Equipment: Part 1 by Wire Journal International, Inc.

Wire Expo

WIRE JOURNAL JULY 2010

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WIRE JOURNAL

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

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

CONTENTS

Volume 43 | Number 7 | July 2010

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26 Fastener Update . . . . . . . . . 28

Wire Expo wrapup

. . . . . . . . . . . .36

A new site, compressed schedule and link to two other events helped make Wire Expo 2010 a vibrant event.

WAI News . . . . . . . . . . . . . . 29 Chapter Corner . . . . . . . . . . 34 Technical Papers . . . . . . . 68-84 Products . . . . . . . . . . . . . . . 86

Equipment: Part 1 . . . . . . . . . . . .50 There was much equipment to see at wire Düsseldorf. This feature, the first of two, presents a sampling of what was displayed at the fairgrounds in Germany. Part 2 will be in the September issue.

Classified . . . . . . . . . . . . . . 91

T ECHNICAL

Career Opportunities . . . . . . 91

Improvement of drawability of shape-memory alloy wire Kazunari Yoshida, Takanori Sato and Shunichi Kikuchi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Advertisers’ Index . . . . . . . . 94

SECTION

Next issue

On the risk of fatigue in extension spring hooks Mark Hayes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

August 2010 WJI

Review of diffusion methods after sequential plating for the manufacture of steel tire cord Thomas W. Tyl and Jeffrey T. Tyl . . . . . . . . . . . . . . . . .78

• Preview: wire China • Preview: Monterrey Mexico ITC • Regional Outlook: Mexico

Cover: Three close-ups of some of the equipment that was on display at wire Düsseldorf. See p. 50.

JULY 2010 | 3

INSIDE THIS ISSUE IN THE WIND IS A

+++ . .34

E QUIPMENT : P ART 1 . . . . . . . . . .50

CONTENTS

BLOWING

The New England Chapter heard from Bill Wall, of Deepwater Wind, whose June 10 presentation on the potential of offshore wind power generation, especially for Rhode Island, had attendees sensing potential.

4 | WIRE JOURNAL INTERNATIONAL

If you weren’t among the attendees at wire Düsseldorf, this feature, the first of two, presents some of the latest and greatest in capital equipment that was showcased at the staging of the 2010 event.

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Straightening machines

Multiwire drawing machines

Cold rolling lines with cassettes

PC strand machines

Spooling equipment

WIRE MACHINERY DIVISION

EDITORIAL WIRE JOURNAL

EDITORIAL

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

Positive signs and times are always welcome, but fortune favors those who plan for it The 2010 staging of the world’s largest wire and cable event, wire Düsseldorf, received very positive reviews from the exhibitor community as it demonstrated the strength of the global economy and the promise of a stronger business cycle ahead. As advocates for the wire and cable industry, we should celebrate these kinds of positive signals as they are keys to both the industry’s health and its ability to continue to provide world-class technology. That same sense of optimism was seen at the co-located Wire Expo, National Electrical Wire Processing Technology Expo and the AWPA Long Products Symposium that was held in May. This unique combination of industry events provided a valuable gathering place for the exchange of information and networking. See p. 36. As a show organizer, I can assure you that all efforts are made to create a winning event with meaningful ROI for attendees as well as exhibitors. When the show goes well, the feeling of satisfaction can be compared to the successful commissioning of a full production line that has been in the works for years. If a show under-performs, I can tell you (from experience) that the feeling of disappointment is deep. Good fortune is involved in the production of trade shows, and the economy is obviously a key driving force, a reality that has not been kind the last few years. Those wonderful periods where the economy is so strong that exhibitors and attendees can’t wait to meet and do business are to be cherished, but as we have seen, such times are not to be expected. And sometimes things can go awry for unpredictable and even improbable circumstances, such as the timing of volcanic eruptions in Iceland. Under the still somewhat uneasy yet seemingly improving conditions that exist today, I believe that events that are successful are anything but accidents. In the case of the recent Wire Expo, the collaborative approach among AWPA, the Electrical Wire Processing organizers and WAI set the stage for a valuable forum for the industry. Look for us to offer more value to the industry in events to come.

Steve Fetteroll WAI Executive Director

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2010 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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CALENDAR

CALENDAR Sept. 21-24, 2010: AWPA Government Affairs Conference Washington, DC, USA. To be held at the Hyatt Regency on Capitol Hill. Contact: Heather Outhuse, American Wire Producers Association (AWPA) at tel. 703-2994434. For more details, go to www.awpa.org. Sept. 21-24, 2010: wire China 2010 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Oct. 18-20, 2010: WAI International Technical Conference Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities. Contact: WAI, tel. 203-453-2777, www.wirenet.org. Oct. 27-Nov. 3, 2010: K 2010 Düsseldorf, Germany. This event for the plastics and rubber industry will be held at the Düsseldorf Fairgrounds, Halls 1-17. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Nov. 7-10, 2010: 59th IWCS Conference™ Providence, Rhode Island, USA. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990. Nov. 18-20, 2010: Wire & Cable India 2010 Mumbai, India. Organized by Messe Düsseldorf and the the Confederation of Indian Industry (CII), this event will be held at the Bombay Exhibition Centre in Goregaon. Contact: Eva Rowe, Messe Düsseldorf North America, erowe@mdna.com, tel. 312-781-5180.. May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show and the Association’s 81st Annual Convention. Contact: WAI, tel. 203-453-2777, www.wirenet.org. June 19-23, 2011: JI Cable Versailles, France. This international conference on insulated power cables, which has multiple organizers and was last held in 2007, will present a comprehensive forum about power cables as well as exhibits. Contact: J1Cable 11, www.jicable.org. ■

W IRE ASSOCIATION INTERNATIONAL E VENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. Sept. 5, 2010: WAI Ohio Valley Chapter 8th Annual Golf Tournament Solon, Ohio, USA. This event will be held at the Grantwood Golf Course.

Oct. 25, 2010: Western Chapter 10th Annual Golf Tournament Rancho Palos Verdes, California, USA. This event will be held at the Los Verdes Golf Course.

Sept. 16, 2010: New England Chapter 16th annual Golf Tournament Boylston, Massachusetts, USA. This event will be held at the Mount Pleasant Country Club.

March 3-5, 2011: Modern technologies and modelling of drawing and manufacturing processes of metal products Zakapone, Poland. WAI’s Poland Chapter members are among those organizing this event. Contact: Dr. Sylwia Wiewiórowska, wiewior@mim. pcz.czest.pl, www.konferencja.mim.pcz.czest.pl.

Oct. 14, 2010: Southeast Chapter 9th Annual Golf Tournament Conover, North Carolina, USA. This event will be held at the Rock Barn Golf and Spa. Oct. 18-20, 2010: WAI International Technical Conference Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities.

8 | WIRE JOURNAL INTERNATIONAL

May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show and the Association’s 81st Annual Convention. Contact: WAI, tel. 203-453-2777, www.wirenet.org.

INDUSTRY NEWS

INDUSTRY NEWS First cable manufacturer in country of Qatar officially launched in May The country of Qatar welcomed the official opening of its first cable manufacturer on May 25, when Doha Cables LLC was officially opened in Messaieed Industrial City. Doha Cables is a subsidiary of Senyar Industries, a 50/50 joint venture between AAMAL Company Q.S.C. and Elsewedy Cables, a leading Middle East integrated cables and electrical products manufacturer, a press release said. It noted that the total investment was about US$100 million, and that the factory is expected “to make a significant contribution to revenues and earnings” this year. Initial contracts, it said are currently in place to supply a number of new customers including Kahramaa (Qatar’s general electricity and water corporation), Ashghal (Qatar’s public works authority) Qatar Petroleum, ABB and Siemens. The new, state-of-the-art 70,000-sq-m manufacturing facility has annual production capacity of 40,000 tons of copper of power cables, flexible cables, building wires, earthing cables, overhead conductors, optical ground wires (OPGW), fiber optic cables, alongside more specialized cables, such as heat resistant flexible cables, fire resistant, flame retardant, lead sheathed and control cables, the release said. The factory has some of the most technologically advanced cable manufacturing machines, which will cut delivery time to the various infrastructure projects in Qatar, allowing greater efficiency and cost effectiveness, it said. Some 700 guests were present for the opening, which included His Excellency Abdullah Bin Hamad Al Attiyah, the Deputy Prime Minister and Minister of Energy and Industry of Qatar, His Excellency Sheikh Faisal Bin Qassim Al Thani, the chairman of AAMAL Company, and Eng. Ahmed A. Elsewedy, the Chairman and CEO of Elsewedy Electric Group, the release said. It added that the new plant “is expected to make a material contribution to the future industrialisation of Qatar by helping to meet the increasing demand for cables driven by the country’s rapid infrastructure development.”

EMEC names Draka Offshore as its main provider of subsea cable Draka Offshore announced that the European Marine Energy Centre (EMEC) has selected Draka as its subsea power cable provider, and has placed an order for approximately 11,000 meters of 20kV subsea power cable for use in EMEC’s tidal and wave energy test sites in Orkney. “The selection of Draka for providing subsea power cables further validates the quality and performance of our products in extreme under-water conditions,’’ said Martin

From l-r at Orkney, Neil Kermode, EMEC Managing Director; Alex Salmond, First Minister; Stephen Hagan, Orkney Islands Council Convenor; and Sandy Cumming, former CEO of Highlands & Islands Enterprise. Dale, commercial director for subsea for Draka Offshore. The cables will be used to extend the EMEC test sites to create three new grid-connected berths, two at the tidal test site and another at the wave test site. Draka will also provide a range of accessories, and direct load out to a vessel from its Drammen factory. The announcement explained that EMEC provides test facilities for a wide range of technologies that can tap into the potential of wave and tidal renewable energy. It noted that wave power alone has an estimated global potential of approximately 1,000-10,000 GW, in the same order of magnitude as the world’s electricity consumption, according to the World Offshore Renewable Energy Report 2004-2008 published by UK Renewables. Located in the Orkney Islands of Northern Scotland, the wave and tidal sites are designed to test a range of machines located down to a depth of 50 meters and up to two kilometers from shore, it said. “Wave and tidal energy is a very powerful source of renewable energy and a very challenging environment for equipment and systems,’’ said Stuart Baird, EMEC operations director. “We need vendors like Draka who can deliver quality products and services that can stand up to the elements over time.”

ABB to build new cable factory in U.S. ABB, a global supplier of power and automation technology, announced that it will build a new factory in the U.S. to manufacture high-voltage land cables for power transmission. A press release said that the new plant will manufacture land cables for use in both AC and DC applications, and

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

10 | WIRE JOURNAL INTERNATIONAL

Tri Star Metals acquires Pinnacle Tri Star Metals Inc. LLC, along with its German parent company, Hagener-Feinstahl, announced that it has acquired Pinnacle Metals, Inc., a U.S. wire and bar manufacturer that will operate as Tri Star-Pinnacle Metals through the yearend, when it will assume the Tri Star Metals name. A press release said that the deal expands Tri Star Metals’ North American footprint via the addition of a 130,000-sq-ft manufacturing facility in Freeport, Illinois, “and establishes Tri Star Metals as a fully integrated wire mill with multiple shipping locations and two production facilities.” The company, it said, will immediately increase manufacturing capacity at the new facility by repurposing 35,000-sq-ft (27 percent) to add equipment that supports new growth markets, such as annealing and drawing capacity for stainless and nickel alloy rod, bar and wire. The move will bolster Tri Star’s competiveness by increasing its global buying power to 35,000 metric tons per year, enhancing its profile among producing mills and empowering it to better negotiate terms and pricing on raw materials, said Tri Star Metals President Jay Mandel. Mandel informed WJI that Tri Star Metals will first focus on merging the existing employee bases, then will work with representatives from Hagener-Feinstahl to determine how best to maximize production and efficiency at the Freeport facility. “At that time, management will be able to more clearly define planned expansion in both sales and production personnel during 2010.” The release said that Hagener-Feinstahl’s owners, Hans Juergen Bender and Ingo Bender, toured the Freeport manufacturing facility and have committed to helping expand its capacity. “We have been working with the technical and metallurgical team from Hagener-Feinstahl for several weeks,” Mandel said. “We currently are finalizing plans to

increase annealing and drawing capacity, along with other production improvements to improve our ability to service customers.” The augmented company will blend the production and administrative employees from Pinnacle Metals with Tri Star Metals’ and expand the expertise of Tri Star Metals’ management with key Pinnacle executives Bill Pigott, Nick Pigott and Kurt Payton. Based in the U.S., Tri Star Metals carries an extensive inventory of aluminum and stainless steel rod, bar and wire stock, and notes that it is the sole source for its proprietary line of premium specialty metals products including: TRICUT® free machining stainless steel bars, TRI-BRITE™ EPQ stainless steel wire, TRI-COAT, and TRI-COAT WAX stainless steel cold heading wire.

Prysmian lands big wind farm contract Prysmian announced that it has won an offshore wind farm contract to supply some 200 km of different cables valued at more than 200 million euros for a North Sea project that it said represents multiple technical milestones. The contract, a press release said, calls for the Italianbased company to provide the cable to transpower gmbh, a German transmission system operator that is a subsidiary of Dutch grid operator TenneT. The grid connection project, called BorWin2, will link two offshore wind farms (Veja Mate and Global Tech 1) in the North Sea to mainland Germany. The turnkey connection, it said, will link the two parks, located 125 km offshore, to the mainland and enable them to transmit their wind-generated renewable power into the German grid. The project, the release said, sets several wind farm firsts. One is the first commercial use of ±300 kV DC cables using extruded technology that represent the highest directcurrent voltage level ever reached as well as the first 800 MW connection to offshore wind parks and the largest Voltage Sourced Converter (VSC) system, which will also have 800 MW capacity, it said. The project will use extruded high-voltage, director current (HVDC) cable technology from Prysmian together with Siemens HVDC Plus® converter technology at the offshore platform and onshore stations, the release said. The HVDC connection supplied by Prysmian will include the ±300 kV DC subsea and land cable types along around 125 km submarine plus around 75 km land route (around 200 km in total) to the land converter station in Diele, near Papenburg. A total length of about 39 km of extruded 155 kV HVAC submarine cable connections will complete the connections from the offshore wind park transformer platforms to the offshore converter platform, it said, adding that the submarine cables will be made at Prysmian’s factory in Arco Felice, Italy, and the land cables at its factory in Delft, The Netherlands. The Prysmian contract is part of a larger contract, worth

JULY 2010 | 11

INDUSTRY NEWS

that ABB plans to invest approximately US$90 million in the new manufacturing facility, which is expected to employ around 100 people. The selection process for the site of the factory “is well under way,” it said. “Cables play a key role in the efficiency and reliability of long-distance power transmission,” said Peter Leupp, head of ABB’s Power Systems division. “The need to upgrade the existing transmission infrastructure in the U.S., to provide grid interconnections and integrate more renewable power into the grid is driving demand for cables.” The release noted that ABB, a global supplier of efficient, high-quality cable systems for a range of voltage levels, has been manufacturing polymeric insulated cables since the early 1970s. Products include XLPE (crosslinked polyethylene) insulated cables for use in highvoltage applications, up to 500 kV (kilovolt), that provide opportunities for energy-efficient power transmission. ABB, it said, has delivered more than 7,200 km of XLPE cables for voltage levels above 100 kV around the world.

INDUSTRY NEWS

more than €500 million, awarded to the consortium between Prysmian and Siemens Energy, which will deliver the VSC system, the release said. It added that Prysmian’s cable-laying vessel, the Giulio Verne, will be among the specialized vessels used for the various operations. The HVDC connection, it said, is planned to commence operation in 2013.

ing US$100 million toward the costs, the report said. It noted that acute power outages in Bangladesh, which can supply nearly 4,000 mw of electricity a day but needs more than 5,500 mw, led to the project.

Bangladesh to lay power transmission line to import electricity from India

India’s Cabrol Group, a supplier of steel reels, reports that SCR Holdings, the U.S. subsidiary it opened last year in Houston, Texas, has positioned itself to serve the U.S. wire industry market through its steel cable drums and packaging solutions. A press release, which described Cabrol as Asia’s largest producer of steel cable reels shipping/dispatch type in CKD (Complete Knock Down) form, said that the group introduced the concept of fully recyclable CKD Reel nearly two decades ago. Cabrol Group Chairman, Nalin Shah said that SCR-Cabrol has the capacity to manufacture 20,000 reels annually. “SCR’s edge is our innovative new CKD reels, which are manufactured to the dimensions and load capacity specifications of NEMA I, II and Western Electric.” In the release, Neerav Patel, SCR senior partner, said that, “this partnership is strategically designed to provide complete reel management solutions to the U.S. wire and cable industry.” He explained that SCR provides customized reel

The Financial Express reports that the government of Bangladesh plans to install a 40-km cross-border power transmission line by 2012 to import electricity from India. The report said that the government wants to install the 400kv cross-border power transmission line, a project that is worth about US$150 million, by 2012. “After getting approval from the highest policy-making body, we will sign a deal with a contractor for constructing the bilateral power grid,” Ruhul Amin, managing director of the Power Grid Company of Bangladesh (PGCB), said in the report. It added that a cross-border power grid of about 100 km will connect Bangladesh’s western Bheramara and India’s eastern Baharampur area in the West Bengal state. The Asian Development Bank (ADB) will finance for the project as it has already assured the government of provid-

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Cabrol Group subsidiary of steel reels has roots in U.S., plans expansion

and repair reels in the future.” The company reports that steel cable drums are better than wooden ones because they are specifically designed for heavier load bearing; are more durable and rugged; and can be recycled, unlike wooden cable drums. “Considering the long life, it is an extremely cost-effective and environmentally friendly option,” it said. Patel can be contacted at tel. 713-851-5713 (cell), npatel@scrholdings.com.

U.S. ITC rules PC wire strand from China sold at less than fair value SteelGuru reports that the U.S. International Trade Commission has determined that the U.S. industry is materially injured by reason of imports of prestressed concrete steel wire strand from China that the U.S. Department of Commerce found was subsidized and sold in the U.S. at less than fair value. As a result of the ITC determination, the Commerce Department will issue antidumping (AD) and countervailing duty (CVD) orders on imports of the product from China, the report said. The Commerce Department had previously set AD margins between 42.97% to 193.55% and CVD margins ranging from 8.85% to 45.85%.

JULY 2010 | 13

INDUSTRY NEWS

fabrication, packaging solutions, logistics, reel refurbishment and scrap management. To date, “SCR has fullfilled customer expectations on the quality, delivery and, most importantly, Cabrol Group Chairman Nalin Shah on the cost with one of his company’s steel reels. part. Currently we project a strong order book for the coming year which ensures running our plants at full capacity,” Patel said. SCR is in the final stages of discussion for confirming a warehouse in Houston with fabrication, reel assembly and welding capabilities, Partel said. “This warehouse will be used to hold inventory for clients who need the reels immediately. This will also act as an in-house unit to refurbish

INDUSTRY NEWS

U.S. Commerce Department sets tariffs on Chinese wire decking The U.S. Commerce Department setting final anti-dumping duties and countervailing duties on imports of some $235.9 million worth of wire decking from China, could cause further trade problems between the two countries, according to a report in China Daily. Wire reports said that the Commerce Department found that Chinese producers/exporters had sold wire decking in the U.S. at 14.24% to 143% “less than normal value.” They added that those same Chinese producers/exporters received net countervailable subsidies of 1.52% to 437.11%, adding

that the Commerce Department will instruct U.S. Customs and Border Protection to collect cash deposits or bonds on imports of certain wire decking from China based on the final AD and CVD rates. Those findings, the China Daily report said, led to “Mr. Chen Deming, Chinese Minister of Commerce (calling on) world governments to remain alert to trade protectionism for the sake of a global recovery.” In it, Deming said, “There is still uncertainties and tough way ahead. As the world is going through an economic recovery, countries across the world need to make concerted efforts to stand against protectionism and support liberalization of trade and investment.”

South African body raids 4 cable makers South Africa’s Competition Commission confirmed that it raided the premises of four electric-cable manufacturers that it suspected of engaging in price fixing, market allocation and collusive tendering. Business Day reported that the four companies (Aberdare Cables, Alvern Cables, South Ocean Electric Wire Company and Tulisa Cables), all with locations in Gauteng, South Africa, produce high-voltage cables for industrial use and low- and mediumvoltage cables for households. The probe is of alleged price fixing, market allocation and collusive tendering, it said, noting that the four companies charged similar market prices, it said. Aberdare Cables is owned by Power Technologies, the parent of which is Altron, which said that management was co-operating fully with the authorities, the story said. It added that Kevin Moodley, a director at Tulisa Cables, said his company would also co-operate fully with the investigation. Tulisa Cables provides electric wire, electric cables and steel armored cables. It also noted that South Ocean Electric Wire, which was formed in 1989 and operates from Alrode, is a subsidiary of South Ocean Holdings and has targeted the export market in Africa, and that Alvern Cables supplies products to the agricultural, mining, industrial, automotive, security and building industries. It could take a year for the investigation to be concluded, it said.

14 | WIRE JOURNAL INTERNATIONAL

release said. Petrovietnam was described as Vietnam’s largest oil and gas utility.

Polish media reports that DSE Dräxlmaier Elektryczne Systemy Sp z.o.o. will close its production facility in Jelenia Góra, relocating to a new factory in Tunisia. At its website, the Dräxlmaier Group, based in Bavaria, reports that it supplies electronic systems and components as well as premium interior parts, modules, and systems for upscale passenger cars and luxury sports cars to automakers such as BMW, Daimler-Benz, Audi, Volkswagen, Porsche, and Toyota Lexus. It notes that the company operates 52 subsidiaries in 20 countries in Europe, North America, Asia and Africa.

C&W Communications plans to build a new Caribbean cable U.K.-based Cable & Wireless Communications (CWC) reports that it plans to build a new major submarine cable in the Caribbean, more than doubling its carrier capacity in the region. The ‘East-West’ cable will link Jamaica and the Cayman Islands in the west of the Caribbean, to the British Virgin Islands (Tortola) in the east, a press release said. It will also

Nexans awarded power contract in Vietnam Nexans announced that it has been awarded a major contract by Siemens AG Energy Sector to supply over 160 km of power and control cables for Petrovietnam’s 750 MW Nhon Trach 2 combined cycle power plant that is currently under construction in Dong Nai Province, Vietnam. A press release said that the company’s Vietnamese subsidiary, Nexans LiOA Wire & Cable, has been selected by Siemens to supply low- and mediumvoltage cables for the Nhon Trach 2 project. The cables, it noted, will feature copper cores and XLPE insulation. The lowvoltage control cables will be shielded to meet the IEC 60502-1 standard, with two types of power cables are being supplied: 10 kV cables comprising single and 3cores that meet the IEC 60502-2 standard; and 1 kV single and multi-core cables that meet the IEC 60502-1 standard, it said. Nicholas Ballas, Nexans’ Executive Vice President for the Asia-Pacific Area, said that the company was delighted to be involved in the future expansion of the company’s power infrastructure, an important strategic project. “The tendering process was extremely competitive, and a key factor in our success was the support of the Nexans Global Key Account Management team who have developed a close working relationship with Siemens going back over seven years.” Nexans LiOA Wire & Cable is one of the two subsidiaries operating in Vietnam and is a joint venture with Nhat Linh, the

JULY 2010 | 15

INDUSTRY NEWS

Poland’s Dräxlmaier to close harness facility, relocate to Tunisia

INDUSTRY NEWS

land in the Dominican Republic, one of the key markets in the region, it said. CWC’s Caribbean business, Lime, has begun installing the cable and is expected to have it operational by early 2011, the release said, noting that this East-West cable represents the third new submarine cable built by CWC in the region since 2008. The other two, it said, are the CBUS cable between Bermuda and the British Virgin Islands and the Gemini-Bermuda cable between Bermuda and the east coast of the U.S. The cable, the release said, will enable Cable & Wireless Communications and its Caribbean business Lime to meet the rising demand for high-speed bandwidth from consumers and business customers in the region.

