Lubrication and Filteration

WIRE JOURNAL SEPTEMBER 2014

®

INTERNATIONAL www.wirenet.org

Lubrication

and filtration  Wire & Cable India preview

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

WIRE JOURNAL INTERNATIONAL www.wirenet.org

Lubrication

and filtration

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

CONTENTS

Volume 47 | Number 9 | September 2014

 Wire & Cable India preview

F EATURES

Calendar . . . . . . . . . . . . . . . . . 8

Lubrication

Industry News. . . . . . . . . . . . 10

AND FILTRATION

Asian Focus . . . . . . . . . . . . . 18 People. . . . . . . . . . . . . . . . . . 20

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

Fiber Watch . . . . . . . . . . . . . 22 Fastener Update . . . . . . . . . . 24

Preview: Wire & Cable India . . . . 36

Chapter Corner . . . . . . . . . . . 38

Organizers of Wire & Cable India, to be held Oct. 28-30, 2014 at the Bombay Convention & Exhibition Center in Mumbai, believe that the industry has many good reasons to attend this biennial event.

Products . . . . . . . . . . . . . . . . 52

Lubricants . . . . . . . . . . . . . . . . . . 42

WAI News . . . . . . . . . . . . . . . 28

Technical Papers . . . . . . 62-76

A range of industry suppliers share their thoughts in this feature, which is followed by a showcase of their collective products.

Classified . . . . . . . . . . . . . . . 77 Career Opportunities . . . . . . 77 Advertisers’ Index . . . . . . . . 80

Next issue October 2014 • Industry Trends • Preview: IWCS

T ECHNICAL PAPERS Optimizing shielded pair manufacturing Juliusz Poltz and Mats Josefsson . . . . . . . . . . . . . . . . . . . 62 Effects of niobium additions to a vanadium microalloyed high carbon wire steel Emmanuel De Moor and Stephanie Miller . . . . . . . . . . . . 69 IWCS Paper: Product environmental compliance in the global wire and cable supply chain John P. Crawford, Eric M. Wall, Eric J. Bulington and Samantha M. Koch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Cover: It may be tempting for manufacturers to cut corners when it comes to lubricants and filtration, but suppliers warn that short-term gains could spell long time woes.

SEPTEMBER 2014 | 3

INSIDE THIS ISSUE CONTENTS

A NEW

INDUSTRY SEARCH ANGLE

. . . . 30

See for yourself what can be found at WAI’s new site.

4 | WIRE JOURNAL INTERNATIONAL

INDIA

BECKONS IN

OCTOBER . . . . . . . 36

Organizers of Wire & Cable India, to be held Oct. 28-30, 2014, at the Bombay Convention & Exhibition Center in Mumbai, believe that India is a land of opportunity for manufacturers. Singled out for having especially strong outlooks were the automotive, telecom and construction fields. For those reasons and more, you may want to consider attending this Messe Düsseldorf event.

EDITORIAL WIRE JOURNAL ®

EDITORIAL

Do loops, public speaking, and the inevitable critique This time of year I think about school. Certain key words come to mind like exam, presentation, and deadline each with its distinct nuance depending on the course. I accept the fleeting angst, then focus on the indelible lessons that still apply today.

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

A few classes stand out.

Computer programming. I chose this nightmarish course simply to fulfill a requirement. So hasty was my selection that I accidentally enrolled in an advanced class. So resolute, I decided to stick it out.

It was and still is truly a foreign language to me. What did I learn?

Choose words carefully (courses, too); a bit about excluding, and including; and being exact because like a mirror a database will reflect just what it is given. At the time I wasn’t smiling.

Public speaking. By comparison, even this class looked promising and I understood its place in my communications training. Some of the techniques used to distract students during speeches seemed peculiar, but I sallied forth. The lessons? Talk about what you know; prepare; lead the audience; captivate them; and by any measure don’t be distracted.

Emphasize; vary your tone; and choose words carefully.

Color theory. My father, a mechanical and electrical engineer in the wire industry, affectionately referred to this period as the semester I mixed paint. We studied hues, values, opacities, and intensities. The messages?

Spend time to fully understand your medium; create and innovate using the tools you have; and vary your tone.

It’s funny what you learn, and when.

Regarding innovation at WAI, it appears that this filtration issue is the most appropriate time to introduce WAI’s new Industry Search (see page 30). The new companion product to the WJI Reference Guide—which now can accommodate full company, product, and service descriptions— will allow visitors to find companies based on key word searches for filtered results. We’ll still include the original 1,100 product types, but now the online system can accommodate brand names, process types, and much more.

On that note, I encourage you to create or update your company profile. Choose your words to describe what makes your company stand out, and let WAI know your reaction to the new Industry Search (wise@wirenet.org). It is a work in progress in beta test mode and it includes just what’s been received to date.

As for deadlines, we’d like to hear from you by the end of September 2014.

Janice E. Swindells Dir. Mktg. & Corp. Communications

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

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»Your quality makes the difference.« Frederik Becker Business Development SIKORA AG

The PURITY SCANNER is a system for the 100% online inspection and sorting of plastic pellets used for the insulation of medium, high and extrahigh voltage cables, but as well for other applications such as the medical industry.

Contaminated pellets are separated and sorted out, assuring that only pure pellets get into the extrusion process. The pellet inspection allows the detection of organic and metallic contamination inside the pellet as well as on the pellet surface, using a special combination of X-ray technology and an optical system. The smallest detectable particle size is 2 mil (50 µm) at a flow rate of up to 4,400 lbs/h (2,000 kg/h).

• Dual inspection: X-ray and optical • Detection of contamination from 2 mil (50 µm) on the pellet surface and inside the pellet • Automatic sorting • Easy to integrate in existing feeding systems • Suitable for all kinds of transparent and colored pellets • Hermetically sealed system • Throughput of 1,100 / 2,200 / 4,400 lbs/h (500 / 1,000 / 2,000 kg/h)

See us at IWCS Conference 2014, Nov 9 - 12, Providence, RI, USA, Booth 413

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. 8-10, 2014: SpringWorld Rosemont, Illinois.China. To be held at the Donald E. Stephens Convention Center. Contact: Tom Renk, CASMI, tel. 847-447-1705, tom@casmi-springworld.org or tomr@ewald.com, www.casmi-springworld.org.

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. This event includes bar, wire, steel rope and more. Contact: Shanghai Aoya Exhibition Co., at 86-21-3351-8138, ayexpo@vip.163.com.

Dec. 2-4, 2014: 3rd Advanced Cable Asia Shanghai, China. This conference, sponsored by Integer Research Ltd., will examine key wire & cable market

developments and business opportunities in the region to help Asia based cable makers determine their R&D and investment plans. Contact: tel. 44-20-7503-1265, www.integer-research.com.

April 27-30, 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, www.wirenet.org.

April 27-30, 2015: Global Continuous Casting Forum Atlanta, Georgia, USA. This event, first staged in Atlanta in 2011, will be co-located with Interwire 2015. Contact: www.castingforum15.com.

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, 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.

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.

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.

8 | WIRE JOURNAL INTERNATIONAL

April 27-30, 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 001-203-453-8384; www.wirenet.org.

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

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INDUSTRY NEWS

INDUSTRY NEWS NEC Corp to supply new Trans-Pacific cable system, Google one of backers NEC Corporation reports that it will supply a consortium of six global companies with a 9,000-km TransPacific cable system, called “FASTER,” that will connect the U.S. to two landing locations in Japan. The announcement led to a good deal of media attention, but the news was overshadowed by the announcement that one of the six investors was Google, the lone U.S. partner, which was the lead in many reports.

doesn’t want latency or a lack of bandwidth to scare people away from the Play Store or other core Google/ Android services. In more general terms, Asia as a whole is the world’s fastest growing market in terms of people coming online, and no matter whether they’re connecting via smartphones, tablets, or conventional PCs, it’s in Google’s best interests to optimize its network for all of those potential new customers.”

In a Google post (where else?), Urs Hölzle, Google’s senior vice president of technical infrastructure, said that, “At Google we want our products to be fast and reliable, and that requires a great network infrastructure, whether it’s for the more than a billion Android users or developers building products on Google Cloud Platform. And sometimes the fastest path requires going through an ocean.”

Insteel Industries to acquire ASW’s PC strand business for $36 million

NEC Corporation notes that it has laid more than 200,000 km of cable. NEC Photo.

A press release and multiple news sources reported the following about the project, which was valued at approximately US$300 million. The system will feature “the latest high-quality six-fiber-pair cable and optical transmission technologies, with an initial design capacity of 60Tb/s (100Gb/s x 100 wavelengths x six fiber-pairs).” The 60 Tbps capacity translates to 10 million times faster than the average cable modem.

The new cable system will be landed at Chikura and Shima in Japan and will feature seamless connectivity to many neighboring cable systems to extend the capacity beyond Japan to other Asian locations. Connections in the U.S. will extend the system to major hubs on the West Coast covering the Los Angeles, San Francisco, Portland and Seattle areas.

The system will “address the intense traffic demands for broadband, mobile, applications, content and enterprise data exchange on the Trans-Pacific route.” The customer is a consortium comprised of China Mobile International, China Telecom Global, Global Transit, Google, KDDI and SingTel. As noted above, Google’s participation led many of the reports, some of which suggested that its role was due to the rapid growth of Android in Asia. “The bulk of Google’s data centers are in the U.S., and Google

Insteel Industries, Inc., has agreed to acquire “substantially all of the assets associated with the prestressed concrete strand business of American Spring Wire Corporation (ASW) for a purchase price of approximately $36 million.”

A press release said that ASW is North America’s largest manufacturer of valve and commercial quality spring wire, manufacturing PC strand at facilities located in Texas and Georgia. For the 12 months ended June 30, ASW’s sales of PC strand were $67.8 million, it noted.

Per the agreement that was reached through a subsidiary, Insteel will acquire accounts receivable and inventories related to ASW’s PC strand business, the production equipment at ASW’s facility in Houston, Texas, and the production equipment and facility in Newnan, Georgia.

Insteel will lease the Houston facility from ASW. “The ASW acquisition significantly enhances the footprint of Insteel’s PC strand business in our largest and highest growth markets,” said Insteel President and CEO H.O. Woltz III. “The transaction offers significant synergy potential for Insteel in the form of reduced raw material and freight costs, minimal incremental selling and administration costs as we leverage off of our existing infrastructure, and lower operating costs through the reassignment of business across locations,” said Insteel Vice President, CFO and Treasurer Michael C. Gazmarian.

“ASW’s PC strand business was highly regarded in the industry and operating profitably. We will be evaluating

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

10 | WIRE JOURNAL INTERNATIONAL

Prysmian to expand U.S. operations The Prysmian Group announced that it will invest in a new compounding facility for medium-voltage cable insulation as well as adding a second Vertical Continuous Vulcanization line (VCV) in Abbeville, South Carolina.

A press release said that the new plant will join the existing medium- and low-voltage power cable manufacturing facilities in Abbeville.

Construction will start later this year and production will begin the second half of 2015, it said. These investments, once up to speed, will bring 16 to 20 new jobs and further The 373-foot Prysmian Copper Wire contribute to Tower in Abbeville is recognized as increased prothe tallest structure in South Carolina. duction capacity at Prysmian’s flagship North American plant.

The Abbeville facility is celebrating its 50th year, and this recent investment is just the latest example of the growth the plant has experienced over the years,

the release said. The first VCV line, housed in a 373-ft tower, was constructed in 2009 and was the first one of its kind to produce extra-high-voltage power cables in North America, it said.

The latest investment comes at a very important time for the group, as medium and high-voltage cable projects across North America continue to increase, the release said. It noted that with the latest expansion, “Prysmian will be better equipped to serve these growing markets.” It added that the Prysmian Group is particularly active in North America, with one recent project being the Hudson Transmission Project.

Encore Wire Corporation to expand its aluminum wire and cable capacity U.S.-based Encore Wire Corporation announced that it will build a 250,000-sq-ft expansion to the company’s existing aluminum manufacturing plant on its McKinney, Texas campus.

A press release said that the project, including related upgrades to the campus and equipment, will cost between $40 million and $45 million, in 2014 and 2015. The expansion of the original aluminum plant that it opened in 2012, it said, “will (eventually) add an estimated 128 new jobs.”

Encore Wire President and CEO Daniel L. Jones said that the time was right for the expansion, which will bolster the company’s ability to meet demand and increase product offerings to its existing customer base in the building wire category. “The aluminum building wire sales have exceeded our expectations, with gross sales totaling over $100 million in the last 4 quarters. With the demand for these products clearly exceeding our capacity, we have decided to go forward and expand the plant to accommodate increased production.”

Jones said in the release that aluminum building wire has helped increase copper building wire sales over the last two years. “Over the trailing four quarters, our copper unit sales are up 13% over the previous four quarters. We believe that is due in some part to the fact we now also offer aluminum wire. We continue to believe that copper will be the conductor of choice in most building wire applications, but we

SEPTEMBER 2014 | 11

INDUSTRY NEWS

the optimum operating configuration for the four plants based on the requirements of our newly combined customer base, but do not anticipate any immediate changes in the business until we have completed our analysis.

The transaction was funded from cash on hand and borrowings on Insteel’s $100 million revolving credit facility.

INDUSTRY NEWS

will offer aluminum to those customers who want it. We will continue to canvass our independent manufacturers’ representatives and our electrical distributor customers, to determine what products they are purchasing that may make sense for us to produce and sell.”

Encore Wire’s strong balance sheet makes it possible to take advantage of such strategic opportunities, said Jones, noting that the company has no long-term debt and more than $19 million in cash on hand. “We have ready access to the capital required to fund this project and we will be poised to take even greater advantage of future upswings in business,” he said.

AMSC reports it will supply a 3-milelong superconductor cable for project AMSC, formerly called American Superconductor, reports that the U.S. Department of Homeland Security is paying $60 million for AMSC and Commonwealth Edison to install a high-temperature superconductor cable to increase the resilience of ComEd’s system in Chicago with an approach that is the first of its kind in the U.S. A press release said that the project, called the Resilient Electric Grid, or REG, will be both the first commercial application of a superconductor cable for resiliency in the U.S., and at more than three miles long, the largest project of this type in the world. The cables, it said, will connect critical substations in the Chicago’s downtown business

A cutaway view of an AMSC cable. district. “We view this project as a natural extension of the infrastructure improvements and technological upgrades that have been underway for the past two years as we develop and deploy the smart grid,” Anne Pramaggiore, president and CEO of ComEd said in a statement.

“We’re trying to bring inherent reliability to the whole system…The magic happens in the wire,” said AMSC President and CEO Daniel McGahn, who noted that the superconductor cable is not competing with FLISR or copper cables. “It’s [the prospect of] building another substation.”

The release said that the current design of the grid infrastructure in many U.S. cities makes restoration of power

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8/11/14 5:38:14 PM

Kobe Steel to expand China JV rod capacity Kobe Steel, Ltd., reported that it and other shareholders in Kobe Special Steel Wire Products (Pinghu) Co., Ltd., have agreed to expand the production capacity of their Chinese joint venture that processes special steel wire rod.

A press release said that Kobe Special Steel Wire Products (KSP) was founded in 2007 in Pinghu, Zhejiang Province to supply cold heading steel wire for use in making automotive bolts and nuts and bearing products. Full-scale operations began in 2009, and Kobe Steel provides all of the special steel wire rod used by KSP, it said, noting the following details.

Driven by automobile production in China, KSP has become the largest supplier of CH wire to Japanese automotive parts manufacturers in China. KSP, which had 106 employees at the end of April, increased its production capacity in 2012 to 2,500 metric tons per month. As the Chinese market is expected to see further growth, KSP decided to further increase capacity ahead of expanding demand to 3,500 mt per month.

KSP plans to add three wiredrawing machines to the existing five units, yielding a total of eight machines. Production capacity will increase from the current 2,500 metric tons per month to 3,500 metric tons per month.

The joint venture partners include Kobe Steel, Ltd., 47%; Shinsho Corp., 25%; Osaka Seiko Co., 10%; Meihoku Kogyo Co., 10%; Metal One Corp., 5%; and Kyodo Shaft Co., 3%.

