product lines applications (see p. 62 for an example) are now being offered at three different levels: /Enter, //Extend and ///Explore. Each level is designed to the strictest Maillefer quality standards and with good upgradability in mind. At all levels, the core driver was putting together a best technical fit for a customer’s investment realities.

For instance, a low total cost of ownership is a must in mature markets, and a significant difference can be achieved in various ways. In some situations, adaptability of your production solution can provide an edge against competitors. Sometimes, it all comes down to product range and type change. Competitiveness can

also be enhanced by optimizing capacity and maintenance requirements, depending on your scope. These variables gave us the boost to renew our offering.

We want to provide valuable solutions that create the significant difference in the customers’ local marketplace.

The new production solution levels of /Enter, // Extend, and ///Explore vary in capacity, cost, automation, flexibility, product range and space and maintenance requirements. The widest services in the industry are available as an option for all levels. /Enter is a compact quality solution for more sustainable Maillefer’s Juha Hiltunen explained production. It is ideal for those searching for an affordable invest- the company’s new levels concept at wire Düsseldorf. ment that is easy to start and maintain in different production environments. as in high-end categories in almost 20 //Extend is a lean and proven applications. production solution for changing Increasing the value of manufacturmarket needs. Its good upgradability ing can be challenging, and accomand versatile product range guarantee plished by many different means. The a technical fit for the future. starting point of the concept develop///Explore is the royal road to ment was to build a portfolio, which demanding deliveries with the lowest gives manufacturers more choices total cost of ownership. It is a high to meet the market demands without output solution to explore the market compromising product quality and in the front row. low total cost of ownership. The iniThere is a perfect match for each tial market response has been excited. market situation – you can find the www.maillefer.net. winning solution in low-end as well

eliminates the need for critical collector and brush devices, thus substantially enhancing the machine’s reliability. The B630-F goes a step beyond as the patented four-twist version can perform at nearly double the productivity of conventional double-twist bunchers while also reducing energy consumptions due to the slow RPMs that it can use.

The line, which can be completed with a wide range of precision motor-driven payoffs, is suitable for producing 1+6 concentric strands, 1+6+12 unilay strands as well as ordinary bunches.

In addition to the above-cited features, the system features heavy mechanical construction with a closed frame for extremely low vibration; radio transmission of the control signal into the cradle; PLC control; carbon fiber bows with a special aerodynamic profile; a haul-off capstan with separate motor drive for stepless adjustment of the winding pitch; precise electronic control of the winding tension by load-cell (optional); automatic adjustment of the traverse stroke; and a reel loading/downloading system that is directly from/to the walkaway outside from the sound-proof cabinet, by means of pneumatic ejector. www.euroalpha.it.

JULY 2014 | 39

FEATURE

A tri-level approach offers options that can serve all cable manufacturers

FEATURE

Eurolls SpA At wire Düsseldorf, Eurolls SpA showcased the company’s new RT600 straightening and cutting line for electrodes, which is capable of producing welding electrode sticks at 10 m/sec, a rate that is unmatched.

Euroll’s new RT600 straightening and cutting line.

The equipment saw considerable attention at the Eurolls booth. The full line includes a seven-step drawing line, whose productivity can be increased by placing Eurolls cold rolling micro cassettes CL25C33 instead of dies. It is designed to process low carbon or stainless steel wire rod diameter 5.50 mm, draw it down to the final product diameters (2.00, 2.50, 3.25, 4.00, 4.80 and 5.00 mm), then clean the wire, straighten and cut it in the two main product lengths (350 and 450 mm). The main characteristic and advantage of this equipment is the capacity to achieve high production speeds maintaining the surface finish and accuracy in stick diameter and length. These are the basic requirements required to guarantee smooth operation in the successive steps of the process.

The line that was displayed at the show is now on its way to Brazil. Requests for quotes came from all the main producers of welding materials, and even from different national branches belonging to the same international group. Similar equipment has already been installed with full success in Turkey, Bangladesh, Peru, Bulgaria, Iran, Spain and Germany. www.eurolls.com.

Frigeco Frigeco introduced a highly efficient multi-wire drawing machine at wire Düsseldorf that goes one giant eight-wire step beyond the company’s TM100-21-16 model which, introduced in 2010, employs a single row of capstans to draw all 16 wires.

The new system, based on the same concept, has been engineered to be able to process 24 wires on a single row of capstans. The company has focused in recent years on developing this new generation of multi-wire 40 | WIRE JOURNAL INTERNATIONAL

wire-drawing machines with several objectives in mind.

One was to improve the performance of the process, but it also wanted to simplify the machine for ease of maintenance, increase reliability and to decrease overall energy consumption.

The results have confirmed that the technology has achieved those goals. For instance, a traditional multiwire drawing machine has eight wires per row of capstans, so the Frigeco design made it possible to eliminate 84 transmission shafts, 168 additional bearings and 126 additional gears that would be required using a traditional system limited to an eight-wire row. Eliminating these mechanical parts also results in an increased efficiency and an energy savings of more than 10%. Further, the decrease in the requirement to lubricate the gears with lubricating oil improves the mechanical output efficiency at high speeds.

This represents hundreds of thousands of KW/hours per year and a substantial reduction in use of electricity.

The size of the first six capstans of multi-wire have been increased to 120 mm diameter, which guarantees a perfect operation and eliminates any possibility of bending and vibration in the shafts. Additionally, with the larger 120 mm and 100 mm capstans the amount the life of the capstans is significantly increased. The capstan shafts are also much larger in diameter and designed to make maintenance easy without the requirement to dismantle major parts of the machine frame of other parts on the machine.

Frigeco Division Director Beniamino Gessaghi by the company’s TM100-21-16 system.

Frigeco divided the machine gear train in half and introduced a second motor. The two motors, which are interconnected with an electronic shaft, allow you to reset the slip half way through the process. This improvement provides an additional energy savings of about 4%. Finally, the new concept die holder incorporated in this machine uses pressure lubrication. That facilitates the cleaning of the entrance and exit cone of the dies, which also increases the life of the die.

Frigeco, a Mario Frigerio Company, also provides a full range of payoffs, take-ups and annealers. www.frigeco.com.

Niehoff GmbH

Nextrom/Rosendahl Yes, we did it. We took the existing line, added tons of knowledge from experienced Nextrom and Rosendahl people, redesigned, rebuilt, tested and fine-tuned the results.

And there it is: the (pimped-up) new Loose Tube Line. A moment we would rather call a ground-breaking new era in fiber optic cable production. It has been challenging: we admit that the existing model has already met expectations.

But what would life be without challenges? Challenges are there to be met. And the outcome? Let’s elaborate.

The current trends in fiber optic cable manufacturing are all connected to the general optimization of each step of the production process. In order to improve cable performance and to reduce the costs of the final product, many technologies and devices have been invented to minimize optical loss, increase production speed and allow more flexibility in the manufacturing process.

That was shown at wire Düsseldorf via live stream to the Nextrom facilities.

Tech advances for the loose tube process include: improved high speed fiber payoff design with reduced footprint for space saving; a special processing unit of the ROEX extruder to optimize the process ability of typical material used for loose tube production; optimized and space saving cooling trough design, safe up to 9.5 m in line length; better process feedback during production; a typical line speed of 600 m/min for standard loose tube types; new development of the crosshead series RX for optimized material flow in the melt distributor, in conjunction with a linear jelly needle guiding system for easier handling; new generation of pulley clenching capstan SCC100 for accurate post shrinkage and EFL control, especially for dry tubes; and improved online EFL measurement system. www.nextrom.com or www.rosendahlaustria.com.

The BMI 124 rotary braiding system introduced by Niehoff GmbH at wire Düsseldorf drew a lot of attention from attendees. Not necessarily because the system can cost-effectively produce bundles of braiding wire with a maximum bundle cross-sections of 24 x 1.5 sq mm, but because the model was neither horizontal nor vertical.

The 24-spool rotary braiding machine’s most striking feature is its inclined braiding rotor. The inclination means a cable deflection of just 45° (instead of 90°) on each deflection pulley, which results in reduced cable deformation and improved braiding quality. If you use a caterpillar haul-off, the machine can be used to manufacture cables with diameters up to 40 mm. Just like the other four models in the BMV series, which are designed for 12, 16 or 24 spools in vertical operation, the BMI 124 also offers infinitely variable electronic control of the braiding speed and pitch. It also has an automatic central lubrication system as well as fully automatic electrohydraulic slideway lubrication.

Niehoff Endex North America’s Frank Knobloch by the company’s BMI 1124 rotary braider.

The BMI 124 enables bundles of braiding wire to be produced with maximum bundle cross-sections of 24 x 1.5 mm². The maximum braiding rotor speed is 90 rpm (using bobbins with 100-mm flange diameters), the maximum production speed is 16 m/min and the maximum braiding pitch is 180 mm.

JULY 2014 | 41

FEATURE

Below, Nextrom/Rosendahl’s new loose tube line. Above, a schematic showing the new line’s reduced length.

FEATURE

Numalliance

The company also offers a line of vertical braiders.

With the BMV models, all the work stages, from the infeed of the cable to be braided to the individual wires and bundles of wires and the final take-up of the braided cable, are monitored by a quality control system.

We can also install an empty bobbin detection system as well if you wish, to ensure that the machine is stopped automatically before a braiding bobbin is completely empty.

You can combine the vertical BMV machines with different types of taping systems so that braiding and taping can be performed in a single operation. This simplifies the manufacturing process, reduces the amount of space required and increases the product quality compared with when individual machines are used. The experience of many cable manufacturers has shown that one BMV machine can be used to replace two to three older types of braiding machine. The main job of BMV machines is to equip cables with EMC protective shielding. Our BMV can be used for the processing of bare or coated round and flat wire made of copper, aluminum and stainless steel with single-wire diameters of 0.05 to 0.3, as well as yarns and fibers made of plastic. www.niehoffendex.com.

Cut. Bend. Repeat. The NUMASLIDE, displayed at the NUMALLIANCE booth at wire Düsseldorf, produces an eight-bend part faster than you can read those three words. While mechanical slide machine revolutionized last-century wire bending, the NUMASLIDE system is the solution for 21st century. Until now, owners of slide machines had to choose between two evils: dedicating machinery to one production or facing eight-hours (and

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FEATURE

often longer) of change-over time. The first option is limited by space while the second is fraught with the scarcity of workforce experience.

In a re-vitalized American industry, bolstered by re-shoring activities from lower-cost countries, the NUMASLIDE was engineered to respond to the needs of flexible production for high volume manufacturing.

The servo-driven machine is designed to produce the same parts of a mechanical machine, at the same rate, without the time-consuming change over. With a faster set-up time comes an additional benefit: set-up scrap reduction. The machine goes even greener with a limited energy impact. All the coupling gear is designed for peak performance, hence the optimized motors are extremely power efficient.

The NUMASLIDE can use current existing tooling that is permanently installed on dedicated mechanical bender. The then-available bender is either dedicated to high-volume production or can be decommissioned and reused for spare parts for the machine left running. With a minimal investment to adapt already existing tooling to the NUMASLIDE configuration, the machine will recycle virtually all useless “mechanical slide” tooling to a top productive and flexible solution.

“The NUMASLIDE will help American wire manufacturers re-capture the business lost in the past year with a cost-efficient and modern solution bringing for speed, flexibility and quality,” said Ludovic VALLET, COO of Numalliance North America, Inc. www.numalliance.com.

OMCG SpA At wire Düsseldorf, OMCG SpA displayed and operated its XMH system, a new workcell concept for muffler hangers that provides automotive customers with a flexible, efficient solution to making hanger wire and tube, both in carbon steel or stainless steel.

The core of the system is based on the eccentric bending head that provides outstanding bending capabilities and on the M140 end forming unit that has been appreciated through the years for its highest quality forming,

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Bob Sears, president of OMCG North America, by a portion of the XMH system. re-engineered and integrated in a 12-axis system with additional bending heads and forming units to reduce cost and cycle time with concurrent operations and overtake the bottleneck of sequential operations with traditional CNC bending machines.

Consider that with the XMH system our customers can make the majority of muffler hanger shapes in less than eight or nine seconds (depending on the cell configuration) even in the case of a double-head. Compared to the traditional sequential solution we can say that on average it’s 50% faster, but in some cases it can even be double that. The cell is also optimizing energy and space occupation saving about 30% when compare with a traditional system of the same capacity.

Not enough? The cherry on the cake is that some parts come in couples: together with the main part with the end forming there is a second shorter part, usually bended with the same radius, that needs to be coupled together with the main part … well the XMH system can make the two parts in the same cycle time required for the main part, and separates the two parts along the way through the cell. That means that the second part comes out with

Pourtier At wire Düsseldorf, Pourtier, part of the Gauder Group, highlighted its multiwire concentric stranding/armoring line, the COS 1200.

The COS 1200 is basically designed to produce high quality round or sectoral compacted strands of 7, 19, 37 or

FEATURE

zero additional time! Basically, the two parts are processed together from a single blank and separated in a special forming unit developed by OMCG. Change-over of the production from one part to the other is as simple as in a traditional CNC bending machine and can be virtually zero if the wire/tube material doesn’t change. Even in the worst case, where a complete new setting is required (for example when changing material diameter), the set-up can be done in less than twohours by skilled operators.

