Testing & Measuring Equipment by Wire Journal International, Inc.

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Interwire 速 Sneak Preview

FEBRUARY 2007

WIRE JOURNAL

I N T E R N A T I O N A L w w w. w i r e n e t . o r g

Testing & Measuring Equipment

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OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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WIRE JOURNAL

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

Volume 40 Number 2 February 2007

C ONTENTS

TECHNICAL

PAPERS

FEATURES

34 Interwire Sneak Preview

A preview of some of the highlights that will be going on during Interwire, which will be co-located with IFE in Cleveland, Ohio this May, including a link to booth listings and more that will be at WAI’s website.

46 Testing & Measuring equipment Suppliers of testing and measuring equipment present a range of technology as well as some comments on the field. This feature represents a WJI first as part of the story will be presented solely at WAI’s website.

56 Improved wire rod properties resulting from controlled cooling in modern water box and Stelmor® conveyor cooling system W.P. Krejdovsky, D.M. Jones and B.V. Kiefer— Advances in technology have made it possible to produce a wider range of steel grades that can be either used either directly from the mill or with much less downstream work/costs.

62 The evolution of wiredrawing coolant filtration and increased wire production and quality Tom Horn—As wire and cable products continue to evolve, so has filtration technology. This presentation traces those advances, notes what is now ‘state-of-the-art’ and cites the need for further advances.

66 Gaining market share in the energy sector 11

Premjeet Saggu and Knut Szemjonneck—Testing and measuring equipment is essential for manufacturers in India to make the quality power cable that is both needed now and for projected increases in electrical demand in India.

(continued)

Cover: At General Cable Corp.’s Lawrenceburg, Kentucky, communications cable plant, tester Donnie Mays prepares an automatic test set terminal board where up to 50 pairs can be tested for high-voltage, as well as high frequency parameters. Photo courtesy of General Cable. See p. 46. Also, look for the “Web-powered” logo to indicate stories continued at wirenet.org.

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10 Industry News Bekaert plans to buy Russia’s Uralkord, Nexans extends contract, completes U.S. acquisition, Morgan Construction reports Poland contract, and more

DEPARTMENTS

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22 Asian Focus An interview with NEMA officials about their organization’s office in China, and more

28 Fiber Watch Submarine cable outage shows vulnerability in routes, and more

29 Fastener Update IFI notes the retirement of Wilson, names Greenslade as new director, and more

WIRE JOURNAL

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

6 Editorial 8 Calendar 26 People 70 Products 74 Media

30 WAI News Award-winning technical papers for 2006 announced, road show to be held in March in El Paso, Texas

31 Chapter Corner Poland Chapter has 33 papers set for its conference, March 1-3, in Zakopane, Poland

4 WIRE JOURNAL INTERNATIONAL

75 Classified 75 Career Opportunities 78 Advertisers’ Index

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WIRE JOURNAL

Editorial

INTERNATIONAL

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

WJI takes first steps beyond printed pages This issue marks a first for Wire Journal International: the “morphing” of a portion of the printed issue with the Internet. By that we mean that we will be presenting editorial content beyond what is presented in the print magazine. The Testing and Measuring feature in this issue is continued at wirenet.org. We have not taken some of the content from the feature and placed it on our website. Instead, we are adding content there, elements that we otherwise would not have been able to publish. WJI will also be highlighting more information that will be found at wirenet.org, wherever and whenever possible. These efforts are part of an overall expansion of how WAI’s website is used. For instance, the Interwire Sneak Preview in this issue tells readers how they can access Internet booth descriptions now, in advance of the March preshow issue. Want to experience the style of award-winning guitarist Andy McKee, who will perform May 7 at the wire cutting and the awards ceremonies? Want to know more about speaker Michael Roberto’s May 8 presentation on business strategy? Or what Integer Research’s Philip Radbourne will have to say at his discussion on May 9? Go to wirenet.org and you are just a few clicks away. Like other publications, WJI is also moving toward offering digital delivery of magazines. Yet that is not enough. A print magazine is inherently limited by the number of pages and what will increasingly matter is the ability to offer readers more, including unique content and ways for them to be an active part of the experience. There is a wide world of resources beyond the printed pages that we hope to develop, from blogs to podcasts. We know that we have plenty of company out there as many manufacturers and suppliers are similarly trying to figure out how to optimize their web presence. We expect this to be a learning experience for us and the industry as a whole, but the Internet’s potential is so enormous that we are committed to this direction.

Mark Marselli Editor-in-chief

6 WIRE JOURNAL INTERNATIONAL

Senior Graphic Designer Bill Branch Director of Sales Robert Xeller Advertising Sales Anna Bzowski Director of Marketing Services Janice E. Swindells Circulation Manager Jan Valois Publications Advisory Board Kurt Breischaft - Belden (Chairman) Antonio Ayala - J.J. Lowe, Mexico Ferruccio Bellina -TKT Group/President ACIMAF, Italy Anand Bhagwat - Wire and Cable Services, India Rick Kristensen - Beta LaserMike, USA Malcom Michael - Australasian Wire Association, Australia Don Schollin - Q-S Technologies, USA Ken Scott - UK Ralph Skalleberg - Skaltek USA Dave Stackpole - Nutmeg Wire, USA Giulio Properzi - Continuus Properzi, Italy Robert Wild - Niehoff Endex North America, USA WAI Executive Committee Liaison Dane Armendariz Henkel Surface Technologies Technical Advisors John Drummond - Scotia Group Nate Rosebrooks - Fluid Coating Technology R. M. Shemenski - RMS Consulting, Inc.

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) is published monthly by the Wire Journal, Inc., a wholly owned subsidiary of The Wire Association International, Inc. Address all correspondence concerning advertising production, editorial and circulation to Wire Journal International, 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA. Tel: 203-453-2777; fax: 203-453-8384; web site: wirenet.org; e-mail mmarselli@wirenet.org. Printed in USA. Subscription rates: $95 per year, USA; $105 per year, Canada and Mexico; other countries, $125 per year (includes air mail). Single copies: $6 in the U.S.; all other countries $7. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2007 by Wire Journal, Inc. All rights reserved. The Publisher of Wire Journal International assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of Wire Journal International 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.

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World Calendar April 18-20, 2007: 7th Wire & Cable Expo International Exhibition & Conference New Delhi, India. Contact: Sameer Nair, Intech Trade Fairs Pvt., tel. 91-22- 26861040; fax 91-22-26863716; e-mail intech@bom5.vsnl.net.in; Internet www.intechtradefairs.com. May 5-10, 2007: Interwire 2007 Cleveland, Ohio, USA. To be held at the International Exposition Center (I-X Center), Interwire incorporates: Interwire Trade Exposition, the technical program and the WAI’s 77th Annual Convention. It addresses both ferrous and nonferrous manufacturing, and electrical/data/voice segments as well as wire forming and related wire and wire products. For more details, go to www.wirenet.org. See p. 34. May 5-10, 2007: International Fastener Exposition Cleveland, Ohio, USA. Co-locating with Interwire 2007 at the I-X Center, IFE is put on by the International Fastener Machinery Suppliers Association (IFMSA). Contact: Ray Zirkle, IFMSA, tel. 800-688-1698; fax 203-743-4810; e-mail rzirkle@bsales.com. See p. 34. May 23-24, 2007: National Electrical Wire Processing Technology Expo Hartland, Wisconsin, USA. To be held at the Midwest Airlines Center, Hall A. Contact: Cheryl Luck, Expo Productions Inc., tel. 262-367-5500 or 800-367-552; fax 262367-9956; e-mail cherylluck@sbcglobal.netInternet; Internet www.expoproductionsinc.com./wireshowinfo.htm. May 28-31, 2007: Wire Russia 2007 Moscow, Russia. To be held at the Expo Centre Krasnya. Contact: Messe Düsseldorf North America, tel. 312-7815180; fax 312-781-5188; e-mail mail: info@mdna.com Internet www.mdna.com. June 10-12, 2007: World Wire & Cable Conference Paris, France. The theme of this conference, to be held at the Paris Rive Gauche Hotel, is creating value and controlling risk in the wire and cable industry. Contact: CRU Events. e-mail cruevents@crugroup.com, Internet www.cruevents.com June 24-28, 2007: JICABLE 2007 Versailles, France. To be held at the Palais des Congres, JICABLE is an international conference and exhibition on LV, MV, HV and EHV (extra high voltage) cables. The event is held every four years. For more details, go to www.jicable.org. June 25-28, 2007: FASTENER TECH™ ’07 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center. Contact: www.fastenertech.com and www.mwfa.net.

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October 16-18, 2007: wire Southeast ASIA 2007 Bangkok, Thailand. This event at the BITEC exhibition centre, formerly known as wire Singapore, is organized by Messe Düsseldorf Asia Pte Ltd. Singapore. Contact: Messe Düsseldorf North America, tel. 312-781-5180; fax 312-781-5188; e-mail info@mdna.com; Internet www.mdna.com. October 17, 2007: Non-Ferrous Bangkok Bangkok, Thailand. This seminar on the latest developments in nonferrous wire and tube technology is jointly organized by the Int’l Wire & Machinery Assn./Int’l Tube Assn. during wire Southeast Asia, BITEC exhibition centre. www.iwma.org.

WIRE ASSOCIATION INT’L EVENTS For more information about these events, contact the WAI, 1570 Boston Post Road, P.O. Box 578, Guilford, CT 064370578, USA. Tel. 203-453-2777; fax 203-453-8384; Internet www.wirenet.org. March 1-3, 2007: Modern technologies and modelling of manufacturing processes of wires and wire products Zakopane, Poland. Organized by the Poland Chapter and the Czêstochowska University of Technology, this event will include tech sessions, tabletop exhibits, banquet and more. For more, go to www.konferencja.mim.pcz.czest.pl (in Polish/English) or e-mail Jan Pilarczyk at pilar@mim. pcz.czest.pl, tel. 48-34-3-250-785; fax 48-34-3-250-714. May 5-10, 2007: Interwire 2007 Cleveland, Ohio, USA. To be held at the International Exposition Center (I-X Center), Interwire incorporates: Interwire Trade Exposition, the technical program and the WAI’s 77th Annual Convention. It addresses both ferrous and nonferrous manufacturing, and electrical/data/voice segments as well as wire forming and related wire and wire products. For more details, go to www.wirenet.org. November 5-7, 2007: Wire 07 Bologna Bolgna, Italy. This technical conference is organized by the Associazione Costruttori Italiani Macchine Per Filo (ACIMAF); The International Wire and Machinery Association (IWMA); Comité Européen de la Tréfilerie (CET); and the WAI. Contact: WAI, tel. 001-203-453-2777, ext. 133; Internet www.wirenet.org. June 7-11, 2008: Wire Expo 2008 Pittsburgh, Pennsylvania, USA. To be held at the Pittsburgh Convention Center, this event incorporates: the Wire Expo trade exposition, the technical program and the WAI’s 78th Annual Convention. The event addresses ferrous and nonferrous manufacturing, and electrical, data and voice segments as well as wire forming and related wire and wire products.

FEBRUARY 2007 9

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World Calendar (cont’d.) October 24-31, 2007: K 2007, the 17th international Trade Fair Plastics and Rubber Düsseldorf, Germany. K 2007 will be held at the Düsseldorf fairgrounds, Halls 1-17. This event for plastic and rubber industries is organized by Messe Düsseldorf GmbH. Contact: Messe Düsseldorf North America, tel. 312-781-5180; e-mail info@mdna.com. November 5-7, 2007: Wire 07 Bolgna Bolgna, Italy. This technical conference is organized by the Associazione Costruttori Italiani Macchine Per Filo (ACIMAF); The International Wire and Machinery Association (IWMA); Comité Européen de la Tréfilerie (CET); and the WAI. Contact: WAI, tel. 001-203-453-2777, ext. 133; Internet www.wirenet.org. November 11-14, 2007: 56th IWCS/Focus™ Conference and Symposium Orlando, Florida, USA. Contact: IWCS/Focus, Internet www. iwcs.org; e-mail admin@iwcs.org; tel. 732-389-0990.

March 31-April 4, 2008: wire Düsseldorf Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180; e-mail info@mdna.com. June 7-11, 2008: Wire Expo 2008 Pittsburgh, Pennsylvania, USA. To be held at the Pittsburgh Convention Center, this event incorporates: the Wire Expo trade exposition, the technical program and the WAI’s 78th Annual Convention. The event addresses ferrous and nonferrous manufacturing, and electrical, data and voice segments as well as wire forming and related wire and wire products. October 15-17, 2008: Spring World 2008 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center, this event is sponsored by the Chicago Association of Spring Manufacturers (CASMI). Contact: Tom Renk, tel. 847-433-1335; fax 847-433-3769; e-mail info@casmi.org; Internet www.casmi.org. ■

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11/09/2006 11.59.55

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Industry News Arcelor Mittal acquires Mexico’s Sicartsa Arcelor Mittal, which became the world’s largest steel producer when it was formed last year, announced that it has acquired Sicartsa, a Mexican integrated steel producer, from its parent company, Grupo Villacero, for approximately US$1.44 billion. Mittal officials have stated in recent years that the steel industry needs more consolidation, and this deal with Sicartsa furthers that direction. At its website, Siderúrgica Lázaro Cárdenas Las Truchas (Sicartsa), an integrated steelmaker of long products and the largest single rebar and wire rod production facility in North America, notes the following. It has annual production capacity of approximately 2.7 million metric tons from its facilities in Mexico and U.S. as well as substantial iron ore reserves through its wholly owned mine, linked directly to the plant via a slurry pipeline. Sicartsa has estimated iron ore reserves of 160 million tonnes, providing 30 years of reserves at current production rates. It was acquired by Villacero in 1991. Arcelor Mittal expects the acquisition to generate $80 million of industrial synergies in addition to a further $50 million from commercial, procurement and selling, general and administrative synergies, a press release said. In addition to the integrated steel making

facility at Lázaro Cárdenas, the acquisition also includes Metaver, a minimill; Sibasa and Camsa, two rolling mills in Celaya, Guanajuato (Sibasa) and Tultitlán, State of Mexico; and Border Steel, a mini-mill in Texas. Sicartsa is sharing its production site with Mittal Steel Lázaro Cárdenas, offering significant synergy potential, once reunited, the release said. Prior to the privatization in 1991 which led to its separation in two entities, the Lázaro Cárdenas steelworks operated as one single integrated site producing both flat and long carbon products. Mittal Steel Lázaro Cárdenas notes that it is Mexico’s largest steel producer and slab exporter. “Combining these two facilities creates Mexico’s largest and one of its lowest cost steel producers and further accelerates our growth plans in this exciting region,” said Arcelor Mittal CFO Aditya Mittal. Arcelor Mittal also announced that it has entered into a 50/50 commercial joint-venture with Grupo Villacero for the distribution and trading of Arcelor Mittal long products in Mexico and in the southwest of the United States, capitalizing on Villacero’s commercial network. Arcelor Mittal has some 330,000 employees in more than 60 countries.

Nucor Corp. plans to buy Canada’s Harris Steel U.S.-based Nucor Corp., has offered US$1.07 billion to buy Canada’s Harris Steel Group Inc., a Canadian company, in a deal that has been said to have the approval of both companies’ boards of directors. A press release noted that Harris Steel has three business units: Laurel Steel, which is a manufacturer and distributor of wire and wire products, welded wire mesh and cold finished bar; Harris Rebar, which is involved in the fabrication and placing of concrete reinforcing steel and the design and installation of concrete post-tensioning systems; and Fisher & Ludlow, a manufacturer of heavy industrial steel grating, aluminum grating and expanded metal. “The acquisition of Harris Steel Group significantly advances Nucor’s downstream growth initiatives,” Nucor Chairman and CEO Dan DiMicco said in the release. “Harris Steel has been a strong partner of ours for almost three years, is a company that we know well, has a management team whom we respect, and will be a highly complementary fit with Nucor. Harris Steel provides Nucor with immediate and broad geographical reach and with considerable scale and growth opportunities.” Nucor, which last year bought Connecticut Steel, reported in the release that it “plans to allow Harris Steel to operate as a separate, wholly owned subsidiary.”

Bekaert plans acquisition of Russian steel cord producer Uralkord Belgium’s Bekaert announced that it has agreed to acquire Russia-based Uralkord, a manufacturer of steel cord products for tire, for approximately US$61million. A press release said that Uralkord, located in Magnitogorsk, serves nearly a quarter of the Russian market, and will be able to help Bekaert meet demands from a growing market. It noted that Bekaert’s plants in Central Europe currently supply Russia with a range of steel cord products for tire

reinforcement, steel fiber for reinforcing concrete and other specialized wire products. “Given the growth potential in the Russian market we want to work closely with the steel industry and anticipate a significant increase in the demand for top quality products,” said Marc Vandecasteele, Group Executive Vice President. “The development of a strong position in Russia is an essential part of our strategic objective

of sustainable profitable growth. Bekaert can offer the Russian tire manufacturers optimal service by having its own production platform.” The deal has not been completed yet but “the parties anticipate to further work out this declaration of intent in order to close the transaction in the coming months,” the release said. Based in Belgium, Bekaert notes that it has a presence in 120 countries and employs 17,000 people.

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

12 WIRE JOURNAL INTERNATIONAL

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2 billion pounds … and counting U.S.-based Encore Wire Corporation reported that its copper rod mill recently topped the two billion pound production mark since it commenced operations in June 1998. “We are very proud of our Rod Mill team and the milestone they have achieved,” company President and CEO Daniel L. Jones said in a press release. He observed that the company’s decision to build the rod mill at its location in McKinney, Texas, has been shown to be a sound investment. “Prior to building the mill, we purchased rod to make wire, as most of Encore’s building wire competitors still do

Celebrating its 2 billion lb production milestone, from l-r, is Encore Wire’s rod mill management team: Darrell Breitling, Dale Horn, Jesse Orozco, Tim Gause, Gary Spence and Osvaldo Torres.

today. The vertical integration we achieved by producing our own rod has resulted in significant cost savings.” Encore Wire has further benefited by its single location, which eliminates the cost of shipping to multiple wire plants across the country, Jones said. “Beyond the facility itself, the key has been our industrious team of employees who run the equipment at exceptional efficiency levels,” he said.

Brazeway acquires Mexico’s Sparvel U.S.-based Brazeway Inc. announced that it will purchase Sparvel S.A de C.V., a Mexican refrigeration component manufacturer described as having a strong presence in that North American sector. A press release said that Sparvel’s production will complement Brazeway’s existing product lineup. Sparvel, which also has a production facility in Cienega de Flores, Mexico, manufactures steel wire for refrigeration condensers, it said. It added that the acquisition will not affect Brazeway’s U.S. operations, which includes plants in Hopkinsville, Kentucky and Shelbyville, Indiana. At its website, Sparvel notes that it was founded in 1967 as a supplier of wire for tube condensers and since 2004 has made evaporators for refrigeration. Its 430,000-sq-ft facility is located in Queretaro.

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2007 Charles D. Scott award recipients named The Wire & Cable Manufacturers’ Alliance (WCMA) announced the recipients of its 2007 Charles D. Scott Distinguished Career Award, who will be honored during an awards meeting on April 21, 2007, at the Hartford/ Windsor Marriott Airport Hotel in Windsor, Connecticut. This year’s recipients are: Dennis Baughman, Supply Chain Manager, Berk-Tek, a Nexans Company; Robert Canny, VP Operations & President Specialty Projects, Belden; Kevin Cassidy, Production & Purchasing Manager, Amphenol Spectra Strip; Dennis Chalk - VP & General Manager Exane Products, RockbestosSurprenant Cable Corp.; Joe Dellagalla (former) VP Operations & Engineering, Mohawk div. of Belden; David DiMartino, Director of Sales, IWG High Performance Conductors; Tom Guida, Senior Staff Engineer, Underwriters Laboratories; and Robert

Meserve, Vice President, New England Wire Technologies. The WCMA continues the tradition of recognizing industry professionals that was started by the late Dick and Harriet Callahan, founders of the Wire & Cable Clubs of America. The award was established in 1985 in memory of Charles Scott, founder and president of Northeast Wire. WCMA, established in June 2004 as the successor organization to the Wire & Cable Clubs of America, is a corporate membership organization for wire and cable manufacturers with an established base in North America, as well as industry suppliers and service providers. For more information about WCMA, the Distinguished Career Award and the awards dinner, e-mail Debbie Mathiasen, executive director, at info@wcmainc.org or call her at tel. 860-873-2311.

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Daikin America notes ETFE expansion done Daikin America, Inc., announced that it had a successful start up of its recently completed ETFE expansion at its plant in Decatur, Alabama, USA, part of a $25 million investment. The expansion doubles the capacity of Dakin’s production of Ethylene– Tetrafluoroethylene copolymer (ETFE), which the company notes in a press release “has become a strategic resin in wire and cable applications.” It said that the investment also provides additional capacity for development of new ETFE grades. “The demand for ETFE in the U.S. has grown for the past several years,” the release said. “The decision to expand the plant in Decatur is consistent with our global supply strategy to position our production in the USA – the region where both consumption and growth rates are very strong,” said Tison Keel, Vice President of Sales and Marketing for Daikin America, Inc.

Allied Wire & Cable adds stocking facility U.S. based Allied Wire & Cable reports that it has added a stocking facility in Elkhorn, Wisconsin, to help serve customers in the Midwestern and Western states. “The extra stocking space for wire and cable frees up both time and space in Pennsylvania and other Allied offices,” a press release said, noting that Allied is one of the largest independent distributors of wire and cable in the country, representing manufacturers such as Alpha Wire and Cable, Belden, Panduit, 3M and Hitachi. Based in Oaks, Pennsylvania, Allied Wire has offices in New England, Tennessee, and South Carolina, as well as warehouses across the U.S. Allied Wire provides wire and cable to sectors such as aerospace, medical, automotive, transportation, computer, telecom and shipbuilding industries. It notes that it stocks many hard to find Mil-spec wires and UL listed wires and offers a variety of insulations.

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Nexans reports extended contract, announces completion of U.S. acquisition Nexans announced that it has won an extension of a major power cable contract and the completion of a U.S. acquisition. A press release said that Nexans has a US$84 million contract to supply power infrastructure cables for the Salt River Project (SRP) that will distribute electricity to homes in the SRP service territory that includes over 900,000 customers in the greater metropolitan Phoenix area, Scottsdale, Tempe and outlying rural areas of central Arizona. The deal, the release said, is a three-year extension to an existing US$64 million, four-year, contract signed in 2003, and has an option to renew for a fourth year. It calls for Nexans to supply SRP with approximately 3,700 km of 15kV cable, it noted, adding that the cables will be made at Nexans’s Weyburn plant in Canada. Nexans also reported the completion of its acquisition of the Valley Group, Inc (TVG), a U.S. supplier of real-time thermal rating technology for overhead power transmission applications to provide reliable power line monitoring for utilities. TVG’s products include the CAT-1 Transmission Line Monitoring System, which provides real-time monitoring of the

load on overhead power lines, the release said. TVG’s overhead lines technology has been used for over 300 systems installed at 50 utilities worldwide, it said. “This acquisition reinforces our leadership position in high voltage transmission systems as TVG’s world-leading technology will enable us to deliver even greater added value for utility customers by helping them to improve the reliability and

operational performance of their networks to ensure security of supply,” said Pascal Portevin, Executive Vice President, Strategic Operations. “It is a strategic development that sees our role expand in scope from product supplier – in this case cables for overhead power lines – to be a provider of optimized power transmission solutions.” (continued on p. 18.)

Ajex & Turner to represent Metalube Ajex & Turner announced that it will represent the wiredrawing lubricants of U.K.-based Metalube Ltd. in India, Srilanka, Nepal, Bhutan and Pakistan. Based in India, Ajex & Turner, which specializes in dies and related accessories, said that it will represent Metalube’s LUBRICOOL line for drawing plain copper wire, plated wire and copper alloys and its ALUMOL line, an advanced specially compounded oil for pure aluminum, electrical and mechanical grade aluminum alloys. The products, it said, contain special cleaners, biocides, corrosion inhibitors and emulsion conditioners that are designed to increase productivity, improve quality and reduce scrap. Contact: Ajex & Turner Wire Dies Co., tel. 91-11- 65167901/ 02 /03; fax 91-11-27452640/ 23940226; e-mail ajex@ndf.vsnl.net.in or ajexturner@gmail.com. FEBRUARY 2007 15

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Morgan Construction Company reports contract for Poland bar and wire rod mill U.S.-based Morgan Construction Company announced that it will build and install a new wire rolling line at the existing bar and wire rod mill of CMC Zawiercie in Zawiercie, Poland. A press release said that the deal will enable CMC Zawiercie, a subsidiary of U.S.-based Commercial Metals Company, to increase its production of wire rod. The line, it said, will consist of a four-stand reducing sizing mill and ten-stand wire rod block capable of making product from 5

mm to 25 mm at rates to 150 metric tons per hour (speeds to 110 meters per second). Installation should take approximately 18 months, it said. Morgan Construction’s T. Michael Shore, Vice President, Engineering Rolling Mill Technology, said that the new line should increase rolling capacity by approximately 100,000 metric tons per year. The rod block will produce coil sizes up to three metric tons, he said. “Markets reward those companies that can respond with flexibility

and new products. These enhancements will strengthen CMC Zawiercie’s ability to use its existing mill more effectively and broaden its product line with higher grade rods,” he said. CMC Zawiercie was described as the second largest steel producer in Poland. Commercial Metals Company recently announced that it also plans to invest $130 million to build a micro-mill in Arizona that would primarily produce reinforcing bar.

Zenergy reports award for product innovation U.K.-based Zenergy Power plc, a manufacturer and developer of commercial applications for superconductive materials, announced that it has been chosen as the overall winner of the 2006 Frost & Sullivan European Product Innovation of the Year Award for its research and development work in the field of high-temperature superconductors. The award, a press release said, was made for the company’s innovative, advanced second generation HTS wires for electric power and magnet applications. “The Board considers this to be of particular significance at a time when the Group is gaining commercial traction for these applications within the field of renewable energy production,” it said. Zenergy has pioneered two classes of HTS wires. To date, industrial production relies on the current generation of HTS wire. The wires are in the form of multifilaments and possess reinforcements in order to meet the varying demands of industrial applications. The superconductor ceramic is made of bismuth-strontium-copper-calcium oxide which enables it to achieve a very high current density. Zenergy Power notes that it has three operating subsidiaries located in Germany (Trithor), U.S. (SC Power Systems) and Australia (Australian Superconductors).

18 WIRE JOURNAL INTERNATIONAL

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United Copper Industries plans $20 million expansion of Texas plant United Copper Industries (UCI), a privately held manufacturer of building wire that is owned by Mexican industrial conglomerate Grupo IUSA, announced that it plans to expand its 420,000 sq ft plant that it opened in Denton, Texas, in 1998. According to wire reports, the company plans to add 50 employees, to

Windings Inc. files trademark suit against Commodity Cables Windings, Inc., announced that it has filed a federal suit against Commodity Cables, Inc., Suwanne, Georgia, for unauthorized use of Windings’ registered “REELEX” trademark. A press release cites claims of trademark infringement, trademark counterfeiting and other charges, and notes that Windings is seeking injunctive relief and monetary damages. “Windings is taking this action to protect our authorized licensees from the growing problem of unauthorized, counterfeit, inferior coils entering the marketplace using the “REELEX” trademark,” said Windings President Tom Copp. “Most of these counterfeit coils are imported from Asia and do not perform as well as coils made by authorized licensees on Windings’ patented REELEX coiling machinery,” Copps said. “We believe these importers are attempting to confuse the buying public by labeling their coils as ‘REELEX’ coils when, in fact, they are not genuine REELEX coils. The counterfeit coils, for the most part, do not offer the dependable tangle and twistfree ease of use that has become synonymous with the ‘REELEX’ name.” The press release said that Windings will continue to take steps to protect its trademark and the rights of its licensees. Commodity Cables did not respond to a request from the WJI for comment.

expand its site by 100,000 sq ft of building space and to switch its inventory to lead-free copper building wire. In the report, UCI Vice President Ronald Pritchett said that the company has quadrupled its size since 2002, and that is now No. 3 in the U.S. copper building-wire industry after Southwire Co. and Encore Wire Corp., with pro-

jected 2006 revenue of just under $1 billion. Pritchett said that UCI, which sells to U.S. wholesale distributors, plans to promote its lead-free wire to city building code officials and to engineers who specify materials for school and hospital construction.