EU body okays Bekaert’s acquisition of Pirelli’s steel tire cord business The European Commission has approved the proposed 255 million euro acquisition of Pirelli’s steel tire cord business by Belgian-based NV Bekaert SA. A press release said the deal, which was announced earlier this year and includes Pirelli’s steel cord facilities in Italy, Turkey, Romania, China and Brazil, was approved by the EU Commission, which noted the following. “The Commission concluded that the acquisition would not raise competition concerns as the merged entity’s customers, which are large, multinational tire companies, have coun-

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SEPTEMBER 2014 | 13

INDUSTRY NEWS

after a catastrophic event such as a hurricane or a terrorist event “time-consuming, costly, and unpredictable.”

A resilient electric grid is designed to be “a self-healing solution that provides resiliency in the event that portions of the grid are lost for any reason,” it said, adding that the ComEd installation would be the first commercial application of this advanced technology in the U.S. The project is expected to take about 3 1/2 years in Chicago, although AMSC expects future deployments to move more quickly.

INDUSTRY NEWS

tervailing buyer power which is further strengthened by over-capacity in the steel tire cord market. The Commission found that Bekaert will continue to face effective competition from ... other strong competitors located outside the European Economic Area (EEA), in particular in Belarus, Korea and China.”

Bekaert joint venture gets EU okay The European Commission has approved a joint venture by Bekaert and Maccaferri that will see the two companies pool their collective technology for concrete

total construction reinforcement solutions.

A press release said that the 50-50 partnership will see Bekaert providing a range of its Dramix® fibers for concrete total construction reinforcement solutions for underground infrastructure projects in partnership with Maccaferri, which supplies complementary solutions, such as steel arches, concrete chemicals and glass fiber soil consolidation elements.

Prysmian wins power cable contract

The Prysmian Group has won a contract worth approximately US$127 million to provide a 110 km of power cable for the interconnection between the island of Syros (Cyclades) and the mainland power transmission system in Lavrion, Greece.

A press release said that the contract, from the Independent Power Transmission Operator (IPTO), the transmission system operator of the Greek electricity system, Model calls for the design, supply and installaCJS 1000 tion of a turn-key HVAC cable system to transmit 200 MVA. It will consist 150 kV extruded cables and an associated fiber optic cable system along a total route of approximately 110 km, 108 km submarine and two km land. The completed interconnection, it said, will enable integration of Syros into the Greek network system as Model BJS 1000* well as allow future expansion to the other Cyclades Islands (Paros, Mykonos, Tinos). * Model BJS 1000 is ISO9001 The submarine cables will be manufacREGISTERED bench mounted. All other tured at Prysmian’s Arco Felice plant in models are free standing.

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American Spring Wire acquires RettCo Steel, LLC American Spring Wire Corp. has acquired the assets of RettCo Steel, LLC, which in 2011 became a contract manufacturer for ASW. Based in Newnan, Georgia, USA, RettCo had been producing seven-wire PC strand for ASW for its customers throughout the eastern and midwestern United States. The company’s assets include a fully automated hydrochloric acid cleaning and coating line for wire rod processing, Frigerio

8/11/14 4:38:08 PM

Industry report: global wire and cable market to near $300 billion by 2019 “Wire and Cable: Materials, Technologies and Global Markets,” a new report from BCC Research, projects that the global market for wire and cable materials will grow to $297.4 billion by 2019, bolstered by a five-year compound annual growth rate (CAGR) of 7.7%.

A press release noted the following about the report, which provides an overview of the global markets for wire and cable materials, and related technologies. It includes analyses of global market trends, with data from 2012 and 2013, estimates for 2014, projections of CAGRs through 2019, and profiles of companies important in the industry.

The wire and cable materials market is segmented into two categories: power cables and those used in the telecom industry. The power cable category, the largest segment of the overall market, is expected to grow to $219.7 billion by 2019 with CAGR of 7.5%. With a steadily

improving global economy and increased energy demand and utilization in emerging markets, power cables will continue to dominate, accounting for more than 73% of the total market. However, the telecom segment, which was valued at just $47 billion in 2013, is projected to jump to nearly $78 billion in 2019. Traditionally focused on global information, communications and technology (ICT) markets, newer domains are now gaining prominence in this segment, including industrial, energy, and consumer electronics.

“In terms of the telecom market, growth will be driven by high bandwidth and the data rich nature of a growing proportion of wireless and wireline communications,” said Kaustubha Parkhi, an advanced materials analyst for BCC Research. “The reach of these communication modes must be supported by fortified back ends; which means wider pipes at backbone and metro levels. BCC Research forecasts that optical fiber, which supports considerably higher data transfer than its metallic counterparts, will become increasingly mainstream and drive the growth of telecom cables.”

For more details, go to www.bccresearch.com.

EIS acquires Insulation and Wires, Inc. EIS, Inc. (EIS), a subsidiary of Genuine Parts Company, announced today that it has acquired the assets of Insulation and Wires, Inc. (IWI), which distributes

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SEPTEMBER 2014 | 15

INDUSTRY NEWS

high speed wire drawing, stranding and stress relieving machines for the production of PC strand, and two Ebner bell type annealing furnaces for high end spheroidized annealed products.

A company spokesman said that RettCo was still operating at time of purchase, and that all RettCo employees were retained.

INDUSTRY NEWS

and fabricates process materials used in electrical OEM, motor repair and energy markets in the south central region of the U.S.

Xtera awarded $31 million fiber optic cable contract Earlier this year, the U.S. Defense Department has awarded Xtera Communications, Inc., a $31,220,394 firm-fixed-price contract for the delivery of an undersea fiber optic cable connecting the remote U.S. Navy base in southeast Cuba with South Florida.

A press release said that the contract has an 18-month base period and five one-year option periods. Work will be performed in the Southern Command area of responsibility, with an estimated completion date of December 2015, it said. The project is a major investment in upgrading services at the remote U.S. Navy base of about 6,000 residents, including about 2,200 soldiers and other temporary staff at the prison camp.

The solicitation was issued as a competitive, total small business set-aside, and eight offers were received.

Defense Working Capital Funds in the amount of $31,220,394 are being obligated at award. The Defense Information Technology Contracting OrganizationNational Capital Region is the contracting activity (HC1047-14-C-4018).

16 | WIRE JOURNAL INTERNATIONAL

Prysmian reports 80 million euro power transmission cable project Prysmian announced that it has been awarded a new order worth approximately 80 million euros for power transmission system expansion projects for the Qatar General Electricity & Water Corporation.

A press release said that the deal includes engineering, procurement, construction, installation and commissioning services for 173 km of 220 kV extra-high-voltage underground cable systems and related network components.

The order, from KAHRAMAA, is part of a Qatar Power Transmission System Expansion project that will strengthen the main transmission networks and secure power supplies to the industrial and residential sectors, it said. The upgrade, it noted, includes replacement of an overhead line with an underground cable system.

“This award reflects KAHRAMAA’S trust in Prysmian’s capabilities to meet the increasing needs for the development of new power grids in Qatar and this strategic region,” said Antonio Chiantore, General Manager for Prysmian Group in the Middle East.

Per the release, the project will be carried out by Prysmian’s offices in Qatar, using production from Gron (France) and Livorno (Italy). Installation of the first circuits will start in 2014 and the scheduled completion date is during 2016.

INDUSTRY NEWS

SpringWorld® organizer predicts strong showing for 2014 event SpringWorld® should see lots of activity when it returns Oct. 8-10 to the Donald E. Stephens Convention Center in Rosemont, Illinois, USA. “The spring industry is a fiercely competitive marketplace, with spring manufacturers facing all sorts of economic pressures and business challenges from their customers: that’s why spring industry executives should be attending this year’s SpringWorld Show,” said event Chairman Rick Ross, Rockford Spring. “It is the perfect time to do strategic planning, to step up and analyze company needs, and determine what equipment will best serve those needs. Spring World gives you a chance to see all the spring making machinery in a single place.”

A press release noted the following. Registration for the event was ahead of the same time period for the 2012 event that had total attendance of 2,700, and more than 90% of the planned floor space has been taken. The show floor will present manufacturing technology from exhibitors from China, Taiwan, Japan, India, and multiple companies from Europe.

Specific categories at the event will include high-speed, computer-driven coiling, bending and wire forming machinery as well as four-slide equipment and tooling; testing equipment and specialized computer software, laboratory analysis, and other metal testing capabilities; and information from companies offering plating, heat-treating, stress relief, ovens, payoffs and turntable equipment as well as equipment leasing options.

SpringWorld is organized by The Chicago Association of Spring Manufacturers, Inc. Advance registration is free up until Sept. 15 for qualified company executives and personnel with primary business in the manufacture of springs and wire forms, $25 after. Registration can be done at www.casmi-springworld.org. For more information, contact CASMI Show Manager Tom Renk, at tel.

847-447-1705, or tom@casmi-springworld.org or tomr@ewald.com.

MAGPOWR seminar set for Oct. 15-17 U.S.-based MAGPOWR, a supplier of tension and torque control technology, will host a three-day seminar focusing on all aspects of tension and torque control in Oklahoma City, Oklahoma, on Oct. 15-17.

The free seminar “will be a wonderful learning opportunity, providing a thorough understanding of web tension and torque control methods,” said MAGPOWR Global Project Manager Chris Harper. It will include topics such as magnetic particle phenomenon, magnetic particle brakes and clutches (including sizing), basics of control theory, open-loop systems, closed-loop systems, load cells, tension readouts, dancers and many more.

For more information and to register online, go to http://www.maxcessintl.com/magpowrschool. n

SEPTEMBER 2014 | 17

ASIAN FOCUS

ASIAN FOCUS CISA report: a third of China’s steel plants are in the red, worse can follow

1966, Xilin was one of only two major steel producers left in Heilongjiang Province. At one point it employed more than 10,000 people in a city of 1.25 million residents.

A recent report in WantChinaTimes.com presents a dire The company became one of hundreds of SOEs that were outlook for steel production in China, noting that about a shaken up by the government, earmarked for restructuring third of the steel plants in the country are losing money under the broader umbrella of revitalizing the northeast. due to oversupply and a stagnant housing market, and One key investor was Wu Jinliang, an academic who warning that conditions may get worse. bought up SOEs under the banner of his company, Tongde The WantChinaTimes report cited China Iron and Steel Industrial.

Restructuring drove up stock prices, and would Association data that said 26 of 88 medium and largefunnel the extra capital into the acquisition of new firms. sized steel companies are in debt, with losses of US$1.4 Eventually, billion during the he bought and first five months merged his comof this year. Those pany into a mas88 firms had revenues of US$241.3 sive conglomerate billion, but profits called Tianxing fell more than Meter Group, in 46% during the which he held a January-May perimajority share. In od to US$281.5 2005, he bought million, it said.

Xilin. He was In the report, successful, at first, Chi Jingdong, but it faltered as CISA’s deputy the years went secretary-general, by. He could no predicted that longer rely on steel prices will his steel empire remain flat and to turn a profit that manufacturers and funnel funds will struggle to Wire rod at a Xilin Iron and Steel Group plant. into further M&A stay profitable. dealmaking.

He added that “the By 2011, profit margins in the Chinese steel industry worst days have not yet arrived.” had fallen from a peak of over US$50 per ton just three The WantChinaTimes article cited Qiu Yuecheng, an analyst with Xiben New Line Stock, as saying that the plants years earlier to below zero, per data from Platts. Although have inventory problems because of all the unsold steel they have now risen above those lows, steel prices remain products piling up. The inventory at major steel plants as of volatile. Overcapacity also continues to plague the indusmid-June was pegged at over 15.1 million metric tons, up try. Consumption of finished steel products collapsed in 11.5% from the same period last year, he said.

2013, even as production totals spiked to a record 800 An online article by China Economic Review provided million metric tons. the following further historical perspective on the steel New environmental regulations to curb pollution added market, which has been edited for length. costs to steel mills while lagging demand from the conAs manufacturing and exports became the main economstruction industry that had boomed in earlier years hurt ic growth drivers in the south and east of the country, the earnings. Late last year the State Council recommended northeast fell behind. Huge shutdowns and layoffs ensued cutting 80 million tons of excess steel capacity by 2017. in the following years as the iron rice bowl system of craPremier Li Keqiang has also said plants may have to be dle to grave support was decisively smashed. moved away from polluted areas.

China’s accession into the World Trade Organization in Xilin stopped paying employees, and at last count had 2001 advanced manufacturing exports, further entrenching not done so for five months, owing some US$32 million. the problems of the industrial north. Embarrassed economThe Yichin city government eventually provided loans to ic planners decided to do something, and in 2003 launched avoid mass layoffs and the risk of social unrest that can the Northeast Revitalization Plan, which called for a masfollow such incidents, but the results have been a sad turn sive overhaul of state owned enterprises, or SOEs. for Xilin, which was supposed to create a blueprint for the One such steel company was Xilin Iron and Steel Group (Xilin), whose product lines include wire rod. Founded in sale and restructuring of state industrial assets.

18 | WIRE JOURNAL INTERNATIONAL

Last year, the Longhai Steel Group was forced to close its steel mill in Xingtai and lay off some 3,000 employees when it lost its $177 million of bank funding due to efforts by the central government to streamline production, cutting overproduction and reduce pollution.

Per a report in The Wall Street Journal, the company, whose overall operations include wire production, is scheduled to start again. The bankers have not returned but the company does have new support: the city of Xingtai, which was said to be arranging a merger to put the owner back in business. “The local government is trying to help us resume production as soon as possible,” Longhai Steel Group ChairmanWang Chaojun was quoted as saying.

The story said that China’s senior leaders were serious about reducing steel production and pollution, and want mills to operate at high capacity rates that are more efficient. Local government officials, who get the bulk of their industrial taxes from factory production, have an incentive to keep companies operating no matter what.

“While a tug of war between local officials and China’s regimes isn’t as unusual as some Westerners might think, this one has already featured a rare public scolding from Beijing as well as the televised spectacle of a province blowing up furnaces without really reducing production.

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The stakes behind this battle are high: economists and Chinese officials (must) ... convince localities that are more concerned about protecting jobs and businesses.”

“Don’t think just of the central government” when considering Chinese economic policy, said John Zhao, chief executive of Hony Capital, a private-equity firm in Beijing.

“China has 30-some provinces and powerful cities and they all run their own economic policies.”

The WSJ report said that Premier Li Keqiang criticized the lack of support in carrying out orders. “Some [local] government officials hold the belief that doing nothing is better than doing something wrong,” he said, per an account posted on the Chinese government’s website.

A key issue is efficiency, the story said. The more a factory uses its machinery, the more efficiently it runs, with costs for rent, power, and other overhead spread across more products. A good target is 85% capacity utilization, but China’s rate across all industries barely tops 70% according to the International Monetary Fund.

When China’s mills were growing at double-digit rates, capacity was not an issue, but as the economy slowed to closer to 7.5%, mills ran into problems. “You can’t overstate the urgency to tackle the overcapacity problem now,” observed Li Xinchuang, chairman of China Metallurgical Industry Planning and Research Institute, a state think tank that helped draft Beijing’s policy to shrink the steel industry. n

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ASIAN FOCUS

Closed steel mill in China to reopen with support from local government

PEOPLE

PEOPLE Michael Blaha has joined Nexans High Voltage USA, Inc., as its regional sales manager, responsible for sales and marketing of high-voltage cable and accessories in the northeast and mid-atlantic regions, and nationally responsible for subsea cable and installation. He has 23 years of industry experience. He previously worked for Marmon Utility-Kerite as national sales manager, HV and speBlaha cialty cable. He previously served in multiple sales management roles at FCI–Burndy. He holds a degree in earth science and mathematics from Southern Connecticut State University. Part of the North American operations of Nexans and based in Goose Creek, South Carolina, Nexans High Voltage USA, Inc., is Nexans’ first extra-high-voltage cable plant in the U.S. Comtran Cable has promoted Joe Barry to general manager, responsible for overseeing the company’s operations at Attleboro, Massachusetts, as well as creating long term strategies for the specialty data cable markets.

