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JUNE 2007

速

WIRE JOURNAL

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

Lubricants and filtration OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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WIRE JOURNAL

®

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

Volume 40 Number 6 June 2007

C ONTENTS

FEATURE

34 Lubricants and Filtration Lubricants and filtration technology present a range of comments about their technology and trends. Also, a brief look at a European directive, called REACH, that one observer referred to as “RoHS on steroids.”

SEE WRAP-UP IN THE JULY ISSUE

TECHNICAL

PAPERS

48 Wiredrawing breaks – A review of mechanical perspectives Roger N. Wright—The impact of ratio of drawing stress to wire strength (DSR) and the implications of flaw size in causing wire breaks are addressed in this study.

60

52 Residual stresses and hydrogen embrittlement in cold-drawn eutectoid steel wires Jose Miguel Atienza, Manuel Elices, Jesus RuizHervias and Luis Caballero—Controlling surface residual stresses has been shown to be a very important factor in terms of improving the performance of prestressing steel wire in aggressive environments.

58 Method and material for manufacture of rectangular wire coil springs without dynamic strain aging Anand W. Bhagwat and Steven S. Wray—Dynamic strain aging, which can result in a loss of ductility, was found to be controllable by limiting the levels of interstitials and the addition of boron. (continued)

Cover: A few of the lubricant and filtration suppliers that exhibited their technology at Interwire 2007. See p. 34.

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10 Industry News General Cable to acquire German cable company, Sweden’s Liljedahlsbolagen AB reports two acquisitions, American Spring Wire acquires J&L Wire Cloth, and more

DEPARTMENTS

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

6 Editorial

22 Asian Focus India joins exclusive US$1 trillion economy club, Teknor Apex expands Asian operations

24 Fiber Watch Corning reopens portion of Concord fiber facility, fiber optic network planned for Indonesia, and more

26 Fastener Update Study projects U.S. industrial fastener market to be $12.9 billion in 2011, and more

28 WAI News Reconvene schedule set, U.K. clockwinder coming to WAI, new Conference Programming Committee members

8 Calendar 20 People 62 Products 67 Media 68 Classified 68 Career Opportunities

32 Chapter News New England Chapter sets date for golf tourney, names scholarship winners

4 WIRE JOURNAL INTERNATIONAL

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WIRE JOURNAL

INTERNATIONAL

Editorial

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

An expansion story outside of Asia

Senior Graphic Designer Bill Branch

Last month’s announcement by ThyssenKrupp that it would build a new steel plant in Mount Vernon, Alabama, USA, is certainly welcome news to the citizens of that region and encouraging news for steel consumers.

The plant, which will be ThyssenKrupp’s first steel-making operation in the U.S., will cost nearly $4 billion to construct and employ 2,700 workers when it opens in 2010. While the tax incentives offered by Alabama are equal to the GDPs of many island nations, the company estimates that the new facility could generate as many as 38,000 new jobs that would be directly and indirectly connected to the operation.

It will be exciting to see the transformation of tiny Mount Vernon, whose population is approximately 1,000. I think it is safe to say that they will experience full employment for the foreseeable future. It will be even more exciting to see the facility operational with today’s technology and production techniques.

The focus today is often on Asia, but ThyssenKrupp has invested significantly in the U.S., where it has 70 companies, 25,000 employees and annual sales of $9.7 billion. The Mount Vernon project is part of its NAFTA initiatives.

The company’s strategy of investing in the North American market is contrary to the shifting of manufacturing to the high growth markets of Asia, but a sure sign that escalated prices connected to high global demand for steel are returning acceptable margins to this consolidating, but competitive industry. For an industry that not that long ago was going through painful changes, the transformation to a more global, more consolidated sector appears to be working. Only time will tell if ThyssenKrupp’s strategy furthered the transformation.

It will be just as exciting to see the continued transformation of manufacturing in general and to see the implications on the wire industry.

Market forces will drive change throughout all segments from equipment to accessories to production practices. Change will be constant and not exclusively driven by economic downturns. And, as it should be, those companies that understand what is happening and know how to plan accordingly will be the leaders.

Director of Sales Robert Xeller

Steve Fetteroll WAI Executive Director

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

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) is published monthly by the Wire Journal, Inc., a wholly owned subsidiary of The Wire Association International, Inc. Address all correspondence concerning advertising production, editorial and circulation to Wire Journal International, 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA. Tel: 203-453-2777; fax: 203-453-8384; web site: wirenet.org; e-mail mmarselli@wirenet.org. Printed in USA. Subscription rates: $95 per year, USA; $105 per year, Canada and Mexico; other countries, $125 per year (includes air mail). Single copies: $6 in the U.S.; all other countries $7. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices.

Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article.

Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2007 by Wire Journal, Inc. All rights reserved. The Publisher of Wire Journal International assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of Wire Journal International are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313-761-4700.

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

6 WIRE JOURNAL INTERNATIONAL

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For quality control of (foam insulated) coaxial cables as well as data cables (CAT5/6/7), SIKORA offers built-in, all digital FFT spectrum analysis and SRL prediction. Aside from measuring diameter, capacitance or eccentricity, the FFT equipped devices allow for precisely locating the source of periodical cable parameter fluctuations and predicting the resulting structural return loss (SRL).

SIKORA devices with built-in FFT spectrum analysis and SRL prediction: 쎲 CAPACITANCE 2000 all-digital capacitance measurement to detect even the smallest fluctuations (0.003pF/m) – with intelligent multi-zone design for cables operating at up to 8GHz. 쎲 LASER 2000 dual- and triple-axis diameter measurement with non-scanning, calibration-free laser diode/CCD technology

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World Calendar June 24-28, 2007: JICABLE 2007 Versailles, France. To be held at the Palais des Congres, JICABLE is an international conference and exhibition on LV, MV, HV and EHV (extra high voltage) cables. The event is held every four years. For more details, go to www.jicable.org.

Week 2007, which includes Wire Steel Ropes 2007 and Cabling Wiring 2007, will be held at the National Complex Expocenter. Contact: Olga Krasko, TDS-Expo LLC, tel. 38044-526-91-84; e-mail olga@welding.kiev.ua; www.weldexpo.com.ua.

June 25-28, 2007: FASTENER TECH™ ’07 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center. Contact: www.fastenertech.com and www.mwfa.net.

October 24-31, 2007: K 2007, the 17th international Trade Fair Plastics and Rubber Düsseldorf, Germany. K 2007 will be held at the Düsseldorf fairgrounds, Halls 1-17. This event for plastic and rubber industries is organized by Messe Düsseldorf GmbH. Contact: Messe Düsseldorf North America, tel. 312-781-5180; e-mail info@mdna.com.

October 16-18, 2007: wire Southeast ASIA 2007 Bangkok, Thailand. To be held at the BITEC Exhibition Centre, this event, formerly known as wire Singapore, is organized by Messe Düsseldorf Asia Pte Ltd. Singapore. Contact: Messe Düsseldorf North America, tel. 312-781-5180; fax 312781-5188; e-mail info@mdna.com; Internet www.mdna.com.

October 17, 2007: Non-Ferrous Bangkok Bangkok, Thailand. This seminar on the latest developments in nonferrous wire and tube technology is jointly organized by the Int’l Wire & Machinery Assn./Int’l Tube Assn. during wire Southeast Asia, BITEC exhibition centre. www.iwma.org.

October 31-November 2, 2007: Kiev Industrial Week 2007 Ukraine, Kiev, Ukraine. The Fourth edition of Kiev Industrial

8 WIRE JOURNAL INTERNATIONAL

November 5-7, 2007: Wire 07 Bolgna Bolgna, Italy. This technical conference is organized by the Associazione Costruttori Italiani Macchine Per Filo (ACIMAF); The International Wire and Machinery Association (IWMA); Comité Européen de la Tréfilerie (CET); and the WAI. Contact: WAI, tel. 001-203-453-2777, ext. 133; Internet www.wirenet.org.

November 11-14, 2007: 56th IWCS/Focus™ Conference and Symposium Orlando, Florida, USA. Contact: IWCS/Focus, Internet www. iwcs.org; e-mail admin@iwcs.org; tel. 732-389-0990.

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March 31-April 4, 2008: wire Düsseldorf Düsseldorf, Germany. To be held at the Messe fairgrounds.

Contact: Messe Düsseldorf North America, tel. 312-781-5180; e-mail info@mdna.com.

June 7-11, 2008: Wire Expo 2008 Pittsburgh, Pennsylvania, USA. To be held at the Pittsburgh Convention Center, this event incorporates: the Wire Expo trade exposition, the technical program and the WAI’s 78th Annual Convention. The event addresses ferrous/nonferrous manufacturing, and electrical, data and voice segments as well as wire forming and related wire and wire products. Contact: WAI, Tel. 203-453-2777; fax 203-453-8384; Internet www.wirenet.org.

October 15-17, 2008: Spring World 2008 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center, this event is sponsored by the Chicago Association of Spring Manufacturers (CASMI). Contact: Tom Renk, tel. 847-433-1335; fax 847-433-3769; e-mail info@casmi.org; Internet www.casmi.org.

November 20-22, 2008: Wire & Cable India 2008 Mumbai, India. Contact: Cheryl Fernandes, Business Fairs, Confederation of Indian Industry, tel. 91-22-24931790, ext.

470; fax 91-22-24939463; Internet www.ciionline.org. ■

WIRE ASSOCIATION INT’L EVENTS For more information about these events, contact the WAI, Guilford, CT 06437-0578, USA. Tel. 203-453-2777; fax 203-453-8384; Internet www.wirenet.org.

June 15, 2007: Midwest Chapter’s 5th Annual Golf Tournament West Chicago, Illinois, USA. The Midwest Chapter will hold its annual golf tournament at St. Andrews Golf & Country Club. A pdf registration form is available online at the Midwest Chapter webpage at wirenet.org. For more details, contact WAI’s Chip Marsh at tel. 203-453-1748, e-mail cmarsh@wirenet.org.

September 13, 2007: WAI New England Chapter 13th Annual Golf Tournament Paxton, Massachusetts, USA.The Kettle Brook Golf Club will host the event, which includes the awards dinner and supports the WAI New England Chapter Scholarship Fund.

For more details, contact WAI’s Chip Marsh at tel. 203-4531748, e-mail cmarsh@wirenet.org.

November 5-7, 2007: Wire 07 Bologna Bolgna, Italy. See main listing.

June 7-11, 2008: Wire Expo 2008 Pittsburgh, Pennsylvania, USA. See main listing.

JUNE 2007 9

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Industry News General Cable to acquire German cable company General Cable Corporation reported that it has agreed to acquire Norddeutsche Seekabelwerke GmbH & Co. KG (NSW) from Corning Incorporated.

Located in Nordenham, Germany, and founded in 1899, NSW supplies offshore communications, power and control cables as well as aerial cables for power utility communication and control networks, a press release said, adding that NSW had 2006 revenues of approximately $120 million.

NSW has a deep-sea pier capable of loading cable laying ships directly from its production facility on the North Sea in northern Germany, the release said. It noted that NSW has manufactured and installed

submarine projects throughout the world, including one of the world’s longest hybrid submarine communications cable systems extending 8,600 km linking 15 countries.

NSW also supplies specialty products that include specialized high-end winding wire for high voltage motor applications and specialty extrusions for various filtration and waste water treatment applications, the release said.

The announcement follows a string of recent acquisitions by General Cable, which has entered two joint ventures in India and acquired a Chinese manufacturer of specialty automotive and industrial cable products.

Swedish subsidiary opens new plant in China Habia Cable China, Ltd., a specialty cable manufacturer that is a subsidiary of Sweden Habia Cable, itself part of the Beijer Alma Group of companies, has moved into a new plant in the Changzhou National Hi-Tech District (CND).

A report from PR Newswire said that Habia Cable China Ltd., described as China’s only plant specialized in the manufacture of special communication cable for 3G base stations, moved into its new plant in the Changzhou State-level Hi-tech Development Zone and added another four production lines on May 10 to keep up with the acceleration of China’s 3G development. The new plant, it said, covers an area of 9,394 sq m, four times that of the original one.

Habia Cable China was formed by Sweden Habia Cable in July 2000, with a total investment of US$2.48 million, the first subsidiary of the corporation in the Asia Pacific Region, the release said. It noted that the total investment to Habia Cable China to date is US$6 million and that its customer base now tops 50, “including world-leading communication equipment manufacturers like Nokia, Ericsson, Lucent, and Motorola, as well as

domestic manufacturers like Huawei, Datang and ZTE.” Habia Cable China, the release said, focuses on special cables used for high frequency communications, which are developed by combining international standard with China’s use requirements. It notes that the company “is China’s only supplier of designing and producing over 18GHz RF cable with high-performance and low loss, ending China’s dependency on the import of high performance cables.”

Habia Cable, at its website, notes that it has a global focus, with sales in more than 25 countries, with almost 90 percent of its total sales to customers outside Sweden.

The company has production facilities in Sweden, Germany, Latvia and China.

“Our sales operations are located globally with 60 of our own sales and technical staff, situated in 13 countries in Europe and Asia,” it notes. “We also support a wide range of agents and distributors in other markets. Habia has been established in the cable industry since 1957. We support a wide range of demanding applications and have specialized in specific market areas such as telecom, defense, power generation and industrial markets.”

Woodside Capital acquisition merges two former competitors Private equity firm Woodside Capital announced that it has completed the acquisition of Rehrig International and United Steel & Wire, two former U.S. competitors that manufacture shopping carts and other material handling equipment for retailers.

“I am pleased to announce that Rehrig International and United Steel & Wire are joining forces. Effective today, the companies will merge to form Rehrig-United,” said a letter from CEO Vince Gurzo. He noted that the former competitors can now better serve as a “one stop” solution for shopping carts, handbaskets, material handling and other wheeled product needs.

The new company, his letter said, will be headquartered in Richmond, Virginia, with manufacturing locations in Virginia and Michigan.

United Steel & Wire notes at its website that the company, which has more than 75 years of experience in the supermarket and retail industries, offers a complete line of shopping carts and wire merchandising displays.

At its website, Rehrig International notes that it produces more than a half-million shopping carts per year from its 317,000sq-ft manufacturing plant in central Virginia.

“As standalone entities, Rehrig International and United were solid, but underperforming, competitors in this industry,” said Benjamin Procter, a Partner at Woodside Capital. “As a combined platform, Rehrig United creates an attractive investment due to a significantly improved competitive position and cost structure.”

In addition to shopping carts and hand baskets, the new company’s product categories include material handling equipment such as flat carts, dollies, inventory management and garden center carts for the larger and heavier merchandise offered by certain retailers.

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

10 WIRE JOURNAL INTERNATIONAL

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VDMA president warns of the perils caused by counterfeiting of technology The German Engineering Federation (VDMA) has begun a worldwide campaign against counterfeiting technology, noting that such plagiarism is an increasing problem for OEM manufacturers.

Speaking at a trade event in Germany, VDMA President Dr. Dieter Brucklacher said that plagiarism has increased enormously throughout the last year according to the latest survey on counterfeiting and piracy in products and brands carried out by his organization.

“The companies which experienced plagiarism told us that in 60 percent of the cases entire machinery had been copied,” Brucklacher said at the opening of a trade event in Munich. “A year ago, this was only 43 percent. According to the latest survey, 42 percent of spare parts and 41 percent of components got copied also.”

Of companies affected by plagiarism, 75 percent named China as the country of origin for most copied products, Brucklacher said.

“Taking into account that further Asian countries - like Taiwan and Korea with 12 percent each - are on the list also, the biggest part of copied products stems from this region alone. With 14 percent, the number of illegal products coming from India is also on the increase.

Within Europe, 17 percent of all copied products come from Italy and 11 percent from Turkey.”

For export markets of the copied products, China also leads, cited by 49 percent of the companies, Brucklacher said. He noted that 22 percent of the counterfeit products made their way to the European market and 18 percent were found on the international market. “More than two thirds (68 percent) of the companies found out about copied products due to their own knowledge of the market. A bit more than half of them (51 percent) came across copies of their VDMA President Dr own products on trade fairs.”

Dieter Brucklacher.

The impact of such technology theft is serious, observed Brucklacher, noting that more than three quarters of the affected companies say such activity threatened their long-term competitiveness. He estimated damage to German machiney in 2006 to top US$6.76 billion. “This is the reason why we at the German Engineering Federation asked ourselves what we, together with our member companies, can do to fight against counterfeiting and piracy.” As more member companies seek ways to prevent plagiarism of their products and brands, it helps to start with customers and make them become more aware of the value of original technology, he said.

Brucklacher said that VDMA has begun a Pro Original campaign that “aims at clearly stressing that outstanding results can only be achieved when using original technology. The campaign can be recognized by its logo and slogan ‘Choose the Original - Choose Success!’” VDMA, he said, is going to present this campaign together with its member companies in the countries where most of their clients are situated.

In 2006, machinery and equipment produced worldwide had an estimated value of some US$1.75 trillion, led by the U.S., Germany, Japan and China, Brucklacher said. Nearly half of all machinery produced was sold on the European Domestic Market.

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Sweden’s Liljedahlsbolagen AB reports making two acquisitions in Europe Sweden’s Liljedahlsbolagen AB, a family-owned parent company whose five divisions include one for wire, reports that it has made two acquisitions in Europe.

Liljedahlsbolagen reported that it has acquired the Elektrokoppar Group, a leading manufacturer of copper wire rod and magnet wire in Europe, from Industri Kapital 1997 Fund. It noted that the

Elektrokoppar Group, which has some 600 employees, had 2005 revenues of about US$1.1 billion.

The Group has manufacturing facilities in Sweden, Germany, Poland and China and refines approximately 200,000 metric tons of copper and aluminum per year.

Elektrokoppar’s customers are mainly manufacturers of transformers, engines,

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12 WIRE JOURNAL INTERNATIONAL

generators, white goods and vehicles.

“During Industri Kapital’s ownership the company has strengthened its position, especially on the fast growing Eastern European markets. The timing is good for Elektrokoppar to continue to build on these successes with an industrial owner such as Liljedahlsbolagen,” says Gerard De Geer, partner at Industri Kapital.

During Industri Kapital’s ownership, Elektrokoppar has expanded its product line with oxygen-free wire rod as well as developed various niche products, the report said. In 2005, the company expanded into the fast growing Eastern European markets through the add-on acquisition of EKS Slaska in Poland. Since then productivity has improved considerably in the Polish plant. Strong demand from the Eastern European markets has further increased turnover and profitability substantially. In addition, Elektrokoppar recently established itself in China.

“Our goal with the acquisition of the Elektrokoppar group is to continue developing the group’s market position both through organic growth, as well as through further acquisitions,” says Bengt Liljedahl, CEO of Liljedahlsbolagen AB. Liljedahlsbolagen AB also reported that, through its subsidiary, AB Hörle Tråd, it has acquired the fixed assets of the Slovakian wiredrawing plant Eurofil Drôty s.r.o. In conjunction with this transaction, it said, Hörle Tråd is establishing a wholly owned subsidiary in Nitra, 80 km northeast of Bratislava. The investment in Slovakia amounts to about US$7.4 million.

“The acquisition strengthens Hörle Tråd’s position within galvanized wire on the European market and results in a substantial increase in production capacity for primarily cable-armouring wire and staple wire, while at the same time the product program is broadened,” the release said. It added that the acquisition in Slovakia “is a step in moving closer to the rapidly growing market in Central Europe.”

“A number of our customers are currently established in the region. We will now be able to offer them Hörle Tråd’s broad product program through our new subsidiary HT Eurofil s.r.o.,” said Liljedahl Group CEO Bengt Liljedahl.

The release noted that Hörle Tråd has operations in Hörle and Gunnebo, Sweden, with 2007 sales of approximately US$40 million.

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Superior Essex to further its magnet wire base with Italian acquisition U.S.-based Superior Essex, which recently completed an acquisition of a Nexans magnet wire operation in Canada, announced plans to further expand its capabilities in that sector. It reported that it has agreed to buy Invex S.p.A. Invex is an Italian magnet wire producer with two plants that is majority-owned by an Italian private equity firm, Investitori Associati.

“The acquisition of Invex fits perfectly with both our European and our global magnet wire strategy,” Superior Essex CEO Stephen M. Carter said in a press release. “In Europe, the Invex acquisition is highly complementary across our product lines, customer base and manufacturing assets.” He said that the addition of Invex should provide near- and long-term syner-

gy opportunities, including the ability to serve European customers “in a more timely, efficient and effective manner.”

At its website, Invex notes that the company was founded in 1948 at Quattordio, about a hundred km from Milan, focusing on the enameled wire market. It reports annual revenues of more than US$240 million and production of some 55,000 metric

tons at its two production plants. “The product range is exceptionally wide and ranges from fine enamel-coated wires to large conductors for transformers,” it states, adding that the business has the following certifications: ISO/TS16949:2002 (auto), ISO9001:2000 (transposed conductors and other covered conductors); and ISO14001 for environmental management.

Cold Is

American Spring Wire acquires J&L Wire Cloth American Spring Wire Corporation (ASW) reported that it has acquired J&L Wire Cloth Company (J&L), a Minnesotabased manufacturer and fabricator of wire decking and racks as well as galvanized and bright basic wire.

“This acquisition introduces ASW to downstream wire using markets,” said company President Timothy W. Selhorst, who noted that J&L’s product lines include Boss Hog® woven wire flooring and confinement panels to the agricultural industry for hog production and Galva-Deck® wire rack decking for warehouse storage, shelving, material handling and logistics. “The nature of these products may provide excellent opportunities for expansion into other markets that are complementary to ASW’s current product offering. The synergy of J&L’s vast wire forming and welding capability along with ASW’s knowledge of wire making and other relevant industry skills is quite powerful. I believe the acquisition makes for an excellent match,” he observed.

J&L Wire Products Inc. was founded in 1980 as a manufacturer of welded and woven wire forms. Its product offerings expanded over the years, and the company began manufacturing galvanized and bright basic wire for its own use. The company remains a market leader in galvanized woven wire flooring for livestock, and a key supplier to many domestic users of galvanized wire decking.

Various PWM models weld non-ferrous wire and rod from .004” - 1.180” (.10 - 30 mm) dia.

Strip metal can also be welded.