We are aware that consistency and reliability are key points for the automotive industry and we extensively tested our XMH workcell on an industrial use with a key client before the launch. Last but not least, we thought to offer the XMH as a stand-alone complete system, but we know that tomorrow’s market is always coming with new ideas so, if required, the cell can be easily integrated with robot or secondary operation units from third parties. www.omcg.com.

Pourtier’s COS 1200 system.

61 wires: the concentric construction enables speeding up to 500 rpm while keeping a short line length thanks to the multiwire process. Moreover, each bobbin is equipped with an individual driven tension control for prevention of wire breakage, optimization of the final section and therefore resistance of the cable.

The line is composed of independent modules of two or four reels with three wires each, individually motorized

by AC motors. Filling of the reels is made from basket

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JULY 2014 | 45

FEATURE

offs with individual capstan to pull the wire and to equalize the tension of each wire, reaching the best winding quality.

Offering higher speed, using smaller space and providing safer production, this flexible line also allows reduction of copper remainders (all parameters adjustable by the touch screen control panel) as well as energy savings, another outstanding advantage thanks to a power recovery system enabling a drastic reduction of the power consumption. The positive results are obtained by using regenerative power from the large and heavy built-in reels to produce electricity through a bus connection. The reels in this case becomes power generator and feed the pulling capstan thus drastically reducing total power consumption. www.gaudergroup.com.

Schlatter Industries At wire Düsseldorf, Schlatter Industries AG showcased the company’s newest welding model, the MG950, which is designed primarily for the production of industrial mesh.

The aim was to offer a welding machine that is flexible in relation to various mesh geometries, achieves high production speeds and exhibits the highest quality right from the first mesh.

Wire mesh manufacture has become increasingly complex, with continuing demands for more accuracy.

Additional functions, such as plug-in connectors for the connection of meshes, are integrated into the welded mesh

The MG950 industrial mesh welder from Schlatter Industries AG. during the production of wire meshes. The graduation tolerances of the functional wires in particular is especially demanding. The newly developed MG950 provides line wire feeds, which are both rigid and quickly adjustable, for this very purpose. Even if there are differences in the narrowness of gradations and varying numbers of line wires that must be welded per welding press, these can be welded at the same time. Two different power levels

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FEATURE

are available on the new MG950 at the same time, which facilitates the economical production of complex meshes.

One trend that contributed to development of the MG950 is that lot sizes continue to shrink and manufacturers of wire products can no longer afford to generate waste that occurs during the production of the first few meshes as settings are optimized. The MG950’s measuring system enables the line wire feeds to be precisely positioned according to the programmed mesh specifications.

The built-in welding assistant thus allows mesh production to have the desired quality right from the first mesh. As a result, productivity is significantly higher for small lot sizes than that of traditional industrial mesh welding machines. For recurring products, a new computer system is available for the line wire feeds so that only those line wire magazines that are in a different position must be moved in case of similar products.

Another advantage has to do with trimming cross wires for products such as oven racks, cable trays, meshes using in shop fitting and so on. For the first time, the trimming heads can be mounted directly behind the welding machine, so an additional trimming station with integrated linear pull-out is no longer required. Finally, the MG950 can be upgraded by additional modules and options to meet a customer-focused expansion, including automatic production plants that produce very high quantities in a short time with minimum personnel required. www.schlattergroup.com.

Spirka/Stolberger Inc.

bins with high precision and efficiency. The model is most suitable for customers who are winding a wide variety of product combinations in short runs. Basically, they get the functionality of two winders in the space of, and for the price of, just one.

The machine was developed in close cooperation with a customer in the medical industry, who was looking for a machine which allows winding of different materials, wire sizes, number of wires and use of different spool sizes at same time on one machine. While the idea to incorporate independently-driven spindles on a single winder is not new, Spirka pulled the feat off with impressive results: the W8-905-2E is compact, stylish and competitively priced.

The duo-function capability represents an important advantage for companies that operate in today’s fastpaced production environment and Just-in-time manufacturing, where flexibility is key. Getting bobbins loaded with the correct wire size and number of ends from the winding process to the braiding operation when needed is a never-ending challenge. Spirka responded to numerous customer requests with the new winder configuration, which looks similar to its predecessor but the two spindles are individually driven and can be programmed separately.

The operator-friendly control system allows for bobbin parameter setting based on data storage system and menu-fed format. The traversing systems are controlled by servomotors which enable the operator infinite control of the wire pitch and ensure precision lay control at the bobbin flange. www.wardwell.com, www.spirka-schnellfletcher.com.

Spirka-Schnellflechter GmbH displayed a winder at wire Düsseldorf that can simultaneously process two different wire sizes and bundle configuration.

August Strecker GmbH

Spirka-Schnellflechter GmbH’s W8-905-2 E winder at wire Düsseldorf.

The semi-automatic, two-spindle winder, model W8-905-2 E, is designed for parallel winding of wires or textiles/synthetics onto most common flanged bob-

48 | WIRE JOURNAL INTERNATIONAL

At wire Düsseldorf, Germany’s August Strecker GmbH & Co. KG presented the electric dual-upset buttwelder with automatic deburring type MS 500.

The unit, which comes with a comparatively high nominal rated capacity of 500 kVA, is equipped with a threephase DC transformer so there would not be a single phase load of the mains’ supply anymore. The amperage absorbed during a welding cycle is reduced substantially, e.g. divided by two approximately. As a result, fuse protection is facilitated, as otherwise often the local power supply’s mains fuses will not be sufficient, but a transformer is installed exclusively for the buttwelding machine.

The Type MS 500 (3P) model offers a welding range for solid copper or solid aluminum conductors from 12 to 42 mm. The main feature undoubtedly is its range for stranded copper conductors (95 to 1.0 sq mm or stranded aluminum conductors (120 to 1.00 sq mm), joining these cables without using any tubes. This welding method is a proven and well-tried process, and is the only solution for joining submarine cables, an issue of major importance these days with cable companies worldwide. The weld is identical in diameter when compared to the unwelded

FEATURE Strecker Sales Director Sigrun Mobus with the company’s MS 500 buttwelder. original material, with a welding zone that is much shorter than on the welds made using tubes. Another positive side effect with using a dual-upset buttwelding machine with automatic deburring is that there are no running costs for purchasing tubes as so-called consumable items or need to keep them stored.

Finally, the welding time is very short: a weld on stranded copper conductors 1,000 sq mm will only take up to a maximum of 30 seconds when using a dual-upset buttwelding machine.www.strecker.com.

WAFIOS AG At wire Düsseldorf, WAFIOS AG, whose main booth was so large and packed with new technology that it was almost a trade show unto itself, featured multiple new systems, including two new models added to its FMU spring- and wire-forming equipment line.

WAFIOS Machinery Corp. President and COO Dave Purcell by the company’s FMU 25 model at wire Düsseldorf.

50 | WIRE JOURNAL INTERNATIONAL

The FMU 16 and FMU 25 models represent the next generation of the FMU line, employing a new software concept, optimized machine design and build and even lower maintenance requirements. The two models can process torsion springs from 0.40 to 1.60 mm (FMU 16) and 0.80 to 2.50 mm (FMU 25) for fields from automotive and appliances to electronics and medical engineering.

The basic version machines in the new series are equipped with eight highly dynamic energy-efficient CNC axes. The modular way in which the FMU series has been designed and built means that the machines can be configured with up to 24 CNC axes and thus made ready to provide the best possible solution to each and every customer requirement. Moreover, the very latest monitoring and control technology safeguards the process of manufacturing springs against errors.

A fundamental innovation compared with the predecessor models in the series (FMU 1.2/1.7 and FMU 2.2/2.7) is the complete revision of the control components. A new and neatly laid out 21.5 in. multi-touch monitor guides the user through a simplified data input process for standard tools. The new “EasyTab” programming module by WAFIOS provides simple and logical preconfigured programming sequences which significantly reduce the amount of data that has to be entered during programming, speeding up the set-up process dramatically as a result. For the first time, operators are able to view and can easily change geometric, technological and axis-specific data inputs and corrections on a unique, clear and redesigned screen mask.

Further, the use of new drive technology combined with the new energy efficiency system developed by WAFIOS means that individual drives can be shut down if necessary. Modules that are not required can thus be parked at the machine, saving space and ensuring safety.

The models also support sequence simulation with collision detection and production/cycle time calculation, a first for the FMU series. The machine retains the position of all axes even after being powered down. The use of motors with the very latest encoder systems means that buffer batteries now no longer have to be used in the axes, simplifying maintenance work and increasing operational reliability. The ability to reuse tools from predecessor models safeguards compatibility within existing production installations.

Customer requirements were the focal point at every stage of the design and development of the two models.

Key criteria included not only maximum output quantities, straightforward and transparent programming, and secured quality standards, but also the cost of investment. This means that whether you choose to get started with the 8-axis, entry-level models or select one of the modular configuration levels which can be expanded to support up to 24 CNC axes, getting started with FMU technology will always be incredibly attractive from a pricing perspective. www.wafios.com.

At wire Düsseldorf, the Windak Group presented new Quickpack QP3-H coiler. It reported the following.

This year, which marked both Windak’s 10th time exhibiting at the world’s largest trade show for wire and cable as well as the company’s 20th anniversary, the new Quickpack QP3-H coiler was introduced. Part of the company’s Quickpack series of coilers, the Quickpac QP3-H and QP3-V models are fast coilers designed for maximum output of short length coils to 100-m lengths/ coils. Both coilers use modern servo technology for accurate and fast movements.

The QP3-H (horizontal) and QP3-V (vertical) coilers can be set up with four different packaging methods: binder, stretch film, shrink film or box.

The Quickpack QP3-H is suitable for high-speed packaging of single conductors for round and flat products. Coil is held together with two elastic binds and with optional shrink film as final package. Specifications are as follows: coil ID of 100 to 160 mm, coil OD of 120-300 mm, coil width of 30 mm to 100 mm and maximun weight of 12 kg. The QP3-H targets products from 2.5 mm to 13 mm in diameter, and coil lengths from 5 m to 100 m per package.

The output is up to eight coils per minute, depending on type of cable and winding length. Almost all movements in this fast single-head machine are controlled by servos with

FEATURE

Windak Group

Windak’s Steffan Edstrom by the company’s QP3-H coiler. very few mechanical setting changes for different packages. Coils can be binded, shrink-filmed or put in boxes, all in one complete solution.

The Quickpack QP3-V is designed for high-speed packaging of single-conductor round and flat products that can be packed into plastic bag, cardboard box or both solutions.

Specifications are as follows: coil ID of 100 to 150 mm, coil OD of 150 to300 mm, coil width of 25 mm to 100 mm and maximum weight of 12 kg. www.windakgroup.com. n

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PRODUCTS AT WIRE DÜSSELDORF

&

WIRE EXPO

‘Running ring’ an impressive component for large systems At wire Düsseldorf, the main entry to the wire event via Hall 9 saw an imposing “running ring” at the Queins Machines booth that is used for the company largest manufacturing systems. In response to a request from WJI, below Queins discusses the line component.

power cable or for applying multiple armoring layers on submarine cables that must sink down deep to the bottom of the water. The same applies to umbilicals that are used to supply power communication and function via hydraulic hoses to the platforms where people are drilling for oil. A different application of this type of machine that also uses the big rings are CTC (continuous transposed conductors) machines that strand flat, enamelled copper wires to square conductors for either heavy-duty transformers or for very big motors, such as those used on ships.

The reels, of course, are designed to last a long time, as the high-quality mammoth systems themselves are expected to serve for a century. That is not an unrealistic expectation, given that we have found in a wire rope company a capstan that was casted in 1857 and was still in service.

Our aim is to deliver comparable quality.

Contact: Queins Machines GmbH, www.queins.com.

This ‘next generation’ reel model was created by customer demand

The pictured running ring, one of two displayed at the event, stood six meters tall and weighs about six metric tons.

Due to limited space at the exhibition, we could only show two rings that could take 12 spools each. The insert shows it in actual deployment. When you imagine that a line can consist of, for example, 96 spools or even 212 spools, as many as 20 such rings could be required. The big rings that were displayed belong to a medium-size armoring machine.

The biggest machine we have made so far can easily handle running rings with a diameter of 8 meters.

The machines that the running rings would be used for are typically for either applying a single armoring layer on 52 | WIRE JOURNAL INTERNATIONAL

At Wire Expo 2014, U.S.-based Mossberg Industries, Inc., a longtime supplier to the wire and cable industry, introduced the company’s next generation of R2 Systems Reels. It reported the following.

The R2 Systems line of products was initiated by two of the industry’s largest energy cable manufacturers, which had tasked Mossberg’s engineering team with designing and building a reel capable of handling heavy coils of power cable in a continual, reusable, sustainable manner.

The intent was to eliminate the large wooden reels used for shipping their 600V URD distribution cable, and have the 48 in. plastic reels used as a tool by electric utility companies.

This paradigm change created huge savings in the cost of cable purchases for both producer and end-user alike, while eliminating disposal costs and enhancing safety for those working with power cables.

As Mossberg Industries continued to grow and develop this line of products, it was again tasked to create the

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next generation of shipping reels. Cable manufacturers wanted a reel they could ship the cable on, then, have the reel fully disassembled and returned for reuse. Mossberg designed and built the Generation II reels that feature two easily removable flanges. The process requires no tools and only takes about 30 seconds. This portability in heavy-duty reels allows the end-user to stack 10 flanges and 5 barrels onto two pallets and provides the efficiency needed to offset the return costs.