He joined Comtran in 2010 as director of technical services and was later named vice president and general manager of communications products.

He previously held key management Barry positions in the data cable market segment with Mohawk, including as sales engineer for copper products and as business unit manager for fiber optics and broadcast products. He then moved to Belden, where he served as director of its fiber optic business unit, with global sales responsibilities, for two years. He has some 20 total years of industry experience, and has served as a committee member of TIA and is a certified BICSI RCDD. Based in Attleboro, Massachusetts, USA, and a business of the Marmon Group, Comtran Cable manufactures cables for multiple applications.

The Lincoln Electric Company has promoted Jennifer Ansberry from deputy general counsel to vice president, deputy general counsel, with responsibilities including participation in legal functions for global mergers and acquisitions, securities law compliance, corporate governance and other general corporate legal matters. She joined Lincoln Electric in 2004. She previously Ansberry served at two law firms. She holds a J.D. degree from the University of Cincinnati - College of Law and a degree in accounting from the University 20 | WIRE JOURNAL INTERNATIONAL

of Cincinnati. Based in Cleveland, Ohio, USA, Lincoln Electric supplies a wide range of welding related technology and products that include welding wire.

Metro Wire and Cable-Detroit announced the hiring of Matt Burtraw and Bruce Arnold as sales consultants in Detroit. Burtraw previously served in several direct selling capacities, including the industrial heating and cooling industry. Arnold, who has experience at consultative selling and cultivating new business in various geographic areas and penetrating new industries, will be charged with focusing on new business development. Based in Sterling Heights, Michigan, USA, Metro Wire & Cable is a warehouse electrical distributor of wire and cable products for a broad spectrum of markets.

obituary Dr. Alan Taylor Gorton, a metallurgist and business owner, published author and inventor, died July 11, 2014, at age 77.

The Georgia resident, born in Moose Lake, Minnesota, was a graduate of the University of Minnesota where he received his doctorate in metallurgy. He worked for Atlantic Steel Company (ASCO) in Atlanta for over 22 years as chief metallurgist and later formed Alan T Gorton Consulting, LLC. He was known both for his knowledge, which resulted in three patents for steel-making, and his Gorton willingness to share his expertise. He also published two books: The Isothermal Transformation of Wustite Below 570°C, 296 pp., 1963, and The Lattice Parameter of Iron and Its Oxides at High Temperatures, 92 pp., 1961. A WAI Life member, he joined the association in 1981, and was a member on several committees.

“I had the pleasure to work with and alongside Alan for many years, both in the steel industry and serving on various WAI committees. His depth of knowledge and easy-going approach will truly be missed!” said Steve Montague, Leggett & Platt.

“Alan was a mentor to us all at ASCO and even tried to train us in basic metallurgy, ignoring that we were salesmen. Alan and I traveled on the original COVAN* calls. I would do the song and dance and Alan would then explain what it would do. Hope he had as much fun with me, as I did with him. I’ll miss you my friend,” said Jack Stowe.

Gorton is survived by his wife of over 50 years, Geraldine “Geri” Gorton; daughters, Christine Gorton, Elizabeth Hancher and Alison Mills; a brother, George Gorton; a sister, Mary Loudin; and four grandchildren. * COVAN was an ASCO structural steel product.

FIBER WATCH

FIBER WATCH Bell Aliant to offer fiber to 125,000 premises in 7 Quebec communities Bell Aliant Inc. announced that it plans to spend some CAN$70 million to deploy fiber-to-the-home (FTTH) technology to connect 125,000 premises in seven Quebec communities.

A press release said that the build “follows successful deployment of the company’s FTTH-based FibreOP services in Quebec City.” The seven communities include Alma, Saguenay (including Chicoutimi, Jonquière, and La Baie), Saint-Félicien, Thetford Mines, and Victoriaville. The company added that it also expects to deploy FTTH in such communities including Rivière-duLoup and Roberval by the end of the year.

“Fiber-to-the-home is a game changer and we are excited to be bringing this world-class network to more people in Quebec,” said Bell Aliant President and CEO Karen Sheriff. “Today’s consumers are more connected than ever and are demanding more bandwidth and speed.

By delivering a 100% fiber-optic connection directly to customers’ homes we can continue to bring the fastest Internet and TV experience today and in the future.”

Bell Aliant offers maximum download speeds of 250 Mbps and upload rates of 30 Mbps through its FibreOP

service. The company has deployed FibreOp Bell in Atlantic Canada and Ontario. Together, the FTTH network links more than 827,000 premises in more than 70 communities throughout Atlantic Canada and Ontario.

The company says it is on track to meet its FTTH footprint target of 1 million homes passed by the end of 2014.

Apollo and Alcatel-Lucent report 7.2 Tbps results over fiber pair test Undersea cable operator Apollo and Alcatel-Lucent report that a recent test on the existing Apollo South system that connects France to the U.S. set a transmission rate of 7.2 Tbps of data per fiber pair, based on 100 Gbps technology.

A press release said that the results were due to Alcatel-Lucent’s advanced optical coherent technology that during the field trial showed a ninefold increase in the system’s original design capability, setting a new capacity record for an upgrade project. The trial follows the recent announcement of the upgrade completion on both Apollo North, which connects the U.K. to the U.S., and Apollo South, with both systems now carrying multiple 100 Gbps of in-service traffic, it said. n

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FASTENER UPDATE

FASTENER UPDATE IDEAL Fastener to expand plant Ideal Fastener Corp. plans to expand its facility in Oxford, North Carolina, investing more than $5.7 million in the project that it expects will ultimately create 155 jobs.

The company, which primarily manufactures zippers, now employs 226 people, a report in The Herald Sun said. It noted that Ideal Fastener is being bolstered in its efforts with an award from the state Job Development Investment Grant (JDIG) program. Ideal Fastener notes that the business was founded in New York in 1936. In 1966, it moved its manufacturing headquarters to Oxford and in 1997, it expanded overseas. The company has some 3,500 employees in six facilities in four countries.

3D printer could be used to produce fasteners/joints for aircraft As 3D printing continues to evolve, some people see the technology as offering potential for some of the most demanding fastener end-uses.

Per an online article in The Engineer, the 3D technology “is slowly moving away from its prototyping roots, and aerospace engineers are now hoping to prove its potential, one component at a time ... some claim that 3D printing

24 | WIRE JOURNAL INTERNATIONAL

could even create new capabilities in the fasteners and joints that hold together larger structures such as aircraft.”

The article noted that one large aircraft can require nearly a million fasteners. “As well as being strong, these components must be flexible, lightweight and aerodynamic,” it said. It said that Airbus Group has been working on an alternative to traditional fasteners known as ‘hyper joining’ (hybrid penetrative reinforcement). The company claims a hyper joint is around six-and-a-half times stronger than a bonded joint and can absorb around 80 times more energy. The technique also leaves the surface of the joint completely level to reduce drag. One unusual design shape that has already been produced thanks to 3D printers, it said, is the “Rotite” non-penetrative system created to, among other applications, attach mechanical and electrical connections in aircraft.

While it may be some time before full joints are 3D printed, for now, aircraft are already using the technology for non-critical components, the story said. “We are on the [brink] of a step-change in weight reduction and efficiency — producing aircraft parts that weigh 30 to 55 per cent less, while reducing raw material used by 90%,” said Peter Sander of the Airbus Innovation Cell. “This game-changing technology also decreases total energy used in production by up to 90% compared to traditional methods.” n

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PLATINUM | Sonoco Reels and Spools • Wire & Plastic Machinery Corp.

SILVER | Carris Reels Inc. • Nexans BRONZE | RichardsApex Inc. SUPPORTING SPONSORS: Chemson • Commission Brokers Inc. • Lloyd & Bouvier Inc. •

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. American Kuhne 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.

Baum’s Castorine Co. Inc. Bechem Lubrication Technology LLC Beijing Orient PengSheng Tech Co. Ltd. Bergandi Machinery Co. Beta LaserMike Blachford Corp.

BLM Group USA Corp.

Boockmann GmbH/The Slover Group Breen Color Concentrates Inc. Brookfield Wire Co. Butt Welders USA Caballe SA Cable Consultants Corp.

Calmec Precision Inc. Canterbury Engineering Co. Inc. Carris Reels Inc. Ceeco Bartell Products, Bartell Machinery Systems Cemanco LC Central Wire Industries Ltd. 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.

EVG Inc. Evolution Products Fabritex Inc. Fenn LLC 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 GIMAX GMP Slovakia s.r.o Guill Tool & Engineering Co. Hangzhou JR Exhibition Co. Ltd. Heany Industries Inc. Heatbath Corp.

Henrich Maschinenfabrik GmbH 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 Kalmark Intergrated Systems Ltd. KEIR Manufacturing Inc. Keystone Steel & Wire Co. King Steel Corp.

Kinrei of America Lamnea Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. LUKAS Anlagenbau GmbH Madison Steel Inc. Magnetic Technologies Ltd. Maillefer Extrusion Oy Mathiasen Machinery Inc. Messe Düsseldorf North America Metal Resource Solutions Inc. Metallurgical Council of China MGS Manufacturing Inc. Micro Products Co. Microdia USA Mid-South Wire Morgan-Koch Corp.

Mossberg Associates Inc. 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.

Pneumatic Power Tool & Co. Polytec Inc. Pourtier & Setic of America Precision Die Technologies Inc. Premier Wire Die PrintSafe Process Control Corp.

Progressive Machinery Inc. Properzi International Inc. QED Wire Lines Inc. Queins Machines GmbH Raajratna Stainless Wire Inc. RAD-CON Inc. Radyne Corp.

Rainbow Rubber & Plastics Reel-O-Matic Inc. Refractron Technologies Corp.

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

SIMPACKS Sivaco Wire Group 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. UPCAST OY Vandor Corp.

VINSTON US Corp.

Vollmer America Inc. Vom Hagen & Funke GmbH W3 Ultrasonics LLC 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) Wire World Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Yield Management Corp.

Zumbach Electronics Corp.

WAI NEWS

Sept. 2014

WAI MEMBERSHIP

SPOTLIGHT This section introduces a new WAI member each issue.

David Sanderson Director of Manufacturing Mar-Mar Wire, Inc.

Q: What does your company do?

A: Mar-Mac Wire, Inc., is a leading manufacturer, importer and distributor of wires and wire products for industrial and concrete construction sectors.

Q: What is your role there?

A: I am the director of manufacturing.

Q: What do you like best about your position?

A: Well, there’s never a dull moment! It’s great to be part of an organization that positively affects people’s lives, both customers and employees. I enjoy being able to teach somebody something new as well as learning something myself.

Q: How has the industry most changed?

A: Changes have been three-fold. First is the advancement in technology in steel making, which has generated somewhat of a global parity in wire rod quality as most mills today can produce a good typical IQ product.

Second is the advances in electronics and off-the-shelf products and programs that once required proprietary electronics and programming, and made repairs, replacements and upgrades very time-consuming and expensive.

Third is the move to lean concepts. The industry was very resistant at first, but more companies are seeing the value and application of lean concepts in their business model.

Q: How does your company remain competitive?

A: We have been in the industry for many years and have a good knowledge base, but that’s not enough.

We have to continuously improve for our customers.

We ask how we’re doing and how we can help them, and then we listen. That, coupled with a sense of urgency, keeps us on our toes.

Q: Why did you recently join WAI? A: Mar-Mac Wire has long been active with WAI. I was encouraged to become a member and attend the Operations Summit and Wire Expo in Indianapolis, which I did. It was great to attend the technical classes there and meet other professionals in the industry.

28 | WIRE JOURNAL INTERNATIONAL

P Craig Hagopian Fld Dev Met Ivaco Rolling Mills

Dean Scheumann Prod Supv SDI LaFarga LLC

Kurt Breischaft Pres SDI LaFarga LLC

Hakan Kilic Bus Proc & System Dev Chief Boycelik

Dov Shaham Cable Eng Dept Teldor Wires & Cables Ltd

Brian Butcher Mech Main Spvs SDI LaFarga LLC

Bryan Liggett Met SDI LaFarga LLC

Sander Silvis Engr Silcom (Pty) Ltd

Sofia Carlile United Copper Industries

Michael Norton VP & Gen Mgr - ESP Marmon Utility

Will Simmons Ops Mgr SDI LaFarga LLC

Lamar Austin Exec VP Henderson Sales & Service, Inc.

Paul Carpenter Ctrl Eng Nexans Energy, USA Deron Dunbar Sls Rep Ivaco Rolling Mills Todd Eagan Sls Mgr SDI LaFarga LLC Jerry Evans Elctrical Main Supv SDI LaFarga LLC Irving Glazer Sales Conslt/Prin

Andrea Phelps Exec VP Encore Recycling, LLC Stephen Pontarelli CEO PKG Equipment Inc Matt Reinoehl Prc Met SDI LaFarga LLC Dave Sanderson Dir of Mfg Mar-Mac Wire, Inc Anthony John Saragusa Pres Onesource Reel

WAI NEWS

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

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.

SEPTEMBER 2014 | 29

WAI NEWS

WAI introduces New Industry Search The Wire Association recently unveiled a beta test version of its new online Industry Search, which is a companion product to the annual printed publication, the Wire Journal International Reference Guide. It is a free service to use, offered on WAI’s home page www.wirenet.org, and like the Reference Guide, basic company listings are free.

WAI’s Charles (Chuck) Szymaszek, Director of Information Technology, developed the Industry Search to replace and improve the former Virtual Trade Show. The new product has been customized and is poised for future mobile applications in preparation for the next generation of wirenet.org.

Additional fields have been included in the database enabling WAI to collect and share more information about suppliers and manufacturers in the industry.

Two of the fields—the introduction and description—allow for companies to customize their profiles, unlike the prior system that relied solely on a more generic alpha-numeric product categorization.

“Now company listings are fully searchable by key word, not just by product type, as in the past, so that brand names used in a company profile will appear in the search results,” Szymaszek said.

Visitors can instantly find wire and cable; supplies and equipment; global companies; maps, driving directions and more using the Industry Search link (the second bullet point on the left of the screen under Login) on the home page.

A global map appears on the subsequent screen.

{

1

How to list your profile Company profiles that appeared in the 2014 WJI Reference Guide were used to populate the Industry Search. Companies with an existing listing need not submit a new listing, simply update their profile instead.

The contact person who historically updated your company listing is the one to whom company profile maintenance has been assigned. That individual can update the profile by logging in to the homepage, and clicking the “my listings” link on the left of the screen. Edits to the record should be saved and submitted, at which point the data goes into a queue for review and approval before changes can be viewed online. Once approved the contact person will be sent an automatically generated email message to signify that the process is complete.

New listings are welcome by using the “Add Entry” link.

While updates can be made at anytime, entries received

by September 30, 2014, will also appear in the 2015 WJI Reference Guide.

Upgrade options Three upgrade options are available to enhance company listings on an annual basis: Club, Premier, and Elite listings at costs of $150, $250, and $500, respectively. Each level ensures that these upgraded listings will automatically filter toward the top of search results before the free listings appear.

30 | WIRE JOURNAL INTERNATIONAL

n The Club Listing accommodates a company logo online and includes a black boldface listing in the printed WJI Reference Guide. n The Premier Listing accommodates all of WAI’s Platinum Member Companies; includes a company logo online; a red boldface listing in print; and these listings appear before the Club level entries. n The Elite Listing includes all of the Premier Listing options plus a video link; up to six images; and the ability to upload corporate literature.

}

3

Results

The system includes several ways to find a company.

These include:

All results are returned in random order. Paid listings automatically filter to the top, followed by a random list of free profiles. The random, rather than alphabetically organized returns ensure that every company gets equal visibility. In short, the order of the returns changes with each new search.

Another way company profiles can be accessed is through the wirenet.org’s global site search on the home page (top left). Prior to entering a keyword, simply click the drop down arrow to turn on or off specific site assets to include or exclude areas of interest (e.g., editorial content, pdf files on the site, abstract searches, companies within the Industry Search, events, people, and forums). The global site search returns a broader slice of information; the Industry search link is much more refined method of searching from the home page.