16 | WIRE JOURNAL INTERNATIONAL

News briefs Germany’s GEO-Reinigungstechnik GmbH (GEO) has named Cable Consultants Corp. (CCC) as its exclusive representation for the U.S. and Canada. With its partners, GEO develops, designs and manufactures equipment to improve the surface quality of metalic components. The range includes ultrasonic, high pressure, spray and mechanical (brush) cleaning systems for in-line or off-line removal of lubricants, stearates, oxides, etc., from wire, strip, cable, tube, rod and bar as well as a range of ultrasonic baths for component cleaning. Contact CCC at tel. 704-375-9313 or 914-834-8865, fhardy@cableconsultantscorp.com; GEO, www.geo-reinigungstechnik.de. … U.S.based Beta LaserMike, a global supplier of precision measurement and control solutions, has named Spectrum Machinery, Inc., as its exclusive New England sales representative for its product line for extrusion and wire and cable markets. Spectrum Machinery has been in business for 23 years, representing industry leaders such as Davis Standard, PSI, Brabender Technologies, Conair and Witte, and its five experienced salespeople in New England are highly recommended by Beta LaserMike’s customers. It will report to Carl Incao, Beta LaserMike’s district sales manager, and be supported by Beta LaserMike’s field service organization. Spectrum Machinery can be contacted at tel. 508-234-0777 or sales@spectrummachinery.com. ... The Sun-News reports that the steelworkers union recently approved contract concessions that they hope will lead to reopening the ArcelorMittal mill in Georgetown, South Carolina. The mill shut down in July 2009 due to a lack of orders and left about 297 workers unemployed indefinitely. The latest pact calls for a pay cut for workers of $3.65 an hour. “There is no doubt in my mind the right decision was made,” United Steelworkers Union 7898 President James Sanderson was quoted as saying. “Now we’re positioning ourselves with the changes in the contract to compete with our

INDUSTRY NEWS

competitors on an equal footing.â&#x20AC;? Whether the concessions will help is unknown. A statement from the ArcelorMittal said that, â&#x20AC;&#x153;Our Georgetown facility will remain idled unless market conditions appreciably improve or the plant is put on a more competitive footing.â&#x20AC;? â&#x20AC;Ś U.S.-based Champlain Cable Corporation, continuing its supply and development efforts of Irradiation Crosslinked Low Smoke Zero Halogen (LSZH) voice and data twisted pair shipboard communication and control cables, reports that it has received its third qualification from the Naval Sea Systems Command

(NAVSEA) for lightweight shipboard cable specification MIL-DTL-24643. This qualification listing is for M24643/62 (all variants), LSPB2SD, LSPB2SDW, LSPB2SDOS, and LSPB2SDOSW. These cables were developed specifically for interconnect between peripheral and controlling devices using Profibus data communications protocol. The variants, it said, include single and dualshielded and jacketed cables, both waterblocked and nonwaterblocked types. â&#x20AC;Ś CRU North America Inc. reports that it has moved. Its new address is 6912 Barton Rd, Hyattsville MD 20784, USA. To contact the office and Florence Kauffman, call tel. 240582-7005, fax 240-582-7008. For B.K. Morris, call tel. 240-9657669. â&#x20AC;Ś U.S.-based American Superconductor Corporation develops and supplies superconductor cable technology, but it has achieved its greatest success to date with its proprietary power electronic solutions that are used for wind farms. The company reports that its technology has supported the production of more than 15,000 megawatts (MW) of wind power worldwide, which it notes represents nearly 10 percent of the worldâ&#x20AC;&#x2122;s 158,000 MW of wind power installed as of the end of 2009. â&#x20AC;&#x153;The fast-growing global wind industry continues to be Ship Ship unassembled unasse ss s mbled re reels eels ee eels the primary business driver for Save Sa S av av ve e on on freight ffrrei re ght costs costs osts s AMSC,â&#x20AC;? said AMSC founder and 14" and and 16" 16" ďŹ&#x201A;anges ďŹ&#x201A;ange es s with w th 5" wi 5" barr b barrels arre rells CEO Greg Yurek. The company Any Any y tra ttr traverse ra rav ave v rs se av available availab vailablle va e notes that its subsidiary, AMSC 10-second 10-se se eccond a e assembly ss sembly y wit w with th n th no o to tools ools Windtec, has more than a dozen customers around the world, 3LWWVÂżHOG 3ODVWLFV (QJLQHHULQJ ( ,QF 3UHFLVLRQ 3UHFLLVLRQ 6SRROV 6SRROV including Chinaâ&#x20AC;&#x2122;s Sinovel Wind 3 2 3 2 %R[ %R[ Â&#x2021; 3LWWVÂżHOG 3LWWVÂżHOG 0$ 86 86$ $ Group Co., Ltd., which it said is HWHU 2OVWD Â&#x2021; 7 H HO Â&#x2021; ) D[ &RQWDFW 3 3HWHU 7HO )D[ the worldâ&#x20AC;&#x2122;s third largest wind tur(PDLO LQIR#SLWWVSODV FRP ZZZ SLWWVSODV FRP LQIIR#SL R WWVVSODV FRP Â&#x2021; ,QWHUQHW ,QWHUQHW ZZZ SLWWVSODV FRP bine manufacturer. â&#x2013;

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18 | WIRE JOURNAL INTERNATIONAL

INTERWIRE 2011 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Convention Dates: May 2-5, 2011 | Exhibit Dates: May 3-5, 2011 Georgia World Congress Center | Atlanta, Georgia, USA

INTERWIRE 2011 IS ALIVE WITH POSSIBILITIES. IT IS RENEWED, INVIGORATED, AND TAKING A NEW TACK. WHO’S AT THE HELM? Senior executives from more than 25 key corporations are skillfully guiding major changes to the show. Their interest in Interwire—the largest wire and cable marketplace in the Americas— is resolute. Interwire affects their business and is clearly worth their personal time. The result is a series of carefully considered and nimbly integrated transformations to better Interwire. Location: Atlanta, Georgia. Relocated and familiar, Interwire returns to the city of its origin where it was introduced in 1981. Compact: 3 full days of exhibits. Interwire 2011 offers a concentrated show schedule. More operating equipment. Interwire is a machinery show. Visitors can count on more operational equipment in 2011. Renewed energy. Exhibitor participation is on the upswing showing a 14% increase between the 2007 and 2009 events. Networking opportunities, ranked as the #1 reason to attend the show, will be part of the landscape. Expect to see production solution demonstrations and other attendance-building activities on the exhibit floor.

Special industry theme days to be announced. Look for presentations, technical papers, and executive discussions to orbit around these central themes: Metals & Materials Manufacturing Best Practices Green Initiatives Also NEW: The Global Continuous

CC Casting Forum.

Uniting worldwide copper continuous casting practitioners for networking, technical and operational presentations and workshops. Fully supported. Show management continues to work with allied organizations, supporting sponsors, and educational supporters to interest a growing number of international participants in the show. Event news is communicated to Wire Journal International readers in 108 countries worldwide.

“Having all or most of the vendors in one location for a face-to-face has always had unmeasured value and still does, especially when times are tougher for travel and the like. Our company believes in the future of the business and that means get out there and find out what is going to take us into new future markets. I’ve already recommended that we return in 2011.” Ed Kozlowski, Senior Design Engineer W.L. Gore & Associates

SAVE THE DATE: MAY 2-5, 2011 AND LEARN MORE ONLINE AT WWW.WIRENET.ORG Interwire 2011 is organized by The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

INTERWIRE 2011 EXHIBITING COMPANIES — AS OF JUNE 2010 FIB Belgium SA Fil-Tec Inc. Filtertech Inc. Fine International Corp. Fisk Alloy Conductors Flymca Flyro FMS USA Inc./FMS AG Foerster Instruments Inc. H. Folke Sandelin AB Fort Wayne Wire Die Inc. Fortune Machinery Frontier Composites & Castings Inc. Fuhr GmbH & Co. KG Fushi Copperweld Garg Sales Co. Ltd. Gauder & Co. Gauder Group Inc. Gavlick Machinery Corp. GCR Eurodraw SpA Gem Gravure Co. Inc. Genca/Canterbury Engineering W. Gillies Technologies Gimax SRL GMP-Slovakia Guill Tool & Engineering Co. V. Hagen & Funke Hall Industries Heacock Metal & Machine Co. Inc. Heany Industries Inc. Heatbath Corp. Henrich Maschinenfabrik GmbH Heritage Wire Die Inc. Howar Equipment Inc. Huestis Industrial Huettner Maschinenfabrik GmbH ICE Wire Line Equipment Inc. IDEAL Welding Systems Ideal-Werk INHOL LLC Inosym Intras Ltd. Italian Trade Commission ITO-SIN (Deyang) Wire & Cable Equipment Co. Ltd. IWE Spools & Handling GmbH IWG High Performance Conductors Inc. IWMA - International Wire & Machinery Association JMS Machinery Joe Tools Kalmark Ltd. Kieselstein GmbH Ernest Koch GmbH & Co. KG Albert Krenn Friedrich Krollman GmbH & Co. KG Lamnea Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. OM Lesmo Lesmo Machinery America Inc. Lloyd & Bouvier Inc. J.J. Lowe Associates LUKAS Anlagenbau GmbH M + E Macchine + Engineering Magnetic Technologies Ltd. MAGPOWR

Maillefer SA Mapre Belgium SA Merritt Davis Metavan NV MFL USA Service Corp. Frigerio The MGS Group (MGS-HallNorthampton) MGS Manufacturing Inc. Micro Products Co. Microdia USA Millennium Steel & Wire Inc. Morgan-Koch Corp. Mountville Rubber Co. MPI Machines Ltd. NEPTCO Inc. Nextrom Oy Niehoff Endex North America Inc. Maschinenfabrik Niehoff GmbH & Co. KG Northampton Machinery NUMALLIANCE Oklahoma Steel & Wire OMA SRL OMA USA Inc. OMCG North America OMCG SpA Paramount Die Co. Parkway-Kew Corp. Pave Automation Phifer Wire Inc. Pioneer Machinery Co. Ltd. Pittsburg Carbide Die Co. Pittsfield Plastics Eng. Inc. Plasmait GmbH Plymouth Wire Reels Pourtier - Gauder Group Precision Die Technologies Inc. Premier Wire Die Promostar srl Properzi International Inc. Proton Products QED Wire Lines Inc. Queins & Co. GmbH Raajratna Metal Industries Ltd. RAD-CON Inc. Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Reel-O-Matic RG Attachments RichardsApex Inc. Rizzardi Rosdendahl GmbH Rosendahl Nextrom Technologies Roteq Machinery Inc. Saarsteel Inc. SAMP SpA SAMP USA Inc. SAMPSISTEMI Sark USA Inc. Sark Wire Corp. Sarkuyasan AS Schlatter Inc. Schunk Graphite Tech Setic SAS Sictra Srl SIKORA International Corp. SIMPACKS Sirio Wire Srl

Sjogren Industries Inc. Skaltek Inc. SKET Verseilmaschinenbau GmbH Smeets SA Sonoco Reels Spirka Schnellflechter GmbH SPX Precision Components FENN Division STAKU-Anlagenbau GmbH Stema/Pedax Steuler Anlagenbau Stolberger Inc. (dba Wardwell Braiding Co.) Stolberger KMB Maschinenfabrik GmbH T & T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Team Meccanica Srl Teknikor Teknor Apex Co. Tensor Machinery Ltd. Teurema Thermcraft Inc. Traxit North America LLC Troester GmbH & Co. KG Paul Troester Maschinenfabrik Tubular Products Co. Tulsa Power Inc. UMC United Wire UNITEK Uniwire International Ltd. UPCAST OY US Reel US Synthetic Wire Die Vandor Corp. Vitari SpA Vollmer America Inc. Wafios Machinery Corp. WAI Connection WCISA - Wire and Cable Industry Suppliers Association Weber & Scher Mfg. Co. Inc. Windak Inc. Wire & Cable Asia Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp. wire 2012/Messe Düsseldorf North America The Wire Association International, Inc. WIRE BULLETIN Wire Forming Technology Wire Journal International Wire Lab Co. Wire Machine Systems Inc. WireCo WorldGroup WiTechs Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. WTC Wyrepak Industries Inc. Ya Sih Technology Yield Management Corp. Zeus Inc. Zumbach Electronic AG Zumbach Electronics Corp.

INTERWIRE 2011 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

A. Appiani Ace Metal Inc. ACM-KSM AFL AIM Inc. Ajax Turner All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American Kuhne AW Machinery LLC Axjo Plastic AB Aztech Lubricants LLC B & H Tool Co. Inc. Balloffet Die Corp. Bartell Machinery Systems LLC/ Ceeco Machinery Bekaert Corp. Bergandi Machinery Co. Besel Basim San Tic Ltd. Sti. Beta LaserMike Blachford Corp. Maschinenfabrik Bock GmbH & Co. KG Bogimac Bongard Machines USA LLC Breen Color Concentrates Bühler-Würz Kaltwalztechnik Butt Welders USA Caballe SA Cable Consultants Corp. Carris Reels Inc. Cemanco LC Chase Coating and Laminating Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. CN Wire Corp./Er Bakir Comapac Wire Machinery Srl Cometo SNC Commission Brokers Inc. Condat Corp. Conneaut Industries Inc. Continuus-Properzi SpA Cortinovis Machinery America Inc. CRU North America Inc. Daloo Machinery Davis-Standard LLC Dem Costruzioni Speciali Srl Die Quip Corp. Domeks Makine Ltd. Sti Dynamex Corp. Ebner Furnaces Inc. Egyptian Galvanized Steel Plant Co. EJP Maschinen GmbH Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Esteves Group USA Etna Products Inc. Etna-Beechem Lubricants Ltd. Eurodraw Energy SpA Eurolls Group Srl EuroWire Magazine George Evans Corp. EVG Inc. Fabritex Inc.

ASIAN FOCUS

ASIAN FOCUS Messe Düsseldorf acquires India show, expands its industry presence in Asia Germany’s Messe Düsseldorf, organizers of wire and cable industry trade shows that include the world’s largest such event, has expanded its presence in Asia with the acquisition of Wire & Cable India from the Confederation of Indian Industry (CII). The bi-ennial event is next scheduled to be held this Nov. 18-20 at the Bombay Exhibition Center in Mumbai. All rights of the show, the brand and the logo now belong to Messe Düsseldorf. A press release said that CII and Messe Düsseldorf will jointly organize Wire & Cable India, which it described as “the most important trade fair on the Indian sub-continent for this sector.” The agreement was signed by Chandrajit Banerjee, director general of CII and HansWerner Reinhard, vice president of Messe Düsseldorf. The organizers are confident that this cooperation will be a plus for wire and cable companies in India and worldwide, the release said.

Finolex Cables Ltd. Managing Director Deepak Chhabria lights a ceremonial lamp to open Wire & Cable India 2008.

The entrance to the tented area that housed Wire & Cable India 2008 in Mumbai, India. “With the two leading trade fair organizers combining their excellence and expertise, this platform will be even more attractive for international export-oriented companies interested in entering the Indian growth market,” Banerjee said in the release. Reinhard welcomed the union as an excellent addition to Messe Düsseldorf’s international trade fair portfolio. “The Indian market is becoming increasingly important for the wire and cable industry, primarily due to growth in the sectors of building and construction, automotive, aviation, energy, engineering and telecommunications. Our experience as an organizer of high-technology trade fairs will benefit Wire & Cable India,” he said in the release. CII serves a proactive role in the country’s development, both in the political and private business sector, said the release, which noted that it organizes important conferences and trade fairs in various industry sectors in India as well as in other continents. Messe Düsseldorf, whose lineup of trade shows includes the renowned event held every two years in Düsseldorf, will along with its subsidiary, Messe Düsseldorf India, be responsible for the worldwide exhibitor promotion for the 2010 staging of Wire & Cable India. “As the founder of Wire & Cable India, CII will remain the coordinating partner ... and will be in charge of visitor promotion and the international conference at Wire & Cable India 2010,” the release said. At the last staging, in 2008, Wire & Cable India featured 223 exhibitors, including 56 companies from Europe, and products were displayed on 38,750 sq ft of net exhibit space to some 8,000 trade visitors from India, Southeast Asia and the Middle East, it said. For further information on visiting or exhibiting at Wire & Cable India 2010, contact Messe Düsseldorf North America, tel. 312-781-5180; info@mdna.com; www.mdna.com. Also, Leena Dugh, Messe Düsseldorf India, tel. 91-11 2697 1745, dughL@md-india.com; and Anil Padwal, Confederation of Indian Industry, tel. 91-22 66611689, anil.padwal@cii.in.

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

22 | WIRE JOURNAL INTERNATIONAL

Fushi Copperweld to acquire Shanghai Hongtai Fushi Copperweld, Inc., reports that, through its Chinese subsidiary, it has agreed to acquire Shanghai Hongtai Industrial Co., Ltd., a move that will enhance its presence in Southeast China. A global manufacturer of copper-clad bimetallic wire, Fushi Copperweld announced that its subsidiary, Fushi International (Dalian) Bimetallic Cable Co., Ltd., had agreed to buy Shanghai Hongtai, a manufacturer of bimetallic wire, for approximately US$3.9 million. Based in China’s Jiangsu Province, China Shanghai Hongtai manufactures bimetallic wire, principally copperclad aluminum (CCA) and copper-clad aluminum magnesium (CCAM). The acquisition, the release said, enhances Fushi’s production capacity and secondary processing capabilities for CCA and CCAM products, and extends its sales network further into Eastern and Southeastern China. Shanghai Hongtai reported 2009 revenues as audited under Chinese GAAP of approximately $10.4 million. The company also announced a strategic investment in Yixing, an industrial center within the Shanghai economic zone, centrally located between Shanghai, Nanjing, and Hangzhou in Eastern China. The release said that the compa-

ny will relocate Shanghai Hongtai assets and key personnel to Yixing and establish Fushi International (Jiangsu) Bimetallic Cable Co., Ltd. “By positioning these assets in Yixing, in the heart of the Yangtze River Triangle, we believe we will establish a strong foothold in Southeast China and in doing so gain access to well over 100 telecom and power cable and wire manufacturers,” the release said.

Chinese company orders 2 wire rod mills ShanDong Fulun Iron & Steel Company Ltd., located in the central Shandong Province in China, has ordered two high-speed wire rod mills from Germany’s SMS Meer. A press release said that each mill will have annual production capacity of 700,000 metric tons of wire rod, with diameters ranging from 5.5 to 25 mm for wire rod and from 6 to 14 mm for rebar. It noted that a broad spectrum of steel grades will be rolled on the mills, from carbon steel and cold heading grades, spring steels, welding wire and ball bearing steels right up to stainless steels. It said that a key to the choice of SMS Meer was its engineering, which enables final sizes to be finish-rolled at low temperatures and with close tolerances. The wire-rod finishing trains are each equipped with a six-stand and a four-stand block. The mills are scheduled to go into service in mid-2011. ■

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ASIAN FOCUS

ASIAN NEWS BRIEFS

PEOPLE

PEOPLE General Cable Corporation has named Emmanuel Sabonnadiere as CEO and president of the Europe and Mediterranean region, and executive vice president of the company. He has nearly 20 years of senior management experience in energy transmission and distribution with Schneider Electric and Alstom. He joined General Cable two years ago as managing director of its Silec operations in France and recently became chairman of the board of the Algerian business. He holds an MBA degree as well as a PhD degree in physics. He succeeds Domingo Goenaga, who has more than 45 years of leadership and demonstrated results in the wire and cable industry. Goenaga will continue to be active with General Cable, including as an executive vice president and vice chairman of its European holding company, and assist Sabonnadiere in the transition. Based in Highland Heights, Kentucky, USA, General Cable Corporation is a global supplier of copper, aluminum, and fiber optic wire and cable products. Davis-Standard, LLC, announced that its Extrusion Systems group has chosen Joseph Wnuk to manage the company’s aftermarket business. This responsibility will be in addition to his current role as vice presidentelastomer. He has been with DavisStandard for about 25 years in various sales and product positions. He will be responsible for all sales and Joseph Wnuk product management activities related to both Aftermarket Services and the Elastomer Systems business. He holds a B.S. degree in business administration. The company also announced that Jerald Warren has been promoted to vice president and corporate controller. He joined Davis-Standard in 2006 as business director–aftermarket and was promoted in 2007 to vice president–aftermarket. He previously had worked for six years as a managing partner with New Harbour, Inc., and prior to that he held numerous financial and general management positions with John Brown Plastics Machinery and Brown and Sharpe Manufacturing Co. He holds a B.S.

degree in mathematical sciences from the University of North Carolina and an MBA from The Wharton School. Based in Pawcatuck, Connecticut, USA, Davis-Standard, LLC, provides a wide range of extrusion technology to sectors that include wire and cable. C&M Corporation has named Mike Norton as vice president of engineering and quality. He most recently served as director of product engineering at General Cable Corporation. Before that, he worked at JDS Uniphase and AT&T. He holds a B.S. degree in electrical engineering from Virginia Polytechnic Institute & State University, a master’s degree in electriMike Norton cal engineering from Cornell University, and a second master’s degree in business management from Purdue University. Based in Wauregan, Connecticut, USA, C&M Corporation manufactures bulk cable, coil cords, and cable assemblies, with manufacturing options in the U.S., Mexico and China. Beta LaserMike has named Sunish Bhatia as customer support specialist for its India-based customer support operations for its office in Gurgaon, near New Delhi. He has more than six years of experience in the instrumentation industry. He holds a three-year diploma in electronics and communications engineering from the Technical Board of Education, Raman Polytechnic Bangalore (Karnataka), and is pursuing a B-Tech in electronics and communications from Rajasthan Technical University. The India operation is part of U.S.-based Beta LaserMike, a global supplier of testing and measuring equipment. PolyOne Corporation reported two personnel announcements. Julie A. McAlindon was named vice president, marketing. She worked for 20 years for The Dow Chemical Company, focusing on strategic marketing and business leadership. Most recently, she served as a key commercial leader with Dow Advanced Materials. She holds a B.S. degree in biology from the University of

OBITUARY The chairman, members of the board of directors and management of Bekaert announce with great sorrow the passing away of Baron Velge, honorary chairman of Bekaert, on May 29, 2010. A grandson of Bekaert founder Leo Leander, he was born in Brussels on Jan. 9, 1930, and obtained a degree in mechanical engineering from the University of Louvain. He joined the Belgium-based

24 | WIRE JOURNAL INTERNATIONAL

company in 1957 and held a series of positions. In 1978 he was appointed president and CEO, and was a director of several companies and organizations. He served as chairman of the company from 1985 until 1997. He had a dynamic personality and was appreciated and respected in Belgium and abroad.