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Nexans reports underground contract with Swiss power company Nexans announced that it has been awarded a US$6.5 million contract from Azienda Elettrica Ticinese (AET), a power company for the Ticino canton in Switzerland, for completion of an interconnection project between Switzerland and Italy.

“This new 400MW line, of an unprecedented scale in Switzerland, could become the first underground merchant line project completed in Europe,” said a press release that noted the project will require Nexans to supply 27 km of high-voltage (380kV)

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20 WIRE JOURNAL INTERNATIONAL

XLPE power cables. The 9 km link between the towns of Mendrisio in Switzerland and Cagno in Italy will be divided into 15 sections, it said. “For this project, the Group will also supply 14 junction chambers, with 3 premolded joints each, as well as all necessary connecting and grounding components.” The cable will be made by Nexans’ Cortaillod plant in Switzerland, with installation beginning in February 2007 and the line is expected to in operation by year’s end, the release said. It cited recent power outages in Northern Europe as heightening “once again the ever-increasing needs” for cross-border power infrastructure networks. “In fact, upgrading older power plants or building new production facilities is a solution to meet demand peaks, but a costly one,” it said. The interconnection, which was approved by the Swiss Federal Council in June 2004, is included in Switzerland’s power transmission master plan, the release said. This project is being done with Italy’s railway company Ferrovie Nord Milano (FNM), with much of the cable in Italy running along a former FNM railway track.

Gore names Petsche as cable representative

U.S.-based W. L. Gore & Associates has named A. E. Petsche Company as the exclusive North America distributor of GORE™ bulk wire and cable. Gore supplies aerospace wire and high data rate cable. A.E. Petsche will stock a wide range of custom Gore products, from basic insulated and impedance controlled cables to complex round cables, a press release said. “This agreement brings together the technical expertise of Gore with the service expertise of A. E. Petsche while benefiting our customers with shorter lead times, lower minimum order quantities and improved sales support,” says Doug Hardy, global product manager for bulk wire and cable. For more details about A.E. Petsche, go to www.aepetsche.com. ■

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Asian Focus Asian Focus Asia news briefs Arcelor Mittal plans to spend US$9 billion for steel plant in state of Orissa, India Arcelor Mittal reports that it has agreed to set up a steel making facility in the State of Orissa in India. The project, expected to cost approximately US$9 billion,calls for the building of an integrated steel plant with a total annual capacity of 12 million metric tons. The project would be developed in two phases, the first phase would be completed within four years once approvals are completed and the second stage five and a half years after the first phase is done. Commented Lakshmi N. Mittal, President and CEO, Arcelor Mittal: "We have always said that we want to have an operational presence in India. The Indian economy is demonstrating excellent growth and steel consumption is set to increase considerably in the future. Furukawa gets top environmental rating Furukawa Electric Co., Ltd. announced that it is the first electric wire and cable company to get a top rating in Development Bank of Japan’s environmental assessment rating, which judges overall service, performance and environmentally friendly management, a press release said. It was cited for its recycling network system, for reusing coating material, for converting diesel to hydropower and reducing landfill deposits by 94% in 2005 (compared with 2000). Nexans wins South Korean cable deal Nexans reported that it will supply fiber optic and copper network cabling solutions for South Korea’s Incheon International Airport, a US$8 million contract that will include Nexans’ LANSense Intelligent Infrastructure Management system. The project is for the Phase II expansion project of South Korea’s largest airport. Nexans will supply some 860 km of CAT6 copper cable, 351 km of single mode fiber optic cable (ranging from 12 up to 144 cores) for the airport infrastructure, and 86 km of single mode fibre optics cable for the new airport buildings, as well as 450 sets of racks. The LANSense IIM system, comprising 22,100 fiber optic nodes and 22,000 Cat. 6 nodes will provide an internet and standards based approach to the airport’s network security control together with advanced asset management features. The standard fiber optic network will comprise 8,700 nodes and the standard CAT6 network will comprise 1,250 nodes.

22 WIRE JOURNAL INTERNATIONAL

New submarine cable to link China and the U.S. Six telecoms operators from China, South Korea and the United States have formed a consortium to jointly lay a new fiber-optic submarine cable directly linking China and the United States. Verizon Business, which signed a construction and maintenance agreement with a consortium that includes China Telecom and China Netcom to build the first next-generation undersea optical cable system directly linking the U.S. mainland and China, reported the following details. The new fiber-optic cable can support the equivalent of 62 million simultaneous phone calls, more than 60 times the overall capacity of the existing cable directly linking the United States and China. While TPE will initially provide capacity of up to 1.28 terabits per second (Tbps), the system will have design capacity of up to 5.12 Tbps to support future Internet growth and advanced applications such as video and e-commerce. In another first, individual customers can access the cable system at wavelengths of up to 10 gigabits per second (Gbps), the equivalent of nearly 121,000 simultaneous phone calls. A report from China Daily notes that the cable, costing about US$500 million,“is expected to ease the strain on Internet networks caused by rapid growth in the number of users in China and the U.S.“ The project, the report said, represents the first undersea cable directly crossing the Pacific connecting China and the U.S. It noted that Internet data between the two countries now has to be routed via Japan, which causes traffic delays. The new cable, which will extend more than 18,000 kilometers, is scheduled to be completed in the third quarter of 2008, it said, The article pointed out that access

to overseas websites from China is usually slow, especially during peak hours, due to growth of the Internet population. In the story, China Telecom Executive Vice-President Leng Rongquan said the current cable network linking China and the US will not be able to meet demand after 2008.“The Internet traffic between China and the US is growing dramatically, which requires significant trans-Pacific capacity,” he was quoted as saying. The capacity expansion will not only benefit China and the U.S., but also the participating countries and regions, the article said. The new system, to be named Trans-Pacific Express (TPE), will use the latest optical technology to provide greater capacity and higher speeds to meet the dramatic increase in demand for IP, data and voice communications with the AsiaPacific region. Verizon Business owns more than 18 submarine cable systems located in the Asia-Pacific region, but company Vice-President Ihab Tarazi said the rapidly-growing demand for highspeed services between the region and the U.S. has made construction of TPE a necessity. According to Verizon Business, TPE will have a landing point at Nedonna Beach, Oregon on the U.S. West Coast, and points at Qingdao, Shandong Province and Chongming, an island in Shanghai. TPE will also have landing points at Tanshui, Taiwan, and Keoje, South Korea. Verizon Business already owns and operates one of the largest global IP networks, spanning 150 countries across six continents with more than 446,000 route miles. The company is involved in more than 65 submarine cable networks carrying mission-critical traffic for multi-national customers worldwide.

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

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NEMA office in China translates to advantages for its members Based in the U.S., the National Electrical Manufacturers Association (NEMA) has approximately 430 member companies -- including large, medium, and small businesses -- that manufacture products used in the generation, transmission and distribution, control, and end-use of electricity. Annual shipments of these products total $100 billion. NEMA also has offices in Brazil, Mexico and China. Gene Eckhart, NEMAâ&#x20AC;&#x2122;s director of international operations, and John Meakem, manager of international trade, recently discussed the organizationâ&#x20AC;&#x2122;s Chinese office with WJI.

issues and very much intend to continue assisting them on as many fronts as possible. One area where there has been change is with regards to medical equipment issues, where interest from our members has been growing considerably. Meakem: In recent years China has very rapidly become our membersâ&#x20AC;&#x2122; #3 foreign export market and trading partner (after Mexico and Canada),

many things much better, such as: frequently represent NEMA concerns at sessions in Beijing and around China; organize conferences bringing together member companies and Chinese counterparts; set up meetings for member companies with government officials; and of course provide individualized information and counseling drawn from on-the-ground understanding of the country.

WJI: Your office in China opened in 2004: has physically being there helped NEMA better serve its members? Eckhart: Having a presence in China has been of tremendous benefit to NEMA and our China Initiative subscribers, be it for directly working with Chinese counterparts, running events, or developing on-the-ground expertise. We continue to hear from our members about a wide variety of

and the future does look bright and exciting. That said, what we have seen is that anyone hoping to succeed there needs to not only have as good an on-site presence as possible, they also need to have headquarters staff fully engaged. It is not a question of having just one or another. Thereâ&#x20AC;&#x2122;s only so much you can do from outside of China, even if you endeavor to visit regularly. Thanks to the office, weâ&#x20AC;&#x2122;ve been able to do

WJI: How beneficial has it been for NEMA that Shanlin Wen, its chief representative, is so well versed in China and was a key part of its standards administration office? Eckhart: Having Shanlin Wen has been crucial. His many years of experience in the Chinese standards community, coupled with expert knowledge of the international scene, the United States and the English language, makes for a rare combination. To put it mildly, he gives us access we otherwise wouldnâ&#x20AC;&#x2122;t have, and provides insights that we otherwise wouldnâ&#x20AC;&#x2122;t fathom. (continued)

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WJI: In terms of standards, what has NEMA been able to accomplish to date because of the office? Is China largely following European standards and to what degree is there flexibility in terms of what NEMA can seek to have accepted? Eckhart: China has officially pledged to be in line with the IEC, but we have also found the Chinese to be practical and flexible with regards to accepting some other standards, especially when a number of products already made to the latter have long been accepted on the mainland. In this respect, early on we were pleased to provide Chinese officials with a CD containing our standards, and were equally pleased to sign a memorandum of understanding with the Standardization Administration of China (SAC) a few months later. Moreover, the Chinese have shown themselves to be quite interested in learning from us about NEMA and our industry. They have shown considerable interest in the many programs we have conducted there, be they on broader themes like counterfeiting, energy efficiency or hazardous substance requirements, or far narrower subjects such as fuse design norms. Several Chinese delegations to the U.S. have also visited our offices for meetings. WJI: Can you provide an example of a specific program you have been able to offer from the China office? Eckhart: We organized a technical seminar with our fuse manufacturers to explain the features of fuses made to North American standards. These products offer many features and capabilities not found in fuses made to IEC standards. Because we had senior technical experts as part of our group – with over 75 years’ of collective experience – we were able to address all the questions that the Chinese participants asked, and provide a clear line of reasoning as to the rationale behind the evolution of the products and associated standards. Meakem: More recently we launched a program with the U.S. Trade and Development Agency (TDA) to administer of a series of U.S. industry-led seminars on standards and conformity assessment matters across the fullrange of industry sectors. Interested industry groups should get in contact with us. With TDA providing matching funds and NEMA providing on-theground organizational support, this

24 WIRE JOURNAL INTERNATIONAL

that matters such as counterfeit products, intellectual property rights and the environment are secondary at best: do you see any signs that China is making more than token efforts in these and other areas? Meakem: The jury is still out of course and we have constantly stressed problems to Chinese counterparts that the status of topics such as counterfeiting remains NEMA staffers (l-r): Shanlin Wen, NEMA Beijing Office dire. But it is also imporChief Rep. Li Hung Wei, Building Manager, and Gene tant to stress that ChiEckhart, NEMA Director of International Operations. nese counterparts have continued to express considerable interest in represents an important option in parthese topics and U.S. perspectives on ticular for industry groups that may them. Wei and NEMA headquarters prefer to conduct some informational staff have given numerous presentaprograms without going to the length tions on intellectual property rights, of actually establishing a permanent energy efficiency, and restrictions on presence. hazardous substances, a recent development that is at the heart of environWJI: What about helping companies? mentally conscious design; all of these Eckhart: We generally respond to presentations attract eager local parthree to five specific questions per ticipation. month from companies either seeking to do business in China, or already doing business there but having specific needs that are best addressed by a third party such as NEMA. Meakem: We’ve had companies ask us to introduce them to two or three manufacturers of particular equipment with whom they could work to develop a new line of products for sales both within China and for export. One asked us to locate possible manufacturers of parts that will serve their component needs but at the same time keep their intellectual property intact. This requires expert knowledge of the various Chinese competitors to ensure that specifications are met without sacrificing IP. This endeavor is well underway. Eckhart: Some companies need to better understand the evolving regulatory landscape, and how to keep Chinese regulations up to date with those in the U.S. and EU. That happened with a medical equipment company. We held joint meetings in Beijing, established a staff position to focus on this specific product sector, and retained a subject-matter expert to guide both the sector and individual companies.

WJI: There is concern that China’s focus is on its economic goals, and

WJI: We understand that NEMA is looking to establish an office in India. How did that decision come about? Eckhart: This really was a combination of our business planning as well as members’ expression of needs. Having established ourselves in offices in Mexico City, São Paulo, and Beijing, we were aware of the attention many companies and industries are now giving to India. In a member survey, 89% identified India as the next area NEMA should consider establishing a presence. The potential for the electrotechnology industry (served by NEMA) in India is enormous. It is one of the last significant growth markets for electrical products in the world -- almost 40% of the population still does not have access to electricity! That’s the very business our members are in, bringing electricity safely and reliably to users. The growth in consumption of electricity in India will be significant for years to come. Any company seriously interested in increasing its sales must be looking at India. For more information about NEMA, go to www.nema.org. ■

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26 WIRE JOURNAL INTERNATIONAL

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Amphenol Corporation announced that it has promoted R. Adam Norwitt to the newly created position of President and COO. Norwitt was described as an industry veteran who will focus on enhancing Amphenol’s growth in new technologies and new markets as well as further strengthening and expansion of its existing business, particularly in international markets. He has lived and worked in Europe and Asia, holding a variety of management, business development and operating positions in Amphenol operations in Asia and the U.S. since joining Amphenol in 1998. He currently serves as a Senior Vice President of the Company and Group General Manager of Amphenol’s Worldwide RF and Microwave Products Operations. He holds a degree from Georgetown University, a law degree from the University of Michigan and an MBA degree from INSEAD, France. Based in Wallingford, Connecticut, USA, Amphenol Corporation produces electronic and fiber optic connectors, cable and interconnect systems. The Industrial Fasteners Institute (IFI) announced that Joe Greenslade has sold his business and accepted the position as the new IFI Director of Technology. He is well known to the fastener industry, having written on technical subjects in industry publications and from his long representation of the fastener industry on a variety of national and international fastener standards organizations. A graduate of Texas A&M University, he was Manager of Corporate Engineering & Development for Camcar-

Textron; Plant Manager of the Camcar Drilltite Division; General Manager of Rockford Headed Products and President and CEO of Greenslade

Joe Greenslade

& Company for 29 years. He served on several industry bodies and committees, including ASME B1 and B18, ASTM F16 and SAE. He served on the U.S. Fastener Quality Act and the multi-industry Aerospace Screw Thread Conformity Task Forces and was a Board Member at A2LA. He also served as the IFI Associate Suppliers’ Division Chairman and regularly contributed time to critical industry committees, task forces and working groups. IFI also announced that long-time staffer Charlie Wilson will retire as director of engineering for the trade association. He had served IFI for 43 years and will consult for IFI as an independent contractor during 2007. Based in Cleveland, Ohio, USA, Industrial Fasteners Institute represents North American fastener manufacturers and suppliers of materials, machinery, equipment and/or engineered services. Lenze/AC Technology has named Eric Klein as its distribution sales manager, a new

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strategic position. He has 16 years experience at Toshiba and four years with Reliance Electric. He holds a B.S. degree in engineering from Cornell University. Based in Uxbridge, Massachusetts, USA, and a member of the Lenze Group, AC Technology supplies a complete range of motion control solutions, including servo drives and motors, clutches and brakes, gears and gear motors and variable frequency AC motor drives. General Cable Corporation announced the promotion of Brian J. Robinson to CFO. Robinson, who began with the company as assistant controller

Brian J. Robinson

in 1999 and became controller in 2000, became treasurer and a senior vice president in 2006. He will continue serving in those posts. He began his career at Deloitte & Touche LLP in 1991, and in 1997 served as an audit manager in London. He holds a B.S. degree in accounting from the University of Dayton and received his CPA certification in 1993. He replaces Christopher F. Virgulak, who worked for General Cable for more than 20 years. Based in Highland Heights, Kentucky, General Cable Corporation manufactures copper, aluminum and fiber optic wire and cable products for the energy, industrial and communications markets.

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Phelps Dodge Corp. has promoted Nancy F. Mailhot to the position of senior vice president-human resources, responsible for leading the company’s human resource programs worldwide and serving as a member of the company’s Senior Management Team. She was named vice president-human resources in October 2005. She had joined Phelps Dodge in 2001 as vice president-global supply chain management. She holds a B.S. degree in engineering and management from Clarkson University. Based in Phoenix, Arizona, USA, Phelps Dodge Corporation is one of the world’s leading producers of copper and molybdenum and is the largest producer of molybdenum-based chemicals and continuous-cast copper rod. Roger P. Schrum, director, corporate communications for Sonoco Products Co., has been promoted to staff vice president, investor relations and corporate affairs. He replaces Allan V. Cecil, who will retire at the end end of this month. Schrum joined Sonoco in October 2005 following more than 20 years of business communications and investor relations experience, including service with NorthWestern Corporation; SCANA Corp.; Ashland, Inc.; and Diamond Shamrock Corp., A former business editor for a Texas publication, he holds a B.S. degree in education and journalism from Pittsburg (Kansas) State University and completed the Executive Development Program at the Indiana University Graduate School of Business. Based in Hartsville, South Carolina, USA., Sonoco Products Co. is a global supplier of industrial and consumer packaging products that includes reels used by the wire and cable industry. ■

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Fiber Watch Submarine cable outage shows vulnerability in routes It did not make headlines around the world, but an earthquake on December 26, 2006, off Taiwan, damaged undersea cable, and subsequently showed how vital and potentially susceptible such a network can be. The quake, which wire reports said registered a magnitude of 6.7, struck off the island’s southern tip Tuesday evening. It was reported to have disrupted services in Taiwan, Singapore, Hong Kong, South Korea and Japan, with a ripple effect felt in other parts of the world. The resulting damage cut several major cables, reported telecommunications executives, including the Asia Pacific Cable Network, which links North and Southeast Asia, and the SEA-ME-WE-2 link, which stretches from South Korea around the Eurasian land mass to the Netherlands. Reports said that Chunghwa Telecom,

Taiwan’s largest phone company, had damage to two undersea cables that route calls and process Internet traffic for several Asian countries. China Telecom, China’s biggest fixed-line telephone operator, said that the earthquake had affected lines from the Chinese mainland to places including the Taiwan area, the United States and Europe, and many have been cut. It also reported serious damage to Internet connections. The reports also said that PCCW, Hong Kong’s main fixed-line telecommunications provider, noted that several of its partly owned submarine cables had been damaged, and that its data capacity was reduced by half. Other telecom companies slow access to Internet pages. One wire story noted that the cables are vital as most of Asia is separated by water, and the data must be carried by undersea

FCC ruling may boost fiber efforts The U.S. Federal Communications Commission (FCC) voted 3-2 to streamline video franchise rules, a ruling that barring a court challenge will help companies like Verizon & AT&T that have invested heavily in fiber technology and are anxious to be able to sign up more customers. The ruling would make it easier for Verizon, AT&T and others to offer video services over their fiber networks by opening up the franchise process to make it more competitive. Some of the problems that were cited include the need for negotiations with local bodies that could be drawn out and include a wide range of unreasonable requirements related to what the local authorities could expect to get. In an FCC press release, the commission found that the current process presents “an unreasonable barrier to entry that impedes the achievement of the interrelated federal goals of enhanced cable competition and accelerated broadband deployment.” The decision covers county and municipal level franchising authorities, not decisions made at the state level. The FCC plans to further consider how its order

28 WIRE JOURNAL INTERNATIONAL

should affect existing franchisees and plans to issue an order in six months. Higher cable television costs were the driver for the case. The FCC release noted that “from 1995 to 2005, cable rates have risen 93%. In 1995 cable cost $22.37 per month. Last year, cable cost $43.04 per month. [Yesterday’s] Communications Daily reports that prices for expanded basic are now about $50 per month.” That increase is notable, the release said, as since 1996 the prices of every other communications service have declined. In a wire story, one FCC commissioner who voted against the ruling agreed with the goal of reducing costs for consumers but “not with the path” the FCC has chosen to take. “It is abundantly clear that cable rates are rising faster than inflation and that wireline cable competition can be helpful in bringing those rates down, but agreeing on the many benefits of video competition is hardly the same thing as coming up with rules that will actually encourage honest-to-goodness competition within the framework of the statutes that Congress has given us.”

cables that rest on the seabed up to eight kilometers, or five miles, below the surface. The damaged cables were much closer to the surface, but it will still take time and money for the repairs. The wire story noted that only a decade ago, Asia was connected to the U.S. by only five cables, all through Japan. Today, cables now connect Australia, China and South Korea directly to the U.S., it said. In another wire report, the issue was whether the incident shows that further investment is needed in such cables. It cited Duncan Clark, chairman of BDA China Ltd., a telecom consulting firm in Beijing, as saying that more cabling between Asia and Europe would make it easier to reroute international traffic in the event of such breaks.

Verizon’s FTTH plan still costly Verizon Communications Inc., which has invested heavily to bring fiber to the home, needs to sign up customers to make its investment work. The company noted that it was on pace to meet its goal of passing its new fiber-optic network by six million homes by the end of 2006, all part of its long-range plans of investing as much as $18 billion by 2010. However, the cost for hooking up an average new customer could still be as high as $9,650, by one estimate. One potential warning sign was a recent notice of reduced sales outlook from ADC, a supplier to Verizon, which is depending heavily that customers will opt for its fiber network called FiOS. Verizon also said that it will increase its monthly charge for TV service by 8 percent and one industry observer questioned whether the resignation of Verizon leader Larry Babbio is a warning sign that all is not well. ■

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Fastener Update IFI notes the retirement of Wilson, names Greenslade as new director The Industrial Fasteners Institute (IFI) announced that long-time staffer Charlie Wilson will retire as director of engineering for the trade association. Wilson, who served IFI for 43 years, will be honored at IFI’s Annual Meeting at the Ritz-Carlton in Sarasota, Florida, USA, this March, a press release said. He will consult for IFI as an independent contractor during 2007, it noted. Joe Greenslade has accepted the position as the new IFI Director of Technology, the release said. Greenslade is well known to the fastener industry, having written on technical subjects in industry publications and from his long representation of the fastener industry on a variety of national and international fastener standards organizations. The release said that Greenslade has sold his business, Greenslade & Company, to focus on his new IFI responsibilities and opportunities. A graduate of Texas A&M University, he was Manager of Corporate

Engineering & Development for CamcarTextron; Plant Manager of the Camcar Drilltite Division; General Manager of Rockford Headed Products and President and CEO of Greenslade & Company for 29 years. He served on several industry bodies and committees, including ASME B1 and B18, ASTM F16 and SAE. He served on the U.S. Fastener Quality Act and the multi-industry Aerospace Screw Thread Conformity Task Forces and was a Board Member at A2LA. He also served as the IFI Associate Suppliers’ Division Chairman and regularly contributed time to critical industry committees, task forces and working groups. Industrial Fasteners Institute is a trade association of leading North American fastener manufacturers and suppliers of materials, machinery, equipment and/or engineered services. Founded in 1931, IFI members combine their resources to seek solutions that advance fastener application engineering.

State suit related to ‘Big Dig’ accident in Boston includes Powers Fasteners A lawsuit has been filed against 15 companies reported to be involved in the design and construction of the ceiling of the Big Dig Interstate 90 connector tunnel that had a partial collapse last July 10, killing a driver. The suit, filed by Massachusetts Attorney General Thomas F. Reilly, states that the joint venture in charge of the entire Big Dig tunnel system, Bechtel/Parsons Brinckerhoff, was “grossly negligent,” while the other companies, including builders, designers, consultants and insurance companies, were simply negligent. The ceiling system, the court document notes, “was based upon B/PB’s preliminary design and specified precast concrete panels placed into steel framing modules and suspended from bolts with metal hanger assemblies with the bolts anchored with epoxy into holes drilled into the roof

of the tunnel shell or anchored with nuts and washers into steel unistruts in the roof of the tunnel.” One of the defendants is Powers Fasteners, a global company specializing in manufacturing and marketing quality anchoring and fastening products for concrete, masonry and steel. In the lawsuit, it notes that Powers supplied the epoxy to another defendant, Modern Continental Construction Co, Inc. It does not state whether Powers supplied the bolts or whether the bolts themselves were the problem. Further, an earlier wire story noted that the process used for the tunnel ceiling is common. It cited Jerome Connor, an MIT structural engineering professor, as saying that one possible reason the collapse occurred could be that not enough bolts were used. He suggested that there should have been a larger margin of safety.

Industry website makes it easier to market/find fasteners Italy’s fasten.it Srl notes that its website, www.fasten.it, is a business trade website dedicated to the world of fastener and fixing elements and to the producers of these elements, with the focus on e-procurement of fastener products. The website is divided into two parts, one part providing free access to anyone while the other part is accessible via a subscription fee, a press release said. The free access section enables visitors to look for a producer of a known brand or type of screw, machine, treatment, etc., by scrolling through the categories listed on the site’s home page and then using the select function.

Companies listed at Fasten.it have paid for their sponsored link. The free-access section also offers the E-Procurement section where inquiries can be inserted. The subscription-access section of the site includes a worldwide database of producers, technical tables and access to the names in the E-Procurement section. The worldwide database of producers, which includes all the sponsored link companies in the free-access section, provides a more comprehensive listing of global fastener and machinery suppliers. Subscribers access this broad resource by clicking on the world map under the worldwide data base, and then choosing from Asia, Europe or America zones. This allows a search by nation (or all nations), by product (fastener or machine) and by product category. Those seeking a technical consultation can go to tables that present and compare products by their specifications, compliance with international standards, etc. Contact: fasten.it s.r.l, tel. 39 031620172; e-mail info@fasten.it; Internet www.fasten.it. ■

FEBRUARY 2007 29

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WAI News Phelps Dodge, WAI team up again for El Paso workshop WAI’s Road Show Workshop is headed to Texas next month for two days of wire instruction and a tour of Phelps Dodge’s operations in El Paso. The program, “Nonferrous Wire Technology,” will be taught by industry expert Dr. Horace Pops on March 29 and 30. Co-sponsored by WAI and Phelps Dodge Copper Products, the seminar will cover topics ranging from principles to practical application. Students will learn wiredrawing basics such as property changes and die geometry; electrical conductor technology, including comparisons of copper and aluminum; and wire breaks

analysis, annealing, and testing of rod and wire. The second day of the program will feature a tour of Phelps Dodge’s rod mill and refining facility. Phelps Dodge previously teamed up with WAI for an educational program in 2002. Pops, president of Horace Pops Consulting, Inc., previously was director, metals laboratory at Superior Essex. He founded the company’s corporate metals laboratory. Look for more information in the March WJI issue and at www.wirenet. org. Contact: Marc Murray at e-mail mmurray@wirenet.org.