Stronger Stronger than the parent materials, cold pressure welds on the EP500 don’t require any set-up, heat or hydraulics.

Used for non-ferrous wire, rod and profiles, our innovative welder uses PLC technology to control weld-upsets and de-flashing. This saves time and effort and makes your welding process more streamlined and semi-automatic.

Among our EP 500’s unique characteristics are: • Automatic De-Flashing • Low maintenance • Quick and easy die changeover • Weld cycle complete in less than a minute • Electro/pneumatically powered • For profiles and wires up to 20mm • No end prep required

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Nexans signs a five-year, US$76 million deal with a Canadian utility company Nexans reported that its plant in Weyburn, Saskatchewan, has further extended its strategic long-term business partnership with SaskPower, agreeing to a five-year deal that could be worth up to about US$76 million.

Under the agreement, Nexans is to provide SaskPower with 56 different types of conductors used to distribute electricity throughout Saskatchewan, a press release said. The products supplied by Nexans include bare copper wire, overhead conductors and underground cables, as well as cables for street lights.

“Long-term supply agreements allow SaskPower to obtain stable pricing and a secure supply of conductors,” said John Nilson, Minister Responsible for SaskPower. “This business partnership has brought economic, employment and other benefits to the province, while allowing Nexans to plan its business more efficiently so that they remain a cost-effective supplier.”

The Nexans factory in Weyburn celebrated its 50th anniversary in 2006 and throughout its life has always provided SaskPower with cables that help it achieve

East African Cables opens 2nd production plant East African Cables plans to open a second production plant in Nairobi, part of the company’s expansion plan to further its presence in the local and regional market.

East African Cables Group Managing Director Mugo Kibati said the new plant would enable his company to manufacture new generation cables for electrical, telecom and related uses as well as fiber optic cables, reported the East African Standard.

“The new plant will handle all new generation cable manufacturing needs and is benchmarked against the best in the world.

The new factory premises will also serve as our regional corporate headquarters,” Kibati said. In the report, he observed that the new facility “would consolidate and

entrench the company’s position as the top manufacturer and supplier of power cables and conductors in the region.” He added that the company’s “expansion binge had taken it to Rwanda from where it plans to serve neighboring countries.”

Noted Kibati in the report, “We are already in Rwanda but we are not planning to build a factory there. We will export our products as we study the market.” In the report, he described the market potential for telecom cables as huge but warned that one challenge to the company’s growth was “the prevalence of sub-standard cables imported from the Far East” that had been “evidenced by fire incidents triggered by electrical faults.”

Fiber optic network planned for Indonesia Seven Indonesian companies will join forces to build a $1.5-billion 34,000 km (21,100 mile) fiber optic cable network in the country, Reuters reported.

Basuki Yusuf Iskandar, Indonesia’s director general for post and telecommunication at the communication and information ministry, said that members of the group planned further meetings to discuss how to implement and finance the project.

Some of the seven companies that have obtained the license for the venture include

PT Telekomuniasi Indonesia Tbk, PT Indosat Tbk, PT Excelcomindo Pratama Tbk, and PT Bakrie Telecom Tbk. The Palapa Ring was described as “part of the government’s effort to refurbish the country’s ailing infrastructure to spur economic growth in the world’s fourth most populous nation.” Its completion, the report said, will open up telecommunication access to eastern parts of Indonesia, the less developed area of the sprawling tropical nation.

its aim of supplying electricity that is safe, reliable and sustainable.

“When SaskPower started to electrify rural Saskatchewan in the 1950s the cable came from Weyburn, and today the local community remains the source of most of the conductors needed by the utility,” said Dr. Gordon Thursfield, Nexans’ Executive Vice President of North America. “By expanding its market in Western Canada and the United States, the plant has required several expansions and now employs more than 130 people full-time.”

SMS reports contract from Syrian company SMS Meer reports that it has received an order from Syria’s Hmisho Trading Group to supply a new combined wire rod and bar mill to produce wire rod in coils from 5.5 mm to 16 mm as well as round bars and rebar.

The contract for the mill, to have annual capacity of 300,000 metric tons per year, also calls for SMS to supply the electrical equipment and automation system, a press release said. The mill, it noted, will integrate the latest technologies, including the EBROS® billet welding machine for the rolling of endless bars.

The wire rod will be produced in a tenstand finishing block with coil diameters of 210 mm and 180 mm, the release said. The product dimensions are rolled in the line on a single-pass series at the maximum mill speed of 80 m/s.

Two water cooling sections and the 65m-long loop cooling conveyor guarantee optimally controlled product cooling.

Behind the cooling section, the line is completed with bundling and transport equipment and a coil compacting and tying station.

The mill, it said, is scheduled to go into production in 2007.

Belden completes purchase of Lumberg Automation Components U.S.-based Belden reported that it has completed its purchase of the assets of Germany’s Lumberg Automation Components from The Lumberg Group.

Lumberg Automation, a supplier of industrial connectors, high performance 14 WIRE JOURNAL INTERNATIONAL

cord-sets and field bus communication components for factory automation machinery, reported 2006 revenues of about $75 million. Based in Schalksmuhle, it has production facilities in Germany and the U.S. and some 300 employees.

“Lumberg Automation will complement the industrial connectivity portfolio of Belden’s recently acquired Hirschmann Automation and Control, as well as Belden’s expertise in signal transmission,” said Belden President John Stroup.

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Page 16

AMSC and Nexans report test of power cable with 2G HTS wire American Superconductor Corporation (AMSC) and Nexans reported that they have successful tested the world’s first power transmission cable made with second generation (2G) high temperature superconductor (HTS) wire, an achievement they say paves the way for commercial use of the technology.

A press release said that the 138kV

Nexans cable was powered by AMSC’s 2G HTS wire, known as “344 superconductors,” which were designed as a drop-in replacement for customers currently using 1G HTS wire. The 344 superconductors comprise 2G HTS wire clad with ultra-thin strips of copper or stainless steel. The 344 superconductors are designed to offer significantly higher power density and effi-

Cold Is

ciency than similar copper-based wire products.

The test, performed on a 30-meter-long, transmission-voltage cable, was done at a Nexans high-voltage facility in Hannover.

The cable, operated at 138,000 volts, contained only 33 hair-thin 344 superconductors, was able to “transmit 435 megavoltamperes (MVA) of power, enough electricity to power over 250,000 homes,” the release said, adding that the rating is more than 50% higher than conventional cables at the same voltage level.

Mossberg a new U.S. rep. for Inhol/PTL brand Inhol BV, a Netherlands-based compounds supplier, has named Mossberg Associates as its U.S. agent for the New England region for its PTL compounds.

PTL Manager Ron Goethals, who made the announcement during Interwire 2007, said his company is looking to further develop the PTL brand in the region. The company’s compounds, which are used by a range of fields that include wire and cable, are already represented in mid-west U.S.

Various PWM models weld non-ferrous wire and rod from .004” - 1.180” (.10 - 30 mm) dia.

Strip metal can also be welded.

Portable

Bring the welder to the wire. Cold pressure welds on the M101 don’t require any set-up, heat or hydraulics and can roll to wherever you need them.The nonferrous wire welds are stronger than the parent materials and the durability of the M101 is unmatched by competitors. This saves time and effort and makes your welding process more streamlined.

Among our M101’s unique characteristics are: • Low maintenance • Quick and easy die changeover • Weld cycle complete in less than a minute • For wires with diameters from 0.1 to 5mm • No end prep required

Bring the welder to the wire and make your welds quicker and stronger with Huestis cold pressure welding and start experiencing the utility today.

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16 WIRE JOURNAL INTERNATIONAL

PTL Manager Ron Goethals, c, with Mossberg Associates’ Rene Mayer, l, and John Henschel at Interwire 2007.

Goethals said that PTL has become a pioneer in supplying high grade (crosslinkable) compounds for the wire and cable industry. He noted that Mossberg Associates has extensive experience in the market representing other suppliers to the wire and cable industry.

Mossberg Associates can be contacted at e-mail mossbergassociates@cox.net., tel. 401-334-3417. For more information about PTL compounds, go to www.wireandcablecompounds.com.

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SuperPower and Sumitomo Electric project results in record HTS cable U.S.-based SuperPower, Inc. announced that it has provided the second-generation high temperature superconducting (2G HTS) wire that was fabricated into a 30-meter cable by Sumitomo Electric Industries Osaka Works in Japan that will be used in what was described as the “the world’s first use of 2G HTS wire in any device and the first installation on a live grid.”

A press release said SuperPower provided nearly ten km of 2G HTS wire to Sumitomo in December 2006 for installation into the cable system at National Grid’s North Albany Service Center later this year. That usage, it noted, will be the world’s first such use of 2G HTS wire and the first installation on a live grid.

“This (achievement) has marked SuperPower’s entry into the commercial manufacture of this superior superconducting wire,” said SuperPower President Philip J. Pellegrino. “The expectation that 2G HTS wire will be a cost-effective replacement for copper by the end of the decade will be an important factor in determining the adoption rate,” he said.

A report from the companies noted that in July 2006, a 350-meter underground power cable, consisting of two sections that are joined in an underground vault, was energized. Since that time the 34.5 kV system has accumulated nearly 7000

hours of run time with routine maintenance work performed on the related cooling systems without interruption to cable operations.

In addition to providing the 2G HTS wire, SuperPower is managing the project that began in 2002. Sumitomo is the cable system designer and manufacturer, and BOC Gases, the U.S. affiliate of the Linde Group, is responsible for the design, engineering, installation and monitoring of the cryogenic refrigeration

system that keeps the cable running at 77º Kelvin.

The project has two distinct phases.

Phase I, which has been completed, consisted of the initial installation of two cable sections, 320 meters and 30 meters, both fabricated with first-generation (1G) HTS wire. In Phase II, the 30 meter section will be removed and replaced with the 30 meter section of 2G HTS cable beginning this July.

MMMS nears end of compound expansion Martin Marietta Magnesia Specialties LLC (MMMS) reports that it has neared completion of the expansion of its MagShield flame retardant (FR) production facility in Manistee Michigan.

The expansion will provide an increase in production capacity of nearly 100 percent, bringing total MagShield capacity to an estimated 52,000 tons per year, a press release said. It noted that with the expansion, MMMS will supply about half of the global total of FR magnesium hydroxide.

“This expansion will alleviate the worldwide short supply of FR grade magnesium hydroxide,” it said, noting that the product is used for a variety of markets including wire and cable, electrical and electronics, furniture, and automotive.

ISO 9000:2000 AS9100 Registered

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JUNE 2007 17

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Forming Systems Inc. to represent OMAS srl Forming Systems, Inc. (FSI), announced that it will represent OMAS srl as its exclusive distributor in North America for the Italian company’s range of precision multi-axes 3-D wire forming machines, automatic ring making and welding machines, and high speed multi-slide style forming machines.

FSI President Tim Weber described the alliance as “a great fit for both companies,” noting that the OMAS product lines complement that of his company.

Weber noted in a press release that

FSI also provides service, training, tooling and technical assistance as well as represents other indstry suppliers.

Those, he said, include HTC spring coilers and formers, HSI conveyor ovens and payoffs, SAS spring testing equipment, TBE automated wire forming systems, Jaykase programmable tabletop machines, Emanon and OMD spring grinders, and Whitelegg 2-D formers and welders.

FSI can be contacted by calling tel.

269-679-3557; or by e-mailing info@formingsystemsinc.com.

Superior Essex reports completion of purchase of Nexans wire unit Superior Essex Inc. reported that it has completed its acquisition of Nexans SA’s Canada-based magnet wire operations. The price was not disclosed.

The facility in Simcoe, Ontario, a press release said, produces rectangular wires, including continuously transposed cable and related products used by large transformer makers in power generators and transformers. The deal, it noted, “includes key operating assets, such as inventory and property, plant and equipment.”

CommScope completes its acquisition of Signal Vision Inc. U.S.-based CommScope reported that it has completed its acquisition of Signal Vision Inc. (SVI), a leading supplier of broadband RF (Radio Frequency) subscriber products.

Signal Vision’s product lines include passives, indoor amplifiers and addressable

18 WIRE JOURNAL INTERNATIONAL

taps. Signal Vision had revenues of less than $30 million in 2006.

“After a successful 31-year history, we believe that it is advantageous for SVI to join with a strategic partner to accelerate the growth of our business,” said Signal Vision President Neil Phillips.

“CommScope represents the ideal fit for us given their global presence, similar core values and their reputation for quality and customer service within the broadband industry.” ■

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People General Cable Corporation announced the promotion of Mark A. Thackeray from Vice President of Supply Chain to Senior Vice President, North American Operations as well as his appoint-

Mark A. Thackeray

ment to the company’s Leadership Team. He will replace Larry E. Fast, who plans to retire from General Cable this June, after nine years with the company. Since joining General Cable in 2001, Thackeray has also served as Vice President of Advanced Manufacturing Engineering, Vice President of Manufacturing for the company’s communications and assembly plants. He

holds a bachelor’s degree in Industrial & Systems Engineering from the Georgia Institute of Technology and has an MBA degree in Business Administration from Xavier University. A certified Six Sigma Champion, he was President of Cincinnati Industrial Consulting, a consulting firm that specialized in operations and process improvement technology using Lean and Six Sigma methodologies, and has held positions at R.D. Garwood Inc., a leading supply chain and operations consulting firm, and manufacturing operations and plant manager positions, including as operations manager for Tomkins Industries. Based in Highland Heights, Kentucky, USA, General Cable Corporation supplies copper, aluminum and fiber optic wire and cable products for a range of markets.

Beta LaserMike has named Bob Stockholm as its Americas Sales Director. He replaces Rick Kristensen, who after 25 years of service

with the company is retiring from the business to pursue a new career in the real estate industry. Stockholm, who served as a product manager and later as an extrusion sales engineer for LaserMike from 1994 to 1997, has been in his current role as northeast district manager since 2003. In between these periods he held sales management positions with the Process Control Corporation, the Newport Corporation and Optical Gauging Products.

Based in Dayton, Ohio, USA, Beta LaserMike supplies testing and measuring equipment to the wire and cable industry.

RAD-CON, Inc., reported a number of organizational changes made following company president Brice Blackman’s retirement after 25 years of service. His interest in the business has been acquired by company vice presidents Christopher Messina and Michael McDonald, who are managing the day-to-day operations. David Blackman

remains in the top post as president, overseeing the strategic direction of the company. Chris Williams and Arno Muennich have been promoted to engineering directors. Williams joined the company in 1997 as mechanical engineer.

Muennich joined the company in 1996 as systems engineer. Based in Cleveland, Ohio, USA, RADCON, Inc. supplies heating/annealing technology and related software to the domestic and international markets.

American Leistritz Extrusion Corporation has announced that Ed Ford has joined the company as product manager for its range of twin screw extruders and systems to produce concentrates and compounds in North America. He will also be responsible for sales of the Leistritz product line in the Southeast, Texas and parts of the Midwest. He has more than 25 years experience in the plastics industry, including as engineering

Obituaries George L. Jones, a plant manager for Mid-South Wire Co., died at home on April 13, 2007, at age 57. He had been hired by Mid-South Wire in December 2006 to help start up and be responsible for day-to-day running of a new U.S. wiredrawing operation in Scott City, Missouri area. He had been active in the wire industry for more than 30 years,

working for companies that include Cargill Wire (now owned by Gerdau Ameristeel) in Carollton, Texas; Sherman Wire, also in Texas; and Mid-States Wire in Crawfordsville, Indiana. A Vietnam War veteran, he is survived by his mother, Genie Hollowell; a son, Marc Jones; a daughter, Marci Jones; two brothers and two grandchildren.

20 WIRE JOURNAL INTERNATIONAL

Roger M. Keller, a long time member of the wire and cable industry, died at his home in Pennsylvania on April 10, 2007, at age 69. He was a plant manager for the Johnson Steel and Wire Co., from 1960 to 1980, and was also responsible for the plant opening in Salvadore Bahia, Brazil. He later went to work as a sales representative/consultant for Elf Atochem in

Homer, New York, retiring in 1995. He attended Akron University and Kent State University and served four years in the Ohio National Guard. Survivors include his wife, Carol Jean Keller; three sons, Robert, Kevin and David; a daughter, Laura Lynn Keller; a brother, Charles A. Keller; and a sister, Marilyn Sue Beal.

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manager for Clariant Masterbatches, North and South America.Based in Somerville, New Jersey, USA,

Ed Ford

American Leistritz Extrusion Corporation supplies extrusion technology to sectors that include the wire and cable industry.

Corning Incorporated reported several changes for its global business leaders.

Eric S. Musser was promoted to general manager.

He joined Corning in 1986 and has held a variety of roles in manufacturing, strategic planning, and quality. For the past two years, he has served as vice president and general manager of Corning Optical Fiber. He also helped lead the successful migration of the Shanghai Fiber Optics Co. into a wholly owned Corning subsidiary, a key to its building access to the Chinese fiber market. Martin J. Curran was promoted to senior vice president and general manager, Corning Optical Fiber.

He joined Corning in 1987 and has held a variety of roles in finance, sales and marketing. Since 2000, he has served as senior vice president and general manager for Corning Cable Systems’ hardware and equipment operations in the Americas. In other appointments, Clark S. Kinlin was named chief operating officer, Corn-

Page 21

ing Cable Systems, and Stuart E. Hoiness was named senior vice president and general manager, hardware and equipment division, Corning Cable Systems.

Based in Corning, New York, USA, Corning Incorporated’s telecom unit produces optical fiber and cable and associated products.

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The International Iron and Steel Institute (IISI) has named Mika Saariaho as Deputy Secretary General of IISI, effective this June. He joins IISI from Outokumpu Oyj, where he is currently Senior Vice President, Corporate Strategy and Plan-

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ning, working out of its head office in Espoo, Finland. He holds a Doctorate of Science in Technology from Helsinki University of Technology.

Based in Brussels, Belgium, the International Iron and Steel Institute (IISI) represents over 190 steel producers, including the world’s 20 largest steel companies. ■

Cable Consultants Corporation A division of EL-TECH TECHNOLOGY, INC. New York Office: North Carolina Office: 7 Woodland Avenue 325 Queens Road, Apt. 7 Larchmont, NY 10538 Charlotte, NC 28204-3256 Tel: (914) 834-8865 Tel: (704) 375-9313 Fax: (914) 834-8903 Fax: (704) 375-9321 e-mail: info@cableconsultantscorp.com e-mail: fhardyccc@carolina.rr.com Website: www.cableconsultantscorp.com

JUNE 2007 21

asian focus.qxp

5/18/2007

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Asian Focus Asian Focus Asia news briefs

India joins exclusive trillion-dollar economy club

India state has unique cable-stayed bridges After laying claim to India’s first cable-stayed bridge and suspension bridge across a river, Kolkata (also known as Calcutta) will soon give the country its first river bridge that is a cross between the two—a single profile cable-stayed extra-dosed river bridge, reports the Indian Express.

Prime Minister Manmohan Singh was expected to inaugurate what is claimed to be the eighth such bridge in the world. He was scheduled to have travelled to the West Bengal capital in the first week of June.

The 6.1-km-long structure straddling the Hooghly river will join the league of Vivekananda Setu (Bali Bridge), Vidyasagar Setu (Second Hooghly Bridge) and Rabindra Setu (Howrah Bridge) with the name Nivedita Setu, after the famous Anglo-Irish social worker and disciple of Swami Vivekananda.

According to Wikipedia, Vidyasagar Setu (2nd Hooghly Bridge) in Kolkata, is the longest cablestayed bridge in South Asia, with the main span measuring 457.2 m (1,500 feet) and total length being 823 m (2,700 feet). The Penang Bridge in Malaysia is the longest bridge in South East Asia, with its longest span measuring 225m.

Swiss investment bank Credit Suisse reported that, bolstered by a rally in the rupee against the U.S. dollar, India has become the 12th country whose economy has topped the US$1 trillion mark.

The report said that India’s gross domestic product (GDP) passed the trillion-dollar mark for the first time ever when the rupee appreciated to below the 41 level against the U.S. dollar.

India’s GDP was estimated at slightly more than US$1 trillion at the then current currency level of Rs 40.76 per dollar.

The other countries whose GDP has

Tata Steel considering Incab acquisition Incab Industries, a cable producer in India that has had difficulty and is currently under the Board for Industrial & Financial Reconstruction (BIFR), is seeking to be acquired by Tata Steel, according to published reports Incab is located on around 176 acres of subleased land adjacent to Tata Steel in Jamshedpur.

Incab Industries Employees Association`s (IIEA) President Rakeshwar Pandey led a delegation of 27 office-bearers of the company with the trade unions of Kolkata and Pune, to meet Tata Steel managing Director B. Muthuraman, requesting him to take over the company. In April 2000, the companystopped operation, having 1,400 personnel on its rolls, while its second small manufacturing unit in Pune, which is said to be operational even today, employs around 500. Its head office in Kolkata had another 200 or so in staff.

China cuts tax rebates on steel wire China has cut export tax rebates on steel wire and other products and removed them on others, according to published reports. Citing information posted at China Iron and Steel Association (CISA), they note that export tax rebates on stainless steel products and some specialty steel, including coldrolled steel coils and silicon-manganese steel wire, will be reduced to 5 percent. The move comes amid growing trade friction between the U.S. and China, the article said, noting that Washington had imposed countervailing duties on Chinese exports on coated paper, among other measures.

22 WIRE JOURNAL INTERNATIONAL

topped US$1 trillion are: U.S., Japan, Germany, China, U.K., France, Italy, Spain, Canada, Brazil and Russia.

The Financial Express of India noted that before the rupee’s value increased, it had been about 45 to a dollar, which made the country’s GDP about US$900 billion. It noted that the news of topping the trillion dollar mark should help India’s stock market as well, citing the Credit Suisse report, which said that stock markets in eight out of 10 countries had risen in the one year after their economies first crossed this mark.

Japan’s largest trading partner is now China China has quietly set another first in 2006: it became Japan’s largest trading partner, displacing the U.S. Japan’s finance ministry reported that in 2006, Japan’s trade with China was approximately US$211 billion, topping its trade with the U.S., approximately US$209 billion, the Wall Street Journal reported. It also noted that China has become the largest importer of goods from Japan.