“Mossberg Industries has always been on the leading edge of technology and bringing new ideas to the table,” said Mossberg President Jim Khorshid (pictured). “Now with new ownership, a new and improved facility, added capacity, and a larger engineering team; we are ready to introduce new products for wire and cable packaging that we believe represent the future for this industry.”

Contact: Mossberg Industries, Inc., tel. 260-357-5141, www.mossbergind.com.

Drum provides torsion-free coiling of large diameter welding wire At wire Düsseldorf, Italy’s Gimax Srl displayed its INF-6 no-twist, drum-packing system that makes it possible to coil larger size welding wires that is torsion free, a necessity for processing by robotized welding equipment. It reported the following.

Innovation meets Tradition

www.strecker-limburg.de www.streckerusa.com

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WIRE CHINA 2014 September 24 - 27, 2014 Shanghai, P.R.China booth W1D42

CHALLENGE US! JULY 2014 | 53

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Coiling large diameter welding wire into drums is a simple task but obliges the end user to rotate the drum to pull the wire out without snags or kinks. The INF series of no-twist drum packers can handle both large and small diameters. A key to its efficiency is that the drum remains at floor level, which makes it more effective vibrating the settling wire in the drum. That makes it easier to thread wire, inspect during operation and perform maintenance.

Different types of drums (round or other forms, with or without pallet incorporated) can be used, and the extractor makes for effortless drum removal.

The INF-4, which is the high speed version of the range, can be adapted with minor modifications to handle solid wire up to 3.2 mm. The INF-6 is designed specifically for large diameters, from 2.0 mm to 5.0 mm. Its totally new design to straighten and layer the wire in the drum results in torsion-free, sub-arc wire. This means that it is not necessary to rotate the drum in order to pull out the wire, a benefit for the end-user in terms of simplicity and cost.

The INF-6 maintains the small footprint that is typical of the Gimax range of INF drum packers while handling large diameter wire and large drums up to 1 meter. In photo at the Gimax booth are, l-r, Roberto Beghetto, Fred Hardy and Enrico Romagnolo.

Contact: Enrico Romagnolo, Gimax Srl, tel. 390444-376-009, enrico.romagnolo@gimaxgroup.com, www.gimaxgroup.com.

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Wire former, with options, can be customized to fit all customer needs At Wire Expo, Vinston U.S. Corp. showcased its CMM12-450 R, a 13-axis wire former that comes with a servo driven spinner and X-Y slide as standard components. It reported the following.

This model, with support of up to 16 axes, can be tailored to the customer’s every need, with the additional axes including a second spinner and hydraulic cutter. It can process wire from 1.2 mm to 4.5 mm with a maximum/minimum wire feed of 10000 mm/0.01 mm, with a maximum

PRODUCTS & MEDIA

wire feed speed of 100 m/min. The X-Y slide (horizontal slide movement, perpendicular to mounted slide) is a distinct feature on most Vinston models as it provides added flexibility to existing design concepts for parts production.

This year also marks the transition of all servo motors and drivers from the LS Mecapion (an LG spinoff) brand to Yaskawa, a brand known for its reliability and durability, and striving for the same reputable name. Vinston is using Yasakwa servo mechanisms for all its models.

Two new features on current software models address issues with power fluctuations and backup systems. The software system designates automatic saves to the current program in increments of one minute, up to one hour.

This feature is crucial during the design phase should any power issues cause outages. Also, before each manual save of a program, the system makes a backup of the current design prior to saving the changes. This feature provides the ability to revert back to the original program should unforeseen circumstances resulting in the current program not saving properly.

The company has two new hybrid benders scheduled for rollouts this summer that will incorporate the best features of a CNC former and CNC bender. The sliding arms of a former will allow this hybrid bender to open up vast possibilities on parts that would require secondary operations on a traditional bender.

Contact: Billy Z Lin, Vinston U.S. Corp., tel. 847-9721098, billy.lin@vinstonus.com, www.vinstonus.com.

ANBAO Coil Nail Shank diameter: 0.083”- 0.131” Length: 1-1/4” - 3-1/2” Surface: Dope (golden), smooth shank, twisted shank, electro galvanized

ANBAO(Qinhuangdao)Wire&Mesh Co.,Ltd Add: No.33 Qinhuangxi Street, Qinhuangdao, P.R.Chin, 066000 Tel: +86-335-3893600 Fax: +86-335-3870760 Email: anbao@anbao.net Website: www.anbao.net

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Compact twist-tying system processes cables with efficient, quiet precision At Wire Expo, U.S.-based Plas-Ties Company introduced the company’s new XL-S SmartTyer system, a compact twist-tying solution built with the “smarts” to provide precision tying finishes. It reported the following.

The latest addition to the company’s XL product series, the quiet, user-friendly machine provides a self-adjusting tying range from .250 in. to 4 in. in diameter that runs on 110V power and only requires a platform space with a depth of less than 40 in.

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The “Smart” feature includes flexible programming that can be specified to provide a looser finish for delicate items and tighter finishes for items requiring a stronger, more secure tying solution. The built-in control panel allows users to pre-program common tying choices: tension, finishes and length. Once the selections have been made, adding a quick succession of multiple ties can provide an extra measure of protection that is faster and less labor intensive than hand tying. Users can also access the built-in PLC to develop their own customized/integrated automation programs.

The XL- S SmartTyer allows users to gain faster, more precise tying, along with the added benefits of greater labor savings and ergonomic safety. For larger diameter tying needs, the company offers the non-programmable, pneumatic powered XL-8 Air Ring Tyer, featuring self-adjusting tying up to 8 in. in diameter.

Contact: Jesse Garcia, Plas-Ties Company, tel. 800-8540137, ext. 230, jgarcia@plasties.com, www.plasties.com.

Equipment excels for measuring wall thickness of both cables and tubes At Wire Expo, U.S.-based Amaral Automation Associates displayed a new wall thickness vision system from Angle Systems that can be used for both cables and tubes.

The model from Angle Systems uses machine vision technology to measure wall thickness of single and dou-

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ble wall tubing using machine vision technology. It can be used for off-line measurements on the production floor as well as in a lab environment. It has an easy-to-use operator interface that features a touch screen monitor and requires minimal operator intervention. The new system is designed to be efficient and accurate, allowing companies to record and document every desired parameter, including: inner and outer diameters, wall thickness (single and/ or dual walls), concentricity, minimums and maximums, averages, range and operational parameters.

Amaral Automation Associates, which has represented the wire and cable industry for more than 30 years, described the addition of Angle Systems as a perfect fit. “This measure-

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ment system is one of the most robust and complete units I have ever seen,” said owner Rick Amaral. “The ease of use combined with ability to measure and record just about anything makes it a ‘must have’ for any company that uses measurements as part of their manufacturing process.”

Contact: Amaral Automation Associates, tel. 401-405-0755, sales@amaralautomation.com.

Building wire lines can be ordered in 3 levels

WTM TK

At wire Düsseldorf, Maillefer showcased the company’s lines of high-speed Building Wire Solutions that are now available in three production solution levels (for more details, see p. 39). It reported the following.

The three building insulation levels (EEL 20/Enter, EEL 20// Extend and EEL 20/// Explore) each represent reliable solutions for different needs. The greatest variation is in capacity, budget and automation levels and maintenance needs.

Before noting what is different, it is important to note what all the levels share. First, each level is designed according to our highest quality standards, and with cost-efficiency in mind. All solutions give you full productivity from day one. Low cost per produced wire meter has been one of the main design principles, a standard made possible by the state-of-the-art technology, easy maintenance, and smart use of materials and energy.

EEL 20/Enter requires low capital investment, making it an easy option for production start. Production speed of 1 sq mm wire with 0.6 mm PVC insulation can attain up to 1000 m/minute. For cable manufacturers with expanding needs, our EEL 20//Extend building wire insulation line offers a 1300 m/minute production speed in 1.5 sq mm wire with 0.7 mm PVC insulation. The production is lean, yet flexible. If the goal is to produce large volumes with quick color changes, EEL 20///Explore is the most profitable option. It gives a 15-20% higher production capacity compared to EEL 20//Extend. There are many value packages available to help master your market with higher throughput and quick color or type change.

Contact: Heikki Saastamoinen, product manager – low voltage cable solutions, Maillefer, tel. 358-40-715-5704. heikki.saastamoinen@maillefer.net, www.maillefer.net.

Testing system offers many pluses for LAN cables U.S.-based Beta LaserMike introduced a new, automated high- and low-frequency LAN cable testing system at Wire Expo. It reported the following.

The DCM SCS-700 LAN/Data cable testing system, a bench-top unit, attracted a lot of attendees to the Beta LaserMike booth. There, staff explained how the model can enable cable producers to completely automate their testing process, increase productivity and realize bottom-line benefits. The unit efficiently tests both the high- and low-frequency characteristics of Cat. 5e/6/6a cables. The high-frequency (HF) test60 | WIRE JOURNAL INTERNATIONAL

Composite bow offers greater durability KEIR Manufacturing’s aerodynamic composite BackBone Bow, showcased at Wire Expo, is designed to incorporate all the positive features of an enclosed bow without any of the negatives associated with operating a totally enclosed flyer bow, as explained below by Sales

PRODUCTS & MEDIA

ing range is to 700 MHz. The low-frequency option includes an integrated LCR meter that enables users to test resistance, mutual capacitance, and capacitance unbalance at frequencies down to 100 Hz. The low-frequency (LF) testing capability also allows cable makers to test longer cable lengths up to 10 Km and avoid the cutting and scrapping of product to perform required tests.

Dual-frequency testing can be performed with a single connection to significantly reduce set-up and testing time.

The automated four-pair switching platform enables HF and LF cable tests to be performed in less than three minutes. As with all DCM cable testing systems, the SCS-700 is equipped with easy-to-use test software for comprehensive test data management and reporting.

Contact: Beta LaserMike, www.betalasermike.com/dcm.

and Marketing Manager Mike Walters, who is holding the bow in the picture.

The semi-enclosed BackBone Bow gives the customer increased reliability and performance needed in today’s competitive environment. The triaxially braided I-beam construction has much greater durability than layered/ laminated designs, allowing the BackBone to take more hits and endure higher stress. This results in significantly increased operating life and less machine downtime.

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The aerodynamic cross section equates to 18-34% lower energy consumption depending on operating speed and machine type. Higher TPM along with superior wire quality and drawdown are also achieved with the BackBone.

Because of these demonstrated benefits, a North American manufacturer recently converted all 65 of their Northampton twinners to BackBones as part of their corporate process optimization/green initiatives program. After a thorough evaluation, they are realizing five to six years of bow-operating life and energy savings of approximately 30%.

Contact: Mike Walters, KEIR Manufacturing, tel. 828885-8444, sales@keirmfg.com, www.keirmfg.com.

Scanning laser micrometer excels at doing spring profile measurements At Wire Expo, U.S.-based LaserLinc introduced a system for measuring the diameter and pitch of springs, coiled tubing, and other corrugated or convoluted products. It reported the following.

The measurement system features a scanning laser micrometer mounted to a linear actuator. The linear actuator traverses the length of the spring. The actuator includes a tilting fixture that allows the micrometer to

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align with the spring’s exact pitch angle. To verify the pitch angle, Total Vu™ software displays the spring’s profile. A digital angle gauge ensures an exact mechanical angle setting. By incorporating measured diameter and pitch angle, the software computes the true enveloping diameter. An encoder provides distance value and measurements necessary for program calculations.

The system includes the following features and specifications: springs load on a customer-provided mandrel; springs can load singly or as multiples up to the number allowable per the actuator’s length; for standard actua-

PRODUCTS & MEDIA

tor, product length 0 to 2000mm (longer lengths available as custom); calibrates in user-defined units; measures both pitch and enveloping diameter; actuator has user-selectable position set points and variable traverse speeds, with limit switches and emergency stop; RS232 communication allows for device control as well as alarm condition evaluation; and applications include springs, coiled tubing, other coiled products, corrugated products, convoluted products, and any product that requires tilting the micrometer to match pitch angle.

LaserLinc manufactures highly-accurate/highly-adaptable non-contact laser scan micrometers and the UltraGauge+™ ultrasonic measurement system. Devices measure OD, ID, wall thickness, eccentricity, concentricity, and other characteristics, for industries including wire, cable, fiber, hose, tube, pipe, centerless grinding. LaserLinc micrometers interface with PLC-regulated or other process control systems via the SmartLinc™ processor, or with any Windowsbased PC. Contact: LaserLinc, tel. 937-318-2440, info@laserlinc. com, www.laserlinc.com.

Brush-cleaning system for wire, cable and pipe is both effective and compact At wire Düsseldorf, Germany’s GEO-Reinigungstechnik GmbH, represented in the U.S. by Cable Consultants Corp., displayed its new DRB-WCS brush cleaning system for wires, cables and pipes. It reported the following.

The system is a compact, environmentally friendly and cost-effective system for removing residual scales, tinsel and dust as well as reducing excess drawing agent. For this purpose, the material passes through a rotating spiral brush where the rotary movement supports the wiping effect of JULY 2014 | 63

PRODUCTS & MEDIA

this well-proven tool. Further contamination removed from the wire does not clog-up the brush because centrifugal force throws a major part of the removed contamination into the base of the unit.