So far it’s been a busy part of the site. In its first three weeks the Industry Search has 551 unique viewers, 1200 visitors, and 3000 page views. “The plan is to have a mobilized version of the website in the future that will work with mobile devices including phones and tablets. It will feature geo-location services and radius searches, to find companies around your present location, which will help when people are on the road,” Szymaszek said.

While the Industry Search is still in the beta testing stage WAI encourages comments and feedback to help build out the system.

Contact wise@wirenet.org for questions, comments, or concerns.

n Geographical search – By clicking on the colorful orbs on the global map visitors can drill down to view the companies in a particular location. Once the map has been enlarged virtual “push pins” indicate the name and address of the company at the location, plus a direct link to the listing. n Business category search – For a broad and global result, visitors can select one of the 24 business type categories. n Keyword search – This function includes result refining parameters such as “all,” “any,” or “exact” word matches. Here, too, search parameter choices include business type, state/province, or country.

Browsers: For security reasons the WAI website requires one of the following browsers to use and view the site properly: IE 9 or above, Firefox, or Google Chrome.

New PWM welders and dies available only from PWM or its authorised distributors.

MADE IN THE UK

Keep the pressure on

Video demo www.pwmltd.co.uk All inquiries within North America for machines, spares and dies, contact:

Joe Snee Associates, Inc. PO Box 236, Seekonk, MA 02771 Tel: 774-991-0504 Email: joe@jsnee.com

Since 1984, wire and cable manufacturers around the world have depended on us for sound advice, expert technical support and reliable products. To find out how our highperformance cold welding machines can help you reach your production targets, call us on +44 (0) 1233 820847 or visit www.pwmltd.co.uk.

Pressure Welding Machines Ltd Tel: +44 (0) 1233 820847 Fax: +44 (0) 1233 820591 E-mail: pwm@btinternet.com www.pwmltd.co.uk

SEPTEMBER 2014 | 31

WAI NEWS

2

How to search

WAI NEWS

Why is this woman resting on a bed of wire?

If you are a WAI member, you should know the answer as this photo and the story explaining it was recently in the Association’s twice-a-month newsletter, The WAI Connection.

The electronic newsletter goes out free to WAI members, however, some members either do not have a valid e-mail address or their companies have “blocked” delivery of the newsletter. To make sure you get your email announcement of the latest edition, add “connection@wirenet.org” to your “safe senders” list. You can also provide a different email address. Finally, to access the newsletter requires that the recipient’s browser be at least Internet Explorer 9 or above, Google Chrome or Firefox.

The newsletter, which can be accessed on mobile devices, includes a range of WAI news, a technical item, a webinar from the Association archives as well as a just-for-fun section called Fact or Fiction. Make sure you are getting the most from your membership.

2015 Interwire/Continuous Casting update Planning continues for Interwire 2015 and the co-located Global Continuous Casting Forum, both of which will be held April 27-30, 2015, at the Georgia World Congress Center in Atlanta, Georgia, USA. As of press time, some 90% of the available floor space for the Interwire trade show had been contracted. The event will include the Association’s 85th Annual Convention, the technical programs, social events and more.

The continuous casting forum, first held at Atlanta in conjunction with Interwire 2011, will return. The event once again is being organized by Gary Spence, Encore Wire, who is adding an aluminum track.

Sponsorships are available for both events. For more on Interwire, go to www.wirenet.org or www.interwire15.com, and for the forum, go to www.castingforum15.com. n

32 | WIRE JOURNAL INTERNATIONAL

CALL FOR PAPERS

THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS. April 28-30, 2015 | Georgia World Congress Center Atlanta, Georgia, USA

Bi

g

id e

as

ro ll

ou

t at

Inter wire.

AbstrAct DeADline: november 3, 2014 AcceptAnce notificAtion: December 1, 2014 mAnuscript DeADline: februAry 2, 2015

Submit your abstract today!

The Wire Association International (WAI), Inc. invites authors to help define its 2015 conference program at Interwire with the latest technical and practical wire and cable industry topics in the world.

Accepted authors receive: • complimentary registration with access to conference sessions, exhibit hall, and opening reception; • Conference Proceedings materials; • industry exposure; and • complimentary 1-year WAI membership.

See the submission form on the reverse side.

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

CALL FOR PAPERS

ABSTRACT SUBMISSION

In order for the Wire Association’s Conference Programming Committee to properly assess the scope and content of your proposed technical article, please submit a 75 word abstract.

PAPERS

Accepted speakers will receive an Author’s Guide with details about manuscript and presentation preparation via e-mail. Only original papers not previously published will be accepted for Wire Association International paper awards and possible publication in Wire Journal International.

Please complete the following information.

Send to: Marc Murray, Director of Education & Member Services, The Wire Association International, Inc., 1570 Boston Post Rd., P.O. Box 578, Guilford, CT 06437-0578 USA, Tel.: (001) 203-453-2777, Fax: (001) 203-453-8384, E-mail: mmurray@wirenet.org.

Check your area of interest: ❏ Operational Presentation ❏ Technical Paper Presentation Check your category: ❏ Ferrous ❏ Nonferrous ❏ Electrical ❏ Fiber Optic ❏ General Author(s) Contact Author (designate one only) Title of Paper Company (affiliations for each author) Address City

State/Prov.

Postal Code

Country Telephone (include country and area code) E-mail [

Fax (include country and area code) ]

Abstract (75 word maximum) Please type your abstract in English on this form. If you need additional space, please use a separate page.

INTERWIRE 2015 The Conference Programming Committee reserves the right to screen all abstracts and reject those abstracts deemed unsuitable or inappropriate for presentation or publication. Everyone who submits an abstract will be notified whether the abstract has been accepted.

And then there were two. With the New England Chapter golf tourney (Sept. 9) over by the time you see this issue, there are just two chapter golf outings left.

The Southeast Chapter will once again 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. Last year, two teams tied with a score of 57, with a match card giving the victory to the Standrd Tytape team of Bob Hermann, Toby Galoway, Bruce Fields and Scott Hutchinson. Contact Art Deming, tel. 252-955-9451, art.deming@nexans.com.

CHAPTER CORNER

2 more golf tournaments remain: Southeast and Western chapters

CHAPTER CORNER

CHAPTER CORNER

A group photo of some of the golfers at The Vannais.

The Western Chapter will stage its 14th annual “Wild West Shootout on Monday, Oct. 20, at the Sierra Lakes Golf Course in Fontana, California. Last year, the Engineered Machinery team of Andrew Stevens, Matt Dron, Derrick Stevens and Jason Chura won tops honors.

Outing Chairman John Stevens, r, with the winning Engineered Machinery team of Andrew Stevens, Matt Dron, Derrick Stevens and Jason Chura.

For more details, contact John Stevens at tel. 909-8515633 or by e-mail at jstevens@emc-wire.com or WAI’s Steve Fetteroll at tel. 203-453-2777, ext. 115, or sfetteroll@wirenet.org.

Each event offers multiple sponsorship opportunities and the chapters welcome donations of items for raffles, held during the awards presentations. n JUNE 2014 | 35

INDUSTRY EVENT

PREVIEW

In an era where much of the world is still struggling with ailing economies, organizers of Wire & Cable India, to be held Oct. 28-30, 2014 at the Bombay Convention & Exhibition Center in Mumbai, observe that the country offers widespread potential for manufacturers.

The event “will be held at an opportune time,” said a press release from joint organizers Messe Düsseldorf and its subsidiary, Messe Düsseldorf India, with the support of well known industry organizations: IWCEA, IWMA, ACIMAF, WCISA and SWMAI. The release identified three key markets for the wire and cable industry: the automotive, telecom and construction fields. “In the past few years, these sectors have experienced a rapid expansion in India, with an annual growth of about 25%. For major infrastructure projects, the Indian government has begun to focus primarily on public private partnerships. With an investment need of about $450 billion, these infrastructure projects are the driving growth factor for the construction industry, especially in the transportation sector. According to the Automotive Mission Plan 2006-2016, the Indian government is geared up to double the automotive industry’s contribution to the country’s GDP by 2016 and furthermore intends to create 25 million new jobs in the industry.”

The telecom market in India, the release said, is the third largest in the world and the fastest growing, particularly in the wireless and telephone sectors. Concerning the Internet

Attendees arrive for Wire & Cable India 2012.

sector, the government plans to provide the rural regions of India with broadband connections.

Two years ago, wire & Cable India featured the collective technology of 291 exhibitors from 25 countries on 59,800 sq ft of net exhibit space. The event featured country group exhibits from Austria, China, France, Germany, Italy and the U.S. The 2014 staging will follow that lead, presenting the latest advancements in wire manufacturing and finishing machinery, process technology tools, auxiliary process technology materials, special wires, cables and materials as well as measuring and control technology, the release said.

The visitor target groups are decision makers from the wire, cable and spring sector, from the iron, steel and non-ferrous industry as well as from the automotive, aerospace, electrical engineering, telecom, computer, chemical and construction industry.

Wire & Cable India will be held concurrently with three related trade shows: Tube India 2014, Metallurgy India 2014 and Welding & Cutting India 2014.

Tube India and Metallurgy India is also organized by Messe Düsseldorf and its Indian subsidiary while Welding & Cutting India is an event of Messe Essen.

The schedule for the Wire & Cable India 2014 is 10 am to 6 pm on Tuesday and Wednesday, Oct. 28-29, and from 10 am to 5 pm on Thursday, Oct. 30. For further information on visiting or exhibiting, contact Messe Düsseldorf North America, at tel. 312781-5180, info@mdna.com, www.

From l-r at Wire & Cable India 2012: Leena Dugh, Messe Düsseldorf India (MDI); mdna.com.

Jörg Dübelt, Messe Düsseldorf; Heinz Rockenhäuser, IWCEA; Dr. Gerhard Bartz, An alpha list of exhibitors from outVDKM; Rahul Sachdev, WCISA; Dr. Kurt Eder, VÖDKM/AWCMA; Erhard Wienkamp, Messe Düsseldorf; Dr. Gunther Voswinckel, ITA; Peggy Deutscht, side India provided by the organizers is IWCEA France; Udo Schürtzmann, MDI; Lata Subramanian, MDI; Winfried Resch, on p. 38.

VDMA; Steven Rika, IWMA; and Ferruccio Bellina, ACIMAF. 36 | WIRE JOURNAL INTERNATIONAL

GMP Slovakia considers the Indian market very important and thinks that it will grow very fast during the next years. For this reason the management decided to open a new factory in Nashik, very close to Mumbai, one of the most important areas of Indian manufacturing. Inside the plant there are new and Ruggenenti modern machineries to manufacture all models of reels and drums. The portfolio already includes many Indian customers, and GMP Slovakia thinks that the upcoming wire show will help us in acquiring new customers and improving business with the old customers. The wire show will also be important to us to promote the new factory and invite Indian customers to visit our plant and personally check the quality of our products. Bruno Ruggenenti, president, GMP Slovakia.

Wire & Cable India is an excellent place for us to present new developments. This year we will highlight our pellet inspection and sorting system, the PURITY SCANNER, and we will present the latest developments for the optical �iber business, which is a strong market in India where we see an increasing demand in quality control equipment. SIKORA recognizes that doing business in India requires patience. The business is growing steadily, but has its ups and downs. We see much potential as there is an enormous investment needed in infrastructure and communication. We are in position to supply that need Lieder through the subsidiary we opened in Delhi in 2005, managed by Premjeet Saggu, a local who has done a great job for us from the beginning.

Another plus is that we provide local service in both Delhi and in Mumbai, where we opened our second subsidiary in 2012. Holger Lieder, sales director, SIKORA AG. Wire & Plastic Machinery has been a regular exhibitor at Wire & Cable India tradeshows since the early 1990s.

With the change of government the business investment outlook is certainly very positive as is evident from the surging BSE index. We have seen numerous solid inquires for quality second-hand machines and a few Indian customers have visited our warehouses to sign contracts. In the last two months several second-hand machines have been shipped to India. The exhibition is

being held right after a major Indian festival when everyone is ready to go to back to work after the holiday. We feel that the country is on a positive track and infrastructure spending is going to increase dramatically and the capital equipment suppliers will see a positive demand for their product offerings. Rahul Sachdev, executive vice president, Wire & Plastic Machinery Corp.

INDUSTRY EVENT

Exhibitor perspectives

Sachdev

The Indian market has long been important for us as cable & wire and optical fiber solution providers, and this has never been truer than today, with economic and political change boosting overall growth. This is leading to a positive outlook for our industry, most especially for fiber optic cable, automotive wire, and power cable production. The market will require the very best solutions in those segments where Rosendahl Nextrom has its expertise. For us, it is not enough that we design, manufacture and Dogra assemble our solutions; it is our joy and motivation to create professional solutions perfectly suited to our market’s particular needs. Kanchan Dogra, managing director, Rosendahl Nextrom India.

Wire & Cable India show gives Micro-Weld an excellent opportunity to meet its current and potential customers in India, understand their requirements for butt welding applications and also display our high-performance welding equipment. For Micro Products Company, a leading U.S. based manufacturer of Micro-Weld butt welders for 85 years, India has become an important market.

Though Micro-Weld has formally been in India for just a few years, we have supplied welders to several leading wire and cable companies in the country. The signs are encouraging and we expect the demand for high-quality butt welding equipment for continuous processing of wire and Dayal cable to grow in India. Micro-Weld wants to be there to meet this demand and offer the most efficient butt welding solutions available. Micro-Weld welders are already operational in several plants in India and we will continue to serve the Indian market in the coming years. H. Dayal, managing director, international, Micro Products Co. (USA).

SEPTEMBER 2014 | 37

REELS AND DRUMS

Below is an alpha listing for exhibitors outside India provided by the organizers. For more details, including booth numbers, go to www.wire-india.com and see the show program at the event.

• Aeroel SrL

• Dongguan Zhangli

• AIM, Inc

• EBNER GmbH

• Alessandro Stella Srl

• Eder Engineering GmbH

• Andritz AG

• ENKOTEC A/S

• Anhui Herrman Impex Co, Ltd

• Ernst Koch GmbH & Co KG

• Applied Composite Material Holdings Ltd

• ESTEVES GROUP

• Ara Makina Imalat Sanayi ve

• Fiber-Line International BV

• Baicheng Fujia Tech Co, Ltd • Beijing Holland Trading Co, Ltd • Beijing Tongdaxinming • Beta Lasermike • Messe Düsseldorf GmbH • Bongard Trading GmbH • Borouge Pte Ltd • Buss AG • Calmec Precision Limited • Ceeco Bartell Products, • Clifford Welding Systems • Condat Lubrifiants • Conoptica AS • CPT SARL • Dalian Tongda Equipment Technology

REEL FOR DRAWING AND STRANDING

CABLE AND ROPE PROCESS REEL

CABLE AND ROPE PROCESS REEL

STRUCTURAL DRUM IN TUBOLAR VERSION

MASSIVE REEL

REINFORCED DOUBLE FLANGE REEL

HANDLING EQUIPMENT

All the necessary accessories for reels and coils handling.

• FIB BELGIUM SA

• Flymca & Flyro

ROLLING SYSTEM FOR DRUMS

TAKE APART REEL FOR COIL’S PRODUCTION

TILTING UNIT FOR REELS AND COILS

TILTING DEVICE FOR REELS

AUTOMATIC LIFTER FOR REELS

AUTOMATIC LIFTER FOR COILS

• FMS Force Measuring Systems • FSP-One S AS • Fuhr GmbH & Co KG • Gauder SA • GCR Eurodraw SpA • GMP Slovakia sro • Guanbiao Electrical Mchry Co • Harditalia SRL • Hefei Smarter • HMP Heinrich Müller • Henan Wanke Diamond Tool Co, Ltd • Henrich Maschinenfabrik GmbH • Herkula Farben GmbH

• Deyang Dongjiagang Mechanical

• Honghui Electrician & Machinery Co, LTD

• Dongguan Ostrich Enterprise

• Hsiang Chuan Mchry Co, Ltd

• Dongguan Wai Tak Lung Machinery Ltd

• ICE - Agenzia per la promozione

Headquarter & Production plant: GMP Slovakia s.r.o., Pribenik - Slovakia Companies of the group: GMP do Brasil Imp. Exp. Ltda, Jandira/SP - Brasil GMP Reels India Private Ltd, Nashik - India sales@gmp-slovakia.com www.gmp-slovakia.com

SEPTEMBER 2014 | 39

INDUSTRY EVENT

Alpha list of exhibitors

INDUSTRY EVENT

Metal reels for wire and cable. Process and trasport.