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Best tech paper presentations in 2006 are named The WAI’s paper rating committees have chosen the winners of the best technical papers in 2006 from those presented at Wire Expo 2006 and at the WAI’s International Technical Conference in India. Ferrous Division: the Allan B. Dove Memorial Award went to Surya Kumar Singh, Tata Steel, India, for his paper, “Effect of high-quality wire rod and micro-alloying on properties of steel wire in PCCP.” The Silver Certificate Award in the Ferrous Division went to Surya Kumar Singh, B.P. Gautham, Sharad Goyal and Amol Joshi, all of Tata Steel, for their paper, “Development of a virtual wiredrawing tool for process analysis and optimization.” Nonferrous Division: the Marshall V. Yokelson Memorial Medal Award went to Roger N. Wright, Rensselaer Polytechnic Institute, USA, for his paper, “Wiredrawing breaks – a review of mechanical perspectives.” The Silver Certificate Award in the Nonferrous Division went to Chitra Baid, Kamal Baid, Naveen Baid and Ashok Bagra, all of JLC Electromet Pvt. Ltd., India, for their paper, “Comparison of the effectiveness of mechanical descaling against acid pickling for cleaning of lowcarbon steel wire rod – a case study.” Electrical Division: The Urbain J. H. Malo Medal Award went to Cho Hoon, Jo Hyung-Ho and Lee Kyong-Whoan, all of the Korea Institute of Industrial Technology, South Korea, and Kim Byung-Min, Busan National University, South Korea, for their paper, “Optimization of pass schedule for copper-clad steel wire.” There was no Silver Certificate Award. In the General Division, the Horace Pops Award went to Donald Sayenga, Cardon Management Group, USA, for his paper, “Wired together.” No Silver Certificate Award was made. ■

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Chapter Corner Poland Chapter program firmed up: 33 papers to be presented The WAI’s Poland Chapter, a co-organizer along with Czêstochowska University of Technology of a technical conference March 1-3 in Zakopane, Poland, reports that as of press time, its program has 33 technical papers. The technical program entitled, “Modern Technologies and Modelling of Manufacturing Processes of Wires and Wire Products,” includes ferrous and nonferrous paper from authors from the U.S., Japan, France, Belgium, Germany, Ukraine, Czech Republic and Poland, said Jan Pilarczyk, president of the Poland Chapter. Companies unable to attend can purchase a disc of the proceedings following the event by going to the conference website, www.konferencja.mim.pcz.czest.pl, or by sending an e-mail to Pilarczyk at pilar@mim.pcz.czest.pl. The event has support from eight companies: Drumet S.A., Telefonika, ZDB Bohumin, Gorak FDW, Spawmet Ltd., Shymko Ltd., Le Four Industriel Belge (FIB) and Alwotech as well as the WAI. The scheduled presentations include: • The FEM simulation of a magnesium alloy wire drawing for chirurgical applications; • Modelling of drawing and rolling of high carbon flat wires; • Application of modern measurement methods and the analysis of 3D roughness to the surface topography of wire rod; • Drawing of tungsten wire at elevated temperatures; • Properties of wire steel (for) endourology; • Estimation of fatigue of wires and steel ropes by using the MMM; • Indicators of deformation in the process of single pass flattening of wires with great drafts; • Analysis of the influence conditions of friction on the band widening in the process single pass flattening of wires with great draft; • Microstructure and properties of titanium wire after oxidation in fluidized bed; • Economical aspect generate of oxidation layer in fluidized bed on titan surface for the biomedicine application; • FEM analysis of multi-clip wire joint; • Some technological aspects of ZnAl15

alloy wire production for thermal spray metallization; • Projects of draw shape designed for wires trolley type; • Thermal resistant Al-Zr alloy wires for overhead HTLS conductors; • The comparison of adhesion between rubber and cord wire with of brass, bronze; • Investigations of the mechanism of plasticity variations in AISI 302 steel; • Change of mechanical properties of wires, triangular strand rope; • New catalytic net produce in Mint – Noble Metals Ltd and influence wires quality on the process their production; • The influence of corrosion on durability the fatigue of wires the ropes equalizing exploited in shaft mining hoists; • FEM simulation of the microstructure evolution during wire drawing process of pearlitic steel wires; • The influence of deformation speed on distribution of temperatures and non-dilational strain in high-carbon steel wires; • The influence of an approach zone and a bearing part of die on the drawing force and mechanical properties of the wires; • Methodology of flow stress curves determination for wires made of austenitic steels; • Analysis of forming process of stainless steel hairbrush pins; • The influence of deformation degree on final stress state for micro-alloyed steel wires; • Drawing of low carbon steel wire with shining surface; • Mechanical properties of aluminium alloys produced by powders consolidation; • Influence of strain hardening on rheological properties of AlMgSi wires; • View from Ukraine on steelmaking processes and possibilities to improve steel properties; • The comparison of the mechanical-technological properties and fatigue strength of wires of the TRIP type structure with those ones of the ferrite-pearlite structure; • Mechanical properties and residual stresses after aging in high carbon steel wires drawn conventionally and hydrodynamically; • Effect of flaw removal on billets and wires in rolling and drawing; and • Microstructural evolution in high strength pearlitic steel wires. ■

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IFE ‘07 is The Only North American Event Exclusively Focused on the Design and Manufacture of Advanced Fasteners and Precision Formed Parts... Industry Suppliers....

Mark your calendar now and make plans to see and explore the widest array of fastener making machinery, materials, tooling, accessories, supplies and services at any trade show in North America— for every application.

IFE is sponsored by the International Fastener Machinery & Suppliers’ Association, a global trade organization which has represented and promoted the best interests of the fastener manufacturing industry since 1992. IFE ‘07 is also supported by the Industrial Fastener Institute and the European Industrial Fastener Institute. IFE ‘07 is co-located with INTERWIRE, the largest and longest running wire and cable event in the Americas, which is sponsored by Wire Association International. The natural affinity between wire and cable, and fastener manufacturers creates a synergistic event which significantly expands the business opportunities for exhibitors at both shows...while providing an additional value for attendees.

Check out the list of exhibitors on the opposite page. IFE is North America’s only ‘machinery show’ for the fastener industry. Plan now to be a part of it. For For more information on exhibiting, contact us at 203.794.0444, 800-688-1698, or by e-mail at: more information on attending, e-mail us:

attendee@IFEtradeshow.com

info@IFEtradeshow.com

Machinery, Materials, Tooling, Components, Accessories, Supplies and Services ...and Co-Location with INTERWIRE. It’s all here at IFE ‘07. And complete information on attending and exhibiting is just a ‘click’ away at: www.IFEtradeshow.com

Supported by the

Industrial Fastener Institute

E x p o s i t i o n a n d C o n f e r e n c e May 7-10, 2007 • I-X Center Cleveland, Ohio USA Co-located with Wire Association International

Manufacturers....

Whether you’re designing intelligent fasteners with on-board sensors, incorporating the latest shape memory materials, or using advanced equipment to produce precision formed parts with built-in fastening capabilities, you’ll find the full spectrum of suppliers at IFE ‘07 who are ready to discuss your most demanding requirements—for both captive, in-plant operations as well as the increasingly sophisticated application-specific and specialty fastener demands of your customers.

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EXHIBITORS (as of 15 January, 2007)

IFE ‘07 is more than 90% sold.

AMBA Johnstown Wire Technologies, Inc. American Fastener Journal Kingsyear Co., Ltd. An Chen Fa Machinery Co., Ltd. Kingwin Precision Co., Ltd. Anderson Controls Konfu Enterprise Co., Ltd. Arken Manufacturing, Inc. L & W Fastener Co., Ltd. If you’re a supplier to the Asahi Sunac Corp. Manufacturing Solutions, Inc. international fastener and Barbarotto International Mectron Inspection Systems, Inc. precision formed parts B.M. Rebuilders, Inc. Metal Forming Systems, Inc. manufacturing industry, Can-Eng Furnaces Nakashimada Engineering Works, Ltd make plans now to meet Carlo Salvi S.p.A. National Machinery LLC the active, buying market Chun Zu Machinery Industry ORT Italia, S.p.A. for the latest advances Cold Header Machine OSG Tap & Die, Inc. in machinery, materials, Computer Insights, Inc. PCC Precision Tool Group components, accessories, Creative Carbide Plan-E-Tech, Inc. supplies and services— Drawing Technology, Inc. Push Up Tools prospective customers ELP Quality Rebuilding Corp. you won’t meet at any E.W. Menn Reed Machinery, Inc. other fastener show on Fastener Equipment Corp. Reg-Ellen Machine Tool Corp. the North American Fastener World Rockford Manufacturing Group continent. Feng-Pei Co., Ltd. Rockform Tooling & Machining/ FH Machinery Gator Die Supplies Formatec GmbH RTM Products Plan now to be a part of Gem International Sacma the success. Reserve your Greenslade Fastener Services Sakamura Machine Co. Ltd. exhibit space today. Hariton Machinery Sanmei Company Heritage Tooling Services, Ltd. Scientific Forming Technologies Contact us—Tel: Heroslam SAL SMART Technologies 203.794.0444 Hilgeland-Nutap GmbH Sterling Die 800.688.1698 Hydro Carbide, Inc. Talleres Saspi, SA Hydropulsor info@IFEtradeshow.com Ticho Industries, Ltd. IMPAX-PTG Truform Equipment, Inc. Industrial Fastener Institute USA Carbide Tooling Intools Inc. Unimatic Engineering For complete show I-TECH International Corp. Universal Punch Corp information, visit: J & J Carbide Tools, Inc. Videx Machine Engineering www.IFEtradeshow.com Jern Yao Enterprises Co., Ltd. Wrentham Tool Products IFE ‘07 is sponsored and produced by the International Fastener Machinery & Suppliers’ Association 107 Mill Plain Road • Danbury, Connecticut 06811 USA Tel: 203.794.0444 • 800.688.1698 • Fax: 203.743.4810 • info@IFEtradeshow.com

IFE ‘07 is The Only North American Event Exclusively Focused on the Design and Manufacture of Advanced Fasteners and Precision Formed Parts... Industry Suppliers....

attendee@IFEtradeshow.com

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Supported by the

Industrial Fastener Institute

E x p o s i t i o n a n d C o n f e r e n c e May 7-10, 2007 • I-X Center Cleveland, Ohio USA Co-located with Wire Association International

Manufacturers....

INTERNATIONAL FASTENER & PRECISION FORMED PARTS MANUFACTURING

Media Support

EXHIBITORS (as of 15 January, 2007)

IFE ‘07 is more than 90% sold.

interwireprev second version.qxp

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Sneak Preview As technology changes so do demands for information, and in the case of Interwire, that includes the need to provide more information sooner so potential attendees can make decisions. The traditional March pre-show issue will present the full picture, but this Sneak Preview is intended--via these pages and

Web-powered

highlighting further information that can be found at WAI’s website--to give readers a better idea of what will be waiting for them at Interwire, which will co-locate with IFE on May 5-10 in Cleveland, Ohio, USA. Go to wirenet.org, click on “attendee information” under the “Wire in Motion” logo and you will find further information on the programs and events highlighted here, and more. WAI’s 77th Annual Convention will run in conjunction with Interwire 2007 and include the technical papers program, plant tours, guest speakers, an awards ceremony, committee meetings, and industry networking activities. See p. 40 for a condensed schedule. 34 WIRE JOURNAL INTERNATIONAL

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Full house likely for I-X Center The city of Cleveland is no stranger to the WAI, which has held its Wire Expo event there twice (1998 and 2004). This marks the first time that Interwire, held in Atlanta since its inception in 1981, will be in Cleveland. The event in Cleveland will be hosted at the I-X Center, which is well suited for Interwire. With over 1 million square feet of space, including an 800,000-sq-ft main exhibit hall, the I-X Center is one of the largest meeting, convention, and exhibition centers in the country. WAI welcomes the co-location at Cleveland this year of the International Fastener Exposition (IFE), organized by The International Fastener Machinery & Suppliers Association. The addi-

tion of IFE increases the overall footprint of the exhibition floor. As of press time, a total of 126,000 sq ft has been contracted for Interwire 2007 and 21,000 sq ft for IFE. A total of 470 companies will be represented on the show floor, which will have good representation both from Europe and Asia. The event is three months away and nearing sold-out status. Expectations are that the final tally will top more than 500 exhibiting companies. The exhibits open following the wirecutting ceremony on Monday, May 7, at 1 pm. The show hours are Monday, May 7, from 1 pm to 5 pm; Tuesday and Wednesday, May 8-9, from 10 am to 5 pm; and Thursday, May 10, from 10 am to 3 pm.

The I-X Center in Cleveland, Ohio, USA, will host Interwire for the first time.

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On-line listings

Keynote Speaker

Which exhibitors will be presenting what at Interwire is of great interest, but the edited listings could not be prepared in Preview of Exhibits time for the February issue. The good news, however, is that the vast majority of those listings will be available on wirenet.org by the time you get this issue. The listings are also interactive, so clicking on them will launch you to the exhibitor’s website. To access them, go to wirenet.org. Right under the Interwire 2007 logo are two headings: “Attendee Information” and “Exhibitor Information.” Click on the former and you can then choose to see the booth listings as well as the product directory. Exhibitors will also be able to see what the edited version of their description looks like and make updates.

NAM Senior Vice President Pat Cleary, the keynote speaker on Monday, May 7, at Interwire 2007, has a wealth of political, business and life experience. A former factory worker, he went on to serve for two U.S. presidents as well as a lecturer at the Stanford Graduate School of Business. Cleary, who joined the National Association of Manufacturers in 1997, is a frequent media spokesman. He previously had served in the Labor Department in the Reagan Administration, as deputy assistant secretary for policy. He also served in the first Bush Administration as a member/chair of

Interwire, the largest such trade show for the Americas, will present the collective technology and solutions for some 500 exhibiting companies over a four-day period. The exhibits will open following a brief ceremony at 12:30 pm on Monday, May 16, and will remain open until 5 pm. They will be open 10 am to 5 pm on Tuesday, May 17, and

Wednesday, May 18. On Thursday, May 19, the exhibits will be open from 10 am to 3 pm. The show floor will see the return of favorites such as the WAI Member Lounge, WAI Bookstore and the Cyber Cafe. It will also host two special presentations (see p. 46) and attendees .should stop by the South African Wire Association exhibit, Booth 1340,

where wire artist Anele Attwel Futshane will demonstrate his talents. The following pages present a preview of exhibits. Alpha/numerical lists of exhibitors begin on p. 54 and a product directory begins on p. 138. For further information on many of these exhibitors, go to WAI’s Virtual Trade Show, which can be accessed at www.wirenet.org

Accra-Wire Controls Inc. USA Booth 2549 Tel. 616-866-3434 fax 616-866-9468 E-mail sales@accrainc.com USA Booth 2549 Exhibiting: Accra-Wire Controls will showcase a variety of its tension controlled payoffs, take-ups, lot control devices as well as present some new and innovative products for the wire and cable industries. Personnel: Jeff Jones, Johnnie Jones, Brian Knuth, Scott Wilson

profit voluntary association also plays an important international role in improving the location and organization of the major wire and cable trade fairs that are held around the world. Personnel: Ferruccio Bellina.

pelletizers. Personnel: Keith Larson, Ron Beaudion, Dane Miller, Nick Depersio, Allen Reeves, Dick Doine, Vinnie Carpentieri.

Ace Metal Inc. Tel. 610-623-2204 E-mail rmedoff@rcn.com USA Booth 655 Exhibiting: Ace Metal will exhibit its full range of metal spools and reels, from a 6” flange diameter through 123/4” flange diameter. Also, its line of tire cord spools and tubular wire carriers. Personnel: Richard Medoff, Charles Zobel, Leo Host, Geraldine Medoff.

ACIMAF Tel. 39-02-541-253-01 Fax 39-02-541-208-25 E-mail acimaf@acimaf.com Italy Booth 2330 Exhibiting: Associazione Costruttori Italiana Macchine Per Filo (ACIMAF), the Italian wire machinery manufacturers association, will present information about the technology of its members for machines and products for the wire and cable manufacturing industry. Led by its president, Ferruccio Bellina (TKT Group) and vice president, Sergio Cortinovis (Cortinovis SpA), the non-

ACM A.B. – KSM Tel. 46-889-2715 fax 46-889-3750 E-mail acm@acmab.com Sweden Booth 2630 Exhibiting: ACM will operate cable cross-section measurement equipment that shows the extremely precise and quick method of performing all twodimensional cable measurements. The KSM model also allows quality control departments to track the efficiency of products or equipment. Customers are invited to bring their cable samples to the show, so that they may experience the innovative measurement system first hand. Personnel: Stefan Askenfors, Willy Hauer, Chris Hauer. ACS Extrusion Group Tel. 810-720-7300 fax 810-720-2598 E-mail klarson@corpemail.com USA Booth 2938 Exhibiting: ACS Extrusion Systems offers complete extrusion process support. It can help increase productivity by offering a full-service partnership including ACS’s quality equipment and 24-hour, full-service support team. Equipment includes: material handling, downstream extrusion, granulating and size reduction, blending and feeding, bulk solid material storage, chilled water systems, temperature control systems, screen changers, melt pumps and

Acufil/Mittal Steel Tel. 514-762-5318 fax 514-762-5388 E-mail john.suchecki@mittalsteel.com Canada Booth 330 Exhibiting: Acufil, now part of Mittal Steel, specializes in industrial wire, from low, medium and high carbon, to grade 1080 as well as for certain cold heading applications. Available wire surface finishes include soap drawn, grease drawn, plating quality, galvanized, patented and cleaned and coated. Personnel: Louis Lemoine, John Suchecki. A.E.B. International, Inc. Tel. 212-752-4647 fax 212-486-6526 E-mail aeb@aebint.com USA Booth 730 Exhibiting: A.E.B., was founded in 1979 by owner A. Erkan Buyuksoy, is one of the world’s largest conductor manufacturers and distributors. It has sister companies in Turkey, France, Germany and others. Its U.S. factory, Atlantic Specialty Wire, in Duncan, South Carolina, handles immediate and engineered product requirements of the customer base. Additional distribution warehouses are located in California, New Jersey, Rhode Island and South Carolina. Personnel: Erkan Buyuksoy, Mitch Jacobsen, Susanne Prosser, Lana Geyman-Babiy, Jessica Barahona, Bob

66 WIRE JOURNAL INTERNATIONAL

Entertainment Award-winning acoustic harp guitarist Andy McKee will provide the entertainment on Monday, May 7, when he plays at

the National Mediation Board. A graduate of Fairfield University and Hamline University School of NAM Senior Vice Law, he is President Pat Cleary. the author of “The Negotiation Handbook.” NAM is the largest U.S. industrial trade association, with 14,000 companies and their subsidiaries as members.

Awards Event/Mordica Lecture The WAI will hold its Kickoff Awards Breakfast on Monday, May 7, at which time it will honor the authors of the best technical papers presented in 2006 as well as the winner of the WAI’s Mordica Memorial Award, Harry G. Petrohilos, and the Donnellan Memorial Award, Sharon Young. The breakfast, which will also include entertainment by Andy McKee and the keynote presentation by NAM’s Pat Cleary, begins at 9 am and leads into the Mordica Lecture, which will be presented at 11:30 am. The winners of the technical papers are presented on p. 30 of this issue. The challenges and successes of Petrohi-

los should make for a memorable presentation. The lecture, aptly named, is “Measuring Progress in the Wire Industry.” A co-founder of what is today Beta LaserMike and the holder of numerous patents, Petrohilos is best known for developing the original in-line laser micrometer, which was developed in 1970, first delivered in 1971 and sent to wire industry customers in 1972. Young, a copper industry veteran who became the WAI’s first woman president in 1997, joined Magma Copper Co. in 1971 and served in many key positions through its acquisition and renaming to BHP Copper Inc.

‘Where is the $ in Wire & Cable?’

Acoustic harp guitarist Andy McKee.

the awards breakfast and the wire cutting ceremony. It is one thing to call someone’s style as “outside the norm,” but in this case you can go to www.wirenet.org and with a few clicks you can hear for yourself just how McKee sounds, and whether this should be on your “make-sure-to-attend” list.

The topic does not get more meaningful than the one in the headline that will be covered by Philip Radbourne, director, Integer Research, who will make his presentation on Wednesday, May 9, at Interwire 2007. Radbourne also plans to compare the performance of the leading Western producers versus the emerging players in China and Taiwan and suggest which Chinese manufacturers are likely to emerge as the leaders. Based in London, Integer Research provided a range of information that was published in the January WJI issue. Recent work ranges from invest-

ment projects/ plant expansion feasibility work in the Caribbean, China, India, Vietnam, Eastern Europe and Russia to the strategic implications of Chinese Integer Research Dir. CV/VCV Philip Radbourne. power cable capacity on the Asian power cable market.

FEBRUARY 2007 35

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IFE & Interwire

Troubleshooting Wire 101

The industry has seen an increasing trend toward co-locations of events, and IFE’s location is a fine example of how this can work to everyone’s advantage. The only North American machinery show for the fastener industry, the organizers of IFE note, “The natural affinity between wire and cable and fastener manufacturers creates a synergistic event which significantly expands the business opportunities

The WAI will present Production Solutions, six shop floor sessions on dies, lubricants, welding and wire breaks, during Interwire. Session 1 is “Nonferrous/ Electrical Wire Breaks”; Session 2 is “Ferrous Wire Breaks”; Session 3 is “How to Improve System Life; Session 4 is “Die Inspection: Take the guess work out of the most pop-

for exhibitors at both events while providing additional value for attendees.” As of press time, IFE had sold approximately 21,000 sq ft of net exhibit space and expected to sell the remaining space. See p. 33 for the list of IFE exhibitors.

ular question in the wire drawing industry”; Session 5 is “Newest Technology Boosts Lubricity as System Ages”; and Session 6 is “Cold Pressure Welding. The sessions, to be presented by industry veterans at various locations, mostly at the booths on the show floor, will focus on causes and prevention of potential industry woes, with the focus on practicality. Sessions 1-3 will be held Tuesday, May 8, at 2 pm, 2:45 pm and 3:30 pm, respectively. Sessions 4-6 will be held Wednesday, May 9, at 2 pm, 2:45 pm and 3:30 pm. respectively. Sessions 1-6 will be repeated on Thursday at 10:15 am, 10:30 am, 11:00 am, 11:30 am, noon and 12:30 pm. See the March preshow issue for more details on the presenters and the range of topics they will Delamination damage to the surface layer of cover. wire can be prevented.

“Paramount Die has been there with us since the beginning.” Is your company utilizing the most advanced die technology available? Meet someone who is… “At Hope Global we are proud of our state-of-the-art wire draw department where we take the deepest draws from 0.218 direct to 0.027" at the highest speeds (up to 10,000 feet per minute). Paramount Die has been there with us since the beginning. We rely on the quality of their dies and on time deliveries to keep us going. Their sales force understands our process and has been instrumental in our success. I look forward to working with Paramount Die in the future both as a supplier and a partner in developing our potential.” John Martin - Hope Global

Call Paramount to get started today.

410-272-4600 www.paradie.com Drawing Systems for the Wire Industry

36 WIRE JOURNAL INTERNATIONAL

1206 Belmar Drive • Belcamp, Maryland 21017 • USA

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Business perils

Basics, workshop & plant tour

At Interwire, Bryant University Professor Michael A. Roberto will present “Strategies for Competing and Winning in the Global Marketplace” on Tuesday, May 8. He will discuss the value of developing and implementing a clear, articulated business strategy. Lest one worry that this talk will not relate well to real life or may be lacking in energy, it is worth noting that he wrote a book in 2002 about an ill-fated attempt to climb Mount Everest. It resulted in the deaths of five climbers, and Roberto relates what happened to a framework for understanding, diagnosing, and preventing serious failures in many types of organizations. The former Harvard Business School professor says that leaders must pay close attention to how they balance competing pressures in their organizations. He also provides insight regarding how firms approach learning from past failures.

The steel wire workshop on manuGet back to the basics on Saturday, facturing and applications will explore May 5, and Sunday, May 6, at Fundapractical features of steel wire. It will mentals of Wire Manufacturing: Prininclude classwork as well as a tour on ciples, which along with a WAI FerThursday of Charter Steel’s plant. The rous Workshop, Wednesday, May 9 tour is open to Interwire attendees. The and Thursday, May 10, and a tour of rolling mill, designed by Sumitomo Charter Steel’s plant in Cleveland Metals and built by Morgan Construcmake for good industry action during tion, has approximate capacity of Interwire. 800,000 tons per year. Fundamentals marks a new start for the program, which ran in a three-year cycle at Wire Expo and Interwire. The central products of wire manufacturing will be presented by eight expert instructors. The course, which covers ferrous and nonferrous products, is intended for people who work on the operational or technical side or are a newAttendees will attend the tour of Charter Steel’s Cleveland comer to the industry. plant as part of the ferrous workshop program.

Can You Tell The Difference? Your Butt Welder Can. Ed Harrington, Quality & Service Supervisor

When was the last time you actually replaced a part on your Micro-Weld butt welder? Though our butt welders work harder, last longer and offer consistent high quality welds, certain parts will eventually wear out. Check your welder for worn out parts, or call the Micro-Weld Service Team. Why go any place else? Get genuine parts from folks who built your welder. All parts may look the same, but ours work better and last longer. Your welder will know the difference. You’ll know it too, because genuine Micro-Weld parts reduce weld breaks and downtime, maximize weld consistency, and increase your productivity.

For more information call 1-800-872-1068.

Genuine Micro-Weld Parts Available: Welding Shoes & Dies • Clamps & Upset Springs • Headpieces & Transformers 1296 Mark Street, Bensenville, Illinois 60106 USA • Phone: 630-787-9350 • Fax: 630-787-9360 • www.micro-weld.com

FEBRUARY 2007 37

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Opening Reception to be joined by 2nd event The Opening Reception has long been a popular draw at Interwire and Wire Expo events, but this year attendees should consider penciling in a new social event that will also be held. The most widely attended social event at WAI trade shows is the Opening Reception, which is a key networking

event for the industry. It will be held this year at the Renaissance Cleveland Hotel on Monday, May 7. Entertainment will be provided by the the Jerry Bruno Orchestra. The opening reception will run from 7 pm to 9 pm. Shuttle bus service from convention hotels will be available. The Opening Reception will include refreshments and an assortment of food, but the real attraction has continued to be the people who attend. As noted above, this year attendees will have a second networking event to enjoy, this one a bit different. “Wire in Motion” celebration will be held WednesThe Opening Reception has been a well-attended event. day, from 3 pm to 5

“Wire in Motion” is the theme of a second social event planned for Interwire 2007.

pm on the show floor at the I-X Center, giving attendees and exhibitors another opportunity to meet, exchange ideas and focus on the many ways that wire influences our daily lives. The emphasis will be on fun and some surprises will be waiting for attendees, so please make plans to see for yourself what it will include.

Keir Manufacturing, Inc.

1-800-992-2402

(1-828-885-8444) www.keirmfg.com email: mwalters@keirmfg.com

38 WIRE JOURNAL INTERNATIONAL

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City of Cleveland offers many attractions Best known to many for being home to the Rock and Roll Hall of Fame and Museum or to the sports-minded for the Cleveland Indians baseball team and the Cleveland Cavaliers basketball team, the city of Cleveland has a lot more to offer attendees. The city’s Flats Entertainment District, once the industrial heart of the city but now known as “the Flats,” is a waterfront entertainment district well worth exploring. Located on the east and west banks of the Cuyahoga River, the area is home to more than 50 restaurants and nightclubs, and water-loving attendees might want to explore the Nautica Entertainment Complex, enjoy food and drink outside on the boardwalks and patios of Shooters and Riverwalk Cafe, taking in great views of the downtown skyline and illuminated bridges while pleasure boats and massive ore boats maneuver the crooked river.

Other museums include the Crawford The Rock and Roll Hall of Fame and Auto Aviation Museum, Cleveland Museum, a 150,000 square-foot faciliBotanical Gardens, Cleveland Museum ty located at North Coast Harbor, of Natural History, Dunham Tavern should be on your “must see” list if Museum, Western Reserve Historical you have not been there before or want Society and more. to make a return visit. Opened in 1995, For more details, go to wirenet.org it has drawn more than 4,000,000 visiand look for links to these and other tors to date. attractions. In addition to a wide assortment of bars (try to stop at The House of Blues), Cleveland has many cultural institutions, including the internationally acclaimed Cleveland Orchestra and Cleveland Museum of Art. Theaters and entertainment centers include Playhouse Square (a complex of four theaters with seating for over 9,000), The Cleveland Play House, Public Auditorium, Karamu House and Severance Hall. Other cultural institutions include Cleveland Opera, Great Lakes Theater Festival, Cleveland Public Theater, Red (an orchesWire Expo 2004 attendees enjoy the views of tra) and Dance Cleveland. Cleveland from a boat cruise.