Depending on the application and material, the brushes can have nylon, brass or steel bristles. The system has a sturdy, clad-steel frame with a working box. Inside the lidded box, two separate compartments include a rotating unit to fix a cut-to-length spiral brush and an air wipe. Removed dirt is caught in the trough and collected in a removable, draw-type container. Following the spiral brush is an air jet nozzle to blow off any remaining loose particles. To change a used spiral brush the two-part rotation unit can be opened and a new brush inserted.

Contact: GEO-Reinigungstechnik GmbH, info@ geo-reinigungstechnik.de or, in North America, Fred Hardy, Cable Consultants Corp, tel. 704-375-9313, fhardy@cableconsultantscorp.com.

As some 40% of copper products are made from copper scrap, the use of 100% copper scrap as the raw material for finished products is of ever-growing interest, so the task of developing and implementing technologies and processes for copper scrap recycling is the most urgent

Company’s line of recycling equipment is designed for all types of copper scrap At wire Düsseldorf, Copper-Lines.K discussed the full range of the company’s manufacturing equipment for recycling of all kinds of copper scrap, as well as units for further processing of fire refined and oxygen-free rods. It reported the following.

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issue today. It is well known that rods made from 100% copper scrap are microalloyed and are not easily being manufactured during the steps of drawing, rolling and heat treating. For these purposes special mills and annealing machines are required.

Using conventional techniques, the stages of electrolytic refining and cathode smelting are highly energy-consuming (gas, electricity, etc.). Our technology uses modern heat recovery system to supply hot water and heating for household use by outgoing gas heat recuperation. We offer our customers a wide range of such equipment, and have long supplied annealing lines that successfully process rods made from 100% of copper scrap for an area up to 100 sq mm. Our company is currently the only one in the world manufacturing an annealing technology with such achievements. Our annealing line allows high-temperature processing, resulting in a modification of the structure of copper and improving its ductility.

Our latest innovation is a hybrid gas and electric furnace, combined with vertical casting machines (for circular and rectangular sections, tubes) from 100% of copper scrap with the possibility of deep refining.

We also offer an in-line rolling mill combined with an annealing line producing rods conform to global standards as well as design equipment for mechanical and pyro-chemical pre-treatment of copper scrap for further processing.

Contact: Copper Lines.K, www.copper-lines.com. n

TECHNICAL PAPERS

TECHNICAL PAPERS Technology production and properties of high-strength, high-conductivity nanostructured copper-silver wires for a new type of overhead line conductors

By Artur Kawecki, Tadeusz Knych, Eliza Sieja-Smaga, Andrzej Mamala, Paweł Kwaśniewski, Grzegorz Kiesiewicz, Beata Smyrak and Kinga Korzeń Materials and technologies for processing wires and conductors are, because of their unique nature and role in society, a key interest of the world’s leading research centers and production plants. High world standards for quality, safety, health and use as well as recycling contribute to the design of material solutions that can ensure (via reducing production costs and using innovative technology and materials) the required level of mechanical and electrical properties.

Research of Cu-Ag alloys with a high silver content and technology conversion began in the 19403, and been intense the last 20 years. The main research centers for this are located in the U.S., Japan, China, Southern Korea and Germany6-7. By analyzing the global results of research of Cu-Ag alloys for wire purposes as well as used as components of strong magnetic fields components, the authors can state that both the amount of alloy component and the sequences of intermediate heat treatment have an influence on the achieved set of products strength and electrical properties. Such research, especially the last decade, indicates it is possibility to use the properties of a considered group of alloys to design materials with very high mechanical strength and electrical conductivity8-10.

One of the possible application of Cu-Ag alloys, especially at the silver contents of 4 to 7% wt., may be as high-strength and high-conductivity wires for cores of overhead electric power conductors.

Fig. 1. Laboratory installation for continuous casting.

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Analyzing operational costs from transmission losses, one observes that during a long-term operation period, their value becomes much higher than the value of conductors used in transmission lines. This fact inspired the development of new material and design solutions for conductors to reduce such transmission losses. One approach was uniform conductors made of aluminum alloys (high conductivity and extrahigh conductivity) that can reduce transmission losses, but do not guarantee a significant increase in current carrying capacity. A second approach was high-temperature conductors that do allow an increase in the current carrying capacity, but generate a discernible increase of transmission losses related to a higher maximum, and more importantly, from a higher average conductor temperature. As the temperature increases, so does material resistivity. Another drawback is non-conductive or poorly conductive cores of high-temperature conductors.

The new concept from AGH UST scientists and called ACCAS (Aluminum Conductor Copper Alloy Supported), is for overhead electrical power conductors that can minimize energy transmission losses. An alternative for electrical power distribution systems, these conductors would have high-strength Cu-Ag alloy cores with electrical properties (UTS>1000MPa, γ>75%IACS) and a conducting layer based on soft aluminum. Its main properties are: a change from a steel core to a high-strength and high-conductivity core made of silver-copper alloys; Cu-Ag alloy wires coated with a special anti-corrosion layer; replacement of hard aluminum wires with soft aluminum wires; and maximal reduction of free space inside the conductor in case of shaped cross-section wires.

It is also possible to use aluminum alloy wires on the external conductor layers to improve mechanical properties with minimal reduction of electrical conductivity. New

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TECHNICAL PAPERS

types of conductors make it possible to transfer electrical energy at a working temperature of up to 150°C in conditions of significantly increased current-carrying capacity in comparison to currently used conductors types1-2.

This proposed solution (patent pending) makes it possible Fig. 2. SEM microstructures of CuAg5 casting in a longitudinal cross-section. (depending on conductor type) Kraków, Poland). See Fig. 1. It consists of a power and to decrease electrical power transmission losses as much control system, an inductive melting furnace, a crystalizer as 40% in relation to alternative solutions of high-temsystem, a primary and secondary cooling systems and perature conductors. The core conductor material (Cu-Ag a drawing system (duo roller). Due to the possibility of alloy) might be easily recycled by remelting, significantly inductive enforcement of liquid metal movement in the reducing the conductor’s total long-term price. This allows crucible, chemical composition repeatability is achieved current capacity to increase about 50% of conventional along the length of the rods.

ACSR (Aluminum Conductor Steel-Reinforced) conducMicroscope observations of rods after casting and at var4-5 tors at the same cross-section . ious stages of their deformation were carried out with the use of a scanning microscope, Hitachi SU70.

Laboratory rod continuous casting method Fig. 2 shows the microstructure of CuAg5 alloy. The and their material properties casting structure of CuAg5 contains areas rich in silver Silver-copper alloys, which belong to precipitation-hard(white), separated from the matrix, which consists mostly ening alloys, have a double-sided variable solubility of of copper (dark background). Due to the mutual, limited Ag in a Cu matrix and of Cu in an Ag matrix that, along solubility of silver in copper and copper in silver, the with temperature change, makes it possible to improve the casting structure matrix contains mostly copper with a mechanical and electrical properties of Cu-Ag alloys by certain amount of silver and precipitations enriched in mutual precipitation reactions. Owing to the mutual limit silver, with some copper. solubility of Cu and Ag at a temperature below the eutecFig. 3 shows exemplary results of composition analysis tic temperature (780˚C), the alloy macrostructure in generwith respect to elements making up Cu with 5% wt. Ag al consists of large grains with a separate crystallographic mass alloy. Chemical composition analysis after casting orientation, inside of which it is possible to observe alterconfirmed the effect of mutual element precipitation. nately copper- or silver-rich subgrains, precipitated from Table 1 shows the results of chemical composition test a matrix consisting of Cu-Ag alloy. Particular subgrains result in the received casting. The true silver content in contain more copper or more silver, but with increased alloy is close to the assumed value. The chemical compomaterial deformation from reducing the temperature of sition analysis showed a very low content of contaminants heat treatments, further mutual precipitation of Cu and in the alloy (total volume less than 20 ppm). Table 2 shows Ag inside the subgrains alone and the matrix is possible. the mechanical properties of the tested alloy after casting.

One purpose of the desribed procedure is to increase the Fig. 4 shows the influence of alloy deformation on alloy’s mechanical properties by precipitation strengthenchanges in strength and electrical properties. The results ing, but it also improves electrical conductivity owing to obtained from the experimental data show that the true the precipitate from the Cu-Ag alloy solid solution of both total strain (drawn ratio n=6) of tested alloy allows the copper and silver. As a target, skilfully conducted plastic achievement of tensile strength of 800 MPa. However, working combined with intermediate heat treatment may there is a very strong influence of deformation on the lead to a situation where the structure of thin wires is made reduction of electrical conductivity. The total true strain of the copper matrix, with very extended precipitations of equal to six of the CuAg5 alloy caused an increase of its Ag with nanometric dimensions. resistivity by over 11%. Such rarely occurring drops in The CuAg5 alloy (from OF copper and Ag granules, electrical conductivity may be explained by the particpurity Ag0) was cast in 9.5 mm rods at 10 mm/s at a ularly intensive generation of structural defects, distortemperature of 1180-1200˚C in a protective nitrogen tions of the crystalline structure, multiplication of disloatmosphere. Crucibles and crystallisers used in the casting cation pile-ups during plastic deformation of material. were made of high-purity pressed graphite, and a graphite casting powder was used to cover the liquid metal to Research prior to drawing process deoxidise the alloy.

The obtained set of wires electrical and strength propCasting tests were done at a continuous melting and erties was insufficient, so research was done on optimicasting laboratory installation (Faculty of Non-Ferrous zating the casting properties before its plastic working Metals, AGH University of Science and Technology, before drawing. The goal was to modify the prima-

TECHNICAL PAPERS Fig. 3. EDX chemical analysis of Cu-5% wt. Ag alloy.

Fig. 3 EDX chemical analysis of Cu-5%wt.Ag alloy

CuAg5

Alloy elements

Content, %wt.

Ag

4,84

Cu

in balance

Impurities

Content, ppm

Bi

0.52

Pb

0.6

Sb

0.19

As

0.27

Fe

1.9

Ni

0.4

Sn

0.42

Zn

1.77

Cd

1.41

Co

0.05

Cr

0.44

Mn

0.38

P

1.8

Se

0.1

Si

1.7

Te

0.012

S

5.5

Total amount of impurities

17.46

Fig. 4. Ultimate tensile strength and electrical properties vs. total true strain during drawing of CuAg5 alloy wires. ry casting microstructure by using the complex and multi-stage heat treatment of the alloy. The primary casting structure, formed during the alloy crystallization, consisted of numerous fine separations of silver-rich phase on the background of grains mainly consisted of copper.

The microstructures in Fig. 2 show the separations of the silver-rich phase also have internal areas that contain copper. This is the result of mutual, two-sided and limited solubility of alloy components (copper and silver) in a solid state. The structure was not advantageous for achieving high mechanical and elec-

Table 1. Chemical composition of Cu-5%wt. Ag cast.

Material

ρ, g/cm3

HB

CuAg5

8.96

71

UTS, MPa YS, MPa γ, MS/m %IACS 222

98

50.5

87.2

Table 2. Mechanical and electrical properties for CuAg5 alloy after casting.

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trical properties of the alloy during its deformation.

To limit the negative influence of deformation in electrical properties of wires, and to enhance their strength properties, tests were carried out with respect to the influence of initial thermal processing of castings before their further plastic working.

It was concluded that by using multistage thermal processing of castings, comprising oversaturation and aging, one can considerably enhance both the strength and electrical properties.

That is due to the precipitation of silver-rich α phase from the copper-rich matrix, and vice versa: precipitation, from silver-rich areas, of copper-rich β phase, as well as an increase in α and β phases, precipitated earlier.

Dozens of variants of multi-stage heat treatment of rods after casting (solutioning, primary aging, second-

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solution processes resulted in CuAg5 alloy with a comary ageing) were tried to determine optimal parameters. plete dissolution of silver in the copper matrix (variant B, The selection of heat-treatment variants for the alloy after see Fig. 7b). The correctly selected temperature and aging casting was determined by the possibility of the significant time enabled the precipitation of numerous, small silver increase of the mechanical and electrical properties. After areas from the entire volume of oversaturated solution. successive stages of the heat treatment, the hardness of samThis resulted in a precipitation hardening of the alloy, ples (Brinell’s method) and their electrical conductivity were allowing the achievement of a better consolidation. measured. Table 3 shows the results of successive stages of Secondary aging of CuAg5 alloy caused an increase and heat treatment for hardness change and the conductivity of coagulation of silver precipitations initiated before. cast made of CuAg5 alloy.

Thermal processing caused a beneficial modification in Fig. 5 shows the forming history of the alloy’s hardthe microstructure of CuAg5 alloy. Maximum extraction ness and electrical conductivity, from the casting phase to solutioning process stages for primary and secondary aging.

Rods were selected at the structure and properties modified to two heat-treatment variants (A and B). Table 3 shows the parameters.

• variant A: cast–low solutioning temperature/short time of homogenization–high primary aging temperature and a long time heat treatment–high secondary aging temperature/short time heat treatment.

• variant B: cast–high solutioning temperature/long time of homogenization–low primary aging temperature/ short time heat treatment–high secondary aging temperature/short time heat treatment.

Table 4 lists the cast’s mechanical and Fig. 5. Evolution of the hardness and electrical conductivity of CuAg5 electrical properties without heat treatment alloy depending on the applied heat treatment. and after applying selected variants (A and B) of heat treatment.

