Interwire Wrapup by Wire Journal International, Inc.

WIRE JOURNAL JUNE 2011

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Interwire wrapup

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WIRE JOURNAL

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

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

CONTENTS

Volume 44 | Number 6 | June 2011

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 20 People . . . . . . . . . . . . . . . . . 22 Fiber Watch . . . . . . . . . . . . . 24 Fastener Update . . . . . . . . . . 27

Wrapup: Interwire 2011 . . . . . . . . .32

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

By the numbers and comments from exhibitors and attendees, Interwire 2011, which featured bolstered educational programs, was a resounding success.

Chapter Corner . . . . . . . . . . . 30 Technical Papers . . . . . . . 74-92 Products. . . . . . . . . . . . . . . . 94

Testing & Measuring Equipment . . . .60 This feature presents testing and measuring equipment that was displayed at Interwire 2011.

Classified . . . . . . . . . . . . . . . 99

T ECHNICAL P APERS

Career Opportunities . . . . . . . 99

Production of thin wires of magnesium alloys for surgical applications Andriej Milenin, Piotr Kustra, Jan-Marten Seitz, Friedrich-Wilhelm Bach and Dirk Bormann . . . . . . . .74

Advertisers’ Index . . . . . . . . 102

Next issue July 2011 • GREEN FOCUS: plant efficiency & energy savings • wire Moscow wrapup

Method to improve straightness and remove torsion of uncoiled wires Kotaro Nishimura, Motoo Asakawa, Masaki Kitazawa and Akihisa Yokoyama . . . . . . . . . . . . . . . . . . . . . . . . .82 Fabrication of biocompatible dental implant screw made of pure titanium Kazunari Yoshida, Yoshio Saiki, Chikahiro Ohkubo, Daisuke Kurihara, Tomoko Osada and Tadashi Tashima . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Cover: There was a decided sense of activity at Interwire 2011, where many exhibitors said that visitors to their booths were serious about doing business, a welcome sign for the wire and cable industry. See p. 32.

JUNE 2011 | 3

INSIDE THIS ISSUE A TIME FOR BUSINESS

. . .32

...

AND A TIME FOR COMARADERIE

. . .38

CONTENTS

INTERWIRE :

Activity at the Niehoff GmbH/Niehoff Endex North America booth, one of many at Interwire 2011 that reported good meetings with attendees. Booth personnel said that they sensed optimism from visitors, and that the projects that were discussed included activity in North America. “It was a good show for us,” one staffer said. A range of comments on the event start on p. 48.

Interwire 2011 was about business and finding new technology and ideas, but it was also a time for meeting up with colleagues and friends. One of the perennial favorite places for doing that that has been WAI’s reception, which this year was held at the Omni Hotel Atrium. The reception has remained an occasion to celebrate being part of this remarkable sector.

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EDITORIAL WIRE JOURNAL

EDITORIAL

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

Interwire reflected the strength of the industry For years, I attended Interwire as a casual observer. I would carve time from my schedule to see what was getting the attention on the exhibition floor or take advantage of the opportunity to meet with our supplier partners. I wasn’t likely to attend the technical sessions, not because I didn’t see the merit, but because I found that spending time with our suppliers in a neutral environment consistently translated into value for my employer. Over time, I took Interwire for granted, always expecting the show to provide value, even though I made a minimal investment in the production of the event. I was happy to leave it up to others to organize and execute the event. However, after being critical of the show with one of WAI’s key volunteers, the late Steve Vannais of Davis-Standard, he suggested that I volunteer some of my time to the Association, with the idea that getting involved would be constructive. It wasn’t long before I was elected to serve on the Board of Directors, and I quickly learned that there is no shortage of passion on the subject of Interwire. Yes, I have heard many proclaim that it was good to have the event back in Atlanta, but more importantly, I sense from all stakeholders that business conditions are improving, and I am convinced that the positive economic climate is the basis from which Interwire was deemed a success. What shouldn’t be lost for those casual observers are the efforts that are directed to this event, some of which span multiple shows. There are nearly 100 volunteers actively working the project for the industry. There are an equal number of presenters and authors. There are specific champions, such as Gary Spence, who put together the highly successful Continuous Casting Forum, and Jan Sorige, who managed the Exhibition Planning Committee through the venue change. Most importantly, the exhibitors and the 400 companies they represent provide the marketplace for the industry to assemble. I can assure you that wire and cable manufacturing in North America is strong and the commitment to Interwire is equally strong. If you weren’t able to attend the event, the show report that begins on p. 32 will give you a sense of what the energy was like there. It’s a good sign for us all.

Richard Miller Southwire Co. WAI Second Vice President

Richard Miller, r, and WAI President Dominiqe Perroud presented a plaque to David Kaczor, ExxonMobil Chemical, one of the key sponsors to Interwire.

6 | WIRE JOURNAL INTERNATIONAL

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2011 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

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CALENDAR

CALENDAR June 15-17, 2011: Wire & Cable Expo, China Tianjin, China. To be held at the Tianjin International Exhibition Center, the 15th staging of this event will include a conference, exhibition and featured events. Contact: AIT Events Co., Ltd., tel. 86-10-85868930, www.bvents.com/event/389490-wire-cable-expo.

Sept. 19-21, 2011: The National Wire Electrical Manufacturing and Coil Winding Expo Nashville, Tennessee, USA. To be held at the Gaylord Opryland Resort & Convention Center. Contact: Electrical Manufacturing Coil Winding Association (EMCWA), tel. 619-435-3629, www.emcwa.org.

June 19-23, 2011: JI Cable 2011 Versailles, France. This forum about power cables, with exhibits, is be held at the Versailles Congress Centre. Contact: JI Cable 2011, www.jicable.org.

Oct. 4-6, 2011: MetalTech 2011 São Paulo, Brazil. To be held at the Centro de Exposicoes Imigrantes. Contact: Cipa LTDA. Correia de Lemos, tel. 55-11-55854357, fax 55-11-55854359.

Sept. 13-15, 2011: wire Southeast ASIA Bangkok, Thailand. Organized by Messe Düsseldorf, this event will be held at the Bangkok International Trade & Exhibition Centre. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Nov. 6-9, 2011: 60th IWCS Conference™ Charlotte, North Carolina, USA. To be held at the Charlotte Convention Center. Contact: Pat Hudak, IWCS, tel. 732-389-0990. fax 732-389-0991, www.iwcs.org, phudak@iwcs.org.

WIRE ASSOCIATION I NTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. June 20, 2011: Midwest Chapter 9th Annual Golf Tournament West Chicago, Illinois, USA. This event will take place at the St. Andrews Golf & Country Club. See p. 30.

Sept. 12, 2011: New England Chapter 17th Annual Golf Tournament Ellington, Connecticut, USA. This event will take place at a new location, the Ellington Ridge Country Club. See p. 30.

Oct. 13, 2011: Southeast Chapter 10th Annual Golf Tournament Conover, North Carolina, USA. This event, which will take place at the Rock Barn Golf & Spa, will also be a scholarship fundraiser for Eric Vannais, the son of the late Stephen Vannais, the former chapter president.

Oct. 24, 2011: Western Chapter 11th Annual “Wild West Shootout” Golf Outing

8 | WIRE JOURNAL INTERNATIONAL

Rancho Palos Verdes, California, USA. This event will be held at the Los Verdes Golf Course.

Nov. 7-8, 2011: CabWire World Conference Düsseldorf, Germany. To be held at the Congress Center Düsseldorf, this technical conference is being co-organized by five industry organizations: ACIMAF, CET, IWCEA, IWMA and WAI. For more details, go to www.cabwire-duesseldorf.com.

2012: Wire Expo 2012 Dallas, Texas, USA. WAI will hold this event, which will include its 82nd Annual Convention and trade show, for the first time in Dallas. The dates and location TBA.

May 2-5, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show, technical programs and the Association’s 83st Annual Convention. Contact WAI, tel. 203-453-2777, www.wirenet.org.

CALENDAR

March 26-30, 2012: wire Düsseldorf 2012 Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, erowe@mdna.com, tel. 312-781-5180.

April 1 – 5, 2012: NPE 2012 Orlando, Florida USA. The NPE plastics and elastomers exposition is a triennial event produced by SPI, The Plastics Industry Trade Association. It will take place at the Orange County Convention Center. The educational program will begin on Sunday, April 1. The first day of the four-day trade show will be Monday, April 2. For more information, go to www.npe.org.

2012: Wire Expo 2012 Dallas, Texas, USA. WAI will hold this event, which will include its 82nd Annual Convention and trade show, for the first time in Dallas. The dates and location TBA.

Sept. 25-28, 2012: wire China 2012 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Oct. 29-31, 2012: Wire & Cable India Mumbai, India. This event is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

JUNE 2011 | 9

INDUSTRY NEWS

INDUSTRY NEWS LS Cable delivers Korean first South Korea’s LS Cable & System Chairman & CEO Christopher Koo announced that his company has developed 1kV 400Hz aircraft power supply cables—an industry first for Korea that was the result of two years of research— and delivered them to Incheon International Airport Corporation. A press release said that the cable is used to supply power directly to airplanes at airports, and as its frequency band is more than five times higher than that of general 60Hz cables, the cable can be used in 400Hz power systems for commercial and military aircraft and even onboard aircraft carriers. It noted that the higher the frequency band, the higher the cable surface resistance becomes, and that to solve this required top-level technologies from 1kV 400Hz aircraft power supply material selection cable unveiled by LS Cable and to structure design System. and evaluation. LS Cable and System, it said, is the fifth company in the world to have developed this product, demonstrating its worldclass R&D abilities. “With this achievement LS Cable and System now has a foothold in the high tech segment of the cable industry,” it said. The market for this type of cable is growing because airplanes have previously generated their own power by running their engines in idle mode, which discharges enormous amounts of carbon dioxide, the release said. The global airport cable market is around KRW 700 billion a year and the 400Hz aircraft power supply cable market is estimated to be KRW 50 to 60 billion, it said. “LS Cable and System is now going to accelerate their marketing activities to supply GPS cables to overseas airports, especially in China, as it has successfully supplied cables to the Incheon International Airport Corporation which can be used as a reference,” the release said. “We tested this cable in actual airplanes for seven months and it demonstrated excellent stability and performance,” said Chun-Ho Kwon, head of the company’s Industrial Special Cable Team. “We will continue to strive to make inroads into the high value-added industrial special cable market starting from this delivery.”

Prysmian will supply a wide range of power, instrumentation and fiber optic cables specially designed for process plant and sulphur recovery units for treating natural gas at the “Shah Arab Field” in Abu Dhabi, UAE, and hydrocarbon resistant instrumentation and signaling cables for the BS 171 oil booster station project in Kuwait, a press release said. The two contracts are worth in excess of 50 million euros and 10 million euros respectively, it said. The cables will be produced in the Italian plants of Livorno Ferraris (Vercelli), Merlino (Lodi) and Ascoli Piceno, with delivery having already started, it said. The release said that the Middle East and the companies operating in the oil, petrochemicals and chemicals industry in the region represent significant further business in this sector. It noted that Prysmian cable systems have been selected for current high-profile projects such as the QAFCO fertilizer plant in Qatar (the largest in the world), the Borouge polyolefin plant in Abu Dhabi and the LNG 2 plant in Yemen. The company notes that it has also been involved in some of the most important strategic and technologically advanced projects in the industry, including the Kashagan oil field in Kazakhstan, the Seadrill, Petrorig and Hull offshore drilling rigs for Jurong Shipyards and Keppel Fels in Singapore, and the Shell Nanhai petrochemicals complex, in China’s Guangdong province.

Multi/Cable expands Bristol plant U.S.-based Multi/Cable Corporation, a manufacturer of custom made multi-conductor and multi-pair electrical wire and cable, announced that it has plans for a 10,000-sq-ft expansion of its plant in Bristol, Connecticut. A press release said that the addition will be made this summer, enabling the company to streamline its manufacturing process. Several new manufacturing lines have already been purchased and are awaiting installation, it said, noting that when done the improvements will allow the company to more than double its extrusion capacity. The company, which now has 15 employees, plans to add as many as seven new jobs, it said. “Multi/Cable is thrilled that in these tough economic times it has the opportunity to expand to better meet the needs of its growing customer base,” it said. The company, founded in 1975, notes that it supplies custom wire and cable solutions for some of the world’s most demanding industries. For more information, call tel. 860589-9035 or go to www.multicable.com.

Prysmian wins Middle East contract

Joint venture between Axjo and Windak introduced at Interwire

Prysmian Cables & Systems announced that it has signed two major contracts with Saipem, a major oil and gas industry contractor, worth in excess of 60 million euros, to supply special cables for applications in the oil, gas and petrochemicals industry.

Axjo and Windak have formed a new company, called AXJO® AMERICA, that will provide spools and drums in North America. The venture was showcased at Interwire 2011, where Axjo America spools and drums were on dis-

10 | WIRE JOURNAL INTERNATIONAL

nies now feel “that the time is right to offer the market in the U.S. a range of ultramodern spools and production plant equipment that together lead to cost savings and higher levels of efficiency for the customer/user.” Machinery and equipment was being installed at Windak’s premises in Hickory, North Carolina, and first deliveries were expected to occur in June and July, the release said. It noted that the production facility will be extremely modern, effective and rational.

Tata Steel invests in Scunthorpe Mill Tata Steel reports that it is investing £1.2 million in two new high-tech machines at its wire rod rolling mill in Scunthorpe to increase quality and efficiency, and to boost production of the most technically demanding steels. A press release said that the investment will not result in increased overall production at the rod mill, but will enable Tata Steel “to increase its focus on the most demanding and safety-critical fastener products for the automotive industry.” The investment includes a new testing machine for the company’s cold heading product range, which includes steels used in fasteners for the automotive, mechanical engineering and construction sectors. “This investment, like the £8 million Clydebridge investment we announced last week, supports our ambition to

JUNE 2011 | 11

INDUSTRY NEWS

play at its booth as well as that of Windak. A press release said that the new business matches the focuses of Axjo, which supplies spools and drums in polymer materials to large cable works in Europe as well as to users in Asia, Brazil and Africa, with that of Windak, which provides reeling equipment. AXJO America’s spools and drums, it said, are made from a recycled polymer material. “This proprietary material ensures that the products are resistant to cold and heat, are not sensitive to UV radiation and that they are ergonomic. Since the spools are manufactured in mono-material and thus do not need to be sorted prior to destruction, Axjo is able to offer its own recycling facility.” The managing director of AXJO® AMERICA is Windak Inc. President Dan Shelander, and the chairman of the board of directors is Jacob Nilsson, managing director of AXJO Plastic AB. Axjo, the release said, has developed systems and products for the European market for many years, and both compa-

INDUSTRY NEWS

focus on making premium products for profitable markets,” said Jon Bolton, Director of Tata Steel’s Long Products Hub. “Steel demand recovery has been slow following the global recession, with some sectors demonstrating particular difficulty in returning to pre-recession levels. But we will continue to invest in our capability to produce specialist and highly technical steel products to contribute to a more competitive and sustainable business.” Both machines are scheduled to be commissioned in October 2011, the release said.

Sandvik plant recovers after fire Three weeks after a fire destroyed equipment and damaged parts of Sandvik’s wire production facility in Sandviken, Sweden, the company reports that the plant has commenced its first production runs. The April 14 fire completely destroyed the pickling plant within the wire production facility, damaging some of the wiredrawing machines and the building, a company statement said. It noted that no one was injured, but once damage was assessed, work began immediately on decontaminating, cleaning, repairing and, where necessary, replacing the plant. That included replacement of all the main services such as high voltage electricity, compressed air, cooling water and protective gases for the furnaces. Some production was transferred to other Sandvik wire production units. The plant is now building back up to operational speeds, which it said “will take some time after such a significant incident.”

US ITC sides with complaint over steel wire from China and Mexico The U.S. International Trade Commission (ITC) determined that there is a reasonable indication that a U.S. industry is materially injured by reason of imports of galvanized steel wire from China that are allegedly subsidized and from China and Mexico that are allegedly sold in the United States at less than fair value. As a result, the U.S. Commerce Dept. will continue its investigation, with its preliminary countervailing duty determination due on or about June 24, and its preliminary antidumping duty determination due on or about Sept. 7, the release said.

NESMA show reflected optimism There was a positive tone at the April 19 staging of the 2011 New England Spring & Metalstamping Association (NESMA) trade show, which was held at the Aqua Turf Country Club in Plantsville, Connecticut, where attendees seemed more positive about the industry outlook since the last show was held two years ago. “These positive comments ranged from ‘warm and fuzzy feelings,’ such as ‘It is great to see that most of us are still here, given what we witnessed in 2008/2009,’ to a more optimistic outlook, such as ‘Business is improving and the attendance seems to confirm it,’ ” said NESMA board member Ted White, Jr., Hardware Products Company, LP. He noted 12 | WIRE JOURNAL INTERNATIONAL

Norman Pierce, TAK Enterprises, talks to attendees at the NESMA show. that a total of 53 exhibitors displayed their technology and services, and that attendance was definitely up. He said that more than 300 attendees representing 86 organizations stayed for the post-show networking hour and dinner, “with all of those numbers representing marked improvement over recent prior years.” White added that it helped that the dinner speaker was ESPN founder Bill Rasmussen, who gave a colorful account of exactly how ESPN was conceived. “All things considered everyone left the Aqua Turf that night with a full belly, a better understanding of ESPN and an optimistic feeling about the industry in which they participate,” he said

Nexans wins additional umbilical contract for Norway project Nexans reports that it has won a 4.8 million euro deal from Norske Shell to supply a 6.5 km infield umbilical for an extension to the Ormen Lange North Field project, a natural gas field on the Norwegian Continental Shelf that started production in 2007. A press release said that the Ormen Lange project represents the fourth subsea production template around 6 km to the north of the existing main production area that contains three templates. The Nexans infield umbilical will be used to connect two legs by supplying the hydraulic fluid, electrical power and fiber optic signals required to operate the subsea production systems located at a water depth of approximately 850 meters. It will produce the infield umbilical at its specialized plant based in Halden, Norway, with delivery set for the first half of 2012, it said. The released noted that Nexans was awarded the contract to supply the two 125 km main umbilicals and the infield umbilical that are now playing a vital role in the successful operation of the subsea systems at Ormen Lange.