INDUSTRY EVENT

Alpha list of exhibitors, continued

• IDEAL-Werk • Inductotherm Heating & Welding Ltd • InnoVites • Inosym Ltd • Intras Limited • IWMA - International Wire & Machinery Association • Jiangsu Dasheng Electron Accelerator Co • Jiangsu Handing Machinery • Jiangyin Kangrui Stainless Steel • Jun-En Enterprise Corp • Kalmark Integrated Systems • Karan Enterprise • Kemtech Int’l Private Ltd • Lämnea Bruk AB • Leyer & Kiwus Ultraschall- und Lasertech •M+E • Madem Gulf Industries • MAG • Maillefer Extrusion Oy • MALI GmbH • Mario Frigerio SpA • Messe Düsseldorf North America • Medek & Schörner GmbH • Messe Duesseldorf China Ltd • Micro Products Company • Nanjing Zhongchao • Newtech SrL

• Ningbo Kaite Machinery Co • Nuova Tecno Tau SrL • ORII & MEC Corp • Otomec SrL • Promostar SrL • Proteco SRL • Proton Products International L • PS Costruzioni Meccaniche SrL • Queins Machines GmbH • Reber Systematic GmbH • Redex SA • Renqiu Bojin Cable Drum • RichardsApex • Roblon A/S • Ronak Industry • Rosendahl Nextrom GmbH • RSD Technik GmbH • SAMP SpA • Sar Medya Altan Kilinc • SAS Engineering & Planning Srl • Hans Schmidt & Co GmbH • Schnell SpA • Shanghai Asahi Polymer Material Co, Ltd • Shanghai DIELEC • Shanghai Hanchuan Machinery • Shanghai Jiajie Tech Co, Ltd • Shanghai Jinglin Packaging

40 | WIRE JOURNAL INTERNATIONAL

• Shanghai Kaibo • TRAXIT International Compounds GmbH • Shanghai Kechen • Troester GmbH & Co KG • Shanghai Kingstrong Special • VÖDKM / AWCMA Verband • Shanghai Singcheer Technology Co, Ltd • WAFIOS AG • Shanxi Yiruidi Electrical • WCISA - Wire and Cable Industry • Shaoxing Kaichen Mica Material Co, Ltd • Welding Wire Machineries SrL • Shikaree Stainless Steel • Windak OÜ • SIKORA AG • Wire & Plastic • Simco Spring Machinery Corp.

Machinery Co • Wirtschaftskammer • Sino Erli Ind & Österreich Trading Co, Ltd • ADVANTAGE AUSTRIA • SKET GmbH • Wuxi Pingsheng • SMEETS n.v./SA • Wuxi Sunlit Science • Spazzolplastica SRL & Tech Co • SPX Precision Components • Wuxi Xinrun Ind • Stolberger KMB GmbH Furnace Co • Supreme Superabrasives • YUANG HSIAN Metal Co Ind Corp • Suzhou Forever Import • Zenkoh Co, Ltd • Tecnofil SpA • Zhangjiagang Victor • Teknor Apex Co Machinery • Tianjin Tianlan Mchry Co, Ltd For more details, including • TKT GROUP SpA booth numbers, go to www.wire-india.com and • Trafco SrL see the show program at the event.

FEATURE

Lubrication & filtration This feature presents a primer on filtration choices as well as a range of perspectives from lubricant suppliers about issues, a brief look at the earliest days and a tin-plated touch of lubrication irony. Highlighted products provided by the below companies follow on p. 52.

Q&A insight from lubricants suppliers WJI: What differentiates lubricant suppliers?

Differentiation among lubricant suppliers reflects the market: leaders and followers, performance-driven and price-driven. Thus, suppliers are differentiated by price, product performance, know how, level of support provided, and product range. Focus–how concentrated a supplier’s

Houghton differentiates itself by providing value added product technology along with technical service and support to our customers after the sale. By establishing customer intimacy, we are able to work closely with them throughout the entire process and identify cost reduction initiatives. Chuck Faulkner, market development manager, heat treatment & metal forming, Houghton International.

The combination of products offered, field and laboratory support and above all good communication between manufacturer and user. Rick Strapple, vice president sales & marketing, Metalloid Corp.

Bruce Calvert resources are on a particular market segment–is another point of differentiation. Suppliers have different performance criteria, cost bases, and margin expectations. Know how includes product innovation and applications expertise.

Support includes technical service, sales representation, and supply chain (e.g. inventory, order entry, and OTIF delivery). Bruce Calvert, director R&D, RichardsApex.

Developing successful lubricant technologies is a matter of long term knowledge of the application and experience in the marketplace. A supplier’s history and organization are keys to achieving this. Francois Chambellant, wire drawing business manager, Condat SA. There are several things that should be looked at to differentiate. First is the supplier a manufacturer or a distributor?

Who will provide answers to process questions and the technical support? In the end the best product in a drum won’t do you and good if you don’t have the proper usage and maintenance instructions. Jack McAfee, business manager, Chemetall.

42 | WIRE JOURNAL INTERNATIONAL

The two main things that differentiate lubricant suppliers are the commitment to research & development of new products and solutions and the technical fortitude to solve issues in the field when they occur. The wire drawing industry is constantly changing and because of that change a supplier needs the ability to develop new and innovative products, like the Unopol AL-series and Unopol S-series, and then help the customer utilize those products in the most efficient manner for their process. Troy Carr, business development manager, metalworking lubricants, fluids and services, Bechem Lubrication Technology, LLC. The focus on customer and the aptitude to research and development activities. Tecnovo provides its customers with a continuous technical collaboration to promptly resolve any problems arising during the drawing process. Besides we’re fully engaged on research of innovative high performance products, eco-friendly and health conscious, by our laboratories and Italian University partnership. The 7-9% of yearly turnover is allocated to R&D activities and this represents Tecnovo’s value added. Another success key is the deliveries flexibility and quickness, to support the customers also when they aren’t able to plan the consumptions on regular and periodic basis. Fabio Bellina, business manager, TKT Group/Tecnovo Srl. A wiredrawing lubricant supplier must be able to firstly provide a technically advanced product for the custom-

Q8Oils/Roloil staffers.

Suppliers with hands-on industry knowledge through the whole wire process have the best capability to help their customers; those willing to react quickly to customers’ needs with an emergency order or fixing a problem, doing more for the customer than just selling them a product. We believe suppliers should be able to understand the needs of everyone who uses our product, from the wire drawers on the floor to the managers making decisions. Jonathan E. Anderson, director of sales, Aztech Lubricants LLC.

er’s application and secondly provide technical support to the customer. This is very important and the technical support can cover all aspects of the product, application, reference, training, health and safety, housekeeping/ lubricant control, specialized analysis and much more.

It is these two fundamental points that differentiates one supplier from another. Andrew Turner, technical sales manager, Roloil, and Stuart Duff, product manager, metal manufacturing, Q8Oils.

WJI: Do most manufacturers have the necessary data (tool life, lost production) to cost justify buying a more expensive, more effective lubricant?

Yes and no. If a manufacturer wishes to make improvements then they must be in control of the process and know their production statistics, if this is done then it is easy for the manufacturer to compare one lubricant with another.

Industry Primer: filtration choices

By Tom Horn I’ve worked in the filtration industry for 25 years, and during that period I’ve seen both the technology and the needs of customers change, but one constant I don’t think will ever change is the reluctance by some manufacturers to think of a nonferrous filtration system as more than just a place to keep the coolant. I know that must sound like a salesman’s lament, and maybe to a degree it is, but based on everything I have learned during my career, our biggest challenge is getting a customer to understand why filtration is a key to long-term savings and product quality.

General overview

Wire production applications

On one level, everyone understands what filtration is supposed to do, from an oil filter for a car or a good cup of coffee. Providing proper lubrication and cooling plus keeping coolant clean is more complicated for the wire industry. There are multiple coolant package choices for continuous casting or wiredrawing today that require special attention to filtration system selection and operation to optimize coolant performance and longevity.

Whether a wire producer’s coolant package choice is conventional, semi-synthetic or full synthetic, the goal should be a system that can maintain the best wetting, lubricity, detergency, flushing, particle transfer to the filter and heat removal. As obvious and desirable that may sound, it’s not so easy to carry out when a company has a hard budget to hold or too many machines added to an existing system.

There is no one “right” filtration system because of the wide range of solids generated during manufacturing need different filters and systems. Continuous casting of copper rod produces a wide range of particle sizes; copper rod drawing produces more and larger copper particulate than intermediate applications; fine wire production produces less and finer particulates than intermediate or multiwire applications; and aluminum rod can be drawn with viscous mineral oil or water-soluble products.

This range of different solids loading requires specific consideration to determine the correct filter or filter system with the right design and sizing. Whether for wiredrawing or any other solid/liquid separation application, the required filter area for the solids loading can be verified through testing for each nonferrous wiredrawing process. This vital element is not a mystery as there is an (continued) SEPTEMBER 2014 | 43

FEATURE

While all suppliers have something to offer, the industry leaders combine all aspects of service: product development, technical service, premier customer service and quality, and environmental awareness. Mike Bell, vice president of technology and sales, Etna Products, Inc.

optimum sizing equation–GPM/ FT² (LPM/M²)–for determining different specific filter designs.

FEATURE

Filter selections A wire producer can select between gravity or air vacuum-type filters in different designs with specific filtering areas and coolant flow capacities for numerous applications. The industry standard for both is a basic rolled-media type filter.

In a gravity filter, liquid head pressure forces the coolant through the filter “cake” that is formed from the solids collected on the filter media and removes the very fine particulate. A gravity filter is commonly used for flow rates under 250 GPM, typically for single machine systems. If air vacuum is added to the filter design, it produces a higher pressure and creates a denser filter cake that can remove more fines as well as help control bacteria growth. This design costs more than a gravity filter, but it requires a smaller coverage area, so a smaller filter can be used.

When it comes to filtration, size matters. Undersized filters allow more fines to pass through to the tank, piping and machines, hurting die life and product quality and more costly maintenance in the long run. A filtration equipment supplier can explain the various options, but you can also ask the supplier of the drawing equipment as they know their machines and can provide critical specs for required flow rate, pressure requirement at the machine and heat dissipation. Another source is your primary coolant supplier, who will coordinate system charging and help to ensure seamless start-ups.

Realistic expectations There are three basic choices for potential filtration systems: good (economy), better (mid-range) and best (advanced), and you have to adjust your expectations to your choice: you are not going to get Mercedes performance from any filtration provider with an economy model. The budget is a reality everyone has to deal with, but you should not purchase any filtration system until you know exactly what performance each will provide. Below is an overview.

Good (economy) HII There are many elements that collectively matter for filtration systems, but if one opts for an economy-style system, focus first on sizing. Such a system may be good enough to maintain a modest level of production, but there are a lot of risks with a borderline system: the longer it is used, the more apparent its shortcomings will be.

A system with undersized filters uses more filter media, increasing consumable costs and allowing more fines to pass through and accumulate. A typical low-volume, single-compartment tank may not have the necessary retention, and as they use less-expensive, high-speed pumps, they may not be effective or dependable. Such a system, stretched beyond its real-world capabilities, will not be able to keep up its end of an industrial production flow. It will have problems maintaining good coolant clarity. Inevitably, operating costs will go up, there will be more die and capstan wear, increased wire breaks and higher labor 44 | WIRE JOURNAL INTERNATIONAL

costs and woes with product quality. These issues become even more apparent when a manufacturer adds drawing machines to an existing system sized for a lower flow rate.

Expectations: Can a “good” system work? Yes, but with all the above-cited disadvantages a strong possibility.

Better (mid-range) HHI A mid-range system will have a two-compartment tank but may have a lower-cost gravity filter. The filter will be sized correctly for the application and for 110% of the required machine flow. The pumps would be supplied for optimum speed and performance and provide a low-cost alternative to the economy system with significant improved performance.

Expectations: A mid-range system will be far more productive and reliable than an economy model. This design offers a reasonably priced alternative to the economy system.

Best (advanced) HHH A manufacturer with either high production rates or demanding product requirements needs a filtration system that can be efficient and dependable, day-in, day-out. This will cost more, but it will also keep the coolant cleaner far longer. Users will also save on die and capstan life as having fewer costly wire breaks, which is especially significant with multiwire applications. An advanced system will provide the desired coolant transfer, coolant heating and cooling, level control, and automatic water make-up. It will allow a company to operate to its potential.

In addition to the 110% flow rate sizing, an advanced system should have features such as media pre-coating, coolant extraction, tramp oil control and controlled indexing.

Expectations: A top-of-the-line system should not just meet all your technical needs, it should provide peace-of-mind in terms of product quality and consistency.

Parting advice Consider this not as a sales plug but a word-of-advice from someone who has seen what happens when a company opts for a lesser system. Yes, such a model may be able to work for a while, but if one consider how much potential grief it will cause with years full of shortened die life, more roll and capstan wear, increased media usage, more wire breaks, shorter emulsion life and more product quality issues, can it really be a good choice? By contrast, quality system, which should be able to easily last more than 20 years, will help provide consistent product quality, which in turn results in higher profits and more business for your company.

Tom Horn is vice president of sales for Filtertech, Inc. A longtime WAI member, he has presented multiple technical papers on filtration at Association technical conferences. He can be contacted at tel. 315-682-8815, thorn@filtertech.com, www.filtertech.

Editor’s note: This article was shortened due to space restrictions.

To read the full version, send an e-mail to mmarselli@wirenet.org.

It may seem like something out of Ripley’s Believe-It-orNot!, but L. Frank Baum who–in 1883 with his brother, Benjamin, co-founded Baum’s Castorine Co., supplying a range of axle lubrication products–later became well known for another endeavor.

Before he changed his focus, Frank Baum served for four years as the company’s superintendent and chief salesman. An ad in the Syracuse Daily Courier declared that Baum’s Castorine grease was “so smooth it makes the horses laugh.”

Per a report by Oil and Natural Gas History, during Baum’s travel as chief salesman he came up with the idea of using a tin woodman as a gimmick.

Later on, the brothers decided it was time to sell and they did. In 1890, Frank Baum began writing stories for children. One of his stories, published in 1900, was The Wonderful Wizard of Oz, which included a tin woodman who will forever be remembered for his yearning for a heart ... and an occasional need for lubrication. The 1939 screen version still places high on multiple lists of the best movies ever made.

Customer and application references are important for the lubricant supplier to provide assurance to any prospect customer. If a customer has no data, then by providing training and assisting the customer, a database of information can be acquired over time. It is also essential for proper health and safety practice that the customer should keep records of lubricant analysis and the data from their process.

Andrew Turner, Roloil, and Stuart Duff, Q8Oils.

Continuous collaboration with the customers facilitates the formulation of new lubricants able to work with higher performance in comparison to the conventional ones.

Obviously the costs of new and customized lubricants could be slightly higher but these are largely recovered by higher dies work-life, better lubrication without product waste, the increase of drawing speed that means higher productivity and the better quality of the final wire. Fabio Bellina, business manager, TKT Group/Tecnovo Srl. It is extremely important to understand the total cost of ownership in the manufacturing process when purchasing a lubricant, not just price per gallon. Some larger companies have the engineering and maintenance resources to evaluate part quality and tool life in relationship to total cost.

FEATURE

Lubrication an unlikely link to a tin woodman getting a heart

A tin woodman with the heart of a lubricant supplier.