The WSJ article pointed out how China has become increasingly important to Japan. It noted that in 2002,

China was responsible for 38% of Japan's economic growth. Four years later, that rate was 68% and a key factor in its export surplus with China.

The article noted that the European Union and the U.S. have been Japan’s most important trading partners, but that the global trade pattern has changed. Coupled with a slower-growing U.S. economy, Japan is constantly increasing investment in China, bringing Sino-Japanese economic and trade cooperation closer and closer.

China to become leader in unwanted category China is about to pass the U.S. in another category, albeit one that no country wants to be the leader: the world’s largest emitter of greenhouse gases.

Citing China’s incredible continued growth pace, the International Energy Agency projected that the country would take over the top spot from the U.S. this year, far earlier than had been previously projected., an article in the Wall Street Journal reported.

The IEA had estimated that China would surpass the U.S. by 2010, but its increasing carbon-dioxide emissions,

which stem from its near-total reliance on domestic coal to power its economy, are expected to dwarf reductions in emissions from Europe, the U.S. and Japan, the WSJ story said. China’s coal is burned in thousands of power plants, and many more are planned. Over the next 10 years, the IEA forecasts, China will add the equivalent of an entire European Union's worth of power plants, it said.

China is a signatory to the Kyoto Protocol, but it has been exempted from its greenhouse-gas limits because it is a developing country.

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

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U.S. company expands operations in Asia with plant in Suzhou, China U.S.-based Teknor Apex Company has begun startup procedures for a plant in Suzhou, China, that will produce compounds for use in the wire and cable and other sectors.

Singapore Polymer Corporation (SPC), a Teknor Apex Company, said the plant will meet international standards. Operating the plant will be a new company, Teknor Apex (Suzhou) Advanced Polymer Compounds Co. Pte. Ltd. The plant will be able to make rigid and flexible vinyl and thermoplastic elastomer (TPE) products like those developed in the U.S. by Teknor Apex and in Singapore by SPC; engineering thermoplastics (ETPs) produced in the U.K. and U.S.A. by Chem Polymer (also a Teknor Apex company); and other specialty compounds developed by SPC. “Teknor Apex Suzhou will provide Chinese processors with fast access to custom compounds that meet UL, NSF, FDA, CSA, ISO, SAE and other requirements for competing in export markets,” said Cheah Sin Hua, managing director of SPC. “At the same time this

same compounds at each one,” Lednew venture represents our first step in erer said.“In addition, our product line building local capacity to supply the is now so wide-ranging that we can fast-growing Chinese domestic marsupply many of these cusket.” tomers with multiple comThe plant has pounds as far different as, two compoundfor example, a rigid glassing lines with a reinforced nylon and a soft, combined initial rubber-like TPE.” nameplate Teknor Apex now operates capacity of production facilities in North 14,000 tons per America, Europe, and Asia. year. Additional The company acquired SPC capacity will in 2001 and has since transcome on stream ferred technologies to SPC within the next for the manufacture of two years, said Teknor Apex vinyl or TPE Bertram M. Ledcompounds, as well as the erer, executive ETP compounds of Chem vice president of Polymer, which Teknor Apex Teknor Apex.

SPC Managing Dir. Chea Sin Hua. acquired at the end of “The Suzhou ini2004. This year, besides starttiative is the lating up the Suzhou plant, est in an ongoing Teknor Apex has begun production of series of expansions and acquisitions TPEs in the U.K. and is adding a new that has established Teknor Apex as a ETP compounding line in the U.S.A. ■ single source for customers that process in different locations around the world and require precisely the

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JUNE 2007 23

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Fiber Watch Corning reopens portion of Concord fiber facility The optical fiber industry saw perhaps the most positive sign yet for the long-beleaguered for the optical fiber industry when Corning Incorporated announced that it plans to reopen a portion of its U.S. optical fiber manufacturing facility in Concord, North Carolina.

Citing continued growth of the optical fiber market and increased demand for its semiconductor materials products, Corning reported in a press release that it will resume some production at a pace to meet market demand. It noted that it will take approximately six to nine months to restart fiber manufacturing.

Corning had seen great success for its optical fiber products in the 1990s and the beginning of the 2000s. In December 2000, Corning announced plans to invest $450 million to further expand the plant, but the telecom bubble soon burst for Corning and other fiber suppliers. In 2002, it “mothballed” the plant. That it is now reopening a portion of it supports the view that the sector has regained stability, albeit not the glory years of high margins.

“The optical fiber market has witnessed volume growth of greater than 15 percent in each of the last two years,” said Eric S. Musser, vice president and general manager of Corning Optical Fiber. “Over 80 percent of worldwide fiber demand now comes from the access and metro segments, and we expect to see continued market growth. The partial start-up of our Concord facility will ensure that we have adequate capacity to capture this

expanding market opportunity.”

The release also pointed out that another factor that led to the decision is the growth in demand for the company’s semiconductor materials products. Corning manufactures fused silica for semiconductor lithography applications at its facility in Wilmington, North Carolina, where it also makes some optical fiber, it noted.

As Corning’s semiconductor business has been growing at double-digit rates, that has resulted in the need for increased specialty glass capacity

there, which in turn has displaced some of Wilmington’s fiber making capacity, it said.

“The manufacturing process at the Wilmington facility produces innovative specialty glass for challenging microlithography applications. The lithographic industry is expected to show continued growth with higher semiconductor content in consumer electronics,” said James R. Steiner, senior vice president and general manager of Corning Specialty Materials.

Fiber optic network planned for Indonesia Seven Indonesian companies will join forces to build a $1.5-billion 34,000 km (21,100 mile) fiber optic cable network in the country, Reuters reported.

The report cited Basuki Yusuf Iskandar, a government official, as explaining that the venture, known as the Palapa Ring Project, is aimed at improving telecommunication infrastructure. The goal is to lower telecom costs from the current system that incorporates satellites.

Iskandar, Indonesia’s director general for post and telecommunication at the communication and information ministry, said that members of the group planned further meetings to discuss how to implement and finance the project. Some of the seven companies that have obtained the license for the venture include PT Telekomuniasi Indonesia Tbk, PT Indosat Tbk, PT Excelcomindo Pratama Tbk, and PT Bakrie Telecom Tbk.

The Palapa Ring was described as “part of the government’s effort to refurbish the country's ailing infrastructure to spur economic growth in the world’s fourth most populous nation.” Its completion, the report said, will open up telecommunication access to eastern part of Indonesia, the less developed area of the sprawling tropical nation.

Telkom President Director Rinaldi Firmansyah said the company will become the majority contributor to the project and lead the group as it would use most of the telecommunication traffic through the network. He noted his company accounts for about half the country’s telecommunication traffic, “so we are likely to invest about 50 percent of the project (cost).”

Firmansyah told reporters. “Financially we are ready,” he said, adding that the company’s involvement was aimed at strengthening its network in the eastern part of Indonesia.

Fiber optic cables can withstand outdoor conditions U.S.-based Belden has launched its redesigned Brilliance Tactical Fiber Optic Cables, a line of cables that excel for rigorous outdoor applications.

The new line of fiber optic cables is

24 WIRE JOURNAL INTERNATIONAL

available in five standard product codes, with up to 12 fibers and a variety of special options to meet an array of application requirements, a press release said. Options include fiber count and type, jacket color and mater-

ial, it said, adding that the cables are fully compatible with all optical fiber connector options.

For more details, go to www.belden.com. ■

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Fastener Update U.S. ind’l fastener market to be $12.9 billion in 2011 The Freedonia Group, Inc., a Cleveland-based industry market research firm, predicts that the U.S. industrial fastener market will rise about 3 percent a year to reach $12.9 billion by 2011.

Demand, a press release about the company’s 262-page report said, will be fueled primarily by healthy growth in aerospace equipment production and nonresidential construction and a rebound in motor vehicle production. It noted that production of many other durable goods will continue to rise, providing some opportunities for fastener suppliers. “However, overall market gains will be limited to some extent by competition from adhesives and other alternative joining technologies and by a moderation in residential construction.”

The release observed that price increases will be challenged by strong competition, both by various types of fasteners as well as alternative joining technologies. Coupled with declining prices for raw material prices, the fastener market is likely to see gains restrained in terms of total market value, it said.

Specific areas will see different results, the release said, noting that the electrical and electronic product market will also see above average gains as will aerospace-grade products, rising 8.2 percent annually compared to 2.0 percent for standard fasteners. “Strong growth in aerospace equipment production will drive demand for aerospace-grade fasteners. However, the growing use of composites in place of aluminum panels on airplane bodies will prevent even faster gains.”

Contact: The Freedonia Group, Inc., tel. 440-684-9600; www.freedoniagroup.com.

Anixter expands with buy of U.K. fastener distributor U.S.-based Anixter International, Inc., announced that it has acquired Total Supply Solutions Limited (TSS), a Manchester, U.K.-based TSS fastener distributor for approximately US$8 million.

A press release said that the acquisition will complement Anixter’s product offering with a broad array of valued-added services and inventory management programs to Original Equipment Manufacturers (OEMs). For 2007, it said, TSS is expected to generate sales of approximately $22 million. Of those sales, about half will be in the U.K., with the remainder coming from Poland and the Czech Republic, it said.

“This acquisition is another step in the geographic expansion of our OEM Supply business through the addition of important customers in Eastern Europe,” said Anixter President and CEO Bob Grubbs.”

Anixter International notes that its distribution network includes 220 warehouses at locations in 247 cities in 49 countries. ■

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WAI News Call for Papers issued by WAI for Wire Expo 2008 The WAI has issued a Call for Papers for Wire Expo 2008, to be held June 711 at the David L. Lawrence Convention Center in Pittsburgh, Pennsylvania, USA. Offering an ever broadening range of topics remains a priority for program organizers.

“We’ve been successful recently in expanding our paper presentations to include a wider variety of subjects,” said WAI Director of Education Marc Murray. “Topics like lean manufacturing and environmental compliance remain popular, so we’re still encouraging authors to think beyond just the technical.”

But technical topics remain the focus, and Murray said he hopes for a balanced program. “Pittsburgh offers us some great opportunities to draw from local industry and universities,” he said. “Obviously the ferrous side of things will be covered in a steel town like Pittsburgh. But we’re making a concerted effort to draw a complementary number of nonferrous and electrical papers as well.”

were presented, several of which were Almost any topics related to wire organized into theme sessions on meaand cable are fair game. Organizers suring and testing, wire rod and fastensaid they hope to see technical papers ers, and category cables. on topics such as wiredrawing mechanics, rod technology, wet and dry lubricants, microalloyed steels, industry trends, wire breaks, and heat treatment.

Abstracts from prospective authors are due to WAI headquarters by December 3, 2007.

For more details on submitting an abstract, please see the Call for Papers and submission form on pp. 41-42 or visit www. wirenet.org and click on the “Tech- Technical presentations at Interwire 2007 drew quite well, nical” tab for the especially those that were part of a theme session. The event Call for Papers. included four theme sessions and the WAI is seeking to offer a At Interwire 2007, similar range of theme sessions for Wire Expo 2008. a total of 35 papers

U.K. Clockwinder to visit WAI headquarters in June Ian Lane is scheduled to visit WAI’s headquarters in Guilford, Connecticut, USA, to carry on the long-standing clockwinding tradition.

Lane, a representative for the U.K. wire industry, is scheduled to visit on June 20,

at which time he will perform the annual “clockwinding” duties. The clockwinding ceremony is an annual event that dates back to 1948 when a grandfather clock was donated to WAI by 32 representatives of the U.K. wiredrawing industry in recognition of assistance provided by Americans in World War II. Traditionally,

a “clockwinder” from the U.K. comes to rewind the clock, renewing the relationship.

The grandfather’s clock, which has a casing made about 1770, bears an ancient sundial motto that reminds one and all that “time can neither be kept nor destroyed.”

WAI contact info

In 2005, U.K. Clockwinder Mark Hayes with then WAI President Anand Bhagwat.

28 WIRE JOURNAL INTERNATIONAL

Name Steven J. Fetteroll, executive director David B. LaValley, treasurer Mark A. Marselli, editor-in-chief Charles H. (Chip) Marsh, membership director Marc Murray, education director Janice Swindells, director of marketing services Robert Xeller, director of sales

Phone e-mail 203-453-2777 sfetteroll@wirenet.org 203-453-0593 dlavalley@wirenet.org 203-453-7579 mmarselli@wirenet.org 203-453-1748 cmarsh@wirenet.org 203-453-2777 mmurray@wirenet.org 203-453-2777 ex.117 jswindells@wirenet.org 203-458-7578 bxeller@wirenet.org

HAMemberTrueFalse.qxp

2/6/2007

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TRUE? OR

FALSE?

it’s really all about: who you know what you know where you go being in the right place at the right time leading the way finding a mentor professional growth personal development a global economy saving money sharing ideas putting words into action the destination the journey education experience working hard playing smart finding an edge staying sharp

>

If you answered “true” to any of these statements WAI membership is for you. Learn what thousands of wire industry professionals from 70 countries already know about WAI. During our last 77 years of program development, we’ve learned that all of the above are true. So, we think you’ll find that our benefits are as individual as your goals.

If you’re already a member, why not be true to a colleague? See www.wirenet.org for details or pass along the application form on the reverse side.

At WAI, it’s really all about you!

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

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

4c, file name: HAmemForm03,

Individual Information LAST NAME

page 32

FIRST NAME

TITLE

M.I.

.

COMPANY

❏ BUSINESS OR ❏ HOME

ADDRESS

CITY OR TOWN

STATE

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

ZIP/POSTAL CODE

COUNTRY

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

[

] BIRTH DATE (MM/DD/YYYY)

Required to receive The WAI Connection member e-newsletter

Business Information (required)

GENDER (M/F)

REFERRED BY

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

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

10 ❏ General & Administrative Management 30 ❏ Technical, Research & Development, Quality Control 20 ❏ Engineering, Operations, Production 40 ❏ Purchasing

:

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

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

SIGNATURE (REQUIRED)

DATE

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

INSTITUTION

..

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

❏ Italy

Membership Dues Calculation Membership Dues:

❏ One year: $95

SAVE! ❏ Two years: $175

MORE SAVINGS ❏ Three years: $255

Chapter Dues (indicate chapter above):

❏ First year: free

❏ Two years: $15

❏ Three years: $30

INDICATE AMOUNT:

NOTE:

Total Amount Enclosed Payment options:

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

Reference Guide

NOTE: All checks must be in U.S. Dollars drawn on a U.S. bank. Credit card payments are preferred for members from outside the U.S. and Canada. If a check or credit card is not used, a wire transfer may be sent in U.S. dollars.

For instructions, contact the WAI Membership Department at membership@wirenet.org or by phone at (001) 203-453-2777.

Your membership dues may be deductible as an ordinary and necessary business expense, not as a charitable contribution.

Membership in The Wire Association International, Inc. is held by the individual, not the company, and is continuous unless cancelled in writing. Membership is not transferable.

Dues are non-refundable and are billed annually based upon the member’s anniversary date. Annual dues are set by the WAI Board of Directors, and are subject to change.

June 07

International Technical

Conference Proceedings

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Reconvene scheduled for October 20-22 in Nashville WAI’s volunteers who serve on its various committees and boards will be meeting for Reconvene in Nashville, Tennessee, on October 20-22. Reconvene is the second of the two series of business meetings the WAI holds each year, the first being held during either Wire Expo or Interwire.

During these meetings, a wide range of issues are discussed, from finances and efforts to increase WAI membership to what areas to focus on for both technical programs as well as the association’s Interwire and Wire Expo trade shows. Subjects range from day-to-day business to strategic decisions, such as the Association’s decision last year to open an office in India.

“These are important meetings because we look to the volunteers for input and because they are the key to making the Association run smoothly,” observed WAI Executive Director Steve Fetteroll. “It helps for the volunteers to not only get together to discuss the specific sectors their committees are addressing, but to better understand what other committees are doing. It’s quite an experience both for them and for staff to be able to discuss various programs, both in place and under consideration.”

Reconvene will be held in conjunction with EIC/EMCW. As a sidenote of interest to golfers, the Mid-South Chapter will be hosting its 6th Annual golf tournament on Friday, October 19, so anyone attending Reconvene can join in on the fun.

Two of the key committees that will be meeting during will be the Exhibition Planning Committee, which will be discussing, among other topics, Interwire 2009, how to make the return

to Cleveland even better and recommendations for the location of Interwire in 2011. The Conference Programming Committee will likewise be having similar discussions about future technical programs.

The Exhibition Planning Committee includes: Chairman Anthony DeRosa, Cortinovis USA; Lou Arcuri, E.C.D. Inc.; Dane Armendariz, Henkel Surface Technologies; Robert Calliham, CommScope; Keith Donahue, Zumbach Electronics Corp.; Bob Stockholm, Beta LaserMike; John Dabbelt, Fort Wayne Wire Die; Tom Maxwell, Jr., Die-Quip Corp.; Richard Pechie, Vollmer America Inc.; Dominique Perroud, SAMP USA Inc.; Anthony DeRosa, Cortinovis USA; Bob Sears, North America OMCG Inc.; Bill Shockey, NUMAMERICA, Inc.; Joe Snee, Huestis Industrial; Jan Sorige, Enkotec Company Inc.; Jeff Swinchatt, Sikora USA; Edmond Torbey, Niehoff Endex North America; Steve Vannais, Davis-Standard Corp.; Carolyn Edwards, REELEX Packaging Solutions.

The Conference Programming Committee includes: co-chairman Nick Nickoletopoulos, Ivaco; co-chairman Masoud Garshasb, Phelps Dodge Copper Products; Eduardo Anaya; John Dabbelt, Fort Wayne Wire Die, Inc.; Ethem Erdas, Beta LaserMike; Ron Garceau, Paramount Die; Bob Glodowski, Stratcor; Brian Holden, Carris Reels, Inc.; Tom Horn, Filtertech, Inc.; Giuseppe Marcantoni, Etna Products, Inc.; Tom Maxwell, Jr., Die Quip Corp.; Don Schollin, Q-S Technologies, Inc.; Doug Sedgwick, Gauder Group, Inc.; Mark Spencer, W. Gillies Technologies LLC;

Interwire 2007 was high on the agenda of the Exhibition Planning Committee at Reconvene.

Boudewijn “Bo” Vandromme, BWC Technologies Ltd.; and Briggs Whitefield, Bekaert Corp.

Other bodies that will be meeting during Interwire include the Board of Directors, Finance Committee and the Executive Committee.

The Board of Directors includes: Eduardo Anaya, Indepa SC; Dane Armendariz, Henkel Surface Technologies; Antonio Ayala, JJ Lowe Assoc; Ferruccio Bellina, TKT Group; Brian Bouvier, Lloyd & Bouvier, Inc.; Kurt Breischaft, Belden, Inc.; Lawrence ElHindi, Filtertech, Inc.; Masoud Garshasb, Phelps Dodge Copper Products; William Jarae, Mittal Steel Georgetown; Eric Macs, Fine International; John Martin III, Mar-Mac Wire; Thomas Maxwell, Die Quip Corp.; Malcolm Michael, Australasian Wire Industry Association; Thomas Moran, National-Standard; Nicolas Nickoletopoulos, Ivaco; Dominique Perroud, SAMP USA; Ronald Reed, Horizon Wire & Cable; William Rump, Davis Wire Corp.; Ken Scott, consultant; Andrew Stromer, Southwire; and Raj Kumar (RK) Tyagi, Assomac Machines Ltd. Finance Committee members include: Scott Higgins, Autac, Inc.; John Kopley; Paul Pawlikowski, Delphi Packard Electric; Ron Reed, Horizon Wire & Cable; Ron Schenk, RichardsApex Inc.; and Bo Knueppel, Wire Machine Systems, Inc. The executive committee includes: Thomas Moran, National-Standard; Ron Reed, Horizon Wire & Cable; Antonio Ayala, JJ Lowe Associates; Dane Armendariz, Henkel Surface Technologies; and Past President Brian Bouvier, Lloyd & Bouvier. ■

Discussing business at the 2006 Board of Director’s meeting, l-r, were: member Paul Pawlikowski, Tom Maxwell, Jr., 1st Vice President Tom Moran, WAI President Brian Bouvier, and WAI Exec. Dir. Steve Fetteroll.

JUNE 2007 31

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Chapter Corner New England Golf tourney: Sept. 13 e-mail WAI’s Chip Marsh at WAI’s New England Chapter has set cmarsh@wirenet.org or call him at September 13 as the date for its 13th tel. 203-453-1748.

Annual Golf Tournament, which will be held at the Kettle Brook Golf Course in Paxton, Massachusetts, USA. The popular event, which last year had more than 150 golfers register, includes continental breakfast, golf with several team and individual prizes, the raffle and sports memorabilia auction to support the WAI New England Chapter Scholarship Fund, and the 19th Hole Reception and Awards Dinner.

Registration materials, including a range of sponsorship opportunities, including individual holes as well as premium spon- The 2006 winning foursome of Vincent Griffin and Mike sorships, are being finalized Swift and Neil Swift of Premier Wire Die, and Jerry and will be available soon. Richards of ADCO Inc. For more information,

August 23 date for Southeast golf tourney The WAI Southeast Chapter will hold its 6th Annual Golf Tournament on Thursday, August 23, 2007.

The chapter returns to the Rock Barn Golf Club and Spa in Conover, North Carolina, the site of last year’s successful tournament. Last year, 96 golfers played at the picturesque course site that saw low scoring the theme of the day. The three winning teams all had sub-60 final scores.

First place went to the team of Scott Ferguson of Hefner Builders Inc., NEPTCO’s Randy Dula and Gary Greene, and Bryan Lefever of Cross Coatings, with a sparkling score of 56.

The chapter looks forward to further success with its 2007 event, which will include the awards reception and dinner are included. Hole and premium sponsorships are available.

For more information, contact WAI’s Chip Marsh, cmarsh@wirenet.org, tel.

203-453-1748.

Two winners names for New England Chapter scholarships Company, Inc. He is graduating from WAI New England Chapter President Wachusett Regional High School in Lori Parent recently announced the Holden, Massachusetts, and will attend Chapter’s 2nd annual scholarship recipiLafayette College to study mechanical ents: Nicole Contois and Devin engineering and/or business.