The final strength CuAg5 variant A CuAg5 variant B Material condition properties of the castHardness HB γ, MS/m Hardness HB γ, MS/m ing after thermal processing increased from Cast 68 50.5 68 50.5 5% (variant A) to 15% After solutioning 65 50.8 66 48.6 (variant B) and electrical properties increased After primary ageing 67 51 65 48.6 to 7% for both.

After secondary ageing 91 54.5 100 54 Fig. 6 shows microstructures of CuAg5 Table 3. Comparison of hardness HB and electrical conductivity of CuAg5 alloy between alloy after casting. cast condition and material after different thermal processing.

Fig. 7 shows the applied thermal proUTS, YS, A100, Hardness γ, cessing technique.

Material %IACS MPa MPa % HB MS/m Fig. 8 shows the alloy microstructure after a CuAg5 as cast 210 105 26 68 50.5 87.1 large plastic deformaCuAg5 after HT tion (draw ratio 6).

225 190 13.5 91 54.5 94 (variant A) The morphology of Ag precipitates was CuAg5 after HT 252 220 8.5 100 54.0 93.1 observed using a scan(variant B) ning electron microscope from Hitachi Table 4. Comparison of the strength and electrical parameters of CuAg5 alloy wires obtained SU70 (PDBSE). The from alloys after casting and exposing them to the various initial heat treatment (HT).

TECHNICAL PAPERS

of silver from the copper matrix considerably improved electrical conductivity of the alloy, while numerous, small silver precipitations improved mechanical properties of the casting (see Fig. 7b-c).

The alloy after initial heat treatment per variant B (comparison to Variant A) is characterized by smaller and more numerous silver precipitates, which leads to higher mechanical properties of wires.

Fig. 6. SEM microstructures of CuAg5 alloy after casting.

Deformation influence Rods made of CuAg5 alloy after selected variants of heat treatment were subjected to a drawing process.

Fig. 9 shows the results of the applied casting heat treatment influence on the change of wires’ drawing stress: the heat-treated wires had 30% higher value of drawing stress than the wires without heat treatment. Further, for the heat-treated wires, with increasing deformation the value of drawing stress is continuously increased, a result of the strong alloy strengthening at the modified structure.

Figs. 10 and 11 present the influence of total true strain deformation on the change of mechanical strength and electrical properties of wires drawn from rods at the structure which is casted and modified by the heat treatment. The preliminary heat treatment of the casting contributed to the intensification of drawn wires hardening.

Depending on the applied heat treatment, wires shown 25% (variant A) to 30% (variant B) higher mechanical strength properties in comparison to wires without heat treatment. The form of the wires’ hardening characteristics suggests the possibility of straight increase of tensile strength in course of further alloy deformation.

It was also observed that the heat-treated wires had a faster decrease of electrical conductivity than the wires without such heat treatment. An excellent electrical conductivity of modified casting (variant A and variant B), obtained before the drawing process, contributed to relatively high electrical conductivity of strongly deformed and strengthened wires.

A large plastic deformation (drawing) induced noticeable elongation of eutectic precipitations and those generated due

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Fig. 7. SEM of evolution of microstructures of CuAg5 alloy after the different casting modification (variant A- left column and B- right column) by thermal processing (a: solutioning, b: primary aging, c: secondary aging).

Fig. 7 SEM of evolution microstructures of CuAg5 alloy after the different casting modification (variant A- left column and B- right column) by thermal processing (a: solutioning, b: primary ageing, c: secondary ageing)

Fig. 8. SEM microstructures of CuAg5 alloy (variant B) after the total true strain equal to 6.

Fig. 8 SEM microstructures of CuAg5 alloy (variant B) after the total true strain equal 6

TECHNICAL PAPERS

to thermal and mechanical processing of the alloy. The structure in the longitudinal cross-section of micro-wires in true total strain equal to 6, consists of numerous thin, strongly elongated silver fibers (almost completely pure silver), against a matrix almost completely copper. See Fig. 6. The diameter of these multiple fibers begins at a dozen-odd nm and ends at ca. 100 nm.

The obtained microstructure is related to the strong consolidation of the alloy due to the numerous grain boundaries and their deformation. A certain type of composite alloy structure was formed, in which the reinforcing phase, responsible for strength parameters, are the numerous silver fibers. The possibly intensive silver precipitation from the solution resulted in its purification (almost pure copper remained). The strongly elongated, numerous silver bands, along with copper, form a certain combination of parallel and perfect current conductors that result in the achievement of very high electrical properties of micro-wires made of CuAg5.

Modification of casting structure and initial heat treatment (HT) enabled the achievement of wires with a particularly good set of strength and electrical properties. CuAg5 alloy wires, at total true strain of ca. 6, have UTS=1200 MPa and Îł=71% IACS. In comparison with material without initial thermal processing, an increase of tensile strength was observed, by ca. 22% (variant A), and ca. 30% (variant B) with a simultaneous from 3% to 10% drop in the wire electrical conductivity.

Fig. 12 shows maps of electrical conductivity changes in a function with ultimate tensile strength in wires drawn with and without initial thermal processing. On the basis of the obtained experimental database, the range of strength and electrical properties of wires with specific deformation can be estimated.

Table 5 shows final strength and electrical parameters of CuAg5 alloy wires, obtained after casting and various initial thermal processing (variants A and B).

Fig. 9. The influence of used CuAg5 cast’s heat treatment or no heat treatment on the change of wire drawing stress.

Fig. 10. True strain deformation influence on the change of mechanical strength properties of wires drawn from rods at the casting structure and modified by the heat treatment.

Summary and conclusions The results presented here constitute a component of studies over the preparation of new and integrated technology that comprise the process of continuous melting and casting rods and the process of their drawing into wires by using the interoperational

Fig. 11. True strain deformation influence on the change of electrical properties of wires drawn from rods at the casting structure and modified by the heat treatment.

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from a large number of grain limits and dislocation accumulation in the alloy structure. This negative effect, however, can be reduced by a properly selected heat treatment scheme during plastic working of the alloy.

The modification of the casting structure resulted in intensification of strain hardening and enabled researchers to obtain wires with a particularly high set of mechanical and electrical properties. As has been proved in this paper, researchers obtained wires that (with total true strain 6), depending on thermo-mechanical treatment of alloy, show UTS=1040 MPa and γ=44 MS/m (76% IACS), or UTS=1200 MPa and γ=41 MS/m (71% IACS).

The microstructural result of properly selected thermo-mechanical treatment of CuAg5 alloy is a Fig. 12. Characteristic of changes in electrical conductivity in the function of UTS wires wires made from CuAg5 alloy structure of numerous, strongly elongated fibers of almost pure silver compared to the matrix consisting drawing with and without initial heat treatment (HT). almost only of copper.

Silver fibers, dependTrue total UTS, YS, γ, Material %IACS ing on heat treatment strain MPa MPa MS/m parameters and the without HT 6 810 740 45,7 78,8 degree of deformation, have a diameCuAg5 after HT (variant A) 6 1040 930 44,2 76,2 ter of between several after HT (variant B) 6 1200 1090 41 70,7 dozen and so nm to 50÷100 nm, and, by Table 5. Comparison of the strength and electrical parameters of CuAg5 alloy wires obtained creating composite from alloys after casting and exposing them to various initial heat treatments (HT). strengthening alloy phase, are simultaneheat treatment in order to increase set of mechanical ously an electrical system of parallel links with copper strength and electrical properties of the good. of very high electrical conductivity.

By the parameterization of the chemical composition There is still research to do into regarding the therof alloys and the use of an appropriate mechanical and mal stability of obtained wires, but the experiments heat treatment, it will be possible to prepare the type discussed here indicate that it is possible for them to series of wires and conductors at the different set of have long-term operation at the temperature of up to mechanical and electrical properties and it will be possi150°C without the significant worsening of mechanical ble to use them in various applications. strength properties. n The work presents results of tests aimed at a modification of the initial casting structure of CuAg5 alloy into a composite structure, consisting of numerous, elongated References silver strands in a copper matrix. In result, a large number of small, evenly distributed within the entire volume, 1. Patent application P.397200 Power overhead line consliver strands, whose final diameter does not exceed ductor, 2011.

50÷100 nm (the finest fibers having several dozen-odd 2. Community designs, Office for Harmonization in the nm), formed a sort of reinforcement phase, considerable Internal Market OHIM (Trade Marks and Designs) No. enhancing strength parameters of the alloy (through 001961939-0001÷0006. grain boundaries and dislocation pile-ups). The correct3. U.S. Patent No. 2,567,560, 1951, Heat Treatment of ly selected thermal and mechanical processing enabled Copper-Silver Binary Alloys. optimal precipitation of silver from the copper matrix, 4. A. Kawecki, T. Knych, A. Mamala, P. Kwaśniewski, through which the formed system of parallel silver-copG. Kiesiewicz, B. Smyrak and E. Sieja-Smaga, New per connections resulted in the achievement of wires with materials for high temperature overhead line conductors excellent electrical conductivity. cores with lower energy transmission losses, Academic The CuAg5 alloy rod, obtained as the result of laboraEntrepreneurship, University of Bielsko-Biala, Poland, tory installation to continuous casting, is characterized by 2012, (in print). a homogenous chemical composition along their entire 5. T. Knych, A. Mamala, A. Kawecki, P. Kwaśniewski, length. The alloy shows considerable potential for hardenB. Smyrak and G. Kiesiewicz, The latest idea of high teming by plastic deformation. At the same time, there is an perature overhead line conductors with lower energy transunexpected high drop in electrical conductivity resulting mission losses, Wire Journal International, 2013, (in print).

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Acknowledgements Presented research results are co-financed by European Found of Regional Development in the frame of Programme Innovative Economy, 20072013, Research and Development on Innovating Technologies, Project title: Developed technologies of functional materials manufacturing for conducting, processing and accumulating energy, Task title: New type of copper alloys functional materials characterized by high strength and electrical conductivity designed for power industry and electronic engineering. Project number: POIG.01.03.01-00-086/09-01.

Eliza Sieja-Smaga

Joined by presenter Tony DeRosa, c, authors (l-r) Grzegorz Kiesiewicz, Paweł Kwaśniewski, Beata Smyrak and Tadeusz Knych accept their award for best nonferrous paper at Wire Expo 2014.

Artur Kawecki is an award-winning assistant professor in the Nonferrous Metals Faculty of AGH University of Science and Technology (NMF AGH), Krakow, Poland. He specializes in metallurgy, material engineering and plastic processing of nonferrous metals, with a focus on new high-conductivity and high-strength materials for electrical applications. Tadeusz Knych is an award-winning full professor at NMF AGH. He specializes in metallurgy, focusing on synthesis of alloys, hot and cold plastic working and testing of new materials. He holds many patents for overhead electricity and rail.

Kinga Korzeń

Eliza Sieja-Smaga is a doctoral student in the NMF AGH. She specializes in metallurgy, plastic processing, material engineering, and production technology of nonferrous metals, especially cooper alloys. Andrzej Mamala is an associate professor in the NMF AGH. He researches new alloys, mechanical behavior of overhead conductors and many process aspects. Paweł Kwaśniewski is an assistant professor in the NMF AGH. He specializes in metallurgy new aluminium and copper alloys, plastic processing and production technology of nonferrous metals. Grzegorz Kiesiewicz is an assis-

Artur Kawecki

Andrzej Mamala

tant professor in the NMF AGH. He specializes in metallurgy of nonferrous metals, plastic working and FEM analysis. Beata Smyrak is an assistant professor in the NMF AGH. She specializes in metallurgy, with a focus that includes minimizing creep in wire for overhead conductors. Kinga Korzeń is a doctoral student in the NMF AGH. Her area of interest is focused especially on the phenomenon of creep wires for overhead conductors. This paper, which was presented at WAI’s 83rd Annual Convention, Atlanta, Georgia, May 2013, won the award for best nonferrous paper.

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6. Y. Sakai and H.J. Schneider-Muntau, Ultra-high strength, high conductivity Cu-Ag alloy wires, Acta Mater., Vol. 45, No. 3, pp. 1017-1023, 1997.

7. A. Benghalem and D.G. Morris, Microstructure and strength of wire-drawn Cu-Ag filamentary composities, Acta mater, Vol. 45, No. I, pp. 397-406, 1997.

8. S. Nestorovic, I. Markovic and D. Markovic, Influence of thermomechanical treatment on the hardening mechanism and structural changes of a cast Cu-6.6 wt.% Ag alloy, Materials and Design, 31, 2010, pp. 1644-1649.

9. H. Cho, B. Lee, B. Kang and K. Kim, Ageing behaviour of Cu-Ag alloys, Advanced Materials Research, Vols. 47-50, 2008, pp. 1051-1054.

10. J.B. Liu, L. Meng and Y.W. Zeng, Microstructure evolution and properties of Cu–Ag microcomposites with different Ag content, Materials Science and Engineering A (MSE-A) 435–436, 2006, pp. 237–244.

TECHNICAL PAPERS

TECHNICAL PAPERS Effects of niobium additions to a vanadium microalloyed H-C wire steel Niobium additions to a high carbon vanadium microalloyed wire steel were found to increase hardness likely resulting from pearlite interlamellar spacing refinement.