The Lincoln Electric Company announced appointments to two new strategic positions. Peter Pletcher has been named director, global consumable development. He joined the company in 1995 as a technical representative and later served in its U.S. sales organization. He was

WCMA award winner, 86, intends to work as long as it remains interesting Among the seven people honored with the Wire & Cable Manufacturers Alliance (WCMA) Distinguished Career Award on April 24 at the Connecticut Convention Center in Hartford was one person who at age 86 still welcomes going to work because he fully expects to learn something each time, and that experience never gets old. “I look forward to coming in on Monday because it’s never boring,” said Stanley Trykowski, a senior R&D chemist at plastic compounder S&E Specialty Polymers, who explained that the challenging nature of R&D has never lost its appeal. Trykowski, who earned a B.A. degree in chemistry from the University of Connecticut, and went on to earn a Master’s degree in chemistry/engineering at Trinity College, began his career in 1951 as a research chemist at Wm. Brand Co. (now General Cable) in Willimantic, Connecticut, and spent the next nine years developing PVC compounds for military applications. In 1960 he became vice president and technical director of compounding at Blane Chemical and in 1964, he joined the Great American Chemical Company as vice president of R&D. In 1968, he and two partners formed Lynn Plastics Corporation, a specialty PVC compounder. In addition to providing compounds for the wire and cable industry, Lynn Plastics was successful in penetrating the footwear and automotive industries. Several innovative products for these industries were developed by Trykowski, including heel and sole compounds for shoes and boots, and body side moldings and windshield encapsulations for cars. After selling Lynn Plastics, instead of retiring, Trykowski joined S&E as a senior R&D chemist, where he continues to lend his expertise and help the company test and develop new compounds. He works three days a week and still enjoys running twice a week (two miles)

promoted to technical manager in 2002 and assigned to Lincoln’s China operations, then moved to Singapore as country manager, where he developed Lincoln’s offshore business and was later promoted to business director, offshore. He holds a B.S. degree in mechanical engineering from LeTourneau University and an MBA from Rutgers University. Ferry Naber has been appointed director, global machine development. He began his welding industry career in 1973 at Smitweld in The Netherlands. He was promoted to manager of welding equipment in the early 1990s, when Lincoln integrated Smitweld into its portfolio of companies. Based in Cleveland, Ohio, USA, Lincoln Electric Company designs, develops and manufactures arc welding products, robotic arc-welding systems, plasma and oxyfuel cutting equipment and has a leading global position in the brazing and soldering alloys market.

and hitting a tennis ball against a wall a thousand times. He and his wife, Cecelia, have been married for 55 years. Asked what drives him to continue, Trykowski said that it is passion for R&D and his persistent personality. “When I work on something, I go on and on and on. I don’t like to give up.” He said that the nature of R&D can never get boring because it never ends, WCMA Board Chairman Ed whether it’s to meet a UL Fenton and Stanley Trykowski. approval or a project for GM. “Either you’re developing something new or trying to improve on something that already exists, and either way it’s a challenge, and that’s what makes it interesting. If it didn’t, I wouldn’t be here.” He said that he enjoys working for S&E, which he described as “a good fit,” and that he plans to continue as long as the company, based in Lunenburg, Massachusetts, will have him. “I like to keep busy.” Also honored by the WCMA were: Thomas Lascoskie, plant manager-New Holland, Berk-Tek, a Nexans Company; Mike Murphy, vice president, sales, Isotec and Gepco brand products, General Cable Corporation; Paul Palmer chairman (retired), Chromatics, Inc.; Lori Parent, strategic accounts manager, wire & cable, Breen Color Concentrates Inc.; Ron Reed, president, Horizon Wire & Cable; Ken Tober, sales manager wire & cable, Daikin America, Inc.; and Janis Webb, North American Sales Manager Cabling Solutions, DuPont. ■

JULY 2010 | 25

PEOPLE

Western Ontario. Kurt C. Schuering, vice president, key account management, was promoted to corporate officer. He joined PolyOne in 2007, and previously worked for GE Plastics, serving as global account manager, industry director, commercial quality leader and global OEM director for automotive. Prior employers include Eastman Chemical Company and Ferro Corporation. He holds a B.S. degree in mechanical engineering from the University of Kentucky. Based outside Cleveland, Ohio, USA, PolyOne Corporation is a global supplier of specialized polymer materials, services and solutions.

FASTENER UPDATE

FASTENER UPDATE Design makes wood screw a winner A new wood screw from Germany’s Schrauben GmbH & Co KG won top honors in the Fastening Technology Innovation Forum at the 2010 International Hardware Fair in Cologne, Germany. Wire reports said that a panel of media and industry experts chose the newly launched Heco Unix screw, a fullthread wood screw that, through a reduction in thread pitch from tip to head, is designed to ensure tighter contact between two wood elements. “Unlike a partial thread screw normally used to ensure this clamping action, the Heco Unix screw maintains continued thread engagement in both pieces of wood for the duration of the joint,” one account said. At its website (heco-schrauben.de), the company reports the following about its Heco Unix screw, which includes the characteristic Heco saw-tooth profile on its lead threads, also features patented milling recesses under the head. “In contrast to the more common raised milling ribs, this design allows the countersunk head to sit tightly when used in a hinge or metal fitting while still aiding efficient countersink-

26 | WIRE JOURNAL INTERNATIONAL

ing and obviating splitting when used straight into wood.” “Thanks to the variable thread pitch of the HECO-UNIX® screws the wooden components are pulled together as the screws are driven in. This permits the use of fully threaded screws without jigging the wood components together. Assembly tasks can therefore be completed much more quickly. Thanks to the full thread, components are also The award-winning Heco Unix screw. fixed in place axially. This prevents the negative effects of creeping und shrinking by wood when using part-thread screws. Furthermore, panels are completely secured even before the head is countersunk leading to a neater finish. Deep countersinking is no longer necessary. ■

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FIBER WATCH

FIBER WATCH Report covers fiber optic contracts in military and aerospace markets This report from U.S.-based Information Gatekeepers Inc. (IGI) is a compilation of key contacts involved in military and aerospace fiber optics research, design, manufacture, installation and testing. The company notes in a press release that there is a limited number of experts in fiber optics in the military and aerospace industry. “Knowing who these experts are and how to contact them is critical to any marketing effort by companies already doing business with the military and those new to the business,” it said, adding that this report presents more than 300 key contacts in government agencies and suppliers to the military, including component and subsystem suppliers, OEMs, research, training and standards organizations. The contacts, the release said, include representatives from the Air Force, Army, DARPA, DSCC, DISA, DOD, Navy, U.S. Coast Guard, Department of Energy and NASA as well as military, commercial, and aerospace fiber optics OEM systems contractors (representative list-

ings). It includes companies from Airbus and Boeing to Israel Aircraft Industries Ltd. and Mitsubishi Heavy Industries Ltd., as well as component suppliers from Alcatel and CommScope and Corning Cable to Amphenol Fiber Systems, among others. “If you are already doing business with the military/aerospace or plan to do so, this report will be an invaluable marketing tool,” the release said. It can be ordered from IGI’s web site www.igigroup.com. For more details, contact Dr. Hui Pan, Information Gatekeepers Inc., tel. 617-782-5033, hpan@igigroup.com. ■

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World Headquarters: FMS Force Measuring Systems AG Aspstrasse 6 8154 Oberglatt (Switzerland) Phone ++41 44 852 80 80 Fax ++41 44 850 60 06

WAI

NEWS

In 2008, Monterrey, Mexico, proved to be a very good host for the WAI’s International Technical Conference (ITC), and the Association has built upon that experience to make the return there this October even better. The different elements of the program are being finalized, and by the time this issue has been mailed the full event schedule will be available at wirenet.org by clicking on the ITC logo. WAI Past President Antonio Ayala, a key to the 2008 program, has once again led the planning efforts for the 2010 event, to be held October 18-20, at the Crowne Plaza Monterrey, which also hosted the 2008 event. The event, co-sponsored by the Asociación Nacional de Transformadores de Acero A.C. (ANTAAC), will feature technical paper presentations, tabletop exhibits, a reception, a plant tour and lots of networking potential as well as local attractions. See pages 66-67 for more details, including registration and tabletop display information. The 2008 event, which had a total of 258 attendees, included representatives from well-known wire compa-

WAI NEWS

Plans nearly set for WAI return to Monterrey, Mexico, for its 2010 ITC

ITC participants will visit the Nuevo Leon plant of Delphi Packard Electrical/Electronic Architecture Division where the company manufactures components and systems for the auto industry. nies such as Conductores Monterrey/Viakable and DeAcero. As of press time, more than 20 technical presentations have been scheduled. A Welcome Reception will be held after the technical program, providing an

JULY 2010 | 29

WAI NEWS

informal networking for attendees to talk to each other and with the more than 30 suppliers (as of June 15) that will be represented at the tabletop exhibits. Monterrey’s Tourism department will also offer city maps, dining suggestions, and information about area attractions. The plant tour should be especially interesting as ITC participants will be able to visit Ensamble de Cables y Componentes, Guadalupe III. The plant, part of the Delphi Packard Electrical/ Electronic Architecture division, is located at Guadalupe, Nuevo Leon, Mexico, where the company manufactures components and systems for the automotive industry. Its main product is automotive harnesses for customers such as Ford, Hyundai and Kia.

The Guadalupe III plant, which started operations in 1999, embodies Delphi’s Excellence Philosophy aimed at exceeding customer expectations. The ISO 9000 and ISO 14001 registered plant has been a recipient of the Q1 Ford Award and the Industria Limpia Award, among others. The plant, headed by Plant Manager Quirino Anaya, has around 2,700 employees. Past WAI ITCs have been held in Istanbul, Turkey (2009); Monterrey (2008); Bologna, Italy (2007); New Delhi, India (2006); The Czech Republic (2005); Mexico (2004); Italy (2003); Canada (2002); and the U.K. (2001). (WAI News continued on p. 33.)

Assistance offered to students to attend WAI’s ITC in Monterrey this October The Wire Foundation Inc. is offering financial assistance to students participating in the fall conference in Mexico. The 2010 International Technical Conference in Monterrey, Mexico, will take place October 18-20, and will feature more than 20 technical paper presentations on ferrous, nonferrous and electrical topics. The Wire Foundation provides scholarships to students studying the wire industry in the form of tuition assistance as well as special awards like the Wire Link Traveling

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Scholarship exchange between the U.S. and the U.K. Students enrolled in an institution of higher learning who will participate in the upcoming conference, either as presenters or regular attendees, are invited to contact the foundation for more information. Contact: David LaValley, Wire Foundation Inc., 1570 Boston Post Road, Guilford, CT 06437, USA, tel. 001203-453-2777, ext. 114, fax 001 203-453-8384; dlavalley@wirenet.org.

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Are you? At 80, WAI isn’t old. It’s mature. And it’s set in its ways of developing services that suit today’s upcoming leaders in the field. Sure. Communication has changed. Our high standards have not. Like some of you, we’ve seen faxes give way to e-mails, instant messaging, and blogs. But they haven’t invented a direction in wire and cable that we’re not interested in learning about and sharing with the thousands of constituents in our international network. WAI now offers: • a series of live and archived educational webinars; • electronic delivery of the industry leading Wire Journal International and twice monthly WAI Connection; • instant chat customer support online for Interwire; and • pdf files of the more than 5300 technical articles in our library. So if you’re still wondering what happened to the letter—Here are three to remember: W A I. Learn more online and join our network today at: www.wirenet.org. We may not be ready to pass the torch but we’re pleased to light the way.

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Business Information (required) A. Which ONE of the following best describes your company’s type of business? WIRE & CABLE MANUFACTURING 10 ❏ Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) 40 ❏ Other Metal (Rod/Bar, Bare Wire, Both) 50 ❏ Electrical Wire & Cable (Insulated Wire) 53 ❏ Communications Wire & Cable (Insulated Wire) 55 ❏ Fiber Optics

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)

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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.

July 2010 International Technical

Conference Proceedings

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

Volunteer spotlight: WAI’s Conference Programming Committee The Conference Programming Committee creates the educational program for the annual conference, WAI’s premier event. The group working on Interwire 2011 is tackling the project with a fresh approach they hope will give the program a decidedly different and improved flavor. With two dozen representatives from the industry’s top wire and cable manufacturers, the panel is designing a program directly geared to the interests and needs of Interwire’s main audience: folks like themselves. “Part of the idea behind this effort was for the association to get back to its roots,” said Co-Chairman and WAI

At Wire Expo 2010, Ron Reed, l, and Dane Armendariz, 2nd from right, co-chair the first “face-to-face” meeting of the WAI Conference Programming Committee.

Past President Ron Reed. “By forming this committee specifically with manufacturers, we went right to the Interwire audience and asked them to create the kind of program they want to see.” The committee began discussions early this year and has been working through numerous topic and format ideas to bring new content to the program. The members are dedicated not only to making a balanced program with something for everyone, but also to shaking up the format that has typically relied heavily on technical paper presentations. The committee is looking into more practical and informal presentations, workshops, panel discussions, and guest speakers to add to the mix. “I’m very encouraged by the committee’s work,” said Dane G. Armendariz, WAI’s President and Co-Chairman

of the committee. “Everyone is enthusiastic, full of ideas, and willing to put a lot of themselves into this effort. With all these resources at our disposal, there’s no way this can be anything but a great program. We are even getting ideas we never thought of for related topics that will result in a forum within our session.” The program is still in the planning stages, but the committee has settled on a format that will focus on three topical themes, a different one for each day of the show. It will also feature a major, first-of-its-kind segment dedicated to continuous casting, which will bring together the greatest experts in the field. “Everyone is taking a fresh look at what can be done at Interwire,” said WAI Director of Education Marc Murray. “Instead of just tinkering with an existing formula, the committee is starting with a blank page. It’s already yielded plans for the continuous casting forum, which we believe is an unprecedented program. I’m looking forward to seeing what else they come up with.” Conference Programming Committee Members Victor Andrade, WireCo WorldGroup Inc. Dane G. Armendariz, Henkel Corp. (Co-Chairman) Daniel Blais, Prysmian Comm./Prysmian Power Cables Douglas Blew, CommScope Inc. Brian Burr, Sumiden Wire Products Corp. Richard Carr, Coleman Cable Inc. Kamesh Chivukula, Algonquin Ind./Rea Magnet Wire Neville Crabbe, Leoni Wire Inc. José Antonio de Miguel, Grupo Condumex Eric Kessler, Insteel Wire Products Co. Ernesto Merino, Deacero SA de CV Richard Miller, Southwire Co. Tom Moran, National Standard Co. Patricio Murga, Viakable SA de CV Nicholas Nickoletopoulos, Sivaco Wire Group Robert Raiti, Owl Wire & Cable Inc. Ron Reed, Horizon Wire & Cable (Co-Chairman) William Reichert, Champlain Cable Corp. Todd Roberts, American Spring Wire Corp. Randy Sheets, Leggett & Platt Inc. Gary Spence, Encore Wire Corp. Andy Talbot, Mid-South Wire Co. Mark Thackeray, General Cable Technologies Corp. Walther Van Raemdonck, NV Bekaert SA David Weinand, Oklahoma Steel & Wire Bhaskar Yalamanchili, Gerdau Ameristeel Liaisons Marc Murray, WAI staff Dominique Perroud, SAMP USA/Exec. Committee ■ JULY 2010 | 33

WAI NEWS

Volunteer Sp✹tlight

CHAPTER CORNER

CHAPTER CORNER Chapter speaker: wind power offers much potential for cable industry The presentation by Bill Wall of Deepwater Wind, “Clean Energy is just over the horizon,” proved to be of much interest to the more than 70 attendees at the New England Chapter’s June 10 dinner meeting at the Crowne Plaza Hotel in Warwick, Rhode Island. “I think this was an excellent presentation because it clearly and concisely explained off-shore wind power and the role of the wire and cable industry,” Chapter President Mike Mathiasen said. “Everyone has heard about the

A utility scale offshore wind farm would use hundreds of kilometers of submarine power cable. Chart courtesy Deepwater Wind.

A typical wind farm and submarine cable layout. Chart courtesy Deepwater Wind.

powerful, and those along the New England coast, especially Rhode Island, are well located and have the potential to meet all of the region’s renewable energy needs, he said. Deepwater Wind was formed solely to develop offshore wind farms in the New England region, and has major projects now under development, two off of Rhode Island and one off of New Jersey. Wall said that Great Britain is planning on powering its entire residential sector with offshore wind by 2020, and that Germany has ambitious plans. The

importance of increasing our use of renewable energy, but Bill’s presentation gave me a better understanding of what goes into the production of deep water wind power, the potential niche for U.S. cable manufacturers, and future impact on the overall industry. It was also good to hear that the New England Coast of the U.S. is a prime location for these projects. In summary, I was ‘blown-away!’ ” he concluded. The vice president, marine operations, for Deepwater Wind, Wall is responsible for offshore wind farm construction and marine operations. He outlined the potential and challenges of offshore wind power, explaining that one weakness of large-scale, land-based wind farms is that the places where they work best tend not to be near the heavily popuA view of the proposed layout for Deepwater Wind’s Block Island project, one lated areas that most need the power. Offshore winds are more sustained and of two offshore Rhode Island projects the company is developing.

34 | WIRE JOURNAL INTERNATIONAL

Chapter golf tourney schedule Four chapter golf tournaments will be held from August to October, with the first one up the Ohio Chapter, which will return Thursday, August 5, to the Grantwood Golf Course in Solon, Ohio, for its 8th Annual Golf Tournament. For more details, contact either Rob Fulop, Wire Lab Co., at tel. 216-362-0800, r.fulop@wirelab.com, or Michael Caranna, American Spring Wire Corp., at tel. 3216-292-4620, mcaranna@amspringwire.com. Next up is the New England Chapter’s 16th Annual Golf Tournament, to be held Thursday, September 16, at the Mount Pleasant Country Club in Boylston, Massachusetts. Contact Mike McKee, Lloyd & Bouvier Inc., tel. 978-3655700, mikem@lloydbouvier.com. The following month, the Southeast Chapter will return Thursday, October 14, to the Rock Barn Golf and Spa in Conover, North Carolina, which will host the chapter’s 9th Annual Golf Tournament. Contact Steve Vannais, Davis-Standard Corporation, tel. 704-799-2258, svannais@davis-standard.com. The final outing is for the Western Chapter, which is scheduled to return Monday, October 25, to the Los Verdes Golf Course in Rancho Palos Verdes, California, for its 10th Annual Golf Tournament. Contact Michael Howard, Coast Wire & Plastic Tech., tel. 310-639-9473, michael.howard@coastwire.com. ■

JULY 2010 | 35

CHAPTER CORNER

EU Offshore Wind Targets call for 5,000 MW by 2010, 15,000 MW by 2015, 40,000 MW by 2020 and 150,000 MW by 2030. The U.S., Wall said, has been active in landbased wind farms but not for offshore sites. “The U.S. is 20 years behind, but can build on Deepwater Wind’s Bill Wall and New England Chapter President European experience,” Mike Mathiasen. he insisted. If U.S. development of offshore wind farm increases, bolstered by a recent federal ruling for a well-publicized project off Cape Cod, it offers much potential for ports, job creation and exports, Wall said. That, he noted, includes the U.S. wire and cable industry, as there is a need for special cables to make offshore projects feasible. Those include inter-turbine submarine cables and offshore sub-station and export submarine cables. Currently, such cables are made outside of the U.S., but that does not have to be the case, he said, adding that he favors bigger projects as they offer economies of scale that result in lower cost per KW generated and delivered.

WRAPUP Activity at the Taubensee Steel & Wire Co. booth at Wire Expo, which was held for the first time in Milwaukee.

Wire Expo wrapup changes make for vibrant event

A condensed format, an overlap with two other industry events, a new location and hopes for a somewhat healthier economy collectively contributed to a successful Wire Expo 2010. The exhibits were co-located May 12-13 with the National Electrical Wire Processing Technology Expo (see p. 46) at the Midwest Airlines Center in Milwaukee, Wisconsin, where the two events had a combined total of 2,931 participants who had crossover access between the shows. Contributing to that number were also attendees who had attended the American Wire Producers Association’s Long Product Supply Chain Symposium (see p. 48), which was held May 10 and 11 at the Pfister Hotel. The AWPA’s first-time event drew 220 people, including presidents, CEOs, sales professionals, and senior managers from its member companies. As a standalone, Wire Expo attendance was 1,457 participants from 38 states and 21 countries. 36 | WIRE JOURNAL INTERNATIONAL

During the Awards Ceremony, WAI President Dane Armendariz recognized Sandy May, whom he noted was not just a WAI Past President and who had also served as WAI interim director when needed, but was the person “who was my mentor when I started out in the WAI.” Armendariz also thanked Past President Sharon Young, who was among those who responded to his prior call for volunteers. “It’s this type of dedication from someone who already gave so much effort and time to us that makes this association great,” he said. He then singled out Don Schollin, president of Q-S Technologies, for special recognition in the form of the President’s Award, which is given at the discretion of WAI leadership to an individual who has truly made a difference within the Association. He cited Schollin’s extensive contributions, from the New England Chapter, where he served as president in 2006, the Conference Programming Committee, chairing the WAI’s Publications Committee, two terms on the WAI

WRAPUP Among those recognized at Wire Expo were (l-r): Takanori Sato and Prof. Kazanuri Yoshida, Tokai University; Bae Jong-Gu, accepting for Kiswire/POSTECH authors; Jan Pilarczyk and Rafal Wludzik, CUT; Tadeusz Knych, AGH University of Science and Technology; Dale King and Walther Van Raemdonck, NV Bekaert SA; Brian Bouvier; Bill Fajardo, accepting for Borealis authors; Antonio Ayala; Don Schollin; Prof. Javier Gil Sevillano; WAI President Dane Armendariz; Prof. Motoo Asakawa; and Peter Funk.

Board of Directors, and more. “The man never says ‘No’,” Armendariz declared. He also thanked 2009 President Antonio Ayala for his many efforts that year as well as all the work he had put in to ensure the success of WAI’s 2008 International Technical Conference in Monterrey, Mexico, as well as his willingness to spearhead efforts for the return there this October. “For those of you who don’t know Antonio, he operates in just one gear: overdrive.” Early in his message, Armendariz recognized that the times remain tough, but

3 Events 1 Location

Encore Wire’s Gary Spence, l, sat in on the Exhibition Planning Committee to discuss a possible educational program. To his right are committee members Joe Snee, Amaral Automation, and Carolyn Edwards, Zumbach Electronics Corp.

declared that, “The volunteers and staff members are constantly scanning the landscape and adjusting course, to ensure that WAI changes to serve the needs of today’s and tomorrow’s industry. We are doing better today than we were a year ago, and we will be even better and stronger a year from now. You have my word on that!” During the Awards Ceremony, Wire Foundation President John Drummond, also a WAI Past President, introduced Talley Metals Process Engineer Peter Funk, the 2010 Wire

SAMP USA’s Dominique Perroud, WAI’s First Vice President, 2nd from left, listens to Horace Pops, Pops Consulting, during a WAI Education Committee meeting. Left of Perroud is Paul Pawlikowski, Delphi Packard Electric. Right of Pops is Jaime Fuente, Condusal SA de CV. JULY 2010 | 37

WRAPUP Bolstered by co-location cross-over, the first day of Wire Expo was especially busy.

Discussions at the Leoni Wire booth.