Schlichting. Each of the two graduating “There were six outstanding candidates high school seniors will receive a $1,000 for this year’s scholarships,” said Parent. award to help them further pursue their education Contois is the daughter of Temp-Flex Cable Company general manager Deborah Contois. She is graduating from Holy Name High School in Worcester, Massachusetts, and will pursue a degree in elementary education at Bridgewater State College.

Schlichting is the son of Peter Schlichting, vice president of sales and marNicole Contois Devin Schlichting. keting of Quirk Wire 32 WIRE JOURNAL INTERNATIONAL

“The committee had tough choices to make and they did a fantastic job.”

The Chapter established this scholarship program in 2006 to improve educational opportunities for academically qualified high school seniors who are involved with their communities and are children of WAI New England Chapter members in good standing. Each student must complete an application, provide school transcripts and write a personal statement in essay form about themselves and how the scholarship will help them further pursue their education.

“The chapter’s board of directors recognizes the importance of furthering the education of our youth, and this program helps us to connect with our members in a worthy way,” said Parent. “Thanks to all who have helped support this program through donations at our annual golf tournament.” ■

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3/1/2007

3:57 PM

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Lubricants and filtration This feature presents a range of observations from suppliers of lubricants and filtration technology, many of which were among the exhibitors at Interwire 2007.

The feature also includes a look at a potentially burdensome regulation for lubricant suppliers, one company’s technology to remove lubricant residue and a contact list.

Lubricants Aztech Lubricants LLC One of the main issues that U.S.-based Aztech Lubricants LLC has faced in its young life is that it does not have a history or reputation that gives it an instant opportunity for new business. It has the right people, the right products, the knowledge and the motivation to earn both respect and business. It understands that the reputation the company wants to build is to be the best at everything Aztech does, and the understanding that it will take some effort and time to get that reputation. Aztech

Aztech Lubricants LLC owners Michael Colvin and Jonathan Anderson.

Lubricants LLC owners Michael Colvin and Jonathan Anderson have recently added a full line of EZDraw wet drawing lubricants for ferrous and nonferrous drawing. They have talked to many customers

34 WIRE JOURNAL INTERNATIONAL

to try and find out what issues they would like to address. That has led to the company’s wet drawing lubricants being formulated to address and eliminate the problems of pH drift, emulsion stability, emulsion and equipment cleanliness while increasing system life. It has also formulated these products to work in just about any type water. Michael Colvin works closely with chemical suppliers to make sure these new products are the best that current technology can offer.

Improvements continue with the company’s powder lubricants. Aztech has worked on new lower cost additives to replace many of the now commonly used additives that are sometimes tough to get and carry a lofty price. The latest tests have shown that drawability is the equivalent or better, with superior cleanability and excellent cost effectiveness.

Aztech Lubricants LLC is also adding new equipment to help reduce its manufacturing costs to help offset the price increases in raw materials. The new WHITE mixer/reactor is being customized to work in the process of manufacturing powdered lubricants. Current tests are looking very promising; this new equipment idea will greatly increase the company’s manufacturing efficiency and give it better reaction control. Aztech works closely with customers to help provide them with the right products and ideas at the right price, helping them control and/or reduce their manufacturing costs, providing them with training, ideas and support wherever needed, while still being able to ship 95% of customer orders the same or next day. www.aztechlube.com.

Baum’s Castorine Co., Inc. Baum’s Castorine Co., Inc., continues to develop its line of liquid lubricants for the wire and cable industry. Dura Draw 891 is our semi synthetic emulsifiable lubricant for drawing copper, plated copper and cop-

per alloys. The synthetic ester chemistry used in this formula has been altered to provide the Extreme Pressure lubrication required for drawing ferrous alloys, high nickel alloys, and nickel coated alloys. This new product is called Dura Draw 747. Like its companion product [Dura Draw 891] Dura Draw 747 is formulated to provide a long service life while keeping machine work areas clean. Dura Quench 690 is a new micro emulsion quench lubricant.

When mixed with water it makes a clear emulsion. During the 690 formula development the formulation focus was to provide

Tom Whitcombe, Baum’s Castorine Co., Inc.

a product that will consistently produce clean, bright copper wire throughout its service life.

Baum’s has continued to experience a rapid increase in its market share of the wire and cable industries by focusing its efforts on the needs of the customer.

Continuous formulation development is customer driven. Laboratory services improvements are responsive to the information needs of the customer. Wire mill personnel training on emulsion testing and maintenance has been developed to assist customers in maximizing quality throughput and extending emulsion service life.

We are proud of our reputation for putting the customer first in every area of our oper-

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REACH program may have a long reach

ations. We feel that this attitude is one of the most important contributors to our success and to the success of the customers we serve. www.baumscastorine.com.

Blachford Corporation Blachford supplies lubricants to the world’s largest wire producers because of its ability to design lubricants that help give customers a competitive edge. It has been supplying customers with meticulously researched and innovative wiredrawing lubricants for over 50 years.

Blachford has over 250 different lubricants and is one of the few companies that manufactures both dry and wet lubricants for ferrous and nonferrous wire applications. The company is well known for its ability to develop lubricants that precisely match our customers’ technical requirements. Its strength in lubricants development helps our customers to differentiate their products and achieve a lower operating cost. Our field engineers analyze and understand the customer’s operations, which in turn enables our R&D team to develop industry-leading lubricants.

Blachford is committed to our ISO 9001 approved product quality. Dr. John Blachford is known throughout the chemical industry through his promotion of Responsible Care® and his strong desire for his companies to act as a responsible corporate citizen.

Wire industry globalization continues to increase the pressure for wire producers to remain profitable through product differentiation and cost optimization. As a result of this trend, we are experiencing an increasing number of large customers approaching Blachford to develop lubricants that will help put them ahead of their competition.

The weaker U.S. currency is also making our lubricants very cost attractive to overseas wire producers. A current challenge for lubricant producers is the increasing cost in the primary lubricant raw material – fatty acids, due to higher demand for tal-

Gary Woods, Blachford Corporation.

low for bio-diesel production. Blachford is meeting this challenge by innovating technologies and streamlining our manufacturing, so that we will continue to provide the very best lubricant products to the wire drawing industry. www.blachford.com.

Condat S.A. By constantly reviewing and rationalizing chemical substances and formulations, the R&D department of Condat is anticipating these future requirements and services.

As our market is also facing currently huge price increases, Condat R&D and sales have managed to provide lubrication with higher productivity levels.

In this context, Condat offers lubricants with low consumption aimed at reducing waste for more cost effective processes,

Patrick Richaud, wire drawing business unit manger, Condat S.A.

Condat to acquire Henkel’s dry lubricant business At press time there was no official announcement from either company, but multiple sources have reported that Henkel Corporation has agreed to sell its dry lubricants business to

Condat S.A. The reported deal, which was talked about at Interwire 2007, does not include Henkel’s wet lubricant business. More details should be available next issue.

It was not long ago that the wire and cable industry had to grapple with meeting the requirements of RoHS, a European directive restricting use of hazardous substances such as halogenated materials used to make cables. It proved to impact markets outside Europe. Now, another directive is on the horizon, this one described as “RoHS on steroids.”

Welcome to the Registration, Evaluation and Authorization of Chemicals, better known as REACH, which is an effort on the part of the European Union to provide a comprehensive registry of all substances in use in the E.U. It creates a legal obligation to register all chemical substances sold in Europe in quantities of 1 ton or more per year. As most lubricating oils are blends of base oils and additives that do not change chemically during blending, the burden of compliance falls on the upstream suppliers of the raw materials.

The REACH Regulation was formally adopted on December 18, 2006. More importantly, it takes effect June 1, 2007.

A staggering amount of information can be found at this website:http:// ec.europa.eu/environment/index_en.htm.

At the “What is REACH?” section in the site, it explains that the REACH Regulation “gives greater responsibility to industry to manage the risks from chemicals and to provide safety information on the substances.” It notes that manufacturers and importers “will be required to gather information on the properties of their substances, which will help them manage them safely, and to register the information in a central database.”

In some ways, REACH is similar to RoHS in that it aims to make the environment cleaner and make the production of products safer, but REACH focuses not on hazardous materials but hazardous chemicals. Most lubricant companies contacted at Interwire, however, were confident that the directive could be managed.

One statement in the “What is REACH” section may give cause for some concern: “The Regulation also calls for the progressive substitution of the most dangerous chemicals when suitable alternatives have been identified.”

JUNE 2007 35

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such as new dry drawing sodium soaps free from boron and a new generation of high-performance, non-reactive pre-coatings for the replacement of zinc phosphate in the case of wire drawing and cold forming operations.

Condat has always worked closely with its customers towards establishing partnerships with the purpose of offering lubricating solutions adapted to their needs and issues. In terms of issues, the regulatory and environmental ones are going to play a larger role in Europe over the next years for the chemical industry.

The recent publication of REACH has focused the industry of metal forming lubricants on this next constraint: Condat, as most companies involved in the development and the production of industrial chemical substances, has dedicated a chemical engineer for this project and involved its marketing organization in an evaluation and communication program.

Such a regulation will deeply impact the producers and end users of wire drawing chemicals (surface coatings, lubricants, corrosion inhibitors) in Europe as the sup-

ply and the production of these substances and their variety might shrink.

For the time being, Condat is looking forward to confirm its impact scenario with experts of the REACH organization. www.condat.fr.

Etna Products, Inc. In the face of continued cost pressures from every facet of its business over the last several years, Etna Products, Inc., and Etna-Bechem Lubricants, Ltd., along with their various global lubricant partners around the world, have continued to focus

Etna Product’s Giuseppe Marcantoni, product manager, and Troy Carr, sales engineer.

the company’s combined efforts on global positioning. The coordinated and combined efforts utilize the global reach to bolster focused products and services offering, but also as a means to control cost pressures through global raw material procurement. The goal of the Etna Companies and its global partners around the world is to provide the industry with leading-edge technology products that are manufactured in strategically located areas throughout the world, while providing unparalleled customer service. The commitment to Research & Development enables the coordinated team to bring new technologies to the increasingly competitive global market place. We have developed new products for copper, aluminum and other nonferrous wiredrawing applications.

Global positioning is a must in today’s market; it is necessary to service customers within a local market on a global basis.

The Etna Companies are able to meet the needs of our global customers through our various partners around the world that facilitate local manufacturing, sales and technical service in Japan, England, Germany, China and India.

36 WIRE JOURNAL INTERNATIONAL

The most important challenge or opportunity is to maintain local capabilities on a global basis as the Etna Companies develop and introduce new products to new markets around the world. We must maintain our capability to source the necessary raw materials from a technology and quality perspective, while leveraging the global positions that are in place within the local market on a cost-effective basis. The objective here is not to compromise the integrity and quality of the products being manufactured globally. With the volatility of the base oil markets, short-supply positions of various key additives and global currency positions over the last years, these events present various challenges to a globally positioned compound/blender, but a much larger challenge to one who is not well positioned globally with a fully integrated company in local markets. The goal of the Etna Companies is to insure our products are all manufactured to the same specifications regardless of where in the world they are being made, while maintaining a committed and consistent service value to our global customers. www.etna.com.

Heatbath Corporation Heatbath® Corporation manufactures an extensive line of metal finishing products that range from cleaning and coating processes for initial fabrication to the application of the final functional, protective or decorative coating on the finished parts. It offers a line of proprietary chemistries for cleaning and coating of ferrous metals to improve performance of drawing and cold forming operations. It supplies products for zinc phosphating, immersion copper coatings and oxalate coatings as well as reactive and non-reactive lubricants. Heatbath offers “Total Line Responsibility” supply-

Heatbath Corporation’s Dennis Bretton, technical director, and Cheryl Hickman, technical service representative.

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ing specialized products for every stage of the following processes: soak, spray and electrocleaners; black oxide finishing; brighteners for zinc, cadmium and tin plating; brightener systems for decorative plating; electroless nickel plating; paint base phosphates (iron and zinc); manganese and heavy zinc phosphates; chromate conversion coatings; rust preventatives; aluminum finishing (cleaners, etchants and deoxidizers); and cold forming zinc phosphates and lubricants. Heatbath has technically trained representatives throughout the country, backed by laboratory specialists available for consultation and service. If you have a metal finishing challenge of any kind, our technical service staff is available to assist in the adaptation of a standard product or the development of a processing protocol to fit your particular needs. You can depend on us and the guaranteed reliability of Heatbath metal finishing products. www.heatbath.com.

MacDermid Industrial Solutions For over 80 years U.S.-based MacDermid Industrial Solutions has been at the forefront of creating new standards for the development of advanced metal working fluids and metal finishing chemistry. Its advanced technology, global work force and worldwide network of manufacturing sites allow MacDermid to truly support its “Yes We Can” slogan. Whether a customer is looking to upgrade to labelfree “true” synthetics, advanced micro emulsions, high speed wire plating electrolytes, copper oxide removal/top coats, or any combination thereof, the answer is, “Yes We Can.” After MacDermid has proved its capabilities to new customers, they are more likely

Steve Leonetti, general manager, MacDermid Industrial Solutions.

to ask for its assistance in regards to issues such as improving die life, roll life, surface topography and EH&S conditions, as well as to reduce wire breaks, staining, etc. “Yes We Can” are not just empty words. Where other suppliers fall short on this promise, MacDermid has the global resources (3,500 employees operating in excess of 28 countries), and more important, the technology to deliver. For example, one of its newest customers is in the process of dumping numerous competitive sumps only three months into a one-year expected sump life. They did this after running MacDermid’s low foaming, true synthetic chemistry in a 90-day, head-to-head comparison. The results: tension breaks went from 20 or more per month with the competitive product, to a total of five over the entire 90 day test period with the MacDermid product! Die life improved dramatically, and they are now preparing to increase their line speeds. They calculated the savings and decided to immediately dump, dispose and change to MacDermid, plant wide. “Yes we can.”

Regarding the REACH directive, The registration for each raw material we use in

our European formulations is the responsibility of our suppliers. As regards Relubro products, MacDermid’s goal is to meet “label free” requirements, world wide.

Because of this, our European compliance staff does not see this initiative as an inconvenience. In the final phase of this regulation, MacDermid will be required to register our products. This registration and approval of our finished products will be based on our use of registered and approved raw materials only. We are not anticipating any problems as a result of this new initiative. www.macdermid.com.

Pan Chemical SpA Italy’s Pan Chemical focuses on being able to help customers correctly apply every element of the wiredrawing process.

It does this by offering single supplier responsibility: offering lubricants and coatings, also made up to specific customer requirements, equipment that includes innovative new machine designs, mechanical descalers and shot-blasting machines, technology and assistance for environmental issues. It recently started a new plant for re-conditioning and recycling waste lubri-

Luigi Vago, PanChemical SpA.

OUR STANDARD IS TO MEET YOUR EVERY STANDARD, WORLDWIDE. For SyncureTM, ECCOHTM, FireConTM, MaxxamTM or for custom Wire & Cable solutions, please call 1-866-POLYONE, or visit us online at www.PolyOne.com.

38 WIRE JOURNAL INTERNATIONAL

© 2007 PolyOne Corporation. All rights reserved.

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Stringing a method for lubricant removal Noting that drawing lubricant residues can interfere with subsequent wire production steps, Germany’s Boockmann GmbH, represented in North America by The Slover Group, reports that its HELICORD technology has been proven in several industrial applications to be an effective method for cleaning and surface preparation of

Boockman GmbH’s HELICORD system.

wires, strands, cables and welding consumables. They explained the technology as follows below.

The HELICORD principle employs 360° surface contact between a constantly renewed and slowly moving flat or round braided textile cord that is looped around the relatively fast running wire or strand. The controlled friction, under high tension, and total surface contact provide a high degree of uniform cleaning efficiency.

Cleansers, solvents, and abrasive can be integrated into the cord.

One can remove interfering residues by wiping or abrading, followed if desired by a second step of coating the surface with appropriate materials. For subsequent surface conditioning, applications of anti corrosion agents, slip agents, or lubricants, can be made. The technology has also been successfully used on aluminum with reduction of the coefficient of friction from 0.30 to 0.11.

The technology has been used in Europe for over 20 years, with some 4,000 units operating for magnet wire lubrication, welding wires, superconductors, strands or cables. Contact: www.boockmann.com or www. slovergroup.com.

40 WIRE JOURNAL INTERNATIONAL

cants, wet or dry. Pan Chemical supplies both wet and dry lubricants. Its dry drawing lubricants are based mainly on calcium, sodium and aluminum stearates and additives. Their combination produces a great number of products that will meet any specific requirements. Most of the products are available in five grain sizes distributions: V (Very fine); T (Fine); M (average size); G (large size); and B (dust free). The dry lubricants come in 25/30 Kg paper/plastic bags on pallet (pallet weight from 1000 to 1650 Kg) and in 150/175 Kg steel drums or cardboard drums. The products, which are free from dangerous, harmful or toxic components, are used for low carbon steel wire, plating quality wire, welding wire, cold heading quality wire, high carbon steel wire and stainless steel wire and alloyed steel wire. The company also offers a full range of oils, greases and pastes developed for a wide range of applications on ferrous and non-ferrous materials. Soluble and emulsionable oils are mainly used for fine wire drawing. Neat oils are used for heavy duty applications on big size wires, bars, tubes and profiles.

Special neat oils have been studied for drawing stainless steel products and special soluble oils for copper wire drawing. In conformity to the new health and safety rules the company’s R&D Department has developed chlorine-free oils for different applications. www.panchemical.com.

RichardsApex Inc. One of the latest technical advances from U.S.-based RichardsApex Inc. is the creation of its HRM series of alcohol-free reducing agents. This new formulation technology helps the company’s global customer base in three significant ways: quality, cost and environmental concerns (VOCs). Customers who typically use Isopropyl Alcohol (IPA) or ethanol in their process and tried RichardsApex’s HRM series in conjunction with IPA have found that they have been able to produce a more consistent quality product than with previous methods. Along with other advances in semi-synthetic and synthetic technology, the HRM series helps customers maintain quality standards while increasing the tons per hour produced. Customers using the HRM series have also been able to significantly reduce their costs by lowering, or in some cases eliminating altogether, the use of IPA or ethanol in their mill solutions.

The unique reducing agent package in the

From l-r, David Richards, John Richards and Drew Richards spoke to Interwire 2007 attendees about technology such as the company’s HRM series of alcoholfree reducing agents.

HRM series achieves better results without the costly evaporation of alcohol-based technology. The immediate cost savings from reducing or eliminating IPA or Ethanol is one very attractive feature of this product line, but perhaps the most significant advantage of the HRM series is that customers are better able to comply with more stringent regulations calling for lower VOC emissions. By replacing some or all of the IPA or ethanol use, customers can show real progress in complying with the ever-tightening environmental constraints.

Additionally, the HRM series improves workplace health and safety concerns by reducing the need for bulk storage of IPA or ethanol as well as the associated risks that come with using them. www.richardsapex.com.

Tecnovo Srl/TKT Group Italy’s Tecnovo Srl has developed new calcium soaps (TECNOLUBRE® FM/180 and TECNOLUBRE® FM/198) that are multi-function products with a low environmental impact. These lubricants: offer greater lubricating capacity, which is needed for today’s faster drawing machinery; provide a final wire covering that is easy to remove and not harmful to equipment and in subsequent treatments; and are free of chemical substances and additives that are difficult to dispose. These demands gave rise to formulate a new generation of lubricants, non toxic and/or harmful for men and for the environment. Toxic and harmful products are eliminated from our range.

Specifically, TECNOLUBRE FM/180T provides: a thin layer of lubricating film; is free of titanium dioxide; is easy to remove;

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Wire Expo 2008.

Photo Courtesy: Bruce S. Cridlebaugh, pghbridges.com

Our technical program connects, supports, and sustains.

Call for Papers

Submit an abstract and watch your research do the same.

The Wire Association International’s technical programs bridge the gap between research and continuing education in the wire and cable industry. And our program strength comes from you.

Help reinforce the manufacturing arts by communicating your research findings to your colleagues, peers, and protégés. Just submit an abstract today to start the process.

If your expertise spans more time than most, you already have something to share at this symposium. Whether it’s a perspective on industry trends, uncommon solutions to common production problems, or the use of specialized materials and procedures, your audience is in suspense.

Technical and practical topics are welcome in the ferrous, nonferrous, electrical, fiber optic, or general disciplines. Accepted authors have a chance to have their work published in the industry’s leading Wire Journal International magazine.

Other perks include complimentary meeting registration, free one-year WAI membership, a copy of the Conference Proceedings, access to all sessions, exhibit hall, and opening reception. Why not join in? See instructions on the reverse side.

Photo Courtesy: David L. Lawrence Convention Center

June 7-11, 2008 Pittsburgh • Pennsylvania David L. Lawrence Convention Center

Abstract Deadline: December 3, 2007

Author Notification: January 1, 2008

Manuscript Deadline: March 3, 2008

Wire Expo 2008 is organized by The Wire Association International, Inc. 1570 Boston Post Road • P.O. Box 578 • Guilford, CT 06437-0578 USA Tel.: (001) 203-453-2777 • Fax: (001) 203-453-8384 • Web site: www.wirenet.org

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Wire Expo 2008 Call for Papers not previously published will be accepted for Wire Association International paper In order for the Wire Association’s Technical Papers Committee to properly awards and possible publication in Wire assess the scope and content of your pro- Journal International. Only papers received by the manuscript deadline will posed technical article, please submit a be included in the Conference 75 word abstract, typed in English, on the form below. Authors will be notified Proceedings materials.

Note: If your paper is received after the of acceptance.

1. Log on to www.wirenet.org.

Papers

3. Select the “Call for Papers” tab from the drop-down menu.

Abstracts

An “Author’s Guide” containing detailed instructions on how to prepare the paper and oral presentation will be e-mailed to accepted speakers. Only original papers

deadline we cannot guarantee that your presentation will be scheduled in the technical program.

Log on to submit your abstract 2. Click on the horizontal tab called “technical” on the main page.

4. Complete and submit the abstract form.

Please complete the following information and e-mail, mail or fax to: Marc Murray, Director of Education, The Wire Association International, Inc., 1570 Boston Post Rd., P.O. Box 578, Guilford, CT 06437-0578 USA, Tel.: (001) 203-453-2777, Fax: (001) 203-453-8384, E-mail: mmurray@wirenet.org.