In his biography of Frank Baum, Evan Schwartz pondered Baum’s role with lubricants. “What if Frank had never sold oil cans? Would we have never met the heartless Tin Man?” Meanwhile, far from the limelight, the company that Frank Baum co-founded has continued to produce lubricants. In a �itting touch, company President Paul Berger recalls that when he was 11 years old, he played the tin man in a neighborhood production of the Wizard of Oz. “I am amazed at how history may not repeat itself, but it surely rhymes.”

Unfortunately, smaller companies do not always have the internal resources and may tend to focus more on price per gallon. Chuck Faulkner, Houghton International.

Yes, most wire manufacturers do a good job of tracking their costs. It can be as simple as tracking a few numbers at the end of the week or end of the month, so rather than shopping by cost only, they can look at the cost per ton on finished product rather than the cost per pound of the lubricant. Jonathan Anderson, Aztech Lubricants.

Some manufactures do have the data to justify a more effective lubricant, but that may not be the most effective one. It requires a lot of man-hours to collect and analyze tool life data. Judging and justifying a lubricant through its contribution at increasing process effectiveness and reducing lost production is easier and straight forward.

Just because it costs more doesn’t guarantee it is a better product. You don’t always get what you think you are paying for. Paul H. Berger, Baum’s Castorine Co. Inc. In many cases they do not. In those instances they must rely on the lubricant supplier to provide meaningful laboratory data that can help predict how a wire draw-

SEPTEMBER 2014 | 45

FEATURE

CHAPTER CORNER FEATURE

ing lubricant will function in the real world. Of course, experience and case studies of product performance are always useful. Mike Bell, Etna Products, Inc. It is difficult to rigorously calculate ROI or life cycle cost, because the number of factors that affect performance make it hard to establish a baseline. That does not stop manufacturers from judging performance, however.

Manufacturers are keenly aware, for example, of the frequency of wire breaks, equipment on-stream factors, and product quality. There are often overriding considerations when selecting a lubricant. Some manufacturers buy largely on price. Others buy premium lubricants to offset equipment limitations. In such cases, the cost of a premium lubricant is less than the opportunity cost of downtime and capital recovery cost for new equipment or modifications to equipment and infrastructure. The broad trend, which parallels developments in the automotive sector, is clear: investment in advanced hardware and intense, global competition are driving the use of higher performance lubricants. Bruce Calvert, RichardsApex.

François Chambellant

Many of our lubricants are based on natural substances, and the unit cost is linked to the quality of such substances. A lubricant with high reliability and consistent performance is likely to be slightly more expensive than a very basic one. Ongoing R&D often requires the use of more expensive raw materials and additives, e.g., the removal of borax in soaps can require adding a more expensive filler. Our customers are ultimately appreciating the benefits of these lubricants through their production indicators.

François Chambellant, wire drawing business manager, Condat.

Unfortunately, the wire drawing industry is challenged, like most manufacturing, to devote enough resources (time and people) to collect the necessary data to objectively justify a particular product. The customer realizes that it is the “value” or cost of use of the product that is more important than the acquisition cost. “Value” is affected by concentration, make-up rate, lubricant life and die life among many parameters and represents the true cost of a product. Troy Carr, Bechem Lubrication Technology, LLC. The simple answer is “No.” Most companies will be able to tell you what their tooling usage/cost is over a time period. The difficult part is to break that down to a small window that you can use to compare to a trial period of the proposed product. The simplest way is to take a machine/ process and run it for a specified time tracking tool life, down time, rejects, and other parameters. Then run the same period with a proposed product and compare the differences. If at all possible try to have the same operator(s). The variable in results with an experienced operator versus a new operator can be huge! Jack McAfee, Chemetall.

Not necessarily, but a trial run of a product will demonstrate benefits and future cost savings in the process. Rick Strapple, Metalloid Corp.

WJI: Are material restrictions likely to become more of a challenge?

Material restrictions will continue to increase and a technically driven supplier must be proactively research and provide alternative materials. The 46 | WIRE JOURNAL INTERNATIONAL

Times change, but not the basic concept of lubrication FEATURE

Lubrication was understood thousands of years ago as one did not need a Ph.D. to understand that reducing friction made life simpler. The state-of-the-art lubrication was either animal fat- or vegetable fat-based.

The opposite illustration is from a wall painting in the tomb of an Egyptian provincial governor, Djehuti Hotep, circa 1900 B.C. The image shows a massive statue, an estimated 60 tons, being moved on a sledge.

The man seen standing in front is pouring liquid (watered oil) from a jar onto the ground. The mixture lubricated the tracks and the skids of the sledge.

An early form of grease, derived from animal fat and applied to the axles of chariots, was found in an Egyptian Pharaoh’s tomb circa 1400 B.C. For the record, one of the earliest U.S. patents for lubrication for wire manufacturing was printed in the July 1879 issue of Scienti�ic American, Vol. 41, Number 01. The American patent, No. 215,875, was issued to A.B. Brown, for “Lubricant materials for use in wire drawing,” Dated May 27, 1879, it listed the following brief description: “A mixture of a solution of alkaline phosphate and �lour.”

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FEATURE

Unopol AL-series was built to meet the needs of the aluminum wire industry to produce a cleaner product and for a cleaner environment in their plant. Troy Carr, Bechem Lubrication Technology, LLC. Raw materials always seem to be increasing. The more sophisticated the lubricant the more you can expect its price and sometimes its availability to be impacted by fluctuations in the commodity markets. Jack McAfee, Chemetall.

This has long been a challenge, both from government restrictions to raw material shortages or sudden drastic price spikes. The government restrictions in the past few years have been increasing rapidly, many without true justifications. We have built this into our ongoing R&D plan.

Jonathan Anderson, Aztech Lubricants.

Lubricant manufacturers aware of new and more restrictive regulations see the issue as a great opportunity for growth. Our TECNOLUBRE FM/913, an incomparable sodium-based drawing lubricant, is 100% free from borax, boron derivatives and nitrites, and TECNOLUBRE FM/195, a new calcium-based lubricant, is 100% free from titanium dioxide, which is suspected of being a danger to humans and capable of causing difficulties with subsequent wire treatments–such as pickling, annealing, coating and wet wire drawing– and is abrasive on capstan coatings.

Fabio Bellina, TKT Group/ Dust test by Fabio Bellina.

Tecnovo Srl.

48 | WIRE JOURNAL INTERNATIONAL

Paul H. Berger

As with all U.S. manufacturing, government regulations continue to provide challenges and distractions to meeting market demands.

Such restrictions are not new to our industry, and our experience at adapting to new materials (engineered to be more acceptable) has enabled us to be more competitive.

Paul H. Berger, Baum’s Castorine Co., Inc.

Over the past 10+ years, the selection and availability of certain raw materials has changed and we are working continuously to develop alternatives in order to secure our customers and our business. François Chambellant, Condat.

Material restrictions and the ever-changing international and regional legislation are a challenge, but it also is a challenge that can result in innovation in development to stay several steps ahead of restrictions or a competitor’s product technology. You cannot stand still; improvements must always be in the development process.

Andrew Turner, Roloil, and Stuart Duff, Q8Oils.

Material restrictions will continue to be a challenge, although it is hard to imagine the rate of change being greater than it has been. Change will continue to be driven by: regulatory mandates, which vary from country to country; raw material rationalization, i.e., suppliers walking away from less profitable, non-core business; lacking reinvestment economics, as many chemical businesses have been run in a cash generating mode that has led to constrained supply; and force majeure, resulting from natural disasters and other unplanned plant outages. The net result is that a significant portion of every R&D dollar is spent approving new sources or

For nonferrous, lubricant additive restrictions are not expected to be an issue in the near future.

One possible exception could be elevated regulation of some biocides used in water soluble lubricants. For ferrous, some of the chlorinated extreme pressure additives are facing an uncerMike Bell tain regulatory environment. Mike Bell, Etna Products, Inc. Houghton has seen a substantial increase in material restrictions and regulations globally in the past decade and we expect this trend to continue. There is an international initiative called the Global Harmonized System (GHS) that is intended to align countries in their regulation of the manufacture and use of chemicals. This effort should ultimately

simplify things but for the next few years it will increase the burden on manufacturers such as Houghton even more as nations have taken different routes and timelines to bring their local systems into alignment with GHS. Houghton takes its leading role in the field of metal working fluids seriously and has devoted the resources to ensure that we will be GHS compliant by all deadlines. This is no small effort when you consider that we have Chuck Faulkner manufacturing operations on five continents. Chuck Faulkner, Houghton International.

Raw material suppliers have changed over the years as a result of acquisitions and mergers. However, most raw materials continue to be readily available. Rick Strapple, Metalloid Corp.

WJI: With so many variables, how hard is it for a customer to pick the best lubricant for their application?

Usually the wire drawing companies can’t determine which type of lubricant is indicated for their specific process. In addition to this, as a function of raw materi-

SEPTEMBER 2014 | 49

FEATURE

alternate raw materials while the ranks of product stewards have swelled. One of the broad challenges is the shrinking list of approved biocides. Combating microbial attack on water-based functional fluids, a never ending battle without a perfect solution, is only going to get harder. Bruce Calvert, RichardsApex.

FEATURE

als, different drawing machines and environmental conditions, for the same productions it’s necessary to use different types of lubricants. For this reason it’s up to lubricant suppliers to suggest the appropriate lubricants based on technical service and information received by the customer. The choice of the right lubricant can determine the commercial success of the drawing companies, by the quality target achievement. Fabio Bellina, TKT Group/Tecnovo Srl. It is never easy to pick the best product. Knowing how a product performs in a similar plant or machine is a good starting point. Given the complex tribology and differences between machines, a trial is often the best option.

Bruce Calvert, RichardsApex.

A supplier’s technical knowledge and experience is invaluable. Our commitment is precisely to help our customers select the optimum lubricant, one that offers the best compromise between performance, cost efficiency and (increasingly important) environmental impact. François Chambellant, Condat.

It comes down to communication again. If you have a well trained, knowledgeable sales force and the end user is committed to working with the manufacturer, the correct product will be matched with the application.

Rick Strapple, Metalloid Corporation.

Rick Strapple

It can be very difficult, but at Aztech we start by looking at the customer’s whole process. How will this wire be further processed or what product will be made from this wire. How can we make our customer’s customer happy? The only true way to for a wire company to know what works for them is a trial process, and we as the supplier will work with our client to find that optimum product for both the performance and cost basis. Jonathan Anderson, Aztech Lubricants.

Customers must rely on reputable suppliers with a positive record at understanding the materials being processed. The capable suppliers must have a full understanding of how their formula ingredients will interact with the materials in the process. Corrosion protection of the process materials and machinery surfaces is a basic requirement that all formulations should contain. Paul H. Berger, Baum’s Castorine Co. Inc. Customers today are well informed but there are many terms in the lubricants industry that are misused or cause confusion. A supplier should be willing to explain the products in a manner that is easy for the customer to

50 | WIRE JOURNAL INTERNATIONAL

Troy Carr by the good word of Bechem. understand. There are many great tools that can help a customer, for instance BECHEM has an app that you can find in the “App Store” (called “BECHEM ABC of Lubrication”) that explains many of the terms commonly used in the industry. This is a great tool for someone who is looking to define a particular term. Troy Carr, Bechem Lubrication Technology, LLC. This goes back to customer intimacy and making sure we completely understand the customer’s process.

Houghton has a wide variety of metalworking fluids based on multiple chemistries and raw materials. The key is to provide the best product for the operation from a technical and economic point of view. Chuck Faulkner, Houghton International.

WJI: Does recycling a lubricant ever make sense?

This boils down to economics and performance of the recycled lubricant. If the product has to be transported to an outside facility then the cost savings and environmental savings is usually eaten up in transportation. We have worked with some customers to develop recycling systems that work for them. On-site systems are available. Jonathan Anderson, Aztech Lubricants.

Yes, it does make sense and product sustainability is even more important in today’s manufacturing process.

At Houghton we engineer our products to last as long as possible without dumping and re-charging. However, it does require a partnership with the customer to establish proactive maintenance programs supported by our technical team and service laboratories. We also have waste treatment experts to evaluate lubricant recycling and determine the most cost effective method. Chuck Faulkner, Houghton International.

If the lubricant is inexpensive and can be easily disposed of, probably not.

It always comes down to “Can we save money by recycling the lubricant?”

Be careful, a recycled lubricant may have depletion of some key components over time. This could lead to higher tooling and downtime costs. Jack McAfee, Chemetall.

Jack McAfee

Recycling is possible in some industry segments, however often the cost of the “recycled” product is a significant portion of the new product and the feasibility just does not make sense. Utilizing the methods to extend the product to its full life are often the best solution. Troy Carr, Bechem Lubrication Technology, LLC.

Over last years attempts have been made to recycle the worn-out lubricant, but unfortunately the results were negative. The main problems derive from the heavy pollution of iron and charred material present in the lubricant to be recycled; for this reason lubricant reuse at the moment isn’t considered feasible. Fabio Bellina, TKT Group/Tecnovo Srl. A distinction is made between on-site fluid reconditioning and recycling. Recycling, collecting and processing spent lubricants, is the reverse of the manufacturing/distribution process, a costly proposition. It is one thing to recycle neat oils, such as gear oils and hydraulics, and another to recycle spent oil/ water emulsions. Neat oils are routinely recycled, but spent emulsions are normally treated and disposed.

Treatment methods include evaporation, UF and chemical splitting, anything to minimize the volume of oily wastewater that must be hauled away. Another aspect of recycling is the use of recycled base oils in the fresh lubricant. If base stock quality or type is important, a recycled base stock may not be the best option. In broad terms, industrial oils, including metalworking fluids, are sensitive to base stock quality and type.

Bruce Calvert, RichardsApex. n

FEATURE

Absolutely, especially in large or central systems using water soluble machining coolants or wiredrawing lubricants. Recycling reduces chemical, labor and disposal costs if combined with a good preventative maintenance program. This is known as “Coolant Management.” Rick Strapple, Metalloid Corp.

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PRODUCTS FROM

THE FEATURE

Baum’s Castorine In response to requests from wire manufacturers across many markets, last June Baum’s Castorine Co., Inc., introduced two products for the wiredrawing industry.

Dura Draw 942, a true multi-metal, semi-synthetic drawing emulsion compound, is currently being used to draw aluminum rod breakdown, both 1350 and 8000 series. It will draw at concentration levels well below what is currently being done with other compounds. Dura Draw 942 represents true advancements in wire drawing formulating. While current trends may be to just increase the concentrations of old copperdrawing formulas in hope of achieving acceptable results, Dura Draw 942 is designed to overcome the problems that these demanding materials present.

Also introduced last June, Dura Draw 898 is a unique addition to Baum’s Castorine’s already extensive line of metal working (wiredrawing) formulas. As more and more companies are purchasing what is referred to as “turn-key” systems, emulsion tanks are being employed that are smaller than ideal. At the same time, in an effort to save money, smaller horsepower, higher rpm pumps are being chosen for these systems. Both of these conditions will contribute greatly to a system’s tendency to be a foam generator.

Primarily for copper wire, Dura Draw 898 employs a unique proprietary blend of raw materials that not only foams less, but actually works to suppress foaming.

And, unlike low foam formulas of recent years, Dura Draw 898 forms a very tight emulsion, allowing for a stable emulsion resulting in lower consumption rates and requiring less tank side additives.

Contact: Baum’s Castorine Co., Inc., tel. 315-336-8154, sales@baumscastorine.com, www.baumscastorine.com.

line of oil-based lubricants for traditional aluminum drawing applications. For aluminum wiredrawing the use of emulsions for both rod and multiwire drawing applications allows for a pleasant and clean working environment which cannot be achieved with conventional drawing oils.

Thanks to well-selected additives, the products from the Unopol AL-series offer excellent lubricating properties, long sump life, and frame the parameters for a stable and efficient drawing process. Unopol AL 560 and Unopol AL 570 cover the range of wire sizes, from rod through multiwire.