Plan okayed for new submarine cable from St. Thomas to St. John The St. Thomas Coastal Zone Management Committee has approved the V.I. Water and Power Authority’s plans to install a new submarine cable from St. Thomas to St. John to

INDUSTRY NEWS

help keep the island fully powered even if another cable fails, reports the Virgin Islands Daily News. “Right now you have one cable that can carry the entire load, and one that can right now but won’t be able to in a year or two,” WAPA executive director Hugo Hodge Jr. said in the article. “We’re just trying to be proactive.” The new 34.5 kilovolt cable, he said, will have a full-load capacity of 22 to 27 megawatts of power, which is more than double St. John’s current peak demand of 10.5 megawatts. TWAPA’s governing board allocated US$3.3 million for the project. Hodge said in the article that there are currently three undersea cables that travel from locations on St. Thomas to St. John’s Frank Bay Pond. One of those, which starts at Cabrita Point, is no longer in service, while another cable, still in good working order, begins at Great Bay, while the third cable, which starts at Red Hook Pond, is in danger of failing and will be replaced through this project, he said.

MTN Group reports that submarine cable system reaches Ghana MTN Group, which notes that it has invested $90 million in the West Africa Cable System (WACS), has seen the 14,500-km-long submarine cable further extended with its recent landing at South La in Accra. The WACS cable has already landed in other African countries with the most recent prior landing at Yzerfontein, along the west coast of the Western Cape, South Africa. Reuters reported that the cable had landed in Accra, which is one of the stops in the ultra-high-capacity fiber-optic submarine cable system, which links Southern Africa and Europe, spanning the west coast of Africa and terminating in London. Ghana News Agency reports that the overall system, valued at $650 million, “is the largest design capacity submarine cable system to ever land on the Africa continent.” WACS, with its 5.2 tetrabite design capacity, is expected to increase overall capacity for transmission of telecommunications data (bandwidth) in Ghana,” MTN Ghana CEO Michael Ikpoki said in a press release. “This single cable will catapult the country deep into the digital age.”

Superior Essex buys the U.S. assets of Japanese company A subsidiary of U.S.-based Superior Essex, Inc., has acquired the U.S. magnet-wire business of a Japanese firm. A press release said that the Essex Group has bought the magnet wire sale and distribution capacity of Tokyo-based Furukawa Electric Co. Ltd. and American Furukawa, Inc., which supplies technology for cars, electronics and specialty products in the Americas. The terms of the deal were not disclosed. Essex believes it will help the company make inroads with Japanese parts suppliers in the hybrid and electric vehicle segment, the release said. It noted that Essex also signed a technical agreement with Furukawa Electric, with which it has had a business relationship since 1988.

14 | WIRE JOURNAL INTERNATIONAL

2011 WCMA award winners were, top row: Stewart Later, Comtran Cable; Peter Sheehan, Cobra Wire & Cable; Randall Crenshaw, CommScope; William Reichert, Champlain Cable; bottom row, Raymond Baril, Temp-Flex Cable; James George, NEPTCO; Jim Anixter, A-Z Industries; Robert Raiti, Owl Wire & Cable. Photo by Mike Dogastino, Casson Foster Photographers.

WCMA honors 2011 award winners The Wire and Cable Manufacturers’ Alliance, Inc., (WCMA) honored recipients of the 2011 Charles D. Scott Distinguished Career Award at a banquet on April 16th in Hartford, Connecticut. The recipients were: Jim Anixter, A-Z Industries; Raymond Baril, Temp-Flex Cable; Randall Crenshaw, CommScope; James George, NEPTCO; Stewart Later, Comtran Cable; Robert Raiti, Owl Wire & Cable; William Reichert, Champlain Cable; and Peter Sheehan, Cobra Wire & Cable. This award, named for the Late Charles D. Scott (19151983), the founder and president of Northeast Wire Co., recognizes wire and cable industry professionals with a minimum of 25 years experience, who during that period have made significant commercial or technical contributions, along with personal attributes of an exceptional degree. The WCMA, which was established in 2004, continues the activities of its predecessor organization, the Wire & Cable Clubs of America. More information about the organization and about submitting nominations may be found at its website at www.wcmainc.org.

CommScope reports 2 wind farm contracts for its copper-clad steel U.S.-based CommScope, Inc., announced that it will supply two U.S. wind farm projects with its GroundSmart™ Copper Clad Steel solution, an alternative to solid and stranded copper that it said is increasingly in demand by utilities for its cost-efficiency and anti-theft characteristics. A press release said that the first project, the 30,000-acre Breckenridge Wind Farm, located outside Breckenridge, Michigan, will use stranded copper-clad steel in the ground grid collector system, producing some 200 megawatts of wind energy, enough to power nearly 54,000 homes. The

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INDUSTRY NEWS

second project, it said, is the Rolling Hills Wind Farm near Massena, Iowa, which it described as being “one of the largest wind farms under construction in the state.” “As renewable energy continues to increase in popularity, developers are racing to keep up with the demand by constructing new wind farms throughout the country,” said Ric Johnsen, senior vice president, broadband, CommScope. “These two projects are vital to the areas they serve and developers see GroundSmart as a simple solution to reducing projects costs without compromising the system’s integrity.”

New owner has been announced for Milliman Extrusion Tool and Design Brian Baker has purchased U.S.-based Milliman Extrusion Tool and Design, Inc., from Aaron Milliman, who has decided to leave the industry to pursue other interests. A press release said that Baker and CEO Ryan M. Otenberger have revised and changed the organization, a tip and die manufacturer for the wire and cable industry, which now operates under the name Southern Extrusion. For more details, call tel. 407-648-7074 or go to www.southern-extrusion.com.

Middle East cable factory opened The Middle East Specialised Cables (MESC) recently inaugurated a new cable plant in Ras Al Khaimah (RAK), one of the emirates of the United Arab Emirates (UAE). MESC’s new manufacturing facility is dedicated to supplying the UAE and the Gulf countries with high-end quality cables, an on-line article, citing Zawya, reported. The factory, it said, is spread over 76,900 sq m on two sites, the larger (52,376 sq m) of which houses the production facility, warehouse, offices and workshops while the latter is for accommodation and storage. In the story, MESC official Abdul Aziz Al Namlah said that the new facility is the company’s third, after Saudi Arabia and Jordan. In it, he said that the company has invested approximately US$45 million and has a workforce of 160 employees, with sales revenues projected to be between US$80 million to US$133 million a year. “Although the 7,000 metric ton output is low compared to industry standards, since the factory produces specialized and standardized cable, the production line will be noticed. It is one of the biggest and high-end technology plants in the region for producing industrial, instrumentation, control and low-voltage power cables.” “The new manufacturing facility gives a further boost to MESC group products and to the economic growth of the

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INDUSTRY NEWS

region,” the story said. It cited surging demand for cable across the MENA region that is expected to fuel MESC’s growth, said Namlah, noting that “the resounding success of the RAK Free Zone has been a major milestone in the emirate’s march towards becoming an investor friendly destination.” Shaikh Saud Bin Saqr Al Qasimi, Supreme Council member and ruler of RAK was among those at the inauguration.

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wireworld.com founder sells business Ulf Svensson, the founder of www.wireworld.com, announced that he has sold the Canadianbased business to Paul Douwes, who has been the general manager of Wire World Internet for the past few years. The deal includes Unicode Inc., and Wireworld founder the following industry web sites: Ulf Svensson. wireworld.com, wirelinks.com and tubelinks.com as well as Wire & Cable Business Review magazine. Svensson recalled that the Internet was decidedly different when wireworld was launched in 1995, when Web-Crawler and Alta Vista were strictly on-line search-byword databases. It was going to be difficult to make it work for the wire and cable industry, which has many relatively small companies, different names for the same products in different countries and more than a few people who are not fluent in English. “It was clear to me that before our database was posted on the Internet, this had to be addressed,” he said, noting that, with help, he designed a search by a menu system based on a five digit product code. It took nearly a year to complete the encoding, the precise indexing of some 4000 products and cross-referencing them to the suppliers, a gigantic task that required intimate detailed knowledge of the industry, Svensson said. The result was some 45,000 html pages that made up the “WHO SELLS WHAT” trade index “that was and still is the heart of wireworld.com,” he said. In 1995, only a handful companies had web sites, so for wireworld.com to sell links “was a tough haul to put it mildly,” Svensson said. “By December 1996, we had seven paying customers to invoice. To boost revenue and sales we offered to design web sites at $50 per web page,” he recalled. “They were no Leonardo da Vinci, but they were good enough to create a web presence,” he said. “As the number of corporate web sites increased, it became apparent that content was key to a success in securing a top listing, and unique specific content was something wireworld.com had to offer.”

LS Cable has changed its name to LS Cable & System “to better telegraph the company’s capability to offer complete system solutions so that the company will more easily enter global markets.” The prior name implied that the company was limited to the cable industry, and failed to convey the image of its complete system solutions for a variety of applications, a press release said. The name change also signifies the company’s eagerness to engender business model innovation as a core strategy. The Korean version of the company name will remain the same. … Southwire’s SIMpull Stack™ reel has been named the wire and cable product of the Year by Electrical Construction & Maintenance magazine. This marks the second straight year, and the third time in five years, that one of Southwire’s SIMpull Solutions™ products and services has received such an honor from the magazine, the company reported. “This latest accolade was the result of a vote by contractors who found the SIMpull Stack reel saved them time and improved job site productivity,” it said. The patent-

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INDUSTRY NEWS

Conference in Orlando, Florida. The award is presented semi-annually to recognize a product supplier that has collaborated with Graybar in an exceptional manner to successfully grow profitable business together. “We are incredibly pleased to present Berk-Tek with this honor,” said Graybar Executive Vice President and COO Kathy Mazzarella. “Berk-Tek was chosen because they understand and support Graybar’s strategic market plan, collaborate effectively at all levels of our organization and demonstrate a commitment to achieving long-term success.” ■

News briefs

ASIAN FOCUS

ASIAN FOCUS Alcatel-Lucent chosen to build a 4,800 km submarine cable system Alcatel-Lucent has been chosen by Leighton Contractors Telecommunications (LCT), a major Australian construction company, to build a 4,800 km multi-terabit submarine cable system. The new system, a press release said, will link Perth, Australia, to Singapore, providing the first open access high-speed connection from Western Australia to South East Asia. Commercial operation of the network is planned to start in 2013. The AustraliaSingapore Cable (ASC), to be constructed and laid by Alcatel-Lucent, will launch at 40 Gbps, but has been designed to be upgradeable to 100 Gbps as capacity requirements increase, reports ITNews. It noted Map showing the route for the that this project Australian-Singapore Cable. replaces a previous joint-venture announced last January that called for Leighton’s NextGen Networks to construct a similar network with Singapore’s Matrix Networks and Indonesian landing station operator PT NAP. That deal did not go forward because of demands from global carrier customers, it said. The new venture, ITNews said, makes it possible to accommodate “branching units” along the route that would allow the contract to be amended to connect facilities along the way of the route, should customers demand. “The cable has been built, for example, with the option of landing in Jakarta, Indonesia, but as yet the company said it has no plans to land there,” it said. The new submarine cable system will provide approximately eight times more capacity than similar regional routes, “filling the much needed gap in the marketplace connecting Australia to Asia,” it said. The system design has an ultimate capacity of at least 6 Tbit/s and potentially over 16 Tbit/s with the 100G

option, the release said. From Perth, traffic will be transported across terrestrial infrastructure, to provide competitive wholesale backbone services in Australia, it noted. Philippe Dumont, president of Alcatel-Lucent Submarine Networks SAS, said that the capability is essential. “Today, 40G is increasingly a key requirement to manage traffic growth and meet multi-terabit capacity demands. 100G technology for submarine links is the next step to meet future bandwidth demand and match high-speed interconnection requirements with terrestrial networks,” he said. In related technology news, the company reported an industry first. Pakistan’s PTCL will be using AlcatelLucent’s VDSL2 bonding technology to provide existing digital subscriber line (DSL) customers with speeds up to 50 Mbps, a press release said. The project leverages Alcatel-Lucent’s VDSL2 bonding expertise and should be completed by the end of the second quarter of 2011. The release explained that VDSL2 bonding takes two copper-based VDSL2 lines per subscriber and aggregates them, nearly doubling the bandwidths available to existing customers. It cited a recent study that said simultaneous access to applications such as peer-to-peer file sharing, online gaming, streaming audio, VoIP and IPTV will soon require bandwidths between 50 and 100 Mbps, supporting the need for greater bandwidth. “This fits exactly with VDSL2’s capabilities, especially when combined with innovations such as bonding and vectoring,” it said.

ASIAN NEWS BRIEFS India has huge need for optical fiber India’s telecom industry may be quite busy over the next three years as the country’s Department of Telecommunications seeks to target 160 million broadband subscribers in the country. Per wire reports, The Telecom Regulatory Authority of India (TRAI) has already submitted recommendations to achieve 160 million broadband subscribers, and the ministry of communications has received plans from the Department of Telecommunications to implement the project to deploy nationwide fiber optic cable network to facilitate the high-speed broadband connectivity. The reports estimated that some 500,000 km of fiber optic cables may be needed in the next three years in India for the project, the total cost of which would be approximately US$ 4.5 billion. Broadband was described as the key to growth for the next generation, and highspeed broadband will provide more opportunities to the growing Indian economy, the reports said.

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

20 | WIRE JOURNAL INTERNATIONAL

U.S.-based Teknor Apex Company has renamed Singapore Polymer Corporation (SPC), an international business based in Singapore that it acquired in 2001. The new name, Teknor Apex Asia Pacific Pte Ltd., was created to establish a single brand for the company’s diversified compounding business, which a press release notes stretches from Saudi Arabia to New Zealand. It noted that the company now shares the same name with its sister company in China: Teknor Apex Suzhou Advanced Stanly L.K. Tan Polymer Compounds Co. Ltd. Stanly L.K. Tan serves as managing director of both companies. The company, founded in 1969, supplies rigid and flexible vinyl, thermoplastic elastomers, nylons, filled polyolefins, conductive compounds, black and white masterbatches and compounds produced on a tolling basis. “Combining all of our operations under the Teknor Apex brand represents the culmination of a decade-long process of integration that has created one company in fact—not just in name,” Tan said. “Whether our customers are based in Saudi Arabia, India, China, or Australia, they now have the assurance of dealing with a single organization having uniform standards, product designations, business practices, and regulatory approvals.”

Asia’s top 400 cable manufacturers A report from Ireland’s Research and Markets, “Top 400 Cable Manufacturers Industry (Asia)—2011 Edition,” presents an in-depth financial evaluation of the Asian cable manufacturers industry. A press release said that the report, which uses the Plimsoll method of analysis, lists the top 400 Asian cable manufacturers, each individually assessed and ranked against each other and compared to industry averages. “Using the most up-to-date financial information available, the two-page-per-company analysis provides detailed financial analysis for each organisation,” it said. Details include: sales growth, trading stability, profitability, employee performance, debt level, gearing ratios, creditor exposure, performance ratios and overall financial rating. Results, it said, are in graphical, numeric and narrative forms, and all individual analyses are measured in both the company’s own currency and U.S. dollars for ease of use. “Companies can change at an alarming rate in a very short space of time, so it is vital that you keep up to date with any changes to your market, and how those changes can affect you,” the release said. Contact: Research and Markets, U.S., tel. 646-607-1907; www.researchandmarkets.com. ■

ASIAN FOCUS

New name for Singapore Polymer Corporation

e -lin n i ic le lab ra son i a av ult ow GEO N h W: wit ning NE a e cl

JUNE 2011 | 21

PEOPLE

PEOPLE ArcelorMittal has promoted Danie Devapiriam to general manager of its U.S. steel mill in Georgetown. He has more than 30 years of experience in the steel industry, has taken over as general manager and has worked for ArcelorMittal since 2006, most recently as division manager of the Georgetown rolling mill, which reopened January 2011 after being closed for more than 17 months because of a lack of orders. He replaces Marcio VanDerPut, who has returned to ArcelorMittal Brazil. Based in Georgetown, South Carolina, USA, and a part of ArcelorMittal, ArcelorMittal Georgetown manufactures steel wire rod products.

and had been trained to install, troubleshoot, startup and provide preventative maintenance of Benshaw Controls and BARDAC Drives in a variety of applications. He is also capable of providing service for Staco Energy Products, Surge Suppression International, Diagraph Ink Jet and W. Gilles contact printers; and is arc flash protection trained. Based in Cumberland, Rhode Island, USA, Amaral Automation is a distributor/manufacturer’s representative serving the extrusion, injection molding and municipal wastewater markets as well as the Northeast representative for numerous industry suppliers.

Jonas Gustavsson has been promoted to president of Sandvik Materials Technology and a member of the company’s Group Executive Management. He had been president of the wire and heating technology product area within Sandvik Materials Technology. He holds an M. Sc. Degree in mechanical engineering from Luleå Technical University. He had been general manager of the company’s tube operations and previously worked for Bombardier Recreational Products and ABB. He replaces Peter Gossas, who is retiring. Based in Sandviken, Sweden and one of three business groups of Sandvik AB, Sandvik Materials Technology supplies products that include wire.