This form can also be completed on the WAI website: www.wirenet.org. (See log-on instructions above).

Please indicate your area of interest:

I would like to present a technical paper.

Please check the appropriate industry segment: Ferrous Nonferrous Electrical General

Tell me about Poster Paper Forums.

Fastener, Forming & Fabricating

Fiber Optic

Author(s): _____________________________________________________________________________________________ Contact Author (designate only one): ___________________________________________________________________________ Paper Title: ____________________________________________________________________________________________ Company (Affiliations for each author): __________________________________________________________________________ Address: ______________________________________________________________________________________________ City: _________________________

State: _________________________

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Please type your abstract in English on this form. If you need additional space, please use a separate page.

Abstract (75 word maximum)

WE 08

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

Wire Expo 2008 is organized by The Wire Association International, Inc. 1570 Boston Post Road • P.O. Box 578 • Guilford, CT 06437-0578 USA Tel.: (001) 203-453-2777 • Fax: (001) 203-453-8384 • Web site: www.wirenet.org

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has an ash content after thermal treatment that is low in quantity and completely soluble in the acids normally employed for pickling before galvanization; and can be used for producing bright wires or wires destined to subsequent heat treatments and galvanization as the pollution of heat treatment ovens and pickling tanks is reduced.

TECNOLUBRE FM/198 provides: optimum lubricating performance with highest wire drawing speeds; a good covering of lubricant on the wire; a lubricating film that adheres very well to the wire but also dissolves easily in the water solutions of lubricants for wet drawing in TECNOVO’s SINTEK® range of products; and is ideal to use for wires for CO2 welding, wires for wire staples, wires for subsequent wet drawing, high carbon content wires (for springs, P.C., metal ropes, etc.) in the first drafts followed by a suitable sodium-base lubricant.

The new lubricants have a softening point which starts at 80-90°C and remain in a plastic viscous state until they reach 250-280°C. Teconovo has also developed

new sodium soaps for wiredrawing that do not contain nitrites, chlorinated and sulfurized compounds and soaps of heavy metals (barium, chrome, lead). www. tktgroup.inc.

Traxit North America, LLC Traxit North America, LLC, which has been serving the U.S. and Canada for over 10 years now, is part of Traxit International, which is now 126 years old.

We are both growing. Thank you for your support. Traxit continues to develop new products that may improve wiredrawing efficiency and lower processing costs. It is about to import new products from our overseas plants that have tested very well.

One product, Traxit DT 405, will be competitive in cost and improve the cleanliness of the operations at the same time.

This is enabled by reducing the waste and residual lubricants on the wire. We have developed a new coating, Traxit ZEL 760 AB, for inline and batch operations that is more soluble in water and costs less to use than our previous coatings.

Traxit is also looking at future requirements for environmental compliance. It is developing products that will draw David Tatum, Traxit better and North America LLC. be more “friendly” at the same time. The biggest challenge to the sector may well be the alternative use of raw materials for making biodiesel fuel. A recent article in USA Today noted that it is easier to make diesel fuel from chicken fat (and other animal fats) than from corn. The price for the fat may well go up in the U.S. as it has in Europe. The price for palm oil that is used in making lubricants is at a historic high.

JUNE 2007 43

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Traxit must work to improve its products and find other sources of raw materials that will make the lubricants of tomorrow. The wire industry is where we work. In North America it is having a tough time. We plan to do our part to help our customers remain competitive with new products and timely supply. www.traxit.com.

Filtration Filtertech, Inc. To remain a competitive leader in the world market today and like most manufacturers, Filtertech is committed to providing the best quality equipment at the lowest prices possible. This means a concerted effort to identify areas for improvement, implementing and then maintaining those improvements. Like many other manufacturers today, we have instituted lean manufacturing practices

Filtertech, Inc. Sales Manager Tom Horn and President Joe Scalise.

44 WIRE JOURNAL INTERNATIONAL

that result in a continual improvement in marketing, systems engineering, procurement practices, manufacturing and customer service. Customer satisfaction is the ultimate goal and supporting our customers for the lifetime of the equipment is our insurance for future business.

Filtertech has always strived for continuous improvement of our product line and the Controlled Level Indexing feature (CLI) is the latest optional design enhancement primarily for the SCF Vacuum Filters. When the dirty coolant enters the filter, the particulate is captured on the media and eventually builds a cake that traps finer and finer particulate. The cake also “blinds” the media over so the liquid level rises to an optimum level just below the designed overflow point within the filter. The CLI feature maintains this optimum operating vacuum and liquid level by regulating the media drive speed which is extremely slow but continuous.

A level float within the filter bed regulates the controls that operate the CLI, the float which is interconnected to the vacuum producer air inlet damper, which also regulates and maintains an optimum vacuum level.

The CLI feature is a marked improvement over our traditional design that required a distinct rise and fall of the liquid level to turn on and off the media drive and advance the media. The CLI advantages are as follows: a consistent liquid level within the filter bed which produces a uniform pressure drop across the media, and in turn a very efficient cake removing even finer particulate; minimizing solids migration through the clean media as it continuously and very slowly enters the filter; a consistent operating vacuum level results in lower power

consumption while minimizing potential misting or evaporation due to the fluctuations that may occur with the standard indexing design; and finally, media usage will also decrease due to the consistency and efficiency of the resulting cake produced by the use of the CLI feature. The CLI feature is available as an option on any new SCF Vacuum Filter, or can be retrofitted to existing filters. www.filtertech.com.

The Hilliard Corporation The Hilco Ceramic Membrane system from The Hilliard Corporation is an ideal way to lower filtration costs. The filtration system utilizes high-velocity “crossflow” across the membrane surface. The advanced technology ceramic membranes deliver outstanding performance, durability, and cost effectiveness. The robust filter design and high efficiency can help solve your tough filtration problems. Case studies demonstrate the effectiveness of a recently developed ultra-filtration membrane technology when

Mark Rose, The Hilliard Corporation.

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applied for the treatment of industrial waste water containing suspended solids, oil, grease, metals, and other contaminants. Although membrane technology has been used for waste water treatment for several years, the newly developed dense pack ceramic membrane element offers the advantage of treating a variety of applications with just one type of membrane due to its broad pH range, immunity to chlorine, high operating temperature, and high flux sustenance capabilities. The dense pack design provides a high volumetric efficiency in a small footprint for greater efficiency, and economical operation, than other cross flow filtration systems available today.

The ceramic membrane system has demonstrated the ability to be an attractive and cost-effective waste water solution, with reported pay-backs of 6-12 months. The desire to reduce or eliminate chemical usage, to reduce waste disposal costs and subsequently lower water consumption has been driving the interest and acceptance of this technology. www.hilliardcorp.com.

Keir Manufacturing, Inc.

1-800-992-2402

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

46 WIRE JOURNAL INTERNATIONAL

Hoffman Filtration Systems/Air Liquid Systems, Inc. The recycling of process liquids in the wiredrawing industry continues to be one of the most important means of minimizing costs for companies worldwide and flat bed vacuum filters are as effective at achieving this as they were when Hoffman introduced the Vacu-Matic in the 1960s.

Since then, the manufacturing hubs of the world have relocated, customers’ expectations have become more sophisticated, and the VacuMatic has evolved to meet those customers’ needs for operational and maintenance simplicity. In addition to design improveA Hoffman Filtration system from Air Liquid ments, successful filtra- Systems, Inc.

tion manufacturers have grown to offer sales assistance, engineering, and on-site services in the countries in which purchasing companies and end users are located.

In the 1970s and 80s, many industrial companies maintained production facilities and purchasing offices in the United States, which allowed domestic filtration manufacturers to grow rapidly and become major presences in the wire drawing industry. The development of a more global economy in the 1990s, in which companies’ borders were not necessarily aligned with a single country, continent, or even hemisphere, have dictated that suppliers offer more flexible and mobile services.

Air Liquid Systems, Inc., manufacturer of Hoffman’s complete line of filtration equipment, continually adds services and qualified representatives to assist customers through each phase of their projects. From design and engineering to startup and afterward, ALS maintains close communications with customers throughout the discourse of each job. Because communication has been a stereotypical shortcoming of engineering companies, ALS makes per-

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sistent efforts to simplify the process of obtaining information about Hoffman’s filtration products for our customers, whether during the sales phase, construction phase, or after startup is complete. Those efforts are carried out by sales representatives located in the country or region of the customer, by translation of product literature or maintenance manuals into the native language of the end user, and by engineers dispatched from the home office to customers’ locations worldwide to provide inperson support and technical advice.

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Wiredrawing breaks – A review of mechanical perspectives

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The impact of ratio of drawing stress to wire strength (DSR) and the implications of flaw size in causing wire breaks are addressed in this study.

By Roger N. Wright

The objective of this paper is to pro-

vide a practical, mechanically based review of the reasons for wire breakage during drawing. The basic ideas of this review will then be applied to a summary of drawing break types.

Drawing stress and wire strength

The wiredrawing process works because the drawing stress (the pulling force divided by the as-drawn cross sectional area) is less than the strength of the wire as it leaves the die. There are many papers and formulas giving the ratio of drawing stress to the wire strength. This paper refers to this ratio as the DSR. As a theoretical limit, this ratio, or DSR, must remain below 1 for the wire not to break (or stretch and break). From a workaday viewpoint, DSR must be much lower than 1, say 0.7, to keep wire breaks at a practical minimum. This is because flaw growth from even small inclusions becomes pronounced above a DSR of 0.7, and because of inertial forces, occasional vibrations, effects of bending stresses at the capstan, and lubricant variations, among other factors1,2. On the other hand, many conventional pass schedules result in much lower values of DSR, say 0.4 – 0.5, simply because the reductions taken are much smaller than could be achieved.

The drawing stress is literally the work done or energy consumed during the drawing pass, and it can be summarized as follows: drawing stress = uniform work (to stretch the wire) + non-uniform work + friction work.

Since all of the work terms to the right of this word equation are proportional to the strength of the wire, it is common practice to divide the equation on both sides by wire strength, resulting in the ratio of drawing stress to the wire strength, or DSR, as noted in the previous paragraph. That is: DSR = (uniform work)/(strength) + (non-uniform work)/(strength) + (friction work)/(strength).

The non-uniform work involves reversed or redundant shearing of the wire as it goes through the die, and is minimal for small die angles and large reductions. If one ignores the non-uniform work, and assumes (unrealistically) that friction is absent, it is easy to calculate a maximum possible reduction in wiredrawing, namely for the case of DSR = 1. That is, the two terms on the right in the above equations can be set to zero, and (uniform work)/(strength)

can be given as the true strain of the drawing pass or the natural logarithm of the initial cross sectional area, A 1 , divided by the final cross sectional area, A2. Therefore, DSRmax = 1 = ln (A1/A2) = ln [1/(1-rmax)],

Eq. (1)

where r is the decimal reduction (100 x r = % reduction). From this, one can show that rmax = 0.632 or 63.2%. Actually, this maximum theoretical reduction can be even larger if the wire work hardens during the drawing pass, as will often be the case in the first passes taken on an annealed wire or as-cast rod. This is because the average strength of the wire during the pass (affecting the drawing work) is less than its strength at the end of the pass and therefore less than its breaking strength.

However, in most drawing passes the strength change is fairly small, and for the most practical analysis the average strength can be used, as though it were constant.

Returning to the subject of this paper, frequent breaks occur when the DSR is too high, and the level of the DSR depends on the reduction, r, on the die semi-angle or half-angle, α (in radians), and on the friction coefficient, μ . A practical basis for calculating DSR,

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inclusive of non-uniform work and friction work, is given as follows: DSR = [(3.2 / Δ) + 0.9] (α + μ) , Eq. (2) where Δ is given by: Δ = (α / r) [1 + (1 – r)½ ] 2 .

Eq. (3) It should be noted that Eq. (2) does not include an effect of back stress, or a tension on the wire going into the die.

Where back tension is significant, its force must be considered in determining the drawing force, and the DSR will generally be higher. The discussion below does not include an effect of back force, and it is often neglected in such analyses. For more information, see the author’s paper on back tension3.

Breaks without significant flaws Basically, wire breaks will become frequent when DSR exceeds a critical level. In laboratory drawing conditions or in contexts where only short lengths of (expensive) wire are developed, DSR may be as high as 0.9. In more typical, high productivity drawing, a DSR limit of 0.7 has been argued to be consistent with the avoidance of flaw growth and with long term drawability 1. Such a value of DSR can easily be designed into the pass schedule if lubrication

Die Semi-Angle

achieves a steady value of the coefficient of friction, μ. Thick film lubrication (solid soaps or high speed hydrodynamic conditions) can be roughly characterized by a μ value of 0.03, wet, bright drawing conditions by a μ value of 0.10, and high (but somewhat practical) friction drawing by a μ value of 0.15. Moreover, low die angles can be advantageous with good lubrication (low values of μ ). To illustrate this, maximum reductions, consistent with DSR values of 0.7, are set forth in Table 1.

The calculations in Table 1 show only a modest affect of die angle on maximum drawing reduction. It should be remembered, however, that the die angle and friction coefficient are not really independent. Frequently a lower die angle will improve lubrication and lower the friction coefficient. On the other hand, marginal lubrication can be made worse with decreased die angle.

Drawing schedule design for the case of high friction has been recently discussed by this author4.

In any case, friction is the dominant factor in limiting the maximum drawing reduction for wire without significant flaws. For the case of good thick film or hydrodynamic lubrication (μ = 0.03 in Table 1), drawing reductions approaching 40% should be practical without frequent breaks due to high DSR. For the wet, bright drawing case

Friction Coefficient

Maximum Reduction

4° (0.070 radians) 4° (0.070 radians) 4° (0.070 radians)

0.03 0.10 0.15

41% 25% 18%

6° (0.105 radians) 6° (0.105 radians) 6° (0.105 radians)

0.03 0.10 0.15

43% 28% 22%

8° (0.140 radians) 8° (0.140 radians) 8° (0.140 radians)

0.03 0.10 0.15

43% 30% 23%

10° (0.175 radians) 10° (0.175 radians) 10° (0.175 radians)

0.03 0.10 0.15

42% 30% 24%

Table 1. Calculated maximum reductions for a range of die angles and friction conditions, based on a DSR value of 0.7.

50 WIRE JOURNAL INTERNATIONAL

(μ = 0.10 in Table 1), drawing reductions approaching the 25 to 30% range should be practical without frequent breaks due to high DSR. However, it is clear that when lubrication becomes marginal (μ = 0.15 in Table 1), even a standard AWG reduction of 20.7% may be inviting frequent breakage.

The practical implication is that a sudden increase in drawing break frequency, with no associated flaw populations, can usually be associated with increased friction, as identifiable by a change in surface quality 5. For that matter, an increase in drawing break frequency associated with historical flaw incidence can usually be related to increased friction.

Wright

Professor Roger N. Wright, who joined the faculty at Rensselaer Polytechnic Institute in 1974, has contributed broadly to the literature in the areas of metallurgy and metals processing, and is active as a short course lecturer and consultant. He previously worked at Allegheny Ludlum Steel Corporation and Westinghouse Electric. He holds B.S. and Sc.D. degrees in metallurgy from Massachusetts Institute of Technology. He has received The Wire Association International’s Mordica Memorial Award and is a three-time winner of the WAI Marshall V. Yokelson Memorial Award. He is a registered professional engineer, and a fellow of ASM and SME. This paper, which was presented at the WAI’s 76th Annual Convention, Boston Massachusetts, USA, May 2006, won the best paper award in the nonferrous category.

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Breaks with significant flaws One reason for not having a DSR value above 0.7 is that, above such a value, ductile fracture mechanics theory suggests that even small “normal,” largely unavoidable inclusions can be expected to grow with each pass, leading ultimately to drawing breaks 1,6.

However, limited quality wire and poor drawing practice may involve pre-existing flaws, or flaws that grow at DSR levels well below 0.7. Many drawing breaks display such flaws.

As noted, levels of the DSR well below 0.7 can lead to the rapid growth of flaws larger than the small inclusions cited above. When flaw size becomes a significant fraction of the wire cross section, A, fracture mechanics analyses often employ the net section stress, σns , or the stress obtained by dividing the tensile load, P, by the cross sectional area, A – Af , that remains after subtracting the area of the flaw, Af , in that cross section. That is,

σns = P/(A-Af) = (P/A)[A/(A-Af)] = σ /(1- Af /A) , Eq. (4) where σ is the nominal stress, P/A. In the case of wire drawing, σ simply becomes the nominal draw stress value, σd , and

σns = σd /(1- Af /A).

Eq. (5)

For example, if a flaw of one-fifth the wire cross sectional area comes along, [Eq. 5] indicates that the net section stress, σns , will be at a level of 1.25 σd.

Of course, in relation to stress terms, DSR = σd / σy , where σy is the wire strength. As noted above, when the DSR is 0.7 or more, even small inclusions can be expected to grow with each pass, leading ultimately to drawing breaks.

Similar reasoning leads to the conclusion that any flaw will grow when the related σns /σy is 0.7 or more. Substituting σd / DSR for σy, one can expect flaw growth when (σns /σd ) x DSR is 0.7 or more. Inserting the relations of the stresses to P, A and Af , leads to the expression: (Af /A) = 1 – [DSR / (0.7)],

Eq. (6)

where (Af /A) is the relative flaw size that should grow rapidly at a given DSR

level. Note that for the previously discussed DSR level of 0.7, the value of Af goes to zero, and any flaw size should, in principle, grow.

Consider the routine conditions of wet drawing (μ = 0.10) with an AWG reduction of 20.7% and a die semi-angle of 8°. Eqs. 2 and 3 lead to a DSR value of 0.53. Inserting this value into Eq. (6) leads to an (Af /A) value of about onequarter. Many drawing breaks reflect flaw sizes of this order.

Another approach to the impact of flaw size on drawing breaks has been taken by this author in a paper on the drawing of ultra-fine wire7. A drawing break frequency model was developed, namely: B/L = (π/4) N C d2 (DSR), Eq. (7) where B/L is breaks per unit length, N is flaws per unit volume, d is flaw size, and C is a “fracture constant” inversely related to wire toughness. A semi-quantitative examination of some common wiredrawing observations suggested that C is about 4 for very tough, fracture resistant wire material, about 8 for average toughness and much higher for relatively brittle wire. In another semiquantitative consideration, experience with ultra-fine wire drawing suggests, by way of Eq. (7), that a cubic meter of high performance copper rod could be expected to contain, develop or sustain no more than the order of 50 flaws that will lead to a drawing break.

The direct implication of Eq. (7) is that, in principle, the number of breaks per length is independent of the wire diameter. This may be a bit surprising, given the extraordinary increases with break frequency observed in drawing ultra-fine wire to lighter and lighter gages. However, the values of C, d, and N may be affected by continued drawing to lighter gage. In particular, with d appearing as a squared term, flaw growth should have a major impact on breaks per unit length.

While Eq. (7) has been developed to provide perspective on break-frequency-sensitive ultra-fine wire technology, its semi-quantitative consideration for heavier gage drawing is recommended.

Certainly the roles of the DSR and flaw size are obvious. On the other hand, the values of N pertinent to ultra-fine wire

drawing are no doubt much higher than those pertinent to intermediate gage.

Applications to wire break phenomenology/classification Numerous studies of wire break phenomenology are available in the literature, including excellent scanning electron fractographs that indicate much about the mechanics, and relevance of flaw development for a given break. A pictorial review of such behavior is beyond the scope of this paper. However, the following break categories are a useful basis for discussion of the above mechanical perspectives.

Category I: Breaks that do not reflect general wire quality or damage from passage through the die. Breaks at cuts, abrasions and welds are prominent examples. The implication of Eq. (6) is that such flaws should be of a size well within an order of magnitude of the wire diameter to lead to short range breaks.

Breaks at capstans, wire crossovers and wire route contacts (sheaves, guides, etc.) are other examples of Category I. It is important to realize that for a wire of diameter D and a “mandrel” of diameter M, the bending strain at the wire surface is given by 1/(1+M/D) or about D/M, when D is much smaller than M. A bending tensile strain of 0.1% on the convex side of the bend will add grossly to the local surface axial stress on the as-drawn wire. Hence, a wire with a diameter of 1 mm will probably undergo plastic deformation in contact with a mandrel with a diameter of a meter, and a wire with a diameter of 0.1 mm will probably undergo plastic deformation in contact with a mandrel with a diameter of only 10 cm. Moreover, any finite contact (not just a wrap or so) will have this effect. Thus, some breaks are seen to occur at initial capstan contact, and wire crossovers can be especially devastating upon initial capstan contact.

Category II: Breaks that primarily reflect mechanical conditions during passage through the die. This category includes some classic drawing break behavior. Cases consistent with the conditions discussed above (under Breaks without Significant Flaws) are generally referred to as “tensile breaks”. In such cases the wire break appears little dif-

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ferent than the fracture of such a wire in a tensile test, complete with radially symmetric necking and final fracture area consistent with the area reduction in a tensile test8 As noted above, such breaks generally reflect a large increase in drawing friction, including “sticking” friction (average friction coefficient of, say, 0.25).

A second major class of a Category II drawing break is that of breaks associated with large “crow’s feet,” which are arrowhead shaped surface tears reflecting stick-slip lubrication 8,9. Though often small initially (10–100 μm), through repeated friction and with relatively high DSR levels, the crow’s feet grow to a size well within an order of magnitude of the wire diameter, and hence cause breaks. As with tensile breaks, “crow’s feet” breaks are generally reflective of marginal lubrication.

A third major class of a Category II drawing break is that of breaks associated with “center bursts”.8 Referring to Eq.[3], it can be shown that with Δ values of 3 of higher, tensile stresses are developed at the wire centerline leading to the opening of pores and even large chevron-like internal cracks, particularly when the centerline is of inferior metallurgical quality from the casting process. In some cases, center bursts may be associated with even lower values of Δ, and will be generally exacerbated with increased die angle and decreased per pass reduction, as well as increased friction. Somewhat like the case of “crow’s feet,” center bursts may be small pores initially, but with repeated drawing grow to a size well within an order of magnitude of the wire diameter, and hence cause breaks.