BETTER BY BENEKE

It’s a simple fact, the quality of the raw material used affects the quality of the finished product. Beneke Wire is known for outstanding quality. If you’re working with aluminum wire, you should be working with Beneke.We offer… Wire and Rod in All Aluminum Alloys - heat treatable and non-heat treatable, ranging from 1/16” to 7/8” diameter. A Variety of Special Finishes - designed to control tool wear, head ovality and minimize surface defects. Engineering Assistance and Advanced Product Quality Planning ensure the best material for a given application. Continuous Coils - on carriers up to 1500#. Screw Machine Stock - 1/8” to 11/16” diameters with lengths up to 14 feet.

Quality Parts Manufactured with Beneke Cold Heading Wire.

Our quality shows in the parts you make. BENEKE WIRE COMPANY 5540 National Turnpike / Louisville, KY 40214 Phone 877-423-6353 or 502-367-6434 (Outside USA) FAX 502-363-1837 / www.benekewire.com An ISO 9001:2000 Company

FEBRUARY 2007 39

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Golf and ‘fast times’ ahead Interwire 2007 will offer opportunities for attendees who either enjoy the links or the idea of some fast footin’ through a stretch of Cleveland. The golf tourney, a charity fundraiser will start at 8:30 am on Sunday, May 6, at Big Met Golf Course in Fairview Park, Ohio, located minutes away from the I-X Center. For more details, contact WAI’s Chip Marsh at cmarsh@ wirenet.org. WAI’s 3rd Annual 5K Industry Run will be held Tuesday, May 8. Sponsored by Leoni Wire, runners of all levels are invited to join in this charity fundraiser. For more details, contact WAI’s Mark Marselli at editorial@ wirenet.org.

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Interwire 2007 schedule The following is a condensed schedule. For more details, go to wirenet.org.

Saturday May 5 Fundamentals Workshop

9 am-5 pm

Sunday May 6 Golf tournament 7:15 am-4:30 pm Fundamentals Workshop 9 am-3 pm Monday May 7 Awards Bkf./Pat Cleary Mordica Lecture Wirecutting Exhibits Production Solutions Opening Reception

9-11:15 am 11:30 am 12:30 pm 1-5 pm 2-4 pm 7-9 pm

Tuesday May 8 Tech Program

9 am-noon

Exhibits 10 am-5 pm Production Solutions 2-4 pm Roberto presentation 4 pm Global Competition Pres. 4-5 pm 5K Road Race (downtown) 6:45 pm Wednesday May 9 Wire Technology Workshop 9 am-5pm Tech Program 9 am-noon Production Solutions 10am-noon Exhibits 10 am-5 pm Charter Steel plant tour 1:30 pm-5pm Integer Research presentation 2-3 pm Wire in Motion show floor) 3-5 pm Social Hour 5-6:30pm Thursday May 10 NASA Sessions 9:30 am-12:30 pm Wire Technology Workshop 9 am-noon Exhibits 10 am-3 pm

Runners at the first WAI 5K Industry Run, held at Interwire 2005. The 2007 event will be sponsored by Leoni Wire.

40 WIRE JOURNAL INTERNATIONAL

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A body in motion stays in motion. And for Interwire 2007—the largest and longest running wire and cable marketplace in the Americas—a surge of activity surrounds its strategic move to the I-X Center, Cleveland, Ohio, USA, May 5-10, 2007, to access a new industry hub.

• • ••

Everything at Interwire 2007 is designed to move you forward in your industry and to accelerate your career. Exhibits. New business forums. New contacts. Tech talk. Hot topics. Everything revolves around the current best practices in the global wire and cable industry. We’ve added a new format as well as the colocation of the International Fastener Exposition to keep things moving.

PRESENTS: “WIRE

Kurt Breischaft Plant Manager Belden Nogales, Sonora, Mexico

Nothing stands still. Why should you? Join the momentum that has thousands moving in the direction of Cleveland for Interwire 2007.

”

•••• Organized By:

Look for program specifics in future issues of WJI, online at: www.wirenet.org, or call The Wire Association International at: (001) 203-453-2777 for details. Interwire 2007. I-X Center Cleveland. Your move!

I-X Center Cleveland, Ohio, USA May 5-10, 2007

••••

The Wire Association International, Inc.

Supporting Sponsors: Society of Plastics Engineers

MOTION”

Interwire 2007 is the only place in the Americas to meet with the most influential industry professionals in the world who travel from more than 50 countries to participate.

“

I attend Interwire because it is the most efficient way to find answers to technical questions, learn about industry trends and meet with colleagues, customers, and suppliers. Interwire is truly the most important industry show in the Americas.

Educational Alliances: AUSTRALASIAN WIRE INDUSTRY ASSOCIATION

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Interwire 2007 Exhibiting Companies as of January 2007 A. Appiani Ace American Wire Die Co. Ace Metal Inc. ACIMAF ACM AB Advanced Plastics Reclaiming LLC AEB International Inc. Agape Industry Inc. AIM Inc. All Forming Machinery Inc. Alloy Engineering Co. Amacoil Inc. American & Efird Inc. American Electronic Components Inc. American Fastener Journal American Wire Producers Association Anbao Wire & Mesh Co. Ltd. Anderson Controls Inc. ASB Industries Inc. Atlantic Wire LLC Automation Kinetics Inc. AW Machinery LLC AXIS Computer Systems Inc. Aztech Lubricants Baker Division of Sonoco Balloffet Die Corp. USA B&H Tool Co. Inc. Bartell Machinery Systems LLC Base Ten Consulting/Software Inc. Baum’s Castorine Co. Inc. BCS Industries LLC Beijing CEW International Fair Co. Ltd. Bekaert Beneke Wire Co. Bergandi Machinery Co. Beta LaserMike Blachford Corporation BMR Group Rolf Bock Maschinenfabrik GmbH Bongard Drummond Trading LLC Bonko Inc./Machine Technology & Control Boockmann GmbH/The Slover Group Bow Shing Metal Manufacturing Ltd. Boxy SpA Breen Color Concentrates Inc. Brookfield Wire Co.

Buhler USA Inc. Bulk Chemicals Inc. Buonforte Machinery Works LLC C.M. Caballe SA Cable & Tubing Solutions Ltd. Cable Consultants Corp. Calmec/MCM CANDOR Sweden AB Canterbury Engineering Co. Carpenter Technology Corp. Carris Reels Inc. Cemanco LC CeramTec AG CERSA-MCI Chengdu Centran Industrial Co. Cheng I Machinery Inc. Chhaperia International Company Chi Ning Co. Ltd. Citma Minmetals Co. Ltd. Clifford Welding Systems (Pty.) Ltd. Clinton Instrument Co. CM Furnaces Inc. CN Wire Corp. Coats North America Cometo Commission Brokers Inc. CommScope Bimetals Condat Corp. Conductix/Delachaux Group Confederaton of Indian Industry Conneaut Industries Inc. Conoptica A/S Continuus-Properzi SpA CoorsTek Copperweld Core Furnace Systems Corp. Cortinovis America Cortinovis SpA Crown Technology Inc. CRU North America Inc. Custom Machining & Fabrication D & S Wire Inc. Davis Electric Davis-Standard LLC Davis Wire Corp. Delachaux Design & Engineering LLC Die Quip Corp. Domeks Makine Ltd. Dynamex Corp.

Easen Corp. E-Beam Services Inc. Ebner Furnaces Inc. Ebner Industrieofenbau ECD Inc. EconoReel Corp. Eddytech Systems Inc. EFAF Engineered Control Systems Inc. Engineered Machinery Group Enkotec Co. Inc. Emmerre srl ERA Wire Inc. Erocarb SA Esteves-DWD USA Etna-Bechem Lubricants Ltd. Etna Products Inc. Eurobend SA Eurodraw Energy Spa Eurolls SpA Eurowire Magazine George Evans Corp. EVG Exel Fil SA Facts Inc. Fasten Group Co. Fenn Technologies FH Machinery Fiber-Line Inc. Fil-Tec Inc. Filtertech Inc. Fine International Corp. Fisk Alloy Wire Inc. FLYMCA SL FMS Force Measuring Systems AG FMS USA Inc. Foerster Instruments Inc. The Foreign Trade Corp. of the Haidian Forming Systems Inc. Fort Wayne Wire Die Inc. Fortune Machinery Corp. Le Four Industriel Belge SA Frey Group LLC Friedr Krollmann GmbH Frontier Composites & Castings Inc. FSP-One Fuhr GmbH & Co. KG T. Fukase & Co. Galvacor Inc. Garg Sales Inc.

••••

Gauder & Co. SA Gavle Trad AB Gavlick Machinery Corp. GBC Technologies Inc. GCR Eurodraw SpA GE-Plastics Gem Gravure Co. Inc. GENCA Corp. Gibbs Wire & Steel Co. W. Gillies Technologies LLC Gimax Srl Global Signal Inc. USA Global Wire Inc. GMP - Slovakia Rudolf Grauer AG GSG GmbH & Co. KG Guill Tool & Engineering Co. Hafner & Krullmann GmbH Hangzhou Sanp Machinery Co. Ltd. Heacock Metal & Machine Co. Inc. Heany Industries Inc. Hearl Heaton Heatbath Corp. The Heico Wire Group Henrich Service GmbH Heritage Wire Die Inc. Hezel GmbH & Co. KG Gebruder Hilgeland-Nutap GmbH The Hilliard Corp. Hitachi America Ltd. Houghton International Inc. Howar Equipment Huanghua Zhonglian Hardware Prod. Huestis Industrial Huettner Maschineenfabrik GmbH Hyradix ICE Group IDEAL Welding Systems Ideal-Werk Imaje USA Industrial Heating Magazine Industrial Steel & Wire Co. Integer Research Ltd. International Wire & Cable Symposium Inc. (IWCS) Intertek Testing Services InterWire Products Intras Ltd. Iowa Steel & Wire Italian Trade Commission IWE Spools & Handling GmbH

IWMA International Wire & Machinery Association Jiangyin Kangrui Stainless Steel Kamatics Corp. Keystone Steel & Wire Co. Kingway Metal Products Co. King Steel Corp. Kinrei of America KMK GmbH Knill USA Inc. Ernst Koch GmbH & Co. KG Kuhar Metallizing Co. Inc. Lamnea Bruk AB LaserLinc Laurel Wire Co. Le Four Industriel Belge SA Leggett & Platt Wire Group Leibinger Inkjet Systems Leoni Wire Inc. Lesmo Machinery America Inc. Lindlar Surface Technologies Lloyd & Bouvier Inc. Loos & Co. Inc. Lors Machinery Inc. J.J. Lowe Associates Inc. L-S Industires M+E Macchine+Engineering SpA MacDermid Inc. Mack-Brooks Publishing Ltd. Magnetic Technologies Ltd. Magnus Equipment MAGPOWR Maillefer SA Mang Systems Mapre Belgium SA Maschinenfabrik Niehoff Mathiasen Machinery Inc. Manidhari Stainless Wire Pvt. Ltd. William McCaskie Inc. Menam Stainless Wire Ltd. Merritt Davis Messe Düsseldorf North America Metavan N V MFL USA Service Corp. - Frigerio MGS Group Micro Products Co. Microdia Mikrotek Machines Ltd. Mittal Canada, Inc., Wire Products Mittal Canada Lachine Inc. Morgan-Koch Corp.

Interwire 2007 is organized by The Wire Association International, Inc.

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Interwire 2007 Exhibiting Companies as of January 2007 (cont.) Mossberg Reel LLC / Boxy Group National Standard National Strand Products Inc. NEPTCO Inc. Nevatia Steel & Alloys Ltd. Nextrom Oy Niagara Composites Industries Inc. Niehoff Endex North America Inc. North American Spring Tool Co. Northampton Machinery Co. The MGS Group Northeast Steel Corp. Norwalk Innovation Inc. NOVA-S a s NUMAMERICA Inc. Oklahoma Steel & Wire OM Frigerio OM Lesmo OMA srl OMA USA Inc. OMCG North America Inc. Otomec Srl P & R Specialty Inc. Paramount Die Co. Inc. Parkway-Kew Corp. Pave Automation Design Phelps Dodge High Performance Conductors Pioneer Machinery Co. Ltd. Pittsfield Plastics Eng. Inc. Plasmait GmbH Plastore Inc. Plymouth Wire Reels & Dies Inc. Polyone

Ets Pourtier Pere & Fils Powder Tech International Ltd. Power Sonics LLC Precision Die Technologies Inc. Precision Payoff Systems, LLC Premier Wire Die Pressure Welding Machines Ltd. PrintSafe Process Control Corp. Process Technology Properzi International Inc. Proton Products Ltd. PS Costruzioni Push-Up Tools Udyog Pvt. Ltd. QED Wire Lines Inc. Qual-Fab Inc. Queins & Co. GmbH Raajratna Metal Industries Rad-Con Inc. Radcliff Wire Co. Inc. Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Reel-O-Matic RichardsApex Inc. Rizzardi Rolf Schlicht GmbH Rosendahl Inc. Roteq Machinery Inc. Saarsteel Inc. SAMP SpA (SAMPSISTEMI) SAMP USA Inc. Sarkuysan SA Schlatter Inc.

••••

Scientific Forming Technologies SCOB Paul Schaaf GmbH Sealeze Seaway Yarns Ltd. Setic SAS Shanghai JinShen International Co. Ltd. Shuster-Mettler Corp. Sictra Srl SIKORA AG Sikora International Corp. Simpacks Simple Packaging Solutions LLC Singleton Reels Sivaco Wire Group Sjogren Industries Inc. Skaltek Inc. SKET Verseilmaschinenbau GmbH SNTN Sonoco Crellin Inc. South African Wire Association South Fence Machinery Ltd. Steeger USA Inc. Stolberger KMB-Maschinenfabrik GmbH August Strecker GmbH & Co. KG Subec AB Summit City Enterprises Sweed Recycling Machinery Sylvin Technologies Inc. T & T Marketing Inc. TAK Enterprises Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co.

Taymer Industries Inc. Team Meccanica Srl Techalloy Co. - Central Wire Group Tecna SpA Teknor Apex Co. Temsa Diamond Division SA Tensor Machinery Ltd. Teurema Thermoplastics Engineering Corp. Tian Jin Yong Ze Metal Ltd. Tianjin Mei Jia Hua Trade Co. Timco Inc. Traxit North America LLC Troester GmbH & Co. KG Tubular Products Co. Tulsa Power LLC Ultimation Machines United Wire Co. Inc. Unitek North America Inc. Uniwire International Ltd. Upcast Oy Urbano Associates US Synthetic Vandor Corporation VARO S.r.l. Vitari SpA Vollmer America Inc. Wafios AG Wafios Machinery Corp. Wardwell Braiding Machine Co. Wardwell Europe GmbH Wardwell Italy SRL Warner Electric Weber & Scher Mfg. Co. Inc. Windak Inc.

Windings Inc. Wire & Cable Asia Magazine Wire & Cable Industry Suppliers Association (WCISA) Wire & Cable Technology International Wire & Plastic Machinery Corp. The Wire Association International Inc. Wire Forming Technology International Wire Industry Wire Journal International Wire Lab Co. Wire Machine Systems Inc. Wire World Witels Albert USA Ltd. Witels Apparate-Maschinen Albert GmbH Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Woywod Kunststoffmaschinen GmbH WRCA Wire Wyrepak Industries Inc. Ya Sih Technology Co. Ltd. Yield Management Corp. YMD Engineering LLC YR Products Zapp USA Zhejiang Minmetals Zhongchen Imp. & Exp. Co. Ltd. Zumbach Electronics Corp.

IMPAX-PTG Industrial Fasteners Institute Intools Inc. I-TECH International Corp. J & J Carbide Tools, Inc. Jern Yao Enterprises Co., Ltd. Johnstown Wire Technologies Kingsyear Co., Ltd. Kingwin Precision Co., Ltd. Konfu Enterprise Co., Ltd. L & W Fasteners Co., Ltd. Manufacturing Solutions Metal Forming Systems Inc. Mectron Inspection Systems, Inc.

Nakashimada Engineering Works, Ltd. National Machinery LLC ORT ITALIA OSG Tap & Die, Inc. PCC Precision Tool Group PLAN-E-TECH INC Push-Up Tools Udyog Pvt. Ltd. Quality Rebuilding Corp. Reed Machinery, Inc. Reg-Ellen Machine Tool Corp. Rockford Manufacturing Group FELM Rockform Tooling & Machining RTM Products, Inc.

Sacma Machinery Corp. Sakamura Machine Co. Ltd. Sanmei Company Scientific Forming Technologies SMART Technologies Sterling Die/OSG Talleres Saspi SA Ticho Industries Ltd. Truform Equipment, Inc. Unimatic Engineering Universal Punch Corp. USA Carbide Tooling Videx Machine Eng. Ltd. Wrentham Tool Products

IFE Exhibiting Companies AMBA American Fastener Journal An Chen Fa Machinery Co., Ltd. Anderson Controls Inc. Arken Manufacturing Inc. Asahi Sunac Corp. Barbarotto International BM Rebuilders Inc. Can-Eng Furnaces Ltd. Carlo Salvi S.p.A. Chun Zu Machinery Industry Cold Header Machine Corp. Computer Insights Creative Carbide Drawing Technology Inc.

ELP E.W. Menn Fastener Equipment Corp. Fastener World Group Feng-pei, Co. Ltd. FH Machinery Formatec GmbH GEM International Co., Ltd. Greenslade Fastener Services Hariton Machinery Co. Inc. Heritage Tooling Services Ltd. Heroslam S.A.L. Hilgeland-Nutap GmbH Hydro Carbide, Inc. Hydropulsor Inc.

Interwire 2007 is organized by The Wire Association International, Inc.

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Advance Registration Form May 5-10, 2007 • Cleveland, Ohio, USA

➊

* Please do not mail or fax registrations after April 4, 2007. After this date you must register on-line or at the show. CANCELLATION POLICY– Refund requests must be received in writing by these dates: Before 4/4/07 – REFUND minus $25 handling fee After 4/4/07 – NO REFUND Substitutions from company can be made at any time.

Note: please print neatly and complete all information to ensure accurate registration. If you choose to mail this form, make sure you keep a photocopy.

Complete and mail or fax this form today to:

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

▲

LAST NAME

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TITLE

MIDDLE

COMPANY

ADDRESS #1

CITY

COUNTRY CODE

E-MAIL

PHONE (include area/city code)

COUNTRY

STATE/PROV.

COUNTRY CODE

[

WJI207 POSTAL CODE

FAX (include area/city code)

INTERNAL USE

ADDRESS #2

]

AMT PD

➋ BUSINESS INFORMATION: These two questions must be completed for proper processing. ➊ Which ONE of the following best describes your company’s type of business? PLEASE CHECK ONLY ONE. WIRE MANUFACTURING 10 ❏ Aluminum & Al. Alloys (Rod/Bar, Bare Wire) 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire) 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire) 40 ❏ Other Metal (Rod/Bar, Bare Wire) 50 ❏ Electrical (Insulated Wire) 53 ❏ Communication (Insulated Wire) 55 ❏ Fiber Optics

FASTENERS, WIRE FORMING, FABRICATING 61 ❏ Fastener Manufacture 62 ❏ Four-Slide Forming 64 ❏ Hot and/or Cold Forming and Heading 66 ❏ Spring Manufacture 68 ❏ Wire Cloth Mesh Screening 69 ❏ Other Forming and Fabricating Please Specify ____________________________ SUPPLIERS TO THE WIRE INDUSTRY 72 ❏ Machinery 74 ❏ Process/Materials 76 ❏ Accessories

WIRE END-USER 11 ❏ Appliance 12 ❏ Communications (Voice/Data) 13 ❏ Computer 14 ❏ Construction/Building 15 ❏ Electrical (Equip./Components/Power) 16 ❏ Transportation/Vehicular 17 ❏ Wire Formed Durable Goods OTHER 80 ❏ Service Cntrs, Distrib.& Warehouses 90 ❏ Consultants 92 ❏ Govt., Library, others allied to field

➌ EVENT REGISTRATION: This section must be completed for proper processing. * Advance (on or before April 19), (On-Site after April 19)

(Check Items)

Note: Member rates are available to members of WAI, IFMSA and IFI.

New WAI Member Applicants Plus Full Registration (BL/AEM) Includes Exhibits, Opening Reception, Awards Breakfast, Technical Sessions, Proceedings, and one year WAI membership

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✓ ❏

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*advance

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DT RCD

5K Road Race Charity Event (FKR) Tuesday, May 8; Proceeds to charity

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Hotel Reservation Form Deadline: April 30, 2007

May 5-10, 2007 • Cleveland, Ohio, USA Complete this form and mail, call or fax (one copy per room): MAIL: Interwire/IFE Housing Bureau 50 Public Square, Suite 3100 Cleveland, OH 44113-2290

PHONE: Toll Free: 866-413-5152 International: (001) 506-637-0317 FAX: (001) 506-433-3033

HOTEL 1. Renaissance Cleveland** (headquarters hotel)

MEMBER RATES* SINGLE/DOUBLE

NONMEMBER RATES SINGLE/DOUBLE

$149/$149

$159/$159

2. Hyatt at the Arcade

$148/$158

$158/$168

3. Cleveland Marriott at Key Center**

$156/$156

$166/$166

4. Crowne Plaza City Centre

$125/$125

$135/$135

5. Marriott Cleveland Airport**

$134/$139

$144/$149

6. Radisson Airport North Olmstead

$ 80/$ 80

$ 90/$ 90

7. Sheraton Cleveland Airport

$129/$129

$139/$139

EMAIL Send reservation to: housing@travelcleveland.com INTERNET Register online at: www.wirenet.org

*MEMBER RATES Enter your member number (WAI, IFMSA, IFI) below. If the number is not indicated, the nonmember rate will apply. Member Number ______________________________________

** Smoke-Free Facility Shuttle bus service will be provided to and from all convention hotels and the I-X Center.

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Reservations will be processed on a first come, first serve basis. If all three requested hotels are unavailable, please process this reservation according to: ❏ Comparable room rate. ❏ Proximity to conference site.

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(Please print clearly) Confirmations will be sent after each reservation booking, modification and/or cancellation. Review it carefully for accuracy. If you do not receive a confirmation via e-mail, fax, or mail within 14 days after any transaction, please contact the Housing Bureau.

Check-In Date

Name: ____________________________________________________________________________

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1st Choice

2nd Choice

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3rd Choice

City: _______________________ State: ___________________ Postal Code: ____________________

➋ROOM INFORMATION

Country: ___________________________________________________________________________

Please list names of all occupants in room and type of room. Only one room per form. Room occupants:

Telephone: _________________________________________________________________________ Fax: ______________________________________________________________________________

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❏ Single

❏ Dbl (2 ppl/1 bed)

[ _____________________________________________]

❏ Dbl/Dbl (2 ppl/2 beds)

Room type & special requests based on availability at Check-In. SPECIAL REQUESTS ❏ Smoking ❏ Disabled ❏ Other (specify) ______________________________

➎ HOTEL INFORMATION

PLEASE READ CAREFULLY - HOUSING DEADLINE IS APRIL 30, 2007.

➌ DEPOSIT INFORMATION A credit card must be provided with each reservation request. Requests received without a valid credit card number will be returned and will not be processed. Please fill out the credit card information including expiration date. Credit Cards must be valid through May 2007 in order to be considered a proper guarantee.

Credit Card Number:__________________________________________________________________

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ROOM RATES/TAXES To take advantage of Interwire rates, be sure to book your reservation by April 30. Rates are subject to a 15% tax (subject to change). Hotels may charge additional fees for additional occupants. MODIFICATION/CANCELLATION Continue to modify and/or cancel reservations through any of these methods with no penalty until April 30, 2007 at 5pm eastern/standard time. After this time, please contact your hotel directly. Cancellations made AFTER April 30th will incur a $15 cancellation fee. In addition, any cancellations made within 3 days of scheduled arrival date may have credit card charged one night’s room and tax. Do not contact your hotel until after April 30th, they will not have record of your reservation until then.

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M EMBERSHIP A PPLICATION Send application and payment to: THE WIRE ASSOCIATION INTERNATIONAL, INC. 1570 Boston Post Road, P.O. Box 578 • Guilford, Connecticut 06437-0578 • USA • Telephone: (001) 203-453-2777 • Fax: (001) 203-453-8384

4c, file name: HAmemForm03,

Individual Information LAST NAME

page 32

FIRST NAME

TITLE

M.I.

COMPANY

❏ BUSINESS OR ❏ HOME

ADDRESS

CITY OR TOWN

STATE

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

ZIP/POSTAL CODE

COUNTRY

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

[

] BIRTH DATE (MM/DD/YYYY)

Required to receive The WAI Connection member e-newsletter

Business Information (required)

GENDER (M/F)

REFERRED BY

A. Which ONE of the following best describes your company’s type of business? WIRE MANUFACTURING FASTENERS, WIRE FORMING, FABRICATING 10 ❏ Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) 61 ❏ Fastener Manufacture 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) 62 ❏ Four-Slide Forming 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) 64 ❏ Hot and/or Cold Forming and Heading 40 ❏ Other Metal (Rod/Bar, Bare Wire, Both) 66 ❏ Spring Manufacture 50 ❏ Electrical Wire & Cable (Insulated Wire) 68 ❏ Wire Cloth Mesh Screening 69 ❏ Other Forming and Fabricating (Please specify) 53 ❏ Communications Wire & Cable (Insulated Wire) 55 ❏ Fiber Optics SUPPLIER TO THE WIRE INDUSTRY 72 ❏ Machinery 74 ❏ Process 76 ❏ Accessories B. Which ONE of the following best describes your primary job function? 10 ❏ General & Administrative Management 30 ❏ Technical, Research & Development, Quality Control 20 ❏ Engineering, Operations, Production 40 ❏ Purchasing

WIRE END-USER 11 ❏ Appliance 12 ❏ Communications (Voice/Data) 13 ❏ Computer 14 ❏ Construction/Building 15 ❏ Electrical (Equipment/Components/Power) 16 ❏ Transportation/Vehicular 17 ❏ Wire Formed Durable Goods OTHER 80 ❏ Service Centers, Distributors & Warehouses 90 ❏ Consultants 92 ❏ Government, Library and allied 50 ❏ Sales & Marketing 90 ❏ Other (please specify)_________________________

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

DATE

Student Membership — Available to students enrolled full-time in an institution for advanced education and who have an interest in the processes, techniques, and methods for the manufacture of wire. Dues waived with proof of enrollment.

INSTITUTION

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Chapter Membership WAI Chapters provide additional networking and educational opportunities on a regional level. Please select appropriate chapter and complete dues line below. ❏ New England US ❏ Mid-South US ❏ Midwest US ❏ Ohio Valley US ❏ Southeast US ❏ Western US ❏ Poland ❏ India

❏ Italy

Membership Dues Calculation Membership Dues:

❏ One year: $95

SAVE! ❏ Two years: $175

MORE SAVINGS ❏ Three years: $255

Chapter Dues (indicate chapter above):

❏ First year: free

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❏ Three years: $30

INDICATE AMOUNT:

NOTE:

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Your membership includes a free subscription to Wire Journal International. Please return this form by fax or mail for proper credit.

Reference Guide

NOTE: All checks must be in U.S. Dollars drawn on a U.S. bank. Credit card payments are preferred for members from outside the U.S. and Canada. If a check or credit card is not used, a wire transfer may be sent in U.S. dollars. For instructions, contact the WAI Membership Department at membership@wirenet.org or by phone at (001) 203-453-2777. Your membership dues may be deductible as an ordinary and necessary business expense, not as a charitable contribution. Membership in The Wire Association International, Inc. is held by the individual, not the company, and is continuous unless cancelled in writing. Membership is not transferable. Dues are non-refundable and are billed annually based upon the member’s anniversary date. Annual dues are set by the WAI Board of Directors, and are subject to change.