Davis-Standard, LLC, reported the following personnel changes in its Extrusion Systems Aftermarket Department. Kevin Breault has been promoted to manager of aftermarket sales. His new responsibilities are to manage the sales efforts of the Aftermarket Business Group for noninventoried products, such as rebuilds, screws, barrels and gear cases, and to Kevin Breault provide aftermarket sales support for multiple business segments within the organization. He is also responsible for management of used inventory sales and management of inter-company business. He has been with the company for more than 18 years, serving in positions of increasing responsibility that include

Amaral Automation has named R.J. Amaral, the son of owner Rick Amaral, as sales and service coordinator. He has worked fulltime for the company since the end of 2010,

OBITUARIES John Cleaver, a fixture for more than a half century at Gibbs Wire & Steel, Inc., died May 4 after a short illness at age 85. A resident of Notre Dame, Indiana, he was a decorated World War II veteran who received multiple awards, including a Presidential Citation, for his bravery during World War II during his time with the Seventh Army, 254 Infantry, in France and Germany. Following the war, he earned a degree in economics from Lafayette University. He met his wife, Marian, to whom he was married for 58 years, at Allegheny Ludlum Steel in Pittsburgh, Pennsylvania. He joined Gibbs Wire & Steel and they raised their family in Mishawaka, Indiana. He worked in sales for Gibbs for 49 years, including a lengthy period as vice president of sales. Don Gibbs, the company’s vice president of sales and sales manager, who noted that Cleaver had been his boss for 30 years, described him as a dedicated man who loved what he did. The company was founded in 1956, and Cleaver was the third employee, he recalled. Cleaver opened the company’s first warehouse in the early 1960s, and even though he technically retired several years ago,

22 | WIRE JOURNAL INTERNATIONAL

he continued as a senior advisor, coming to work on a fairly regular basis up until a month or so before his death, he said. “He loved his work. I think it kept him going.” He was predeceased by his wife. Survivors include children John Cleaver, Lisa Brunckhorst, Leslie Moran and Danielle Pittman; a sister, Anne Cleaver Marsh; and 10 grandchildren. William Henry Chase, Jr., who had been working in technical sales for Fil-Tec Inc., died April 25 at age 83. A world War II veteran, he worked most of his life in New Jersey and lived in New Jersey, then North Carolina, and lived his last several years in Virginia. He worked up to near the end for Fil-Tec, which he joined in the mid 1990s after retiring from Belding Corticelli Thread Company. He was known for his jovial nature, generosity and professional dedication. He is survived by his wife, Kathleen B. Chase; four sons, William H. Chase III, Mitchell L. Chase, Mark M. Chase, and Bruce F. Chase; and 12 grandchildren and nine great grandchildren.

Houston Wire & Cable Company named James L. Pokluda III, its longtime vice president of sales & marketing, as the new company president. He will also assume the additional responsibility of CEO at the end of the year. He replaces Charles A. Sorrentino, who after 13 years has decided to move to other challenges. It also reported the promotion of Christopher R. McLeod to senior vice president of operations. Based in Houston, Texas, USA, Houston Wire & Cable Company is a major supplier of wire and cable. Bill Houle

Rick Reigelsperger

General Cable Corp. reported two additions to its Gepco International sales team. Jeff Peters will serve as director, business development. He has spent the last 15 years in various positions with ADC Telecommunications, Inc., and prior to that he worked for Telex Communications for nine years. He holds a bachelor’s degree in business management from the University of St. Thomas. It also named Lance Thompson as regional sales manager for the Northeast. He has 29 years of experience selling Belden products, most recently serving as regional channel manager. He holds a bachelor’s degree in international studies from the University of Toledo. A business of U.S.-based General Cable Corp., Gepco International supplies high-end cabling solutions for the professional broadcast and entertainment markets. ■

JUNE 2011 | 23

PEOPLE

assembler, field service engineer, senior field service engineer, and sales engineer-aftermarket. Bill Houle has rejoined Davis-Standard as sales engineer-aftermarket, responsible for making field contacts with customers and prospective customers in DavisStandard’s Aftermarket Department. He joined the company in 1997 as a welder on the production floor and was then promoted to senior sales engineer in the parts department where he spent nine years in aftermarket. He most recently was regional sales manager for Xaloy. Rick Reigelsperger has re-joined Davis-Standard as a salesman in the Spare Parts Department. Reigelsperger was originally hired in 2000 as a quality control technician, and was then promoted to sales parts coordinator/quality control technician in 2001. Based in Pawcatuck, Connecticut, USA, DavisStandard, LLC, supplies extrusion technology for sectors that include wire and cable.-

FIBER WATCH

FIBER WATCH Vietnamese company to invest $250 million in fiber optic network in Peru Vietnamese-based Viettel plans to invest $250 million to create its own fiber optic network in Peru to provide telecom services. LivinginPeru.com reports that the company will invest the $250 million over the next five years. Minister of Transport and Communications Enrique Cornejo said that the company’s policy in Vietnam as well as in other areas where it operates is to invest in its own fiber and to not rely on the networks of other companies. “They are interested to get (optical fiber) to the entire country so they first will target large markets and then smaller markets. They want to get to the mountains and the Amazon and have very good will and intention to get it done,” Cornejo said in the article. It noted that the fiber optic networks will carry “all kinds of information at high speed and quality.” The current fiber optic network deployed in Peru, the article said, only extends along the country’s coast, from Tumbes to Tacna, with parts of it going to the heights of Arequipa and Huancayo. The rest of the country’s entire communications system depends on other technologies, such as satellite and wireless, which do not have the quality that optical fiber brings in terms of speed, durability and loyalty, it said. Per Viet Nam Business, Viettel, an army-run telecom group, has been very active in Peru, where it has won licenses over competitors that include Wynner Systems from Russia, Americatel from Chile and Hits Telecom Holding Company from Brazil. The group, it said, plans to invest US$400 million in network infrastructure and telecom business in Peru, which represents the company’s fifth foreign market, joining Cambodia, Laos, Haiti and Mozambique. It added that Viettel has become the largest mobile service provider in Vietnam, and the first in the country to offer service in foreign countries.

Stimulus project to use 339 miles of optical fiber in northeast U.S. One of the latest U.S. federal stimulus investment projects calls for the installation of 339 miles of fiber-optic cable in Rhode Island and southeastern Massachusetts. The Providence Journal reports that the $32.4-million project will connect hospitals, universities, school districts, libraries, law-enforcement organizations and governments around Rhode Island and southeastern Massachusetts. The article said that funding for the project, set to be completed in the spring of 2013, comes from a $21.7-million federal stimulus grant plus $10.7 million in private funding. The cable will be installed and maintained by Cox Business, mostly on existing poles, with each cable con24 | WIRE JOURNAL INTERNATIONAL

taining 48 strands of optic fiber, the story said. It added that the cable will link 150 sites around the state to members of OSHEAN, a nonprofit coalition of educational, health-care and government institutions. One of the OSHEAN goals, it said, was to have at least one fiberoptic link for every school district in the state, generally at a high school.

African Development Bank provides loan for SEAS fiber optic project The African Development Bank (AfDB) has approved a US$12 million loan to finance Seychelles East African System “SEAS,” a project designed to connect Seychelles to global internet exchange centers using high bandwidth link at lower costs. At is website, AfDB reports that the SEAS project will be co-financed by the European Investment Bank, with equity contributions split between the three shareholders: Seychelles government, Cable and Wireless Seychelles and Airtel. The project calls for the construction of a submarine optical cable system and associated equipment to link Seychelles (Victoria, on Mahé Island) to Tanzania (Dar-el-Salam). The system, it said, will have a pair of optical fibers configured to provide 32 wavelengths, allowing a maximum throughput of 320 Gbit/s. It added that from Tanzania, Seychellois telecom operators will have access to international connectivity. The project, AfDB reports, is expected to reduce broadband service costs and provide an alternate and more competitive traffic route as well as “provide Seychelles businesses with advanced and cost-effective technology that would make them more competitive.”

New Hampshire company to build a fiber optic ‘middle mile’ connection A small Nashua startup, along with a long-established Massachusetts firm, has won a $34 million contract to build a fiber-optic “middle mile” connection. The Nashua Free Journal reports that New Hampshire Optical Systems, a telecom firm, was awarded the contract by Network New Hampshire Now (NNHN), which was described as a public-private collaborative that received $66 million in federal stimulus money last year to create a broadband highway system. The fiber-optic backbone is supposed to swing through the western and northern portions of the state, it said. The award to New Hampshire Optical Systems is a major step in the project process, which officials say should lead to fiber-optic cable being placed on poles as early as this summer, the article said. ■

WAI’s resources helped put the fun into hard work. Seriously. Q: Why did you join WAI? A: I was given the project of bringing some new technology developed in Europe to the North American wire and rod market. Before that time I had never worked in this industry. I joined WAI to receive the Reference Guide and meet people involved in the market. I got involved and it became more fun than work!

Q: What are the three most valuable benefits you receive through WAI? A: Contacts and friends in the industry. Keeping up-to-date on changes in technology and market direction. Getting involved in committees and feeling like I gave back to the industry that supported my family. Q: If you were to nominate yourself for an award what would it be for? A: Stubborn Optimist of the Year. In my job there is a new challenge and sometimes a frustration every day. But, I believe any person can be successful with the true desire to do so. The same applies to organizations.

Dane G. Armendariz Business Development Mgr. | Henkel Corp. Member Since: 1993

Q: What do your co-workers say about you? A: They think I am an amiable fellow who works too hard and takes the work too seriously.

Meet Dane G. Armendariz. One of WAI’s worldwide members. One compelling story.

Q: Who was your mentor? A: My parents because my mother was optimistic that my brother and I could achieve anything and my father pushed us to do better.

Dane delights in the serious fun of hard work. With a self-directing compass, his keen optimism lands him North of goal, everytime. His ceiling? Unlimited. The reason? Brilliant ideas have traction. Dane’s profile reveals key themes familiar to all distinguished personalities, namely:

Q: What did your most valuable WAI contact help you do? A: Confirm that an individual can make a difference.

Keen Optimism | Tenacity | Positively Charged | Pace Setting | Goal Realizing | Perpetual Reciprocity He’s a card-carrying go-getter with a will-do attitude. You won’t find him resting on his laurels or confined by the Internet. He meets his friends face-to-face, just like his challenges. He’ll travel the world for either to turn hurdles into history.

Q: What can you help people do? A: Learn more about taking an idea or goal and making it happen.

In dogged pursuit of greatness, the only barrier he acknowledges is off the coast of Australia.

to talk with him after one of his speaking engagements. He is an amazing person.

He’s out there; a WAI resource. Inspiring success. Defining it. Delivering new technology to the market. Even rubbing elbows with astronauts.

Q: Where would you most like to visit? A: Australia. It’s my lifelong ambition to retire and travel with

And you’ll recognize him. He’s the one who will pass on the credit to help someone else soar.

MNEMONIC TIP: DANE G. ARMENDARIZ GREAT DANE DARES TO INSPIRE.

Q: Who is the most famous person you’ve met? A: Jim Lovell of the Apollo 13 crew. I had the opportunity

my wife and best friend, Karen.

Q: What is your greatest accomplishment? A: My very successful son and daughter, but I guess I would have to say Karen should be given most of the credit.

Meet your peers. Achieve your goals. Join WAI’s community at www.wirenet.org. The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

Columbus fastener show to cease Citing “baffling” results for the recent 2011 National Industrial Fastener & Mill Supply Expo in Columbus, event organizers announced that they have decided to end the event and focus on the Las Vegas fastener show. “Show management is very disappointed with the low exhibitor participation and lack of distributor attendance at the 2011 National Industrial Fastener & Mill Supply Expo held last week in Columbus, Ohio,” a statement said. “We employed our best efforts to heavily promote the event ... We are baffled by the poor turnout.” The announcement said that the fastener industry “needs and wants to reduce the number of trade shows held.” It noted that the National Industrial Fastener Expo in Las Vegas “is the one big event everyone points to,” and that smaller state, regional and national shows are suffering. “There simply are not enough marketing dollars and travel funds to support all of the shows.” To that end, the organizers said that they have made the “painful decision to end the historic Columbus Show and focus 100% of our energy, talent, time and resources on making the National Industrial Fastener Expo in Las Vegas even bigger and better than ever before.” The goal is to

made the Las Vegas show “the center of the fastener industry universe,” they said. “In making this huge sacrifice, we are taking the lead in reducing the number of fastener industry trade shows. We trust that the entire industry will appreciate our initiative and follow our lead. We also thank all those exhibiting companies and attendees which have supported our Columbus Show for over three decades. We ... look forward to a bright future for everyone in Las Vegas,” said Jim Bannister and Mike McGuire, general partners. In a blog report by Traveling Salesman, the industry veteran wrote that he had just got back from the Columbus fastener show. “Did not do a lot of Tweeting because there was not a lot to Tweet about. The good news for show management is that they run the largest and most successful fastener show in the U.S.: the National Fastener Show West in Las Vegas. Unfortunately, one of the costs of turning that show into such a big success is that it has caused the Columbus Show to diminish.” The National Industrial Fastener & Mill Supply Expo will be held Oct. 19-21, 2011 at the Sands Expo & Convention Center in Las Vegas, Nevada USA. For more information. Contact Susan A. Hurley at tel. 614- 895-1279, info@fastenershows.com, www.fastenershows.com. ■

JUNE 2011 | 27

FASTENER UPDATE

WAI NEWS

WAI

NEWS

President’s Award given to Steve Vannais’s widow at Interwire 2011 At the WAI’s annual meeting held at Interwire 2011, WAI President Dominique Perroud presented the President’s Award posthumously to the widow of Steve Vannais, who died Jan. 5 at age 58 in a plane crash in Texas that claimed his life and that of the pilot, James Polewchak, 40, both WAI members. Elizabeth (Beth) Vannais and her son, Eric, accepted the

Joined by Larry Fitzgerald, Tim McElhaney and Bob Malo, Beth Vannais and son, Eric, accept the President’s Award from WAI President Dominique Perroud.

award, accompanied by Larry Fitzgerald, Tim McElhaney and Bob Malo, all of whom were close to Steve, a 16-year employee of Davis-Standard Corporation. “Sadly, Steve passed away at the beginning of the year, much too soon for his family and many friends in the industry,” Perroud said. “It is difficult to make sense of the loss, especially when you see his beautiful family and know that he would have loved the next stage of his life, continuing his professional success at Davis-Standard, and sitting beside Beth, while watching Eric succeed in school and eventually in his career. However, today is an opportunity for the WAI to recognize Steve for his contributions to the industry and the Association. And, it is a chance to give something to Eric and Beth, much like Steve gave to the Association.” Vannais, an active WAI member, was a key force to the Southeast Chapter’s being created in 2001. He and McElhany, Tulsa Power, worked together on the chapter golf tournament, with Beth often helping out on registration. She will also help out on this year’s tournament, which will also serve as a scholarship fundraiser for Eric. The President’s Award is given at the discretion of the WAI president to recognize an individual for outstanding contributions to the Association. ■

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

WAI’s Memorial Awards Committee Every year, the Wire Association may bestow its two most prestigious awards to individuals who have made a truly remarkable contribution to their industry and association. The Donnellan Memorial Award is given in honor of former WAI Executive Secretary J. Edward Donnellan, and it recognizes outstanding volunteer contribution to the association and its mission. The Mordica Memorial Award is given in honor of WAI’s first president, John Mordica, and it recognizes an individual’s outstanding contribution to the overall wire and cable industry. “Our job is to collect nominations and help determine the credentials for each candidate,” explained Chairman Brian Bouvier. “Only the best candidates should be nominated, but we also have to be careful not to overlook anyone who’s truly deserving either.” The Memorial Awards Committee is composed entirely of former winners of these two awards. Together this group compiles and refines the list of potential nominees to create each year’s slate of candidates. Planning years into the future, they nominate candidates, assign members 28 | WIRE JOURNAL INTERNATIONAL

or other interested parties to champion a candidate, and compile the nomination packages that will be presented to the board of directors, which votes each year to award these two special honors. “The members of the committee take their task very seriously,” said WAI Director of Education Marc Murray, staff liaison to the committee. Committee Members Etienne Aernoudt, Catholic University of Leuven Brian Bouvier, Lloyd & Bouvier Inc. (Chairman) John Drummond, Scotia Group Inc. Robert J. Glodowski, East Metals North America LLC Bogdan Golis, Czestochowa University of Technology Heijirou Kawakami Sanford R. “Sandy” May, SMS Enterprises Jan Pilarczyk, Czestochowa University of Technology Horace Pops, Horace Pops Consulting Inc. Giulio Properzi, Continuus-Properzi SpA Thomas Renner, South Shore Controls David Richards, RichardsApex Inc. Don Sayenga, Cardon Management Group Robert Shemenski, RMS Consulting Inc. Bhaskar Yalamanchili, Gerdau Ameristeel

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CHAPTER CORNER

CHAPTER CORNER Midwest Chapter tournament set for this month at St. Andrews in Illinois The Midwest Chapter chapter will return to the St. Andrews Golf & Country Club, West Chicago, Illinois, to hold its 9th Annual Golf Tournament on Monday, June 20, 2011. For prospective players not familiar with the course, it is described as offering “an unbeatable variety of holes in a park-like setting that are fun to play and challenging enough to keep the game interesting.”

the front nine, said event organizer Aaron Nolan, sales engineer, Sumitomo Electric Carbide, Inc., Materials Group. He noted that sign up will be at 10:30 am, with lunch served around 11 am before play starts. The post-tournament dinner will follow at 5 pm. A range of sponsorship opportunities will be available for companies. For more details, contact Aaron Nolan at tel. 614-410-3375, a_nolan@sumicarbide.com. At the golf course’s website, it notes, “The Grantwood golf experience has been rated by Golf Magazine as one of the “Top Five Courses You Can Play In Cleveland Under $50.” Further details can be found at the chapter’s page at www.wirenet.org.

New England Chapter looks forward to new location for its 2011 golf tourney

The Midwest Chapter will hold its gof tourney this month at St. Andrews Golf & Country Club. Players can sign up individually or as teams for the bestball scramble format, with the $125 registration fee covering greens fees, cart, lunch and the reception and awards dinner. Check in and warm-up is at 10 am, the shotgun start is at 11:30 am and the reception, dinner and awards presentations is at 5 pm. The event supports the WAI Midwest Chapter Scholarship Fund, which provides financial assistance to graduating high school seniors who are children or dependents of WAI Midwest Chapter members in good standing. The program, which began in 2008 in conjunction with The Wire Foundation Inc., has awarded two $1,000 scholarships in each of the past three years. “We’re looking forward to another great golf tourney,” said event Chairman Kevin Sopczak, director of marketing and sales for Shaped Wire/Legget & Platt, who noted that 64 people attended last year. A range of sponsorships are still available for companies that would like to support the event, he said. He can be contacted at kswire@aol.com.