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Category III: Breaks where metallurgical or microstructural flaws greatly accelerate the mechanisms of Category II. These flaws include centerline porosity and centerline impurity concentrations due to casting, residual surface scale not removed in rod conditioning, and so-called exogenous inclusions such as rolled-in “dirt” and primary processing or melting hardware particles.

Though often small initially, through repeated drawing and with relatively high DSR levels, the exogenous inclusions grow to a size well within an order of magnitude of the wire diameter, and hence cause breaks.

Summary Mechanical perspectives regarding drawing breaks have been set forth, using the ratio of drawing stress to wire strength (DSR) as a basis, together with the implications of flaw size. In the case of breaks in wire without significant flaws, i) a critical DSR level of 0.7 has been cited, ii) drawing reduction limits have been developed for combinations of die angle and friction coefficient, and iii) increased friction is seen as the most important factor en route to high DSR levels. In the case of breaks in wire with significant flaws, a relationship between DSR and critical flaw size has been developed, and the implications of an ultra-fine wire drawing model have been examined. The mechanical perspectives set forth have been applied to the explanation of three categories of common drawing breaks.

References 1. R. N. Wright, Wire Journal International, April 2005, pp. 116-118.

2. B. Avitzur, Conference Proceedings, 65th Annual Convention, Wire Association International, Inc., Guilford, Connecticut, USA, 1998, p. 85.

3. R. N. Wright, Wire Journal International, May 1999, pp. 118-122.

4. R. N. Wright, Wire Journal International, January 2005, pp. 76-78.

5. R. N. Wright, Process ModelingFundamentals and Applications to Metals, 1981, American Society for Metals, Metals Park, Ohio, USA, pp. 409-28.

6. J. R. Rice, Fatigue Crack Propagation, ASTM Special Technical Publication 415, American Society for Testing and Materials, Philadelphia, Pennsylvania, USA, 1967, p. 257.

7. R. N. Wright, Wire Journal International, January 2004, pp. 56-57.

8. R. N. Wright, Wire Journal International, May 1982, pp. 86-90.

9. R. N. Wright, Wire Journal International, August 2002, pp. 86-90. ■

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Residual stresses and hydrogen embrittlement in cold-drawn eutectoid steel wires Controlling surface residual stresses has been shown to be a very important factor in terms of improving the performance of prestressing steel wire in aggressive environments.

By Jose Miguel Atienza, Manuel Elices, Jesus Ruiz-Hervias and Luis Caballero

Cold-drawn eutectoid steel wires can

be considered as a nanocomposite material (consisting of very fine ferrite and cementite lamellae) with outstanding properties of strength and toughness.

These wires and strands are the active tendons in prestressed concrete structures, form the cables in mine shafts and off-shore petroleum production, and are used as reinforcing steel cords for tires.

Although prestressing steel wires have excellent mechanical properties (high strength and high elastic limit combined with reasonable ductility), there is a pressing need for the improvement of their durability in aggressive environments. A significant number of prestressed structures (mainly bridges) near marine environments have suffered problems of stress corrosion cracking.

Delayed fracture of cold-drawn eutectoid steel wires may be due to a subcritical crack initiation and its subsequent propagation, as occurs in failures due to fatigue, or to environmental-assisted cracking, or to a combination of both.

There is general agreement that hydrogen embrittlement plays an important role in the environmental cracking of eutectoid cold-drawn steels1. This paper focuses on this aspect of the problem.

Delayed wire failures are influenced by surface defects and by the presence of residual stresses, as was shown by the authors2-3. Later improvements in the measurement of residual stresses and of

computing power have provided more information on this subject, and recent work on the role of residual stresses in the hydrogen embrittlement of eutectoid cold-drawn wires is reported here.

Three types of wires were tested: wires as-drawn (with high surface tensile residual stresses) were compared with stabilized wires, wires after a thermomechanical stress-relieving treatment (with

Table 1. Mechanical properties of steel wires.

Fig. 1. Residual longitudinal (axial) stresses as a function of relative depth, for as-drawn, stabilized and rolled wires. Results from combination of finite element calculations and experimental measurements by X-ray, neutron and synchrotron diffraction techniques7-11.

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Fig. 2. Rupture times (hours) in the stress corrosion test at different applied loads, for as-drawn, stabilized and rolled wires. low residual stresses) and with rolled wires (with surface compressive stresses). The differences in the times to rupture of these wiresâ&#x20AC;&#x201D;with the same microstructure, surface quality and mechanical propertiesâ&#x20AC;&#x201D;appear to be due to differences in the profiles of the residual stresses. The presence of residual

Atienza Jose Miguel Atienza teaches in the materials science department at Madrid Polytechnic University, Spain, where he started as a researcher in 1998. His areas of scientific interest include steel wire for prestressed concrete and biomaterials. He has a Ph.D. in civil engineering from Madrid Polytechnic. M anuel Elices is a full professor of materials science and technology at Madrid Polytechnic and dean of the faculty for materials science and engineering. He is a Foreign Member of the National Academy of Engineering (USA). His professional

54 WIRE JOURNAL INTERNATIONAL

stresses may also help to explain the scatter in times to rupture, the disappearance of a hydrogen embrittlement stress threshold, and the saturation in rupture time above certain values of the testing loads.

All these findings call for a control and, whenever advisable, to act on the

Elices

Ruiz-Hervias

and research work has been centered mainly on cracking and fracture of materials. Jesus Ruiz-Hervias is an associate professor in the materials science department at Madrid Polytechnic. His research interests include residual stress measurement by X-ray, neutron and synchrotron diffraction in metals and ceramics, structural integrity assessment of Zr-alloy claddings and environmentally assisted cracking in prestressing steel, and high-strength aluminum alloys. He began his career as a researcher in 1988. He holds a Ph.D. in physics from

surface residual stresses to improve the mechanical performance of cold-drawn eutectoid steel wires in aggressive environments. Also, in this work, a postdrawing treatment to generate compressive residual stresses at the surface is proposed.

Caballero Complutense University of Madrid.

Luis Caballero is associate professor in the materials science department at Madrid Polytechnic. He has experience in structural integrity assessment, corrosion, and environmentally-assisted cracking in prestressing steel and high-strength aluminium alloys. He holds a Ph.D. in physics from Complutense University of Madrid. This paper was presented at WAIâ&#x20AC;&#x2122;s 76th Annual Convention, Boston, Massachusetts, USA, May 2006.

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Materials: cold drawn wires As the purpose of this paper is to compare the stress-corrosion susceptibility of commercial steels for prestressing concrete with different residual stresses, steels were selected with the same microstructure and similar mechanical properties, differing only in their profiles of residual stresses. With this aim, three sets of wires were prepared and tested: The first one, “as-drawn,” was manufactured by cold-drawing 12 mm eutectoid steel rods, following a commercial procedure. After eight drawing passes the final diameter was 5.20 mm. This set, without any further treatment after drawing, was intended to have high tensile surface residual stresses.

The second one, “stabilized,” was obtained by applying a commercial thermo-mechanical stress-relieving treatment known as stabilizing to the as-drawn wires. They are the type used nowadays in prestressed concrete structures.

The third set, “rolled,” was processed in the laboratory by a controlled rolling of stabilized wires. A small plastic deformation is produced on the wire surface by an apparatus composed of three rollers. Two of them are used only for alignment and the third one produces a lamination similar to a “massage” on the wire surface. The resulting final residual stress profile depends on the lateral force imparted to the main roller. It is thought that compressive residual stresses can be induced on the wire surface. The literature4 includes a description of this procedure, which has an effect similar to the use of a specific last drawing die, yielding a very little reduction of area. This treatment, called a skin pass, can also decrease -or even change- the sign of the tensile surface residual stresses 5-6 .

Despite its advantages, the skin pass has been discarded by the prestressing wires manufacturers, at least in Spain.

Table 1 summarizes the mechanical properties of the three types of wire. The figures are the average in 12 tests of asdrawn wires, nine tests of stabilized wires, and six tests of rolled wires.

Fig. 3. Computed axial stress profiles (applied plus residual stresses) in the cross section of the wires at different loads. A. As-drawn wires: notice that σm and 0.5σ σm bear similar stresses at the surface. B. wires loaded between 0.8σ σm bear similar near surface stresses Stabilized wires: wires loaded of 0.8σ σm or 0.30σ σm. C. Rolled wires: wires than as-drawn wires loaded at 0.40σ σm bear similar surface stresses than as-drawn wires loaded at loaded at 0.8σ σm.

0.06σ

Residual stresses In recent years, the authors have sought to characterize the profiles of residual stresses generated by drawing, how they are modified by subsequent treatments

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and their influence on the final properties of the wires, with a summary of the main results reported in this work. Fig. 1 shows the profiles of axial residual stresses along the wire diameter as a function of relative depth in as-drawn, stabilized, and rolled wires. These results were obtained by the combination of finite element calculations and experimental measurements7-14.

The numerical computation used the finite element method with the help of ABAQUS Code 15 . The material was considered homogeneous and an elastoplastic law with strain hardening was chosen to model the rod behavior. The constitutive equation employed as the initial data of the model is the stressstrain curve of the eutectoid steel before drawing, measured in the laboratory. The dies have been modeled as an elastic material with the elastic modulus of tungsten carbide. The contact between the rod and the die has been reproduced with a Coulomb friction coefficient. A detailed description of numerical modeling was reported in7-9.

The accuracy of numerical simulation was checked with experimental results of stresses measured by synchrotron, neutron and conventional X-ray diffraction.

In this work, measurements were carried out in three different neutron diffractometers (NFL-Studsvik-Sweden8, ISISGreat Britain10 and NIST-EEUU11 and in the ESRF-synchrotron in Grenoble (France)10. Cold-drawn eutectoid steels are a nanocomposite of two phases: ferrite and cementite. Macrostress in this material was determined by the stress experimentally measured in the two phases weighted with the relative percentage of every phase (rule of mixtures, with 90% ferrite and 10% cementite in this case). The non-destructive measurement of residual stresses in the cementite phase of cold-drawn pearlitic steels is difficult because of its low volume fraction and its orthorhombic structure. An effort was made to measure a profile of stresses in cementite in cold- drawn eutectoid rods by using synchrotron radiation. Details can be found in the literature10.

Hydrogen embrittlement tests Susceptibility to environmental cracking should be assessed by testing stressed samples exposed to the pertinent

56 WIRE JOURNAL INTERNATIONAL

aggressive environment and by recording times to fracture. As already mentioned, there is a general agreement that hydrogen embrittlement plays an important role in environmental assisted cracking in cold-drawn eutectoid steels. The International Federation for Prestressing (FIP) proposed the ammonium thiocyanate test in 197816-17 to control the susceptibility of these steels to hydrogen embrittlement. This test is suitable for quality control of one grade of steel and for comparison of different grades of the same type of steel. A statement of general agreement from prestressing concrete engineers, which in the authors’ opinion has hardly changed since then, was published in 198218.

The FIP test uses an aqueous solution of ammonium thiocyanate (NH4SCN) in contact with the steel. The test determines the time to fracture of a steel wire loaded at a constant tensile force of 0.8 Fm (where Fm is the maximum tensile load) and immersed in a NH4SCN solution (200 grams of NH4SCN in 800 ml of distilled water) at a constant temperature of 50±1°C. A drawback of the FIP test is the occasional scatter in the rupture time. This is influenced by the presence of residual stresses, as was shown by the authors2-3.

With the advent of powerful experimental techniques for the measurement of residual stresses—such as neutron and X-ray diffractometers—and of faster computers to simulate numerically the wire drawing processes, this phenomenon is seen now in a new light.

The hydrogen susceptibility of the three sets of wires was measured by the FIP test. Six samples of each steel, following ISO recommendation 17, were tested. The average time to rupture was: 2.0 hours for as-drawn wires, 4.2 hours for stabilized wires and 12.0 hours for rolled wires.

In addition, to explore the influence of external loads and their interaction with residual stresses, additional tests at lower loads were performed. The as-drawn wires were tested at 0.70, 0.60, 0.50, 0.40, 0.30, 0.20, 0.10 and 0.06 and 0.02 of the maximum load (Fm = 41.2 kN).

The stabilized wires were tested at 0.70, 0.60, 0.50, 0.40 and 0.30 of their maximum load (Fm = 39.3 kN), and the rolled wires were tested at 0.75 and 0.70 of their maximum load (Fm = 39.7 kN). The

experimental results are given in Fig. 2 (Time to rupture and applied load).

Discussion Rupture times in the NH4SCN tests of as-drawn wires loaded at 0.8 σm = 1550 MPa, 0.7 σm = 1360 MPa, 0.6 sm = 1165 MPa and 0.5 σ m = 970 MPa, show a striking coincidence—of about two hours—whatever the stress level, as shown in Fig. 2. Residual stresses can explain this behavior. When the specimen is loaded in the stress corrosion test, the actual stress profile in the cross section is obtained by adding the constant applied stress to the existing residual stress profile until the yield stress is reached at any point. In the case of the as-drawn wire, the axial residual stress is tensile at the surface (see Fig. 1). Consequently, the resulting stress at the surface during the test is higher than the applied stress and it can reach the yield stress even at small applied loads.

Fig. 3a shows the actual computed profiles of axial stresses, as a function of relative depth (r/R), at different applied loads in the tests. This figure clearly shows that the stress level inside the wire’s outer layer—a thickness of about 0.75 mm—is almost the same at all loads between 0.8 σm and 0.5 σm, due to the early plastification of this zone. Previous results2,3 showed that the surface damage—modeled as an ideal surface crack—that can trigger fracture by hydrogen embrittlement, should have a crack with a depth of 0.1 mm, or less.

Consequently, all the samples loaded between 0.8 σm and 0.5 σm are subjected to the same damage.

In the case of the stabilized wires the average time to rupture measured in the FIP test (0.8 σ m = 1480 MPa)—4.2 hours— is similar to the rupture times of as-drawn wires loaded at 0.4 σm = 776 MPa, or even at 0.3 σm = 582 MPa, as shown in Fig. 2. Fig. 3b shows the actual profiles of longitudinal stresses as a function of relative depth (r/R) in stabilized wires loaded at 0.8 σm, and in asdrawn wires loaded at 0.4 sm and 0.3 σm.

As shown in the figure, the outer layers of wires are subjected to similar stress values. This may explain the coincidence of rupture times in these different tests, provided that both types of wire had the same surface conditions.

The large differences in rupture times

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between rolled wires and as drawn wires may be justified, again, by the presence of quite different profiles of residual stresses. The time to rupture for rolled wires, tested at 0.8 σm = 1500 MPa, was 12.0 hours, similar to the average time to rupture (11.0 hours) for as-drawn wires tested only at 0.06 σm = 116 MPa. Looking at the surface stresses—where cracks originate—it can be noticed, from Fig. 3c, that both wires sustain similar loads able to trigger the fracture.

Finally, from Fig. 2, it appears that asdrawn wires do not exhibit a stress threshold for hydrogen embrittlement, while stabilized wires may have a threshold at stresses below 500 MPa, which amounts to 0.27 of the rupture load and rolled wires appear to have a much higher threshold, as tests performed at 0.70 of the rupture load lasted for more than 1000 hours. It was suggested that in similar steel wires, a stress threshold of hydrogen embrittlement of about 600 MPa should exist 3. The absence of a stress threshold of hydrogen embrittlement in the set of as-drawn wires can also be justified by the presence of high surface tensile residual stresses. The asdrawn wires we used have tensile surface residual stresses of around 500-600 MPa (see Fig. 1), enough to explain the absence of a stress threshold, particularly when cracks with depths less than 0.1 mm can trigger fracture in this test. The same can be said for rolled wires: Residual stresses at the surface can “mask” the actual stress threshold of the material.

Summary A good correlation was found between residual longitudinal stresses and times to rupture in the stress corrosion test proposed by the International Federation of Prestressing. Important differences in rupture times can be achieved in colddrawn pearlitic wires by changing their profiles of residual stresses, specially at the wire surface. All these findings call for a control of surface residual stresses to improve the performance of prestressing steel wires in aggressive environments. Residual stresses after cold-drawing can be substantially modified by thermo-mechanical treatments, such as stabilizing, which is the one employed nowadays by manufacturers, and improved further by rolling, or by a supplementary drawing with a very small

reduction of area. Decreasing the adverse surface tensile stresses, or even changing to compressive stresses, the wire fatigue limit and the environmental assisted cracking will be significantly improved.

This would be important for prestressing industry, specially for structures in the vicinity of aggressive environments, i.e. near the coast.

Acknowledgements The authors gratefully acknowledge the support of the Spanish Ministry of Fomento by means of the grant “Durability of prestressed concrete tendons.”

Help and useful comments from Luis del Pozo, from Emesa Trefilerías, S.A. are also acknowledged.

References 1. D.G. Enos and J.R. Scully, “A critical-strain criterion for hydrogen embrittlement of cold-drawn, ultrafine pearlitic steel,” Metallurgical and Materials Trans. A, 2002, Vol. 33, pp. 1151-1166.

2. M. Elices, G. Maeder and V. Sánchez-Gálvez, “Effect of surface residual stress on hydrogen embrittlement of prestressing steels,” British Corrosion Journal, 1982, Vol. 18(2).

3. V. Sánchez-Gálvez and M. Elices, “On hydrogen induced cracking in prestressing steels wires,” In Life Assessment of Dynamically Loaded Materials and Structures, (L. Faria, Ed.) 1984, Vol. 2, pp. 1003-1014.

4. O. Maluf, M.T. Milan and D. Spinelli, “Effect of surface rolling on fatigue behaviour of a pearlitic ductile cast iron,” J. Materials Engineering and Performance, 2004, Vol. 13, pp. 195-199.

5. H. Godfrey, F. Richards and S. Sason, “The benefits of using wiredrawing dies with smaller inlet angles and longer nibs,” Wire Journal International, June 2000, pp. 102-113.

6. M. Asakawa, T. Hatakeyama, Y. Tamura, S. Kajino, S. Shishido and S. Shimizu, “Producing bar and wire with ultra-smoothing and lower residual stress by new drawing,” WJI, April 2004, pp. 144-151.

7. J.M. Atienza, “Residual stresses in cold drawn steel wires,” PhD Thesis, Polytechnique Univ. of Madrid, 2001.

8. J.M. Atienza, M.L. Martinez-Perez, J. Ruiz-Hervias, F.J. Mompean, M. Garcia-Hernandez, M Elices, “Residual

stresses in cold drawn ferritic rods,” Scripta Materialia, 2005; 52: pp. 305309.

9. J.M. Atienza, J. Ruiz-Hervías, M.L. Martínez-Perez, F.J. Mompeán, M. García-Hernandez and M. Elices, “Residual stresses in cold drawn pearlitic rods.

Scripta Materialia, 2005, 52, pp. 12231228.

10. M.L. Martinez-Perez, F.J. Mompean, J. Ruiz-Hervias, C.R. Borlado, J.M. Atienza, M. García-Hernandez, M. Elices, J. Gil Sevillano, Ru Lin Peng and T. Buslaps, “Residual stress profiling in the ferrite and cementite phases of cold-drawn steel rods by synchrotron Xray and neutron diffraction, Acta Mater, 2004, (52), pp. 5303-5313.

11. J. Ruiz-Hervias, V. Luzin, H. Prask, T. Gnaeupel-Herold and M. Elices, “Effect of thermo-mechanical treatments on residual stresses measured by neutron diffraction in cold-drawn steel rods,” Submitted to Acta Mater, 2005.

12. M. Elices, “Influence of residual stresses in the performance of colddrawn pearlitic wires,” J. of Materials Science, 2004;39 (12), pp. 3889-3899.

13. J.M. Atienza, M. Elices, “Influence of residual stresses in the tensile test of cold drawn wires,” Materials and Structures, 2003, 36, pp. 548-552.

14. J.M. Atienza and M. Elices, “Influence of residual stresses in the stress relaxation of cold drawn wires,” Materials and Structures, 2004;37: pp. 305310.

15. Hibbit, Karlsson & Sorensen, ABAQUS Manual, Version 5.8, 1998.

16. FIP-78 (Stress Corrosion Test), “Stress corrosion cracking resistance test for prestressing tendons,” Technical Report No. 5 (FIP, Wexham Springs, Slough, UK), 1978.

17. ISO/DIS 15630.3, “Steel for the reinforcement and prestressing of concrete. Test methods. Part 3: Prestressing steel,” Section 10.

18. M. Elices, V. Sánchez-Gálvez, I. Bernstein and R.N. Parkins, “Summary of a meeting of stress corrosion cracking and hydrogen embrittlment of steels for prestressing concrete,” In Hydrogen Problems in Steel, (C.G. Interrante and G.M. Pressouyre, Eds.), ASM, 1982, pp.

304-307. ■

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Method and material for manufacture of rectangular wire coil springs without dynamic strain aging Dynamic strain aging, which can result in a loss of ductility, was found to be controllable by limiting the levels of interstitials and the addition of boron.

By Anand W. Bhagwat and Steven S. Wray

ynamic strain aging is a phenomenon D in which metals experience localized and sudden loss of ductility and increase in yield strength. It occurs when the interstitial atoms

and dislocations interact during deformation.

Conditions under which the phenomenon occurs in steel include strain rate and temperature, and are unique to the steel chem-

Fig. 1. A regulator spring in finished condition.

58 WIRE JOURNAL INTERNATIONAL

istry, primarily carbon content. Increasing the strain rate raises both the lower and upper temperature limits associated with the dynamic strain-aging phenomenon.

In spring coiling of metal wire containing interstitial solutes atoms, such as carbon, nitrogen and oxygen in iron, the work hardening rate or loss of ductility occasionally becomes abnormally high in the heat affected zone (HAZ) during the coil formation.

The work-hardening rate of the metal wire is also strain-rate and temperature dependent.

Literature has documented that there is a maximum work hardening rate for the metal wire corresponding to a specific strain rate, above and below which the work hardening rate is lower. Further, if the temperature

Table I. Composition of steel to control interstitials (in weight percent).

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of the metal wire being coiled is raised, the strain rate at which maximum work hardening occurs also rises.

In steel, the dynamic strain-aging phenomenon is frequently called blue brittleness. The term blue brittle comes from the blue oxide formed on the fracture surface.

Dynamic strain aging is particularly experienced in spring forming applications.