Joan Park greets attendees at the booth of South Korea’s Whanghae Precision, a first-time Wire Expo exhibitor. 38 | WIRE JOURNAL INTERNATIONAL

Link Traveling Scholarship winner, whose report on his two-week European trip was in the June issue of WJI. WAI Second Vice President Nick Nickoletopolous, general manager, Sivaco Wire Group, presented the Mordica Memorial Award to Prof. Javier Gil Sevillano, University of Navarra, and the Donnellan Memorial Award to Brian Bouvier, vice president of Lloyd & Bouvier. Awards were also presented to authors of the best technical papers presented in 2009 and new WAI Life and 25-Year Members were recognized. Commenting after the events in Milwaukee were over, Armendariz observed that there was much to be pleased about. “Scheduling three industry events within the same week helped a lot of visitors justify their trip to Milwaukee. The two-day exhibit format worked very well and with the convenience of the co-location we saw a steady flow of traffic between the shows on both days.” WAI First Vice President Dominique Perroud said that the show co-location, exposure to a downstream business segment and condensed show were very well received. “For attendees and exhibitors, the ability to establish new contacts and the networking opportunities are always critical and this show provided all of this in a very efficient way. I see this as a turning point in the way Wire Expo is perceived in the industry. It demonstrates that under a different format, Wire Expo still provides value to its participants and fills a need in our industry, especially for the North American wire and cable industry.” WAI Executive Director Steve Fetteroll deemed the firsttime co-location between Wire Expo and the National Electrical Wire Processing Technology Expo a success. He added that he was “especially gratified by the early feedback from a number of key exhibitors and the positive responses we’ve received from local attendees,” he said. A total of 157 exhibiting companies participated at Wire Expo, and with crossover access, attendees had an additional hundred exhibits to visit. The shared show floor format appeared to work.

Joe Memmott, US Synthetic Wire Die, discussed synthetic diamond dies as part of his company’s Production Solutions presentation. The show floor talks were also done by Condat Corp.’s Neil Lowdon and by Horace Pops/Pops Consulting at the Continuus Properzi booth.

WRAPUP The Education Committee discussed topics from possible areas of technological focus to theme sessions. “Having attended both Wire Expo and the Wire Processing Expo separately in earlier years, I found the co-location to be a great piece of synergistic planning and congratulate the organizers on a job well done,” said Peter M. Blackford, special projects manager, Cable USA, Inc. Another attendee, Leesa Williams of Emerald Spring Processing, said that she liked the mix of the shows. “It allowed me to visit with some of the long bar people as well as the wire/coil people at the same time,” she said. Blachford Company’s Dan Howar said that he heard a number of people who liked linking AWPA with Wire

Southwire Company’s Richard Miller, r, makes a point during the Exhibition Planning Committee meeting. Expo. “I think this should continue as it consolidates the entire industry. Some folks are only members of one of the associations. By having both together, it brings both sides together and makes it much easier to justify attendance.” By and large, exhibitors also appreciated the structure. “The two-day show format was good,” said Bob Eisele, marketing manager, Amacoil, Inc. “It cut costs and I think it forced attendees to get focused and decide what they wanted to accomplish at the show. Co-locating the other show was also good since we had many visitors to our booth—with whom we had meaningful dialog—who oth-

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WRAPUP Q-S Technologies’ Don Schollin, l, received the President’s Award from WAI President Dane Armendariz.

Donnellan Memorial Award winner Brian Bouvier, l, and Mordica Memorial Award winner Javier Gil Sevillano.

erwise would not have talked to us. Now they’re in our database and we can follow up to see what develops.” SAMP USA Area Business Manager Marco Gerardo said that he views the show activity “as a very positive sign the economy is improving.” He said the mood was positive and the level of attendees (potential customers) was good, with many of them decision makers, which is

critical for making a show a success. He also liked the colocation. “That allowed us as suppliers to learn more about a downstream industry segment and that is very beneficial for our own customer base who have more common connections and business relationships in both segments,” he said. “Wire Expo proved that the economy is picking up at a

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After each WAI WEBINAR one question remains...

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Highlighting the operations of Charter Steel’s Saukville plant is Customer Service Manager Mark Terrian, who welcomed the 70-plus attendees who toured the plant. steady pace for (us),” said Carolyn A. Edwards, marketing manager, Zumbach Electronics. The leads the company got reflect that the industry is alive and active, she said. “It was important for us to meet with existing customers although we also met with several likely prospects for active business in the future.” Engineered Machinery Group, Inc. CEO John Stevens said that he was concerned that a shorter Wire Expo would mean less attendee traffic, especially with the other wire event. “When the Expo opened, the traffic was a bit light, then all of a sudden we were busy the whole day talking with customers and generating leads on new equipment. This carried over into the next morning as well. I see this Wire Expo as a complete success; the short program gave us a lot of continuous activity instead of drawn out over the three-four days with lighter traffic. It also saved us money of not flying in early to set up and get ready for a Monday start. … I liked the combined show and look forward to this format in future Expos. Those that stayed away missed out on the new opportunities presented at this Expo.” “We were very pleased with the level of traffic and serious nature of the contacts,” said Ramona Krogman, mar-

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The winner of WAI’s 5K Industry Run, sponsored once again by Leoni Wire, was OMA USA Sales Manager David Tietze, front row, second from left. keting manager, Gem Gravure Co. “The visitors to our booth were discussing new projects, a breath of fresh air after last year’s slow down. Running the show in conjunction with the National Electrical Wire Processing Expo gave us an opportunity to meet with our wire processing customers as well. This is a real advantage. Hopefully future shows will be planned in this way.” The Milwaukee event also included WAI’s 80th Annual Convention, which saw the presentation of 30 technical papers as well as a “Phosphating 101” class; the Annual Awards Breakfast honoring the Donnellan Memorial Award winner, Brian Bouvier and the Mordica Memorial Award winner, Professor Javier Gil Sevillano, as well as technical paper authors; an ASTM presentation; Fundamentals of Wire Manufacturing; plant tours for the Charter Steel facility Saukville, attended by more than 60 people, and Rockwell Automation facility in Cleveland; three Production Solutions presentations on the show floor as well as a reception; and many behind-the-scenes meetings of WAI committees and boards. The WAI also held its 6th Annual 5K industry Run, sponsored by Leoni Wire, which was won by OMA USA’s speedy sales manager, David Tietze, who outdistanced the small field of runners on what had at first appeared to be an ugly rainy day that fortunately turned into a surprisingly good experience for one and all. The WAI’s next major event is its International Technical Conference, Oct. 18-20, in Monterrey, Mexico. See Electrical Wire Processing Technology Expo and AWPA symposium wrapups on pp. 46 and 48.

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The WAI’s next trade show will be Interwire 2011. 44 | WIRE JOURNAL INTERNATIONAL

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WRAPUP

Great results reported for Electrical Wire Processing Technology Expo The 10th Annual National Electrical Wire Processing Technology Expo, the nation’s largest dedicated wire processing event held at the Frontier Airlines Center in May, exceeded industry expectations with increased show attendance and machine sales and services. The six seminars that were held during the two-day expo kept the crowd’s attention and many attendees were present at multiple seminars, indicating a strong interest in the relevant topics. The organizers, Expo Productions, report that the show’s attendance was up 16% from last year, with exhibitors reporting increases in machine sales and services. It noted the following: The show attendees and exhibitors were reporting a promising outlook for industry’s future. Due to co-location with the Wire Expo at the Frontier Airlines Center, attendees were able to branch out and visit with other companies not typically at the Electrical Wire Show, resulting in higher attendance for those companies. Two seminars stood out with high attendance and topic relevancy to the industry’s current state. Crimping

Product Manager, Rob Boyd of Schleuniger presented “Crimp Quality Verification Methods and Trends” to a packed house of over 100 attendees. This seminar was an overview of traditional quality verification methods that are most commonly used today. Boyd introduced an additional level of crimp quality assessment using micrograph systems (crimp cross-sectioning equipment). A discussion of new crimp quality standards and trends completed the seminar. Another capacity-crowd seminar, “Wiring the Next Generation of North American Automobiles,” was presented by the Electrical Wiring Component Application Partnership, a sub group of the United States Counsel for Automotive Research (USCAR). Presenters from Ford, General Motors and Chrysler discussed common electrical interfaces, interface performance, and processing these interfaces into durable wiring assemblies. “The USCAR group was a perfect addition to this year’s schedule because the automotive industry has been hit so hard lately in many different aspects of manufacturing,” said Jay Partington, show manager. “The group really reinforced the turnaround of the automotive industry and gave a positive outlook for the future.” Two additional wire industry programs, WHMA recertification seminars and the Long Products Supply Chain

46 | WIRE JOURNAL INTERNATIONAL

Wire Expo attendees were able to visit booths at the 10th Annual National Electrical Wire Processing Technology Expo, the largest U.S. dedicated wire processing event. Symposium, a new event put on by the American Wire Producers Association, provided a great buzz about the industry’s rebound and created notable positive economic impact on area hotels, restaurants and entertainment facilities. Nearly a year of research and planning goes into the development of the seminar schedule to ensure that the topics are timely and beneficial to the attendees. The 11th Annual Electrical Wire Processing Technology Expo will be held Wednesday, May 18 & Thursday, May 19, 2011 at the Frontier Airlines Center in downtown Milwaukee. Companies interested in exhibiting or holding a wire industry seminar during the show can contact Cheryl Luck, Expo Productions Inc., at tel. 262-367-5500, or go to www.electricalwireshow.com for more information.

WAI Executive Director Steve Fetteroll at the co-located National Electrical Wire Processing Technology Expo, with its organizer, Jay Partington, Expo Productions.

WRAPUP

AWPA: long products symposium provided good picture of steel industry The American Wire Producers Association (AWPA) reports that, with the support of 10 sponsoring associations, its inaugural Long Products Supply Chain Symposium held May 10-11 at the Pfister Hotel in Milwaukee was well received. The AWPA, which also held its annual meeting prior to the symposium, reported that the symposium was attended by approximately 220 people. The audience was “engaged and involved in this knowledge-packed program that offered information and ideas to presidents, CEOs, sales professionals and senior managers of our member companies,” it reported in its wrapup of the event. “From 1 pm on Monday to 7 pm on Tuesday, including the receptions and commercial meetings surrounding this event, the participants heard about timely issues and had many opportunities to ask questions and discuss among themselves those things which directly impact the success of their own businesses,” it said. The results were resounding enough that AWPA plans to hold its 2011 symposium with WAI’s Interwire 2011 event. “The current discussions center around when, where and how long – ways to make sure we’re building on the momentum of this very successful event,” said AWPA Executive Director The rod supply panel included, l-r, Kimberly Matthew Brace, executive v. p. of sales Korbel. “I & marketing, CMC Americas; Jim would like Kerkvliet, v.p. commercial sales, Gerdau to add that Ameristeel; David Brooks, senior v.p. of over 75% of American Metal Market; H. Woltz, chairthe survey man/CEO, Insteel Industries; and Jack respondents Lynch, sales manager, Charter Steel. visited Wire Expo as part of their Symposium experience. That bodes well for continuing a very successful partnership with the Association. Our experience in working with the WAI staff was absolutely a pleasure we are happy to repeat.” AWPA’s first-ever Long Products Supply Chain Symposium began with a speech by Jay Timmons, the executive vice president of the National Association of Manufacturers. He asserted that a resurgence of manufacturing is necessary for the stability and future of the U.S. economy and that NAM’s Jobs for America Plan is a

48 | WIRE JOURNAL INTERNATIONAL

comprehensive approach to fulfilling this need. Monday afternoon’s lively U.S. Economic and Manufacturing Policy Panel consisted of Charlie Blum, the Coalition for a Prosperous America/the Fair Currency Coalition; Kurt Fowler from SteelFacts; David Phelps, the American Institute for International Steel; and Tom

Danjczek, the Steel Manufacturers Association. Their presentations, as well as those of other speakers in Monday’s policy panel and the speakers in Tuesday’s rod supply panel can be found at www.awpa.org. Blum began by discussing the difficulties faced by the industry in the current state of the economy, the national debt, the rise of state capitalism in places like China, and lack of a comprehensive U.S. Trade Policy. He emphasized the need for a trade strategy, and rebalancing of trade, to include more comprehensive enforcement of current trade laws, and a broadening of agreements to “more than just tariffs, quotas and other obvious non-tariff barriers, that would mean disciplining the use of subsidies, border tax adjustments, and currency manipulation.” Fowler covered statistical information that would help in discussing these issues with government representatives, providing a variety of information on the current trade situation, and that of the economy. Phelps provided another perspective – noting that much has been made of the crumbling American infrastructure, and the decline of American competitiveness, but that the American system is still the most efficient in the world, and it is still America that drives the world’s economic engine. Phelps asserted that Free Trade and a business-friendly regulatory environment and tax structure are essential to ensuring this continues in the future. Danjczek agreed that a reasonable regulatory environment was essential and a lack of energy policy is stunting development, but argued that more trade law enforcement is necessary. The question and answer period after the presentations was energetic, and the audience appreciated the active debate of the issues from differing perspectives, which highlighted the difficulty in resolving these complicated trade conflicts. On Tuesday, the Symposium provided a general economic outlook, and then more specifically in the steel markets, a look internationally and domestically. Attendees heard from Clare Zempel, founder of Zempel Strategic, who presented the view that the economic recovery is happening, and there will not be a “doubledip” or w-shaped recovery. That afternoon, Ken Simonson spoke regarding the Construction Sector, and offered the opinion that the recovery is progressing slow-

the AWPA website at www.awpa.org so you can see the stellar quality of the information that was offered. But, you missed the interaction and the value of AWPA Executive Director Kimberly discussion and Korbel with Policy Panel speakers (l-r) debate with Kurt Fowler, SteelFacts; Charlie Blum, others who the Coalition for a Prosperous America; face what you David Phelps, the American Institute do in the mar- for Int’l Steel, Tom Danjczek, Steel ketplace. Manufacturers Institute; and moderator The next Mark Marselli, WJI. Supply Chain Symposium for producers in the rod, wire and wire products sectors is scheduled to be held May 2-3, 2011, in conjunction with Interwire 2011, in Atlanta, Georgia, USA. For more details, contact AWPA at tel. 703-2994434 or go to www.awpa.org. ■

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WRAPUP

ly, and will continue to progress very slowly through the next two years. Developer financing is difficult to find, due to low occupancy rates, the slowness of approval of stimulus funded projects (partly due to “Buy American” provisions) will keep new construction slow. Edwin Basson, vice president of commercial coordination for ArcelorMittal, discussed structural shifts in the global steel market, emphasizing that steel producers must reposition how steel is marketed, and new markets should be found. Despite a long day of presentations at the Symposium, Tuesday’s final session kept attendees both interested and engaged. It began with H. Woltz, Chairman and CEO of Insteel Industries, describing the challenges for independent wire producers and the need for a stable supply of rod, making access to imports necessary. AWPA thanks the trade associations representing manufacturers throughout the supply chain for supporting and promoting this important event and the AWPA Member company sponsors for their financial support. We believe that cooperation in the supply chain will benefit the manufacturers and the associations, as we work together to address policy and legislation that affect us all. If you participated, we thank you! If you missed this opportunity, we’ve provided the presentations at

part 1

FEATURE

Equipment his feature presents a wide range of capital equipment, much of it displayed at the

wire Düsseldorf show that was held earlier this year. Below are brief write-ups

provided by equipment suppliers. More equipment will be featured in the second equipment issue in September.

AIM Inc./U.S. AIM Inc., a global supplier of CNC wire bending solutions, demonstrated its AFE3DH6 double-head bender and AFC6 3D, single head bender. Both machines feature highly reliable design that make them versatile robust and economical. The AFE3DH line is targeted mostly to automotive production where large wire parts are required. All AIM machines feature graphics animation with collision detection, allowing the users to watch the machines producing parts on their computer screens before they actually produce anything! This minimizes operator errors and simplifies programming of complex parts. A dual contrarotating rotary straightener assures good quality straight wire without much effort. The AFC line carries most of the features of a high-capacity, three-dimensional bender without the large layout or the high price tag. Unlimited arm rotation, 22 roller straighteners, four different fixedbend radii (unlimited programmable) along with the latest-in-technology servo motors and controllers assure the best value on a low-cost machine backed up with excellent worldwide technical support. Along with features

More new ‘stuff’ in Products Note: Capital equipment is inherently interesting, but the essentials matter too. The Products section that begins on p. 86 includes new/updated products that were presented at either wire Düsseldorfand/or Wire Expo.

50 | WIRE JOURNAL INTERNATIONAL

AIM Inc. President Constantine Grapsas with the company’s AFE3DH6 double-head bender. unmatched by the industry, such as email reporting, barcode labeling, barcode reading, production scheduling, remote internet service and control, AIM presented more than just equipment: the future of CNC wire bending! The company, which has a second production and support location in Europe, manufactures a broad line of wire, tube and rebar bending machines, from less than 2 mm to more than 25 mm wire diameters. AIM is a uniquely qualified wire shop automation company. AIM, Inc., www.aimmachines.com.

Euroalpha Srl/Italy

Domeks Makine displayed its Quadromatik 400 model, a new multi-purpose, wide production range coil/spool packing line. The company notes that investment cost is very important to cable producers in any time, but especially so now given the world economic situation. One investment that would make sense is a system that would enable a cable producer who has need for both a coil packing line and a spool packing line to be able to use just one system that can do both, including processing cables that are very small or large. Domeks’ Quadromatik 400 can do just that. The double-head coil/spool packing line automatic palletizes product for high-speed coiling or

Euroalpha Srl’s display included the R1 compact rod breakdown machine, a new system that is designed so that the capstans are arranged onto two superimposed rows that have a total length of less than 5 meters. This results in an extremely compact system that can meet the most severe space requirements. Each capstan has its own drive motor, a unique feature, and a sophisticated SW algorithm provides precise motor control that has been perfected by the company’s technical team, which has more than 17 years of experience. This combination of design and experience results in the R1 being able to operate with an extremely limited slip rate of just 0.5% ÷ 1.0% between the wire and capstans. This system can provide the same level of performance and produce wire quality that is the equivalent to that of single-row rod breakdown machines. It is highly effective to use, in terms of capital investment and operating expenses, for drawing copper, aluminum and aluminum alloys rod, as for capital investment and operational expenses. The company also showed its B630-F “Four-Twist” bunching machine, a patented dual-bow rotating group that performs four-twists each revolution of the transmission shaft, in contrast to conventional bunchers that perform

The Domeks Makine staff by its Quadromatik 400 line. spooling of single wire and multi-cores cables with diameters from 2.5 mm up to 12 mm. It can process 150 mm inner-diameter coil types with outer diameters from 210 mm to 400 mm and coil heights from 30 mm to 190 mm; and 80 mm inner diameter spool types with outer diameters from 140 mm to 350 mm and heights of 40 mm to 250 mm. Some of the available cable types the system can coil include: rigid, flexible or multi-stranded single wire insulated cables with cross sections from 1 sq mm up to 16 sq mm (1.5 sq mm, 2.5 sq mm and 4 sq mm at line speeds of 500 m/minute, and 6 sq mm, 10 sq mm and 16 sq mm at speeds of 400 m/minute); rigid or flexible multi-core cables with cross sections from 2 x 0.75 sq mm up to 4 x 2.5 sq mm (2 x 1.5 sq mm and 2.3 x 1.5 sq mm at a line speed of 400 m/minutes, and 4 x 2.5 sq mm at a line speed of 300 m/minute. It can also spool: flexible or multi-stranded, single wire insulated cables with cross section from 1 sq mm up to 16 sq mm at a line speed of 400 m/minute; rigid or flexible multi core cables with a cross section from 2 x 1.5 sq mm up to 4 x 2.5 at a line speed of 300 m/minute; and flat twin and earth type cables with cross sections from 2 x 1 +1 sq mm up to 2 x 4 + 2.5 sq mm at a line speed of 350 m/minute. Domeks Makine, www.domeksmakine.com.

Euroalpha Srl Engineer Parise Massimo by the company’s B630-F buncher.

only two twists. This results in double the productivity at the same RPM, and energy consumption can be reduced by running the machine at lower RPM. This machine is suitable for producing 1+6 concentric strands and 1+6+12 unilay strands as well as ordinary bunches. Euroalpha Srl, www.euroalpha.it.

Fine International Corporation/U.S. Fine International Corporation (FIC) exhibited a highspeed, fine wire braider, Model GSB-1Q, that has an electronic lay control system and uses 16 carriers with a JULY 2010 | 51

FEATURE

Domeks Makine/Turkey

FEATURE

400W servo drive capstan system. It includes a 400 mm payoff and take-up, each of which is driven with dancertension control. The unit will handle braid wires from 0.03 mm to 0.08 mm in diameter with a braiding pitch up to 60 mm. Maximum rotation is 120 rpm. FIC notes that it provides a wide variety of machinery for wire and cable and fiber optic manufacturers. That includes: horizontal

great numbers to witness the operational capability of its machine and the quality of the final product. The mill features a combination of a horizontal spooler (payoff), a twohigh rolling machine (WSR-type), two edge-rolling devices (WSE) and two Universal Turks Head (WST) rolling machines, as well as two combined dancers, three Vollmer measurement systems and an oscillating spooler. This very compact rolling mill is ideally geared toward the production of high-precision rectangular copper wires (e.g., CTC) or copper flat wire, such as PV ribbon (interconnect wire and bus bar). In general, applications for CTC cables are windings in transformers, motors and generators, but high-precision rectangular copper wires with small cross-sections are also needed for high-efficiency hybrid motors and wind generators. Tolerances for some rectangular wire has been reduced to +/- 0.005-0.010 mm, which cannot be achieved with the traditional cold rolling technology. Fuhr’s new con-

Fine International Corp. Co-owner and General Manager Bruce Ceres talks to customers about the GSB-IQ braider.

extruders from 20-150 mm and vertical units from 20-65 mm. While most have a 24:1 L/D ratio, there are circumstances where a longer L/D is required, such as in coaxial cable manufacturing (CATV coaxial cable, LAN category cable, minicoax cable and RF microwave cable). In the majority of coaxial foam applications, FIC uses up to a 40:1 L/D configuration to accommodate a two-stage proprietary screw design. The added length allows for proper melting/mixing within the full 24:1 first stage and then homogenization of the dissolved gas in the second stage while providing the necessary polymer cooling after the N2 injection point. Vertical extruders are designed in a wide range of support stand configurations. Adapter connecting ports are included with all coextruders to a wide variety of crossheads. Bleeding valves (both manual and pneumatic operation) can be supplied as well. FIC also supplies breakdown lines, stranders, cablers, bunchers, twisters, drawing equipment armoring lines and more as well as a complete range of extrusion line ancillary equipment. Fine International Corporation, finesales@gmail.com, www.fineinternational.com.

Fuhr GmbH & Co. KG/Germany Fuhr GmbH & Co. KG, a manufacturer of world-class wire rolling machines, showcased a state-of-the-art wire rolling mill, its latest development for the production of high-precision rectangular copper wires to the public. It was the only exhibitor to display an entire rolling mill, this one capable of processing copper wire in real-time from round to rectangular with tolerances of +/- 0.005 mm with excellent surface quality and material properties at the same time. Visitors came in

52 | WIRE JOURNAL INTERNATIONAL

Fuhr GmbH & Co. KG Technical Director Volker Gerth by the company’s new rolling mill for producing rectangular copper wire. cept and contemporary layout of its wire rolling machines results in a rolling mill capable of processing copper round wires into a wide range of rectangular and flat shapes, achieving width/thickness ratios of up to 40:1. Fuhr also serves the needs of ferrous, nonferrous and special alloys producers. Fuhr GmbH & Co. KG, www.fuhr-wire.com.

Gimax Srl/Italy Gimax Srl displayed an addition to the company’s line of respooling lines, the MULTISPIRA. This respooling line, a semi-automatic unit, requires an operator to start the respooling cycle, and then the unit will continue to respool automatically. An operator is also needed to change the spool and to tie on/off the wire. The MULTISPIRA is a very basic unit. It is designed to run generally at speeds of 20-25 meters/sec, although with the appropriate options it can reach much higher speeds, in excess of 30 meters/second. It is perhaps more limited in the range of what it can handle in terms of wire diameter and spool size/type compared to other Gimax machinery, but it is

IDEAL Werk GmbH/Germany IDEAL Welding Systems/U.S.