February 07

International Technical

Conference Proceedings

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Testing & Measuring Manufacturers seeking testing & measuring equipment have a wide range of suppliers to contact. Advances in electronics and software have made for more equipment that can help reduce scrap and wasted product. Below, suppliers highlight their technology as well as offer some comments on their field. This story also marks the first effort by WJI to “morph” a feature by offering content on the web at wirenet.org that will not be in the print magazine. The section starts on p. 49, where there are two flow charts, one for a ferrous line and the other an extrusion line, and continues on the web. If you like the format or have ideas on how it could work better, please send an e-mail to editorial@wirenet.org. ACM/HOWAR Equipment In-line measurement tools serve a purpose, but have limited measurement accuracy as readings are taken in 2 or 3 axes only, calculated from 500 to 2000 measurements and filtering odd low values, making it quite possible that the true dimension escapes this measurement. A true and accurate measurement of conductor/cable diameter, wall thickness, eccentricity and cross section can only be reliably achieved through off-line measurement. While traditional off-line measurements are done mostly with manual processes such as profile projectors, pin gauges and microscopes, there is an alternative: KSM computer-assisted technology from The KSM off-line Sweden’s ACM, system from represented in Sweden’s ACM. North America by Canada’s HOWAR Equipment. The KSM provides off-line measurement of insulation as well as jacket cross section verification that is required to comply with the various certifications such as UL and CSA. The system serves as an invaluable

Web powered

tool to monitor and adjust the actual extrusion output. The highly accurate measurement and data acquisition system uses a high definition camera to visually capture and then calculate the exact dimensions of the sample insulation slice to an accuracy within 0.2%, compared to manual measurements that usually have a statistical accuracy of 5-7%. The KSM is also much faster, taking about two to three seconds, whereas manual measurements need anywhere from 5-30 minutes. This technology is important because it means that these samples and measurements can be used to verify the in-line system. With that, one can identify “over insulation” for each product and reduce the 4-5% of insulation material given away for free each year. The KSM unit goes well beyond simply measuring by adding each measurement into an appropriate database with the capability of graphically displaying trends and other statistical data. By having easy to follow trends and statistics, managers, operators and quality control personnel may work together quickly and efficiently at implementing change in order to maximize savings on the extrusion line.

tion upon which to build an applicationspecific system, provides: high-performance optics with standard per facet calibration for the highest achievable accuracy and low drift at rate of 2400 scans/second; sophisticated measurement software including STAC (Stranded, Twisted, Armored and Corrugated) Logic for accurate meas- Beta LaserMike’s urement on AccuScan 5010 system. complex geometries; rugged case construction sealed to NEMA4 and IP65 standards; ultra-bright integrated display and operator interface; integrated air purge for extended operation; and flexible communication for easy integration anywhere.

Beta LaserMike

Clinton Instruments

U.S.-based Beta LaserMike’s line of non-contact AccuScan gauges is legendary for consistently accurate diameter measurements, minimal maintenance requirement, extraordinary reliability and an expanded field of options and accessories. AccuScan 5000™ gauges can be used by wire and cable manufacturers anywhere in the line where diameter and ovality parameters are critical. Advanced DSP based electronics is utilized to provide exceptional accuracy and high-speed communication via RS232, DeviceNet, CANopen, Profibus and Ethernet protocols. This flexibility ensures that there is always an optimal solution for getting data to the system of your choice of a PLC, PC, or Beta LaserMike controller. Because it is digital, the transmission is error-free, untainted by electrical interference or signal degradation. The DSP architecture also provides sophisticated data processing capabilities, such as in-head tolerance checking, flaw detection, and FFT analysis. The AccuScan 5000, the founda-

Spark testers for today’s applications must be flexible in setup, communications, and process control options. Wire and cable products vary enormously in size, shape and complexity, and production line space is always limited. Spark test equipment must be flexible in configuration and space efficient. Different communications systems in the modern production line demand equipment that can relay fault information by analog signal as well as a variety of digital communication protocols. Clinton’s HF-15A High Frequency Sine Wave Spark Tester was designed to meet

Clinton Instrument’s HF-15A high frequency sine wave spark tester.

FEBRUARY 2007 47

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Supplier observations Aside from the obvious need, such as starting up a new product line, how should a manufacturer be able to determine whether it is time to upgrade its testing & measuring equipment? Often, the sensor is adequate but the data processing is inadequate. With LaserLinc’s TLAser400 Interface and Total Vu Software, an old laser micrometer can provide previously unseen feedback on the process and product, at low cost. However, if you’re using a single-axis micrometer to measure jacketed wire or cable, a dual axis or even a triple axis Triton™ Micrometer can provide substantial benefit. Upgrading to higher speed measurement with rates as high as LaserLinc’s industry leading 8000 measurements per second can also be beneficial. LaserLinc. Continuous improvement programs demand adequate test and measuring equipment. Most wire and cable products undergo a series of production steps from primary extrusion to packaging, yet spark testing is usually done only when compulsory. Manufacturers who want to improve quality and eliminate waste will add spark tests at key production points to instantly find flaws and damage, minimizing the possibility that imperfect components will be further processed into expensive assemblies. Clinton Instruments. There are basically two strong reasons for upgrading the testing & measuring equipment: payback and product development. Through payback calculations the manufacturer should be able to learn about the immediate payback period of upgraded testing & measuring equipment, either only assuming the use of present production means or both upgrading the testing & measuring equipment and production means. Product development issues often bring up questions that can only be answered by use of upgraded testing & measuring equipment. Conoptica.

48 WIRE JOURNAL INTERNATIONAL

today’s production challenges. Small in size, it will fit almost anywhere it is needed on the wire line. The HF-15A may be purchased as an all-in-one unit or as two pieces, with the controller located up to 200 feet from the test module or PLC. Wiring and setup are done externally—no need to open up the unit. Digital readouts, visual/audible alarms, and flexible onscreen programming for extrusion or rewind applications simplify daily operation. Through a standard RS-485 port, the HF-15A can receive and respond to digital commands from a computer or PLC, or it can be equipped with a plug-in analog, Ethernet or Profibus communication module. These modules allow a PLC or computer to receive fault information, control and monitor the spark tester’s voltage, and activate or shut off external devices such as respoolers, lights or alarms when a fault is detected. Bead chain, brush, and roller assemblies are available to accommodate the wide range of product shapes and sizes. Conoptica Conoptica is launching several new production and quality control systems aimed specifically at the challenges facing the shaped wire and rod industry. It is necessary to measure both the drawing die and

out with reference to exactly the same definitions and coordinate ranges, and simplifies the task of modifying the die so that the nominal product geometry can be achieved. It makes tool making more cost effective, especially in the finishing stage where measurements play an important role. It also improves the communication between toolmaker and wire producer through objective comparison between tool and product. Tool making skills are accumulated while human measurement errors are reduced to a minimum. Conoptica offers systems for fast, accurate and low cost measurement of round/shaped die and/or wire diameter to high end 3D full profile measurement of any geometrical object (drawing/shaped/enamelling die/wire/rod/ pin/needle/tube) within system specifications (0.010 mm–400.00 mm). EddyTech Systems Inc. EddyTech provides reliable eddy current testing equipment for continuous, in-line inspection of wire and rod in diameters from 3–35 mm (0.125–1.375 in.) as well as bar up to 130 mm (5.114 in.). For wire and rod products the best method of detect-

A view of Conoptica’s technology for shaped wire and rod..

Prüftechnik AG’s RS35SH rotating system, available through EddyTech Systems, Inc.

the product for efficient quality control of shaped wires and rods. If the wire or rod dimensions deviate from nominal values, the drawing die might need modification. A quality control system that can measure corresponding parameters for both product and tool is needed to specify the correct drawing die parameters. Conoptica’s quality control system is perfectly suited for this task. Measurements are closely linked through a common model for both product and tool. This ensures that measurements of corresponding parameters are carried

ing long but shallow surface defects is with a rotating probe system. This technology enables the high speed RS35HS rotating system to detect a notch as small as 30 µm (0.0012 in.). By scanning the test piece in a helical pattern, it generates a defect signal each time a probe crosses a flaw, such as a seam defect. As a result, the rotating system generates consecutive signals that can identify both the length and relative severity (depth) of the flaw. Signals appear on a color touch screen display in real-time. The length of the shortest detectable defect

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depends on how the test piece is scanned. Ideally the probes should cover the entire surface without leaving any untested zones. This is a function of the rotational speed of the probes and the production speed, with the shortest defects detectable at higher rotational speeds and lower production speeds. Defect detection also depends upon surface quality, and polished or ground surfaces yield the greatest sensitivity to minor flaws. The rotating system is essential in production lines where longitudinal defects (cracks, seams, laps, etc.) in the material surface are of major concern. Due to its high resolution and transverse movement across the crack (rather than along it), the rotating system finds defects sometimes missed by conventional “through-coil” systems.

Emmerre/Lesmo Machinery North America France’s Emmerre s.r.l, represented in North America by Lesmo Machinery North America, offers a range of testing equipment. One notable unit is its MH30-AH1 model for electronic length measurement that is suitable for production and rewinding cable lines. It has a strong steel base supporting the system in contact with the cable. The system, which includes a metric calibration device, has two crown pulleys complete with encoder. Pulleys are connected via a belt. Various models are available for diameters from 10-50 mm, 20-100 mm and 30-120 mm at speeds of 500, 300 and 150 m/min respectively. The model

Emmerre s.r.l.’s MH30-AH1 model for electronic length measurement.

measures produced lengths, indicates line speed, calculates weight of product, offers bi-directional count and preselects partial or total length measurement. A second model, the spark tester,

Testing & Measuring: to be continued -- on the Internet Suppliers in this feature have been offered the opportunity to present technology they would recommend for the hypothetical lines (tire cord and primary extrusion) shown here in the two flow charts. They were asked to note what piece or pieces of equipment they would suggest using for the chosen line and why, the focus on being practical. They were also asked to point out potential aspects that manufacturers should be especially aware of, and to explain how their equipment can help. To see their responses, go to www.wirenet.org, and click on the icon of the February issue cover.

Tire Cord Manufacturing

Tire cord chart courtesy of RMS Consulting, Inc. Extrusion chart courtesy of Hitachi Cable Manchester.

Insulating Extrusion Line

FEBRUARY 2007 49

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is installed on insulated and sheathing cable lines to detect faults on electric single core cable. It can identify the kind of spark detected and whether it is due to low insulation (fault) or to residual humidity on cable insulation. In the latter case the spark is not recorded as a fault, but indicated and identified on a separate display. Instron Instron® responds to the needs of wire manufacturers by developing side acting grips for use with Instron’s KN Series of universal test machines. The side acting grips feature long jaw faces and clamping forces up to 900 kN (202,300 lbf) for positive gripping of single wires or multi-wire strand with no slippage. The side acting design also eliminates problems associated with traditional wedge grips that include grip failures, time-consuming grip changes and inaccuracy of total elongation measurements. The open front design makes loading specimens easy and efficient. The KN Series

50 WIRE JOURNAL INTERNATIONAL

machines feature a crossheadmounted actuator that brings the test space to a convenient working height without pit mounting. The dual-acting actuator controls the movement of Instron’s 600KN unithe upper versal testing machine with 600 kN side acting grip with grips. testing and return speeds up to 200 mm/min (7.87 in/min) for fast, efficient testing. Instron also offers a variety of extensometers for wire testing including clip-on and non-contacting video. With these devices, material properties, such as extension under load, modulus, offset yield and total elongation, can be

determined automatically by the system software. Machine control, data acquisition, automatic result calculation and reporting are handled by Instron’s Partner™ or Bluehill® software and the industry leading 5500 control and data acquisition system. The testing system conforms to international testing standards, including ASTM, ISO, BS, EN, DIN and others. LaserLinc A LaserLinc diameter measurement and control system offers accuracy, the highest measurement rates in the industry and excellent features and benefits for the best return on investment. The system starts with the laser scan micrometers. Depending on the wire and cable application, the system may be outfitted with several micrometers, up to 16, for monitoring multiple wires from one or more production lines. Examples range from a magnet wire line producing 20 or more wires; a wire draw installation monitoring 16 wires from a single PC; a THHN line

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employing 4 micrometers to measure core wire, PVC, nylon and final diameters and both wall thicknesses; to a simpler wire jacketing operation measuring hot diameter only. The micrometers are connected to a standard windows-based PC containing LaserLinc’s TLAser400 Interface Card, running Total Vu™ Software. This unique combination improves quality and cuts costs for wire and cable producers by providing: 100% inspection of diameter and short-term defect detection from one device; complete process analysis using real-time SPC statistics

An assortment of equipment offered by LaserLinc.

and charting, attribute data collection, and Process Tracker™ Event Reporting; Profit Maximizer™ Feedback Control for optimal product quality at minimal material costs; and detailed reporting of product quality including charts, statistics and permanent electronic records of raw data from every run. A LaserLinc system is a comprehensive tool to satisfy operator, engineer and management needs. Magnetic Analysis Corporation Magnetic Analysis Corporation’s Minimac® MAC 40 eddy current tester is a simple, economical production line testing of wire, ideal for locating welds and continuity checking of single-and multi-conductor insulated wire and cable. The Windows® XP based, single channel eddy current tester’s standard frequency range is 2.5 Hz to 200 KHz. Optional extended range software can increase this to 2 MHz. Sensitivity, phase, and filter are easily set while viewing a full color polar and linear display of real time test wave form signals on

The Minimac® MAC 40 eddy current tester.

the optional monitor. The Minimac MAC 40 tester can save, annotate, transfer, or print test data on site or at remote locations using the keyboard or optional keypad and standard computer interface procedures. An infinite number of setups can be stored on the hard disk and recalled with the touch of a button. Test reports can be created and edited for batch or setup information by the user in easy-to-use Excel® spreadsheet format. With the addition of PC Anywhere® software, one or more of the testers can be completely controlled and operated from any computer. It is also suitable for networking on most company network environments. The tester’s high

State-of-the-art equipment for the latest in stranding, twinning & cabling solutions. HK-560L Horizontal Double Twist Buncher for manufacturing Unilay and Concentric Wire strand.

Simple e to install,, operate and d maintain. PV6D Backtwisting Payoff capable of handling up to 24” reels for LAN cable. Backtwisting to get you where you want to be!

Features: • Rugged construction with steel bow design allowing for lower friction and gentler wire path. • Use of 3” diameter Sheaves throughout the entire wire path. • Automatic take-up tension control, variable in 256 steps, from empty to full reel. Load cell is available on HK-560 models. • Complete selections of machines for Ultra thin wire, Unilay and Concentric, Litz, automotive, medical, twinning and cabling in tubular, single or double twist. • Complete systems are available with our state of the art tension control payoffs: single, multiwire, twinning, cabling and backtwisting.

KINREI

of America LLC

KINREI of America 26 North Center St., Orange, NJ 07050 Tel: 973-677-9500 ext 143 • Fax: 973-677-2360 • www.kinreiusa.com

FEBRUARY 2007 51

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frequency option includes an additional allphase threshold, bridge drive, band pass filter, and a “system-not-ready” control of the common relay output. Additionally, a sync input synchronizes the linear display to a rotary probe test mechanism, such as MAC’s Rotomac® rotary eddy current tester. For more demanding wire applications MAC also offers the MAC 175, one or two channel eddy current tester and the ERIC VI four channel high frequency equipment. MTS Systems Corporation U.S.-based MTS Systems Corporation, whose equipment is appropriate for performing static (monotonic) testing of any wire specimen at loads between 0.1 and 300kN, has made several recent additions to its MTS Insight™ line of electromechanical testing solutions, enhancing the overall utility of the offering and providing customers with accurate and reliable solutions to virtually any static testing challenge they encounter. The recently introduced additions include: High-Force, twin-

MTS’s line of insight electromechanical testing solutions.

column floor-standing models for 100, 150, 200 and 300 kN applications; extended length models, available in 1, 2, 5, 10 and 30kN force capacities, for high elongation test applications; high-speed models, available on 2 kN Extended Length, twin column frames for testing of high strain specimens with increased productivity; and wide configuration 50 kN models for testing multiple specimens, larger samples that

System Solutions Straighteners ER PO Rolls Guides Drives Preformers

Defined and reproducible roll adjustment for straighteners. Do you waste time and material on setting up your straighteners while producing bad quality? Simple methods to preset defined straightener roll positions result in large advantages in the routine of wire processing.

WITELS-ALBERT USA Ltd. Phone: 410 228 8383, FAX: 410 228 1813 info@witels-albert-usa.com, www.witels-albert-usa.com

52 WIRE JOURNAL INTERNATIONAL

require a wider envelope, or accommodating an integrated environmental chamber. The MTS Insight solution integrates a leading edge electromechanical load frame technology with best-in-class TestWorks® software to perform static tests on a wide array of materials, such as plastics, metals, adhesives, ceramics, composites and elastomers, as well as subcomponents and finished products. TestWorks provides test engineers with the flexibility to create, customize and share test methods to meet both industry standards and unique testing requirements. Alternatively, test engineers can save development time and effort by turning to MTS for custom designed or pre-packaged methods. Proton Products Int’l/ Weber & Scher As more cable manufacturers concentrate on reducing cable “give away” and focus on material consumption, Proton Products International, represented in North America by Weber & Scher, is able to provide a range of products to measure diameter,

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length, speed, spark faults, lumps, neck downs, as well as providing pre heating technology and a comprehensive range of diameter control systems. The InteliSENS SL2550 Laser Doppler Speed and Length Gauge has been successfully introduced to cable makers as far apart as New Zealand and New England. The positive feedback in the user friendliness of the SL2550 has been excellent, the “In – Head” Digital Signal Processing (DSP) means all the measurement and processing is done right in the gauge and this allows Proton Prod-

ucts International to offer an indicator that can be fitted directly on the gauge. This gives the operator a clear view of the cable length when working at the take up end of the extruder. While the PSU-ARQ unit provides analogue outputs of speed, three quadrature pulse outputs, RS232 and relays for pre set length 1 and 2 as well as gauge diagnostics. Additionally the ARQ features a USB port for connecting the gauge to a PC. Profibus, Ethernet IP and DeviceNet are all available for integrating into a PLC or Network. The company also offers PCIS PC software that displays, trends and datalogs the speed and length data that is measured by the InteliSENS SL Series of Non Contact Speed and Length gauges. SIKORA AG The arrival of the X-RAY 2000 in 2004 ushered in a new answer to a demand cable producers have had for years, and the high degree of success of this product has demonstrated the importance of this issue. The X-ray’s physics are not influenced by any ambient changes, the technique used

Proton Product’s InteliSENS SL2550 Laser Doppler Speed and Length Gauge.

SIKORA AG’s X-RAY 2300 model.

by SIKORA requires absolutely no calibration and the system is easy for the operator to use. Making the application simple is the key to success. Making such a step change in the technology available for an application is the most exciting motivating factor for customers looking to upgrade their existing line instrumentation. The X-RAY 2000 brings X-rays to the application in a very simple package. With 15 years experi-

QUEINS: YOUR BEST PARTNER FOR CABLE MACHINES MANUFACTURING RANGE FOR NEW MACHINES

Tubular stranders Rigid stranders: disc-type design Rigid stranders: fork-type design Rigid stranders: fast-loading design, by rows Planetary stranders Power cable drumtwisters Telephone cable drumtwisters Armouring lines Bow twister machines Skip stranders Pay-offs and take-ups portal traversing design bridge type design column-type design caliper-type design Rewinding lines Belt-type caterpillar capstans Single- and double-disc capstans Rotating caterpillar capstans for drumtwister-lines Taping heads for plastic- and steel tapes Transposed wire machines KEVLAR serving lines

A GENERATION OF EXPERIENCE IN MANUFACTURING WIRE AND CABLE MACHINES MADE IN GERMANY

NEW ENTRIES: First-class pre-owned drawing and bunching machines for sale: • • • • • •

HENRICH 12-wire line NH 1, MM 29 dies • NIEHOFF 2-wiredrawing rod drawing line 85, 14 dies NIEHOFF intermediate drawing machine M dies • NIEHOFF 8-wire drawing line MMH 101,30, 2525 dies NIEHOFF double twist bunchers 630 (24,8”) • NIEHOFF 8-wire drawing lineDMMH 80, 21 dies SAMP double twist buncher 560 (22”) • HENRICH 12-wire drawing line NH 1, 29 dies MALI planetary cage for 36 bobbins, ø 630 mm (24,8”) • NIEHOFF intermediate drawing machines M 30, 25 and NORTHAMPTON planetary cages, 24 bobbin cage, 17 dies ø 630 mm (24,8”) plus 24 bobbin cage; ø 800 mm (31,5”) • NIEHOFF fine wire drawing machines M5, 21 dies • QUEINS steel taping heads, NEW, 2 x 600 mm (23,6”) • NIEHOFF double twist bunchers D 630 • QUEINS belt type capstans, NEW, 8 kN, 12 (24,8”) kN, 15 kN, 20 kN pull • SAMP double twist buncher BM 630 mm and (6”), 560 L/D (24,8”/22”) • REIFENHÄUSER extruder, screw ø 150 = 25 For contacts in USA:

QUEINS & CO.

D-52156 Monschau QMS Inc. GERMANY Tel.: ++49 2472 8080 Miami, Florida Fax: ++49 2472 3014 Phone: ++1 305 665-2523 Email: info@queins.com Fax: ++1 305 740-9460 Homepage: www.queins.com e-mail: usa-info@queins.com

FEBRUARY 2007 53

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ence with the technology, safety, reliability and performance deliver results and value never seen with prior equipment installations. The X-RAY 2000 uses state of the art X-ray regression analysis to look at up to three wall thicknesses in a variety of applications in power cable jacketing lines, RF cable core conductor insulating lines and hose and tube lines. Where no process variables influence the performance of the system or the measurements, all the operator has to do is select a recipe, turn the system on and look at the measurement values. This ease of operation has resulted in immediate operator acceptance and impressive return on investments. Sjogren Industries Best known for its wire tooling, U.S.based Sjogren Industries also offers a torsion twist tester that rotates a wire sample about its own center to test the wire for brittleness, inclusions, hidden seams and other flaws. Sjogren offers three different models for wire diameters ranging from .010 in. to .750 in. (0.2 mm to 19 mm). The models feature: programmable counter with automatic forward and/or reverse capability; 12 possible twisting programs with memory of the complete cycle; a digital display and positive holding chucks with replaceable jaws; and interlocked guard to ensure operator safety. Benefits include: safe, automatic operation; consistent output test results; and ability to meet ASTM Test Specifications E558 and A930. The testers can be used whenever wire needs to be tested for brittleness, inclusions, hidden seams and other flaws for material such as high-carbon steel wire and copper and aluminum rod. The light duty

A TTT-312 torsion twist tester from Sjogen Industries.

54 WIRE JOURNAL INTERNATIONAL

model has an input range of .010 in to .090 in (.25 mm to 2.3 mm) at 450,000 PSI (3100 Mpa) max. tensile strength. The heavy duty model has an input range of .090 in. to .312 in. (2.3 mm to 8.0 mm) at 450,000 PSI (3100 Mpa), or with extended capacity up to .375 in. (9.5 mm) material at 220,000 PSI (1860 Mpa). The extra heavy duty model has an input range of .200 in to .750 in (5 mm to 19 mm) at 70,000 PSI (484 Mpa) tensile strength.

Zumbach Electronics Corp. Zumbach Electronics Corp., a subsidiary of Switzerland’s Zumbach Electronics AG, reports that its patent-pending, non-contact ODEX® 10 is a non-motorized concept for very accurate and reliable monitoring of insulation diameter and conductor eccentricity/concentricity during extrusion or other insulating processes of ferrous and non-ferrous conductors. It was developed based on Zumbach’s extensive experience

Witels Albert USA In the intermittent processing of straightened process materials in defined lengths, there is a trend toward the minimization of length tolerances. This objective can only be achieved if length measurements are taken directly at the process material at high speed. For that, Witels Albert USA offers the company’s low-cost LM 12 D

Zumbach Electronic AG’s patent-pending, non-contact ODEX® 10.

A schematic of Witels Albert’s LM 12 D digital length meter.

digital length meter that can be easily integrated in existing lines. While the process material is guided precisely by two roller guides, a rotary encoder along with an arrangement of metering wheels are used to measure the length. Depending on the specific process material size the LM 12 D, the LM 50 D or the LM 100 D unit should be used. The LM 12 D can be used for lengths to 12 mm, the LM 50 D to 50 mm and the LM 100 D to 100 mm. Encoder data: accuracy – 0.0036º/0.001%, output signal Type TTL, 5,000 impulses, Input Voltage 5 V, cable 1 m or 3 m radial, max. speed 12,000 rpm, protection Class IP 67 (housing) and IP 64 (shaft exit), max. temperature 100ºC.

with thousands of inductive EX-TEST and METREX® monitors, and ODAC® laser diameter sensors. ODEX measures eccentricity, diameter and ovality within a few microns (1µ = 0.001 mm [.00004 in.]). In applications of modern data cables Cat. 5-8 and many other cable products, this often decides if the product passes or fails Quality Control Requirements. Because of the outstanding linearity, the ODEX can be mounted stationary in most applications and without the need of a servo or mechanical tracking system to keep the product centered. The acquisition of the outer diameter in two axes is achieved with high frequency laser scanning technology while the measurement of the inner conductor position is performed inductively, utilizing several measuring coils. It is very fast ( 4 x 1200 magnetic readings per second, 2 x 1200 optical readings per second and 1200 synchronized concentricity values per second) and that it can be used for outside diameters as small as 0.08 mm (.003 in.). No recalibration is required and it is as easy to operate as a diameter gauge, able to be used on ferrous and nonferrous conductors. No servo mechanisms are needed and it comes in RS and PROFIBUS DP versions.

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Listings Below is a contact list, with an electronic contact, for suppliers whose product lines include testing and measuring equipment. The companies in this feature have listings with descriptions. To view them, go to www.wirenet.org and click on the image of the February issue cover. ACM A.B. Sweden N. American rep.: HOWAR Equipment sales@howarequipment.com

Easydur Italy www.easydur.com

MAGPOWR USA magpowr@magpowr.com

EddyTech Systems, Inc. USA rfisher@EddyTech.com

MTS Systems USA info@mts.com

Emmerre Srl France emmerresrl@libero.it N. American rep. Lesmo Machinery North America sales@lesmoamerica.com

Proton Products Ltd. U.K. sales@protonproducts.com N. American rep.: Weber & Scher www.webscher.com

The Eraser Company, Inc., U.S. www.eraser.com

Beta LaserMike USA sales@betalasermike.com

FMS USA, Inc. USA paul.smith@fms-technology.com

Benz Material Testing Instruments USA ted@benztesters.com burster GmbH Germany www.magtrol.com/burster

Foerster Group USA www.foerstergroup.com Force Measuring Systems AG/ FMS USA www.fms-technology.com

Cenith Germany www.cenith.com

Forming Systems Inc. USA www.formingsystemsinc.com

CERSA-MCI France www.cersa-mci.com U.S. rep.: Finoptics www.finoptics.com

HiVolt GmbH Germany www.highvolt.de

Clinton Instrument Company USA support@clintoninstrument.com

iNOEX Germany www.inoex.de

Conoptica Norway conoptica@conoptica.com

Instron Corporation USA www.instron.us.