This paper relates to regulator springs, as shown in Fig. 1, made of a rectangular cross-section wire. In practice, the wire breakage occurs at the intersection of 10a and 10b in Fig. 1. The paper outlines modifications to steel chemistry and a method of forming springs to combat such breakage.

Procedure The current steel grade contained 0.65% carbon by weight percent. In the revised steel grade, the carbon content was limited to a maximum of 0.63% to control the amount of interstitials. Further, boron was

added to contain nitrogen in compound form instead of free interstitials. The boron addition was aimed at maintaining the N/B ratio at 0.84%, which is the stoichiometric ratio for boron nitrides. Both the current and revised steel chemistries are given in Table I. A rectangular wire size 0.150” (3.81 mm) x 0.625” (15.87 mm) was selected for the experiment. The wire was cold rolled, and quenched and tempered to hardness of RC 42-45. Wire from the current chemistry was identified as “Wire A,” whereas, wire from the revised chemistry was identified as “Wire B.” In a typical spring coiling process, approximately one half inch of wire is heated to 1100oF–1300oF (600oC–700oC) to soften the wire. The wire is then held in a rotatable shaft of a spring coiling machine and a 90o bend is made to form the center bar, as shown in Fig. 2. The spring is then formed by rotating the shaft. In the current experiments, the diffused temperature of the wire

Fig. 2. The spring coiling process for a regulator spring. Rectangular wire (10) from a coil (20) is fed through a set of straightners (32) and heated at station 24. The wire is held in a rotatable shaft (30) and coiled into a spring.

at the intersection of 10a and 10b in Fig. 1 was measured. Hardness measurements were also made in this area and the results were compared with the remainder of the wire.

The wires were coiled into springs under following conditions and the coiling perfor-

Bhagwat Anand Bhagwat is managing director of WAI Wire & Cable Services, Pvt. Ltd., Pune, India. Most recently, he was vice president, quality and technology at Seneca Wire & Manufacturing Co., Fostoria, Ohio, USA. Prior to that he was principal metallurgist at the Goodyear Tire & Rubber Company. He has experience in wire manufacturing processes, product development and design, product failure analysis, and development of steel rod suppliers. He holds an M.B.A. degree and an M.S. degree in materials science, both from Case Western Reserve University, Cleveland, Ohio, USA, and a B.S. degree in metallurgy from the College of Engineering, Pune, India. He holds five patents in wire and tire reinforcement technology. Steven S. Wray is president of Seneca Wire & Manufacturing Co. He has a degree in metallurgical engineering from the University of Oklahoma. He has more than 20 years in the wire industry working in areas of quality management, operations and general management before coming to Seneca Wire in 1999. This paper was presented at WAI’s International Techncial Conferenmce, New Delhi, India, October 2006.

Fig. 3. A finished spring is sheared at point 14 to separate from the coil.

Formation of a center bar (16) and hook (18g) is accomplished by heating the wire at station 24.

JUNE 2007 59

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Conclusions The phenomenon of dynamic strain aging and the role of interstitials as one of the root causes have been understood for decades.

The present work recognized occurrence of this phenomenon in regulator springs and developed a boron-added steel to eliminate it.

The results showed that dynamic strain aging in AISI 1065 grade steel occurs at a characteristic strain rate and temperature if a high level of interstitials was present.

However, dynamic strain aging can be controlled by limiting the level of interstitials or by controlling its state. With the addition of boron, the free nitrogen was tied in a compound form as boron nitride. Similar effect can also be achieved by adding other elements, such as titanium.

Fig. 4. Fracture surface of a rectangular spring wire. Dynamic strain aging or blue brittleness was evident from the color at the initiation site.

mance, namely wire breakage, was noted under four different conditions: Condition 1: Coiling at a linear speed between 30 ft/min (10 m/min) and 150 ft/min (50 m/min), with the center bar still at an elevated temperature; Condition 2: Coiling at a linear speed below 30 ft/min, with center bar still at elevated temperature; Condition 3: Coiling at a linear speed above 150 ft/min, with center bar still at elevated temperature; and Condition 4: Coiling at a linear speed between 30 ft/min (10 m/min) and 150 ft/min (50 m/min), after allowing the center bar to cool to room temperature Results and discussion The present work describes two techniques to limit wire breakage during coiling, namely strain rate and control of inter-

60 WIRE JOURNAL INTERNATIONAL

stitials in steel. When wire with current steel chemistry was coiled under Condition 1, the dynamic strain aging occurred resulting in breakage of wire as illustrated in Fig. 4.

Hardness at the break was measured between RC 48 and 51, as compared to RC 42-45 in the rest of the area. However, when the same wire was coiled under either Condition 2, 3 or 4, the breakage did not occur.

When wire B made from the modified steel chemistry was coiled, breakage did not occur under any of the four conditions. Wire temperature in the center in Fig. 1 by 10b was consistently measured between 450oF and 600oF (230oC and 315oC).

Effectiveness of the new steel chemistry has been seen in terms of the reduction of the rejection rate at Seneca Wire & Manufacturing. The new chemistry was applied in June 2002. The drop in the number of occurrences and rejected weight was dramatic.

References 1. Method of Manufacturing Flat Wire Coil Springs To Improve Fatigue Life and Avoid Blue Brittleness, A. W. Bhagwat and S. S. Wray, U.S. Patent 7,055,244, 2006. â&#x2013;

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If you haven’t seen the latest WAI Connection online... ...you may be in the dark about late-breaking industry news.

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.

is all it takes to help us deliver The WAI Connection directly to you. But without your update, you may miss out.

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

Because when you move, so does WAI.

But if we don’t have your most current e-mail address, we’re both missing Connections! A quick e-mail message

Enlighten us with your updated e-mail address today!

The WAI Connection is an online publication of The Wire Association International, Inc. 1570 Boston Post Road • P.O. Box 578 • Guilford, CT 06437-0578 USA Tel.: (001) 203-453-2777 • Fax: (001) 203-453-8384 • Web site: www.wirenet.org

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Products Cable offers ultimate resistance to harsh conditions U.S.-based General Cable announced that its new line of Carol® Brand Super Vu-Tron® Supreme rubber cord, available in Types SOOW and SJOOW, features a proprietary, vulcanized jacket formulation that makes it virtually impossible to tear and provides the ultimate resistance to heat, cold, oil, ozone and chemicals.

Super Vu-Tron Supreme can withstand temperature extremes from -50ºC all the way to +105ºC and perform flawlessly even in the toughest industrial environments, a press release said, noting that the cable “is tough enough to be warranted for life.” The cable offers Class M stranding on all constructions for maximum flexibility and tinned copper conductors for enhanced soldering performance and corrosion resistance, it said. The integral Flexfill® design allows the jacket to be extruded into the

interstices of the cord instead of using a filler material, it explained, noting that “this provides a more compact cord, which enhances crush resistance, will not absorb water or oil, adds flexibility and makes it easy to strip for ease of handling.”

The design also allows “for a more consistent, convolution-free product appearance, which is often a major factor with standard rubber cord,” the release said. Its bright yellow jacket assures high visibility for safety and the jackets legend is permanent, helping to assure life-long, safe operation, it said. The durable jacket, it noted, is printed with RoHS, sequential footage marking and CE Mark on 10 and 12 AWG SOOW. Contact: General Cable Corporation, www.generalcable.com.

Cable makes pulling and identification easier Alcan Cable, a division of Alcan Inc.’s Engineered Products group, reports the introduction of its new STABILOY® FeederPlex™ cable, which it described as “an innovative solution for phase conductor identification in commercial and industrial applications.”

A press release said that FeederPlex consists of a plexed assembly of STABILOY Type XHHW-2 conductors with color coded phase conductors that saves on wire installation costs while providing clear phase identification. The STABILOY FeederPlex cables, which are UL listed and approved for use in accordance with NEC recommendations in the U.S., are available in three and four conductor assemblies in a

wide range of sizes, it said.

The light weight and flexibility of STABILOY aluminum conductors makes it easier to pull the conductor assemblies into a raceway during installation, the release said. The cable eliminates the need to assemble and parallel multiple conductors and minimizes the number of reels and product, it noted. It added that use of FeederPlex improves cable performance by providing lower voltage drop than the assembly of paralleled conductors.

Alcan Cable manufactures aluminum and aluminum alloy cables for a range of markets.

Contact: Alcan Cable, tel. 770-3949886; alcancable@alcan.com.

Lighting system offers easy connection via flat wire U.S.-based Southwire recently introduced a low-voltage wall lighting system based on the company’s patented FlatWire technology that allows the fixtures to be mounted anywhere on walls or ceilings and connected to an electrical outlet without drilling holes, pulling electrical wires or using extension cords.

The FlatWire Ready® lighting system, which includes a wide range of decoratorstyle sconces and complete Add-A-Light™ installation kits, is possible because of an ultra-thin flat wire, a press release said.

Unlike conventional round wire, FlatWire when finished with standard concealing and painting techniques creates a virtually invisible installation, it notes, adding that the system is UL-listed, safe, easy and quick for a professional to install.

Nearly 30 different lighting sconces are offered in a wide variety of decorator finishes and styles ranging from traditional to contemporary, the release said. Each kit can accommodate up to two fixtures and includes connectors, a wall plate, transformer, spray adhesive, mesh tape and 25 feet of low voltage FlatWire, it said. The sconce fixtures use a 12 volt, 20-watt halogen bulb, which uses less energy than a 60watt incandescent bulb but still gives about the same usable light output, it noted.

Contact: Southwire, www.southwire. com or go to www.flatwireready.com.

Mandrel wire for extruding catheter tubing offers a low coefficient of friction A new mandrel wire for extruding catheter tubing and other applications requiring a smooth, biocompatible mandrel which has a low coefficient of friction has been introduced by Applied Plastics Co., Inc. The medical extrusion mandrel is a silver-plated copper wire with a PTFE coating that allows over 25% elongation with-

62 WIRE JOURNAL INTERNATIONAL

out flaking and failure for the purpose of extruding precise small diameter medical tubing, a press release from the U.S.-based company said. It noted that the mandrel has a 0.05 dynamic coefficient of friction that provides a smooth, slippery surface to permit faster production.

The release said that the mandrel, developed to assure optimum tubing I.D. quality,

comes in .010 in. to .080 in. sizes with tolerances of ±.0003 in., depending upon the size. The product is supplied in continuous lengths on spools, is chemically inert and can withstand up to 315°C (600°F) service, it said. Samples are available upon request.

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

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Cable line designed for motion control applications U.S.-based Cicoil reports that it has introduced a standardized line of flat cables, designed specifically for motion applications, that are encapsulated in “glass-clear” silicone for superior flexibility.

The Motion Series cables are typically twice as flexible as other cables, with a bend radius as little as 1.5 inch, making them ideal for linear motion and tight-space applications, a press release said. The cables come in three designs for 1, 2 or 3 axes of servo motion, it said, noting that each config-

cables and eight signal cables for each axis of motion while the silicone encapsulation provides a solid, one-piece construction that creates a highly durable cable package, the release said. The cable will not deform, break or wear during a lifetime of more than 10 million cycles, even under high flex conditions and can handle extreme environments (temps from -65°C to +260°C), it said, noting standard cables are in stock for minimum lead times.

Contact: Cicoli, tel. 661-295-1295; www.cicoil.com.

urations is further available sized for 1KW, 2KW and 3KW servomotors.

The cable has four shielded power

Magnetic brakes work well for tubular stranding U.S.-based Magnetic Technologies Ltd. reports that it is supplying two new “Magnetic Pancake” brakes that excel for applications such as tubular stranding.

The brakes are 3.25 in. in diameter but only .5 in. thick, making it easy to replace existing rope or belt tensioning

designs, a press release said. “Unlike ropes and belts, the MTL pancake units hold the same torque day-in-dayout. They are not affected by RPM, temperature or time. They are infinitely adjustable and require no electricity.”

The brakes have a narrow design that makes it easy to use them to replace

Baum’s Castorine Co., Inc.

existing pulleys and ropes when retrofitting old stranders, the release said.

The smaller brake has a torque range from 0.03 to 1 in. lb and the larger brake from 0.5 to 3.5 in. lb, it said.

Contact: Magnetic Technologies, Ltd., tel. 508-987-3303; sales@ magnetictech.com.

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Gel-free, loose-tube fiber cable line offered in 3 plenum constructions Hitachi Cable Manchester (HCM) has introduced its NanoCore™ line of fiber optic cables, which includes three new constructions of plenum-rated gel-free, loose tube fiber optic cables.

The constructions, a press release said, include a 12 to 24 fiber optic strand zip cord, a single jacket construction that can accommodate from 2 to 12 strands and a more robust dual-jacket construction capable of accommodating up to 72 strands.

Where more than 12 strands are present, they are separated by a colored binder

into12-strand bundles, it said.

The cables, designed to work with MT, MTP/MPO and other small form function connectors, offer higher fiber strand counts in smaller diameter cables, the release said.

The cables have a UL rating of OFNP and are easy to terminate for installation in plenum environments and virtually anywhere in a building, it said. The smaller diameter of the cables allows the use of

Panel offers improved ability to monitor and control U.S.-based Process Control Corporation notes that its new “Director Series Plus” sequencing control panel is an easy-to-use touch screen loading panel that gives processors the ability to monitor and control all aspects of a central vacuum loading system.

The new panel, a press release said, can be configured to control multiple vacuum pumps, in-line dust collectors, continuous run valves and up to 48 vacuum pellet and/or powder receivers. All of the information and operating controls are now located on a simple 10 in. color touch screen user interface that allows users to activate, adjust and monitor

all aspects of a central vacuum loading system from a single point, it said.

The new panel incorporates the Allen Bradley MicroLogix 1500 PLC to control the entire loading process, the release said, adding that standard configurations can be specified to load up to 48 stations using one or more vacuum pumps.

The panel is supplied based on original plant requirements, but can be easily upgraded with the addition of I/O cards and software upgrades as the plant expands, it noted.

Contact: Process Control Corporation, tel. 770-449-8810; Internet www.process-control.com.

Commodity and UL welding cable lines introduced U.S.-based Therm-O-Link announced that it has introduced rubber-based 90ºC and 105ºC 600V commodity and 90ºC 600V UL approved flexible welding cables in sizes from 4/0 to 8 awg.

The UL-approved welding cables, which may be used in wet conditions, meet all the strenuous requirements of UL Style 1276 including those for Long-Term Insulation Resistance (LTIR), Vertical Flame Test, Crush and Impact Resistance, Physical Properties, and Cable

64 WIRE JOURNAL INTERNATIONAL

Construction, a press release said. These cables, it noted, are available in a wide variety of colors and stripe configurations.

The commodity cables are derived from heat and moisture resistant EPDM and the UL cable is manufactured from a moisture, fluid, and flame-resistant CPE proprietary compound, it said.

Contact: Dr. Vipin M. Kothari, Therm-O-Link, Inc., tel. 330-527-2124; vipin_kothari@thermolink.com.

smaller diameter conduit or inner duct, thus saving the owner money, the release said.

Cable constructions are available in 8.3 micron singlemode and 62.5 and 50micron multimode, including optical fiber for 10 Gigabit Ethernet applications, it said.

Contact: Hitachi Cable Manchester, tel.

800-772-0116; www.hcm.hitachi.com.

Riser-rated corrugated conduit helps protect optical fiber cable U.S.-based ARNCO Corp. reports that its ARNCO® Fiber-Guard® riserrated corrugated conduit, recently added to its line of specialty conduit, can be used as a nonmetallic, flexible raceway for protecting and organizing optical fibers in riser applications.

The conduit has a lightweight and flexible corrugated design for easy installation, which also provides optimum crush resistance for long-term protection of delicate optical cables, a press release said. The internal corrugations reduce surface contact between the inside wall of the conduit and the cable jacket, lowering friction and protecting the cable from high tensile stress during installation, it said.

The conduit comes in standard lengths from 250-ft coils to 5,000-ft reels in 1.0 in., 1.25 in., 1.50 in. and 2.0 in sizes. Sequential footage markings and product identification are printed every two feet on the conduit, which is available in orange or white color for easy identification in the telecom industry, it said.

Contact: ARNCO Corp., tel. 440322-1000; info@arncocorp.com.

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Cable stripper is described as light but durable The Eraser Company, Inc., reports that, weighing only two lb, its Model 824 Portable Coaxial Cable Stripper is a highly portable yet durable cable stripper that can process material from .030 in. to .430 in.

The stripper can process RGU, semirigid, plenum and heliax cables, a press release said. With an all metal cutter head for longevity, it can strip up to four levels in less than five sec-

onds and is widely used by major telecom companies for installation of 734, 735, RG58, RG59, and HDTV cables, it said. The unit, it added, offers onestep stripping action and is an ergonomic, reliable solution for remote or field cable installation jobs.

The Eraser Company invites companies to send a 10-20 ft sample of material and it will recommend its best solution for processing from its line of

more than 200 products.

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

Series of media control cables is designed for the structured wiring sector U.S.-based Coleman Cable Inc. announced that it has introduced a new series of media control cables for the structured wiring industry. The products, it said, are engineered to meet or exceed the protocols for the AMX®, AMX AXLink™, CRESTRON®, CRESNET®, ELAN® systems and VIA!® touch screens*.

Constructions include low capaci-

tance shielded twisted pairs or Cat 5e for control, two conductors for power, and an optional RG59 for video, a press release said. The cables have color-coded, riser-rated jackets: teal with a yellow stripe, teal with a red stripe, and solid purple. Applications may include home offices, commercial offices, hospitals, educational institutions, or any locations where multi-

media and automation controls are installed, it said.

“Sophisticated control systems require multiple runs of multi-purpose cable to each location,” said Coleman Cable’s Deane Myers. “With our new media control cables, installers can save time and money on the job.”

Contact: Coleman Cable, Inc., www.colemancable.com ■

Redesigned Cat. 6 cable eliminates spline, results in lighter product easier to install Berk-Tek, a Nexans Company, announced that it has introduced a Cat. 6 UTP cable, LANmark® 6, that has been redesigned to eliminate the spline, making it lighter, smaller and easier to install.

A press release said that significant advances in twisting and cabling technology that have been incorporated into Berk-Tek’s manufacturing facility resulted in the cable’s reduced diameter of 0.195”, bringing it close to the diameter of a Cat. 5e cable, which is typically 0.180”. The Berk-Tek LANmark-6 cable meets the industry standard requirements for a Cat. 6 cable without the center spline that is common in most Cat. 6 cables today, it said.

“We developed this cable to vie for installations which currently specify Cat. 5e,” states James A. Frey, Copper Products Manager for Berk-Tek. “With its similar diameter and construction to a Cat. 5e, this cable is as easy to install yet outperforms Cat. 5e by providing more headroom and an increased bandwidth from 100 to 250 MHz,” he said.

This cable does not replace LANmark™-1000 or LANmark™2000, Berk-Tek’s higher performing Cat. 6 cables, which both contain a spline, the company noted. “Both the LANmark-1000 enhanced Cat. 6 and LANmark-2000 premium Cat. 6 cables provide capabilities that exceed industry standard minimum electrical requirements,” said Berk-Tek Marketing Director Todd Harpel. “The longitudal spline,” he explained, “increases the separation of pairs to maintain the cable geometry needed for increased crosstalk performance for installation environments and applications where additional headroom is an advantage.”

Contact: Berk-Tek, www.berktek.com.

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Media Belden launches comprehensive master catalog U.S.-based Belden has introduced its very first single volume Master Catalog for the European, Middle East and African markets.

The catalog, which is available both in hard copy and on-line versions, makes it easy to read the company’s comprehensive reference manual showing its thousands of cabling and signal transmission products as well as related products, a press release said.

The release noted that the catalog, which is classified by end-user industry, offers customers a wealth of

technical and professional background information.

The Belden EMEA Master Catalog contains more than 500 pages of comprehensive tables and nearly 20 chapters, providing an industry-by-industry overview of products and solutions, it said. Additional chapters, it noted, provide technical product background and descriptions of the latest developments in signal transmission.

A copy of the catalog from Belden can be downloaded at www.belden-emea.com.

Report look at impact of new FTTP standard U.S.-based Information Gatekeepers (IGI) has released a new report on the RBOCs’ Fiber to the Premise (FTTP/x) plans, which stem from FTTP becoming a standard method of designing residential access networks.

IGI notes that Verizon alone has now passed nearly 7,000,000 homes using this design and is adding homes at a rate of 3,000,000 a year. With this kind of program in place, it said, FTTP has certainly become a standard design approach.

IGI President Dr. Paul Polishuk said that the new report, “FTTP – The New Standard and How It Is Changing Already,” includes detailed discussions of network and local loop traffic requirements and resulting forecasts of deployments, not only for the announced

RBOCs but also for those yet to deploy FTTP/x. The report had support from the major telcos, which is a key in making forecasts that are accurate, he said, noting that IGI has been preparing FTTP reports since 2003. “Since then we have published four FTTP reports as well as several IPTV reports.”

This report “treats FTTP as an established technology,” said Polishuk, noting that it includes detailed architectural and equipment forecasts as well as of FTTP, other architectures (FTTx), PONs, IPTV and extensive vendors’ listings and discussions, with unique traffic requirements and forecast sections.

Contact: Dr. Paul Polishuk, Information Gatekeepers Inc., tel. 617-7782-5033; ppolishuk@ igigroup.com.

Updated welding guide promotes safe pratices The Lincoln Electric Company has released an updated publication, Arc Welding Safety Guide (E205), that explains in a straightforward way the issues relating to arc welding safety as well as recommended safe practices based upon practical experience.

The guide, a press release said, incorporates recommended safe practices for the shop floor.

Written with the welder in mind, topics covered include personal protective equipment, arc rays, noise, inspecting and maintaining for equipment and workplaces, handling gas cylinders, shock hazards, fire risks, fume and gas ventilation, and more.

The guide has been published since 1992 as a basic reference for the welder on the topic of welding safety, the release said. The publication, it added, may be freely copied for the educational or training purposes.

Copies from The Lincoln Electric Company can be requested at www.lincolnelectric.com.

Upgraded Americas’ website now offers more tech information Sartomer Company, part of Total’s Chemicals, reports that it has added features to its Americas’ website that enhances its online technical library, including improved search functionality for its product selection guide and provides easier access to its growing archive of new product alerts.