For copper, there has been continuous development of fully synthetic drawing lubricants. Bechem has faced the challenge to replace drawing emulsions with its Unopol S-series line of fully synthetic lubricants. The Unopol S-series exceeds the performance of drawing emulsions while minimizing the maintenance requirements. A core product to this series is Unopol S-643. This water-soluble, mineral oil free drawing lubricant is achieving die and lubricant lifetimes never achieved before. It offers outstanding process stability when drawing bare, tin, nickel and silver plated copper wire with finish sizes from 0.4 mm to 0.05 mm.

Contact: Troy Carr, Bechem Lubrication Technology, LLC, tel. 440-543-9845 or 440-263-4236 (cell), carr@bechem.com, www.bechem.com.

Chemetall U.S. Chemetall U.S., a business of Rockwood Holdings, Inc., offers Gardo® hybrid technology for phosphate-free cold forming operations that it notes represents the first one offered for cold-forming conversion coating without phosphates, which is of special interest for the automotive market.

Bechem Lubrication Technology, LLC Bechem Lubrication Technology, the U.S. subsidiary of Germany’s Carl Bechem, a long-time supplier to the wiredrawing industry, notes that technology is the cornerstone of the company’s brand.

Bechem, known for its outstanding Unopol product line of water-based lubricants for both copper and aluminum wire, also offers the Berudraw product 52 | WIRE JOURNAL INTERNATIONAL

The product replaces the zinc-phosphate layer by a phosphate-free metal-organic one. This innovative conversion layer provides the same excellent properties and behaviors as a traditional zinc-phosphate. However it fulfills more stringent safety and environmental requirements: the product does not contain any heavy metals and the formation of the metal-organic layer consumes less energy.

Gardo Hybrid can be easily integrated into current cold forming operations since no major modifications to the lubricant, treatment line or application process is needed.

The reason for this is that the tribological system was not

Condat France’s Condat reports that VICAFIL SUMAC 5, the company’s new powdered lubricant, represents the latest development of the SUMAC family, which is designed for high-speed wiredrawing applications.

in a range of particle size distributions, tailored for the particular application, process and diameter of wire being drawn.

Another lubricant of note is VICAFIL TFH 1167, an oil-based lubricant for aluminum and aluminum-alloy wiredrawing that preserve dies and draws high quality wires without compromising simplicity of use and long service life. The low-viscosity base oil improves cooling and reduces consumption by minimizing the amount of residue on drawn wire, while its additives limit production of sludge, thus reducing machine maintenance and extending lubricant life. No further additives are required, so VICAFIL TFH 1167 reduces bath maintenance costs. It suits most drawing operations and diameters, and can be used in either immersed or sprayed type drawing machines, without damaging equipment.

Contact: Condat, www.condat.fr, www.condat-lubricants.com.

Etna Products, Inc. A versatile product providing high lubricity and thermal stability, VICAFIL SUMAC 5 is suitable for use on a wide variety of steel types and applications. This includes stainless/nickel-based alloys and high carbon steels for demanding products such as spring wire, tire bead wire and steel cord wire. The product is available

Two products from the Etna Products, Inc., are each designed to provide superior performance for a range of drawing processes.

MASTERDRAW® 5129 was developed to provide a low-viscosity aluminum rod breakdown and wiredrawing product with superior lubrication for both EC and magnesium-alloyed rod in low- and high-speed oper-

SEPTEMBER 2014 | 53

PRODUCTS & MEDIA

changed; it is still divided into two parts: the conversion layer providing the unique surface and the lubricant on top.

With this innovative technology, Chemetall has responded to the market requirement for an environmentally-sound, cold-forming technology that provides high-forming performance.

Contact: Dane Armendariz, Chemetall U.S., dane.armendariz@chemetall.com, www.chemetall.com.

PRODUCTS & MEDIA

ations. Its proprietary lubrication package allows for faster drawing speeds and lower die temperatures over an extended period of time while providing a bright and clean finish. With adequate filtration and routine system maintenance, MASTERDRAW 5129 offers exceptional sump life.

MASTERDRAW® 5182 was developed specifically for drawing ultra-fine nickel-chrome, stainless steel, nickel-plated copper, precious metals and high-carbon steel wire. It provides the lubricity and extreme pressure properties required for diameters down to 0.00015 in., at a low viscosity. The residues are easily cleaned by solvent washing, alkaline cleaning, or vapor degreasing the wire. If the wire is left uncleaned prior to annealing, residues of MASTERDRAW 5182 will bright anneal, given a bright annealing atmosphere.

Contact: Etna Products, Inc., tel.440-543-9845, etna@etna.com, www.etna.com.

Metalloid Corporation Metalloid Corporation introduces WireWorks 10005, a technological breakthrough in the dry drawing of highand low-carbon steel wire.

54 | WIRE JOURNAL INTERNATIONAL

The latest “green” product from Metalloid, WireWorks 10005 is a solid, flaked lubricant that contains no soap, borax, lime or phosphates. The lubricant has remarkable die life and none of the drawbacks of powdered sodium or calcium soaps. It will not produce dust or require air filtration. It will provide excellent corrosion protection and it can go directly to the annealing furnace.

WireWorks 10005, formulated with American-made natural ingredients, is biodegradable, biorenewable and biosustainable. It is used as received in the ripper box or single die box, where it will produce clean and bright wire with a high finish.

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56 | WIRE JOURNAL INTERNATIONAL

ness and exceptionally long life even at elevated operating temperatures.

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TECHNICAL PAPERS

TECHNICAL PAPERS Optimizing shielded pair manufacturing This paper proposes a method for estimation of expected tolerance of cable propagation properties based on available manufacturing tolerances and calculated sensitivities.

By Juliusz Poltz and Mats Josefsson Twinax or twin-axial cables were introduced as an inexpensive, stable and noise resilient connection media in very early computers and networks. Traditional designs of twinax pairs include two balanced signal wires, a simple helical metallic foil screen around the conductors, and possibly one or two drain wires located under the screen. The twinax cables are already adapted for 10 Gbit/s Ethernet connectivity options in data centers, enterprise wiring closets and service provider transport applications. Twinax cables offer a highly cost-effective way to connect within racks and across adjacent racks. Typically, twinax is used between the server and top of the rack switch. Individual pairs of twinax cables may be bundled together in multi-pair configurations. Each pair of these cables is currently able to handle short distances with speeds up to 10 Gbit/s.

Since twinax cables are very common today there is still a high interest in enhancing twinax performance. In recent years researchers discovered that these cables showed fierce bursts of insertion loss (IL) at GHz frequencies due to periodicity that results from the wrapped foil1-3. Since cables with longitudinal wrapping do not demonstrate these negative effects, they are slowly replacing the original helical screen, but the twinax concept is still considered as the most cost-effective solution for short length interconnectivity.

Sensitivity analysis is the first step in guiding a designer into optimization of twinax cable. Sensitivities not only provide a clear indication of how design dimensions and materials influence cable propagation properties, they also offer a very valuable estimate of tolerances for cable propagation properties based on expected distribution and tolerances of design parameters. The main building blocks of twinax cables are the two insulated copper wires manufactured in extrusion lines. See Fig. 1. Consequently the design parameters considered in this investigation are related to dimensional and material parameters of these wires.

variables against which the sensitivities of objective functions are calculated. These are typically called parameters. Voltages, currents and their ratios are frequently used as properties in circuit analysis, whereas component values L, R, C and G, etc. are the parameters. The situation is drastically different for a cable designer who would rather consider unit cable parameters (L, R, C and G) and corresponding propagation parameters: time delay (Td), attenuation (a) and characteristic impedance (Z) as properties of the design and the geometrical dimensions and material constants as the variables or parameters.

The conducting in insulating material related process data and the geometrical parameters are already monitored by manufacturers. During the manufacturing of insulated conductors in an extruder line the machinery data are sampled in-line and displayed on a screen. See Fig. 1.

Subsequently, the dimensions of the manufactured insulated wire are sampled in-line (Fig. 2) and collected for subsequent analysis. Fig. 1. Machine and product The diameter of the parameters are monitored in an insulation extruder line.

Manufacturing Parameters Electrical and electronic engineers have used sensitivity analysis for many years. To define sensitivity one needs to specify the objective functions called properties and the 62 | WIRE JOURNAL INTERNATIONAL

Fig. 2. Diameter, eccentricity and lump detector equipment in an insulation extruder line.

Fig. 3. Machine and product parameters are monitored in a twisting line. metallic conductor and the diameter of the overall insulation are normally sampled in-line by non-contact laser scanning equipment. Although this equipment can also measure the diameter in different directions to record deviation from the circular shape, the ovality of the conductor was not considerd as a parameter in this study.

Several parameters are measured in-line while twisting. See Fig. 3. The lay length of the pairs, the backtwist ratio and the tension in the conductors are monitored and saved during the manufacturing process. In fact, the collected manufacturing data can exceed the ability to process it entirely in order to increase performance and quality of the cable.

The following parameters for sensitivity analysis of the STP cable were used: diameters of conductor, inner skin, foam and outer skin; eccentricities of conductor, inner skin, foam and outer skin; conductivity of conductor; dielectric constant and loss tangent of the inner skin, foam and outer skin The eccentricity of the metallic conductor in the insulation can be measured in different ways. For example, by using an inductive principle to find the position of the metallic conductor in the plastic insulation. In certain cases x-ray technology is used.

One can also use frequency as an input parameter6 but it is not useful for performing statistical analysis for manufacturing tolerances, which is the objective here.

Considering that the cable is constructed from two wires of non-correlated shapes, the above list creates 30 independent parameters.

Propagation parameters: Td, attenuation and Z will be considered as properties of the investigated cable geometry in the following investigation.

Definition of sensitivity Sensitivity analysis is nowadays frequently used by designers of electronic circuits4. Less common and known is its use for interconnect analysis. Extending the definitions of circuit properties to cable propagation properties (Td, a, Z), one can observe that each of

The dimensional parameters are defined in Figure 4. Typically used material parameters include wire conductivity (γ), together with relative permittivity (er) and tangent delta (tan(δ)) for all layers of insulation (inner skin, foam, Fig. 4. Dimensional parameters skin). It is importused for sensitivity analysis. ant to notice that these parameters may independently control each of the wires, although the nominal design most likely is based on nominal and symmetrical values: Eq. (2)

Changes of any property due to incremental changes of dimensional and material parameters can then be represented by Taylor series expansion: Eq. (3)

The partial first derivatives of cable properties against dimensional and material parameters are defined as differential sensitivities4. In practice, they are calculated from finite differences and sometimes called smallchange sensitivities: Eq. (4) Since design parameters carry different units and values these derivatives may have vastly different numerical values and are difficult to compare. Therefore, it is sometimes more meaningful to define normalized differential sensitivities as follows: Eq. (5) The normalized differential sensitivity offers a quick insight into the relative influence of the parameter on the property. For example, if the normalized differential sensitivity is equal to -0.45, then a 4% change of the SEPTEMBER 2014 | 63

TECHNICAL PAPERS

them is a function of multiple dimensional and material parameters. For example, attenuation depends independently on dimensional and material parameters of each of the wires: Eq. (1)

TECHNICAL PAPERS

parameter (in this case conductor diameter) will cause a 1.8% shift of attenuation. Accordingly, by using normalized differential sensitivities one is able to compare the impact of changes in conductor diameter on attenuation with the impact of changes in insulation permittivity on attenuation. Also, it would be possible to decide if the conductor diameter changes affect more attenuation or characteristic impedance. The sign of the sensitivity also has important meaning. If negative, it indicates that an increase of the parameter (conductor diameter) is causing a reduction of the cable property (attenuation). All sensitivity figures in this paper show normalized differential sensitivities. The important disadvantage of normalized sensitivities is the necessity of defining variables with non-zero nominal values (due to division in Eq. 5). As a result the classical definition of eccentricity was replace with radius r (Fig. 2) defined as a max distance from the surface of the insulation to the center of the conductor.

Numerical analysis of sensitivities There are many dimensional and material parameters that are already monitored in manufacturing. However, without knowing sensitivities one cannot estimate their impact on quality of the manufactured cable. It is very difficult to calculate sensitivities from manufacturing data since the results of manufacturing and testing (measured properties of the cable) carry the impact of numerous parameters. Simply, it is difficult to separate the impact of eccentricity from diameter changes if a given sample carries non-nominal data for all design parameters. On the other hand, numerical calculation of sensitivities is very simple and reliable. It is very easy to introduce small changes in the design parameters and recalculate the properties. It is simple to separate the impact of a single parameter on a single property from all other random relationships. In addition, if a software package is able to create designs from parameters listed in an Excel spreadsheet5, then one can setup numerous experiments in a very short time. See Fig. 5.

However, setting up consequential numerical experiments requires detailed knowledge of the manufacturing process, since some of the design parameters may be purposefully manipulated by the manufacturing lines with automated in-line testing and feedbacks. In general terms, Eq. (3) provides a good approximation for changes of properties as a function of small changes of parameters, providing that they are not mutually linked or correlated as a result of the manufacturing process quality control feed-back loop.

To calculate the normalized differential sensitivities, the nominal design and all small-change variations initially specified in the Excel spreadsheet (Fig. 5) were imported into numerical analysis software5 and simulated. The results, in the form of ASCII reports, were then assembled in a final report sheet for calculation of small-change sensitivities. Sensitivities were

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calculated against material and dimensional variations associated with only one wire of the cable, leaving the other with nominal material parameters and dimensions for all simulations.

The normalized differential sensitivities of the time delay, attenuation Fig. 5. Excel interface used to and characteristic create design variations in a impedance against software package for calculation the set of selected of small-change sensitivities. material parameters are presented in Fig. 6. All three selected properties show the strongest sensitivity to changes of dielectric constant of the foam. However, the increase of foam permittivity by 10% leads to less than 2% increase of time delay and attenuation and reduction of characteristic impedance.

This relatively difficult to explain link of attenuation with dielectric constant variations results from the impact that the permittivity has on characteristic impedance. The impact of inner and outer skin parameters on the selected properties is small since their volume is marginal in comparison with the foam. One can notice that if both skins have identical thickness (as assumed in this test case), the inner skin located in a much stronger electric field affects the properties twice as much than the outer skin. The only other material parameter that influences attenuation is copper conductivity. Here, too, the impact is not as strong as one would hope for, because increase of conductivity leads to reduction of the skin depth. At the selected analysis frequency of 100 MHz and with low loss polyethylene, the dielectric loss tangent plays a marginal role.

The normalized differential sensitivities of unit parameters, attenuation and characteristic impedance against the set of selected dimensional parameters are presented in graphical form in Fig. 7.

Properties of the simulated STP cable demonstrate much stronger dependence on dimensional parameters.

The overall diameter of the insulation, which is represented in our test by the (outer) skin diameter, plays the most significant role. Again the dielectric impact on reduction of attenuation is somehow extraordinary but can be justified by two factors. Increase of the overall insulation diameter leads to increase of characteristic impedance (which lowers the current needed for transmission of unit power) and also leads to reduction of eddy-current losses in the Al tape screen of the cable.

The relative locations and sizes of copper conductors are the next strongest factors, impacting our three properties.

The dimensional sensitivities of the time delay are insignificant. In fact, this is the only property that is more strongly

TECHNICAL PAPERS

influenced by material changes than by dimensional variations. The dimensional variations may only affect the overall balance between different dielectric regions. The propagation speed of the quasi-TEM wave is controlled by the dielectric constant of the dielectric material that carries most of the energy of the wave, which is the foam. See Fig. 6. This is clearly visible in Fig. 8, which presents all factors that influence time delay sorted by their relative strength.

Critical Parameters One can now look at individual properties and assess the impact that different parameters have on their values. By sorting the parameters by their impact strength it is possible to find critical parameters that control time delay (Fig. 8), attenuation (Fig. 9) and characteristic impedance (Fig. 10).

The main factor impacting attenuation is the overall insulation diameter (skin diameter). The most unexpected conclusion from our comparison is the relatively low level impact of copper diameter and conductivity (5th and 6th factor) on attenuation. However, this test was set up for frequency 100 MHz and the impact of these parameter increases with the frequency.