Contrôle Mesure Systemes France www.cmseddyscan.com

LaserLinc USA www.laserlinc.com

Dynisco USA www.dynisco.com

Magnetic Technologies Corporation (MAC) www.mac-ndt.com

Rishikesh Alectromatic Pvt. Ltd. India sales@wireknitting.com SIKORA International Corp. USA sales@sikora-usa.com Sjogren Indsutries USA www.sjogren.com Taymer Industries Inc. Canada info@taymer.com Tinius Olsen Inc. USA www.tiniusolsen.com Vollmer America, Inc. USA info@vollmeramerica.com Witels Albert USA www.witels-albert-usa.com Zumbach Electronics Corp. USA sales@zumbach.com

INSIDE

March 2007

WIRE JOURNAL

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

INSIGHT:

Featuring: Interwire 2007 Preview

Make sure your company message is seen in all the right places beginning with the March Interwire Preview issue. To add an ad to your marketing mix in any upcoming issue of Wire Journal International (WJI) contact Bob Xeller or Anna Bzowski on WJI’s sales staff. Tel.: 001-203-453-2777 E-mail: bxeller@wirenet.org or abzowski@wirenet.org

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Improved wire rod properties resulting from controlled cooling in modern water box and Stelmor速 conveyor cooling system Advances in technology have made it possible to produce a wider range of steel grades that can be used either directly from the mill or with much less downstream work/costs. By W.P. Krejdovsky, D.M. Jones and B.V. Kiefer

echnical developments to the water T boxes and Stelmor controlled cooling con速

veyors on modern wire rod mill installations have resulted in practices for producing superior wire rod properties. The effectiveness of the Stelmor conveyor cooling is closely coupled with the temperature uniformity and controlled rolling conditions prior to the conveyor. When a properly cooled product with uniform austenite grain size is then introduced onto the Stelmor conveyor, the rod will undergo further controlled cooling, either retarded or fast depending on the grade, to determine the final as-rolled properties. The design of the Stelmor conveyor has undergone various developments to improve both the level and

uniformity of properties. Many of the latest systems are in continuous use on new high speed rod mills and in modernized mills. The mechanical property results for wire rod products from several of these systems are presented and compared. Introduction Over the last several decades, the wire rod industry has experienced tremendous changes in the rate of production of rod as well as in the quality of rod that is capable of being produced. Mechanical equipment innovations such as the No-Twist速 Mill in the 1960s; the Vee No-Twist速 Mill in the 1980s, mini-block technology, the high

Fig. 1. Effect of grain size on spheroidization rate6. 56 WIRE JOURNAL INTERNATIONAL

speed laying head, coil reforming developments and the Reducing/Sizing Mill in the 1990s have all contributed to the increase of finishing speeds in modern mills to over 115 m/s with associated increases in production capability. Other technological developments such as to the water-cooling boxes and Stelmor-controlled cooling conveyors have enabled the achievement of mechanical and metallurgical properties in rod products at high production rates that were previously possible only with expensive post-processing1-3. In recent years, newer advances include the use of high-efficiency, water-cooling nozzles, further Stelmor enhancements and improved process control systems to link together the water boxes and Stelmor-controlled cooling systems with the rolling operations. This type of combination leads to the ability to produce superior mechanical properties in a wide range of steels. The previous general consensus, that a wire rod mill only improved the properties of high-carbon grades but did little for other grades (or was even detrimental in some cases), is now changing. The modern mill is much more flexible and it is possible to improve the as-rolled properties of an everincreasing number of wire rod grades. This paper describes how developments in rolling mill equipment and processing technology have resulted in benefits to the as-rolled product properties of various grades, as well as providing significant sec-

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Fig. 2. Graph showing cooling rate of 5.5mm rod for standard Stelmor® cooling (dashed) and lead-patented (solid).

ondary processing advantages to the downstream end user. Modern wire rod mills To explain how improved properties are obtained, it is necessary to provide a brief history of the main developments on wire rod mills together with a description of a current ‘state of the art’ mill. This is done by reference to the key features that are responsible for controlling the properties of as-rolled wire rods. Water box cooling systems. Water boxes are used to either reduce stock temperature between rolling stands for purposes of controlled temperature rolling or for rapidly cooling the stock after rolling, prior to controlled cooling on a Stelmor conveyor. In general, the water boxes are used to retard grain growth, as a preliminary step toward the further grain size refinement during rolling or the development of the final product microstructure on the conveyor, as well as for minimizing scale formation. The number and placement of water boxes in the cooling line are dependent on the maximum rolling rate, maximum rolling temperatures and on the product requirements, factors that dictate the laying temperatures required. Ideally, the water boxes are controlled with a temperature control system designed to maintain a constant preset temperature after the boxes and therefore reduce variations in properties along the length of the product caused by temperature differences. Typically, a well-designed control system can maintain ± 10°C (± 18°F) or better at the laying head.

Fig. 3. Graph showing cooling rate of 13mm rod for standard Stelmor® cooling (dashed) and leadpatented (solid).

Stelmor® controlled cooling systems. The Stelmor process is a proven method for the in-line controlled cooling of plain carbon steel rods immediately after delivery from a rod finishing mill. This process offers the opportunity of controlling rod surface scale con-

Krejdovsky

ditions, metallurgical and physical properties. Several variations of the Stelmor process are available for processing in a rod mill. These are: • Standard Cooling, using forced air for high cooling rates;

Jones

Wade P. Krejdovsky is a metallurgist for the Rolling Mill Process Group at Morgan Construction Company, Worcester, Massachusetts, USA, where he has been since 2005. He previously worked as a Metallurgist for six years at SPS Technologies Aerospace Fastener Division, Jenkintown, Pennsylvania, USA. He holds a B.S. degree in materials science and engineering from Lehigh University as well as an M.B.A. degree for management at Saint Joseph’s University. At the time this paper was written, David M. Jones was a process metallurgist in the Rolling Mill Process Group at Morgan Construction Company, Worcester, Massachusetts, USA. Pre-

Kiefer

viously, he was Q.A. and Q.C. manager for Thai Special Steel Industry. He holds B.Sc. and Ph.D. degrees in metallurgy from the University of Newcastle upon Tyne in England. Bruce V. Kiefer is manager of mill process modeling & analysis at Morgan Construction Company, Worcester, Massachusetts, USA, where he has been since 1986. He holds a B.S. degree in mechanical engineering, plus an M.S. and Ph.D. in applied mechanics from Lehigh University. Bethlehem, Pennsylvania, USA. This paper was presented at WAI’s 76th Annual Convention, Boston, Massachusetts, USA. May 2006.

FEBRUARY 2007 57

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Table 1. Expected tensile strength of 5.5 mm (7/52”) rods. • Retarded Cooling, using insulated covers for slow cooling rates; • Natural Cooling; without forced air for intermediate cooling rates; and • Hybrid Cooling, using a combination of the other three modes. The entry to the Stelmor conveyor is defined by the inclined laying head, which forms the rod into rings and deposits them in an overlapping pattern onto a continuously moving roller conveyor. The rod temperature at the laying head is one of the most important parameters during the Stelmor conveyor process as it has a large influence on the scale condition and metallurgical properties of the final rod. Modern mills typically use a temperature range of 750-950°C (1380-1740°F), depending on the material being produced. For medium- and high-carbon grades where highest tensile strength is required, these grades will benefit from a large grain size. A laying temperature in the range of 850-920°C (1560-1690°F) is generally the case. Grades that benefit from a fine grain size, such as the hardenable steel grades, cold heading and spring steels products, benefit from lower laying temperatures in the range of 750-850°C (1380-1560°F); although thicker rod sizes may need a higher laying temperature in order to form good rings on the conveyor. Standard Stelmor cooling is controlled by the amount of air forced through the rod ring pack. The most effective cooling is provided through the use of centrifugal fans positioned below the conveyor with plenum chambers. Due to the physical nature of overlapping rings, the ring density varies from the edge to the center of the conveyor, with the highest density occurring at the outside edges of the conveyor where there is maximum ring contact. As a result, more air is needed at the edges of the conveyor than

58 WIRE JOURNAL INTERNATIONAL

at the center4,5. Air distribution systems such as the Optiflex System, which directs air flow within the plenum chamber, or the Optimesh System, which distributes the air just below the nozzle deck, are designed to improve the cooling uniformity of the rod and therefore around-the-ring tensile uniformity. Insulated covers on the conveyor provide a means for reducing the cooling rate to obtain a microstructure yielding the lowest possible tensile strength. Covers are used with grades such as plain low carbon to achieve a large grain size, alloy steel grades to attain a microstructure consisting of ferrite and pearlite, and high Si-Mn welding rod to reduce the chances of forming retained austenite and/or martensite which have a negative impact on drawability. In some cases, the use of covers can eliminate the need for subsequent heat treatment operations, such as annealing prior to cold heading. Ancillary equipment and metallurgical principles As significant as the impact of modern water box and Stelmor air-cooling conveyors are on rod properties, these features cannot be discussed in isolation without reference to Reducing Sizing Mills (RSMs) and the principles of thermo mechanical rolling in a modern wire rod mill. Reducing Sizing Mills. Reducing Sizing Mill (RSM) technology offers a unique system of high speed, close tolerance and thermo mechanical rolling of steel rods. This presents many advantages, including the opportunity to roll rods with a very fine grain size. The productivity and cost benefits of postNTM rolling are numerous, but some of the

specific downstream related issues include: • The reduced number of NTM stands being used minimizes the temperature buildup for small sizes, thus reducing the cooling required in the post-NTM water boxes, producing a more uniform grain size. • The unique patented pass design guarantees a precision tolerance of ±0.10 mm (0.004”), and an ovality of 0.10 mm (0.004”) for all product sizes, even on a twostrand mill. Mill operators can consistently produce rod within ±0.05 mm (±0.002”). • “Free size” rolling provides the rod producer with the ability to produce both inch and metric sizes from the same pass, within ±0.3 mm (0.012”). Thermomechanical Rolling (TMR). Modern high quality mills have the ability to roll at low finishing temperatures. The general term for this is Thermomechanical Rolling (TMR). This promotes grain refinement which can result in improved as-rolled properties, improved response to subsequent heat treatment and improved rod surface quality. To fully understand the benefits to the downstream user of wire rods, it is necessary to explain how combining the modern technology from improved water boxes, Stelmor-controlled cooling systems and RSM enhance the properties of many wire rod grades through TMR. Controlled rolling is a mechanical and metallurgical process used to improve as-rolled properties of the product. The improvement is realized by achieving fine grain structures in products by controlling both the steel chemical composition and the thermomechanical processing parameter. These two factors determine the final microstructure and properties of the material. The chemical composition determines the critical transformation temperatures and recrystallization rates, whereas the thermomechanical parameters control the kinetics of recrystallization and recovery through temperature and deformation. In the frequently encountered case where the chemical composition is fixed, as in customer-specified steel grades, properties and therefore product performance can only be controlled through thermomechanical processing. From the standpoint of the materials, the time-temperature-transformation behavior is the critical determining element for the evolution of the desired microstructure. From the process point of view, the control of deformation and equalized temperature are crucial to obtaining the proper path through the time-temperature-transfor-

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Fig. 4. Average 5.5 mm high-carbon rod tensile strength over three generations of Stelmor® cooling compared to lead patenting.

mation diagram to get the desired microstructure and properties. Grain formation. For the downstream user, fine grain size produces the following advantages: • The decreased transformation time to ferrite/pearlite microstructures, is particularly useful for many low-alloy grades susceptible to transformation to hard, brittle products, i.e., martensite and bainite, under normal rolling and retarded Stelmor cooling conditions. This would be applicable to such grades as AISI 4140, 5140, 5160, 6150, 8640, 9254, 9260, 52100, 50CrV4; • Direct production of ‘normalized’ structures suitable for some direct heading grades; • Reduction in the amount of carbon in supersaturated solution that can cause strain age-hardening due to the heat generated during cold-heading; • Reduction of spheroidize annealing times for cold-heading and bearing steel grades; • Elimination of grain-boundary cementite networks in hyper-eutectoid grades; and • Enhanced tensile strength and ductility of micro-alloyed, direct-drawn high carbon steels for applications such as PC strand, roping and spring wire. Spheroidize annealing. For some grades of steels subjected to subsequent cold forming operations, the as-rolled material must be spheroidize annealed to produced a soft, ductile microstructure sufficient for cold forming. This is a very time-consuming process, since spheroidization is a diffusion

Fig. 5. Graph showing Tensile Strength Range (dashed) and Standard Deviation (solid) on collected 5.5 mm data.

controlled process and is slower with increasing coarseness of the pearlite structure. Decreases in furnace time can be achieved with TMR due to the decreased time required for the conversion of fine lamellar carbides to spheroidal carbides. Fig. 1 shows that the rate of annealing can be reduced by up to 50% by reducing the grain size to less than ASTM 8 or < 22μm6. An ideal structure would be the smallest possible grain size with the finest pearlite, a combination that becomes closer to reality with TMR. Temperature control. A system such as the Morgan Enhanced Temperature Control System (METCS) provides monitoring and control of stock temperature to ensure that the correct mechanical and metallurgical properties are obtained accurately and con-

sistently throughout the process. By monitoring product speed and temperature, cooling water and air flows, pressures and temperatures, the system can provide real-time feedback for closed-loop control of cooling zones, from the furnace exit to the reform tub. Such a system provides uniform strandto-strand, billet-to-billet, and heat-to-heat temperature profiles to maximize the uniformity and consistency of properties thereby aiding downstream operations, such as wiredrawing. Wire rod grades, considerations The superior wire rod properties provided by the progressive improvements made to wire rod mills through the combination of water and air cooling systems and TMR in

Table 2. 13 mm AISI 1080 physical properties after different processing routes.

Table 3. 6.5mm AISI 1065 rod as-rolled properties for conventional and thermomechanical rolling.

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RSMs is best illustrated by considering two groups of steels: high carbon steels and hardenable steels, such as low-alloy, bearing, spring and welding wire grades Although this is an over simplification as several different types of cooling are now actually possible on a modern wire rod mill, as previously described, it serves to show the progress made. High-carbon steels. In the past, air or lead patenting was the normal process route prior to wiredrawing because of the higher and more consistent tensile strengths provided by patenting in comparison to rods available from wire rod mills. The lead-patented strengths were a function of the fine lamellar pearlite formed during isothermal transformation as a result of the relatively coarse austenite grain size and the high heat transfer coefficient during cooling. This enabled transformation to occur near to the nose of the isothermal transformation diagram. The Standard Stelmor® process produces a pseudo-patented microstructure. The rod is continuously cooled at rates of approximately 7-9°C (12-16°F) per second for larger diameter 14.2 mm (9/16”) to 20-22°C (36-40°F) per second, for small diameter 5.5 mm (7/32”) rod. This cooling rate is faster than that of air patenting. Thus, the microstructures obtained in the Stelmor process are intermediate between lead-patented and air-patented microstructures in regard to the proportions of the fine unresolvable pearlite and the coarser resolvable pearlite. Figs. 2-3 show a comparison of the continuous cooling curves for lead patented and Stelmor rods for sizes 5.5 and 13 mm, respectively. The slower cooling rates and resultant higher transformation temperatures of Stelmor rods are self evident. Lead-patented properties are regarded as the ideal properties to be achieved and, therefore, provide a definitive and comparative target to be reached from wire rod mills. For many years, the ultimate goal for high-carbon rod producers has been to achieve properties equal to the lead-patenting process, particularly on the thicker rod sizes. Over the past 40 years, progressive improvements to the as-rolled wire rod properties have been achieved through the design improvements to modern wire rod mills. The situation has now been reached where as-rolled wire rod can be used for virtually all direct drawing applications, there-

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by saving end users considerable costs as well as eliminating the serious environmental problems associated with either lead or fused salt baths. Current as-rolled properties are not only very close to the definitive target, but in some cases can be considered to be superior to traditional lead-patented rods. The properties are best referenced by considering two rod sizes. First, the most popular size, 5.5 mm (7/32”), which is used for general purpose high-carbon wire rods of many grades. Second is a large diameter rod, 13.0 mm (½’’), grade AISI 1080, which is used for PC wire and strand, and is one of the most difficult applications with respect to producing an as-rolled rod structure suitable for direct drawing. Small diameter 5.5 mm (7/32”). Table 1 shows the reported tensile strengths for high-carbon Stelmor® rods with carbon contents from 0.40% to 0.80%. This table represents nine different sets of reported results from operating Stelmor installations and also reflects results obtained from steels made by the basic oxygen, open-hearth, electric and Thomas processes. The tensile values have been adjusted to a nominal manganese content of 0.60% in order to create a common base. With a combination of steel chemistry and cooling control, it is possible to obtain both the strength levels and the consistency of properties that approach those of leadpatented rods. See Figs. 4 and 5. Fig. 4 shows that strengths have increased over the progressive generations of wire rod mills and that strength levels now approach lead-patented values. Current cooling provides as-rolled strengths of ~60MPa lower than lead-patented. Little further improvements can be expected, as the fundamental scientific basis is different during cooling to the transformation point– heat conduction for patenting and the less efficient forced air convection on the wire rod mill. The forced air cooling rate cannot be increased further because the rings start to “float” at faster rates, which then creates serious operational difficulties and the air delivery system becomes too large. For many applications, strength consistency is of paramount importance and not the absolute strength level for a given carbon content. In recent years, wiredrawers have changed the emphasis on required high-carbon rod properties for some grades from highest tensile strength to tensile strength uniformity, though of course not at the total expense of the former. There are continual

requests from producers for improved tensile strength consistency throughout the rod coil length. With good control of the overall process, the tensile variability levels now approach those previously obtained through patenting. For display purposes, 5.5 mm (7/32”) represents the best size to reviewing the improvements made with respect to tensile variability and the effectiveness of current systems, because it is the most popular size for a wide range of plain high-carbon steels used for many direct drawn applications, such as springs, spokes, ropes, baling and other general purpose wire. Being the smallest size, it is the most sensitive to cooling rate variations and, thus, shows the maximum tensile variation in as-rolled wire rod. Fig. 5 shows the tensile strength variation around one convolution (~3.3 meters in length) of 5.5 mm high-carbon rod. If the user demands a particular tensile, this can be given, albeit with an extra four or five points of carbon. Although this change would traditionally have had a reduced ductility, modern processing systems enable improved ductility at higher carbon levels compared to lead-patented properties. This is primarily achieved through the refined grain size made possible in TMR. Large diameter 1080 grade. High carbon steels at rod sizes 11 to 13 mm (7/16” and 1/2”) represent the most difficult application for accelerated cooling systems because of the heat mass that must be removed quickly from the product to enable the transformation to fine pearlite to occur. Fig. 3 shows a comparison of the continuous cooling curves for lead patented and Stelmor® 13 mm rods. Forced-air cooling on a Stelmor conveyor is a continuous-cooling process, not isothermal, and consequently cannot produce a truly ideal, uniform non-resolvable sorbite structure. The immediate goal therefore, is to improve the structural uniformity while not detracting from the necessary strength/ductility requirement of the wiredrawer. The normal aim is to start the final Stelmor cooling process at between 800-950ºC because of the required grain-size and scale requirements. In lead-patenting, scale is not such a major consideration because the rod-surface is largely protected from the surrounding air during heating and cooling. If, therefore, the process could combine a very fine grain-size with lead-patenting, the resulting rod could have both high tensile strength and ductility. This represents the ideal situation.

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At the larger wire rod sizes, one of the most popular grades is AISI 1080, which is used for PC wire and strand. Current asrolled properties are now equivalent to or even superior to traditional lead patented materials. See Table 2. For plain carbon steel, the as-rolled cooling rate is much below that achieved through patenting, resulting in a coarser pearlite and lower strength. However, it is of note that the ductility can be higher in asrolled rods, primarily as a result of the finer grain size. By modifications to the steel chemistry by micro-alloying, commonly with chromium and vanadium, and with fine process control, as-rolled properties can be achieved that are comparable to or even superior to patented properties. 6.5 mm AISI 1065. Thermomechanical rolling provides an opportunity to introduce a fine grain-sized rod onto the conveyor7. Table 3 shows data from 6.5 mm AISI 1065 rod for both a typical rolling (910°C) and a thermomechanical (820°C) rolling condition8. Both products were successfully drawn to 1.2 mm. Hardenable steel grades. TMR exploits one of the most basic metallurgical principles, but in a slightly different concept in a rod mill situation. Grain refinement is well known to be the only mechanism that improves both the strength and ductility of steels. However, on a modern wire rod mill some of the traditionally more hardenable steel grades are made softer as well as more ductile than on earlier generation mills. This is through minimizing the presence of hard, undesirable phases such as bainite and martensite. In doing this, the steels are much more amenable to secondary processing and downstream processes. For example, some grades can be processed directly to the end application without any prior or final heat treatments; whereas the spheroidize annealing times are reduced significantly for other grades. Some examples of typical grades and applications are: • Low alloy cold heading quality grades (such as 4140, 5140) are now available in a wider size range with tighter tolerances, and the as-rolled material is softer. Thus, some grades can be direct used whilst for other grades downstream operations, such as spheroidize annealing (S.A.) are much reduced. • For spring and bearing steel grades, the refined as-rolled structure has no hard phases and S.A. times can be reduced by >50%. • For alloyed welding wire grades, such as

AWS ER-S6, neither prior or intermediate heat treatments are necessary. Rods are available that can be mechanically descaled and direct drawn to the end product at sizes below 1.0 mm. Summary and conclusions It has been shown how modern wire rod mill technology of rolling through a RSM and using a combination of carefully controlled cooling through water boxes and air cooling systems produces an ever-increasing number of steel grades that can be either used directly from the mill or have significantly reduced downstream processing operations and costs. This is achieved through creating the most appropriate steel microstructure after rolling. Careful control of the entire reheating, rolling and subsequent cooling conditions must be maintained to enable this. Process conditions are established dependent on the steel grade and property requirements. Whereas the Stelmor® cooling systems have shown a progressive development over many years, creating a continual improvement of the properties of as-rolled high carbon wire rods, it is the more recent Morgan innovations that are now starting to show significant benefits for many other wire rod grades. These developments include: • Closed-loop process control systems of both the pre and post rolling water cooling systems, enabling much more precise temperature control through the last rolling stands. • Design changes to the water cooling nozzles, enabling more efficient and better control of the rod temperature. • Ability to roll to much tighter tolerances and at much lower temperatures than was possible on earlier generations of rolling mills because of advances from the Morgan RSM. • Improved Stelmor design to enhance both accelerated cooling for high-carbon grades and retard cooling for hardenable grades.

3. Y. Hanada, K. Ueno, A. Noda, H. Kondoh, T. Sakamoto. and K. Mine, “New Type Stelmor Equipment of Wire Rod and Bar Mill,” Kawasaki Steel Technical Report, No. 15, October 1986. 4. S.K. Cho. and S.W. Choi, “Effect of wire rod size and its packing density on the tensile strength deviation of high carbon steel wire rod in the Stelmor process,” Proceedings, Annual Wire Association International Conference, Atlanta, Gerogia, April 1987. 5. P. Hastings and J. Heerema, “Influence of test method, rolling conditions and steel chemistry on tensile variation for high carbon wire rod,” Proceedings, Annual Wire Association International Conference, Atlanta, Georgia, USA, May 2001. 6. K. Aihara, K. and S. Kanbara, “Influence of Prior Structure Upon Spheroidization Rate and Cold Forgeability of Annealed Wire,” Proceedings, 57th Annual Convention of the Wire Association International, Atlanta, Georgia, USA, October 1987. 7. R.A. Varo, W.P. Krejdovsky and B.V. Kiefer, “Thermomechanical Processing of Spring Steel Rod With Reducing Sizing Mills For Improved Properties and Microstructure,” Proceedings, Annual Wire Association International Conference, Boston, Massachusetts, USA, May 2006. 8. J.C. Vincent and B.V. Kiefer, “Improvements in Thermomechanical Processing for High Speed Rod and Bar Rolling with Reducing Sizing Mills,” Proceedings, AISE Annual Convention and Steel Expo, Nashville, Tennessee, USA, September 2002. ■

References 1. V. Vitelli, “The application of Stelmor rod to high-carbon wire commodities,” Wire Journal International, July 1972. 2. P.L. Keyzer and B.V. Kiefer, “Stelmor In-Line Controlled Cooling Process for high Speed Rod Mills,” Proceedings, ASM Materials Solutions Conference, Indianapolis, Indiana, Sept. 1997.

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The evolution of wiredrawing coolant filtration and increased wire production and quality As wire and cable products continue to evolve, so has filtration technology. This presentation traces those advances, notes what is now ‘state-of-the-art’ and cites the need for further advances. By Tom Horn

ince Thomas Doolittle developed the S first copper wire mill in 1877, the production of copper wire has undergone a stunning evolution, with significant improvements in production speed and quality of wire produced. The U.S. industry was driven in no small part by the innovations required to participate in numerous wars around the globe. Other nations followed suit and evolved technologically from advances in space exploration and the cold war military build up. All required improved technology to get ahead and stay ahead of their philosophically different competition. There was also an

insatiable appetite for more of everything technical to make life easier. According to the Copper Development Association’s website (copper.org), three quarters of all copper ever consumed in the known 10,000 year history of copper use, was after World War II . A large contributor to the increase of wire production and quality was improved filtration of coolants. By removing more and finer particulates there was less friction, more heat was removed, more and better quality wire was produced, and in addition longerlived dies and capstans saved time and money.

Fig. 1. Large over-under tank filter system, an early technology that required much space and long retention times.

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To understand this evolution, this paper will review the components to the wiredrawing filtration process and note how they have changed over the years, with advances in filter system equipment design, reliable controls and better forms of filtering media. In the beginning Tank retention was the typical means of solids separation. See Fig. 1. By letting the coolant reside in a very large tank for a very long time, solids would accumulate on the bottom of the tank. Drawing lubricants were soap-fat compounds and soluble oils that tended

Fig. 2. Schematic of hydro-cyclone filtration system, an upgrade from that in Fig. 1.

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Fig. 4. Schematic of vacuum filter, typically used for processes with higher flow rates.

Fig. 3. Schematic of gravity filter, typically used for processes with lower flow rates.

to form insoluble copper soaps that would pack dies and cause breaks. To allow solids separation, the tank would have residence times of up to 45 minutes. This method required vast amounts of expensive coolant; the tanks took up too much precious plant realestate and had to be cleaned out frequently. As is known now, the accumulated copper mud severely affected coolant performance and life. It was beginning to be universally recognized that by removing the copper in a continuous mechanical manner, there could be an overall process cost saving. Hydro-cyclones appeared in the next stage of evolution and did a fair job of removing solids. Typically grouped together to meet the required flow rate, the hydro-cyclones would separate the heavier solids, and periodically purge them into a small media conveyor. See Fig. 2. However, the hydro-cyclone had limitations and could separate only the larger particles. The finer particulate would by-pass the separator and over time would accumulate in the system. This eventually became intolerable when demands for increased production of good quality intermediate and fine wire increased. This increase required cleaner coolant. Current technology There have been continuous improvements in filter design, but the basic media type filter today is the industry standard for solids removal. Lubricant manufacturers strive for products that

not only lubricate and cool but provide good detergency, which has become highly desirable, as well as extends charge life. With that said, the need for advanced filtration methods are more important today than ever due to higher speeds, multi-wire production and modern dies that produce a high quantity of very fine particulate. The sizing of coolant maintenance systems is much more critical than in the past. This is especially true for multi-wire filtration systems, where efficient wire lubrication, cooling and particulate removal saves costly down time due to wire breaks. The filter is sized by the wiredrawing machine manufacturerâ&#x20AC;&#x2122;s required flow rate and the proper sq. ft. area of filtration for the application. For lower flow rates (50-200 gpm range), a gravity filter can be used to meet the requirements. See Fig. 3. With this type of filter, head pressure forces the coolant through the filter cake that is formed, removing the very fine particulate. The clean coolant will drain to the clean supply reservoir for transfer back to the drawing machine. This is done by a system clean supply pump that has to be properly sized according to the drawing machine manufacturerâ&#x20AC;&#x2122;s required pressure, with any lift or friction loss added to the equation. For higher flow rates (typically 150 gpm and up), a vacuum filter is used because it produces a thicker cake and remove more fines. See Fig. 4. This is due to the increased pressure differen-

tial across the media developed by the integral vacuum producer. For either unit, a liquid pool of coolant is formed on the media by the positive barrier side seals, and supported by internal rollers, as shown in Fig. 5. This retains the particulate on the media producing a filter cake, as shown in Fig. 6. Once the cake is produced, the very fine particulate can be removed. Only recently have manufacturers had the vast selection of filtration media to choose from to optimize their filtering process. There currently is a wide variety of filter media types available in the

Horn Thomas Horn is the technical sales manager for Filtertech, Inc., Manlius, New York, USA. He joined the company in 1998 as technical field engineer. With 25 years of engineering, sales, and marketing experience in the process equipment manufacturing industry, he has authored technical papers and numerous articles supporting the related industry associations. He has been an active member of Wire Association International since 1998. This paper was presented at WAIâ&#x20AC;&#x2122;s 76th Annual Convention, Boston, Massachusetts, USA, May 2006.