A press release said that the improved product selection guide

offers new multiple search criteria for preferred features, quantitative properties like specific gravity and viscosity, and applications. After selecting product criteria, a list of applicable products appears with links to their respective technical data sheets, material safety data sheets, and more, it said.

The new product alerts section was redesigned to permit searching by mar-

ket (adhesives, coatings, composites, electronics, inks, sealants, etc.) and by publication date. There are some six years of new product alerts in the archive, which are accessible from the website homepage, it noted, adding that the site also includes a user guide.

Go to the Sartomer website at www.sartomer.com. ■

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WJI Classified Ad Information Wire Journal International classified advertising is the most cost-effective way to get your sales message out through WJI’s circulation of more than 15,000. Your ad will also appear on wirenet.org and wcexpo.com, adding thousands of viewers.

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

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

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 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. PAYMENT POLICY: No agency commissions or cash discounts allowed. Ads are billed upon publication, or on secure cyber-cash sites on-line.

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 “on-line classified” booking will run in the next available issue of the WJI. USE OF THE WIRE JOURNAL CLASSIFIED ORDER BLANK located on the reverse side. Please type all copy submitted. Fax copies are acceptable; our fax number is 203-4538384. Telephone orders will not be accepted.

A leading copper wire fabricator specializing in specialty nickel and silver-plated copper alloys Seeks to fill the position of:

WIRE & CABLE ENGINEER The Wire & Cable Engineer will be working in a team, result oriented environment.

Candidates should have experience with tooling-die, statistical process control knowledge, annealing-heat treatment, electroplating silver-nickel, wire production equipment, product development and market (“application”) knowledge. The candidate must be service focused, have a bachelor’s degree in Engineering and have 5 years minimum experience.

Applicants meeting these requirements should submit their resume to: Email: littleton_nh@yahoo.com EEOC

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

Apply via fax 860-599-5461 or call 860599-5877. WJI07.

I N S U L AT E D C O P P E R W I R E SALES MANAGER. A wire and cable company located in the Southwestern United States is searching for an Insulated Copper Wire Sales Manager with experience in the Consumer Appliance, Automotive, and related primary wire markets as well as distributorship channels. Relocation may not be necessary, pending residence vs. primary areas.

Please send all resumes to ism@ webatron.net.

Serving the non-ferrous and ferrous industries since 1983

68 WIRE JOURNAL INTERNATIONAL

WANTED: A Mfg. rep who is now calling on Rod, Wire, and Wire Forms Companies with straighten & cut facilities and wants to add a new product. For a unique and lucrative association, call 704-882-2167 or e-mail jes1930@aol.

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WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME _________________________________________________________________________TITLE_________________________________________________________ COMPANY ___________________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY_______________________________ PHONE ______________________________FAX________________________________EMAIL ______________________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________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”)

Send to: Attn: Classified WIRE JOURNAL INTERNATIONAL P.O. Box 578 Guilford, CT 06437-0578 USA

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

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

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

DIES 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.

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

FOR SALE 1 - NORTHAMPTON 760mm D.T. Buncher 1 - NORTHAMPTON 630mm D.T. Buncher 1 - NEW ENGLAND BUTT 12-Head 18” Planetary Cabler 1 - WATSON 36” Rotating Cabler Line 1 - SYNCRO FX-13 Rod Breakdown Drawing Line, Copper 2 - VAUGHN 10-Die Rod Breakdown Drawing Lines, AL and CU 1 - ENTWISTLE 4.5” 24:1 L/D PVC Extruder 1 - DAVIS STANDARD 2.5” 24:1 L/D Nylon Extruder 1 - D/S 2” 30:1 L/D Hi-Temp Extrusion Line 1 - D/S 2” 24:1 L/D / 1.25” 30:1 L/D Extrusion Line 6 - BARTELL 60”, 72” Payoffs and Take-ups 1 - 30” Core Neutralizer Payoff 1 - CORTINOVIS 72-Wire 20” Rigid Strander

1 - NEB 18-Head 22” Rigid Strander, L-R 1 - CLIPPER Model PS50 Parallel Axis Dual Reel Take-up 1 - CLIPPER Model PS36 Parallel Axis Dual Reel Take-up 1 - ENTWISTLE 36” Dual Reel Take-up, Model THE 24/36 1 - DAVIS STANDARD 30” Dual Reel Take-up 1 - SYNCRO DFH Spooler, 30” Reel w/ENDEX Dancer 1 - DAVIS ELECTRIC Model CRS30 Rewinder 1 - E.J.R. Triple Head Taper, Model 2002HT 1 - VIDEOJET Model 37e InkJet Printer, new 2000 1 - ADVANTAGE Chiller, Model MK25AM-41HBX, 9/98 41 - 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

APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural & PCD

JUNE 2007 69

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DIES

MACHINERY

DIAMOND DIES. Fair prices & excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ wmconnect.com.

TRAVERSE UNITS. High quality “rolling ring” design. Better warranty and 30 percent less than Amacoil! "YR" Products, Inc. Phone/Fax 708-672-5007.

CARBIDE SPECIALISTS, INC. offers excellent quality, price and delivery on all carbide wire die needs (R2-R12). Yes, you can have all three! Give us an opportunity to prove it. For personal attention to your specific requirements, contact Ray Northern at 440-951-4027; fax 440-954-9094.

EQUIPMENT WANTED WE BUY SURPLUS LASER MICROMETERS. For a quote simply fax or email the manufacturer name and model #'s. Any condition. Fax 1-386426-2056; e-mail: johnknight@ microtex.net; www.microtex.net.

WWW.URBANOASSOCIATES.COM. For New & Used Wire & Cable Equipment.

Tel. 727-863-4700; fax 727-863-4711; or by e-mail at urbassoc@verizon. net.

WHITELEGG CFM-610-TWR, 2D FORMING AND WELDING MACHINE. Wire range .080" to .250", maximum ring and frame size 32".

Includes 30 KVA TWR automatic butt welding unit, RS615/5 twin plane roller straightener with indexing bracket, WSP-1000 power driven coil holder, and industrial PC with windows touch screen. Machine demonstration available upon request. E-mail: harrisj@ indwire.com. ■

WAI members: Did you get your WAI Connection?

If not, send an e-mail to membership@wirenet.org, so you can get the WAI’s electronic newsletter, the best way to keep up with all the activities going on in the WAI, from shows and workshops to chapter news and events and more.

70 WIRE JOURNAL INTERNATIONAL

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Advertisers’ Index/Key Contacts ADVERTISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE

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

AIM, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4 Peter Zafiro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 630- 458-0008

ESTEVES-DWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Steve Marcum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 260-728-9272

Alloy Wire International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Angus Hogarth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 44-1384-566775

The George Evans Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 David Evans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 309-757-8300

Amacoil, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3 Bob Eisele . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 800-252-2645

Fisk Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Eric Fisk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 973-427-7550

Anbao Wire & Mesh Co. Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 BJ Hur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 86-335-389-3600

Gavlick Machinery Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Sue Pare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 860-589-2900

Baum’s Castorine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Tom Whitcombe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 315-336-8154

Global Wire, Inc./Montgomery Division . . . . . . . . . . . . . . . . . . . . .65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 603-444-0550

Beneke Wire Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Michael Beneke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 502-367-6434

Hitachi America Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 914-631-0600

Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Bob Stockholm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 937-233-9935

Huestis Machine Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13, 16 Joe Snee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 800-972-9222

Blachford Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Mike Yazum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 815-464-2100

KEIR Manufacturing Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 800-992-2402

Bomco Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Patricia M. O’Neill . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 978-283-2800 ext.1218

Kinrei of America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Steve Hess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 973-677-9500

Bongard Drummond Trading LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 John Drummond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 260-625-6275

Kiswire Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 An G. Lee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 82-2316-6122

Cable Consultants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Fred Hardy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 704-375-9313

Luvata (formerly Outokumpu Copper Products) . . . . . . . . . . . . . .5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.luvata.com

Carris Reels, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 David Ferraro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 802-773-9111

MacDermid Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 203-575-5700

Commission Brokers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Martin Kenner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 401-943-3777

Mathiasen Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Mark Mathiasen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 860-873-1423

Condat S.A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 33-478-073-838

Micro Products Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Bill Keiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 630-787-9350

Die Quip Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Tom Maxwell, Jr. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 412-833-1662

Paramount Die Company Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Richard Sarver . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 410-272-4600

SALES OFFICES NORTH AMERICA

EUROPE

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

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks P.O. Box 33 Moulton Newmarket, Suffolk, England CB81SH Tel: +44-1638-751132 Fax: +44-1638-750933 E-mail: franksco@ btopenworld.com

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 E-mail: DMelcher@t-online.de

Anand Bhagwat Wire & Cable Services Pvt. Ltd. (WCS) E-mail abhagwat@wirenet.org or mobile 91-98-508-38467

JUNE 2007 71

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

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

PolyOne Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Bob Eiden . . . . . . . . . . . . . . . . . . . .Ph. 440-930-1000 or 866-PolyOne

Wire & Plastic Machinery Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Rahul Sachdev . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 860-583-4646

RichardsApex Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Ron Higgins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 215-487-1100

Woodburn Diamond Die, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Jackie Lichty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 260-632-4217

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Wyrepak Industries, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Ray Browne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 860-632-5477

Sanxin Wire Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Doug Thornton . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 434-906-2340

Zumbach Electronics Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Keith Donahue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 914-241-7080

Sheaves Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Stew Walton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 866-344-6786 SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Jeff Swinchatt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 770-486-1233 SIKORA International USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Jeff Swinchatt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 770-486-1233 Sjogren Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Carl Sjogren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ph. 508-987-3206 Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Bob Douglas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ph. 256-480-5124 Teknor Apex Co./Vinyl Division . . . . . . . . . . . . . . . . . . . . . . .Cover 2 Mike Patel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800-554-9892 Wafios Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Donald H. Fisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203-481-5555

Wire Association International ads Contact: . . . . . . . . . .Ph: 203-453-2777 Fax: 203-453-8384 WAI Membership/Application . . . . . . . . . . . . . . . . . . . . . . . . .29-30 Call for Papers: Wire Expo 2008 . . . . . . . . . . . . . . . . . . . . . . .41-42 WAI Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Coming next month • Equipment, Part 1 • Interwire/IFE wrapup

VISIT OUR UPDATED WEB SITE

LARGEST INVENTORY OF WIRE & CABLE MACHINERY IN THE WORLD

www.wireandplastic.com EXPL296 Tandem Line with NIEHOFF, M30, VG30, EXTRUSION Beta MCS190LINES preheater, PLANETARY CABLER Nokia 90 mm 24:1 extruder, 350mm multipass capstan, Screen, Control EXPL231 3 1/2” D.Std. 24:wire 1Touch Therm III jacketing line.

CBR751 22” Watson 37 (6+12+18) planetary Panel with Eurotherm drives, Yr.cat, 1996 withTDV-260-3 Nokia (2) Skalteks 40” Hall belt Viteck cabling line A12PS, with dual capstan, taper, binder, 84” shaft45mm piggyback extruder, 500mm EKP-5, Yr. 22” vert.24:1 accum 16’, (2) D.E. TURA 36” takeups, CTC less 72” S/L payoff.

2001,takeup, Medek & Schoerner bandmarker RS707. tape payoff, cone former, binder, Lasermike, Zumbach TAKEUPS TBR157Fusion 22” CEECO 7 wire 22” Tubular Strander, CAPAC, UV cure, Hall footage counter, Videojet TKU846 NEW Samp dualw/dual shaftless parallel encircling bearing type,560mm 1000 RPM capstan.

9900 printer, trough. axis hi speed takeup forJacketing telephone.

CLR188 42” BONGARD drop coilers, EXPL232 6” NRM 24:1 line, Yr. 2000, TKU845 EKP50 parallel axis hi(2) SkaltekNokia A12PS payoff,mm s (2)dual 60” reel Bartell takeups w/OH traverse, 36” Royle B/W capstan, 30” horiz accum, 30T speed takeups.

HI TEMP EXTRUDERS Carrier chiller, Zumbach CAPAC, Videojet 9900 printer, TKU837 36” Davis Electric TAP-36, parallel shaft (YR 1998): EXP740 1 1/2” D.STD. 30:1, (2) EXP742 Hall footage counters, Fusion cure,1trough.

45mm NEXTROM 30:1, EXP770 1/2” D.STD.24:1, w/dancer.

EXP666 30:1. 2.2 EXPL230 6”D.STD. Davis Standard 24:1mTherm Jacketing TKU7922”NEW Rosendahl portalIIItire type traline, (1987), versing take40” upMGS/Hall w/accum.belt caterpuller, (2) 60” Bartell DUAL HI10 SPEED TAKE UPS CAPAC, Beta lasertakeups, ton chiller, Zumbach TKU841 60” - 96” Bartell shaftless take ups/payoff.

NOKIA (1) EKP-5 2001, (2) EKP-50 1993, (2) EKPmike, footage counter, trough, Viteck TDV-240-4 22” vert Skaltek portal payoffs & takeups Models: UX25T, 100 1995.

16’ accumulator.

UX28T, U30T, U20T, U16T, U25T, U12P4K, U26T, TKU903 24” Davis CLIPPER S/L, 24:1 parallel axis PS-24HS, EXPL229(7) 4 1/2” Standard Thermatic III, 1997, A12P-4K,Line, A204, AX28, A30, A264K. 1990’s.

Jacketing 40”AX26, Hall belt caterpuller, Viteck TDV-400COILERS 4 22” vert. accum, (2) 60” Bartell takeups, footage LINES/MULTI WIRE/ ROD WIRE DRAWING CLR127 (5) Reelex/Windings dual figure 8 UV winders, counter, Videojet, 20 ton chiller, trough, fusion cure WRD779 (2) SAMP TRB-3 (MS200) w/ RC15 oven, dryer, (2) Skaltek A12PSlines payoffs.

Modelhopper D1000/D1001. annealer, TE42 spooler, 40 DC Eurotherm drive.

EXTRUDERS EXPL233 4 1/2” Davis Standard 24:1 Therm III, 1995, WRD781 SAMP 13 die rod draw box, MS400 Jacketing Line, (2) 48” Hall driven Payoffs, Lot: D. St. extruders, 6” 24:1, 4 1/2” 24:1,30”Sterling 3 1/2” 24:1, w/WRD804 RC 80 400KVA annealer, 45DC. dual capstan, Viteck TDV-300-4 vertical accum, (2) 2 1/2” 24:1 vertical, 2”wire 24:1.(14)14” WRD795 SAMP multi drawing line 60” Bartell takeups, footage counter, lasermike, trough, MT8R.1.8.27 w/R16M.14.1000 annealer, Yr. 1995.

Fusion UV cure oven, print head.

RECENT PURCHASES NEW PURCHASES

KW1050KT, 32 stems, Reliance drives & PLC. EXTRUDERS RWD418 120” Samp ROSENDAHL trav., column1type, EXP604 NEW Deangeli TE35/24, 1/2” vershaftless rewind EXP637 (2) 1 with 3/4”line.

Entwistle, tical extruder motor. hi-temp (FEP), TherCBR906 ALLARD bow twister, 1+4, 20” USM moflite extruders, 24:1 L/D, 42” Centerline, 5-Zone.

EXP588 236” 1/2” D.Std. extruder, 24:1, Thermatic.

III, conc. taper, AC Vector drives, 60” Take up.

CABLERS w/40 HP AC Vector.

CBR913 48” EDMANDS bow twister, 1+3, dual 48” CBR798(2) 48”conc.

Entwistle single rotating takeup, CABLERS capstan, tapers, 84” twist takeup. w/conc. unit oscillating plate, 25 CBR759 22”binder, 37W 1+6+12+18 NEBconc rigid strander, CBR807 (4) 760mm SAMP BM760D, Yr. binder, 1997.

(10) pair 16” payoff. (1989), 250 RPM max, 3” - 18” lay dual capstan.

1993-1995. range, 1” OD max, 6000 LB max, 30 HP DC cradle CBR741/CBR743 36” Cook S. twist bunchers, drive, 15 HP AC reel(3) drive.

BH-36, Yr. Mfg. 1972, 14” conc. taper,w/annealer, also (1) BHWRD770 MT25.2 wire drawer, CBR800 SAMP 48” Northampton (NMC) D. Twist strander (2) 30, BH24, Yr.spoolers, 1978. Yr. 630mm TE65-M (bow(3) type), Uhing traverse, S/L1987/1989. cradle, dual capstan, (2) WRD769 NIEHOFF (9) M40 wire drawer die,bunchers, with CBR716/CBR722 760 mm Samp17D.T. conc. binders.

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Taper, multipass payoff.

A164K payoff, U16T takeup, cutter counter, copper, L-R, w/FX-13 Drawer,L100 F Annealer, 36” CBR708 60” Ceeco 1+6 planetary cabler.

Dual dancer accumulator, footage counter. (1 - w/SC4 24” BEKAERT coiler.

ECC taper, 72” Cat, portal trav. takeup. accumulator).

WRD787 COOK Rod96” Breakdown Line for Alum L-R, CBR720 2.2m Pourtier drum (5)Syncro 1.8m w/Cook DH4+8 Drawer, Endex Annealer, 36” RWD376 40” Viteck rewind linetwisting with S/Lline takeup, S/L coiler. rotating payoffs, rot. Cat, driven payoff, dancer, Betatapers, sparkerbinder. & counter.

WRD796 (2) ENDEX 30” dropcoiler w/ turntables, conWIRE DRAWING COILERS trols.

WRD677/WRD678 (2) Samp 14D.E. wire, 31 die, CLR157 (1) Reelex D1000 with 36”HP driven WRD805 SYNCRO FX-13 dual Rod (2) LineTE/65-M w/200 DC,mm MLS/5T.14 with annealers, 630 payoff, Hall accum, footage counter, controls, 24” dual R100, 125 KVA annealer, 30” DFH Spooler. spoolers.

(1997/1993). rewinder, 1990’s.

WRD689 CookD1000 DH 5+8 die Hall roddriven machine, CLR158 Reelex dual13 w/40” payoff, INSULATING/JACKETING LINES accum, footage rewinder, 1990’s.

EXPL253 3 1/2”counter, D.STD.24” 24:dual 1 Therm II, (2) Skaltek

CBR899 (3) NORTHAMPTON SLB800 D.T. BunchCLR156 (2) Reelex D1000 dual coiler with controls, ers, Yr. 1995-1998. ceramics, RA5, 300 KVA annealer, 30” spooler, dancer/accum.

MSC1221 (2) NIEHOFF VZ-01 Tin Electroplaters Mfg 1980’s.

CLR154 (2) Reelex26” S500 (1)coilers LH, 1 (Yr. RH, 1994/1996). single w/ w/Bongard ST/650, drop WRD690 Syncro F13 13 die, 350 HP drive, controls,(3) dancer.

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BRAIDERS ceramics, 100 HP DC, C3 annealer, 30” spooler.

BRD303 (10)Wardwell 16Carrier Rebuilt, Model H, on TUBULAR STRANDER wire, mot 30” x 16” frames. (still in crates) TBR143 30”Hall Stolberger 12+ wire tubular stran1.2m payoffs, payoff accum, (2) 40” Hall S/L Take BRD302 16 Carrier, on wire, motorder, dual(41) cap,Wardwell 84” Bartell takeup. up.

Viteck accum. ized, Model G/H, 30” or 24C braider frames.

EXPL229 4 1/2” D.STD. 24:1 Therm 1997, JackTBR145/TBR146 (2) 630mm 1+6III,(2) 1+12 BRD305 Wardwell 24 Carrier cable. eting Line,Ceeco 40” Halltubular belt caterpuller, Viteck TDV 400 4 630mm stranders, encircling 22” vert. accum, (2) 60” Bartell take ups, footage DANCERS/ACCUMULATORS bearing, spin safe cradles. counter, 20 motorized ton chiller,AC300 trough,dancers. fusion UV cure DAN187Videojet, (6) Reelex MISCELLANEOUS oven, hopper dryer, (2) Skaltek A12PS payoffs.

DAN184Sciences (16) Hall dancers 10’ +/Unit Yr. Mfg. 1990, Energy Irradiation nitrogen generator.

WIRE DRAWING LINE PLANETARY CABLERS CBR917 37W 12 Planetary 6 (24”) drawer + 12 (19”) +18 WRD717NEB Nextrom wire multiwire w/anneal(19”) w/48” dual cap,spoolers, (2) 48C 12 horiz braiding er, (2) 630/800mm stem payoff,heads.

100 HP CBR920 NEB Planetary LineEnter 24”, 6+12 bays DC drawer, 5019 HPWire annealer.

(1995).

12 AWG w/2 pad eccentric flat wheel capstan, 2.05mm, Finish 38taper, AWG60” 0.10mm, 29 dies, 500078” FPM, take up.

MGH529A. CBR916 Wire Planetary LineAG-16 16”, 12 +12Drawing Bays, (2) WRD71824 (20) Syncro Machine Wire 16” Conc tapers, 6 posSyncro ECC binder, 30” dual capstan, Machine, 5000-FPM, Annealer/spooler, WST 48” S/L take up. annealing controls

Wire & Plastic Machinery Corp. 100 Franklin Street Bristol, CT 06010 USA Phone (860) 583-4646 Fax: (860) 589-5707 sales@wireandplastic.com www.wireandplastic.com

72 WIRE JOURNAL INTERNATIONAL

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Wind up with an Amacoil/Uhing assembly for perfect pitch every time Pitch is adjustable (10:1) without requiring gear changes or adjusting motor speed. A single Amacoil/Uhing assembly may be used for winding many different diameter materials. Automatic reversal of the traverse is mechanically controlled – without clutches, cams or gears. No electronics or programming needed.

FEATURES • Zero backlash.

• Automatically synchronizes pitch with take-up reel rotational speed.

• Traverse drives with up to 800 lbs. axial thrust.

• Smooth, unthreaded shaft won't clog or jam – no bellows assembly needed.

• One inexpensive, unidirectional motor drives both the traverse and take-up reel.

• Free movement lever – no need to "jog" system on and off to position linear drive.

• Options and accessories for every winding situation.

• Light, medium and heavy-duty systems.

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

email: amacoil@amacoil.com

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

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