Gimax Srl’s Enrico Romagnolo with the company’s MULTISPIRA respooler. intended for users that do not require all the options and features that are available on the more sophisticated machines. This is a basic machine meant for users who are not looking for extreme outputs, yet still want a certain amount of flexibility as well as simplicity of use. This all

Germany’s IDEAL Werk GmbH, whose U.S. business is IDEAL Welding Systems, demonstrated some exciting new enhancements to its already Quick Setup GAM100 series mesh welders. The new “Green Line” that was demonstrated uses the latest in Siemens Servo drives that significantly reduces the power consumed by the servo drives on the machine. This is done by pushing energy back into the electrical network during deceleration of the motors. A further energy saving technology that is employed is the company’s MFDC (Medium Frequency Direct Current) welding system. Energy reduction of as much at 35% is reported during welding because of improved PF (Power Factor) and a fully balanced load. This ultimately results in a lower energy cost and also makes it possible to reduce the size of the electrical supply to the machine. Apart from the energy savings of the Quick Change mesh welder, IDEAL also introduced a LASER SETUP assistant to facilitate easy of setup and thus reduced setup times. But probably the most signifi-

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translates into a much more economically priced machine, but one that still retains the quality and reliability of a Gimax machine. Gimax Srl, www.gimaxgroup.com.

FEATURE

tooling. The start scrap length for a weight change ratio less than 1.25 is 20 to 50 m. A production schedule that wisely uses the advantages of the CTC can reach production times of up to three weeks. With downtime savings of one to two hours per type change, start-up scrap reduction and improved production flexibility, the CTC product fits well to Maillefer’s program of offering overall equipment effectiveness to its customers. Maillefer SA, www.mailleferextrusion.com.

Niehoff GmbH/Germany

IDEAL Welding Systems Sales Manger Clive White by the new “Green Line.” cant improvement in setup times is Ideal’s completely new line-wire feeding system. IDEAL demonstrated that a complete line-wire change could be achieved in less than five minutes, compared to as long as an hour for traditional systems. With many customers looking for more cost-effective ways to produce better quality products, the new IDEAL hi-tech “Green Line” machinery is a good solution. IDEAL, www.idealweld.com.

Maillefer SA/Switzerland The Maillefer SA booth included CTC (Continuous Type Change) component of a medium-voltage cable manufacturing line. This component allows manufacturers to make cable type changes on the fly, without timely and costly line stops. It is available for MV XLPE (10 to 35 kV) production systems. So far nearly 20 CTC components have Manuel Felder in front of the CTC comrecently been ponent of a Maillifer SA medium-voltage installed in cable line. Europe, Asia and the Middle East. Encouraged by the results proven in various factories, the company decided to present the CTC equipment. Characteristics include type changes for conductor sizes from 50 to 300 sq mm with a max variation of 10 mm in diameter from one type to the other using the same

54 | WIRE JOURNAL INTERNATIONAL

Niehoff GmbH, a leading European machinery manufacturer represented in North America by its subsidiary, Niehoff Endex North America, Inc., displayed a doubletwist stranding line consisting of a double-twist stranding machine, model DSI 631, with a backtwist payoff, model ARD 630 D. and a longitudinal tape payoff, model ALB 600. The DSI 631, and the larger DSI 1001 model, have been developed to strand insulated conductors into pairs or quads or to strand conductor pairs into LAN cables (current and future generation cable design) and Niehoff GmbH President Heinz Rockenhaeuser by the company’s other speARD 630 D payoff. cial cables of best quality, either with or without back twist, at high speeds with highest quality. The DSI machines are built for a wide conductor cross-section range and a maximum stranding diameter of 8 mm or 15 mm and can be combined with numerous other production equipment—such as bobbin payoffs, longitudinal tape payoffs, a motorized payoff for applying tape during the stranding operation and a new type of backtwist device—to create stranding lines that can be used to realize completely new production processes. The new DSI machines are equipped with Class IE2 energy-saving AC drive technology and energy optimized components. The machines meet current safety regulations of the machinery directive RL 2006/42/EG and feature a completely new and functionally optimized

FEATURE

machine design. These lines are the result of Niehoff’s continuous improvement development efforts to maximize energy and material efficiency, as well as the performance of its machines for the sake of the environment and for the benefit of its customers. Niehoff GmbH, www.niehoff.de; Niehoff Endex North America, www.niehoff-usa.com.

NUMALLIANCE/France The NUMALLIANCE booth featured an updated version of its FRX04 wire forming and spring manufacturing machine, first released in 2008, which is now even faster and sleeker. “It is a wire forming machine that has spring capabilities,” said David Galas, U.S. business development manager. “This 7 servo driven axis machine takes advantage of all the side of its tooling and gives endless bending capability and almost deletes tooling cost for prototyping and medium production runs!” declares NUMALLIANCE CTO Jean-François Counilh. The FRX04 is based on the company’s advanced hybrid bending technology, which combines the mandrel and nose bending in one machine. The complexity of the movements allowed by the Human Machine Interface Touch &

E-mail: fukaseco@ja2.so-net.ne.jp http://www.fukase.co.jp

NUMALLIANCE COO Ludovic Vallet by the company’s FRX04 model. Form generates a virtual 8th axis for the cut. The FRX04 can process a wide product range, from 0.8 mm to 4 mm. With an optional laser probe and external cutter, the

Sk Bldg #1 2- 6 -1 Hamada Mihama -Ku Chiba Bhiba-Ken 261-0025, Japan FAX 81-43-276-0463 TEL 81-43-276-0630

JULY 2010 | 55

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machine is capable of producing parts with loops on both ends. “The new FRX04 received a warm welcome at Düsseldorf,” said NUMALLIANCE CEO Joël Etienne. “We are excited about its future applications on the market and of course our ‘Beyond bending’ motto applies to the FRX04 if secondary operations or robotic integration needed to be applied to the machine.” NUMALLIANCE, www.numalliance.com and www.numamerica.com.

O.M. Lesmo Group/Italy Lesmo Machinery America/Canada Italy’s O.M. Lesmo Group, represented in North America by Lesmo Machinery America Inc., introduced a new single-twist machine that has an innovative direct haul-off system design and incorporates the best features learned from the company’s small machines (400 mm to 1000 mm) and those of its larger machines (1250 mm to 2000 mm). The new MTO-1250-CT is equipped with pintles and an open-type carbon fiber flyer arm. The pintles allow use of bobbins with different arbor diameters, while the open arm carbon fiber flyer allows higher speeds. One important advantage of this machine is that it eliminates the need for slip rings. This reduces the maintenance and

Who makes cold pressure welding easy? Huestis Industrial, of course!

Attendees at wire Düsseldorf look at O.M. Lesmo’s MTO-1250-CT model. parts replacements on the electrical components. It can be used for producing: copper flexible strands and ropes up to 240 sq mm; aluminum flexible strands and ropes; screening with copper or aluminum wire; armoring with galvanized steel wires; and laying-up of insulated special cable, telephone cables, data cables, control cables with

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both small- or large-scale production of special wire and cable. This system has been engineered to match various plating requirements: wire sizes from 0.40 up to 2.60 mm, for base materials (copper, brass, steel, aluminum, copperclad and alloys), to be plated a concentric and uniform depo-

Otomec Srl/Italy Otomec Srl engineers and manufactures a full range of equipment for cleaning and plating of metal wires, strips and bars. Its exhibit displayed the OTOâ&#x20AC;&#x2122;FF Line mod.1W ECOPLATER, a new concept reel-to-reel and reel-to-basket electroplating system for ferrous and nonferrous wires. The system has a fully integrated electronic quality control system for all production parameters. It controls the wire tension, thickness, temperature and physical properties of the chemicals and rinse water, which are monitored by sensors and recorded. The unit has a very compact design, is easy to set up, is made from acid-resistant materials and is responsive to environmental issues. It can run at adjustable speeds from 60 to 180 mt/min, which makes it attractive for

Otomec Partner and Managing Director Alberto Rusconi by the companyâ&#x20AC;&#x2122;s new electroplating system.

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or without tapes. The main motor drive is controlled by inverter, AC motor. It can process reels with a flange diameters from 800 mm to 1250 mm, variable bore diameters, gross weights to 4000 kg and operate at a maximum rotation speed of 600 rpm. The company has more than 45 years of experience in developing and introducing advanced stranding, cabling and wiredrawing machinery. OM Lesmo Group, www.omlesmo.com; Lesmo Machinery America, sales@lesmoamerica.com.

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sition of silver, tin, nickel and zinc in thicknesses as thick as 50 microns or more. The model shown in the photo can be used for electro-plating capillary wires from 0.08 mm to 0.30 mm with silver, gold and nickel. Another Otomec innovation is the OTO BAR, a complete line for continuous accurate plating of round bars, threaded bars, rectangular bars and pipes. The products are automatically loaded one by one and pulled into the galvanic treatment cells. This lowcost line can plate copper bars with tin, silver and steel bars or pipes with zinc and chrome. Otomec Srl, info@otomec.it, www.otomec.it.

manufacturer. The PS 200/8 Combo that can process a wide range of cables: insulated flexible cable, 2 mm to 10 mm; solid insulated wires, 2 mm to 5 mm; multicore flexible cables, 2.5 mm to 10 mm; and flat cables, 5.5 mm x 3.5 mm 13 x 5.5 mm. It can coil/spool to lengths of 100 meters. It can process coils with ODs from 95 mm to 230

PS Costruzioni/Italy PS Costruzioni displayed its PS 200/8 Combo, a fully automatic model that is capable of winding wires or cables onto coils or spools, a combination that saves customer investment as a single line can produce two different products, and it can collectively process a wide range of cables. Further, the companyâ&#x20AC;&#x2122;s design engineers paid particular attention to improving the shape of the final product, the result being that the PS 200/8 Combo is a very versatile machine. Those advantages led to the recent purchase of the model by Austech, an Australian cable

58 | WIRE JOURNAL INTERNATIONAL

PS Costruzioni General Manager Franco Parma with the companyâ&#x20AC;&#x2122;s dual-purpose system.

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mm, interchangeable internal cores from 70 mm to 115 mm and heights from 35 mm to 114 mm, and spools with flange diameters from 120 mm to 230 mm, barrel diameters from 40 mm to 109 mm, overall widths of 42 mm to 114 mm, bores from 35 mm to 104 mm and internal flanges from 35 mm to 105 mm. PS Costruzioni, www.pscostruzioni.com.

Queins & Co. GmbH/Germany Queins & Co. GmbH showed components of a newly manufactured heavy-duty rigid strander for round or pretwisted sector conductors as well as for trapezoidal wires. The main features of the design include: heavy-duty gearboxes with direct motor-drive that guarantee best acceleration, deceleration or synchronization between stranding cages; computer controlled synchronization for stops by power failure; rotors made of machined parts (not just one welded piece) and thus they never suffer from any welding cracks; smooth torsion-free guidance for conductors inside our cages by stationary tubes; the sturdiest rigid strander design; and favorable prices for a heavy-duty machine design. The complete cage was not shown at the exhibition in order to avoid too many competitors from

Queins & Co. GmbH Managing Director Manfred Hoffmann by a portion of a rigid strander. getting a close-up view of the new design, but interested customers were invited to the companyâ&#x20AC;&#x2122;s Monschau factory to see the entire system. Queins & Co. GmbH, www.queins.com.

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SAMPSISTEMI/SAMP USA Italy/U.S. The SAMP booth included a new medium-voltage power cable insulation line for continuous production of XLPE and EPR insulations on medium-voltage cable cores. The insulation process is executed by a wellproven, triple layer crosshead equipped with an independent centering unit for each material flow channel distributors. The three water-cooled extruders, MHV type, are designed to process sensitive polymer and elastomeric materials at a low melt temperature. Each heating/cooling

SAMP USA Area Business Manager Marco Gerardo with the company’s new medium-voltage power cable insulation line. zone is equipped with a separate heating and cooling element, directly applied to the barrel. Proportional valves connect directly to the PID control guaranteeing very tight and stable melt temperature tolerances. The system has continuous controlled temperature stability. Crosslinking of the insulation materials is done by an inert gas (nitrogen) pressurized within a catenary tube and heated by eight independent zones. The production parameters set-up is automatically adjusted and homogenized by the SAMP MHV-CAL software to reach maximum production speed while maintaining a constant insulation thickness. The cable is cooled by a water circulation system, optionally also by gas if completely dry processing is required. SAMPSISTEMI, www.sampsistemi.com; SAMP USA, sampinc.com.

SAMPSISTEMI/Italy SAMP USA/U.S. The SAMP booth also featured a new self-traversing portal, model PT 3000, for payoff and take-up processing that benefits by use of energy-saving technology. The new payoff and take-up series excel for reels in CV lines,

60 | WIRE JOURNAL INTERNATIONAL

SAMP USA Managing Director Dominique Perroud with the company’s PT 3000 portal. insulation and sheathing extruders, lead extrusion lines, and stranding lines as well as rewinding lines. The sturdy but compact design has a telescopic cross beam that features high-speed quality motors which are dimensioned just right for the job. The measuring systems for the winding and unwinding process and the direct motor response guarantee a very precise cable distribution on the reels. The automatic wheel tension control ensures the constant pressure on the reels, independently from surface and material. Mechanical and optical safety fences guarantee a very safe operation, especially during the loading process. Operators are supported by an intuitive user interface with automated functions. SAMPSISTEMI, www.sampsistemi.com; SAMP USA, sampinc.com.

Schlatter Industries AG/Switzerland Schlatter North America/U.S. The Schlatter booth included the company’s MG 930 industrial mesh welding system for the competitive production of dimensionally accurate mesh in small and medium batch sizes. Some of the key features of the machine included: ESG 13 single weld groups with direct welding, which provide flatter mesh panels; MF welding

Setic s.a.s./France Gauder Group/Belgium

Schlatter North America General Manager Ronnie Meiers by the companyâ&#x20AC;&#x2122;s MG 930 mesh welder. technology in the form of individually controllable transformers for more accurate weld control; a QF 12 cross wire feeder, which reduces set-up time and tooling costs;

The Setic division of the Gauder Group, known for its rotating machines for automotive, LAN and control cables, chose to highlight its equipment for low voltage conductors and cables. It displayed a heavy-duty (20 tons) 1600 mm double-twist strander/cabler, type TA 1600 RN-4M, for producing copper, aluminum and aluminum alloy strands as well as for the assembly of insulated conductors. A powerful 96 kW motor drives the bow, allowing a wide range of production speeds, up to 1500 tpm. The final product has very high quality thanks to a very

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and PLS Win, a computerized production control system to store individualized mesh programs and weld settings. Schlatter is a world leader in plant manufacturing, providing resistance welding systems for specific industrial solutions as well as weaving and finishing machines for paper machine clothing, wire cloth and mesh. Thanks to its extensive industrial engineering expertise, spirit of innovation and reliable customer service, the company can offer superior manufacturing systems to customers. Schlatter Industries AG/ Schlatter North America, www.schlattergroup.com.

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smooth wire path (pulley dimensions are 530 mm for first twist, 700 mm for second twist and 800 mm on capstan) and a carbon bow equipped with specific eyelets. Product ranges up to 150 sq mm for 19 wires with heavy compaction

Setic Sales Manager Christian Pavailler with the companyâ&#x20AC;&#x2122;s TA 1600 RN-4M model.

Few cold welders are this versatile

Fast, reliable and easy to operate, our portable HP100 air/hydraulic machine can be wheeled quickly to the work area. The welding head can be detached to fix breaks in confined spaces, and the HP100 is also available with an automatic setting, offering effortless welding at the touch of a button. For full details, call +44 (0) 1233 820847 or visit www.pwmltd.co.uk. PWM. Precision you can depend on. All inquiries within North America for machines, spares and dies, contact: AMARAL AUTOMATION ASSOCIATES PO Box 7816, Cumberland, RI 02864 Tel: 401 405 0755 / 774 991 0504 Fax: 401 405 0757 E-mail: joe@amaralautomation.com www.amaralautomation.com Welders and dies available from PWM or authorised distributors only.

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rollers. The motorized capstan (86 kW) allows a pulling force up to 1.8 tons and a very high compaction ratio for large section, without reducing production speed. The machine is delivered with an easy reel loading and unloading system thanks to an integrated shovel and can be installed within short time, without any foundation. For bigger strand, Gauder Group can offer the very innovative Pourtier concentric strander, type COS1200, allowing power consumption saving through the regeneration of the wire braking power. Setic s.a.s, sales.setic@gaudergroup.com

Sictra SpA—The Eurolls Group/Italy Responding to customer feedback about how difficult it was to thread and maintain a vertical annealer for a multiwire line, Sictra’s experienced technical team developed the first horizontal annealer for multiwire lines. The company, part of the Eurolls Group, now offers a complete range of horizontal annealers in various sizes to process products from fine wire to heavy duty wire sizes. At wire Düsseldorf, it exhibited a 28-wire line equipped with an RCO 320/28 horizontal annealer for wires from 0.20 up to 1.00 mm. Customers using this highly ergonomic machine recognize a

Sictra SpA Managing Director Andrea Camparada by a 28-wire line that uses his company’s horizontal annealing technology.

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significant reduction in downtime related to what is needed for a traditional vertical design. The increasing need for larger, more flexible conductors—such as those used in the production of wind energy cables—is driving the industry toward drawing lines with higher capacity in terms of size and number of wires. This has also increased the demand for larger multi-wire annealers to handle this requirement. Sictra is meeting this demand with high quality products and tall vertical annealers is not an issue for it. Customers also come out ahead because each of the individual companies that make up the Eurolls Group (Eurolls, Cortinovis Machinery, Sictra, Team Meccanica, Teurema and Vitari) benefits from the Group’s collective core competencies. Sictra SpA, www.sictra.it, www.eurolls.com.

such as high-voltage cables. The reel is not optimal for transportation since reels are almost never in balance. As MoveX does all the lifting, this allows the take-up CoilX to be made very simply. The Coil X costs drastically less than a traditional take-up for weights up to 60 tons and 4.5 meter reel sizes. No portal is required, there is less mass and it is very easy to transport. The container ReelX carries all the weight. There are very few moving parts and few that can break. The CoilX has four wheel drive and if a motor would fail, it can just keep going. For CV line applications, cable can be finished without any stops. With Skaltek’s SimplX system, reels can be delivered to the field in the frame, making them easy to ship and load. When arriving in the field, a simple drive wheel can be attached and the end-user technically has a driven payoff. Skaltek AB, www.skaltek.com.

Skaltek AB/Sweden In 1975, Skaltek founder Oystein Skalleberg had a vision of enclosing a reel in a container frame so it was fixed and permanently removed from the floor. This would also allow for better material flow and possibilities to stack reels for smarter material flow. In 2003, Skaltek delivered such a container system for a complete aluminum tubing plant. Then, in 2007, it got an order an order for a new high voltage plant, and as a result of the vision from 1975 and the experiences from the aluminum industry, SimplX became a reality. The SimplX patent is based on three steps: the reel in a container (ReelX); a fixed transportation to be moved with an AGV (MoveX); and a traversing take up CoilX. With the reel placed in the container, it is permanently removed from the floor. As a result, the reel flanges do not have to carry the total weight and reels, which can drastically cut reel costs. By attaching the reel in a frame, lifting without damaging the cable is made possible, which is significant for products

Tulsa Power Inc./U.S. At wire Düsseldorf, as well as the recent Wire Expo event, Tulsa Power Inc. continued to discuss its new line of 100,000 lb capacity Traversing Frame Gantry systems. These units are offered in both payoff and take-up configura-

A heavy-duty Tulsa Power traversing frame gantry system.

Skaltek’s SimplX take-up, which has no portal, draws attention at the show. 64 | WIRE JOURNAL INTERNATIONAL

tions. Reel capacities range from 2175 mm thru 4350 mm flange diameter, reel widths to 4572 mm and maximum reel weights to 100,000 lb. The entire structure offers easy loading and unloading of reels with true walk-thru capabilities. The telescoping superstructure’s portal design conforms to the reel size to minimize floor space requirements. Each system traverses on rails to offer material payout or take-up with no fleeting angle. Electromechanical drives are utilized to allow for up/down and in/out manipulation of the main frame during reel load/unload sequences. Main drive systems are engineered to customer specifications and are complemented with a full-color operator touchscreen interface that is used to communicate parameters used by the operator

in relation to the product being run, the reel being used, display status, position and fault alarms of the unit. Tulsa Power Inc., www.tulsapower.com.

Vitari SpA presented its NR200 high-speed straightening and cutting machine, which it noted emphasizes electronic technology but also includes some new mechanical features that enhance machine quality and reliability. The result is a system that has an excellent productivity coefficient and little or no maintenance at all. The main innovative features include: elimination of all gears with consequent noise factor reduction; four servo-motors enabling independent control of wire feeding (with encoder), spinner, cutting-off and benchlength; all rotating elements assembled on ball bearings; a reduction of general maintenance; bar length measurement by encoder and mechanical stop to obtain the maximum pre-

Vitari’s NR200 high-speed straightening and cutting system.

cision on the bar lengths (tolerance +/- 0.2 mm); and electronic control of the cutting bench by means of brushless motor synchronized together with the cutting unit. The system can process wires from 2.0 mm to 8.0 mm (R < 800 N/mm2) at speeds of up to 200 m/min, with up to 180 cuts per minute. The major components used for all mechanical, pneumatic and electronic parts are easily obtainable, guaranteeing reliability and local access to replacement parts. The motors are high-efficiency models that are save energy. Vitari SpA, www.vitari.com.

FEATURE

Vitari SpA/Italy

Welding Wire Machineries Srl Sales Manager Renato Dall’O with the company’s new wet drawing line. wet drawing line guarantees the final user higher efficiency and product quality. It also helps reduce production costs, as this is a simple machine, so it can be operated by people who are not very experienced. As with the best dry drawing machines, the TB.NS guarantees zero slipping, as all the cones are singularly motorized and are directed by a special wire speed control system. The dies all rotate as the cones are dipped into the lubricant, and this cools the material are in this way guaranteed obtaining working speeds much higher than the dry drawing machine. Some system specs are: max. inlet wire size, 3.50 mm; max. outlet wire size, 0.40 mm; number of drafts, seven, with pre-setting of threaded dies set; max. speed, 35 m/s; max. section reduction per draft, from 30% to 10%; standard motor power,17.5 to 21.5 kW; capstan motor power, 25 kW; tungsten carbide coated drawing capstans; compensator built in the machine frame; possibility to skip drafts. Welding Wire Machineries Srl, www.wwmsrl.com. ■

Welding Wire Machineries Srl/Italy Welding Wire Machineries Srl (WWM) introduce its revolutionary wet drawing machine, model TB.NS (zero slipping), with seven independent drafts, that is suitable for drawing metal wires, especially carbon steel, stainless steel, welding wires, aluminum and copper/aluminum alloys. WWM, which knows the advantages and disadvantages of the wet drawing process, designed a new line that includes the benefits of both wet and dry drawing machines. This new

JULY 2010 | 65

INTERNATIONAL TECHNIC AL CONFERENCE

M O N R E Y

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T E R Wire and Cable Technical Program Tabletop Exhibits | Networking

18-20 O CTOBER 2010 M ONTERREY, N.L. M EXICO | C ROWNE P L AZA H OTEL

Venture to a place where wire and cable best practices and technological answers are much more than theory. And leave with ideas you can put into place immediately. Join WAI and educational sponsor ANTAAC for the 2010 International Technical Conference that will leave you both informed and inspired. Learn more at www.wirenet.org or contact WAI’s educational director, Marc Murray at mmurray@wirenet.org; Tel.: 001-203-453-2777, ext. 121. To register complete and return the form at right. Conference organized by:

The Wire Association International, Inc.