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Fig. 5. End view of seal assembly used to trap particulates.

Fig. 6. Formation of particulate on media that forms filter cake.

Fig. 7. Control package for typical sump transfer application.

Fig. 8. Schematic showing typical heat removal system

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process speed,and the best filtration to keep the coolant clean and performing at the highest degree of efficiency. Continuous improvements in filter system design, controls and filter media materials will advance as required with the advent of new and challenging applications in the future. Bibliography/Contributors Fig. 9. Example of typical process heat addition equipment.

global market that can fine tune the filtration process, removing even more particulate while remaining permeable. The different media types come in numerous materials, such as polyester, polypropylene, rayon, nylon and combinations (blends), of the aforementioned and cellulose. The materials are also produced differently, which can help or hurt a process. Some are spunbonded, point-bonded, layered, unidirectional, wet-laid and loft. All come in a multitude of densities for different applications and filtering expectations. System controls Today’s modern coolant maintenance system employs a combination of different processes that all come together. Besides the main job of filtration, it provides liquid transfer, coolant heating and cooling, level control, automatic lubricant and water addition systems and bacteria and pH control. Sophisticated control packages with programmable logic save time and increase system reliability, making life simpler for process workers. Although the typical system pump has changed little, the mode of pump operation has. Variable speed pumps used for coolant transfer are becoming more common and are made more practical due to good availability, lower cost and high reliability of electric control. Typically used for sump transfer applications, this control package provides a constant flow of coolant to the filter without the use of ball floats that require the pump to turn on and off repeatedly. See Fig. 7. A sensor is set to detect differing head pressures and sends a signal to the Variable Frequency Drive (VFD), that in

turn raises and lowers the pump motor speed and flow of coolant. The result is a very smooth delivery of coolant to the filter system. Proper system coolant temperature control requires both heating and cooling and remains an important factor in good coolant performance. Today, the typical temperature control package includes a tank heater that keeps the coolant warm during process down times and a plate and frame heat exchanger that precisely removes the heat from the process coolant. Both are controlled by electronic digital controllers that give a constant temperature read out and can be easily changed to suite any required temperature needed for optimum performance. See Figs. 89.

1. Copper Development Association, www.copper.org. Bibliography and thanks to contributors; 2. Giuseppe Marcantoni, EtnaBechem Lubricants, Ltd., general comments on the history and future of wiredrawing lubricants. 3. Joe Scalise, Filtertech, general information and illustrations from a previously published technical paper, “A Comprehensive Program for Reducing Wire Breaks Through Process Control and Effective Filtration.” ■

Tomorrow and beyond There is little doubt that wire production will continue to become even more efficient. Lubricants will continue to improve, providing stable performance in wider ranges of water conditions while meeting the increased speeds of production. New uses for copper wire products are being discovered every day. Superconductivity applications and electric vehicles are examples of very near future uses for copper products. The one constant will be that waste particulate will be formed from the process and the removal will be advantageous to the process. Conclusion Modern wiredrawing production practices require the producer to use every possible advantage to gain a profitable edge. This means having the right coolant, the right dies, the optimum

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Gaining market share in the energy sector Testing and measuring equipment is essential for manufacturers in India to make the quality power cable that is both needed now and for projected increases in electrical demand in India. By Premjeet Saggu and Knut Szemjonneck

This paper addresses the need for better

testing and measuring technology in India, where increasing demand for electricity makes it essential for power cable makers to provide this badly needed resource. The U.S.-based Energy Information Administration (EIA) predicts that worldwide electricity consumption will double from 2003 to 2030. Growth for mature countries is relatively slow, but China is expected to see its demand triple from 2003 to 2020, while India is expected to follow that trend. India, which has a vast and relatively cheap labor force, is expected to see its living standard continue to rise. As its population continues to grow, electrical demand, especially for private households, may climb by a multiple of four, the EIA notes. The Indian power market overall is rather

closed and regulated by the government which still needs to pump billions of U.S. dollars into power generation every year. Many villages are not connected to the electricity network and power cuts due to load shedding are a regular event in Indian cities. Official figures from 2003 show that about 27% of the electricity is lost in transmission but even the government admits that the figure may be closer to 50%. India loses more electricity in the transmission than is consumed by countries such Sweden, Turkey or South Africa. India’s electrical sector requires adequate and timely investments in generation and network infrastructure as well as repairs to the aging existing network. With GDP growth projected to climb 5.5 percent a year, energy planners project that India’s

Fig. 1. Global electricity consumption. Chart courtesy of EIA.

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generating capacity will need to expand sevenfold over the next 25 years, which will require massive spending on power stations and transmission lines. India’s cable market The total India cable market was US$2 billion in 2004, which represents about 2.4% of worldwide demand. (For a comparison, China’s market was about five times as big at that same timeframe.) India’s government estimates that it needs to invest more than US$20 billion for power cables from 2002 to 2012 as part of its 400kV expansion. China is believed to have more than 150 X-ray-based installed measuring systems for power cable production. In India this number is less than 10. The result is that the quality of power cable made in China

Fig. 2. Consumption by members of OECD versus nonmembers. Chart courtesy of EIA.

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Fig. 3. Electricity availability, use, and distribution loss, including imports/exports. Source: IEA.

is generally much higher. Power cable manufacturers in India need to use state-of-the-art measuring equipment to produce a higher quality cable that will convince private companies to invest in the energy network and to reduce the transmission loss to an absolute minimum. This will also result in fewer rejected cables and lower costs for service, repair and replacement. Cable quality parameters The need for reliable on-line measurement of cable quality parameters, especially for insulating and jacketing lines, is recognized worldwide. Such equipment should include: outer diameter gauge heads using laser technology; a spark tester; eccentricity and wall thickness measuring systems; and capacitance gauge heads. Specifications. Diameter, wall thickness, ovality and eccentricity are the most important factors for the quality of a cable. If these factors are out of the minimum tolerance, the resulting product does not meet required specifications and cannot be sold. Up-to-date measuring equipment, like laser diameter gauge heads, offers accuracy down to 1 µm. This extremely high precision allows a very accurate regulation of the extrusion process. Shielding and insulation faults. Cleanliness of insulating material is one of the most important quality criteria in the production of XLPE insulated cables. Many measures like the use of clean and super clean material have been taken, especially in the production of high voltage and extra high voltage cables, to reduce the contamination of the cable insulation.

Fig. 4. An electricity pylon in New Dehli.

Other problems are short interruptions of the inner semiconductor (strand shield) at the production of medium voltage cables. This phenomenon occurs occasionally at very thin insulation layers and is not safely detected at a discharge test. Such faults often are discovered by end-users, with unpleasant consequences. Pinholes. This is a small puncture in the surface or interior of a material. The insulation at this point is not optimal and there is some material missing to perfectly cover the conductor. Especially for power cable production, this can become a huge problem when after some time the insulation cracks down during a heavy load with high voltage. It would cause a shortout and the cable at that position will be destroyed and needs to be replaced. Periodic faults.These are faults occurring repeatedly in the cable with a certain frequency. For example, a periodical diameter change can be caused by a defective ball bearing in the payoff, the “pumping” effect of an extruder or a defective preheating unit with fluctuating temperatures, among other reasons. On-line FFT analysis, which will be described later, is an effective tool to find the cause of these periodic faults.

Cable cost parameters

Prem Saggu represents Sikora International at its office in New Delhi, India. Knut Szeernjonneck is area sales manager at Sikora’s headquarters in Bremen, Germany. He joined Sikora in 2006 after working more

than 13 years in the electronics industry. This presentation was made at WAI's International Technical Conference held in New Delhi, India, October 2006.

One vital goal is to correct problems cited earlier to reduce the amount of material that is unnecessarily consumed, the amount of start-up scrap and the percentage of cable that is rejected. All these factors have an influence on the overall production costs of a cable. Material consumption. The material costs make up the largest part in the overall production cost of a cable. If the production process is not well under control, to be on the safe side and not go below the minimum tolerances at any time, it is mandatory to put more insulation or jacketing material than necessary. As shown in Fig. 6, a small reduction of 80µm in the production of a 2 mm wall thickness can add up to savings of US$100,000 a year, depending on the material price, extruder output/hour, the overall production time per day and production days per year. Examples for returnon-investment calculations can be found on several websites in the internet, e.g. at www.sikora.net. Start-up losses. In a ramp-up phase of a production line, the parameters like material temperature or extruder output may vary until the process is stable. When no measuring equipment is available, the produced

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Fig. 6. Presentation of potential cost reduction. Fig. 5. Periodic fluctuations of cable diameter caused by extruder pumping.

Fig. 7. CV line with different measurement systems.

cable can only be checked after the cable or wire has run through the entire production line until a cut is possible. Depending on the line length and process speed, this may take several minutes until the first cable specimen can be taken, during which hundreds of meters could have been made. This situation, referred to as “start-up loss,” cannot be avoided completely but by using modern online measuring technology such as non-contact diameter gauges or eccentricity measuring heads, it is not necessary to stop the process or to wait until the product went through the entire line before measuring the values. Scrap production. As noted above, if no measuring equipment is available in the production line, the cable quality can only be checked by spot tests when either a reel is completed or the line is stopped. Meanwhile, problems such as too thin a wall thickness can happen, resulting in poor quality cable that needs to be scrapped. There is also the danger, even with a high 68 WIRE JOURNAL INTERNATIONAL

Fig. 8. On-line quality control at the cable extrusion.

degree of random testing, to miss these kind of problems completely. Insufficient productivity. Continuous measurement can prevent the need to stop the line and do further tests if, for example, the crosshead needs to be adjusted or the temperature of a preheating unit needs to be changed. This could be improved significantly by measuring continuously during the production process. Combining constant quality and efficient cost control.The instrumentation to keep both quality and cost under control is supported significantly through the use of easy-to-operate and at the same time very precise measurement technology. This will also help the operator at the line to concentrate on the core cable production process. Cable dimension measurement. A cable’s outer diameter, wall thickness and eccentricity are important data. Several different gauge heads are available: diameter measuring-only gauge heads and wall thickness measuring systems like the Sikora X-Ray

2000, which can also determine the outer diameter and eccentricity. In addition, several different kinds of X-ray-based systems for energy cable exist where three layers can be measured at the same time. This is very often used for high-voltage cables with PE insulation which are produced in CV lines. Fig. 7 shows a standard jacketing line with such measuring systems: Shielding and surface inspection. Fig. 7 also shows a cleanliness scanning system to visualize extremely small contaminants before they go through the crosshead of the extruder. The molten and therefore transparent XLPE insulating material is transilluminated and inspected online with a high speed CCD color camera. To detect short interruptions of the inner semiconductor a completely new developed system is now available. Defects will be reported during production and the distribution of defective cable can be stopped. Shortest interruptions of only 10 mm can safely be sensed at a line speed of up to

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Fig. 10. Transformation between Time and Frequency Domain: Fourier Transform.

ing systems are inevitable. For power cable, X-ray-based measuring systems are essential to improve cable quality, reduce scrap and minimize material consumption. As material costs can represent more than 80 percent of production costs for some cable, it is clear that material savings are essential. A tool that helps the cable manufacturer reduce the wall thickness will make that producer more competitive. Initial costs for buying this measuring equipment can sometimes be amortized by the savings of the material cost in as little as a year. If cable manufacturers are able to raise quality to a competitive level, imports from China can be averted and the opportunity arises to even export energy cable to other countries. ■

Fig. 9. Strand-shield measuring tube.

Fig. 11. Periodic fluctuations of outer diameter caused by a faulty guide roller.

600m/min. Spark testing. A spark tester, mainly used for power, LAN, coaxial, RF, telephone and optical fiber cables, is a reliable way to find defects, such as pinholes, in the insulation of cables and wires. The testers are mostly similar to meet international safety standards like DIN/VDE 0800, etc. There are two different standards: U.L., from the U.S.-based organization, and B.S., the British standard, which is used for energy cables. FFT Analysis. FFT-analysis, well known in the communication and data cable manufacturing industry, is becoming a more important tool for the overall cable branch. FFT-analysis is basically available with diameter, eccentricity, wall-thickness and capacitance measuring devices used in the cable manufacturing process. To minimize over consumption of insula-

tion material, it is vital to measure the diameter of a cable precisely and to control it to the nominal value. In practice, there are variations of the insulation thickness arising from the production line, which require an excessive amount of insulation wall thickness to avoid a drop below the permissible nominal value, meaning the minimum wall thickness. By means of FFT-analysis, the cause of such periodical diameter variations of an insulated cable can be determined and eliminated. Conclusion India’s demand for energy cable will show an exorbitant growth rate over the next couple of years, with billions of U.S. dollars needed to be invested. To meet cable manufacturers’ requirements for performance, quality and cost efficient production, sophisticated measur-

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Products Vacuum lifter can process spools and reels from the side for ‘eye-to-the-sky’ stacking U.S.-based Anver Corporation has introduced a high air flow, hoist-based vacuum lifter designed for picking up spools and reels from the side to allow “eye-to-thesky” stacking. A press release said that Anver VB4 Vacuum-Hoist Spool Lifter uses a variable speed hoist for up/down and has a remote vacuum station to provide the attach and release power, with fully integrated fingertip controls located on the handlebar. The

lifter, designed for rapid pickup and “eye-to-thesky” stacking, has a donut-style foam vacuum pad with two adjustable locators, it noted,

Straighten-and-cut system ends ‘trial and error’ setup Germany’s Jouhsen-bündgens Machinery, represented in North America by Jouhsen-bundgens USA, LLC, reports that its MJCE model, its newest innovation for straighten-and-cut machinery for the wire and cable industry, is a true “set and forget” system designed for the precision component and both high- and low-volume manufacturers. The MJCE offers a completely new drive system that uses a fully synchronized and maintenance-free linear induction motor that enables it to deliver high-speed straighten and cutting performance without sacrificing quality and high tolerances, a

press release said. The system “means an end to the trial and error system of setting up a cutting length, as lengths are automatically set by the computer which calculates the acceleration and speed of all drives,” it said, making it a “true set and forget” machine. The model can process wire from 0.2 mm to 1.5 mm for lengths as small as 4 mm, straighten and cut at speeds to 800 parts per minute, the release said. The MJCE does not have any maximum length for cutoff and for lengths up to 35 mm and can hold length tolerances within 0.03 mm, it said. “Both labor and cost savings are achieved by the MJCE, as the fully automated machine will set the lengths and control all parameters resulting in increased up-time and tighter tolerances.” Contact: Jouhsen-bündgens Machinery, U.S. contact: Steve Van Duzen, tel. 770-642-6358; e-mail steve@jouhsen.com.

Wire twister series can safely process wires The Eraser Company, Inc., notes that its WT series of wire twisters are quick to set up, easy to use and can twist wires with or without connectors. The units, a press release said, can twist wires up to ¼” OD (6.35 mm) or two 16 awg (1.30 mm) stranded wires. Twisting is completed without damaging the conductors, it noted, adding that the twisters incorporate a speed control and a counter for a consistent number of clockwise or counter-clockwise twists. The units are electric-foot-

70 WIRE JOURNAL INTERNATIONAL

pedal activated and custom twisting heads can be quoted for unique applications, it said. The company manufactures a wide range of industrial products including wire, cable and tubing cutters, wire and cable strippers, wire twisters, wire brush wheels, dereelers, infrared heating equipment, measuring tools, and fybRglass® erasers. Contact: The Eraser Company, Inc., tel. 315-454-3237; Internet www.eraser.com.

adding that it is powered by a remote vacuum station that provides a constant, high air flow for handling porous wood spools. The ergonomic lifter is offered in capacities of 250 lb and 500 lb variable speed hoists. It has a vacuum gauge and quickrelease lever and provides positive holding power without drift, the company notes. Contact: Scott Dillon, Anver Corporation, e-mail: sdillon@anver.com; Internet www.anver.com.

New product line can be used for cable jackets U.S.-based Polymer Additives Group (PAG) reports that its new line of combined flame retardants/smoke suppressants can be used for applications such as wire and cable, specifically for jacketing. The non-toxic products, which are being sold under the Charmax FS™ name, use technology from Addenda Corporation a press release said. The process deposits a few nanolayers of a smoke suppressant onto the surface of several of PAG’s popular flame retardants such as Hydrax™ (ATH), Hydramax™ HM-B8 (magnesium hydroxide) or HM-C9 (huntite/hydromagnesite), it said. Smoke suppressants currently in use for this new application, it noted, are based on molybdate and stannate chemistries. The coated products provide “more bang for the buck” than adding the additives separately to the compound, a company spokesman said. “There is a definite synergy developed by depositing these high performance smoke suppressants onto the surface of hydrated, endothermic, flame retardants,” the release said. “Customers can expect improvements in LOI and smoke reductions.” The Charmax FS products can also be used as full or partial replacement for antimony (tri)oxide in many applications, the release said. Contact: Polymer Additives Group, tel. 317-290-5006; e-mail info@ pagholdings.com.

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Ink jet printer can lay up to 4 lines on cable U.S.-based Videojet Technologies Inc. reports that its new Videojet Excel® DN ink jet is ideal for printing multi-line variable codes and messages at high speeds. The printer offers a low-cost, flexible way to print up to four lines of variable information on wire and cable, a press release said. The printers can apply data such as serialized length marks and images; production batch, date and line data; corporate logos and end-user installation marks and cues at speeds over 1,100 feet per minute, it said. The model is the fastest multi-line printer in the Excel family of reliable, industry-proven ink jet printers for

variable data printing, the release said. It noted that the printer delivers high-quality, multi-line codes from a single printhead and has an updated electronics package includes a WYSIWYG display, logo creation and Ink jet ® memory cards that simplify set up, back up, cloning and upgrading to multiple units. Contact: Videojet Technologies Inc. at tel. 800-843-3610, or go to www.videojet.com.

Line of round and flat cables offer reliable flex life W. L. Gore & Associates (Gore) reports that it has introduced GORE™ FireWire® High Flex Round and Flat Cable Assemblies that provide motion control and vision systems with reliable flex life performance. The new cable assemblies, which offer reliable system performance and equipment uptime, are meant to be used where it important to maintain data and data integrity, a press release said. The release noted that most FireWire cables on the market are designed for static environments and that when they are put in motion environments, they fail to meet IEEE1394 electrical specifications. Further attenuation increases

significantly when these cables are flexed, it said, adding that the GORE’s new high flex cable assemblies maintain stable attenuation over the flex life as they are designed to flex with no bit errors or loss of data. The round cable assemblies have been tested to achieve 5 million cycles in rolling flex motions on bend radius of 50 mm while the flat cable assemblies have been tested to achieve 20 million cycles in rolling flex motions on bend radius of 20 mm, the release said. Both cables, it noted, experienced minimal change in insertion loss and impedance during these tests. Assemblies are available in lengths of 2 m, 3 m, 4.5 m and 7.7 m, with maximum use length calculated from the attenuation value of the cable during flex. Contact: W. L. Gore & Associates at www.gore.com.

Harmonic drive is said to be award winning The U.S. division of ABB reports that subscribers and online visitors to a leading trade journal serving mechanical, electrical and plumbing system designers have voted ABB’s Ultra-low Harmonic Drive the best product in the Motors, Starters, Drives category. A press release said that the company’s drive earned more votes than all other product entries, making ABB’s entry a double-gold winner in the ratings by Consulting-Specifying Engineer Magazine. Jeff Miller, vice president of ABB Low Voltage Drives’ HVAC business, noted that harmonics issues related to motor installation and control “have grown up in the HVAC side of the market, as drives installed in buildings are placed alongside a wide, and growing, array of microprocessor-controlled equipment. The challenge is growing rapidly to help end users minimize radio frequency interference and, increasingly, prevent, rather than mitigate, any harmonic generation to a facility’s power network,” he said. The judges cited the ease of integrating the ABB ultra-low harmonic drives, which offers users extremely precise motor control and prevention of harmonics via built-in, active filtration, the release said. The drives, offered in wall-mount units (7.5 to 125 hp range) and cabinet-built configurations (125 to 2,800 hp), do not require any multipulse transformer, external filters or other additional equipment for harmonics reduction, it said. Contact: ABB, Automation Products, Low-Voltage Drives, www.abb.us/drives.

Gas-shielded, flux-cored welding wire is intended for high-volume carbon applications U.S.-based Hobart Brothers reports that its Tri-Mark TM-770 gas-shielded, fluxcored wire, available in .035 in., .045 in., .052 in. and 1/16 in. diameters, is designed for use on high volume carbon steel applications that require high impact properties. A press release described the TM-770 wire as combining superior welding performance with excellent mechanical properties and low diffusible hydrogen levels to make it suitable for use on shipbuilding,

offshore structural and general fabrication applications. The wire is rated at a tensile strength of 83,000 psi and 79 foot-pounds at sub-zero temperatures down to -40ºF, it said. The TM-770 wire meets the needs of most general fabrication applications where high impact values are required, the release said. The TM-770 wire’s smooth, stable and soft arc creates virtually spatter-free welds to minimize post-weld cleanup time

and help increase productivity, it said, noting that it is engineered for single- and multiple-pass welding in all positions. The product, ideal for use with mixed shielding gases, produces a flat weld bead profile, even in the vertical-up position, and is designed for use with mixed shielding gases, it said. Contact: Hobart Brothers, Internet www.hobartbrothers.com.

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Process can form and join end termination on wire and cable FisherTech, a division of FisherCast Global Corporation, reports that its Injected Metal Assembly (IMA™) process has been increased 10-fold with the launch of the AM 51 system that can be used to form and join an end termination directly onto a wire, cable, rod or shaft as well as simultaneously joined to other components in an assembly. The system has a stationary operating head, shot control and a two-stage melt pot

that provide options for advanced automation up to full robotic operation, a press release said. Pneumatic injection increases operating capability by 50 percent for greater productivity, reduced operating costs and improved die cast integrity, it said. IMA technology, the release noted, uses molten zinc alloy to join an end termination directly onto a wire, cable, rod or shaft and to die cast a component. This manu-

facturing process eliminates one or more pre-manufactured parts from the assembly as well as multiple joining methods for increased cost saving, it said. ” Contact: FisherTech, tel. 866-536-2278; e-mail info@fishertech.com.

Line of gold bonding wire has been expanded, offers better looping results U.S.-based Kulicke & Soffa Industries Inc. notes that it has expanded its AW 66 and AW 99 family of gold bonding wires with the AW66i/AW99i products, which it notes are engineered for superior looping results in all stacked die applications. The lines were expanded to meet the challenges in advanced and complex stacked die packages, the company notes at its website. The two new prod-

ucts offer: enhanced looping for stacked-die applications; precision loop formation; lower top of loop, parallel profile, higher last kink; loop stability for in-board loops; consistent looping over a range of loop heights; stable low loop capability; loop capability; and more, it states. AW 66 provides robust ball bonding process at low stress; is suitable for sensitive pads; offers long term stabili-

The world’s ONLY one-stop wire tooling source… Inch Series Straightener

European Style Straightener

Sjogren also offers: • 5 Additional Styles of Roll Straighteners • Roll Replacement for ANY Style Straightener • 4 Styles of Wedge Grips and Replacement Parts • 3 Styles of Wire Guides • 3 Styles of Magnetic Brakes & Clutches Sjogren Industries, Inc. Tel: 1-508-987-3206 Fax: 1-508-987-1965 Email: sales@sjogren.com

72 WIRE JOURNAL INTERNATIONAL

ty of ball bonds through robust intermetallic growth; and has versatile looping capabilities, while AW-99 (99.99% pure) is a broad performing alloy with mechanical properties comparable to leading 2N alloys while retaining the electrical properties of 4N wires, i said, adding that the product is beryllium free. Contact: Kulicke & Soffa Industries Inc. at www.kns.com.

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Clad molybdenum wire is said to be ideal for harsh applications U.S.-based Anomet Products, Inc., notes that its lines of metallurgically bonded platinum- or nickel-clad molybdenum wire is deal for use in devices subjected to high temperatures, high vacuum and oxidation. The clad molybdenum wire, a metallurgically bonded alternative to solid wire, is capable of withstanding temperatures up to 1,200°C, depending upon the material and application, a press release said. The wire comes clad with either platinum or nickel

depending upon the desired surface properties, it said, adding that the wire is available straight, spooled and as ribbon. The clad molybdenum wire has ductility, formability and weld-ability properties that are superior to those from wire that is plated or produced using deposition methods, the release said. The Anomet clad molybdenum wire is offered in sizes from 0.004 in. to 0.060 in. with claddings from 14% to 38% by weight, and 4.5 to 55 microns,

depending upon diameter, it said. Samples are available on request. Contact: Anomet Products, Inc., tel. 508-8423069; www.www.anometproducts.com.

An adhesive cartridge makes for easier processing TAH Industries, Inc. is offering adhesive cartridges from 200 ml thru 600 ml that it notes have a sturdy onepiece design that fits industry standard dispensers and make it easi-

er for processing. The cartridges have a robust uni-body design with a rugged connection between the cylinders and offers a generous lead-in for ease of piston insertion, a press release said. They incorporate a patented “snapoff” closure that is molded in one operation in either PP or nylon that eliminates many of the assembly steps required in open-end cartridges, it said. The release added that multiple piston

designs are offered for greater flexibility. The company also offers a complementary line of static mixers in varying lengths and diameters to fit applications, including the patented TAH TURBO™ square-geometry mixers, as well as other two-component mixing solutions. Contact: Doris Booth, TAK Industries, Inc., e-mail dbooth@tah.com; www.tah.com. ■

Call Cemanco for

Drawing Cones and Capstans (by Ceramtec)

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

FEBRUARY 2007 73

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Media Company launches new website for extrusion business U.S.-based Davis-Standard, LLC, announced that it has launched new web sites for its Extrusion Systems and Converting Systems Business Groups. The sites, a press release said, “have a new look and improved features for 2007,” redesigned to enable easier navigation and provide more specific equipment information, including additional graphics and photos. Both sites offer access to updated news and events as well as safety bulletins for a variety of product areas to help customers optimize the maintenance and safety of their equipment, it said. At www.davis-standard.com, DavisStandard customers will be able to find information about specific types of extruders, complete systems and applications. They will also have access to a

new online parts store to conveniently place orders for commonly ordered parts. The company notes at the site that it presents the combined technologies of Davis-Standard and Merritt Davis Electric. “We manufacture complete wire and cable systems for building and communication wire, construction wire, coaxial cable, automotive wire, high temperature wire, and specialty wire applications. Systems are available with a wide range of extruders, payoffs and tension brakes, take-ups, and auxiliary equipment including cooling troughs, capstans, caterpillars, and accumulator systems. Laboratory equipment, customized feedscrews, and control systems are also available.”

Catalog cites tapes to use to seal and insulate A catalog from U.S.-based Del City offers four different types of tapes as solutions for different types of electrical applications. Del City’s UL rated standard Vinyl Electrical Tape can be used for basic jobs, a press release said. It has excellent adhesive ability with a temperature rating of 80°C (176°F) and is available in single rolls or case lots of 100 rolls. For cold weather applications, it offers 3M Scotch Super 88 (8.5 MIL), a tape that it said is resistant to weather, UV rays, abrasion, corrosion and acids and provides excellent insulation for all wire and cable splices rated up to 600

volts. For sealing out moisture, it offers Del City’s Amalgamating (Cold Shrink) Tape, which it noted was first developed for power and distribution cables but now can be used for a variety of other applications, from bundling and underground wiring to industrial and marine applications. For smaller jobs, it offers 3M Scotch (30 MIL) Liner Less Electrical Rubber Tape, a general purpose insulating tape that it said is flame retardant and moisture resistant, and thus well suited for terminating and splicing jobs. Contact: Del City, tel. 800-654-4757; Internet www.delcity.net.