By Emmanuel De Moor and Stephanie L. Miller An increased demand for higher strength wire steels exists in a number of applications, driving further alloy development. Hypereutectoid carbon levels for increased strength are used in combination with silicon additions to prevent grain boundary proeuteuctoid cementite formation that can detrimentally affect drawability1,2. Chromium additions are used to alter pearlite reaction kinetics, yielding optimized microstructures for strength through interlamellar spacing (ILS) refinement3. ILS refinement can be a major strength contributor according to:

Experimental procedure

Laboratory materials were prepared using a vacuum induction furnace. Table 1 shows the chemical compositions of the studied materials. A vanadium and chromium alloyed 0.80 wt pct carbon steel was used as a reference material.

Niobium alloying levels of 100 ppm were used in the second alloy. The steels are identified as 1080V and 1080V+Nb in the present paper. Nitrogen levels of approximately 60 ppm were employed to mimic nitrogen levels of industrial as-cast electric arc furnace material.

Eq. (1) The castings were sectioned and hot-rolled.

(1) Reheating (1) was (1) conducted using a reheating ramp to 1200°C over approximately two hours and a 20-minute soak. A six-pass deforschedule was of employed with an approximate yield strength ininMPa, a term term representing the combination solid solution and and 20% with with theyield yield strength in MPa,athe arepresenting term representing the combination of solid solution yield strength inthe MPa, a term representing combination of mation solid solution and with the strength MPa, reduction per pass resulting in an overall reduction ratio of the combination of size solid and cementite volume colony size the ILS µmin [4,5].

Experimental cementite volume strengthening, colony inand µm, and theinILS µm [4,5].

Experimental cementite volume strengthening, colony insolution µm, and the ILSinsize inµm, µm [4,5]. ume strengthening, 3 to 1.Experimental A 15-minute reheating was performed following the 4,5 strengthening, colony size in µm, and the ILS in µmpct .wt data for carbon contents ranging from 0.75-1.8 wt have shown good correlations with this on contents ranging from 0.75-1.8 wtranging pct have shown good correlations with this data for carbon contents from 0.75-1.8 pct have shown good correlations with this third reduction pass.

Experimental data for carbon contents ranging from 0.75-1.8 Samples were machined from the hot-rolled plates with wt pct have shown good correlations with this equation5. a cylindrical geometry of 5.5 mm and 72 mm in length.

Yield strength follows a Hall-Petch type relationship with Continuous cooling experiments were conducted using a colony size and ILS, and since ILS is generally several orders Gleeble® 3500 thermomechanical simulator in high vaccum of magnitude less than colony size, it is the dominant strength conditions (< 10-3 torr). The thermal profile for continuous contributor. Alloying and processing strategies for increased cooling experiments consisted of heating at 20°C/s to 109 °C, strength are hence effective when ILS refinement is obtained. holding for five min, and controlled cooling to room temperaIn addition to microstructural refinement, precipitation ture at constant rates of 2.5, 5, 7.5, 10 and 12.5 50°C/s. strengthening can also be employed to improve strength.

Microstructural analysis was performed on all samples For instance, the addition of vanadium to a eutectoid steel and Vickers hardness testing was conducted per ASTM is reported to result in 9.6-11.0 MPa strengthening per E-92, using a grid of nine measurements per sample cen0.01 wt pct vanadium in the presence of nitrogen through tered along a bisecting line at one quarter of the sample vanadium carbonitride precipitation strengthening without diameter8. Following hardness testing, a six second etch drawability impairment6. of 4% Picral was applied to the polished surfaces and Niobium microalloying is frequently used in low-carbon optical metallography was conducted. Pearlite intersteels where significant strengthening is obtained through lamellar spacing was measured using Field Emission grain size refinement when thermomechanical processing is Scanning Electron Microscopy (FESEM) images taken at conducted. Effects of niobium additions to eutectoid alloys a magnification of 10,000x, employing a circular inter7 have received only limited attention . cept method according to ASTM E-1129. Error bars 1 1 1 reported for all plots represent the standard error of the data sets.

Table 1. Compositions of Experimental Test Alloys in wt pct.

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TECHNICAL PAPERS

Table 2: Vickers hardness, ILS, and pearlite colony size measurements obtaine for cooling rates 2.5 and 5 °C/s.

Fig. 1. Vickers hardness as a function of cooling rate.

Results and discussion Hardness values are shown in Fig. 1 as a function of cooling rate for both alloys. It is apparent that the 1080V+Nb alloy exhibits greater hardness values than the 1080V alloy. Hardness data are only shown for cooling rates of 2.5 and 5°C/s for the 1080V+Nb steel since non-pearlitic microstructural constitutents including martensite and occasionally bainite were observed via FESEM at higher cooling rates in the Nb containing alloy. In addition, more martensitic/bainitic constituents were observed at these cooling rates in the Nb alloyed steel versus the 1080V steel as qualitatively shown in Fig. 2 for a cooling rate of 12.5 °C/s. Both samples were etched using a 4% Picral etchant and the regions that appear light correspond to pearlite whereas the darker regions not attacked by the etchant correspond to martensitic regions. Although no quantitative analysis was conducted, it is apparent that more martensite formed in the 1080V+Nb alloy which suggests increased hardenability or slower pearlite transformation kinetics.

Figure 4: toa)fully Average The obtained hardness values corresponding pearlitic microstructures are also presented in Table 2 and greater hardness values are obtained in the Nb alloyed steel. The hardness values are also observed to increase with cooling rate for both alloys.

As evident from Eq. (1), pearlite colony size and ILS contribute to strengthening in pearlitic steels. In addition, microalloying may contribute to increased strength through precipitation strengthening. Effects of niobium additions to eutectoid alloys have received only limited attention; Jansto reports ILS refinement through niobium additions in high carbon construction steels7. Fig. 3 shows FESEM micrographs of the alloys investigated in the present study for constant cooling rates of 2.5 and 5°C/s. A refinement of ILS and pearlite colony size for the 5°C/s cooling rate is qualitatively observed for the 1080V+Nb alloy. Results from ILS and pearlite colony size measurements are shown in Table 2 and plotted in Fig. 4 as a function of cooling rate. Increased ILS refinement is observed with cooling

Fig. 2. Low magnification FESEM taken from samples continuously cooled from 1093 °C at 12.5 °C/s for a) 1080V and b) 1080V+Nb steels. Samples etched with 4 pct Picral.

rate whereas pearlite colony size seems less dependent on cooling rate for the 1080V steel. ILS refinement is observed for both cooling rates in the niobium alloyed steel. A different trend with cooling rate is observed for pearlite colony size; similar colony sizes are obtained for a cooling rate of 5°C/s and greater pearlite colonies were observed in the 1080V+Nb steel at 2.5°C/s. The dependence of colony size on cooling is also different forcolony both alloys.

Thefor 1080V ILS and b)rate average pearlite size the 1080V (fil exhibits no measureable dependence, whereas a refinement 1080 steel (open squares). was observed withV+Nb increasing cooling rate in the 1080V+Nb steel for the two cooling rates investigated here.

Using Eq. 1, strengthening contributions from the quantified microstructural differences were calculated and results are shown in Table 3 along with the measured hardness diftheMPa, yield strength i with in ference between the two alloys. Yield strength, was correlated to Vickers hardness, HV at1kgf, according to: cementite volume strengthe

data for carbon Eq. (2) contents ra The expression given in Eq. 2 is the result of a regression analysis conducted by Pavlina for over 150 hypoeutectoid steels ranging from yield strengths of 300-1700 MPa10. The reported differences in Table 3 are the data obtained for the 1080V subtracted by the 1080V+Nb data. It should be noted that precipitation strengthening is not taken into account here. Perspectives on precipitation JULY 2014 | 75

TECHNICAL PAPERS

strengthening have been discussed11. From Table 3 it is apparent that for the 5°C/s condition the strength difference seems to correlate with ILS refinement and a reasonable agreement between observed hardness difference and calculated difference is obtained. The calculated strengthening for the 2.5°C/s cooling rate does not correlate with the measured hardness difference.

The increased pearlite colony size with niobium alloying was not expected and further work is required to confirm this observation in particular of Stelmor® deck cooling profiles. It is reasonable to expect that niobium would refine austenitic grain size, in particular when thermomechanical processing is employed, which would also result in reduced pearlite colony size12.

Pearlite ILS refinement was obtained for both cooling rates with niobium alloying and is calculated to result in a 17-31 HV increase in hardness, or a 89-49 MPa increase in yield strength according to Eq. 2. More Table 2: Vickers hardness, ILS, and pearlite colony size measurements obtained in both alloys research is needed to elucidate the mechafor cooling rates 2.5 and 5 °C/s. nism by which Nb affects the pearlite transFigure3.3:FESEM FESEM micrographs of 1080V and c) and (b and d) alloys cooled(b from Fig. micrographs of(a1080V (a1080 andV+Nb c) and 1080 V+Nb and formation and ILS. Precipitation reactions °C at from constant1093°C cooling rates 2.5 °C/s (acooling and b) andrates 5 °C/s of (c and d). d) alloys1093 cooled at of constant 2.5°C/s (a and and solute drag may influence pearlitic b) and 5°C/s (c and d). boundary movement and these mechanisms are likely dependent on transformation temperature and alloying levels. In addition, solute partitioning through (in) solubility in cementite may affect pearlite growth and 4 ILS. For instance, vanadium has been reported to enrich in cementite13.

Conclusions

Figure 4: a) Average ILS and b) average pearlite colony size for the 1080V (filled circles) and

Fig. 4. a) Average ILS and1080 b) average pearlite colony size for the 1080V V+Nb steel (open squares). (filled circles) and 1080 V+Nb steel (open squares).

The effects of an addition of 0.01 wt pct niobium to a vanadium alloyed, 0.80 wt pct C steel were investigated. Hardness increases were observed, predominantly resulting from pearlite interlamellar spacing refinement.

Non-pearlitic microstructural features including martensite were more prevalent in the Nb modified alloy, which may result from improved hardenability or reduced pearlite transformation kinetics.

1080V Cooling Rate (°C/s) 2.5

Vickers Hardness (HV, 1kg) 380 ± 6

ILS (nm) 177.3 ± 4.8

5.0

394 ± 10

168.0 ± 4.0

1080V+Nb Pearlite (2) Vickers Colony Size Hardness (μm) (HV, 1kg) 393 ± 14 4.0 ± 0.2 4.0 ± 0.2

430 ± 12

ILS (nm) 158.2 ± 4.7

Pearlite Colony Size (μm) 5.4 ± 0.4

138.1 ± 5.7

3.8 ± 0.3

Table 2. Vickers hardness, ILS, and pearlite colony size measurements obtained in both alloys for cooling rates 2.5 and 5°C/s.

76 | WIRE JOURNAL INTERNATIONAL

2.5

13 ± 14

19.1 ± 4.8

-1.4 ± 0.4

17.0 ± 0.6

-32.0 ± 1.6

-15.1 ± 2.2

5.0

36 ± 12

29.9 ± 5.7

0.2 ± 0.3

30.6 ± 0.3

6.0 ± 2.2

36.6 ± 2.5

Table 3. Calculated strengthening contributions from the ILS and pearlite colony size differences (data for 1080V+Nb subtracted by 1080V data) between the 1080V and 1080V+Nb alloys.

Acknowledgements The International Wire & Machinery Association Educational Trust Fund is gratefully acknowledged for financial support as well as ArcelorMittal for supplying the laboratory prepared steels. The support of the sponsors of the Advanced Steel Processing and Products Research Center, an industry/university cooperative research center at the Colorado School of Mines is gratefully acknowledged.

References 1. K. Han, G.D.W. Smith, and D.V. Edmonds, “Pearlite Phase Transformation in Si and V steels,” Metall. and Mater. Trans. A, 26, 1995, pp. 1617-1631.

2. K. Han, T.D. Mottishaw, G.D.W. Smith, D.V. Edmonds, and A.G. Stacey, “Effects of Vanadium Additions on Microstructure and Hardness of Hypereutectoid Pearlitic Steels,” Mat. Sci. and Eng. A, 190, 1995, pp. 207-214.

3. T. Tauri, J. Takahashi, H. Tashiro, N. Maruyama, S. Nishida, “Microstructure Control and Strengthening of High-carbon Steel Wires,” Nippon Steel Tech. Report No. 91, 2005, pp. 56-61.

4. E. Taleff, C. Syn, D. Lesuer and O. Sherby, “Pearlite in ultrahigh carbon steels: Heat treatments and mechanical properties,” Metall. and Mater. Trans. A, vol. 27A, pp. 111–118, 1996.

5. E. M. Taleff, J. J. Lewandowski, and B. Pourladian, “Microstructure-property relationships in pearlitic eutectoid and hypereutectoid carbon steels,” JOM, vol. 54, no. 7, pp. 25–30, July 2002.

Emmanuel De Moor

Stephanie Miller

6. M. Korchynsky, “Microalloyed High-Carbon Rod,” Wire Journal International, 1988, pp. 129-136.

7. S. Jansto, “Niobium-Bearing Construction Steels and Global Applications Trends”, Proc. of Value-Added Niobium Microalloyed Value-Added Construction Steels Symposium, Singapore, Nov. 5-7, 2012.

8. ASTM Standard E92, Standard Test Method for Vickers Hardness of Metallic Materials, 2nd ed., ASTM International, West Conshohocken, PA, 2003.