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Improvement of drawability of shape-memory alloy wire

TECHNICAL PAPERS

TECHNICAL PAPER

This paper looks at the ‘drawability’ of three types of shape-memory alloy wire, all of which can be drawn to a thin size, and offer advantages for use for certain applications. By Kazunari Yoshida, Takanori Sato and Shunichi Kikuchi

Shape-memory alloys are used in various applications, such as connecting components, medical equipment, lingerie, and toys1. While Cu and Fe shape-memory alloys, as well as Ni-Ti shape-memory alloys, have been developed, their workability is poor and it is difficult to accurately control their transformation temperature2. They are also expensive and their applicable temperature range is limited, which hinders the expansion of their applicability. Studies on the properties of shape-memory alloys have already been carried out by many researchers. One of the authors has reported a study on the workability of Ni-Ti alloys; however, the number of reports on processing technologies and shape-memory heat treatment—which mostly rely on

the experience of engineers—is limited3. The primary goal of this study is to improve the drawability of Fe and Cu shape-memory alloys, which are less expensive than Ni-Ti alloys. In addition, drawing experiments are carried out using a conventional hole die to clarify the factors that affect the improvement of drawability and to examine the optimal drawing conditions. In concrete terms, the effect of removing hard and brittle parts from the surface of Fe shape-memory alloys on their drawability, and the drawability of Cu shape-memory alloys are examined. Moreover, various aspects of drawability are compared among Ni-Ti, Fe and Cu shape-memory alloys.

Table 1. Diameter and transformation temperatures of the as-delivered wires.

Fig. 1. Wiredrawing by conventional die.

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TECHNICAL PAPERS Fig. 2. SEM surface images: a) starting wire; b) after first pass; c) after second pass; and d) breakage after third pass.

Materials and experimental method Three types of specimens (Ni-Ti, Fe and Cu shapememory alloys) were used in this experiment. The chemical composition, austenitic transformation end temperature Af, martensitic transformation start temperature Ms, and the diameter of the mother wire for each specimen are summarized in Table 1. In drawing, a conventional ultrahard conical die (Fig. 1) was used and the drawing speed was fixed at 300 mm/min. The die half-angle (α) was fixed at 6°, and the reduction per pass (R/P) was varied mainly in the range of 3-25%4. A resin lubricant was used.

Experimental results and discussion Drawing of Fe shape-memory alloys. Although Fe shapememory alloys are inferior to Ni-Ti alloys in terms of memory characteristics, they are less expensive and are applicable at high temperatures from 473Ko to 623Ko, therefore one can expect their use in applications involving high temperatures. However, the poor workability of Fe shape-memory alloys hinders their practical use. Therefore, negative

factors leading to the poor drawability of Fe-27.2%Mn5.7%Si-5.0%Cr alloys are examined. Drawability. Hot-rolled mother wires were annealed at 1223oK and then drawn at α = 6° and R/P = 15%. After one drawing pass, the wire did not break but cracks developed on its surface. Fig. 2 shows SEM images of the surfaces of the mother wire and drawn wires. Images of the mother wire, the wires after one and three drawing passes, and the wire that broke during the fourth drawing pass are shown in Fig. 2. Cracks developed on the wire surface during each drawing pass and finally led to the breakage of the wire, which indicates extremely low drawability. Effect of deposit layer on drawability. As above, the drawability of Fe alloys is extremely low; accordingly, the elements in the wire surface were analyzed by energy-dispersive X-ray spectroscopy (EDS) to examine the reasons for the poor drawability. Fig..3 shows an SEM image of the mother wire, the result of element analysis to determine the amount of Mn, and an SEM image of the wire on which cracks developed during drawing, respectively. The surface of the mother wire comprises three layers denoted as A, B and C from the top.

Fig. 3. SEM images of: a) starting wire; b) Mn content analysis; and c) cracks on drawn wire.

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TECHNICAL PAPERS Fig. 4. Chemical compositions in wire surface layers by EDS.

The thicknesses of layers A and B were approximately 26 μm and 60 μm, respectively. Fig. 4 shows the result of measuring the amounts of Mn, Fe, and O in the three layers. For layer A, Mn accounts for more than half the layer, 56.4%, and Fe and O account for 6.74 and 28.9%, respectively. This is considered to be due to the oxidation of the surface layer during hot rolling. Moreover, the hardness of each layer was measured using a micro-Vickers hardness tester, the result of which is shown in Fig. 5. The oxidized layer A showed the highest hardness, 580 HV, and the hardnesses of layers B and C were 330 HV and 380 HV, respectively. Thus, the surface layer of the mother wire is hard and brittle, and cracks are considered to develop on it owing to the tensile stress generated during drawing. Moreover, the repetition of drawing promoted the growth of these cracks, leading to the breakage of the wire. Effect of removing hard and brittle layer from wire surface on its drawability. The hard and brittle layer of the

Fig. 6. Three sample wires for drawing.

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Fig. 5. Hardness of each layer of mother wire.

wire surface was found to be one cause of cracks. Three types of wire were prepared: mother wire with the triplelayer surface (wire 1); a wire from which the hard and brittle layer A was mechanically removed (wire 2); and a wire from which layers A and B were mechanically removed (wire 3). See Fig. 6. The wires were drawn and observed to detect whether or not cracks developed on the surface of the drawn wires. Fig. 7 shows the results. For wire 1, deep cracks developed during the first drawing pass, and grew further during the third drawing pass, resulting in wire breakage. For wire 2, small cracks developed during the first drawing pass and grew with repeated drawing. In contrast, no cracks developed on wire 3, from which layers A and B were removed, even after repeated drawing. However, wire 3 broke before or during the fourth pass in some cases. Therefore, the wires were annealed at 1223°K after three drawing passes, which enabled the further thinning of wires (Fig. 8).

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Drawing of Cu shape-memory alloys that their drawability was improved by roller-die (see Fig. Drawing limit and changes in mechanical properties. In 14) or dieless drawing8; however, the dimensional accuracy this study, the Cu-17%Al-11.5%-Mn alloy developed by in these drawings is inferior to those made using the convenIshida et al. was used as the Cu shape-memory alloy5. tional hole die. When the optimal lubricant and die shape are Mother wires were annealed at 873°K and then drawn at α = adopted in the conventional hole-die drawing, the drawing 6o and R/P = 15%. The result of drawing is shown in Fig. 9. limit is successfully increased to approximately 70%. Fig. The drawing limit of the Cu alloys used was 93%, showing 15 shows the drawing limits of Ni-Ti alloys and the Fe and excellent drawability compared with those of other shape-memory alloys. Next, the drawn wires were subjected to tensile tests to examine the changes in mechanical properties, the results of which are shown in Fig. 10. The tensile strength of the mother wire was 520 MPa and increased after every drawing pass, reaching 1530 MPa at Rt = 86%. In contrast, the breaking strain decreased with increasing Rt. Thickening ratio of wires after drawing and shape-memory heat treatment. Dimensional accuracy is an important factor for drawn wires. However, the drawn wires of shape-memory alloys do not always maintain the same diameter as that of the die hole because of their own elastic recovery characteristics. The diameter of drawn wires was measured to determine the thickening ratio ηw and thinning ratio ηh with respect to the die hole diameter. Changes in the wire diameter after heat treatment were also examined because the shapememory alloys memorize their shape through heat treatment. The drawn wires were heated at 1173°K for five min during shape-memory heat treatment and then aged at 473°K for 15 min6 while changes in the wire diameter were measured. Fig. 11 shows the results. After drawing, the wires thickened with a thickening ratio of approximately 2%. The drawn wires then thickened by approximately 1% after heat treatment, and no change in the diameter was observed during the subsequent aging treatFig. 7. SEM images of each wire. ment. Next, the change in ηw was examined by repeating drawing at R/P = 10% and 20%, the result of which is shown in Fig. 12. It was revealed that the magnitude of R/P and the number of drawing passes negligibly affect ηw. Even when Rt increases, ηw remained at around 1-2% for R/P = 10% and 20%. These findings are important in determining the final dimensions of wires and the improvement of dimensional accuracy. Metal structure of drawn wires. The metal structure of drawn wires was observed using an optical microscope7, the results of which are shown in Fig. 13. Fig.13a-c show the metal structures of the mother wire and the wires drawn to Rt = 36% and 84%, respectively. Owing to drawing, the metal structure was extended in the drawing direction and became a fibrous structure. Fig. 8. Fine wire obtained after Comparison of drawability for different shapedrawing. Fig. 9. Drawing limits. memory alloys. Although Ni-Ti shape-memory alloys are difficult to process, it has been reported

TECHNICAL PAPERS Fig. 10. Changes in mechanical properties depending on drawing conditions.

Cu shape-memory alloys examined in the previous sections. The value for tough-pitch Cu is also shown for reference. The drawing limits were approximately 90% and 40% for the Cu and Fe shape-memory alloys, respectively. Moreover, it was possible to obtain thin wires by intermediate annealing for all of the alloys. The thus-obtained wires can be applied to spring actuators, orthodontic wires and catheter guide wires9 in medicine, and washers for easyrelease screws10.

Conclusions Fig. 11. Thickening ratios of drawn wires and subsequently annealed ones.

Fig. 12. Relationships between thickening ratio ηw and reduction per pass. 72 | WIRE JOURNAL INTERNATIONAL

Experiments and examinations were carried out on shape-memory alloys with the aim of improving the drawability of low-formability, shape-memory alloys. The results are summarized below. • For Fe shape-memory alloys, the drawability was improved by mechanically removing the hard and brittle layer that contains a large amount of Mn from the mother wire before annealing. Moreover, further fining was possible by repeating annealing subsequent to each of the three drawing passes. • Cu shape-memory alloys have good drawability and their drawing limit reached 90%. The wires thickened by 1% or 2% after drawing and shape-memory heat treatment; therefore, it is important to take into consideration the thickening ratio in the dimensions of drawn wires. • Cu shape-memory alloys have the highest drawabiliy, showing a drawing limit of approximately 90%. Ni-Ti alloys have the second

TECHNICAL PAPERS Fig. 13. Change in metal structure of mother wire and drawn wires.

Fig. 14. Micro roller die drawing.

Fig. 15. Drawing limits for various materials. highest drawabiliy with a drawing limit of approximately 70%. Fe shape-memory alloys show poor drawability and their drawing limit is approximately 40%. However, it was clarified that all of these alloys can be drawn to a thin wire. • The shape-memory alloy wires obtained are expected to be applied to various fields, such as springs that can be used as actuators, and washers for easy-release screws.

Fig. 16. Cu-Al-Mn SMA spring.

References 1. N. Iguchi, Story of shape-memory alloy, February 1984, pp. 6-15. 2. N. Iguchi, Story of shape-memory alloy, February 1984, pp. 48-56. 3. K.Yoshida, “Drawability and Diametrical Recover of Ni-Ti Shape-Memory Alloy Wires,” Journal of the JSTP, Vol. 31, no.355, 1990-08, pp.1015-1016. 4. H.Tanaka and K.Yosihida, “Drawing from fundamen-tals to up-to-date techniques, October 1990, pp. 8-21.

Fig. 17. Easy-release screw by SMA washer.

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5. T. Omori, Y. Sutou, J.J. Wang, R. Kainuma and K. Ishida, J. de phys. IV, 112, 2003, pp. 511-514. 6. Y. Sutou, T. Omori, K. Yamauchi and K.Ishida, “Metal.Mater,” Trans., 43, 2002, pp. 2360-2362. 7. R. Tanaka, Standard Micro Structure, Yamamoto Scientific Tool Laboratory, 1988, pp.110-117. 8. K. Yoshida, T. Shima and M. Takano, “Drawing of NiTi shape memory alloy wire using cassette roller dies,” The proceedings of the 1989 Japanese spring conference for the technology of plasticity, Vol. 1989 (1989.05), pp. 163-166. 9. M. Miyagi, “Medical application and biocompatibility of Ti-Ni alloy,” J. Japan Inst. Metals, Vol. 24, No. 1 1985.01, pp. 69-74. 10. A. Ema, Performance Improvement of Easy-Release Screw with Shape Memory Alloy Washer, Tokai University master’s thesis, 2008, pp. 3-6. ■

Kazunari Yoshida is a professor of precision mechanics at the school of engineering at Tokai University, Japan. He researches wiredrawing, extrusion, and forging processes and has served as a member of the steering committee for Japanese Wire Drawing. He holds a Ph.D. degree in engineering. He authored Yoshida Sato Kikuchi a prize-winning paper for the Japan Society for Technology of Plasticity in 1984 and won medal awards from The University, Japan. Shunichi Kikuchi is a graduate stuWire Association International, Inc., for the best paper dent at Tokai University, Japan. This paper, which was in the nonferrous division in 1999, 2001, 2003, and 2004. presented at WAI’s 79th Annual Convention, Cleveland, Takanori Sato works in the precision engineering Ohio, USA, won the Horace Pops Medal Award for best department of the school of engineering at Tokai paper in the General Division.

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TECHNICAL PAPERS

TECHNICAL PAPER On the risk of fatigue in extension spring hooks A new computer program makes it possible to make design adjustments in extension spring hooks so that the final product meets fatigue requirements. By Mark Hayes

The hook of an extension spring is its most vulnerable part. This paper quantifies the risk of fatigue failure in the hook and sets out strategies to eliminate that risk. The simplest and cheapest way to design and manufacture an extension spring is to make the end hooks and spring body out of a single piece of wire and for the hooks to be the same diameter as the spring body. The position of maximum stress in this spring is at the inside surface of the hook where a bending stress operates. See Fig. 1. The applied stress is additive to the residual stress remaining after coiling and stress relieving, and it matters not if the spring has German, English or D-type hooks. The bending stress qb at the inside of the hook at position X is calculated using the following formula, and is made up of a large bending component and a smaller tensile component.

Fig 1. A typical extension spring design (top) and a basic extension spring design.

Ď&#x20AC;

Eq. (1)

Ď&#x20AC;

Where d = wire diameter; DL= mean diameter of the loop or hook; F = applied load; and KL= curvature correction factor (unbending). It will be observed that the residual stress is not calculated, as that will depend upon the spring index and the stress-relief

Fig. 2. Diagram showing end hook stress.

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heat treatment. All the carbon steel springs tested here were stress-relieved at 250270°C, and the 302 stainless steel springs at 350°C.

TechSpring analysis

Table 1. Fatigue test results.

A European Commission Collective project known by the acronym “TechSpring,” studied stress analysis methods for springs. One of many topics studied in that project was extension springs, with the goal being to provide sufficient data so the risk of fatigue failure in the end hook could be accurately predicted. The results presented below were all generated in the TechSpring project and are published here for the first time. The results have been incorporated into a computeraided program so that these data have become accessible to spring manufacturers and their customers. Typical results from that program are also published here for the first time.

Experimental method

Fig. 3. Goodman diagram showing spring body at risk at close to one million cycles, with end hook at risk of fatigue failure at less than 30,000 cycles. Figure is for spring shown in Fig. 1.

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Extension springs were manufactured to the basic design shown at the bottom of Fig. 1. The amount by which the end hooks were made smaller than the body diameter was varied. Springs with end hooks slightly smaller than the body always failed on dynamic testing in the end hook. Those with a greater reduction in end hook diameter failed either in the hook or the body coils and it was an equal chance which fatigue failure mode occurred. The springs with the smallest end loops always had fatigue fracture from the inside surface of the full diameter coils of the spring body, and the stress at this position was entirely torsional. If the end hooks are smaller than the body coils, it is essential that the coils at either end of the body had to be tapered down so as to avoid a stress raiser where the hook was made directly from the body coil diameter. The springs of the above design were fatigue-tested on forced motion-fatigue test machines over a wide range of test conditions. When the stress range was high, fatigue failures occurred at short lives, and as the stress range was reduced the fatigue life increased. At the lowest stress range used, no fatigue failures occurred.

TECHNICAL PAPERS

Results A typical set of results for carbon steel springs made from 3.24 mm diameter EN 10270-1 DH wire are shown in Table 1. In these fatigue test results, the superscript L indicates failure in the end hook, and the superscript B indicates failure in the spring body coils. These fatigue test results and other similar results have enabled the drawing of Goodman diagrams for both the extension springs body (which has been available previously) and extension spring end hooks (which is new). Typical examples of these diagrams are shown in Fig. 3. This figure shows that the spring body is at risk at close to one million cycles, but that the end hook is at risk of fatigue failure at before thirty thousand. These data are for the spring shown in Fig. 1. If the end hook diameter is reduced from 20 mm to 16 mm the risk of fatigue failure in the hook only occurs well after one hundred thousand cycles.

Fig. 4. Goodman diagram for spring with reduced-diameter end hooks.

Conclusion A spring manufacturer now has a number of strategies available to advise his customers of the predicted fatigue life of extension springs. The expected fatigue life of end hooks in springs as they are supplied today can now be predicted with reasonable precision. The deflection in service can be limited to achieve the required life. If the life of the hook is insufficient, the spring manufacturer can see by how much the end hook needs to be reduced so that the required life is achieved. Alternatively, the spring can be made with swivel loops and the size of wire for the end loops (which are often the same diameter as the body) can be calculated using the new software.

Reference 1. TechSpring Project 027943, “Improving technical performance of springs through scientific understanding of dynamic stress profiles using advances in software design and measurement technologies.” ■

Hayes Mark Hayes is the senior metallurgist at the Institute of Spring Technology (IST), Sheffield, England, where he manages IST’s spring failure analysis service and all metallurgical aspects of advice given by the Institute. He also gives the majority of the spring training courses that the Institute offers globally. He has participated in numerous U.K. government- and EU-funded research projects related to spring technology, and he is currently the project coordinator on the “Techspring” project. He holds a degree in metallurgy from Leeds University; is a member of the Institute of Metals, Minerals, and Mining; and is a chartered engineer. He delivers a range of training courses on behalf of IST, regularly presents papers at major international technical conferences, and produces a regular “Cautionary Tales” column in Springs magazine. This paper was presented at WAI’s International Technical Conference, Istanbul, Turkey, November 2009.

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TECHNICAL PAPER Review of diffusion methods after sequential plating for the manufacture of steel tire cord The pluses and minuses of three diffusion methods are presented, along with a table that can help manufacturers of steel tire cord decide which one makes most sense for their operations.

By Thomas W. Tyl and Jeffrey T. Tyl

Sequential plating replaced cyanide plating from 19701985. Cyanide plating consists of one plating process and a single electrolyte plating solution, sequential plating uses as many as three plating processes and solutions and a diffusion process. The change, made for environmental and health reasons1, resulted in minimally a four-fold increase in brass-plating complexity. With sequential plating, the type of brass obtained depends on the composition of the plating solutions and the diffusion process, while the brass-plated weight is a function of as many as three immersion current densities and electrical uniformities during plating and the diffusion process. The diffusion

process is vital. This paper will discuss three common types of diffusion.

Diffusion goals, reporting, profiles & type

The goal of diffusion is to properly mix copper and zinc to form alpha brass on the wire designated for steel tire cord, the composition and quantity of which is near the values specified by the customer. Various tire manufacturers require different compositions and weights of brass that maximize adhesion between the brass and rubber top coat material1. Since every tire manufacturer uses a proprietary rubber top coat, the brass coating weight and composition requirements can vary significantly. A typical brass specification (62.5 to 64.5% copper and 35.5 to 37.5% zinc) can be close to the two-phase region of alpha and beta brass in the binary zinc-copper phase diagram shown in Fig. 1, which also shows the area of greatest interest in the manufacture of steel tire cord. It is important that the amount of alpha brass developed during the diffusion process is maximized due to the difference in microstructure between alpha brass and beta brass. The crystal structure of copper is face centered cubic (FCC). The crystal structure of zinc is hexagonal close packed (HCP). The crystal structure of alpha brass is FCC and that of beta brass is body centered cubic (BCC). See Fig. 2. It is well known that FCC crystals and HCP crystals have many more slip planes than BCC crystals, making FCC and HCP materials much easier to deform than BCC crystals. Some common FCC materials are copper, gold and silver all of which are well known to be soft and pliable. Fig. 1. Diagram showing copper-zinc ratio in typical brass It can easily be shown from the copper-zinc phase specification1. 78 | WIRE JOURNAL INTERNATIONAL

Joule Effect diffusion The Joule Effect results from passing electric current through sequentially plated and patented steel tire cord,

releasing heat. Fixing the current and wire length produces heat that is proportional to the wire’s resistance and varies by the square of the applied current. Joule’s first (physical) law, known as the Joule effect, expresses heat generated as a function of current resistance and time. The Joule Effect is commonly written as: Q = I2 * R * t where: Q is heat generated (joules), I is constant current (ampheres), R is electrical resistance (ohms) and t is time (seconds). Joule Effect diffusion heats wire directly by inducing current into sequentially plated wire by stringing the wire across electrical contacts (one positive pole, one negative pole). The wire is heated due to resistance of the wire to current flow, the value of which is given by the above equation. This method is rapid and requires less space for equipment. A roller is generally used to transfer current from a power source to the wire, with individual current control by wire or by a common roller for a group of wires. As more current is applied, the wire temperature increases. The amount of voltage necessary is a function of the wire diameter and the length of wire heated. Capital investment. Capital equipment costs for common roller systems are generally lower than other diffusion processes as are operating energy costs. The components are relatively simple: a tensioning device, contact rollers, a power generation unit and brushes or slip rings. Capital costs can increase significantly if individual current control for diffusion is used as each roller must be electrically separated and have its own slip ring or brush system to transfer power from the supply, through the roller and into the wire. In some cases, wire pitch must be increased to accommodate rollers for Joule effect heating; this may require wire realignment prior to diffusion resulting in surface defects and loss of zinc22. This can be a serious consequence for Joule Effect heating as deviation rollers, usually in sets of at least three per wire, will remove zinc from the wire surface, especially after rollers become worn. Product quality and maintenance costs. Wire tension to

Fig. 2. Structures, l-r, of: Face Centered Cubic (FCC), Hexagonal Close Packed (HCP) and Body Centerred Cubic (BCC) crystals.

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diagram that the crystal structure developed during diffusion is a function of diffusion temperature and composition. The area of interest for the manufacture of steel tire cord (see Fig. 1) is enlarged and shown in Fig. 3. Note that the horizontal axis of Fig. 3 has been converted to percent copper since steel tire cord brass specifications are commonly listed in percent copper. Fig. 3 clearly shows that the common tire cord specification for percent copper is dangerously close to the two phase (alpha + beta) region, making the diffusion process difficult to control due to plating variations in percent copper. Crystal structure quality reporting methods. The brass crystal structure can be determined by use of x-ray diffraction where it is common to determine the amount of alpha and beta brass by either determining the area under the alpha and beta peaks or by comparing the peak heights for the curves1. Determining the area under the curves is more precise than using peak height. There are four common methods of reporting brass quality (1) alpha/beta ratio, (2) beta/alpha ratio – termed beta+ ratio, (3) percent alpha, (4) percent beta. The generally accepted limits for brass quality are: alpha/beta Ratio (min. 7, max infinity); beta + ratio (min. 0, max. 0.14); Percent alpha (min. 87.5%, max. 100%; and Percent beta (min. 0%, max. 12.5%). Diffusion temperature profiles. An optimum diffusion process consists of heating sequentially plated wire to a specified diffusion temperature, holding it for a specified period of time, slowly cooling the wire to a specified terminus temperature and quenching the wire to freeze the microstructure. If the plating process is accurate, the resulting brass microstructure will have at least 87.5% alpha brass. Fig. 4 shows typical x-ray diffraction profiles of steel tire cord brass with differing proportions of alpha and beta brass1. Diffusion types. There are three common methods of heating wire for steel tire cord to the diffusion temperature: Joule Effect diffusion, air-fluidized sand-bed diffusion, and induction diffusion. Following are brief descriptions and a comparison of the advantages and disadvantages of each method.