WAI’s Ohio Valley Chapter sets the date and location for its golf tourney WAI’s Ohio Valley Chapter reports that on Wednesday, August 3, the chapter will return to the Grantwood Golf Course in Solon, Ohio, for its 9th Annual Golf Outing The event will feature a modified shotgun start at noon on

30 | WIRE JOURNAL INTERNATIONAL

The New England Chapter will be playing at a new location when it holds its 17th Annual Golf Tournament on Monday, Sept. 12, at the Ellington Ridge Country Club (ERCC) in Ellington, Connecticut. Wherever it is held, the New England Chapter golf outing is well attended, with serious interest in the bragging rights that are up for grabs. Last year, the The clubhouse at the Ellington Ridge team of Dick Country Club in Ellington, Connecticut. Palmer, Ron Reed, Scott Reed and Al Divincenzo won the tourney, which had more than 140 players take part. “This will be the first time at the Ellington club, and we think that players are really going to enjoy playing this course,” said New England Chapter President Marie Geary, Geary Procurement Consulting. She said that chapter representatives who toured the course were impressed with the layout. ERCC, founded in 1959, was recently cited by Connecticut Magazine for being among the 10 best country clubs in Connecticut. At the ERCC website, it notes that since its inception, the course has hosted more major state and regional golf championships than any other course in the state. The course has been consistently rated in the top five in Connecticut and three of its golf holes were selected by the Connecticut PGA as among the 36 best in the state. Geary said that a range of sponsorship opportunities are available for companies. She can be contacted at tel. 401309-5977, gearyprocurement@cox.net. ■

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INTERWIRE WRAPUP

Interwire wrapup The combination of a bolstered technical program, better economy and the return to familiar grounds added up to very successful results for Interwire 2011, which received overwhelmingly positive reviews from exhibitors, many of which reported that attendees were there to do business. Total attendance was 4,022, up 19% from the 2009 event in Cleveland, with attendees coming from 53 countries. “Interwire had tremendous support from the wire and cable manufacturing community. More than 750 wire and

cable facilities sent representatives—many sent multiple attendees—all with action items to accomplish at Interwire,” said WAI President Dominique Perroud. He added that support from sponsoring companies (see p. 50) helped bolster the scope and depth of the event. More than 400 companies were represented at the threeday exhibition. Comments from exhibitors and attendees begin on p. 48. The overall technical programs were well received, with nearly 100 technical and operational presentations. The

A contingent from Viakable, led by Director of Technology & Development Patricio Murga, fourth from left, meeting at the Rosendahl booth at Interwire.

32 | WIRE JOURNAL INTERNATIONAL

INTERWIRE WRAPUP Interwire returned to the Georgia World Congress Center with a new look and a new vitality.

WAI’s educational programs included three new theme days: metals and materials; manufacturing best practices; and green initiatives (see p. 55 for the roundtable on safety); Fundamentals of Wire; Doug Relyea’s Productivity Workshop; and the return on the show floor of the Production Solution demonstrations (surface treatment technology/Boockmann GmbH andThe Slover Group; roll straightening/Witels Albert USA; FEP foaming technology/Fine International Corp.; wiredrawing lubricants/Etna Products Inc. & Etna Bechem Lubricants; and wire breaks/Horace Pops Consulting at the Properzi International Inc. booth). It also included the first-time Global Continuous Casting Forum for copper

WAI’s programs included three days of “themed” technical presentations.

An attendee searches exhibitors at a kiosk.

WAI President Dominique Perroud welcomes attendees at the Awards Ceremony.

JUNE 2011 | 33

INTERWIRE WAPUP

The father-son team of Willy and Chris Hauer at their company’s booth.

An overhead view of activity on the show floor.

Seated at right, GCR’s Lorenzo Facchinelli checks out options for attendees.

George Webb II discusses his company’s payoff technology with attendees.

34 | WIRE JOURNAL INTERNATIONAL

WireLab’s Rob Fulop talks business at the company booth.

INTERWIRE WRAPUP

practitioners, which ran concurrently with Interwire, a comprehensive event created by Gary Spence, Encore Wire Corporation (see p. 38 for details). Also held in conjunction with Interwire was the American Wire Producers Associationâ&#x20AC;&#x2122;s (AWPA) 2011 Wire Rod Supply Chain Conference (see p. 36 for details). At the Awards Ceremony on Monday, May 2, WAI bestowed its highest honors on Prof. Kazunari Yoshida, Tokai University, Japan, and Thomas E. Moran, National Standard Co., USA, winners of WAIâ&#x20AC;&#x2122;s Mordica Memorial Award and Donnellan Memorial Award, respectively. The ceremony also saw awards presented for the best technical papers in 2010. Winners included the following: in the Ferrous Division, the Allan B. Dove Memo-

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AWPA WRAPUP

2nd supply chain conference furthers AWPA’s goals of providing information

Adam Parr, Steel Manufacturers Association, discusses legislation, regulation and public policy matters. More than 160 attendees from all levels of the supply chain took advantage of critical information and business opportunities at the 2011 Wire Rod Supply Chain Conference, which was held at the Omni Hotel at CNN Center in Atlanta in conjunction with Interwire. The 33 sponsoring organizations included AWPA member companies, affiliated associations and industry press. “Holding this conference alongside WAI’s convention continues to be a formula for success and we are looking forward to 2012 in Dallas, May 21-23,” said AWPA Executive Director Kimberly Korbel. The event saw a range of speakers from both industry as well as “big picture” experts. Speakers included Joseph

AWPA Past President H. Woltz with speaker Kenneth Simonson.

36 | WIRE JOURNAL INTERNATIONAL

Alvarado, President and COO of Commercial Metals Company; Adam Parr, Steel Manufacturers Association (SMA); Claire Zempel, principal, Zemple Strategic; Kenneth Simonson, chief economist, Associated General Contractors of America; Eric Klenz, Metals & Mining Practice Leader, KeyBanc Capital Markets; and John C. Robertson, senior economist for the Federal Reserve Bank of Atlanta. The event also included a wire rod supply outlook panel as well as networking events, and was held in conjunction with Interwire. Many attendees visited the show at the Georgia World Congress Center. As noted above, AWPA plans to hold a supply chain conference next year in conjunction with Wire Expo in Dallas.

Supply Chain Conference speaker Eric Klenz.

INTERWIRE WRAPUP Amaral Automation’s Joe Snee, l, and Steve Mepstead, PWM, welcome attendees.

rial Award went to Ryan Pennington, Bekaert Corp., USA, Walther Van Raemdonck, NV Bekaert SA, Belgium, and David K. Matlock and George Krauss, Colorado School of Mines, USA, for their paper: “The effect of silicon and aging on mechanical properties and fracture response of drawn high-strength pearlitic steel wire.” No Silver Certificate was awarded.

Attendee shopping lists could be filled at the Wire & Plastic Machinery booth.

In the Nonferrous Division, the Marshall V. Yokelson Memorial Award went to Tadeusz Knych, Andrzej Mamala, Beata Smyrak and Monika Walkowicz, AGH University of Science and Technology, Poland, for their paper: “Research on the influence of the structural state of Cu-ETP wire rod on the annealing susceptibility of wires.” (cont’d. on p. 42)

Horace Pops explains wire breaks at the Continuus Properzi booth for his presentation for Production Solutions.

JUNE 2011 | 37

FORUM WRAPUP

An industry niche gathers

The Global Continuous Casting Forum drew more than 200 attendees from 25 countries.

It started with one person, Gary Spence, vice president of nonferrous materials for Encore Wire Corporation, and one idea, that it would be a plus for Interwire if a meeting could be hosted alongside the event for the entire global continuous casting sector. Some 18 months later, that concept resulted in a phenomonally successful program that saw 205 attendees from 25 countries meet for what is believed to be the most comprehensive such program ever held. The rave reviews e-mailed in by attendees of the Global Continuous Casting Forum spell out just how much they appreciated the opportunity to sit in on a single program that included all of the major continuous casting technologies. Programs have been held on the topic, but usually they are limited to one or two of the major technologies for continuous casting. The four-day program held alongside Interwire in Atlanta included the SCR, Contirod, Properzi and UPCAST OY processes, presented by speakers that were both well-known and highly regarded. Spence said that his goal was for the forum to be a blend of four elements: networking, education, value and fun. By the reviews, that goal appeared to have been met. “It was an excellent conference with a great mix of papers and social events. The timing and agenda for each day was just right to keep people refreshed and connected.

38 | WIRE JOURNAL INTERNATIONAL

On behalf of the ASARCO guests, Thanks again!” said Steve Jones, ASARCO. “Thanks a lot for perfect organization of this meeting. Was nice to be a part of it!” said Dr. Michael Schwarze, SMS Meer GmbH. “It was a very beneficial occasion for my career, to meet new people from the sector. I hope to see you in Turkey one day,” said Tolga Ediz, Sarkuysan. “I would like to thank you for havSpeaker Hal Moss, Lucent Teching organnologies (Ret.), spoke about the ized the early history of continuous castGlobal Coning and rolling of copper rod. tinuous Cast-

G L O B A L

CONTINUOUS

CASTING —

F O R U M

—

WAI acknowledges the following contributors to the Global Continuous Casting Forum program Gil Baker Milton Berry Juan Carlos Bodington Carmelo Maria Brocato Kevin Carpenter James D. Cooper Tolga Ediz Miquel Garcia Steve Griffin Tom Horn Bruce Huffman

John Hugens Daniel L. Jones Jörg Köhlhofer Tadeusz Knych Wade P. Krejdovsky Randall Luebcke Timm Lux Andrzej Mamala Kiran Manchiraju Hal Moss Kyle Moye

Hari Muthuswami Michael Nairn K.H. Patel Herman W. Pilats Horace Pops Giulio Properzi J. Angelica Ramos Matt Reinoehl Joseph Scalise Ronald Schenk Michael Schwarze

Beata Smyrak Julio Spadaccia Mark Spears Gary L. Spence Tim Stahlhut Reed von Gal Monika Walkowicz Christine Wenzl Noell Wilson Sharon Young

THANK YOU TO OUR SPONSORS:

FORUM WRAPUP

Fetteroll, Janice Swindells and Adrienne Simpson (marketing), Chuck Szymaszek (computers) and Marc Murray (program coordination). Spence said that he had expected the event to draw about 150 people from various companies and countries, including the major OEMs as well as copper rod manufacturers, copper producers and suppliers, and realized that there was a strong base of support. Further, if the event is held again, the attendance likely would be much higher, he said. “I had several people tell me Early copper continuous casting pioneers of the 1960s-70s, l-r: at the end first row: Hal Moss, Tony Stevens, Horace Pops, Rene Mortier, that if they Miquel Garcia; second row: Dale Proctor, David Barnes, John knew what Durscher, Milton Berry, and third row: Gary Spence, Noell the event Wilson and Andrea Peviani. would be like, they would ing Forum: an incredible opportunity given for technical have had three or four growth. I might also add that the overall organization of people there with them.” the event has been more than perfect,” said Carmelo Maria Spence outlined the Brocato, commercial director, Continuus-Properzi. technical program, “The forum was certainly excellent, it was a great which included operaEncore Wire President idea to create an event specifically to copper continuous tional and technical paand CEO Daniel Jones casting industry. Thank you again for the opportunity of pers, workshops, and spoke about process and participating in this important forum,” said Angelica panel discussions. He product innnovation. Ramos, Viakable. then began contacting Spence said that one reason he wanted to hold the event colleagues he considwas that it would make it possible for many people in a ered to be experts for each topic. “The feedback from relatively small niche to meet together, regardless of the those I contacted was extremely positive and full of enthucasting process they use. “I have worked on three different continuous casting processes, and have met really good practitioners on all systems from different parts of the world. I feel our connection is people, people with similar visions, goals, and objectives.” The general program theme was innovation and process improvement. A key element was the support from Encore Wire President and CEO Daniel Jones, who also served as a keynote speaker, his topic being process and product innovation. He also thanked WAI staff, A group photo of forum attendees, most notably including all casting practioners. Executive Director Steve 40 | WIRE JOURNAL INTERNATIONAL

FORUM WRAPUP

siasm. Many said that we should have done this a long time ago, and some people contacted me directly after hearing of the forum asking to participate. Within several months I was having to turn away presenters since I filled the program so fast. We could have extended the forum another day very easily with additional papers and workshops.” Spence said that he met friends he had not seen in many years, including some he first met in the 1970s. “A participating company could not have received a better training value or networking opportunities on the planet in my opinion for the cost of registration. The opening reception and dinner was great fun for everyone,” he said.

Gary Spence displays a plaque presented by WAI President Dominique Perroud and WAI Past President Dane Armendariz. Based upon our survey, we had an overwhelming response to repeat this forum again in three or four years, said Spence, who already has ideas for improvements. Pictures from the event can be found by going to www.wirenet.org, and clicking on “Global Continuous Casting Forum.”

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INTERWIRE WRAPUP

Authors of winning technical papers with WAI President Dominique Perroud, second from left, and moderator Erik Macs, fifth from left.

The Silver Certificate Award went to Andriej Milenin and Piotr Kustra, AGH University of Science and Technology, Poland, and Jan-Marten Seitz, Friedrich-Wilhelm Bach, and Dirk Bormann, Institute of Materials Science at the University of Hannover, Germany, for their paper: “Production of thin wires of magnesium alloys for surgical applications.” In the Electrical Division, the Urbain J.H. Malo Memorial Award went to Octavio Parra, Centro de Investigación y Desarrollo Condumex (CIDEC), Mexico, for his paper: “Life prediction for an optical fiber cable.” The Silver Certificate Award went to Ethem Erdas, Beta LaserMike, USA, for his paper: “An in-process SRL predictor system

Dr. Kazunari Yoshida, Tokai University, accepts the Mordica Memorial Award from WAI President Dominique Perroud.

42 | WIRE JOURNAL INTERNATIONAL

for data cable manufacturing.” No awards were issued in the General category. During the Awards Ceremony, WAI President Dominique Perroud presented the President’s Award posthumously to Beth Vannais, the widow of Steve Vannais, who died Jan. 5 at age 58 in a plane crash in Texas that claimed his life and that of the pilot, James Polewchak, 40, both WAI members. See p. 28. Also at the Awards Ceremony, former WAI President John Drummond, who heads the Wire Foundation, introduced Scott Barker, the 2011 WireLink Scholar, who was attending Interwire as part of his twoweek tour of wire and cable companies in the U.S. His report will appear in a future issue.

Thomas E. Moran, National Standard Co., accepts the Donnellan Memorial Award from Executive Committee member Tom Maxwell.

INTERWIRE WRAPUP

While Interwire 2011 was going on, the Exhibition Planning Committee was busy discussing plans for Interwire 2013.

Astronaut Mike Mullane told attendees not to settle for being “passengers” in life.

At the Board of Director’s meeting, from l-r, are Encore Wire’s Gary Spence, WAI Executive Dir. Steve Fetteroll, WAI President Dominique Perroud, First Vice President Nick Nickoletopoulos, Second Vice President Richard Miller amd Past WAI President Dane Armendariz. 44 | WIRE JOURNAL INTERNATIONAL

On Wednesday, keynote speaker and astronaut Mike Mullane, sponsored by Gem Gravure Co. Inc., encouraged listeners to “Dream Big” at his presentation, during which he shared his experiences of living and working in space, some of which was far from glamorous. He explained how determination, not inherent talents, made it possible for him to become an astronaut. “My success did not come from destiny,” he declared. He noted that in his case, destiny “did not have a genius to work with.” He was not a gifted athlete, didn’t date the prom queen and was lucky to get into West Point, but once there it challenged him hard every day. “It takes guts to set goals and get them,” he said, noting that one needs the courage

INTERWIRE WRAPUP Attendees at the Fundamentals of Wire & Cable Manufacturing course. Sanxin Wire Dieâ&#x20AC;&#x2122;s Doug Thornton introduced author Al Zhangx.

to not just be a â&#x20AC;&#x153;passengerâ&#x20AC;? in life. He cited the Jan. 28, 1986, Challenger disaster that claimed the lives of seven astronauts as a case of what happens when expediency is allowed to overrule valid concerns. Later on Wednesday, Leoni Wireâ&#x20AC;&#x2122;s Alex Boekholt won the WAIâ&#x20AC;&#x2122;s 7th Annual 5K Industry Run, his third straight win in a row from the race that started and ended outside the Georgia World Congress Center. The event, sponsored

by Leoni Wire, drew more than 30 runners, with all proceeds going to charity. Many attendees also took to the familiar streets of Atlanta, but mostly for networking dinners and meetings with customers, colleagues and friends. And, as ever, while Interwire went on, many WAI volunteer groups met to discuss Association business. One news item that was announced is that the next Interwire will be held Atlanta on April 23-25, 2013.

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INTERWIRE WRAPUP

Participants in the WAI’s 7th Annual 5K Industry Run, which was won for the third straight year by Leoni Wire’s Alex Boekholt, back row, third from right. Leoni Wire once again sponsored the event.

Some 80 Interwire attendees went on the tour of Southwire Company.

Blachford Corp.’s Dan Howard with company founder John Blachford at the WAI reception.

The Leoni Wire contingent at the reception included, l-r, Albin Dickert, Neville Crabbe, Andy Zinner, Florian Hettich, Alex Boekholt (winner of the 5K Industry Run) and Scott Wordsworth.

Attendees on the Southwire Tour also get to see the company’s “12 for Life” student program in action.