9. ASTM E112, Standard Test Methods for Determining Average Grain Size, ASTM International, West Conshohocken, PA, 2010.

10. E. Pavlina and C.J. Van Tyne, “Correlation of Yield Strength and Tensile Strength with Hardness for Steels,” Journal of Materials Engineering and Performance, vol. 17, June 2008, pp.

888-893.

11. S.L. Miller and E. De Moor, “Vanadium and Niobium Microalloying to Increase Strength of High-Carbon Wire Steels”, Interwire, Proc. of the 83rd Annual Convention of the Wire Association International, pp. 1-13.

12. A.J. DeArdo, H. Mingjian, and C. Garcia, “Basic Metallurgy of Modern Niobium Steels,” International Symposium on Nb Microalloyed Sheet Steel for Automotive Appication, TMS, 2006, pp. 499-549.

13. T.D. Mottishaw and G.D.W Smith, “Microalloyed Pearlitic Steels for the Wire Industry – Mechanisms of Alloy Element Redistribution and Strengthening Processes in Cr-V Eutectoid Steels,” HSLA Steels, Technology and Applications; Philadelphia, Pa, USA, Oct. 3-6, 1983, pp. 163-175.

Emmanuel De Moor is a research assistant professor with the Advanced Steel Processing and Products Research Center (ASPPRC) at the Colorado School of Mines (CSM), Golden, Colorado, USA. He is involved in advanced high strength sheet steel, high-carbon wire steel, and abrasion plate steel research.

He joined the CSM in 2008 and holds Ph.D., M.S., and B.S. degrees from the Ghent University, Belgium. Stephanie Miller is currently working with the ASPPRC in pursuit of a doctorate in metallurgical and materials engineering. She holds an M.S. degree in metallurgical and materials engineering from the CSM and a B.S. degree in materials science and engineering from the University of Illinois at Urbana Champaign. This paper was presented at CabWire World Conference, Milan, Italy, November 2013.

JULY 2014 | 77

TECHNICAL PAPERS

Measured Vickers ILS Pearlite Colony Strengthening Strengthening Strengthening from Cooling Hardness Difference difference Size difference from ILS from colony size ILS and colony size Rate (°C/s) (HV, 1kg) (nm) (μm) difference (HV) difference (HV) combined (HV)

TECHNICAL PAPERS

TECHNICAL PAPERS Changes in mechanical parameters of stored patented cold-drawn steel wire In a recently completed research project, 48 wires were prepared by varying the carbon content, type of smelting, type of patenting, chemical drawing preparation, single cross-section reduction and drawing speed.

By Rüdiger Lux, Ulf Kletzin, Veronika Geinitz and Peter Beyer

The wire and spring research group at Technische Universität Ilmenau has cooperated with wire and spring manufacturers (Eisendraht- und Stahldrahtvereinigung and VDFI, the German spring manufacturers’ association) in researching the long-term stability of mechanical parameters of patented drawn steel wire. Long-term natural aging effects on the mechanical parameters of patented drawn spring steel and rope wires were investigated in relation to multiple initial and process parameter variables.

Two types of Stelmor air-cooled rolled wire, 5.5 mm, with 0.6% or 0.8% carbon, were produced from steel made with two different forms of steel smelting: electric-furnace and converter. As preparation for drawing, one portion of the rolled wires was simply pickled in a standing bath while the other was also patented in a lead bath. The wires patented in the lead bath were

Rolled wire

Rolled wire from converter steel

then subdivided and either pickled in a standing bath or a continuous pickling plant. The 12 rolled wires thus derived were shared between two wire drawing machines and then drawn in either 8 or 11 stages to 2 mm, this done at two drawing speeds, 6 m/s or 12 m/s. The process resulted in 48 experimental wires of which the long-term stability was to be investigated. See Tables 1 and 2.

The first step was to establish the mechanical parameters from tensile and torsional tests carried out shortly after the wires had been drawn. To document the change over time in these mechanical parameters, the same measurements were repeated after 2, 12, 28, 166 and 370 days. The wires were also subjected to heating in ways similar to what could be expected in further industrial processing of the material in question. The mechanical parameters were measured after all the heating episodes, and these tests were repeated after periods up to eight months.

Rolled wire from electric furnace steel

Table 1. Variations set up in the wire production and drawing preparation.

Number of drawing stages

8 stages

Table 2. Variations set up in the wiredrawing experiments.

78 | WIRE JOURNAL INTERNATIONAL

11 stages

The tests on the wire samples confirmed some already known relationships between mechanical values and such factors as carbon content, patenting method and so on. But also carried out new findings: The greater the increase in strength gained by a wire from heat treatment, the greater the age-related alterations to the properties of non-heat-treated wire. Tests on heat-treated wires make it possible to predict likely parameter changes due to time spent in storage. See Figs. 2 and 3.

As most components made of patented wires are submitted to heat treatment after manufacture, it makes sense to establish the nominal strength and yield values for the wires in their heat-treated state. See Figs. 1 to 4.

The increase in occurrence of longitudinal cracks during torsion tests after heat treatment of 150°C-200°C for 30 minutes is significant.

No conclusions can be drawn from the values established in tensile tests for the torsion behavior of the wires in helical springs. Compare Fig. 2 with Fig. 4.

Necking failure and number of twists, which are characteristic values for deformation, were not factors enabling any predictions to be made about alteration in wire ductility.

In use of drawing machines with an increased number of drawing steps and/or more intensive cooling of the wires, there will be greater alteration of the characteristics with storage time or with heat treatment, respectively. Long storage may mean that the tensile strength ranges detailed in the standard fails to be met.

crack type 2: the longitudinal crack is not along the whole wire axis, “fracture with local cracks, smooth–fracture plane perpendicular to wire axis and partially cracked (roughly 2a according to EN 10218-11); crack type 3: complete longitudinal crack along the wire axis, “fracture with cracks along the entire length,” smooth–fracture plane perpendicular to wire axis and partially cracked (3a according to EN 10218-11) and crack type 3*: longitudinal cracks distributed irregularly over the length of the wire, the fracture plane parallel to the wire axis in parts.

If one compares the graph for stress strain under torsional stress (curve from the torsion test on wires) with

Detection of longitudinal cracks based on the torsion-testing-curve To establish the ductility of patented drawn steel wires it is common to use the simple torsion test, which entails twisting a fixed length of wire until it breaks. A significant feature of wires limited in their plasticity is the development of longitudinal cracks, called torsion cracks. See #3 in Fig 5. More of them are also found after the wire has been heat-treated between 150 °C and 300 °C. This is the conventional temperature range for the tempering of springs and shaped wire parts after they have been manufactured. The surface of a wire with good plastic properties should be smooth after the torsion test and the fracture should be at right angles to the wire axis, as seen in crack type 1 in Fig. 52.

Torsion tests (with measurement of the torsion-angle and torsion-moment) of the 48 sample wires found that there were also intermediate stages in the fractures as described2. Disregarding certain mixed forms and fractures from recoil, these fractures can be roughly categorized into three types. As Fig. 5 shows, the distinctions are: crack type 1: no longitudinal crack, “normal torsional fracture,” smooth–fracture plane perpendicular to wire axis (or slightly oblique). No cracks in fracture plane (1a according to EN 10218-11);

Figs. 1-2 and 4. Results for 8, 11 and 14 draws. Torsion yield with 0.04% residual strain under torsional stress τ t0,04 after 2, 12, 28, 166 and 368 days following wiredrawing, and five days after drawing post 150°C heat treatment for 30 minutes.

JULY 2014 | 79

TECHNICAL PAPERS

Changes in characteristic values for the mechanical properties

TECHNICAL PAPERS Fig. 3. Torsion yield with 0.04% residual strain under torsional stress Ď&#x201E; t0,04 with varied conditions. these different types of cracks (Fig. 6), it can be seen that for all wires that do not have the normal torsional fracture represented by 1a in EN 10218-1, the torsion stress first increases up to an initial peak, then falls abruptly.

When the torsion stress has fallen, the wires (with type 2 and 3 cracks) start to become strong again and achieve a further maximum of torsion stress. It is after this that the fracture occurs. Only in the case of wires with type 3* cracks is there no further strengthening, i.e. no further peak in the torsion testing curve. However, even for wires with this type of crack, the crack can be recognized clearly from the torsion testing curve. The significance of this is that it is possible to recognize a crack simply by examining the torsion testing curve. However, the curve does not give any indication of whether the fracture plane can be classified as being at right angles to the axis.

A search was made for one characteristic as an objective and automated means of evaluating the cracks using the torsion testing curve. The value for this characteristic should permit evaluation of the wire in respect of probable cracks without further close examination of the curve.

In the course of the search the total strain under torsional stress in the torsion test was related mathematically to the distance traveled in one traverse of the measuring machine so as to keep the tensile stress constant in the torsion-test (the quotient between total strain under torsional stress and traverse distance was found) See Fig. 7.

For wire that does not crack (crack type 1 in Fig. 5), this quotient is approximately -0.05, for wire that cracks partially it is approx. -0.10 and for wire cracking along the complete length it is -0.25. These are the values for 2 mm and length under stress of 300 mm, as found with the instruments at the research center.

A second step is a novel evaluation of the torsion tests that makes it possible to detect cracks directly in the graph of stress plotted against strain under torsional stress by establishing the maximum torsional stress on cracking and the strain (under torsional stress) on cracking. See Fig. 8.

Correlations of wire strength and spring geometry/components When rolled wires are manufactured for the spring steel industry there are various speeds of cooling during the Stelmor air-patenting process for different sections of the wire. As with every steel product, the alterations in the crystalline structure of rolled wire are set by the speed of cooling and the length of time for which a temperature is maintained3. The variations in the cooling of the separate sections of wire will thus cause an inhomogeneous distribution of crystalline structure and thus less -than-satisfactory distribution of the strength in the wire.

For extremely-high quality products which require very high uniformity and strength, the rolled wire is given additional cost-intensive patenting in a continuous lead bath. However, to save money this step is often omitted.

It is now intended to shape the unpatented wire into a high-tech product with sophisticated geometrical and resilience requirements: the industrial spring. When springs are manufactured, for instance using an automatic coiling machine, the principle is to bend the wire in a defined space until it has passed its yield point. Any variation in strength of the spring steel wire will have an effect on the geometry at exactly this point. Varying strength along the wire axis, i.e. varying yield points, will cause deviations in the shape of the end product. Fig. 9 demonstrates the point with two springs: in material that is irregular (top)

Fig. 5. Crack types.

Figure 5: Crack types

80 | WIRE JOURNAL INTERNATIONAL

Wires 1 and 2 are presented as an example of this phenomenon. Looking first at the signal from the sensor wheel as recorded and then represented in relation to wire length (Figs. 13-14), far greater variation is clear for wire 1 than for wire 2. The significance is that for wire 1, the sensor wheel has recorded much greater differences between the forces produced by the wire

Fig. 6. Graphs of stress against strain under torsional stress for crack types 1–3 from Fig. 5.

Fig. 7. Quotient between strain under torsional stress and traverse distance.

Fig. 8. Comparison of maximum torsion stress on cracking and maximum torsion stress overall.

JULY 2014 | 81

TECHNICAL PAPERS

and uniform (below). The extreme variations in coil diameter D of the spring section in the case of the non-uniform material can be clearly seen. The equation for the spring ratio (1) makes it clear that such diameter variations will affect the spring ratio to the power of three, which is, obviously, a considerable modification.

Even in the case of shaped wire parts or leg springs, variations in strength will play a significant role, for example influencing the angle between the two legs and thus often preventing automatic assembly of parts.

Conventional practice is currently only to test the tensile strength at the beginning and end of a wire coil.

Absolute accuracy would only be possible if many tensile tests were made across an entire wire lot, but as wire is an “endless” product this is not practicable. To find out the variations in strength present in a wire, there is the time- and cost-intensive option of a high number of tensile tests on the wire. See Fig. 10. This figure shows the results from 50 tensile tests on two different wires, one very uniform and one very far from uniform. The samples were cut from the wire coil in the form of wire rings and subjected to this series of tests. The range of tension in the case of “wire 2” was only about 30 MPa, while it was 160 MPa in the case of “wire 1.”

A different test of spring steel wire reflects the EN 102701 norm: the determination of the free wap diameter W and the axial displacement fa of a ring taken from a wire coil. See Fig. 12. While the standard intends the measurement to be made from a single ring of wire, it is possible to take numerous random samples from the coil, make the same measurement, and come to conclusions about the wire’s uniformity. For instance, Fig. 11 gives the data for the coils of wire used for the tensile tests in Fig. 10 and the winding tests in Fig. 9. The method provides an initial comparison between variations in geometry and variations in strength. There is an obvious association between the tensile strength Rm and the changes in wap diameter W. To eliminate any influence of the drawing machine on the measurements, both wires were drawn on the same machine using the same set of dies. The lower spring in Fig. 9 was made from “wire 2” and the upper from “wire 1.”

A “sensor wheel” measuring setup developed by the research group made it possible to find the uniformity of wire properties along the entire length4. Continuous wire can be monitored for uniformity for the whole coil.

For each wiredrawing process, the wire is deformed, not just for reduction in cross-section but also in the direction of bending by interaction with the drawing machine, such as by bending at the guide rollers and fluctuations in the tuner rolls for the individual drawing stages. If one imagines two pieces of wire of different strength which are shaped into an identical curve, the wire with the higher strength will deform with less plasticity. In theory, the same thing happens when wire is being drawn.