Website offers career center for electroindustry The National Electrical Manufacturers Association (NEMA) announced that it has launched eicareers.org, a full-service online career center designed exclusively for the electroindustry. The NEMA career portal allows employers to post open positions and search for potential employees, while job seekers can search for open positions, upload their resumes, and submit their applications to potential employers, a press release said. It noted that the service

is free to job seekers; employers pay much less for listing their openings on eicareers.org than on traditional advertising venues. The career center has an anonymous resume bank so job seekers can list their experience and qualifications in a protected environment while employers have the option to pay only for the candidates, or resumes, that are a good fit for them, the release said. “eicareers.org is an efficient, convenient, and central source of qualified applicants, the best place for electrical industry career positions available today,” said NEMA President Evan Gaddis. “By creating a job portal dedicated specifically to the electroindustry, NEMA is creating value for the entire industry.” For more details on the NEMA site, go to www.eicareers.org.

Book explains how right choices are need to make a Kanban method work well A new book from Productivity Press, Custom Kanban: Designing the System to Meet the Needs of Your Environment, by Raymond S. Louis, provides the direction that enables a company to develop and implement a correct and successful kanban system. A press release explained that the book will help readers avoid “the most

74 WIRE JOURNAL INTERNATIONAL

probable consequences” from opting for a kanban design that is not suited to a company’s environment, such as: high inventory coupled with shortages, a triggering mechanism that is augmented by hot lists, and late customer orders and high operating costs from not eliminating the non-value-added activities. Kanban is a powerful tech-

nique when designed and implemented correctly, it noted. The book details each respective kanban technique and includes a description of the environment it is intended to serve so readers can select the right technique, it said. Contact: Productivity Press, www.productivitypress.com, tel. 888319-5852. ■

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WJI Classified Ad Information Wire Journal International classified advertising is the most cost-effective way to get your sales message out through WJI’s circulation of more than 13,000. WAI MEMBERS seeking employment are entitled to FREE “Position Wanted” classified ads. Limit: one ad per issue, maximum three ads per year. This WAI membership benefit is not transferable to nonmembers or to companies.

receipt. Mail responses to: WJI, Box number (from entry), Guilford, CT 06437-0578, USA. PAYMENT POLICY: No agency commissions or cash discounts allowed. Advertisements must be prepaid unless credit terms have been previously arranged.

CLASSIFIED AD RATES: • $1.25 per word for Wire Journal International (20 word minimum). • Blind box numbers, add $10. • Boldface headlines, add $5 per line (up to 18 characters per line). Be sure to specify category.

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

BLIND BOX INFO: Blind box numbers assure advertiser confidentiality in both the WJI and the on-line publication. Responses are mailed out within two business days after

USE OF ORDER BLANK on reverse side. Please e-mail copy to classified@wirenet.org or fax copy to 203-453-8384. Telephone orders will not be accepted.

POSITION WANTED

CAREER OPPORTUNITIES

PERSONNEL SERVICES

POSITION SOUGHT BY MEXICAN ENGINEER. Mexican Engineer with 20 years experience in products, process and equipment for low and high carbon steel wire seeks position. His philosophy is to look for the full satisfaction of internal and external clients, to foment the continuous improvements, the collaboration, the communication and the team work in order to make the administrative and operative processes as simple as possible. He has knowledge and experienced in development and implementation of ISO 9001:2000 Quality Systems, 6 Sigma Philosophy, 5’S and Balanced Score Card tools. Please send an e-mail to cta_5959@hotmail. com.

efforts with Customer Service; and • Forecasting and meeting defined sales goals. Candidates should posses the following qualifications: • Self–Motivated with a positive attitude; • Team Player; • Willingness to travel; • Bachelor Degree preferred but not required; • General understanding of steel products; • Strong Computer Skills: Working knowledge of Microsoft Office; • Excellent Organizational Skills; • Ability to get along with others and work with other department; • Excellent Communication Skills; and • Customer Service oriented. Qualified applicants should send their resume to Tracy Guyette, Nucor Steel Connecticut PO Box 928, Wallingford, CT. 06492. Or email: tguyette@ nucorct.com.

DUNHILL PROFESSIONAL SEARCH OF GREENWOOD. Serving the Wire and Cable Industry since 1978. Phone: 864-366-5555; e-mail dunhill@ wctel.net. Contact: Hal Freese.

CAREER OPPORTUNITIES OUTSIDE SALES POSITION. Nucor Steel Connecticut is now accepting applications for an Outside Sales Position in Wallingford, CT. This position will be responsible for product sales including Wire Rod and Welded Wire Reinforcement within a defined territory. Job Responsibilities include: • Managing a Sales Territory/taking care of Customer needs; • Quoting prices for Wire Rod, Welded Wire Reinforcement (WWR) and Structural Welded Wire Reinforcement (SWWR) for Job specific requirements; • Coordinating sales

SUPERVISOR. Plastic Extrusion Company is looking for a manufacturing Supervisor for our Pawcatuck, CT facility. The candidate will be responsible for production supervision, training, manpower utilization, scrap reduction and inventory control. A strong Plastic Extrusion and Wire, Cable, or Fiber Optic background is desirable. Salary is based on the candidate’s experience. Apply via fax 860-5995461 or call 860-599-5877.

“LET OUR SUCCESS BE YOUR SUCCESS.” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. For 30 plus years our clients have secured the services of thousands of key individual contributors, managers and executives. For corporations we provide recruitment, outplacement, and salary assessment functions. For the job seeker exploring new opportunities, we provide a wealth of information. Our services are performed in absolute confidence. Contact: WIRE RESOURCES, INC. 522 E. Putnam Ave, Greenwich, CT 06830, tel: 203-622-3000 or 800394-WIRE, email: wri@wireresources. com, Internet www.wireresources.com.

DIES CARBIDE SPECIALISTS, INC. offers excellent quality, price and delivery on all your carbide wire die needs (R2-R12). Yes, you can have all three! Give us an opportunity to prove it. For personal attention to your specific requirements, contact Ray Northern at 440-951-4027 or fax 440-9549094.

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WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME _________________________________________________________________________TITLE _________________________________________________________ COMPANY ____________________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________ NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

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

Send to: Attn: Classifieds Wire Journal International P.O. Box 578 Guilford, CT 06437-0578 USA

HEADLINE (MAXIMUM 18 CHARACTERS) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ HEADLINE, 2ND LINE (18 CHARACTERS) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ENTER COPY HERE: RATE: Head @ $5 line $ _________ Full run: word count @ 1.25 $ _________ Blind box @ $10 $ _________ Total cost of insertion $ _________

DIES

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

FOR SALE 1 - NEB 12-Head 18” Planetary Cabler 1 - COOK BH36 Cabler 1 - SYNCRO FX-13 Rod Breakdown Drawing Line, Copper 1 - VAUGHN 10-Die Rod Breakdown Drawing Line, Aluminum 1 - D/S 3.5” 36:1 L/D Nitrogen Gas Extrusion Line 1 - D/S 2.5” 30:1 L/D Nitrogen Gas Extrusion Line 1 - D/S 3.5” 24:1 L/D Jacket Extrusion Line 1 - D/S 2” 24:1 L/D Hi-Temp Extrusion Line 1 - ENTWISTLE 4.5” 24:1 L/D PVC Extruder 1 - DAVIS STANDARD 2.5” 24:1 L/D Nylon Extruder 1 - MERRITT DAVIS 1.25” 24:1 L/D Vertical Extruder 6 - BARTELL 60”, 72” Payoffs and Take-ups 1 - 30” Core Neutralizer Payoff 1 - CORTINOVIS 72-Wire 16” Rigid Strander

1 - NEB 18-Head 22” Rigid Strander 1 - CEECO 7-Wire 22” Tubular Strander, Encircling Bearing 1 - ENTWISTLE 36” Dual Reel Take-up, Model THE 24/36 1 - DAVIS STANDARD 36” Parallel Axis Dual Reel Take-up 1 - DAVIS STANDARD 30” Dual Reel Take-up 1 - SYNCRO DFH Spooler, 30” Reel w/ENDEX Dancer 1 - DAVIS ELECTRIC Model CRS30 Rewinder 1 - VIDEOJET Model 37e InkJet Printer, new 2000 1 - SCHLEUNIGER Model PF3000 Payoff 1 - ADVANTAGE Chiller, Model MK-25AM41HBX, 9/98 1 - Complete PVC Compound Facility 100 - 760mm x 410mm ID x 400mm x 127mm Steel Reels

Contact: Martin Kenner

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

76 WIRE JOURNAL INTERNATIONAL

MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904-388-3654. APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural & PCD DIAMOND DIES. Fair prices & excellent lead times. Contact Paulette, OwnerSales, by telephone at 1-508-2261508 or by e-mail at apollodie@ wmconnect.com.

MACHINERY HANGER PLANT CAPACITY 1250 BOXES/WEEK. (3) Liberty hanger machines with hopper; (2) Chin Yn Chang Hanger machines converted to American twist with hopper; (2) Electric hanger oven white & gold; (1) Phosphate dipping system (1) Chin Yn Chang Capped hanger machine. Financing available. Call: J-M or M-A Perron #450-447-5000 ext: 23. MACHINERY. (2) Lamnea Bruk wire drawing lines. Dry Double deck bull blocks. Wet drawing machines 11 dies 1000 Spoolers Years 1996 & 1994 speed 5000 fpm with controls. Still being manufactured. Financing available. Call : J-M or M-A Perron, #450-447-5000, ext: 23.

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MACHINERY

AJAX #5 (1") AND AJAX #4 (3/4") Wire draw/straighten/cut off machines complete with uncoilers, shot blasters, tooling, 1978/1979. Contact Westway Machinery Ltd., tel. 905-803-9999, fax 905-803-9109.

GALVANIZING LINE. (A) Annealing Furnace Fluid Bed ICE, 24 Strands Gas 34 Feet Length. (B) Take-ups V-Groove Kosch Design NAKO made in Canada. (6X 16"/22") (12X22"/26") Variable Speed Siemens Controls. (C) Pre-owned used 6 months. Financing available. Call: J-M or M-A Perron, #450-447-5000, ext: 23.

EXTRUDER. Davis Standard Thermatik II 2 1/2", 24:1, w/Screw. Guill Crosshead Flange heater kit, Price: $40,000. PreOwned - Used 2 months. Financing available. Financing available. Call: J-M or M-A Perron, #450-447-5000, ext: 23. â&#x2013;

MACHINERY. 7/8 HRS Vaughn w/Mounted Dead Block, 35 HP each block, Speed 3500 FPM. Morgan 4BW, 125 HP DC Motoro with controls 26: Block. Morgan 5B, 22" finish, 100 H.P. AC motor and drive, 1950 FPM. Morgan 7C, 16" Blocks, 22" finish, 75 H.P. AC motor and drive, 1500 FPM. Morgan 6B, 22" finish, 100 HP DC and drive. Dead Block Morgan, Dead Block Vaughn. Financing available. Call: J-M or M-A Perron, #450447-5000, ext: 23.

WWW.URBANOASSOCIATES.COM. For New & Used Wire & Cable Equipment. Tel. 727-863-4700; fax 727-8634711; or by e-mail at urbassoc@verizon.net. Serving the non-ferrous and ferrous industries since 1983

GAVLICK MACHINERY CORPORATION 100 Franklin St., Bristol, CT 06010 USA Phone: 860-589-2900 Fax: 860-589-0863 email: sales@gavlick.com www.gavlick.com

Buying & Selling Used Ferrous & Non-Ferrous Wire & Cable Machinery JUST PURCHASED:

.((3 ,7 6,03/( (&2120,&$/ ()),&,(17 3POOL CAPS AND TENSION BRUSHES &LYER ARMS "ELT WRAPPED TENSION CAPSTANS 4O LEARN MORE ON THE ABOVE AND MUCH MORE SEE WWW WYREPAKIND COM

792%0!+ ).$5342)%3 -IDDLE 3TREET -IDDLETOWN #4 53! 0HONE s &AX SALES WYREPAKIND COM s WWW WYREPAKIND COM

â&#x20AC;˘ Macbee Style 30" x 75/100 HP Bullblock; .625 rod enter; 500-950 FPM; SCR controls

STRAIGHT & CUT MACHINES: - Shuster Model 4AV; .375"-.625"; 3' runout; new 9' track in crate; 1991 - (6) Lewis Model 1SHV-HS; .031"-.062" to .135"; 4' runout; 250-400 FPM

WIRE DRAWERS: - Morgan 5BW; 5x22" blocks; start .218", finish .086", 300HP AC - Morgan 6BW; 4x26"/2 x 22" blocks; start .218", finish .076"; 300HP AC - Morgan 6BW; 6x22" blocks; start .218"; finish .076"; 200HP AC - (2) Vaughn Model DST Rod Drawers; .375" start Al., 10block-die tandem, 200HP DC with coiler - (3) Shaving Lines for .250" aluminum rod â&#x20AC;˘ Vaughn Heavy Duty #22 Bullblock; 42" x 250HP; start 1"; Sabina controls (2001); stripper, crane system, 6000 lb. turntable payoffs

BUTT WELDERS: â&#x20AC;˘ Micro T-HD; .125"-.500" â&#x20AC;˘ (2) Strecker Model 2B Butt Welders; 5-16mm, new 1997

BAG-BAR TIE MACHINES: â&#x20AC;˘ (4) Bag-Bar Tie Machines; 16 ga.; 5"-12" lgths. â&#x20AC;˘ (4) Bar Tie Wire Spooling Machines; 3- 3-1/2 lbs.; 16 ga.

TURKHEADS: - Fenn Model 5U + 5P tandem, 28" shedding drum, 25/30HP - Fenn 6U Turkshead - Fenn 5TH Turkshead; max. sq. .437" - Karl Fuhr 3-stand Turkshead

WE WANT TO BUY YOUR GOOD SURPLUS EQUIPMENT. SEND US YOUR LIST.

VISIT WWW.GAVLICK.COM TO SEE OUR COMPLETE LISTINGS FEBRUARY 2007 77

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Advertisersâ&#x20AC;&#x2122; Index/Key Contacts ADVERTISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE

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

ACM-KSM/HOWAR Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Chris Hauer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 905- 738-4010 AIM, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4 Ken Olsen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 630- 458-0008 Amacoil, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3 Bob Eisele . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 800-252-2645 Anbao Wire & Mesh Co. Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 BJ Hur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 86-335-389-3600 Beneke Wire Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Michael Beneke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 502-367-6434 Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Rick Kristensen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 937-233-9935 Bomco Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Patricia M. O'Neill . . . . . . . . . . . . . . . . . . . . . . . .Ph. 978-283-2800, ext.1218 Bongard Drummond USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 John Drummond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 260-625-6275 Carris Reels, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 David Ferraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 802-773-9111 Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Rainier Lashofer . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 954-630-1323 Clinton Instrument Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 860-669-7548 Commission Brokers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Martin Kenner . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 401-943-3777 Cortinovis SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Dr. Sergio Cortinovis . . . . . . . . . . . . . . . . . . . . . . .Ph. 39-03531-3222 EddyTech Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Rich Fisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 440-234-4809 Esteves-DWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Steve Marcum . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 260-728-9272 George Evans Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 David Evans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 309-757-8300 Fisk Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Eric Fisk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 973-427-7550

FMS Force Measuring Systems . . . . . . . . . . . . . . . . . . . . . . . . .10 Paul Smith . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 847-392-7872 Gavlick Machinery Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Sue Pare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 860-589-2900 GMP Slovakia/HOWAR Equipment . . . . . . . . . . . . . . . . . . . . . . . .8 Chris Hauer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 905- 738-4010 W. Gillies Technologies LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Mark Spencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 508-852-2502 HOWAR Equipment/ACM-KSM . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Chris Hauer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 905- 738-4010 HOWAR Equipment/GMP Slovakia . . . . . . . . . . . . . . . . . . . . . . . .8 Chris Hauer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 905- 738-4010 HOWAR Equipment/Plasmait . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Chris Hauer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 905- 738-4010 Huestis Machine Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Paul Cugno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 800-972-9222 IFMSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-33 Ray Zirkle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 203-794-0444 Kamatics Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Doug Voge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 860-243-9704 KEIR Manufacturing Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Mike Walters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 800-992-2402 Kinrei of America/Watson . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Steve Hess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 973-677-9500 Mathiasen Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Mark Mathiasen . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 860-873-1423 Messe Dusseldorf Asia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Beattrice Ho . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 65 6332-9620 Micro Products Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Bill Keiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 630-787-9350 Northwire Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 800-468-1516 Paramount Die Company Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Richard Sarver . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 410-272-4600

SALES OFFICES NORTH AMERICA

EUROPE

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

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks P.O. Box 33 Moulton Newmarket, Suffolk, England CB88SH Tel: +44-1638-751132 Fax: +44-1638-750933 E-mail: franksco@ btopenworld.com

78 WIRE JOURNAL INTERNATIONAL

FAR EAST Germany, Austria, & Switzerland Dagmar Melcher Media Service International P.O. Box 103 D-82402 Seeshaupt Germany Tel: +49-8801-914682 Fax: +49-8801-914683 E-mail: DMelcher@t-online.de

Anand Bhagwat Pune, India Tel: +91-985-083-8467 E-mail abhagwat@wirenet.org

LARGEST INVENTORY OF WIRE & CABLE MACHINERY IN THE WORLD

VISIT OUR UPDATED WEB SITE www.wireandplastic.com

JUST PURCHASED JUST PURCHASED WRD779 (3) SAMP TRB-3 (MS200) lines with RC15 annealer, TE42 spooler, 40 DC Eurotherm drive. WRD781 SAMP 13 die rod drawbox, Model MS400. WRD784 NIEHOFF multi wire (7) drawing line, Model MMH120 w/RM250 annealer, WSV800 static spooler (1993) WRD794 SAMP multi wire (8) drawing line MT8R.1.8.22 w/R16M.8.8260 annealer, Yr. 1995. WRD795 SAMP multi wire (14) drawing line MT8R.1.8.27 w/R16M.14.1000 annealer, Yr. 1995. RECENT PURCHASES CBR807 (4) 760mm SAMP, Model BM760D, Yr. of Mfg. 1997. (10) 19931995. CBR869 22” KRAFT planetary cabler, 18 wire. 24” conc. taper, 72” wheel capstan, 60” takeup. CBR870 16” KABMATIK 12 + 12 Planetary cabler, 1982, 30” dual capstan, HiSpeed taper, 1.6m portal payoff & takeup, individual VAC drives. EXP759 D.Std. 2.1/2” Extruder, for Nylon Model 250-Slll, Therm. III. EXP727 45mm NOKIA MAILLEFER piggyback extruder, 24:1 L/D, (1996). EXPL287 Tandem Line with Samp TRB 2, annealer, multipass capstan. EXPL289 D.STD. 3 1/2” Extrusion Line with 30” B.W. capstan, Viteck 875 ft horiz. Accum, DR-30 takeup. PRN167 Gem Band Marker Gems Model Super S. PRN159 MEDEK & SCHOERNER bandmarker RC707, (1996). SHAFTLESS TAKEUPS/PAYOFFS Takeups: Hall 40”, 42”, 48”, 60”, 72”, 96” portal. Bartell: 60”, 72”, 84”, 96”. Payoffs: Bartell 48”, 60”, 72”, 84”, 96”. DUAL HI SPEED TAKE UPS NOKIA EKP5 (1) Yr. 2001, EKP50 (4) 1997, EKP100-124 1995 TKU903 (7) 24” CLIPPER dual hi speed takeup, shaftless, parallel axis, Model

WRD796 (2) ENDEX 30” dropcoiler with turntables, controls. WRD781 FILTERTECH CFG4270 filtration units (New). CAT359 (6) CONAIR/GATTO 36” belt caterpuller, 210-6P, 6” belt. CAT356 (3) GATTO 15” belt caterpuller, 205-4, 3” belt. DAN242 48” COOK 5 pass horizontal accumulator, 2” w sheaves. MSC1221 (2) NIEHOFF VZ-01 tin electroplaters w/Bongard ST/650, 26” drop coilers (Yr. 1994/1996). HI TEMP EXTRUDERS (YR 1998): EXP740 1 1/2” D.STD. 30:1, (2) EXP742 45mm NEXTROM 30:1.

EXP757 (3) D.STD. 24:1 Therm II/Mark V air cooled extruder with temp/drive panels. EXP741 3 1/2” D.STD. Thermatic extruder, 32:1, air/water cooled, DC motor (1996 yr. mfg.). PLA535 CONAIR DHD-30 desiccant dryers (new) & MODEL SC-30, CD30, DHD6, DHD4, CD200. CBR897 SUMITOMO 60” fork style single twist cable dual capstan. CBR899 (5) NORTHAMPTON SLB800 double twist bunchers, Yr. 1995-1998.

PS-24HS late 1990’s. TKU968 36” D.ELEC. dual take up Rebuilt recently w/caliper disc brakes, VCD703 drives, GE PLC.

WRD791 SYNCRO C-13 Intermediate Drawing Line for Copper., w/Syncro C-13 Drawing Machine, Syncro 36” DFH Spooler, Syncro C3 annealer, tin pot. WRD788 SYNCRO Upgraded Within the Past Five yrs, w/New Controls, Syncro BG-16 Drawers, Syncro C-3 Annealers, Endex 630mm Spoolers. WRD797 SYNCRO 18” Barrel Packer, ENDEX Head upgrade 1145, w/motor control panel. WRD799 EMCOFilter System South Side MF-2428, Mag drawbox take ups.

WIRE DRAWING LINES WRD722 NEXTROM 7 wire multi-wire, annealer, 630mm single spooler, stem P/Os, 1999, 100 HP DC, 20 HP DC for annealer, Touch Screen controls. WRD717 NEXTROM 12 wire multiwire drawer w/annealer, (2) 630/800mm spoolers, 12 stem payoff, 100 HP DC drawer, 50 HP annealer. (1995). Enter 12 AWG 2.05mm, Finish 28 AWG 0.10mm, 29 dies, 5000 FPM, MGH529A. WRD770 SAMP MT25.2 w wire drawer, w/annealer, (2) 630mm TE65-M spoolers, Yr. Mfg. 1987/1989. WRD769 NIEHOFF M40 drawer 17 die, with GBC rod drawer 5 die, VG-30 annealer (1997), Samp 800mm spooler (1993) 5/16”-22 AWG. WRD700 (3) SAMP MS200 (TRB-3) lines with RC15 annealer, TE42 spooler, 40 DC Eurotherm drive. WRD766 SYNCRO C17DC Tandem Telephone Wire Drawing/anneal/Preheat/Dancer, DC drive (1990’s). WRD786 SYNCRO FX-13 Rod Breakdown Line for Copper, L-R, w/FX-13 Drawer, F Annealer, Bekaert 36” Coiler. WRD787 COOK Rod Breakdown Line for Aluminum, L-R, w/Cook DH4+8 Drawer, Endex Annealer, Syncro 36” Coiler.

INSULATING/JACKETING LINES EXPL252 3 1/2” D.STD. extruding line, (2) Skaltek A12PS portal payoffs, 3 1/2” 24:1 Thermatic II extruder, Touch Screen panel with Eurotherm controllers, hopper, loader, dryer, 60” MGS belt caterpuller, Beta dia., (2) 36”/40” D.E. TURA S/L take ups, Viteck accumulator. - (3) 3 1/2” lines as above available, w/Skaltek A12 P4K & 40” Hall T/U. EXPL262 4 1/2” D.STD. 24:1 Therm III Ext. Line (1996), 150 DC Reliance drive, 30” Clipper dual driven flyer P/O, multipass capstan, Clipper PA-30 dual T/U, spark tester, Zumbach dia., Gem printer, trough, loader, colormeter, Roots tech preheater, chiller etc. EXPL265 3 1/2” 24:1 EXT. line w/(2) 72” Bartell P/O’s, (2) 84” Bartell T/U’s, 60” D.E. belt cat., W & S corrugator, Nordson pumps.

Wire & Plastic Machinery Corp. 100 Franklin Street Bristol, CT 06010 USA Phone (860) 583-4646 Fax: (860) 589-5707 sales@wireandplastic.com www.wireandplastic.com Reader Service No. 35

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

Plasmait/Howar Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Chris Hauer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 905-738-4010 Queins & Company GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 H. G. Queins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 49-2472-8080 Reel-O-Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Brian Rich . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 405-672-0000 Rosendahl Maschinen GmbH/Knill USA . . . . . . . . . . . . . . . . . . .21 Mike Kos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 828-328-4319 SAMP USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 David Graff, Debbie Harwood . . . . . . . . . . . . . . . . .Ph. 301-223-8584 Sanxin Wire Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Doug Thornton . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 434-906-2340 Sheaves Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Stew Walton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 866-344-6786 SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Jeff Swinchatt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 770-486-1233 SIKORA International-USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Jeff Swinchatt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 770-486-1233 Sjogren Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Carl Sjogren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 508-987-3206 Summit City Ent. Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Craig Martenson . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 260-478-6954 Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Bob Douglas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 256-480-5124

Teknor Apex Co./Vinyl Division . . . . . . . . . . . . . . . . . . . . . . . . . .C2 Mike Patel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 800-554-9892 Wire & Plastic Machinery Corp. . . . . . . . . . . . . . . . . . . . . . . . . . .79 Rahul Sachdev . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 860-583-4646 Witels Albert USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Bob Flower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 410-228-8383 Woodburn Diamond Die, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Jackie Lichty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 260-632-4217 Wyrepak Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Ray Browne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 860-632-5477 Zumbach Electronics Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Keith Donahue . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 914-241-7080

Wire Association International ads Contact: . . . . . . . . . .Ph: 203-453-2777 Fax: 203-453-8384 Call for Papers: Bologna 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Interwire 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41-45 Membership application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

If you haven’t seen the latest WAI Connection online...

Coming next month • Interwire 2007/IFE 2007 preview WAI moves information The Wire Association International (WAI), Inc., delivers The WAI Connection, its comprehensive online newsletter, to our members twice each month. Featuring the latest WAI, Chapter, and industry news—as well as late-breaking event and people items—it’s a great way to stay informed about the industry. But if we don’t have your most current e-mail address, we’re both missing Connections! A quick e-mail message is all it takes to help us deliver The WAI Connection directly to you. But without your update, you may miss out.

Stay in touch with WAI Please contact Chip Marsh, Director of Membership, today at membership@wirenet.org to update your address and any contact information that may have recently changed. Because when you move, so does WAI.

...you may be in the dark about late-breaking industry news.

80 WIRE JOURNAL INTERNATIONAL

Enlighten us with your updated e-mail address today! The WAI Connection is an online publication of The Wire Association International, Inc.

Wind up with an Amacoil/Uhing assembly for perfect pitch every time Pitch is adjustable (10:1) without requiring gear changes or adjusting motor speed. A single Amacoil/Uhing assembly may be used for winding many different diameter materials. Automatic reversal of the traverse is mechanically controlled – without clutches, cams or gears. No electronics or programming needed. FEATURES • Zero backlash. • Automatically synchronizes pitch with take-up reel rotational speed. • Traverse drives with up to 800 lbs. axial thrust. • Smooth, unthreaded shaft won't clog or jam – no bellows assembly needed. • One inexpensive, unidirectional motor drives both the traverse and take-up reel. • Free movement lever – no need to "jog" system on and off to position linear drive. • Options and accessories for every winding situation. • Light, medium and heavy-duty systems.

For Brochure or CD-ROM Call toll free 800-252-2645

email: amacoil@amacoil.com

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

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