46 | WIRE JOURNAL INTERNATIONAL

INTERWIRE WRAPUP

Event Observations

John Stowe, general manager, and Roseanne Rietdyke, production manager, Sandvik Wire and Heating Technology Corp. You must keep pace with whatâ&#x20AC;&#x2122;s new in the industry from an equipment standpoint and consumable supplies, i.e., dies, lubricants, in-line inspection/measurement and fault detection. Basically, we were looking for innovative ideas to improve our process and reduce cost. Interwire for us is the venue where hundreds of suppliers are available to discuss how their products can help us in our effort to continuously improve. The amount of information and insight into our industry is invaluable. We attended two technical programs on wire manufacturing along with a number of technical papers related to todayâ&#x20AC;&#x2122;s challenges as a manufacture. Collectively we spent roughly 20 hours in an effort to further expand our knowledge and learn from the actual experiences of others. Another intent was to arrange trial runs on new-found products that help improve our process; this we accomplished with two suppliers. We believe this particular wire show was one where the targeted objectives prior to the show were all accomplished and more. Good show. John Stowe, general manager, and Roseanne Rietdyke, production manager, Sandvik Wire and Heating Technology Corp. We exhibited for the third time at in Interwire, and we did not have many visitors before in Cleveland but Atlanta was good. The show was successful for us, and we left with some solid leads, although we would prefer that the show was still four days as we want attendees to be able to see our equipment. We were pleased to see interest in our 48 | WIRE JOURNAL INTERNATIONAL

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From l-r at the Domeks Makine booth: Ugur Gural, Dogan Ozbaran, Huseyin Ozturk and Orhan Ozbaran. latest development for cable packing, the Quadromatik 400 automatic cable coiling/spooling line, which has many advantages for the American market as it can do spool packing for single wire and coil packing for multicore cables in the U.S. market. Dogan Ozbaran, principal, Domeks Makine. We had cautiously optimistic hopes for a good Interwire. There is a lot of bad news in the press so we were pleased to see customers arriving at the booth with plans to improve their facilities and interest in new technology. The focus is shifting from commodity products to more engineered high end products. This is a good move on the part of the U.S. wire producers. They can keep that niche going and differentiate their products from cheaper imports. We had many solid leads for new products offered at the show. There was not really unexpected business, however the quantity of business decision makers was a pleasant improvement over past Interwire shows. Woody Holland, sales manager, Clinton Instruments. Itâ&#x20AC;&#x2122;s great to be back in Atlanta! Between location, improving business levels, and general optimism, the mood at Interwire was refreshing. Show days can be long, but traffic, developing projects, and positive sentiment made this Interwire productive. Dave Ferraro, vice president sales & marketing, Carris Reels. This was the first time for both of us at Interwire. We took the opportunity to follow the Fundamentals Course and the Productivity Workshop. Some of the lectures were interesting and others were refreshing. We went to the show floor to have face-to-face contact with some of our suppliers, and we also looked for new ideas or techniques

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Maarten Meinesz and Gary Huzinec, Oxford Instruments.

We had a good flow of visitors to our booth. Many of the customers and prospects we spoke with were experiencing some application challenges and had real projects in mind. We considered many of the leads good opportunities. Our sales team is in the process of discussing the application specifics with these customers and potential customers in more detail. We’re confident these opportunities will turn into real business. Jay Luis, marketing manager, worldwide, Beta LaserMike.

Interwire 2011 has seen improvements compared to recent years. It gave us an indication of an upward economical trend in North America. The OM Lesmo Group and Lesmo Machinery America, Inc. booths were visited by several customers and new prospects. In all, we hope that the discussions at Interwire will turn to be real projects very soon. Allan Brown, sales manager, Lesmo Machinery America Inc. Wire & Plastic Machinery had a successful outing at Interwire 2011. We recorded over 150 quality visits to our booth. Some stopped in to say a quick hello and many new prospects emerged over the 3 days. A 12 in. Hall fiber optic respooler owned by Wire & Plastic was also on display at the Hall/MGS stand and generated quite a lot of interest from visitors. Rahul Sachdev, Wire & This year we featured a new booth design showcas- Plastic Machinery Corp.

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INTERWIRE WRAPUP

that were displayed or discussed at several booths, such as the latest measurement techniques from the different manufacturers like Zumbach, Beta LaserMike, Proton Products, Sikora and LaserLinc. Maarten Meinesz, project engineer, and Gary Huzinec, continuous improvement engineer, Oxford Instruments.

INTERWIRE WRAPUP

ing our new website, pictures of latest wire and cable machinery acquisitions, and, of course, a full bar. Rahul Sachdev, executive vice president sales, Wire & Plastic Machinery Corp. We certainly expected better than the last two Interwires in Cleveland. We were pleased with the turnout, more like past Interwires. We received quality prospects, much like the past, and we received the amount that we expected. I don’t want to completely blame the Cleveland location on the disappointing past turnout because I believe the economy in 2007 and especially in 2009 had a big role in those years. We did get many good opportunities but we expected that with the economy and change of venue. While we saw many current customers, we were impressed with the number of new companies we met. Scott Miller, sales manager, Magnus Equipment/Power Sonics. Our expectations were high but the results were even better. We left with numerous solid leads, some expected but many new and unexpected. We received an order directly from the show and expect several more order in the very near future. Also, for us, it was a great opportunity to introduce our new co-venture, Axjo America, to the wire and cable industry in North America. Dan Shelander, president, Windak Inc.

Ron Neuman, l, at the JoeTools booth. Per the poster at its booth, the staff was not “idling” during the show. Great show! Exceeded by 100% my expectations. Everyone that stopped by (and at times we had them five deep!) were excited about the vendors and all the creative displays. I would say about 50-60% are good solid leads. Ron Neuman, JoeTools.

Michaela Boockmann was one of the participants in the Productions Solutions show floor presentations. We did expect higher attendance for this year’s Interwire and companies being prepared for investment. Our expectations were 100% correct. A very positive feature was the possibility to give a Production Solutions presentation. This time our preparation for this presentation was very short, but the idea was excellent and we hope it will be continued. We had very good contacts, finalized contracts are not generally expected during the show. Gerhard Boockmann and Michaela Boockmann, Boockmann GmbH. Our expectation was to have a strong show. I believed being back in Atlanta, the uptick in the economy and the program the WAI put together would make for a good outcome. I was happy that our expectations were not only met but exceeded. The floor traffic was good and more importantly, those walking the floor were decision makers. Another positive was the number of visitors I spoke to who were looking for not only used equipment, but also new. This is a good sign for the industry. We left with many solid leads that we are working on turning into business. Some of those leads were unexpected or new visitors to our booth which was a bonus. Attendance was beyond my expectations and I really liked the international presence of the visitors. This was certainly not just a North American show as we did business and visited with customers and prospects from all over the globe. Drew Richards, CEO, RichardsApex, Inc. Thank you for a successful Interwire 2011. The show was very well organized and all the feedback from our customers has been positive so far. Of course a better

52 | WIRE JOURNAL INTERNATIONAL52 | WIRE JOURNAL INTERNATIONAL

INTERWIRE WRAPUP Standing tall at the company booth, Marco Gerardo, SAMP USA Inc. economy always helps the mood of the industry, but in any event the feeling is of a much better show than the last one in Cleveland. Marco Gerardo, vice president sales & services, SAMP USA Inc. We went into show preparations expecting a better turn out than the show in 2009 simply because market conditions have improved. Even with higher expectations, we were pleasantly surprised. The show generated solid leads for new projects with existing customers and opportunities with new customers. The tone of the show was upbeat. The response to Mike Mullane’s speech and presence on the show floor made the efforts to bring him to Atlanta all worthwhile. Ramona Krogman, marketing manager, Gem Gravure Co. Inc. We were optimistic heading into Interwire. I personally visit wire and cable manufacturers throughout North America and the “tone” of my contacts during the six month period prior to the Expo were generally very positive about the economy and upcoming show. The reality JUNE 2011 | 53

INTERWIRE WRAPUP

for KEIR was that our exhibit had a continuous flow of traffic and our expectations were exceeded. We left with several solid leads and a wealth of market information covering all of our product groups. Mike Walters, sales and marketing manager, KEIR Manufacturing, Inc. After the last two shows in Cleveland, we did not have very high expectations for the turnout at Atlanta. We were

675$,*+7(1(56 Â&#x2021; *8,'(6 Â&#x2021; )(('ERS &/2 7)2% s #!",%3 s 45"%3 s 342)03 Mike Patel, Teknor Apex, center, was among those reporting good visits at Interwire. pleasantly surprised by the quality and quantity of customers that attended. The encouraging aspect was discussions with many customers working on new projects. This was a successful show after a couple of disappointing ones. Hopefully WAI will not experiment with future Interwire locations and stay in Atlanta. Mike Patel, industry manager, wire & cable compounds, Teknor Apex Co., Vinyl Division.

WITELS-ALBERT USA Ltd. Phone 410 228 8383 info@witels-albert-usa.com

Fax: 410 228 1813

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54 | WIRE JOURNAL INTERNATIONAL

We had very positive expectations going into Interwire 2011. Going back to Atlanta was also a big plus. Having the hotels and restaurants close by made for a less stressful event. We experienced a very solid flow of present customer and potential customer. Our teaming up with WiTechs of Germany certainly helped with the constant flow of customers stopping by our booth. Many of our customers also expressed a positive feeling about this show. Al Kozlowski, international sales manager, Paramount Die Company.

INTERWIRE WRAPUP

Safety Roundtable The industry focus for wire and cable is inherently on productivity and margins, but a roundtable during the Manufacturing Best Practices theme session at Interwire focused on another element: safety. The session, moderated by Richard Carr, executive vice president, operations, Coleman Cable, included four panelists: Tim Wampler; vice president manufacturing communications & assembly team, General Cable Corp.; Kevin Porath, HR director, Coleman Cable; Nick Johannes, safety manager, Leggett & Platt; and Rob Gaines, director of health & safety services, U.S. Compliance Corp., which works with Coleman Cable. Following are edited excerpts from their comments.

Participants in the Safety Roundtable included (l-r): Kevin Porath, Coleman Cable; Rob Gaines, U.S. Compliance Corp.; Nick Johannes, Leggett & Platt; moderator Richard Carr, Coleman Cable; and Tim Wampler; General Cable Corp.

NEW MACHINES, shortly available Ref. no. 12-6038 QUEINS, high speed bow strander for 7 wires, type QSS 1+6/630, max 1400 rpm, new machine Ref. no. 12-5651 QUEINS, bow twister for stranding insulated conductors, type QRL 1+3 or 1+4 or 1+5/1600 (63“), reel ø 1600 mm (63“), new machine Ref. no. 32-7573 QUEINS, extrusion line for XLPE, 3-layer crosshead, extruders 65/25D, 150/25D, 90/25D, new machine Ref. no. 61-7557 QUEINS, rod drawing machine for Al and Al alloys, 13 dies, inlet ø 12 - 9,5 mm (0,47 - 0,37“), outlet ø 1,7 - 4,5 mm (0,06 - 0,18“), double spooler, new Ref. no. 61-7630 QUEINS, rod drawing machine for CU, 13 dies, inlet ø 8 mm (0,31“), outlet ø 1,2 - 4 mm (0,04 - 0,15“), annealer, double spooler, new machine Ref. no. 80-7593 QUEINS, horizontal annealer for copper rod drawing machine, wire range ø 1,35 – 4,0 mm (0,053 - 0,16“) Ref. no. 82-7591 QUEINS, automatic dual spooler for rod drawing machines, bobbin sizes 630 and 800 mm flange diameter (25 - 31“)

Pre-owned machines Ref. no. 14-7647 QUEINS, fast loading rigid strander, 2 cages 30+36 bobbins, 630 mm ø Ref. no. 60-7618 MALMEDIE, MZT 5 block drawing line, block ø 800 mm, for round and profiled wires, inlet 9,5 mm, finished ø 2,0 mm, spooler max. 1250 mm ø Ref. no. 61-7619 HENRICH, copper rod drawing machine model 30R13, 13 dies, inlet 8,0 mm, finished ø 1,4 mm, continuous annealer, dual spooler for bobbins 630 mm ø, plus bundle packer / static coiler for bobbins 1250 mm ø

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JUNE 2011 | 55

WAI ACKNOWLEDGES THE FOLLOWING CONTRIBUTORS TO THE INTERWIRE 2011 TECHNICAL PROGRAM The educational program at Interwire 2011 was the result of the combined efforts of dozens of experts, volunteers, and special guests. This year’s successful program would not have been possible without their dedication to the Wire Association International’s educational mission. AUTHORS/ PRESENTERS Justyna Adamczyk Victor Andrade Carole Anton Doug Anton H. Artzi José Miguel Atienza Friedrich-Wilhelm Bach Bae Gi-hyun Ban Deok-young Gerhard Boockmann Michaela Boockmann Dirk Bormann David Brender Rafael Bueno Luis Caballero Troy Carr Cédric Chauvin Rebecca D. Cioffi Patrick De Bruyne Emmanuel De Moor Stuart Duff Manuel Elices Bob Flower Steve Foust Rob Gaines Jason D. Gillen Robert J. Glodowski Bogdan Golis Guo Songshou Mark Hayes Huh Hoon Im Jae-duk

Nick Johannes John Keane Wynn H. Kearns Yuri Khoptiar Adam G. Kimura Tadeusz Knych Gabriel Kohn Ryoto Koyama Jan Krnac Piotr Kustra Grant Latimer Lee Byung-ho Erik Macs Andrzej Mamala David K. Matlock Gaël Mauron Stephen Mayott Mordechai Melamud Andriej Milenin Ralph Noonan Piotr Osuch Marcus Paech Ray Pahler Mike Philips Jan W. Pilarczyk Marzena Piwowarska Horace Pops Kevin Porath Peter M. Power Michael Eugene Puckett Jose Ranc Art Raymond Roberta Rocheleau Jesus Ruiz-Hervías

Stephen J. Ruth Arthur Seibert Jan-Marten Seitz H. Sheinkopf G. Shemesh Shen Hesheng Robert Sinclair Beata Smyrak Sun Fanghong Ofer Tevet Doug Thornton Jessica Toellner Thomas W. Tyl Piotr Uliasz Walther Van Raemdonck Ken Vandenberghe David Villegas Tim Wampler Michael Weiss Rory A. Wolf Roger N. Wright Bhaskar Yalamanchili Kazunari Yoshida Zhang Wenhua Zhang Zhiming Karl Zimmer

Bill Jarae Erik Macs Malcolm Michael Steve Montague Tom Moran Don Neville Dale Olp Paul Pawlikowski Ronald Reed Bill Reichert Tom Renner Randy Sheets Bo Vandromme Briggs Whitefield Bhaskar Yalamanchili

MODERATORS Dane Armendariz Antonio Ayala Richard Carr John Drummond Mark Garretson David Gemelli

GUEST SPEAKERS Paul Molitor Mike Mullane Robert L. Snyder

COURSE INSTRUCTORS Donald Dodge Rick Gordon Paul Kulongowski Tom Maxwell, Jr. Horace Pops Douglas B. Relyea Sandy Scroggs Thomas W. Tyl

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Bongard Machines USA Bongard Machines USA LLCLLC 832160 Mill· 6920 LakePointe RoadInverness Way Suite Fort Wayne, IN. 46845 Fort Wayne, IN 46804, USA Phone 260-338-2634 Phone +1 260 225 4510 Fax 260-338-2635 Fax +1 260 225 4513 E-Mail chris.z@bongard.us E Mail jh@bongard.us www.bongard.us www.bongard.us JUNE 2011 | 57

INTERWIRE WRAPUP

havior in general, because you cannot “foolproof” everySafety is a leading indicator of manufacturing performance. thing. Rather, we want people to constantly consider the conIf you don’t have a world-class safety program, you’re not sequences of their actions prior to acting. going to be a world-class manufacturer. To obtain a worldLastly, our goal is zero and beyond, meaning we strive for class safety record, we are focused on driving safety into our zero accidents and want to influence our employees to be culture, and one way we do that is by holding hundreds of safe not just at work but in their personal life as well. Our brief meetings every month where we cover a topic with an safety focus is effective because we care, and we believe employee to assure they understand what we expect of them. that the employees recognize and appreciate that concern. While we have documented job instructions, we know that Tim Wampler, General Cable Corporation. no one is going to read them every day prior to performing a task. That’s why we prefer to talk to employees on a When it comes to very frequent basis. Then safety we’ve found we randomly go out on the that the small details floor and audit to assure really do matter, and compliance. Usually you that includes undersee the right thing, but in eistanding what isn’t ther case it is an opporturight even if there nity to have another wasn’t an accident. conversation with the emOften, there is not an ployee. Further, while hazaccident but a near ard elimination is a focus, accident, and underwe want to influence beKevin Porath, Coleman Cable, and Tim Wampler, General Cable Corp. standing how one al-

INTERWIRE WRAPUP

most came to be has to be important to both the company and the employee. Some people put themselves at risk and don’t realize it or view their actions as risky, anything from driving a forklift too fast to just not following safety requirements. The employee has to believe that such actions really do matter, and one way to do that is to by making safety an important part of their evaluations. When a manager says what he expects, employees will listen. This takes a lot of work, but it has to be fun as well, because if employees just get a lecture every time you see them, that is not a good thing. One way to teach safety is through bulletin boards. If you post a photo, say, of a forklift lifting a forklift, people will look at that. Maybe next month, you pin up a photo showing another risk. Employees will not only look forward to such photos, they will talk to each other about it. Safety needs to be driven, and part of the challenge is human nature. At one plant I worked at, there was an area where molten metal was being poured, and employees were very aware of the inherent dangers and were accident-free. However, there was a sit-down area where assembly work was being done, and there were accidents there that never should have happened because the employees didn’t consider it a dangerous place and were complacent. There’s also a fi-

58 | WIRE JOURNAL INTERNATIONAL

nite amount of time available for any company, and it really helps to have a consultant, like Ron, who’s on this panel, or an in-house expert who can tell us about changes, such as in OSHA regulations. Kevin Porath, Coleman Cable Inc. In 1987, when I started with the safety program, it originally was based on what OSHA was going to do. That was a key factor in what we did. Our focus has changed since then. Our goal is to make sure everyone is going home safe. OSHA has always been a driver in terms of us focusing on where we should be more careful, but we are looking at all areas where we can improve. It’s in our best interest to have safe employees, and that goes from the hiring process through the training process. Safety is a mindset, and we have to make sure all employees understand what that means. Safety is the responsibility of every employee from management all the way down. We hired a consultant to talk to employees so they would understand what we as Nick Johannes, Leggett managers have to do, why this & Platt.