TECHNICAL PAPERS

maintain good contact between wire and contact rollers should be high as any looseness in wires creates arcing or sparks that can result in fine drawing breakage and result in twisting breakage. Good operator and maintenance technician training practices are required to keep contact rollers clean and free from surface damage that can lead to arcing. High tension can lead to breakage during diffusion. This process is maintenance intensive for contact roller surface, brush or slip rings to transfer current to rollers. For instance, if production stops due to a wire break upstream of the diffusion process or from high tension between contacts, the stationary wire will melt rapidly as it quickly overheats due to high current. If that wire is “fed” current by a common roller, all the other wires on that share the “extra” current from the now missing wire, resulting in overheating during diffusion. Common sense dictates that electrical control components are maintained in a conditioned atmosphere although electrical components can suffer corrosion if subjected to condensation. Trying to save money by cutting such “frivolous” systems may result in lots of off-quality material. Assorted costs. Loss of zinc due to oxidation or vaporization is low and uniform compared to air-fluidized, sand-bed diffusion, but higher than induction heating. Wire realignment can result in some loss of zinc when wires are re-routed2. Pickling costs to remove zinc oxide are relatively low since heating is rapid. However, use of special protective coatings is limited since these can interfere with the electrical contact between rollers and wire. Joule Effect diffusion is very energy efficient. Energy losses are generated by power losses through brushes, slip rings, contact rollers and generation of light at higher temperatures. Ease of operation. In theory, Joule effect diffusion technology should be easy to operate although preventative maintenance to prevent arcing can be high. Proper tension must be

maintained during diffusion to keep the wire in contact with rollers and avoid necking or wire breakage. The key is not the equipment but operator and technician training. Since heating depends on resistance (diameter, chemistry) different set-ups must be maintained for every combination of diameter and chemistry. Arcing can be a major issue, especially for high line speeds, resulting in surface martensite and subsequent poor drawing and twisting performance2. Optimally used, Joule Effect diffusion works at DVs as high as 75. Strength loss. Strength loss during Joule effect diffusion is simple to control as the wire temperature can be directly measured within a range using, for example, welding temperature preheating crayons. Direct temperature measurement via infrared technology is difficult since the amount of copper per wire can influence temperature measurement. However, for a given diameter, speed and power setting, the wire temperature is constant, meaning that the same conditions can be duplicated identically. Joule effect diffusion can significantly affect the wire’s strength if too much current is applied, and small changes in diameter and chemistry can result in different wire temperatures2. For higher strength steels like ST, UT and MT, diffusion losses (the wire’s tensile strength prior to diffusion minus the wire’s tensile strength after diffusion) can exceed 40 MPa. One must maintain a steady, low diffusion temperature while maintaining appropriate brass properties. Overall operating costs. Overall operating costs exclusive of energy and maintenance costs for Joule Effect diffusion are high due to constant monitoring of the unit and the relatively low speeds necessary to preclude arcing. Even when labor costs are low, teammates must frequently check the process for irregularities. It is not unusual for plants to report large improvements in productivity, material costs and downtime when converting from Joule Effect diffusion to other types of diffusion, like induction diffusion3.

Air-fluidized, sand bed diffusion

Fig. 3. Zn-Cu phase diagram area of interest for steel tire cord manufacturers.

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In its simplest form, a sand fluidized bed is a hot box containing sand with air blown from below the wires to “fluidize” the sand. In this state, the sand acts just like a liquid, seeking its own level. A heat source can be incorporated with or separated from the fluidization system. Heat transfer is mainly by conduction as sand particles impart heat energy to the surface of sequentially plated wire. There is a limited amount of convective heat transfer from the hot gas to the wire, but this is a fraction of the conductive heat transfer. Use of a fluidized sand bed for diffusion increases equipment complexity and costs much more than the Joule effect, but the process is not limited in concurrencies or speed. There are many means to heat the sand as well as other methods to fluidize the sand4. The sand is an intermediate carrier that transfers the heat to the wire. The type of sand used affects heat transfer efficiency. Zirconium sand (ZrO2.SiO2) has the highest thermal conductivity (2-6% higher) but it is falling out of favor for fluidized bed applications. Some major users and manufacturers of fluidized beds use alumina (Al2O3). It is important that the grain should have a rounded surface, produced by a special process, without sharp edges.

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In theory, air-fluidized sand beds are simple to design and above the wires, resulting in excessive zinc oxidation and operate as they are basically a â&#x20AC;&#x153;hot boxâ&#x20AC;? of sand that is fluvaporization on the wireâ&#x20AC;&#x2122;s bottom. The greater the bed heat, idized with a gas, through which sequentially plated wires the higher the fluidization level and the less the conductive run. In reality, sand fluidized beds suffer from dramatic heat transfer as there is much more gas in the sand. U-tubes thermal expansion from room temperature to about 600oC may burn out and crack prematurely when the burners fire or even higher if the designs a high temperature plenum for fluidization. This is further complicated since (low grade) stainless steels used for construction operate below their scaling temperature but are notorious for extreme thermal expansion. This can be greatly exacerbated if one or both ends of the fluidized bed become pinned or fixed during operation, making expansion in one or both directions parallel to the wires (the long direction) impossible. Another aspect is keeping the sand in the box. Fluidized beds are notorious for spilling large amounts of sand on the factory floor. As sand tends to move with the wire, especially at high speeds, a sand return system is needed, which increases maintenance requirements. Capital investment. Capital costs are significantly higher than Joule effect diffusion. Capital costs include the actual fluidized bed, one or more blowers, a heat source (generally gas and a rather complicated and expensive gas train), one or more sand return systems and a control panel containing instrumentation to measure sand temperature and fluidization pressure. Unlike Joule and induction diffusion, capital costs should never include re-routing of wires2. Product quality. Most airfluidized sand diffusion beds are heated from above or below the wires4. The most common method uses u-tubes with fluidization holes in the bottom of the tubes4. A burner fires into the tube and the exhaust gases fluidize the bed Fig. 4. Evolution of (200) a brass diffraction line according to dispersion time1. as wires pass over the u-tubes. The sand is hotter below than

TECHNICAL PAPERS Table 1. Diffusion process comparison. Note: the totals for the first three columns came from multiplying the individual column numbers by the number in the fourth column. This table is for a fictitious company and the results will vary depending on how important the different factors are to a particular company. harder, and if they fail, the result could be extended shutdowns to remove all or a portion of the sand to replace the tube(s). Care must also be taken with top heaters, which use burners to heat the top of the sand while cool air fluidizes the sand. This can create a large gradient in temperature, resulting in serious uniformity issues as more zinc is oxidized and vaporized from the top of the wire. The burners must be well aligned across the surface or sand can be pushed to the edges of the bed, resulting in “cold’ spots for the end positions and lower percentages of alpha brass. Maintenance costs. Maintenance of air fluidized sand beds is a main complaint of users. Sand returns, especially those where sand impinges on the inside of an “elbow,” are notoriously unreliable. Some systems have imbedded sand returns and the sand must be removed to replace worn parts. Zinc costs. Regardless of the heating type, air-fluidized sand beds are commonly set to operate well above the melting point of zinc (420oC). Systems are usually set to diffuse at about 600oC so that the zinc in the sequentially plated wire immediately melts as the wire enters the unit and is vaporized by the hot fluidization gas. The zinc can melt in the first zone2, which usually results in zinc losses that are significantly higher than any other diffusion method. After the wire surface oxidizes and some diffusion occurs, the melting point of the brass alloy rises dramatically, arresting the zinc loss. It is much more difficult to control brass chemistry when using an air fluidized sand diffusion bed due to zinc losses. Some suppliers claim that zinc loss is controllable by controlling the composition of the fluidization gas, but this is dubious as the source is either air (oxygen), combustion by-products (water) or a combination, all of which quickly lead to oxidation. Pickling costs. Pickling costs to remove zinc oxide are relatively high since fluidized beds generally form more oxide than Joule effect diffusion (heating is rapid and non-linear). Special protective coatings are not used as they either contam-

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inate the sand or are abrasively removed by the fluidized sand. Energy costs. As this method heats wire due to the conduction between the hot sand and the wire with minimal convective heating due to hot gasses, heating occurs only when sand is in contact with wire so the process is very sensitive to fluidization pressure. Thus, for diffusion by air-fluidized sand, a large volume of sand must be heated, and subsequently the energy costs are relatively high. Ease of operation. One advantage of air-fluidized bed sand patenting is that if a wire stops in the diffusion unit it will generally not break unless the tension is excessive. Zirconium and alumina sand are commonly used. Zircon sand has higher heat transfer properties and is about the same price as alumina sand. The angle of repose for both sands is a function of the diffusion temperature. At lower diffusion temperatures sand may tend to lay on the top of larger diameter wires, dragging sand past the air-fluidized sand bed and into the next process. This is more pronounced for alumina sand due to the difference in its angle of repose. Alumina sand, even the special “rounded corner” type, is more abrasive than zircon sand due to its sharper edges. This can cause more maintenance issues, but this issue can be avoided if a proper stringing system is used. Set-up parameters are independent of steel composition, diameter and steel strength level (NT, HT, ST, UT, and MT) and are limited only by the temperature set-up of the unit2. Strength loss. Air-fluidized sand diffusion can significantly affect the wire’s strength if the diffusion temperature is too high or the retort is too long, or both. Again, as with Joule Effect diffusion, diffusion losses commonly exceed 40 MPa when the diffusion temperature is set near 600oC, especially for steels like ST and UT. A steady, low diffusion temperature is needed to maintain appropriate brass properties. Overall operating costs). Overall operating costs, exclusive of energy and maintenance, is fairly high since the process consumes zinc. The cost of sand must also be considered since heat transfer is related to the sand particle size and the sand particle size changes during operation as sand grains collide during fluidization.

Induction diffusion Induction heating results from resistance of sequentially plated wire to the flow of electrical current. The wire is indirectly heated as it passes through an inductor coil carrying high frequency alternating current. Identical to the Joule Effect, heat is generated due to resistance and current in the wire: Q = I2 * R * t where: Q = heat generated (joules); I = constant current (ampheres); R = electrical resistance (ohms); and t = time (seconds). Some claim that due to high frequencies used for diffusion in tire cord manufacture, heat tends to flow at the wire’s surface5. This can be disputed by empirical data that show significant tensile strength losses for higher strength products like ST, UT and MT when the inductive diffusion temperature exceeds the patenting temperature. The equation for effective

where: p = depth of penetration in mm; ρ = resistivity in microhm centimeters; F = frequency in cycles per second; and μ = relative permeability. From a laymen’s position, it is counterintuitive to presume that a 1.5 mm wire is not through-heated by conduction when the outside wire temperature can be measured at about 560oC, regardless of any induction calculations. Capital investment. Capital costs are quite high for induction diffusion as it uses an inductive coil at high frequency to create a current in sequential plated wire running through the coil. Costs for power units increase rapidly with increasing frequency; the price of a 50 kHz unit is about double the price of a 10 kHz unit. Three other considerations are the power required, the induction coils and the cooling water treatment requirements. Power needs are complicated as the heat of steels change greatly with temperature5. Decisions should be based on being able to process the smallest wire diameter running at the highest speed. The coil generally has a wound copper tube through which deionized water passes for cooling. A flat copper strip must be brazed to the inside of the copper tubes to increase the effective surface area for induction. Coil efficiency, which is usually low for induction diffusion, is a function of coil length, internal diameter, number of turns, and percentage of free, nonconductive space along the coil length5. Several variations of coil geometry are common, from one coil per wire to 40 or more wires per coil. When one coil is used for one wire, its shape is round while coils that carry multiple wires are oblong, with end wires situated away from the edges of coils. Each coil comes in a set where one coil is wrapped in the opposite direction of the other coil to help reduce stray current from leaving the system via the sequential plated wires. Coil length varies, but longer coils are generally less expensive, although prone to maintenance issues as wires drag on the inside surface of the coil depositing zinc, zinc oxide and brass dust. Shorter, sealed coil cassettes are much more durable and less prone to damage. Coils are usually protected from touching the wire by ceramic tubes that run through the center of the coils. The coils can be easily cleaned during use by compressed factory air. In some cases, wire pitch must be increased to accommodate ceramic tubes; this may require wire realignment prior to diffusion resulting in surface defects and loss of zinc2. Another expense is the high quality de-mineralized water that must be used to cool the coils2. Product quality. Induction diffusion systems are the largest capital cost, but as the sequentially plated wires can be heated without touching anything, there is no possibility of arcing and a higher quality product is made. Further, simple coatings can be applied to the wire’s surface, dramatically reducing zinc loss during diffusion. Also, diffusion temperature and uniformity can be easily controlled.

Maintenance costs. Maintenance costs for induction diffusion are low if small coil cassettes are used and power supplies are isolated from harmful chemicals. Coils must be water-cooled so water quality is important. The largest wire size must be able to fit through ceramic guides without touching them as any rubbing will quickly result in clogged guides and broken wires. Any contact with wire guides after plating could result in flaking, resulting in unwanted deposits inside. As with the Joule Effect, it is vital that electrical control components not be allowed to suffer corrosion. Zinc and pickling costs. The small amount of zinc oxide produced during induction diffusion can be controlled by applying a coating to the wire to help prohibit zinc oxide formation at high temperatures. Unlike air fluidized sand diffusion, induction diffusion heating is linear, allowing a significant amount of diffusion to occur and preventing zinc liquid or vapor from forming. Energy costs. Heating through the induction diffusion system is linear, regardless of the number of cassettes or the length of coils. Wires enter at around room temperature and exit at the diffusion temperature. Unit efficiency depends on the load. Smaller wires are more difficult to heat and require a higher frequency or a more powerful energy supply. The efficiency to convert from normal plant frequency to that required for induction diffusion alone can be as low as 85%3. Some suppliers claim that induction diffusion creates a “skin” heating effect, however this is doubtful. For even a large diameter wire, like 2.0 mm, if the “skin” effect penetrates 0.5 mm, this is ½ the wire diameter of the wire and 75 % of the wire volume. It is likely that the entire wire is heated by induction and conduction through the body of the wire. Energy costs are relatively high, depending on the equipment’s frequency. Although efficiency of induction systems has improved, approaching sand fluidized bed efficiency, induction diffusion remains the low efficiency alternative. Ease of operation. It is easier to control brass properties during induction diffusion as the zinc oxide coating is minimal and uniform. Energy consumption is similar to that of air fluidized sand diffusion. Similar to the Joule Effect, since heating depends on resistance (diameter, chemistry) different setups must be maintained for every combination of diameter and chemistry2. However, the units are easy to operate. Strength loss. Strength loss during induction diffusion is relatively easy to control as the wire temperature can be directly measured within a range using, for example, welding temperature preheating crayons. Direct temperature measurement via infrared technology is difficult as the amount of copper per wire can influence the temperature measurement. However, for a given diameter, speed, power and frequency setting the wire temperature is constant and can be duplicated identically. Some argue that since the amount of energy produced using induction diffusion is a function of resistance (diameter, temperature), small changes in diameter and chemistry can result in different wire temperatures2, but it is questionable whether these differences are relevant for a given set-up. Overall operating costs. Overall operating costs for induction diffusion, exclusive of energy and maintenance, are rela-

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penetration depth is given by5:

TECHNICAL PAPERS

tively low. They are basically nil with the exception of clean water to cool coils and isolation of power supplies from typical steel tire cord manufacturing chemical vapors or injection of fresh air into power cabinets.

Conclusion Control of the diffusion process is extremely important in the manufacture of steel tire cord, particularly high strength products like ST, UT and MT product. The diffusion process plays a major role in fine drawing and twisting performance as well as final cable strength6-7. Table 1 shows advantages and disadvantages of Joule Effect diffusion, air-fluidized sand diffusion and induction diffusion. The values in Table 1 are not “real” and are shown only for example. Although Table 1 indicates that induction diffusion may be the best overall choice, what may be most important is the fourth column, which cites what are the most important features for a particular steel tire cord manufacturer, in this case a fictitious steel tire cord manufacturer. Please note that a refined table can be developed by placing an actual estimated dollar value, normalized over a one year period, on each “feature.” In this way, a valuable purchasing decision matrix can be generated.

References 1. B. Bolle, et al., “Thermal Diffusion Analysis of Brass Coated Steel Wires,” Wire Journal International, June 1999, pp. 82-88. 2. R. Branders, “Comparison of the diffusion process with the fluidized bed, induction healing and Joule effect,” FIB Belgium SA, USA, Private Correspondence, June, 2008. 3. V. Dorsten and V. Pilic, “Induction heating assures high quality high strength steel wire for tire cord with improved productivity,” Wire Journal International, Sept. 1990, pp. 7278. 4. R. Branders and C. Verschuere, “Philosophy of the design of fluidized bed typical applications in the wire industry,” WAI European Technical Conference, Berlin, Germany, 1993. 5. K.D. Spain and B. Kirkwood, “Selecting the correct frequency and power requirements is critical to the wire heating process,” Wire Journal International, Feb. 1997, pp. 220-228. 6. T.W. Tyl, “Control of strengthening mechanisms in the manufacture of steel tire cord,” Wire Journal International, February 2006, pp. 122-128. 7. T.W. Tyl, “Control of Patenting in the Manufacture of Steel Tire Cord,” WAI International Technical Conference, “Wires in Automotive Applications,” Pune, India, January 2008. ■

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T. Tyl

J. Tyl

Thomas W. Tyl is the principal for Tire Wire Technology (TWT), LLC, Siler City, North Carolina, USA. He is also contracted to GCR for long-term support as its technology and product development team leader. He retired from the Goodyear Tire & Rubber Company and worked for 23 years in steel reinforcement. He is the inventor of five new technologies in the past five years with patents pending in the US and other countries. He holds a master of engineering degree in metallurgical engineering and materials science from Carnegie Mellon University, an M.B.A. degree in manufacturing management from the University of Pittsburgh, and a B.S. degree in materials science from North Carolina State University. Jeffrey T. Tyl is the executive vice president, sales and marketing for Jigsaw Thermal Technology, LLC (JTT), Siler City, a green manufacturer of heat treating equipment for the wire industry. JTT markets and sells energy-efficient, lowemission, direct-fired gas furnaces and air fluidized sand beds manufactured in the USA by JTT’s partner, Joe Moore & Company Inc. This paper was presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, April 2009.

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Air wipers have ceramic-lined inserts for better production, longer life

This section presents new products that were introduced at wire Düsseldorf or Wire Expo, including a few that were shown at both events.

Huestis Industrial reports that its ceramic-lined “Air Miser” air wiper, introduced at both wire Düsseldorf and Wire Expo, was designed in response to customer demand for a better, longer-lasting product. For years, a press release explained, human error in centering and aligning wire in an air wiper has resulted in offposition wire causing premature wear and damage to plastic air wiper bodies, and often to the wire itself, as it rubs and cuts into the plastic. Air wiper suppliers have tried using ceramic eyelets and partial ceramic inlet guides that lead into the canal or cavity of the air wiper, but most of these designs failed due to poor performance, breakage and higher costs, it said. Later versions of full-bodied inserts were somewhat better albeit not stellar, and they cost a lot more, it noted. In response, Huestis decided to make an air miser with a full-bodied ceramic insert that could perform exactly as the standard air miser and allow the inserts to be replaced, the release said. Design work began, the right ceramic was chosen and prototypes were tested in the field. The photo shows the Air Miser unit with and without the ceramic lining. The results, it declared, were outstanding. Not only did it meet customer needs, and use less air than other air wipers, it proved quite rugged, able to stand up to the daily wear and tear rigors of manufacturing. The new air wiper has all the advantages of the standard air miser— including air economy, where it may be even better—and it takes away the need for centering guides and frequent supervision and adjustment. The all-new ceramic air miser will be offered in the most popular sizes for 2010 and sizing will be expanded up to one inch (25.4 mm) in 2011. Contact: Howard Fancher, Huestis Industrial, 401-2535500, sales@huestis.com.

Bio-based plasticizers for insulation and jacketing called an ‘industry first’ At wire Düsseldorf, Dow Wire & Cable, a business unit of The Dow Chemical Company, launched DOW ECOLIBRIUM™ Bio-Based Plasticizers, a new family of phthalate-free plasticizers for use in wire insulation and jacketing that are made from nearly 100% renewable feedstocks. A press release said that the use of the plasticizers in PVC compounds for wire applications can help cable-makers and original equipment manufacturers (OEMs) reduce greenhouse gas emissions by up to 40% if used instead of traditional PVC plasticizers. The new plasticizers, it said, were developed to meet growing demand for more sustainable options in wiring applications such as personal electronics and appliance wiring, residential and commercial building wiring, communications and data cabling, and automotive wiring. Jonathan Penrice, global marketing director for Dow Wire & Cable, said that the company was excited about the results of field trials by a select group of customers. “The field trials demonstrated that the new plasticizers exhibit the same performance and feel as incumbent PVC plasticizers while meeting all regulatory requirements for flame resistance,” he said. “DOW ECOLIBRIUM BioBased Plasticizers are truly a breakthrough for the wire and cable industry but their introduction here is just the tip of the iceberg; in time they will also open up differentiation opportunities for OEMs in other industries that use PVC compounds.” The company plans to license select cable makers to commercialize the product consistent with its Dow Inside program, which includes a wide range of support and resources from Dow Wire & Cable, the release said. For details on specific applications go to the company’s website. Contact: Dow Wire & Cable, www.dowwireandcable.com.

86 | WIRE JOURNAL INTERNATIONAL

Special polymers for photovoltaic wire and cable meet multiple regulations At wire Düsseldorf, U.S.-based PolyOne Corporation presented a comprehensive portfolio for photovoltaic wire and cable applications that it said offer manufacturers more options while meeting environmental requirements. The Solar-T system offers a fully compliant solution for photovoltaic cables that includes: ECCOH™ Solar-T compounds, OnColor™ Solar black color concentrate, SmartBatch™ Solar red or blue color with UV additive

Green pigmented ink has low VOC At Wire Expo 2010, U.S.-based Gem Gravure introduced a new ink, GNG5765, that has low VOC (volatile organic compounds) content and no reportable HAPs (hazardous air pollutants). A press release described GNG5765 as a bright green opaque ink that is based on pigment dispersions specifically designed for ink jet fluids. It noted that codes stand out on a variety of colors, allowing one ink to be used on a variety of packaging colors. Ink jet fluids cannot be chosen by regulatory status alone because they have to work and work well. GNG5765, it said, does just that. The company noted that creating such inks is important because of environmental concerns that are not going to go away. VOCs emitted into the air can react with other chemicals, leading to the formation of ground level ozone or “smog,” so from an environmental standpoint, reducing VOCs helps to improve air quality. An environmentally friendly ink also makes sense from a business standpoint, the release said, as eliminating these materials can reduce the

need to obtain emissions permits. This is particularly important in EPA non-attainment areas where clean air standards have not been met, it noted, adding that all of the fluids made by the company comply with RoHS regulations. Contact: Gem Gravure Co., Inc., tel. 781-878-0456, www.gemgravure.com.