The variations in strength due to the rolling of the wire will also result in different radiuses of bending and consequently in varying free wap diameter.

TECHNICAL PAPERS Fig. 9.9:Comparison ofspring two sections spring(“Wire sections: top, wire 1; Figure Comparison of two 1” above; “Wire 2” below) below wire 2.

Fig. 10. 50 tensile tests on two different types of wire.

Fig. 11. Axial displacement fa and free wap diameter W on two different types of wire.

Fig. 12. fa (axial displacement) and W (diameter of a free wap) as indicated in EN 10270-1 (2012).

Fig. 13. Sensor wheel signal represented across wire length, “wire 1.”

Fig. 14. Sensor wheel signal represented across wire length, “wire 2.”

along its axis than for wire 2. The representation is of the frequency distribution for the signals recorded.

The method shows clearly how often the sensor wheel recorded the measured values in the particular classes: the narrower the distribution, the more “uniform” is a wire. Conversely, wide frequency distribution means the values varied very considerably, indicating that the

wire is far from uniform. Figs. 15-16 compare the frequency distribution of the sensor wheel signals and the distribution of the tensile strength Rm of the relevant wires. This comparison makes it plain than a wire possessing wide variation in tensile strength also possesses much variation in its geometrical properties, and vice versa. The method permits definite prediction of varia-

82 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Fig. 15. Frequency distribution of sensor wheel signals for “wire 1” and tensile strength Rm5.

Fig. 16. Frequency distribution of sensor wheel signals for “wire 2” and tensile strength Rm5.

tion in tensile strength for a wire to be made from the (non-)uniformity of shape.

funded by BMWI (the federal German ministry for industry and technology), channeled through a scheme under the aegis of the German Federation of Industrial Research Associations (AiF). It has been actively supported by the Eisendraht- und Stahldrahtvereinigung e.V. and its project supervision committee. 

Prospects and usefulness to industry The research sheds light on the natural and artificial age-related alterations in mechanical properties in relation to numerous wire manufacturing parameters.

Using the sensor wheel measuring method here presented, 100% monitoring of wire uniformity (both of tensile strength and of shape) will be possible during production. The experiments are applicable and potentially useful not only for spring steel wires, but also for welding wires, bead wires, steel cord or rope wires.

The sensor setup might also be applied to the monitoring of the drawing parameters during drawing. The method of crack detection and evaluation could also be transferred with little further effort to the torsion test benches used in industry.

References

1. EN 10218-1, Stahldraht und Stahlerzeugnisse, Allgemeines Teil 1, Prüfverfahren, 1994.

2. F. Schneider, Stahldraht, VEB Deutscher Verlag für Grundstoffindustrie, 1973.

3. H. Schumann and H. Oettel, Metallografie, Wiley-VCH, 14, Auflage, 2005.

4. I. Bretschneider, F. Wauro, S. Lutz, V Geinitz and P. Beyer, Neue Ansätze zur Ermittlung der Werkstoffkennwerte von Federdrähten, Tagungsband 44, IWK/1999 der TU Ilmenau, 1999.

Prof. Dr.-Ing. Ulf Kletzi Acknowledgment 5. R. Lux, et al, Langzeitstabilität der mechanischen Pa- Ulf Kletzin) (Professor This research project, ref. no. AiF 17043 BR of the rameter patentiert-gezogener Stahldrähte, AiF-Projekt Bornhas 1968; with German Diplom 2013.

(Master’s equivalent) in Mechanical Eng Gemeinschaftsausschuss Kaltformgebung e.V., beengraduated 17043BR: Abschlussbericht

at Ilmenau University of Technology, Germany in 1993; received Doctorate in 2000 2000 FEM-engineer at Brose Fahrzeugteile GmbH & Co. KG, Coburg, Germany, 2005 CEO (HeadatofIlmenau Development) at Friendly Sensors (IUT), AG, Jena, Germany, since 20 Ulf Kletzin heads the Department of Machine Elements University of Technology Ilmenau, of the Department ofand Machine Elements at aIlmenau of Technology and on Germany, where he earned a degree in mechanical engineering a Ph.D. He is also head of University springs technology HeadBeyer of Springs Technology Steinbeis Transfer Centre, Ilmenau.He preat Germany’s Steinbeis Transfer Centre. Peter is a laboratory engineer at the same IUT department. viously performed quality assurance for VEB Relaistechnik Grossbreitenbach. Rüdiger Lux heads wire technology at the Steinbeis Transfer Centre. He holds a degree in mechanical engineering at IUT, where he provides scientific assistance. He previously headed special engineering at Zander GmbH. Veronika Geinitz, Ph.D, is a member of the wire and springs research group at IUT, where she studied mechanical engineering.

This paper was presented at CabWire World Conference, Milan, Italy, Peter Beyer Ulf Kletzin Prof.

Dr.-Ing. Rüdiger Lux Veronika Geinitz November 2013.

Dipl.-Ing. Peter Beyer (Professor (Graduate engineer Peter Beyer) JULY 2014 | 83

Ulf Kl Ulf Kletz

Born 1968; graduated with German Diplom (Master’s equivalent) in Mechanical Born 1951 at Ilmenau University of Technology, Germany in 1993; received Doctorate in 2

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ROSEBURG Assets

CEECO 42-Wire Rigid Frame Strander Line w/96” Payoff and Take-up KRUPP 12-Wire 31” Tubular Strander CEECO 7-Wire 31” Tubular Strander, w/ CEECO 72” Take-Up (2) 1990 NIEHOFF M8511A 11 Die Rod Breakdown Mills, w/ Dancers & 31” Auto-Spoolers HERBORN H-125 4 Die Rod Breakdown Mill w/ Spooler 2008 KALMARK Single Wire Redraw Line, w/ Payoff, Dancer, Take-Up EDMANDS 3+1 60” Bow Twister Line, w/ HOCK 84” Payoff, CEECO 84” Take-Up WATSON Reverse Twist Taping Head DAVIS STANDARD 4.5” Jacketing Line w/ GENCA 2” Striping Extruder, Caterpullers, AFA Overhead 40” Payoff and Take-up Accumulators, (2) AFA 84” Traversing Reel Payoffs and Take-Ups BULK MATERIAL HANDLING SYSTEM Including (4) CLEMMER Silos; NUCON 2 Vacuum Bulk Blower System; (2) NOVATEC PHH-600 Dryer/Hoppers; CONAIR CD-600 Dryer/Hoppers

KRUPP 54 Wire 27”‘Star Type’ Rigid Frame Strander Line, w/ CEECO 84” Payoff and Take-up NEB 54 Wire 27” Rigid Frame Strander Line w/ MGS 96” Shaftless Payoff KRUPP 37 Wire 26”/27”‘Star Type’ Rigid Frame Strander, w/ MGS 84” Payoff, CEECO 84” Take-up KRUPP 6+1 26” Tubular Strander Line, w/CEECO 84” Take-up VAUGHN 12DMT18-RH 12 Die Rod Breakdown Mill, w/26” Dual Spooler (2) VAUGHN 11DSXT-RH 11 Die Rod Breakdown Mills, w/26” Dual Spooler VAUGHN 10DST-RH 10 Die Rod Breakdown Mill, w/26” Dual Spooler 2002 NIEHOFF RA501 Type M85.ABZIEHK Inline Annealer (2) NIEHOFF Stem Packers, Models ECC 42, 2003; ECC42.2, 2007 EDMANDS 3+1 60” Bow Twister Line w/BARTELL 84” Payoff ; CEECO Type 42 Concentric Tape Head; 24” Eccentric Tape Head; CEECO 84” Shaftless Take-up DAVIS STANDARD Insulating Line components to include: UNA-DYN Hoppers and Loaders; MAGUIRE WSB-1800 Weigh Blender; (3) DAVIS STANDARD 60” Belt Wrap Capstans; BETA LaserMike; TEC 1-1/4” 24:1 Striping Extruder; Water Trough; Overhead 36” Payoff and Take-up Accumulators; (2) MGS 84” Powered Shaftless Payoffs; MGS 84” Double Shaftless Take-up 96” REWIND LINE w/ MGS 96” Powered Shaftless Payoff ; BARTELL 96” Take-up 84” REWIND LINE w/ MGS 84” Powered Shaftless Payoff ; ENTWISTLE EV-2H 42” Dual Coiler

SUPPORT ASSETS OFFERED AT BOTH AUCTIONS Include: Pay-Offs; Power Take-Ups; Scrap Winders; SWEED Scrap Choppers; MICRO Butt Welders; Kold Welders; Pointers; Material Handling; Oil Filters; Spark Testers; HIPOTRONICS Test Sets; BETA LaserMike Measuring Equipment; ZUMBACH Equipment; Tensile Testers; Rewind Lines; Forklifts; Cranes; Hoists; Machine Shops; Maintenance Shops; Stretch Wrappers; Coil Wrappers; Packaging Equipment; Air Compressors & Dryers; Boilers; Chillers; Cooling Towers; Racking; LISTA Cabinets; GREENLEE & RIDGID Hand & Power Tools; Parts Inventory; Bearings; Wire & Cable; Motor Controls; Switch Gear; Reels, Stem Packer Baskets, etc.

In Conjunction With:

PerfectionIndustrial.com 847.427.3333

In Conjunction With:

Commission Brokers Inc. 86 | WIRE JOURNAL INTERNATIONAL CommissionBrokers.com • 401-943-3777

Commission

B r o k e r s

CommissionBrokers.com 401.943.3777

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

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

AlphaGary Corp . . . . . . . . . . . . . . . . . . . . .Cover 2

Foerster Instruments Inc . . . . . . . . . . . . . . . . . 26

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

Frigeco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Amaral Automation Associates . . . . . . . . . . . . 43

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

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . 56

Gem Gravure Co Inc . . . . . . . . . . . . . . . . . . . . . 54

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

Gimax Srl . . . . . . . . . . . . . . .insert between 40-41

Caballe SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Howar/Boxy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cable Consultants Corp . . . . . . . . . . . . . . . . . . 14

Howar/Metavan . . . . . . . . . . . . . . . . . . . . . . . . . 58

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . .Cover 4

Huestis Industrial . . . . . . . . . . . . . . . . . . . . 12, 42

Cemanco LC . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Inosym Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 44

CM Furnaces Inc . . . . . . . . . . . . . . . . . . . . . . . . 20

KEIR Manufacturing Inc . . . . . . . . . . . . . . . . . . 85

Commission Brokers Inc . . . . . . . . . . . . . . . . . 85

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . 62

Conneaut Industries Inc . . . . . . . . . . . . . . . . . . 55

Lesmo Machinery America Inc . . . . . . . . . . . . 17

DeWal Industries Inc . . . . . . . . . . . . . . . . . . . . . 58

Lesmo Machinery America Inc/Tramev. . . . . . 62

Eurolls SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Lloyd & Bouvier Inc . . . . . . . . . . . . . . . . . . . . . 34

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . 86

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . 51

Flymca & Flyro. . . . . . . . . . . . . . . . . . . . . . . . . . 13

Perfection Industrial Sales . . . . . . . . . . . . . . . . 86

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pressure Welding Machines Ltd . . . . . . . . . . . 25

JULY 2014 | 87

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX PEOPLE

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

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

Properzi International Inc . . . . . . . . . . . . . . . . . 37

WTM Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Proton Products Ltd . . . . . . . . . . . . . . . . . . 11, 23

Wyrepak Industries . . . . . . . . . . . . . . . . . . . 15, 46

Queins Machines GmbH . . . . . . . . . . . . . . . . . . 19

Zumbach Electronics Corp. . . . . . . . . . . . . . . . 57

Radyne Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Rainbow Rubber & Plastics Inc . . . . . . . . . . . . . 2 REELEX Packaging Solutions Inc . . . . . . . . . . 47 Ridgway Machines . . . . . . . . . . . . . . . . . . . . . . 45 Rosendahl Maschinen GmbH. . . . . . . . . . . . . . 29 Schlatter Industries AG . . . . . . . . . . . . . . . . . . 63 SCR Holdings . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sjogren Industries Inc. . . . . . . . . . . . . . . . . . . . 28

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2015 . . . . . . . . . . . . . . . . . . . . . . . . 32-33 Global Continuous Casting Forum, . . . . . . . . . 35 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . 84 WAI Industry Search . . . . . . . . . . . . . . . . . . . . . 87

Stolberger Inc dba Wardwell Braiding Machine Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 August Strecker GmbH & Co KG. . . . . . . . . . . 53 TMS Specialties Manufacturing Co Inc . . . . . . . 4 Tramev/Lesmo Machinery America Inc. . . . . . 62

September 2014 WJI • Lubricants & filtration • preview: wire China

Tubular Products Co . . . . . . . . . . . . . . . . . . . . . 24 Windak USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wire & Plastic Machinery Corp . . . . . . . . . . . . 65

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

SALES OFFICES NORTH AMERICA

EUROPE

Robert J. Xeller/Anna Bzowski Wire Journal International Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. Tel/fax: 44-1223-360472 franksco@btopenworld.com

ASIA/WAI India Office 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

Germany, Austria, & Switzerland Dagmar Melcher Media Service International Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

88 | WIRE JOURNAL INTERNATIONAL

Advertising Deadline: August 1