We advise some 600 companies, including Coleman Cable, about OSHA and environmental compliance, and we believe that measurement of safety is important. There should be a way to assess how a company is doing, something that provides accountability, something that lumps all the nuts and bolts together, and one way to do that is by establishing annual objectives. There needs to be a benchmark. Coleman Cable has done that by putting safety in its review process. It’s easy to just look at incident rates, but you need to have more. What caused that accident? Was it an unsafe act? Proactive efforts toward safety can be measured on a set frequency (i.e., weekly) and graded. For example, a company report can show how many safety inspections were done and what steps were taken to improve a facility. In terms of safety training, I used to think that more was always better, but now I also see the benefits of keeping it simple. Identify what’s

important and focus on that. We have found that the employees who are most at risk are the new hires, because they are less experienced and aren’t used to company systems, and the longtime employees, because they tend to get complacent. All companies desire to be looked at as a safe place to work. OSHA has recently focused their efforts on targeting “high hazard” employ- Rob Gaines, U.S. ers based on random annual sur- Compliance Corp. veys performed by the Bureau of Labor Statistics. The core of this program is a company’s DART rate, essentially the incident rate involving cases with loss time, restricted duty or job transfer. The Bush administration focused on alliances and working with business; however, under President Obama, it has become clear that OSHA is there for enforcement. It is important for companies to focus on safety as it keeps their employees safe, helps control costs and ensures compliance with state and federal regulations. Rob Gaines, U.S. Compliance Corp. ■

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INTERWIRE WRAPUP

matters so much to us. We also try to make this fun. There are rewards for meeting certain goals, such as having cookouts. I can tell you that it’s not so easy to grill a steak in January when its 8 degrees outside and the wind is 40 mph. That one made the local newspaper, and our employees remembered it, which makes it worthwhile. Nick Johannes, Leggett & Platt.

FEATURE

g i n r u s a e M & g Testin e r i w r e t n I t a t n Equipme nterwire 2011 featured equipment, products and services from more than 400

companies. Here, suppliers of some of the testing & measuring technology that was

on display in Atlanta highlight their offerings.

ACM AB/Howar Equipment Inc. Sweden/Canada The KSM off-line system from Sweden’s ACM AB, represented in North America by Howar Equipment, Inc., is designed to help manufacturers reduce costs by eliminating the 5-7% insulation wastes that result from not being able to tightly measure and control tolerances. The KSM system has four main components: a measuring system with backlit sample carrier and digital imaging cameras; measuring software that carries out the actual measurement at unprecedented accuracy and repeatability and stores them in a summary report database (KSMDB); the full optional Database Software (KSMLDB) that allows for instant comparison of the measured sample values with specification data, with over insulation cost, trending, Cpk and Sd available; and the optional Evaluation Software (KSMEval), which allows a user to precisely determine which products have the largest over-dimensional cost. As a replacement for manual methods, the KSM units have a dramatically higher repeat meas-

ACM’s Stefan Askenfors with Howar Equipment’s Willy Hauer by a KSM system. 60 | WIRE JOURNAL INTERNATIONAL

uring accuracy and are replacing measuring microscopes, pin gauges and shadowgraphs. The KSM system displays the result within 0.2 to 2 seconds, depending on the complexity of the slice. Nearly 200 KSM systems for cables, tubes and profiles are now in full operation, and in actual usage they have shown to provide typical repeat accuracy of 0.004 in. (0.01 mm) or better. Information is able to be used, not lost, via the summary protocol manager. Proper use of the system can result in substantial savings as 1/10 mm of “extra wall,” with one manufacturer of 12 and 14 AWG PVC-insulated bunched conductor reporting savings of $240,000 a year. Using the KSM database, statistics and evaluation program, engineers will be able to assess the data and begin determining the root causes of dimensional fluctuation and subsequently the cause of over-insulation. Stefan Askenfors, ACM, and Willy Hauer, Howar Equipment, Inc. Beta LaserMike USA Beta LaserMike, a global provider of precision measurement and control solutions, debuted its new and revolutionary LayScan measurement system. The LayScan system (patent pending) accurately and consistently measures the lay length of twisted pairs used in telecommunication cables. The system uses optical, noncontact measurement technology to perform on-line, highspeed lay length measurements with the highest precision to within 1 mil. Providing high-data rate capabilities, LayScan precisely determines the variations in lay length within each lay. Systematic lay variations that are typically caused by twinning and cabling operations can be readily observed and measured. A data acquisition system effectively collects and processes the lay length data, and reports the measurement results. The LayScan measurement system provides cable manufacturers: improved product performance by better controlling lay lengths and delivering a higher level of cross-talk

Jay Luis, Beta LaserMike.

performance; minimized product cost and scrap by optimizing the lay set; the ability to consistently control lay lengths over time; reduced product development cycle through precise measurements of lay length values during design trials and experiments; and standardized pair lays across various

FILOWIRE, INC.

bogimac nv sa Belgium At Interwire, bogimac presented its technology for material fatigue testing, which it notes typically happens in the mechanical labs of material manufacturers and their customers to validate new products first and then assure the quality. Where the validation of materials generally still is done with static or quasi-static test methods, more and more manufacturers are concerned about testing close to realusage conditions. They need to lower the cost on final product validation, shorten the time to market while increasing the level of confidence because of higher product liability issues and more stringent product standards. During the fatigue test, as in real-usage, cracks are initiated in the material structure, especially on the location of inclusions that are likely to at some point result in product breakage. The testing is done at high speed to achieve in a short time the conditons that exist after thousands, up to millions, of cycles.

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JUNE 2011 | 61

FEATURE

twinning systems, reducing the need to limit production scheduling to qualified equipment. Jay Luis, marketing manager, Beta LaserMike.

FEATURE

To test with a “big motion, high speed, high and variable load,” the machine design requires very specialized knowledge in dynamic mechanics as well as high-speed mechatronics. With 20 years of dedication to this field, bogimac has the required in-house expertise in design, supply and servicing of material fatigue testing worldwide.

control limits are approached. Profile360 employs CrossCheck laser line sensors manufactured by Bytewise that have been in service measuring rubber and plastic extrusions since 2002. Multiple sensors are calibrated and aligned in software using a patented method that assures a highly accurate and repeatable measurement. The system

Philippe van Bogaert, bogimac nv sa. Jim Williams, Bytewise Measurement Systems. The global cable, rope and wire industry uses the following equipment: bend rotation (Hunter, Stuttgart) reverse bending, up to 6000 bpm; torsion testers for cable, rod, rope and spring wire, up to 3000 bpm; bend over Sheave (“shoeshine”), up to 1500 bpm; and traverse contact clamp multiaxial loading on rope wire tensile test. bogimac provides mono- and multi-head versions depending on the customer test requirements. Also, special attention is given to high sensitive monitoring of the sample behavior. The “Early Warning” functions stop the test at the early stage of degradation, enabling in-depth observation of the reasons of material breakage, and by “Adaptive Control,” the machine conditions can be regulated continuously to achieve a predefined sample temperature. The company’s new BRM single head bend-rotation and the high speed BSCD dual head bend-over-sheave testers will also interest the smaller test labs.Philippe van Bogaert, managing director, bogimac nv sa. Bytewise Measurement Systems USA At Interwire, Bytewise Measurement Systems, a global supplier of on-line profile measurement systems, introduced a special version of the Profile360 On-Line Profile Measurement System aimed at dimensional measurement of wire profiles, including rectangular wire, magnet wire, and other complex profiles. The system monitors multiple channels of width and thickness. It measures the complete 360 degree profile simultaneously at frequencies up to 15 measurements per second, resolute to 5 micrometers (0.0002 in.). This enables wire makers to monitor the size and shape uniformity in realtime, including corner angles and radii, and be alerted when

62 | WIRE JOURNAL INTERNATIONAL

acquires up to 4800 points per profile. Accuracy can be easily verified using an automatic checking routine. The PSViewer Software Suite provides a complete set of dragand-drop measurement tools for checking thickness, width, radius, angle, and other parameters. Profiles are matched to CAD templates to provide an optical comparator view. All data is saved to a history log file that can be used to produce QC statistical reports for each run. Measurements are not affected by movement of the wire profile in the field-of-view, a major advancement over two axis ovality gauges. As Profile360 has no moving parts, it is inherently reliable compared to oscillating gauges. Profile360 is a major step forward for wire manufacturers interested in achieving better quality control for wire profiles using proven and reliable laser measurement technology. Bytewise offers a sample testing/web conferencing program to demonstrate measurement performance, and an inplant demonstration program. Jim Williams, sales director, Bytewise Measurement Systems. Clinton Instrument Company USA The FL-20A Cable Fault Locator is Clinton Instrument Company’s newest quality tool for the wire and cable industry. Cable rejected during the hi-pot test has always been an expensive problem for the manufacturer. Until now, finding opens and shorts with an analog cable fault locator took expertise and patience, since the procedure required tedious meter and sensitivity adjustments as well as mathematical calculation once the test was completed. The digital FL-20A automates cable fault detection,

Woody Holland, Clinton Instrument Company. greatly reducing the time and training required to find these problems. Opens, metallic shorts, or high-voltage shorts between conductors or between conductor and shield are pinpointed quickly and with ease. The operator simply connects the FL-20A test probes to each end of the cable under

DCM Industries, Inc. USA At Interwire, DCM Industries introduced its model 3SXLD LAN Cable Testing System. The latest addition to the DCM family of automated cable testing systems, the Model 3S-XLD provides the most reliable and repeatable test platform available for testing high-performance LAN cables. The 3S-XLD includes a 28-pair test platform for testing 4-pair cables, 25-pair backbone and bundled cables, up to seven 4-pair UTP or STP cables connected at one time, and

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test, enters the cable length and maximum test voltage on the touch screen display, and selects “Shorts” or “Opens” to begin the test. The unit calculates the distance of the fault site from each test probe and displays the location in feet or meters. The failure can then be cut out or repaired and the remaining good product salvaged, resulting in great savings to the producer. The FL-20A Cable Fault Locator, a compact 15 in. w x 14 in. d by 10 in. h weighing only 30 lb, is significantly smaller and lighter than its predecessors. It promises a great return on investment by salvaging expensive cable assemblies and lowering the costs associated with salvage. Woody Holland, sales manager, Clinton Instrument Company.

FEATURE

fully compliant, 6 around 1, 28-pair alien crosstalk. The 4-pair ISTP fixture enables the testing of individually shielded twisted pairs (S/STP, ISTP) up to 1 GHz. Both Low Frequency (Capacitance and Resistance) and High Frequency (Insertion Loss, Crosstalk, Return Loss) tests are standard features and are all tested in one cable

Perry Chattler, DCM Industries.

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connection. Network analyzer calibration reference standards are fully integrated into the measurement system and automatically checked in seconds when required due to changes in frequency range or network analyzer settings. The 3S-XLD utilizes a DCM-designed, solid-state switching system that eliminates the need for electronic and mechanical relays. The use of solid-state components enables customers to obtain greater technical performance together with very fast test speed and high reliability. The system enables a full, 2-port calibration quickly and automatically performed within seconds. Existing DCM CMS2XLD customers can simply and easily upgrade to the new 3S technology. Both the 3S-XLD and 3S upgrades to legacy systems provide full compliance with TIA-568-C.2 in both balun and test performance requirements. Perry Chandler, president, DCM Industries. FMS USA Inc. USA At Interwire, FMS USA introduced its innovative RTM X2 system for the wireless measurement of wire tension in rotating machines such as bunchers, twisters and planetary/tube stranders. The RTM X2 system provides the critical strand tension information to optimize the production process and offers additional advantages, such as: the elimination of problematic slip rings; tension control possible via

Paul Smith at the FMS booth, which highlighted its new RTM X2 wireless technology.

For applications up to 32 strands, FMS makes available the RTM 01/RTM 02 systems to monitor tension in real time. They can be configured to handle nearly any tension measurement or control task. Actual tension values are displayed graphically on a PC monitor and also logged for possible quality assurance reference. The monitoring system has tension sensors, tension measuring amplifiers, a bus system with radio transceivers, a control unit and software. Possible configurations include the capability to provide a high /low tension alarm signal, or an output to stop the machine immediately in case of a wire break. With the standard Data Logging feature, the RTM system will record the tension value of each strand correlated to the product running length. With increased production rates and improved quality, RTM System investment payback time is typically quite short. The technology may also be used to open new markets to a manufacturer where applications demand documented and verifiable manufacturing conditions. FMS USA, Inc. Foerster Instruments, Inc. USA At Interwire, the Foerster Instruments, Inc., exhibit included the companyâ&#x20AC;&#x2122;s model RO 20 P system, which has 30micon flaw detection capability. The sensor systems are designed with the highest precision, with attention to every

JUNE 2011 | 65

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machine PLC; and elimination of need for major machine modifications for installation. The RTM X2 provides for the continuous acquisition of wire tension values, the processing thereof and the secure transmission of data from the rotating machine part to the static machine part.

FEATURE Tommie Nilsson, Foerster Instruments, Inc.

Zander Baptista de Araujo, Josaphat Engenharia de Telecomunicacoes.

detail, including material guidance precision, dynamic balancing, vibrations, bearing quality, bearing precision and more. The Ro20P’s sensor system can inspect diameters from 2.0 to 20 mm, but with a special guidance system it can test wire as small as 1.0 mm. The RO 20P’s rotating head is designed for a max. rotational speed of 18,000 RPM (linear speed of 3.0 M/s or 600 FPM), the highest in the industry. It also offers reduced changeover time, which is critical to ensure maximum productivity. This is made possible from the unit’s fast and easy dimensions change (simultaneous adjustment of both heads), snap lock nozzles, self-clamping adjustment of test heads, ease of opening doors and ease of clamping roller guides. It also has increased bearing life, and an optional oil-air lubrication system is available for operating rotational speeds of 12,000 RPM and higher. Further, the unit has a compact design, with total in-line dimension about 308 mm, including the mounted dual roller guides. Without these roller guides the length is 272 mm. The model offers clearance compensation (automatic gain adjustment) to accommodate variations due to dimensional and geometric tolerances in the product. If sensitivity is exceeded due to reduced air gap, it could result in pseudo rejects. In the converse situation, flaws might be missed. Both are detrimental to reliable inspection. Foerster has the same clearance compensation feature extended to cover ovate section wires. Foerster Instruments, Inc.

for Cat. 5, 6, 6e and 7 products, eliminating the need for wire striping; and the ability to guarantee data rates for customers. The system was developed by closely working with customers and to the requirements of the International Telecomunications Union (ITU) L.75 standard. Founded in 1990, the company’s engineers and collaborators conceive and have implemented an innovative technique for acceptance of cable and broadband systems. This SEM technique is in two standards of the International Telecommunication Union (ITU-T), the UN agency that regulates the worldwide telecommunication sector. These recommendations can be accessed on the Internet at http://www.itu.int/rec/T-REC-L.75-200805-I/en. Zander Baptista de Araujo, Josaphat Engenharia de Telecomunicacoes.

Josaphat Engenharia de Telecomunicacoes Brazil At Interwire, Josaphat Engenharia de Telecomunicacoes announced the new MERKURO 1 cable measuring system for the final quality assurance of Cat. 5e, Cat. 6, Cat. 6A, coax multipair and broadband cables. Company President Zander Baptista de Araujo explained that the Spectral Emulation Method (SEM) cable testing system provides cable manufacturers with the unique features of: an automated system for coax, LAN, and broadband cables in the same system; a patented quick adapter 66 | WIRE JOURNAL INTERNATIONAL

LaserLinc USA At Interwire, LaserLinc displayed the company’s bestin-class scanning laser micrometer technology for diameter and ovality measurement, and ultrasonics for wall thickness, concentricity and inside diameter measurement. Our scanners include 1-, 2-, and 3-axis models, which are some of the most compact, fastest and reliable available. The three-axis Triton™ series and the high-speed models provide added value in detecting flaws too. Our UltraGauge+ system provides immediate feedback for die-centering during startup, reducing scrap, maximizing valuable production time, and, of course, it monitors wall thickness throughout the run. Gauging is a critical and a fundamental requirement for manufacturing the best wire and cable. While our equipment offers definite advantages, some customers are satisfied as long as they have any gauge on their lines. To get the full value of their equipment, however, manufacturers must have an effective interface to the technology. Our Total Vu™ system offers unique capabilities for process improvement, inspection, and quality reporting. Not only will it process data from our gauges, it can be outfitted

to capture temperatures, pressures, RPMs, loads, tensions—and it will correlate that data with product dimensions for a complete “audit trail” of the process. This information is presented in a useful format designed to help, not burden the operators, who are presented with only the information they require while functions such as data logging, SPC, and reporting happen Jeff Kohler, LaserLinc. without operator involvement. Total Vu systems will also interface with your existing laser or ultrasonic gauges, no matter the manufacturer, providing one common platform for operators and for all of your lines. This unique capability minimizes new investment and ongoing costs and maximizes the value of what is already in place. LaserLinc is U.S. owned and operated, and and that’s where its products are designed and manufactured. Jeff Kohler, vice president, LaserLinc. Polytec GmbH Germany At Interwire, Polytec GmbH focused on its LSV1000 non-contact length and speed measuring systems that are designed to maximize yield, reduce maintenance and increasing profits. The LSV1000 Series sensors are high performance, noncontact length and speed measurement systems designed to directly replace contact encoder wheels for footage counting, speed control, accurate printing and other precision processes found in the wire and cable industries. They avoid the drawbacks of traditional contact encoder wheels, like slippage between the wheel and the cable, changing wheel diameter due to wear or pick up on the wheel surface. These and other issues associated with encoder wheels can lead to increased error and unpredictable drift, resulting in yield loss, decreased quality and increased maintenance costs. The LSV1000 Series sensors provide precise length and speed data for footage counting, accurate printing, speed matching and other quality control applications. They are easily integrated into the production process through the quadrature encoder pulse output, serial or ethernet interfaces. Fast sensor response and high data rates enable sophisticated control applications, while field proven accu68 | WIRE JOURNAL INTERNATIONAL

Felix Rominski, Polytec GmbH. racy and repeatability contributes to minimized product waste. There is no need for frequent recalibration, process calibration or service issues as as is the case with contact wheels. The technology is supported by Polytec’s service and support team. Felix Rominski, international sales business unit, Polytec GmbH. Proton Products International U.K. At Interwire, Proton Products International launched two new products, and the response was nothing short of outstanding. The first was the SLR3060 noncontact speed and length gauge with direction detection and zero speed. These capabilities were extremely popular as many of our existing customers have been waiting for such functionality. The sec-

Grant Latimer, Proton Products International.