Fault detector offers simple method for pinpointing cable problems At Wire Expo 2010, Clinton Instrument Co. introduced its new FL-20A Cable Fault Locator, a quality control tool designed to allow cable producers to pinpoint the problem area of finished cables. A press release noted that cable rejected during hi-pot testing has always been an expensive problem for the manufacturer. Until now, finding opens and shorts with an analog cable fault locator took expertise and patience, since the procedure required tedious meter and sensitivity adjustments as well as mathematical calculations once the test was completed, it said. The digital FL-20A unit, it said, automates cable fault detection, greatly reducing the time and training required to find these problems. The operator simply connects the FL-20A test probes to each end of the cable under test, enters the cable length on the digital front panel display, and selects “Shorts” or “Opens” to begin the test. In seconds, the unit calculates the distance of the fault site from each test probe and displays the location in feet or meters. The failure can then be cut out or repaired and the remaining good product salvaged, resulting in great savings to the producer. The locator, a compact 15"W x 14"D by 10"H weighing only 30 lb, is significantly smaller and lighter than its predecessors, the release said. It promises a great return on investment by salvaging expensive cable assemblies and lowering the costs associated with salvage, it said. Customers were able to test the unit as it was demonstrated at the show. Contact: Clinton Instrument Co., tel. 860-669-7548, www.clintoninstrument.com, support@clintoninstrument.com.

Indoor compact drum handlers can easily handle large weights At wire Düsseldorf, U.S.-based Elof Inc. introduced its range of indoor cable drum handlers for the cable manufacturing industry. The handlers, a press release said, which are available for maximum loads of 7, 15, 30 and 50 metric tons, use

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concentrate and OnCap™ Solar dry silane concentrate for crosslinking (e-beam irradiation can also be used), a press release said. It noted that solar photovoltaic technology requires specific cabling systems with zero-halogen, flame-retardant insulation and sheathing layers. The outer jacket must also be resistant to moisture, sunlight, heat, chemicals and abrasion, and while specifications for these cables vary by region, PolyOne’s Solar-T solution complies with TÜV 2 Pfg 1169/08.2007, a worldwide recognized norm, it said. Among the advantages, the release said, is that the ECCOH materials can be used for both internal (insulation) and external (sheathing) layers in cable applications, allowing solar cable producers to choose a single material. Further, ECCOH low smoke and fume, non-halogenated, flame-retardant materials offer operating temperature from -40°C up to 120°C, good flexibility and flex crack resistance, and weathering resistance up to 20 years based on resistance to moisture, UV, heat, chemicals and abrasion, it said. It added that ECCOH products are highly flame retardant, non-corrosive, offer low toxicity and smoke density and are classified as PolyOne Sustainable Solutions. Contact: PolyOne Corporation, www.polyone.com.

PRODUCTS & MEDIA

the company’s ‘low lift’ technology, which can lift and move extreme loads without the use of a counterweight. That, it said, results in a machine that is both compact and light. The Handler’s small footprint allows it to access most areas on the production floor while its low weight minimizes potentially damaging floor pressure and keeps power consumption low, it said, adding that the electrically driven and emissions-free Handler is ideal for indoor use. The new introduction follows an advance reported two years ago by Elof that it said enables its cable drum handlers to pick up cable drums in both directions, both parallel and perpendicular to the lifting forks (applies to models for loads of 15, 30 and 50 metric tons). This added versatility allows the already compact Handlers to directly pick up or leave a drum in either direction, without time consuming realignment, it noted, adding that the Handlers are available with three driver sitting configurations: standing behind drive unit, sitting behind drive unit, or sitting on top of drive unit. Contact: Patrick O’Brien, Elof, Inc., tel. 972-740-2209, patrick.obrien@elofhandler.com, www.elofhandler.com.

Lubricants meet toughest demands of both carbon and stainless wire At wire Düsseldorf, Italy’s Pan Chemicals SpA showcased its new PANLUBE S 1500 series of sodium lubricants, which it said were designed to meet the increasing needs related to environmental aspects. “These products are free of borax, nitrates, phosphates, carbonates (and) chlorides,” a press release said. It noted that the lubricants were designed to be safe and ecologically friendly while also being suitable for high-speed drawing of high-carbon steel wire, steel cord wire, bead wire, spring wire, roping wire and PC wire (final dies) as well as for very high speed drawing of low-carbon wire. Ecology and environmental safety have been foremost in the company’s development of new lubricant and coating products, the release said. It noted that the application of the new European directive, REACH, “has given a further push toward the development of new products which are completely safe for the operators and the environment.” The most evident result of that pressure for the wire industry has been the elimi88 | WIRE JOURNAL INTERNATIONAL

nation of borax in the formulation of the drawing lubricants and the coatings, it said. Contact: Pan Chemicals SpA, tel. 39-0359-77488, info@panchemical.com, www.panchemical.com.

SCR infrared system designed to detect bar porosity in real time At wire Düsseldorf, U.S.-based Southwire Company introduced the IRIS 5000 infrared inspection system, which was developed via a joint collaboration between Southwire and Oak Ridge National Laboratories for the inspection of continuous cast copper bar in real time. The company noted the following. As molten copper flows into a mold, both dissolved and aspirated gases are typically trapped as gas bubbles inside the molten pool. After solidification, flaws will develop in the form of gas porosity in the solid metal unless the casting process provides a mechanism for the escape of these gases. A major advantage of the SCR system is that it provides such a mechanism for the escape of these gas bubbles. However, if proper casting parameters are not maintained, gas bubbles may be trapped in the solid metal, forming gas porosity. The key is to detect and eliminate porosity during the casting process, thereby significantly improving the quality and productivity of wire and cable. The IRIS 5000 uses an infrared camera that measures surface temperature as the copper bar exits the casting wheel and aftercooler. A proprietary algorithm then uses that temperature profile from the IR camera along with advanced statistical techniques to detect flaws less than 1/8th of an inch in diameter. Contact: Scott Warren, Southwire Co., tel. 770-8325069, scott_warren@southwire.com, www.southwire.com.

Product line focus is on high tech and environmentally friendly solutions At wire Düsseldorf and Wire Expo, France’s CONDAT displays reflected its R&D philosophy of systematically searching for substitutes to potentially dangerous raw materials. The company notes that its lubricants have always been free of SVHC (substance of very high concern) and are compliant with most standards (RoHs, etc). At the two trade shows, its staff was ready to discuss a range of new products that the company has developed. VICAFIL SUMAC 3, for example, is a new generation sodium soap developed for technical, environmental and

Cable design and quotation software designed for multi-plant operations At wire D端sseldorf, U.K.-based Cimteq launched its CableBuilder Enterprise software for managing cable design and quotation processes in multi-plant environments. CableBuilder is already widely used by cable manufacturing companies around the world to increase productivity in areas associated with cable design and quotation. The software helps cable manufacturers monitor key performance indicators across the enterprise, as well as factory, by factory, hence providing a benchmark for improvement of

Tape formers now in larger sizesAt wire D端sseldorf, U.K.-based RG Attachments Ltd. reported much interest in its two new larger tape former models. The Model H unit is designed for tape widths of 211 mm (5 5/16") to 310 mm (12 3/16") while the Model I unit is designed for tape widths 311mm (12 村") to 480 mm (18 7/8"). Both tape formers were developed in response to requests from cable manufactures for tape formers for larger cable diameters.

Robert Gent, RG Attachments, with a special tape former on display at wire D端sseldorf.

Cutoff C utoff KKnives nives and Q Quills uills

RG Attachments is constantly developing new tape former designs to customer requests almost on a weekly basis. The company has also completed a new tape former catalogue that is available upon request. Contact: RG Attachments Ltd., tel. 44-116-261-1038, info@tapeformers.com.

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economical reasons. It improves wiredrawing of highcarbon steel and stainless steel at very high speeds. The lubricating film is even more resistant, helping reduce wire breaks and die erosion. It comes in powder or a beaded version to reduce soap consumption and dust. Other products include surface coatings such as VICAFIL TS 7853, which has a low borax content, and VICAFIL TS 7101, which has a zero borax content, the company reports. It notes that the surface coatings comply with new borax regulations. Another product, VICAFIL WC 6C, a soluble lubricant for weaving applications, has been developed with renewable raw materials, it said. Contact: Condat SA, www.condat-lubricants.com, and for its U.S., Condat Corp., www.condatcorp.com.

PRODUCTS & MEDIA

efficiency, material utilization, cost, lead time, and more. CableBuilder Enterprise will now allow design engineers to optimize their designs to the manufacturing conditions and material availability by using “alternative designs,” which enable production controllers to maximize the use of machines and materials without compromising quality. Contact: Cimteq, info@cimteq.com.

2 new cleaners are very cost-effective At wire Düsseldorf and Wire Expo, RichardsApex, Inc., introduced two new cleaners to the company’s “DEOX” line of acid-based cleaners: DEOX 22 and DEOX 29. DEOX 22 is an inhibited, acidic base cleaner, containing specially selected metal wetters for removing calcium and sodium stearates from ferrous and alloy wires. For cleaning jobs that require the removal of oil as well as soap powders, there is DEOX 29, an inhibited, acidic-base cleaner that contains an emulsifier package to facilitate the removal of residual drawing oils. It is also effective for removing insoluble dry drawing soaps permitting the use of this product in fully integrated alloy wiredrawing facilities. DEOX 29 has additives to inhibit foaming to promote

WHEN IT COMES TO TROUBLE-FREE

MULTI-WIRE STARTUPS,

WOODBURN IS THE PERFECT MATCH!

90 | WIRE JOURNAL INTERNATIONAL

less product loss during the cleaning process. Both products are significantly less expensive then typical phosphoric acid or acid-based cleaners and have been shown in field tests to be as effective as cleaners mentioned. Typical DOEX 22 and 29 running temperatures for these products are 120 to 180°F with a typical concentration of 10-15% by volume. Bath life is very dependant on the amount and type of soil being removed from the processed wire. Both of these products gained considerable interest at the wire Düsseldorf and Wire Expo trade shows. The company, which is based in the U.S., has a subsidiary in the U.K. (RichardsApex Europe) and in Australia (RichardsApex Australasia), as well as an international network of distributors and agents to provide customers the products and service they need. Contact: RichardsApex, Inc., tel. 215-487-1100, www.richardsapex.com. ■

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

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

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

PAYMENT POLICY: All ads must be pre-paid.

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

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

CAREER OPPORTUNITIES

PERSONNEL SERVICES

SALES. Established European supplier of Wire Drawing, Extrusion and Cabling equipment is seeking a proven sales professional to join our team as a Sales Area Manager. The ideal candidate should have a minimum of 3 - 5 years of technical selling experience in the wire and cable industry and would be expected to have a broad knowledge of wire and cable manufacturing process and related equipment. Extensive travel throughout the USA, Canada and Mexico is required. Salary is commensurate with experience. Please forward all inquiries to Box 7-1.

“LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors, managers and executives. For corporations we

CONTRACT SALES REPRESENTATIVE. Measurement instrument supplier seeking technical sales representatives for a variety of territories in North America. Technical and process knowledge of wire and cable manufacturing a plus. Commission based compensation. Respond to beansteve@gmail.com.

provide recruitment, outplacement, and salary assessment functions. For the professional exploring a new opportunity, we provide career evaluation and guidance. Our services are performed in absolute confidence. Contact: E-mail Peter Carino at pcarino@wireresources.com or Jack Cutler at jcutler@wireresources.com, or visit the Wire Resources website at

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

FOR SALE

132710 117 1121115-

SALES REP AVAILABLE

SALES REP AVAILABLE. Do you need an experienced sales representative in Mexico, Central, or South America? Someone with strong industry experience in both ferrous and electrical segments? If so, e-mail cablesyalambres@gmail.com.

212-

HALL 500’ Vertical Accumulator, 1997 NEB 48-Carrier CB-1 Cable Braiders WARDWELL 24-C Speedmaster Braiders WARDWELL 12-Carrier Braiders NEB #2 Braiders, 12-C, 16-C, 44-C, 96-C FRIGECO 8-00mm D.T. Buncher LESMO 760mm, 630mm D.T. Bunchers WATSON 36” Rotating Cabler Line WATSON 37-Wire 22” Planetary Cabler NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 CEECO 6-Bobbin 60” Closer w/ 96” Caterpuller, 120” Take-up DAVIS ELECTRIC Model CAT-TRAK 22 Caterpuller Capstan VITECK 24” Horizontal Belt Wrap Capstan NEIHOFF MultiWire Drawers: MMH101 7Wire; MMH121 14 and 16-Wire DAVIS STANDARD 3.5”, 2.5” 24:1 L/D Extruders D/S 2.5” 24:1 L/D, 2” 30:1 L/D Hi-Temp Extrusion Lines D/S / KILLION 1” 24:1 Extruder L/D, 2001 TULSA 24” Motorized Shaftless Payoffs, Model HSPO-1, 12/02

1 1 1 3 5

151122115129 -

EJR 18”, Model 260FWPPO, Motorized EUBANKS 6415 Prefeeder, Model 6415-03 NEB 54-Wire 22” Rigid Strander Line MGS 18-Bay 10” Tubular Stranders DAVIS STANDARD Dual Reel Take-ups, 36” (1), 30” (4) DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up NOKIA Model EKP50 Parallel Axis Dual Reel Take-ups CLIPPER Model SP16 Dual Spooler DAVIS ELECTRIC Model CRS30 Respooler WATSON/AFA 84” Rewind Lines, 6,600lb cap. TEC Model 24STC Hi-Speed Twisters, rated 1300rpm w/2-Wire Payoffs EUBANKS Model 4000-04 Cutter & Stripper w/HUESTIS 36” Payoff AUTOJECTOR HCS-40 Injection Molder SCHLEUNIGER MP257, MP8015, PS9500RS, PF2200, PF2000 IMAJE Inkjet Printer, Model Jaime 1000 S4, ‘98 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal 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

JULY 2010 | 91

CLASSIFIEDS

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

BLIND BOX? YES____ NO ____

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

w w w. w i r e r e s o u r c e s . c o m . Wi re Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE.

DIES DS HAI, LLC IS A NEW and growing diamond die maker with locations in the United States and Korea. We can supply high quality Diamond and PCD dies at very competitive prices. A few of our specialities are dies for high performance bunching (silver/nickel etc.), dies for hard drawing material, and dies that combine Carbide coating with PCD which can be very efficient on a long order for big cables. DS Hai services wire manufacturers in the United States as well as Internationally. We also provide very competitive recutting services. We are looking for sales agents in Europe to assist in our growth. Attractive commissions. Please contact Simon Farjoun by e-mail at either simonfar@yahoo.com or Simon@dshaidies.com, tel. 860-8841270. AJEX & TURNER WIRE DIES CO. offers a wide range of PCD/ND/ Carbide Dies, Extrusion Tools, Die Polishing Machines, Ceramic & Diamond Tools. www.ajexturner.com. Send inquiries to ajexturner@ gmail.com/sales@ajexturner.com A53, G.T. Karnal Road, Delhi-33 India. Ph: 0091-9811078882 (Ravi Bansal). SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest

92 | WIRE JOURNAL INTERNATIONAL

Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service. 60+ years of quality products and service to the wire industry. Contact Bill Drumm at 1-800-332-0747, or E-Mail at sales@sancliff.com. APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ wmconnect.com. 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.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & Non-ferrous; Marldon Rolling Ring Traverses) and Used Wire & Cable Equipment. Available (Cleaned, painted & checked operational) Buttwelders: Micro Models E1S, J4S, J5S, J6S, THD, J45C, GP-0 and AD-5. Coldwelders: Koldweld Models KBM-5 & KBM-9. Babcock Models CBW-2, CBW-10 & CBW-20. Printers: Gillies Models GS500 & GS100HD. Roll Pointers: Morgan Models #250 and Hand Operated. Inquire on other used equipment. Please contact by telephone at #727-863-4700 or by e-mail at urbassoc@verizon.net.

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org. For more details, you can call her at 203-453-2777, ext. 116.

WIRE PLANT SOUGHT WANTED LRPC PLANT, 10,000 tons capacity per year. With or without wire drawing. Please contact M. Sarkar, e-mail at msarkar@mikisteel.co.in, mobile no+91-9342543555.

MEDIA INTRODUCTION TO EXTRUSION SET (DVD). This video series (total running time of 1 hr., 45 min.) by extrusion expert Tom Black includes Part 1, Materials & Equipment (50 min.), and Part 2, Extrusion Processing (55 min). List Price: $425, WAI Member Price: $325. To purchase, go to wirenet.org and click on The WAI Bookstore. ELECTRICAL WIRE HANDBOOK. Focusing on the special needs of the insulated wire and cable industry, this three softcover book set examines materials, equipment, and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire, and other applications. The original version remains available while the revised Electrical Wire Handbook is divided into three separate handbooks: Part 1 Wire and Cable Production Materials, Part 2 - Wire and Cable Production Processes, and Part 3 - Types of Cables. While the updated handbook includes

WIRE BREAKS, by Horace Pops and Julie Steininger. 2003, 49 pages. Breakage of copper, steel, or aluminum wire is one of the most common and costly problems facing the wire industry today. To help minimize the number of breaks, drawing personnel must first be able to recognize and identify the type and cause of material failure. With this need in mind, the following refer-

ence manual was prepared. It contains pictures of the most frequent examples of broken wires found in the wire mill and at the customer’s facility. List price: $15, WAI member price: $10. To purchase, go to wirenet.org and click on The WAI Bookstore. THE BOOK OF WIRE & CABLE TERMS. This 350-page book is an indispensable publication covering both ferrous and nonferrous terminology. More than 5,000 entries are offered. Price $75, $50 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Bookstore.

WAI President Robert M. Shemenski. It is a modern-day reference tool for those working directly in the steel wire or manufacturing, engineering, or operations sectors of the industry. At 1,168 pages, the publication’s comprehensive 36 chapters cover a broad range of topics including many of the equipment types, processes, and specialty applications of steel wire manufacturing. The book begins with a history of the steel industry and includes the evolution of ferrous steel manufacture, appendices and a complete index. List Price is $235, $195 for WAI members. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

FERROUS WIRE HANDBOOK. This comprehensive WAI hard-cover book is a definitive industry resource for ferrous wire written by members of the Association and edited by former

WIRE JOURNAL

INTERNATIONAL

DRAWING LINES

TO CAPITAL EQUIPMENT.

E X TRUDE D R A W B R A I D T W I S T B E N D

SEPTEMBER 2010 | EQUIPMENT: PART 2 Part 2 of this two-part feature will showcase some of the newest technology and machinery displayed at wire Düsseldorf. If you sell machinery for wire and cable making, make plans to advertise today.

Contact the WJI Sales Team to reserve your space today. Bob Xeller | ext. 119 | bxeller@wirenet.org or Anna Bzowski | ext. 126 | abzowski@wirenet.org

JULY 2010 | 93

CLASSIFIEDS

the latest information available, this new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. The handbooks provide basic information to those people working in the wire and cable industry. List Price: $99, WAI Member Price: $59. To purchase, go to wirenet.org and click on The WAI Bookstore.

ADVERTISERS’ INDEX

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

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

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .90

Drawing Technology, Inc. (DTI) . . . . . . . . . . . . . . . . . . . . .89

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

Elof Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .40

Esteves Group USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Caballe SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Eurolls SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Cemanco LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Flymca & Flyro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Chicago Association of Spring Manufacturers Inc . . . . .27

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .91

T Fukase & Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Conneaut Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Gem Gravure Co Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Domeks Makine Ltd Sti . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Howar Equipment Inc/Metavan . . . . . . . . . . . . . . . . . . . . .63

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

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 WAI 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.

94 | 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.

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

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30, 56

OM Lesmo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Jinyoungtech Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .18

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

Power Sonics/Magnus Equipment . . . . . . . . . . . . . . . . . . .53

Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . . . . .14

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .62

Lloyd & Bouvier Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . . . . .43

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

PS Costruzioni Meccaniche Srl . . . . . . . . . . . . . . . . . . . . .35

Madem SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Magnus Equipment/Power Sonics . . . . . . . . . . . . . . . . . .53

Reel-O-Matic Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Metavan/Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . .63

SAMP USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23, 49

Numalliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

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

WAREHOUSE SPACE AVAILABLE: PAWTUCKET, RI - ATTLEBORO, MA - MONROE & MORVEN, NC - BONHAM TX

RECENT PURCHASES — INVENTORY HIGHLIGHTS SKALTEK 1.2, 1.6, 2, 2.2, 2.6, 3 Meter Portal Traversing Payoff’s/Take ups DRUM TWISTERS:96” CEECO(1), EDMANDS(2); 84” CEECO; 78” CARTER/CORTINOVIS; 72” CABALLE(1), TEC(2), EDMANDS(3); 60” POURTIER, CEECO; 48” POURTIER, EDMANDS (3); 12”-120” BELT CATERPULLERS: MGS, BARTELL, DAVIS STD. DAVIS ELEC, STOLBERGER, NOKIA MAILLEFER BARTELL TUBULAR STRANDERS 6, 12 wire 6.5”/10” (50+) (3) NIEHOFF 800mm DROPCOILERS (Yr. 2000) BRAIDERS: WARDWELL 16C/24C Wire/Textile Braiders (500+) New Speedmaster 150 Heads (30). BRAIDERS: SPIRKA 16C/24C OMA Hi Tech 16C/24C, NEB, TMW Braiders. EXTRUDERS: DAVIS STD. 1 ¼”, 1 ½”, 2”, 2 ½”, 3 ½”, 4 ½”, 6” 24:1 Air cooled Extruders. DUAL TAKE UPS: CLIPPER PA-16, PA-24, PA-30, PS-24, PS-36,

PS-50 Dual Parallel Axis. EXPL351 NEXTROM 80 mm 24:1 Ext Line w 500mm Split Capstan, S.S. trough, 1200 mm BCA-12 Belt Cat (New). Yr Mfg 1999. CBR984 WATSON 19 wire 22” Planetary cabling line (still installed). WRD831/WRD678 SAMP 8 wire MT8.2.4.21 drawing machine/SAMP 14 wire MLS/5.T.14. CBR957 COOK 48” BH-48 S.T. Cabler, Cook BH-36, BH-30, BH24, BH-22, BH-16. TKU1149 NEXTROM Take ups EKP-63 Yr. 2000 Never used.(4) EKP 50, Yr. 1998, TKU1118-1121/EKP-5, Yr. 2001 (2). WRD890 (3) SAMP TR2TP Wire Drawing/Annealing /Preheating Yr. 2000 Never Used. CBR998 (8) SETIC 630mm PA630i D.T. Twinners, 1998. MGS/BARTELL Payoffs: 60”, 72”, 84”, 96”. Take ups 60”, 72”, 84” 96” (some rebuilt).

ALWAYS LOOKING TO BUY/TRADE GOOD SURPLUS MACHINERY PREOWNED HIGH QUALITY WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY AVAILABLE EX-STOCK FROM EIGHT US WAREHOUSE LOCATIONS.

JULY 2010 | 95

ADVERTISERS’ INDEX

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

ADVERTISERS’ INDEX

September 2010 WJI ADVERTISER . . . . . . . . . . . . . .PAGE Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Stolberger Inc DBA Wardwell Braiding Machine Co . . . .15

• Equipment: Part 2 ADVERTISING DEADLINE: AUGUST 1, 2010

Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . . .4 Paul Troester Maschinenfabrik . . . . . . . . . . . . . . . . . . . . . .45 Tubular Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Wire & Plastic Machinery Corporation . . . . . . . . . . . . . . .95 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .90 Zumbach Electronics Corporation . . . . . . . . . . . . . .Cover 4

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21 Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-33 WAI Webinars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42, 44 WAI Monterrey ITC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66-67

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

NORTH AMERICA

EUROPE

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

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

96 | WIRE JOURNAL INTERNATIONAL

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

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

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