Main factors of the characteristic impedance sensitivity are in order of importance: the wire diameter, the overall diameter of the insulation and to a smaller extent the dielectric constant of the foam. It is rather interesting to see that copper eccentricity, which affected attenuation very strongly, has rather small impact on characteristic impedance.

Combining sensitivities of all three properties one can present critical design parameters of our STP cable. See Fig. 11. Although the relative impact of parameters is dependent on the selection design objectives (properties), one will be safe to conclude that the most critical design parameters for STP cable are insulation (outer skin) diameter of the wire. Copper diameter and eccentricity and foam dielectric constant are impacting the three selected properties with a similar magnitude. Other parameters play insignificant roles. Since STP cable is contained (compressed) by the screen, the eccentricity of copper and the eccentricity of the (outer) skin are closely related.

Fig. 6. Time delay, attenuation and characteristic impedance material sensitivities.

Fig. 7. Time-delay, attenuation and characteristic impedance dimensional sensitivities.

Statistical Analysis During the automated manufacturing process, statistical data is automatically collected from in-line measurement (Fig. 12) at all manufacturing levels and displayed. Similarly to wire extrusion details, manufacturing the cable requires control over the thickness of the sheath. This not only allows controlling the overall diameter of the cable but also reduces the cost by minimizing the consumption of the plastic material, especially for large cables. In sheathing lines it’s common to use ultrasonic equipment or x-ray technologies for measurements of the wall thickness of the sheath. See Fig. 13. Sheathing lines have normally the same in-line

Fig. 8. Time delay sensitivity factors. measurement equipment as the insulation line except the capacitance measurement equipment.

Drawing on the collected statistical data, an experienced designer has a very good understanding of manufacturing process tolerances for all processes used on the floor. However, it is not straightforward to connect the impact of individual manufacturing tolerances on resultSEPTEMBER 2014 | 65

TECHNICAL PAPERS

Fig. 12. Diameter and lump detector equipment in a sheathing line.

Fig. 9. Attenuation sensitivity factors.

Fig. 10. Characteristic impedance sensitivity factors.

ing tolerances for time delay, attenuation and characteristic impedance of the manufactured cable.

Here comes the most valuable design and manufacturing information that is available from Fig. 13. Machine and product sensitivity analy- parameters are monitored in a sis. The estima- sheathing line. tion of expected tolerances of cable properties based on available or estimated tolerances of parameters can be calculated from individual tolerances of parameters. Since sensitivity provides linear mapping between small changes of parameters and properties, the first order estimate for the tolerance of any property comes from the transformation of Eq. (5). For attenuation and conductor diameter this linear relationship has the following form: Eq. (6) More complex is the estimation of attenuation tolerance resulting from tolerances assigned to all design and manufacturing variables. Most comprehensive results can be achieved here by Monte Carlo analysis, which regrettably requires repetitive and long simulations. However, if selected parameters are independent, normally distributed and the tolerances represent some common multiplier of standard deviation (typically used is 3), then attenuation tolerance can be calculated as7: Eq. (7)

Fig. 11. Critical design parameters of the simulated STP were calculated from time delay, attenuation and characteristic impedance sensitivities.

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where Tk = is the relative tolerance of parameter k.

If the tolerances of all variables were similar, then Tk could be moved outside the square

TECHNICAL PAPERS

root in Eq. (7) and one could estimate the global tolerance sensitivity of selected properties. In case of time delay this estimate is: Eq. (8) The interpretation of this evaluation is simple.

If the tolerances of all design parameters were ,for example, 5%, then the tolerance of the time delay would be 0.30 * 5% = 1.5%. Since inclusion of additional parameters can only increase the value estimated in Eq. (8), the calculated 1.5% is only a lower estimate of the time delay tolerance.

If important parameters (with large individual sensitivities) escaped examination, the resulting tolerance value may be much higher than our estimate. Until one can collect statistical information about the manufactured cables, it is not possible to empirically approve or reject estimate 8.

The impact that design parameters have on properties is very well represented by first order sensitivities that were calculated earlier.

However, the statistical impact that parameters have on the tolerances of time delay, attenuation and characteristic impedance carry very different magnitude. Assuming that the parameters are independent (not correlated or linked) and that they all have normal distribution, Eq. (7) controls the cumulative impact of parameter tolerances on a property. If one now assumes that all parameters were defined with similar tolerance (as done in estimate 8), their relative contribution to the overall tolerance is a square of the sensitivity. Therefore, their sequence of importance remains the same, but the magnitude impact is magnified. Small sensitivity parameters have negligible impact on the tolerance of selected property. There is virtually only one critical parameter that affects the time delay tolerance – it is the dielectric constant of the foam. See Fig. 14. The global tolerance sensitivity of attenuation is much bigger:

Fig. 14. Foam dielectric constant is almost entirely responsible for the tolerance of time delay of the cable.

Fig. 15. Insulation diameter and copper/skin eccentricity are responsible for the attenuation tolerance.

Eq. (9) This estimate tells us that attenuation tolerance would exceed 6% if the tolerances of all design parameters were 5%. Also, the tolerance of attenuation is affected by more than one parameter.

Although the overall diameter of the insulation (skin diameter) is the most dominant factor, the eccentricities of copper/skin have a strong impact.

See Fig. 15.

The global tolerance sensitivity of characteristic impedance is smaller than 1: Eq. (10) Fig. 16. Copper and skin diameters are responsible for the tolerance of characteristic impedance of the cable.

SEPTEMBER 2014 | 67

TECHNICAL PAPERS

This indicates that 5% tolerance assigned to our manufacturing parameters leads to 4% tolerance of characteristic impedance. Characteristic impedance tolerance is only affected by the copper and insulation (skin) diameters. See Fig16.

• Insulation diameter and copper/skin eccentricity are responsible for the attenuation tolerance.

• Copper and skin diameters are responsible for the tolerance of characteristic impedance of the cable.

Conclusions

References

• Sensitivity analysis of a 100 Ohm twinax cable led to the following set of observations and conclusions: • Calculated sensitivities not only provide a clear indication of how design dimensions and materials influence cable propagation properties, but also offer a very valuable estimate of tolerances for cable propagation properties based on expected distribution and tolerances of design parameters.

• Although the increase of copper diameter always leads to lower unit resistance values, it is also lowering characteristic impedance, forcing stronger currents for transmission of unit power and lowering attenuation.

• Increase of insulation diameter causes reduction of attenuation by reducing eddy current loss in the screen and increasing characteristic impedance.

• Loss tangent of the dielectric material plays a marginal role in the propagation characteristics of the cable at 100 MHz. • The eccentricity of wires has almost no impact on characteristic impedance but significant impact on attenuation.

• The most valuable design information that is available from sensitivity analysis is the estimation of expected tolerance of cable properties, based on available or estimated tolerances of parameters.

• Foam dielectric constant is almost entirely responsible for the tolerance of the cable time delay.

1. A. Nowak, “High Speed Copper Cable – The Impact of Materials, Process Parameters and Laboratory Testing on Electrical Characteristic Consistency,” Proceedings of the 59th International Wire and Cable Symposium, Providence, RI, Nov. 2010, pp. 386-390.

2. D.N. de Araujo, G. Pitner, M. Commens, B. Mutnury and J. Diepenbrock, “Full-wave, TwinAx, differential cable modeling,” Proceedings of the 58th Electronic Components and Technology Conference, 2008, pp. 1684-1689 .

3. M. Josefsson and J. Poltz, “Measuring and Modeling of Insertion Loss in Cables with Helical Screens,” Proceedings of the 60th International Wire and Cable Symposium, Charlotte, North Carolina, Nov. 2011, pp.

139-145.

4. R.K. Brayton and R. Spence, Sensitivity and Optimization, Elsevier Scientific Publishing Company, New York, 1980.

5. OptEM Cable Designer User’s Manual, Version 7.0, OptEM Engineering Inc., Calgary, Alberta, July 2011.

6. J. Poltz and M. Josefsson, “Sensitivity Analysis of Shielded Cables,” Proceedings of the 61th International Wire and Cable Symposium, Providence, RI, Nov. 2012, pp. 130-137.

7. E.R. Dougherty, Probability and Statistics, PrenticeHall, Englewood Cliffs, New Jersey, 1990.

Juliusz Poltz with the award presented at Wire Expo by David Hawker, a WAI executive committee member.

Dr. Juliusz Poltz is a co-founder of OptEM Engineering Inc., a software company in Calgary, Alberta, Canada, that specializes in EM analysis and circuit simulation. He holds M.Sc. and Ph.D. degrees in both mathematics and electrical engineering from universities in Poznan, Poland. He has published over 70 techniJosefsson cal papers related to EM field analysis. Mats Josefsson works in the transmission technology department of Ericsson AB, Hudiksvall, Sweden, where he has worked since 1980. He holds an M.Sc.E.E. degree from Chalmers University of Technology, Göteborg, Sweden. This paper, which was presented at the WAI’s 83rd Annual Convention, Atlanta, Georgia, USA, May 2013, won the award for best electrical paper.

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Effects of niobium additions to a vanadium microalloyed high carbon wire steel Research shows that vanadium alloying can be used to increase strength levels of pearlitic high-carbon wire steels, predominantly through precipitation strengthening.

By Emmanuel De Moor and Stephanie 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 which 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:

through grain size refinement when thermomechanical processing is conducted. Effects of niobium additions to eutectoid alloys have received only limited attention7.

Experimental Procedure

Laboratory materials were prepared using a vacuum induction furnace, and chemical compositions of the studied materials are shown in Table 1. 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 Eq. (1) 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 with the yield strength in MPa, a term representing the electric arc furnace material. combination of solid solution and cementite volume The castings were sectioned and hot rolled. Reheating strengthening, colony size in μm, and the ILS in μm4-5. was conducted using a reheating ramp to 1200°C over Experimental data for carbon contents ranging from approximately 2 hours and a 20 minute soak. A six pass 0.75-1.8 wt pct have shown good correlations with this deformation schedule was employed with an approxequation5. Yield strength follows a Hall-Petch type relaimate 20% reduction per pass resulting in an overall tionship with colony size and ILS. Since ILS is generally reduction ratio of 3 to 1. A 15 minute reheating was several orders of magnitude less than colony size, it is the performed following the third reduction pass. dominant strength contributor. Alloying and processing Samples were machined from the hot rolled plates with strategies for increased strength are hence effective when a cylindrical geometry of 5.5 mm in diameter and 72 mm ILS refinement is obtained. in length. Continuous cooling experiments were conductIn addition to microstructural refinement, precipitation ed using a Gleeble® 3500 thermomechanical simulator in strengthening can be employed to improve strength. For high vacuum conditions (<10-3 torr). The thermal profile instance, the addition of vanadium to a eutectoid steel for continuous cooling experiments consisted of heating is reported to result in 9.6-11.0 MPa strengthening per at 20°C/s to 1093°C, holding for 5 min, and controlled 0.01 wt pct vanadium in the presence of nitrogen through cooling to room temperature at constant rates of 2.5, 5, vanadium carbonitride precipitation strengthening with7.5, 10 and 12.5 50°C/s. out drawability impairement6.

Microstructural analysis was performed on all samples Niobium microalloying is frequently used in low-carand Vickers hardness testing was conducted according to bon steels where significant strengthening is obtained ASTM E-92 using a grid of nine measurements per sample centered along a bisecting line at one quarter of the sample diameter8. Following hardness testing, a 6 sec etch of Table 1. Compositions of Experimental Test Alloys in wt pct.

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4 pct Picral was applied to the polished surfaces and optical metallography was conducted. Pearlite interlamellar spacing was measured using Field Emission Scanning Electron Microscopy (FESEM) images taken at a magnification of 10,000x, Fig. 1. Vickers hardness as a employing a circufunction of cooling rate. lar intercept method according to ASTM E-1129. Error bars reported for all plots represent the standard error of the data sets.

of 2.5 and 5°C/s for the 1080V+Nb steel since nonpearlitic microstructural constituents, 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. The obtained hardness values corresponding to fully 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 Results and Discussion both alloys.

Hardness values are shown in Fig.1 as a function of coolAs evident from Eq. (1), pearlite colony size and ILS ing rate for both alloys. It is apparent that the 1080V+Nb contribute to strengthening in pearlitic steels. In addialloy exhibits greater hardness values than the 1080V tion, microalloying may contribute to increased strength alloy. Hardness data are only shown for cooling rates 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. FESEM micrographs are shown in Fig. 3 for the alloys investigated Fig. 2. Low magnification FESEM taken from samples continuously cooled from 1093°C at in the present study 12.5°C/s for a) 1080V and b) 1080V+Nb steels. Samples etched with 4 pct Picral. 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 presented in Table 2 and plotted in Fig. 4 as a function of cooling rate. Increased ILS refinement is observed with cooling rate whereas pearlite colony size seems less dependent on cooling Fig. 3. FESEM micrographs of 1080V (a and c) and 1080 V+Nb (b and d) alloys cooled rate for the 1080V from 1093°C at constant cooling rates of 2.5°C/s (a and b) and 5°C/s (c and d).

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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.

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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 Table 2. Vickers hardness, ILS, and pearlite colony size measurements obtained in both 300-1700 MPa10. alloys for cooling rates 2.5 and 5°C/s.

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 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 coolFig. 4. a) Average ILS; and b) average pearlite colony size for the 1080V ing rate does not correlate with the (filled circles) and 1080 V+Nb steel (open squares). measured hardness difference. The steel. ILS refinement is observed for both cooling rates increased pearlite colony size with niobium alloying was in the niobium alloyed steel. A different trend with not expected and further work is required to confirm cooling rate is observed for pearlite colony size namethis observation in particular of Stelmor® deck cooling ly, similar colony sizes are obtained for a cooling rate profiles. It is reasonable to expect that niobium would of 5°C/s and greater pearlite colonies were observed refine austenitic grain size, in particular when thermoin the 1080V+Nb steel at 2.5°C/s. The dependence of mechanical processing is employed, which would also colony size on cooling rate is also different for both result in reduced pearlite colony size12. alloys. The 1080V exhibits no measurable dependence, Pearlite ILS refinement was obtained for both coolwhereas a refinement was observed with increasing ing rates with niobium alloying and is calculated to cooling rate in the 1080V+Nb steel for the two cooling result in a 17-31 HV increase in hardness, or a 89-49 rates investigated here.

MPa increase in yield strength according to Eq. (2).

Using Eq. (1), strengthening contributions from the More research is needed to elucidate the mechanism quantified microstructural differences were calculatby which Nb affects the pearlite transformation and ed and results are shown in Table 3 along with the ILS. Precipitation reactions and solute drag may measured hardness difference between the two alloys. influence pearlitic boundary movement and these Yield strength, in MPa, was correlated to Vickers mechanisms are likely dependent on transformation hardness, HV at1kgf, according to: temperature and alloying levels. In addition, solute partitioning through (in)solubility in cementite may Eq. (2) affect pearlite growth and ILS. For instance, vanadium has been reported to enrich in cementite13.

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Conclusions 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, likely 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.

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 and S. Nishida, Microstructure Control and Strengthening of High-carbon Steel Wires, Nippon Steel Technical Report No. 91, 2005, pp. 56-61.

4. E. Taleff, C. Syn, D. Lesuer and O. Sherby, Pearlite in ultrahigh carbon steels: Heat treatments

Emmanuel De Moor

Stephanie Miller

72 | WIRE JOURNAL INTERNATIONAL

and mechanical properties, Metall. and Mater. Trans.

A, vol. 27A, 1996, pp. 111–118.

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, July 2002, pp. 25–30.

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 HighCarbon Wire Steels, WAI’s 83rd Annual Convention, Atlanta, Georgia, May 2013.

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, Pennsylvania, U.S., 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, Golden, Colorado, USA. He is involved in advanced high-strength sheet steel, high-carbon wire steel, and abrasion plate steel research. He joined the Colorado School of Mines in 2008 as a postdoctoral research associate and has held his current position since 2010. He 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, with intended completion in Spring 2015. She holds an M.S. degree in metallurgical and materials engineering from the Colorado School of Mines 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.

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