SAS Testers/Forming Systems, Inc. Israel At Interwire 2011, SAS Testers, represented in the U.S. by Forming Systems, Inc., introduced the CT-VX series of combined load and geometric inspection systems. These testers are unique in that they incorporate a complete squareness, parallelism (e1e2), pitch-ODconcentricity trace vision system directly on the load test surface. An endless rotation, rigid body turntable is mounted on the load cell, allowing for complete 3D tracing of the geometric profile The CT-VX inspection system from of compression SAS Testers. springs either in their unloaded or loaded states.

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ond, the DG2030-10K model (pictured), has the highest measurement rate diameter gauge that we know of, with up to 10,000 measurements per axis per second was inundated for much of the show. The DG2030-10k not only measures diameters extremely fast, it can also perform lump and neck detection using the SMFD (Single Measurement Flaw Detection) and is available in single-, dual- and triple-axis versions. All communication options are built right into the gauge with TCP/IP as standard while Industrial Protocol (IP), Profibus and Devicenet are optional. We also displayed included lump and neck detectors, preheaters, capacitance gauges and the nexis series of control and display systems. And, in the technical programs, Grant Latimer, managing director of Proton Products International, presented a paper on material savings using noncontact laser doppler technology. The technical presentation explained how a 1% material saving can translate to an increase in profits of up to 16%. From extensive factory demonstrations performed around the world, it has been shown time and time again that a 1% saving in material through noncontact speed and length measurement is achievable. Grant Latimer, managing director, Proton Products International.

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The systems height measurement transducer includes an ultra high resolution height gauge (0.00014 mm or 0.0000055 in.) ideally suited for measuring high spring rate low index springs. The system is further enhanced with the capability of accepting a squareness under load XY gimbaled system on the test platen. Whereas the CT-Vx can test both tension and compression springs, it is most suited for testing high geometric and load critical compression springs either in their ground or un-ground state. These springs can be measured directly off the coiler, mapped against their geometry and load gold standards allowing for the correction of the differences to those standards via the coiler setup program. The CT-VX user interface incorporates a touch screen 17 in. display and the squareness under load system is hot pluggable allowing for testing of all load, geometry and squareness variable results within one test sequence. SPC reporting modules together with a full 2D general vision measurement software package can be provided as options. The 2D general vision measurement option is well suited for measuring torsion springs and tension spring hook geometries. Tim Weber, Forming Systems, Inc. Sikora International/Sikora AG USA/Germany At Interwire, Sikora International, the U.S. business of Germany’s Sikora AG, highlighted the LENGTH 6000 with a huge reception for this device, which uses unique and innovative optical techniques to bring a new level of reliability to the measurement of cables in the wire and cable industry. By means of optical image comparisons, we are able to measure forward, reverse, vibrating, rotating and shiny products. This technique characterizes the cable surface, then measures the transit time for the movement of that surface to the opposite side of the camera array. This simple technique eliminates conflicts with surface shine, cable vibration and demands, alignment and change of direction. As long as the bottom surface of the cable is seen in the camera window (1” height) we get measurements to perfection. The LENGTH 6000, with its 0.05% accuracy, is designed for cables in the range of 0.4 in. to 7 in. in diameter, with systems under development for products smaller in diameter. Customers were impressed and highly interested

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in getting on the schedule for our upcoming road show of the device. In addition to the LENGTH 600, the Sikora booth highlighted the full range of the company’s X-RAY based systems. Customers concerned about reliable means to measure wall thickness were able to see the performance of the technology perfect for their applications. The technology included: the X-RAY 8000 NXT for CCV and VCV Jeff Swinchatt, Sikora International. lines and the X-RAY 6000 series for a variety of jacketing and insulating lines in power and RF cable as well as oil and gas applications. Jeff Swinchatt, president, Sikora International. Taymer International, Inc. USA At Interwire, Taymer’s technology included a new development for cable marking: the Print View 1400, a print inspection system that can ensure that cable markings from wire and cable printers are accurate and of high quality. The Print View 1400 is a setup and monitoring tool for high-speed printers, which include high speed Gravure ink printers, hot-foil printers and ink-jet printers. This unique technology allows markings on either smooth or convoluted cable jackets to be effectively monitored, at line speeds up to 1,400 feet per minute or 430 meters per minute. The unit (pictured) uses high-speed, digital imaging to capture real time images of cable markings. The digital images are enhanced, magnified and displayed on a remote

TUBULAR STRANDING MACHINES s Available in sizes from 315 to 900 mm and up to 48 spool positions s Accurate spool breaking with load cell tension control s Fully enclosed in soundproof cabinet s Individual bearing temperature control and automatic greasing

NOT ONLY A MACHINERY MANUFACTURER

GCR EURODRAW S.p.A. Via Camillo Chiesa, 19/21 - 20010 Pogliano Milanese (MI), Italy Tel. +39 02.93963.1 - Fax +39 02.93540452 - gcr@gcrgroup.com - www.gcrgroup.com

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monitor, enabling the operator to oversee the print quality while supervising other processes. Images of bad quality or inaccurate prints can be stored in a database for further analysis with the position in the length of the wire. Further, when combined with any printer, the Print View 1400 can optically recognized the message as well as verify the sequential mark. The message is compared to a message inputted by the operator and the sequential mark is compared to a value from the printer, and variances result in an alarm being set off. Printer maintenance can initiate before the printer actually malfunctions because the operators Taymer’s Print View receive very current feedback on 1400 inspection model. print quality. Incorrect print legends are identified before the entire run is misprinted. Depending on the process and the location of the operator, this cost savings alone can easily justify the investment. Taymer International, Inc. Vollmer America, Inc. U.S. At Interwire, Vollmer America highlighted its Vollmer Touch Screen (VTS) system, which can monitor up to four digital gauges. Utilizing a panel-mounted PC with a 5.7 in. touch screen, the VTS system is an easy-to-use, intuitive operating measurement system when coupled with Vollmer gauges having digital probes. The VTS measurement program runs on a PC with a color TFT screen that communicates with interfacing modules connected via a bus connection. These interface modules are for the connection of digital transducers and pulse sensors, for the input of digital signals and for the output of analog and digital signals. By using a Profibus interface module, the control signals, nominal values and tolerances can be preset and digital output signals, the deviation, nominal, and actual values can be passed. The VTS system can be configured many ways. It can be used for thickness measurement for gauges with single digital transducers or digital transducers in sum measurement. It can also be used for width measurement or for thickness and width measurement. Per a customer’s requirements, the measurement values can be displayed in absolute form or as deviation from the nominal. The measurement value displays can also be changed from metric to imperial. The introduction of digital probes allows for larger measurement range without the mechanical offset needed in the past with the normal LVDT measurement devices. Tolerances are set and display color backgrounds are changed according to alarm conditions. Monitoring screens also give real time status of digital

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inputs, measurement probes, and analog signals. Whether dealing with the sometimes harsh environment of the wire industry or the close tolerances of very fine wire, Vollmer’s new VTS system is ready to provide Dick Pechie, Vollmer America, Inc. “Accuracy when it Counts.” Dick Pechie, vice president, Vollmer America. Witels-Albert Germany/USA Witels-Albert is best known for its straightening equipment, but at Interwire it presented the concept of a device from the IWD series which, on the basis of a patented method for automating the wire straightening process, enables the inline diagnosis of round steel wires in determinable quality and size. In addition to the familiar identification of the process material’s geometrical parameters, changes in the process material's strength are continuously measured and documented in order to be able to use the data for subsequent technical and economic purposes. The continuous availability of information about changes in the wire's diameter and yield point creates a new system of values for the classification of wire grades which focuses on permanently determining the constancy of these properties and their correlating economic aspects. For users such as wire drawing companies this opens up the innovative possibility of marketing their products on the basis of a consistently verifiable quality and producing selective grades through their choice of tools and/or machines. Bob Flower, general manager, Witels-Albert USA Ltd., and Marcus Paech, technical managing director, Witels-Albert GmbH.

Bob Flower, l, and Marcus Paech, Witels-Albert.

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

FEATURE

Zumbach Electronics Corp. Germany/USA Zumbach Electronics Corp., was pleased with the positive response that its equipment received at Interwire 2011. The newer equipment that was on display included the PMM80 Profile Measurement System, the SPEEL3000 Speed and Length Measuring System, and a new platform of USYS processors and ODAC Scanner Models. The SIMAC® 63 camera-based surface inspection system received a considerable response, with many applications and inquiries. The SIMAC 63 (in picture) is the latest model available in Zumbach's line of surface inspection systems using image processing. The new design was focused to achieve the best price/performance ratio for in-line surface and fault detection of tubes, hoses, cables and similar products made of plastic, rubber and other materials. The system also provides 100% surface coverage and can detect dimensional and non dimensional defects, and can eliminate the need for post-process or manual inspection. The SIMAC 63 is very intuitive, with the latest generation graphical user interface (GUI). The compact design allows installation in tighter spaces. It also offers high resolution and is capable of capturing surface faults down to 100 μm. Main data are as follows: measuring field: 63 mm; product diameter range, approximately

Carolyn Edwards, Zumbach Electronics. 2 to 50 mm; product lighting, LED; scan rate: up to 35,000 scans/second; cameras, line scan; and operating system: Windows™ XP embedded. Carolyn Edwards, marketing manager, Zumbach Electronics. ■

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

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Production of thin wires of magnesium alloys for surgical applications

LV E R TE A C I F I CERT AWA R

TECHNICAL PAPERS

TECHNICAL PAPER

A three-stage process (casting, extrusion and drawing) for a new alloy that offers increased biocompatibility has been found to offer excellent properties for this very demanding end use. By Andriej Milenin, Piotr Kustra, Jan-Marten Seitz, Friedrich-Wilhelm Bach, and Dirk Bormann

Due to their bioresorbable characteristics, magnesium alloys with increased bio-compatibility present an alternative implant material for medical use. These alloys appear as possible alternatives for bioinert materials such as titanium, tantalum and 316L steel. Research into the corrosion of magnesium alloys in a human environment showed a good degradation behavior in-vivo. For this reason, the biodegradable character of magnesium-based materials provides the hope to avoid an implant explantation after a successful healing process1-5. In this case, the production of magnesium-based sutures, e.g. for the reintegration of tissue or the support of bone healing, can be a reasonable area of application. This kind of application requires fine wires with diameters from 0.1 mm to 0.9 mm. In the Institute of Materials Science of the Leibniz Universität Hannover, new degradable Mg-Ca alloys with an increased biocompatibility (e.g. MgCa0.2 and MgCa0.8) and methods for extrusion, drawing and rolling processes, concerning an optimal plastic deformation of magnesium alloys, have been developed6-7. Here, Bach et al.8 designed a new manufacture technology for tubes made of Mg alloys using a heated die. The theoretical description of the wiredrawing process with a heated die has been specified9-10. The MgCa0.8 alloy has excellent and promising properties in terms of strength and biological stability, which are thereby the focus of interest. The low plasticity of MgCa0.8 influences the complexity of the alloy’s cold drawing process. The model of ductility is a very important element of FEM program for optimizing the wiredrawing process on the basis of FEM simulations. Fracture problems are very precisely described in literature of magnesium alloys10-12. However, these works only take into 74 | WIRE JOURNAL INTERNATIONAL

account a few parameters of drawing, such as the die angle and the reduction ratio. Aluminum- and zinc-containing magnesium alloys (such as AZ31) are investigated materials, which have a bigger plasticity than Mg-Ca and ZEK100 alloys. However, in literature, ductility models of Mg-Ca and ZEK100 alloys are not presented. The goals of this paper are the development of mathematical models of yield stress and ductility; the implementation of these models into a FEM-code; and simulations of the extrusion and drawing processes. Finally, this paper shall provide optimized parameter sets for extrusion and drawing processes with which thin wires made of magnesium alloys can be realized.

Material and procedures In this study, magnesium alloys, which had already been proven in previous studies, were chosen. The alloy’s in vitro and in vivo behaviors seem to be potentially suitable for use in the field of resorbable suture materials1-4. Here in particular, the results of CRC 599 (Collaborative Research Center) “Sustainable Bioresorbable and Permanent Implants of Metallic and Ceramic Materials” could be drawn on.

Manufacturing using casting technology The magnesium alloys MgCa0.8 (Mg 99.2 wt.%, Ca 0.8 wt.%) as well as ZEK100 (Mg 98 wt.%, Zn 1 wt.%, RE 0.5 wt.%, Zr 0.5 wt.%) were manufactured using a gravity die casting process. To avoid undesirable reactions with the surrounding atmosphere, the casting of ZEK100 and MgCa0.8 was carried out in a dynamic argon atmosphere (gas supplied at 2 l/min.). For each alloy, the material was

melted at a temperature of 750°C and subsequently stirred. The available die-sets with diameters of 130 mm were preheated to 450°C.

parameter representing fracture is called ductility function and is given by the following equation:

Materials tests and models In the present paper, the flow stress and ductility models for MgCa0.8 and ZEK100 magnesium alloys were developed. The material tests were performed in a static strength testing machine “Zwick Z250” at the AGH University of Science and Technology, Krakow, Poland. The interpretation of the tensile and upset test’s results was done using an inverse algorithm13. Here, models of tensile and upsetting tests were developed to determine fracture conditions using the method of finite elements. Yield stress model. The yield stress model σ for the analyzed magnesium alloys was proposed as a modified Henzel-Spittel equation:

Eq. (2)

where: k = triaxility factor (k = σo/ σs The critical deformation function εp (k, t, ξi) is obtained and is based on experimental studies. In the Drawing2d code14, Eq.(2) was implemented as the following integral:

Eq. (3) Eq. (1)

where: A, m1-m8 = empirical coefficients, t = temperature, ε = strain intercity, and ξi = strain rate. Experiments have shown that σs is independent of the strain rates in low temperatures; as a consequence the following module was added:

where: τ = the time of deformation, Δτ(m) = the current time increment, ξi(m) = the values of the strain rate in the current time, and m = the index number of time step during numerical integration along the flow line. The relation for εp (k, t, ξi) is presented as: εp = d1 exp(-d2,k)exp(d3t)ξid4

Eq. (4)

Parameters of Eq. (4) were obtained using ductility test for different values of k, t, ξi Ductility model. This theory was developed especially for cold-metal working processes. A detailed description of this theory can be found in the literature10,13. The key

Extrusion process FEM numerical simulation of extrusion process. The 12channel die displayed in Fig. 1 was used within the wire extrusion process. The following parameters were used for

Table 2. Coefficients of Eq. (4).

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Table 1. Coefficients of the yield stress function per Eq. 1.

TECHNICAL PAPERS Fig. 1. The 12-channel matrix for extrusion: a) shows a CAD model of one half of matrix, and b) shows dimensions of one channel.

simulation: The alloy’s diameter in the pre-extrusion condition was 30 mm, the velocity of extrusion was 1 mm/s and the initial temperature of the die and the alloy was 400°C. An FEM model (Forge 3) was used to optimize the extrusion process. During the development, the FEM model’s symmetry conditions were taken into account. For this reason it was sufficient to simulate the 12th part of the metal volume as displayed in Fig. 2. The initial number of nodes was about 5000 while the number of four-nodes tetrahedral elements was 23,000. During the simulation process these parameters were increased by remeshing and grid adaptation procedures. The temperature distribution in beginning stages of wire extrusions was changed from 380°C to 410°C. The maximum of temperature is localized in matrix channel (Fig. 2, a). The pressure distribution has a direct influence on triaxility factor and on technological plasticity of material. On the basis of distribution in Fig. 2b, the maximum of compressive pressure is localized on center of container (red color in distribution on Fig 2b), but in the channel the significant tensile stress is dominated. The simulated results of wire extrusion showed that the proposed form of extrusion die is not optimal and must be modified for increased material plasticity. Pre-extrusion of materials. The impurities as well as the pores, which result from the casting process, were removed from the alloy billets. Further processing was subsequently carried out using a direct extrusion operation in a 10 MN extruder. See Fig. 3a. The extrusion die (position 1 on Fig. 3a), which has an orifice diameter of 30 mm (position 2 on Fig. 3a) and its recipient were heated to a temperature of 380°C. Subsequent to this, the respective cast billets were inserted into the extruder and pressed through the extrusion

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die. The optimal profile velocity was found at 1.9 m/min while the deformation was carried out at an extrusion ratio of 16. Wire extrusion. Extruded bar with a height of 40 mm and a diameter of 30 mm were produced from the pre-extruded rods. An 0.8 MN extruder was employed for the wire extrusion process. See Fig. 3b. The extrusion die that was used had 12 holes, each with a diameter of 0.5 mm. See Fig.1a. To obtain optimum results during the wire producing process, the most influential parameters for the individual extrusion passes were varied. The experimental temperature field was limited to within 300°C to 450°C and the extruded force was varied within the range of 600 kN to 800 kN.

Drawing process and schedule determination FEM numerical simulation of drawing process. Mechanical models were implemented into Drawing2d software14. Fracture model (3)-(4) was helpful to evaluate the material critical deformation during drawing process and drawing schedule of MgCa0.8 magnesium alloy from an initial diameter of 0.5 mm to a final diameter of 0.1 mm. The temperature of drawing die was 400°C. The aim of the numerical simulation was determination of a deformation schedule and the technological drawing parameters (drawing velocity, drawing angle) for initial diameter 0.5 mm to final diameter 0.1 mm. For modeling the drawing process, the following parameters were used: initial diameter 0.5 mm, final diameter 0.1mm, friction coefficient 0.03 and a drawing angle of 6°. The die temperature was determined by the solution of the heat for the system metal, which was a drawing die at around 400°C. Simulation was carried out for a drawing

TECHNICAL PAPERS Fig. 2. Results of numerical simulation of wire extrusion process: a) shows the distribution of temperature; b) shows the distribution of pressure.

velocity of 0.01-1 m/s for the MgCa0.8 alloy. Distributions of ductility function for the drawing velocity 0.5 m/s and 0.05 m/s are shown in Fig. 4 e/f. The results of numerical analysis show a significant impact from drawing velocity. For a drawing process with velocity of 0.05 m/s, the ductility function reaches a value of 0.789. Increasing the drawing speed to 0.5 m/s increases this value to 1.34. That means that for this variant of the drawing process, a crack will be occurring. The limit of drawing velocity for this

alloy, observed in the simulation, is about 0.1 m/s. Analysis of temperature distribution showed that an increase of drawing velocity results in a decrease in the temperature of wire. In turn, according to the model of ductility (3)-(4), plasticity is decreased. The triaxility factor distribution is not dependent on the drawing velocity. See Fig. 4 c/d. Determination of wire drawing schedule. Modeling of multipass drawing technology assumes that the value of the ductility function should not exceed 0.9 in each pass.

Fig. 3. Presses for extrusion: a) shows the 10 MN extruder; a1 shows an extrusion die; a2 shows extruded 30 mm rod; b) shows the 0.8 MN extruder; b1 shows the monitor of the observation camera, b2 shows an extrusion die; b3 shows the automation system; and b4 shows the container for the 0.5 mm extruded rod. JUNE 2011 | 77

TECHNICAL PAPERS Fig. 4. Distribution of temperature (a, b); triaxility factor (c, d); and ductility function (e, f) for drawing velocity 0.05 m/s (a, c, e) and 0.5 m/s (b, d, f).

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TECHNICAL PAPERS Fig. 5. Results of numerical analysis for all passes: a) ductility function; b) drawing force; c) temperature after deformation; and d) value of triaxility factor k.

The high value of metal temperature is needed during deformation to bring about the crystallization of microstructure. The goal function condition was used, then modeling and optimization of multipass drawing process were done. In the case of the optimal variant MgCa0.8 alloy drawing, it contains 23 pass with a coefficient of elongation S0/S1 equal to 1.15. The values of ductility function, drawing strength, temperature and coefficient k for each sequence are shown in Fig. 5. The analysis shows that the value of ductility function during multipass drawing process does not exceed the value of 0.9. Therefore, the optimization condition is satisfied. Drawing force during the performance is decreased, which is associated with decreasing the diameter of the drawn wire. Fig. 6 shows the distribution of ductility function for two passes (0.5 mm to 0.464 mm, and 0.106 mm to 0.1 mm). Numerical analysis showed that the distribution ductility function is similar in the first and last pass. The maximum value is located in the center of the drawn wire. Proposed draft plan for MgCa0.8 magnesium alloy is as follows: 0.5 mm→ 0.464 mm→ 0.431 mm → 0.4 mm→ 0.371 mm→ 0.344 mm→ 0.32 mm→ 0.298 mm→ 0.277 mm→ 0.258 mm→ 0.24 mm→ 0.223 mm → 0.208 mm→

0.194 mm→ 0.181 mm→ 0.169 mm→ 0.158 mm→ 0.148 mm→ 0.138 mm→ 0.129 mm→ 0.121 mm→ 0.113 mm→ 0.106 mm→0.1 mm, with a die angle of 4°, a drawing velocity of 0.05 m/s and a coefficient friction of 0.03.

Conclusions The manufacturing technology for thin wire made of new magnesium alloys with increased biocompatibility was proposed. Here, the production of thin wires made of magnesium alloys for surgical applications is based on a threestaged process including casting, extruding and drawing. The mathematical models of the yield stress and the ductility function were proposed for the alloys MgCa0.8 and ZEK100. To identify the empirical parameters for the developed material models, tensile tests as well as compressive tests were performed on the strength testing machine “Zwick 250.” The FEM models of the production processes were developed. The results of the simulation of the extrusion and the drawing processes could be used to find optimal production parameters.

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TECHNICAL PAPERS Fig. 6. Distribution of ductility function: a) pass 0.5 mm to 0.464 mm; b) pass 0.106 mm to 0.1 mm.

Acknowledgments The authors would like to thank the Ministry of Science and high Education of Poland, project no. 416/N-DFGSFB/2009/0, and the German Research Foundation (DFG) within the scope of the individual grants program for their financial support.

References 1. M. Thomann, C. Krause, D, Bormann, N. Höh von der, H. Windhagen and A. Meyer-Lindenberg, “Comparison of the resorbable magnesium alloys LAE442 and MgCa0,8 concerning their mechanical properties, gradient of degradation and bone-implant-contact after 12 month implantation in rabbit model,” Biomaterials NRW - Fundamentals and Clinical Applications, 2008, pp. 107-108. 2. A. Meyer-Lindenberg, C. Krause, D. Bormann and H. Windhagen, “Entwicklung der mechanischen Eigenschaften von degradablen intramedullären Implantaten auf Magnesiumbasis nach unterschiedlicher Implantationsdauer,” Biomaterialien, 8, 2007, No. 3, p. 180. 3. M. Thomann, C. Krause, N. Höh von der, H. Windhagen and A. Meyer-Lindenberg, “Vergleich der resorbierbaren Magnesiumlegierungen LAE442 und MgCa0,8 bezüglich der Degradation und Biokompatibilität,” Zeitraum von 12 Monaten, Biomaterialien, 8, 2007, No. 3, p. 182. 4. M. Braun, C. Krause, D. Bormann, J. Stahl, W. Bäumer, B. Schwab, S. Kramer, M. Kietzmann, Fr.-W Bach and T. Lenarz, “Untersuchungen zur Biokompatibilität von Magnesiumlegierungen als degradable Implantatwerkstoffe,” Biomaterialien, 8, 2007, No. 3, p. 183. 5. Fr.-W. Bach, R. Kucharski and D. Bormann, 80 | WIRE JOURNAL INTERNATIONAL

“Magnesium compound structures for the treatment of bone defects,” Engineering of Biomaterials, 56-57, 2006, pp. 58-61. 6. H. Haferkamp, V. Kaese, M. Niemeyer, K. Phillip, T. Phan-Tan, B. Heublein and R. Rohde, “Exploration of Magnesium Alloys as New Material for Implantation,” Mat.-wiss. u. Werkstofftech, Wiley-VCH Verlag GmbH, Weinheim, Germany, 32, 2001, pp. 116-120. 7. T. Hassel, Fr.-W. Bach, A. Golovko and C. Krause, “Investigation of the Mechanical Properties and the Corrosion Behavior of Low-Alloyed Magnesium-Calcium Alloys for Use as Absorbable Biomaterial in the Implant Technique, Magnesium Technology in the Global Age”, 45th Annual Conference of Metallurgists of CIM., Montreal, Canada, 2006, pp. 359-370. 8. Fr.-W. Bach, T. Hassel and A.N. Golovko, “The Influece of the Chemical Composition and Extrusion Parameters on the Mechanical Properties of Thin-Walled Tubes Made of Magnesium-Calcium Alloys,” Suczasni problemy metalurgii, Naukovi visti, Vol. 8, Systemni technologii, 2005, pp. 379-384. 9. Fr.-W Bach, A. Milenin, R. Kucharski, D. Bormann and P. Kustra, “Modelowanie za pomocą MES procesu ciągnienia drutów ze stopu magnezu wykorzystywanych w chirurgii,” Hutnik, nr 1-2, 2007, s. 8-11, in Polish. 10. A. Milenin and P. Kustra, “The multiscale FEM simulation of wire fracture phenomena during drawing of Mg alloy,” Steel Research International, 2008, nr 79, vol.1 pp. 717-722. 11. J. Eickemeyer, A. Guth, M. Falter and R. Opitz, “Drawing of magnesium wires at ambient temperature,” Proceedings of the 6th Int. Conference “Magnesium alloys

Milenin

Kustra

narzędzie do analizy procesów technologicznych ciągnienia wielostopniowego,” Hutnik, 2005, Nr. 2, T.72, s. pp. 100-104, in Polish. ■

Seitz

Andriej Milenin is a professor at AGH University of Science and Technology, Krakow, Poland, where he is head of the mechanical simulation group in the department of applied computer science and modeling. His research interests include FEM modeling, ductility of Mg alloys, and drawing. He is the author or co-author of more than 200 papers. Piotr Kustra is a Ph.D. student and assistant professor at AGH University of Science and Technology. His research interests include the magnesium wiredrawing process for medical applications. He graduated from AGH’s department of metal engineering and industrial computer science. Jan-Marten Seitz is a scientific assistant at the Institute of Materials Science at the University of Hannover, Germany.

Bach

Bormann

Friedrich-Wilhelm Bach is a professor at the Institute of Materials Science at the University. He has been a dean of the faculty of mechanical engineering and a director of the institute since 2005. He holds honorary doctoral degrees from Clausthal University of Technology and the University of Bremen. Dirk Bormann has been head of the Biomedical Engineering and Lightweight Structures at the BML Department at the Institute of Materials Science since 2005. He earned his doctoral degree from the University of Hannover. This paper was presented at WAI’s 80th Annual Convention, Milwaukee, Wisconsin, USA, May 2010, where it won the Silver Certificate Award in the ferrous division.

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and their Applications,” Edited by K.U. Keiner, WileyVCH Verlsg GmbH & Co., 2004. pp. 318-323. 12. K. Yoshida, “Cold drawing of magnesium alloy wire and fabrication of microscrews,” Steel Grips, 2, 2004, pp. 199-202. 13. A. Milenin, P. Kustra and M. Paćko, “Model matematyczny procesu ciągnienia na ciepło stopu MgCa08 z uwzględnieniem tendencji do pękania,” KomPlasTech2010, Białka Tatrzańska 10-13.01.2010 CD, in Polish. 14. A. Milenin, “Program komputerowy Drawing2d –

TECHNICAL PAPERS

TECHNICAL PAPER Method to improve straightness and remove torsion of uncoiled wires Wire can become plastically deformed when it is placed in drums because of the bending and twisting stresses. This study considers whether changing the shape of the wire being placed in the drums drum can reduce the torsion and improve the straightness of the wire. By Kotaro Nishimura, Motoo Asakawa, Masaki Kitazawa and Akihisa Yokoyama

Wire can become plastically deformed as it is placed in drums because of the bending and twisting stresses. Residual twisting and curvature are observed in such wires even after they are removed from the drums. As shown in Fig. 1.1, a coiled wire is twisted by 360° along the vertical direction when it is pulled out from the drum. Fig. 1.2 shows the coiling of a straight wire while it is being placed in a drum. The straight wire is twisted by 360° per coil. The bending force acting on the wire results in a bending stress σm on the wire surface. Twisting force acting on wire gives rise to a twisting stress τt on its surface. The equivalent stress

satisfies the yield criterion, although σm and τt do not. If the equivalent stress satisfies the yield criterion, a wire gets

Fig. 1:1. Twisting of wire when pulled out in vertical direction.

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permanently deformed, namely, the wire shape becomes worse after being picked up from the drum. Very few studies have been conducted on the change in the shape of wires placed in drums. The purpose of this study is to improve the straightness and remove the torsion of wires placed in drums.

Experimental method Fig. 2.1 shows the experimental method used in this study for placing wires in drums to obtain straight twistfree wires. After straightening by a roller leveler, a wire coiled on a spool was fed to a pinch roll and then placed in a drum by coiling in the clockwise direction. Two parallel markings were made on the wire between the roller leveler and the pinch roll, as shown in Fig. 2.2 (a). A piece including both the markings was cut off from the wire. The twisting angle β is defined as the angular dif-

Fig. 1:2. Schematic illustration of twisting of wire when placed in drum.

TECHNICAL PAPERS Fig. 2.1. Schematic illustration of placing wires in drum.

Fig. 2:2. Experimental method and definition of twisting angle Î˛.

Fig. 2:3. Experimental method and definition of spring-back angle Î¸.

Fig. 2:4 Definition of height of wire after uncoiling. JUNE 2011 | 83

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Table 1. Mechanical properties.

Fig. 3:1. Straightness before coiling.

ference between the two markings on the wire divided by the circumference of the drum, shown in Fig. 2.2 (b). The twisting angle β is defined to be positive when the wire is coiled in the anticlockwise direction. Fig. 2.3 shows the state of: (a) wire in drum; (b) several coiled wires after bending;(c) one coiled wire; and (d) uncoiled wire. The spring-back angle θ is defined as the angular difference between two bent parts divided by the circumference of the drum, D, as shown in (d). The springback angle θ of a twist-free wire is 360°. Similarly, the wire height H is defined as the vertical length of the wire after uncoiling per round, as shown in Fig. 2.4. The height H increased up to the circumference of the drum D as the straightness of the wire improved. A 0.1% carbon steel coiled wire with a diameter of 1.2 mm was used in the experiment. Its mechanical properties are listed in Table 1.

Experimental results Effect of straightness before coiling. The straightness of the wire before coiling is defined by its curvature κ, as shown in Fig. 3.1. The deflection width δ was varied from 1 mm to 5 mm in steps of 2 mm by adjusting the roller leveler, and the height H and the spring-back angle θ were measured. Fig. 3.2 shows that the height H increased as the straightness κ decreased. Thus, the straightness κ can be estimated by measuring the height H. Fig. 3.3 shows that the springback angle θ increased as the straightness κ decreased. These results indicate that improving the straightness of the wire before coiling affected its shape after uncoiling. The reason is that as the spring-back angle θ increases to 360°, the plastic deformation become smaller, as mentioned before.

Fig. 3:2. Relationship between straightness before coiling and height after uncoiling.

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TECHNICAL PAPERS Fig. 3:3. Relationship between straightness before coiling and spring-back angle after uncoiling.

Effect of torsion before coiling. The effect of torsion before coiling on the straightness of the wire was investigated. Consider a case when the axis of a spool is in the horizontal direction, i.e., normal direction, and the spool and wire are parallel to each other, as shown in Fig. 3.4 (a). In this case, no torsion acts on the wire when it is pulled out from the spool. On the other hand, when the axis of the spool is vertical and the wire is pulled in the vertical direction by a pulley, the wire is subjected to torsion and twisting, as shown in Fig. 1.1. The torsion is positive when wire is pulled out in the clockwise direction (Fig. 3.4 (b)) and is negative in the counterclockwise direction (Fig. 3.4 (c)). Fig. 3.5 shows that the twisting angle β varies with changes in the spool setting. Fig. 3.6 shows the relationship between the spool setting and the springback angle θ. The spring-back angle θ increased when the wire was pulled out in the clockwise direction. Fig. 3.7 shows that the height H was not affected by the spool setting.

Fig. 3:4. Spool direction.

Discussions Placing wire in drum. Fig. 4.1 (a) shows the relationship between the equivalent stress and the equivalent strain, . When the wire is in the spool, the state of the wire is the same in all spool settings. When the spool axis is along the horizontal direction, as shown in Fig. 3.5 (a), the wire is subjected to a strain per round during coiling, because of the

Fig. 3:5. Relationship between spool setting and twisting angle. JUNE 2011 | 85

TECHNICAL PAPERS Fig. 3:6. Relationship between spool direction and spring-back angle after uncoiling.

Fig. 3:7. Relationship between spool setting and height after uncoiling.

twisting and bending stresses acting on the wire. On the other hand, when the spool axis is in the vertical direction and the wire is drawn in the clockwise direction, as shown in Fig. 3.5 (b), the twisting direction of the wire from the spool to the pinch rolls is the same as the twisting direction when placed in the drum. Therefore, the wire is subjected to extra twisting stress when it is pulled out from the spool, as compared to the case of normal spool setting. Therefore, the equivalent strain in this case is larger than in the case of normal spool setting. However, when the spool axis is vertical and the wire is drawn in the anticlockwise direction, as shown in Fig. 3.5 (c), the twisting direction is opposite to that of the previous case. Therefore, the net twisting stress decreases. Hence, the equivalent strain in this case is smaller than in the case of normal spool setting. After removing wire from drum. The wire is untwisted after it is removed from the drum. As shown in Fig. 4.2, the spring-back angle after the wire is removed from the drum is large, because the equivalent strain in the drum is large. denotes the spring-back strain in the normal spool setting; , the spring-back strain in the clockwise setting; and , the spring-back strain in the counterclockwise setting. in the clockwise setting is the largest strain, because the equivalent strain is the largest. Moreover, as shown in Fig. 4.2, the spring-back strain is large because the equivalent strain exceeds the elastic strain. It is known that the equivalent strain increases with the wire’s twisting. Therefore, it is advisable to twist the wire before placing it in the drum, by pulling out wire from the spool in the clockwise direction. Further, twisting the wire results in an increase in the spring-back angle θ and a decrease in the residual twisting after the wire is removed from the drum.

Conclusions

Fig. 4:1. Relationship between equivalent strain and equivalent stress after uncoiling.

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The effects of straightening and twisting a wire before placing it in a drum on the wire’s straightness and torsion after removing it from the drum were investigated and discussed. The following results are obtained. 1. Wires may get plastically deformed while they are placed in drums, because of the bending and twisting stresses acting on the wires. 2. When the straightness of a wire before placing it in a drum is large, the deformation (high straightness and small twisting) of the wire after removing from the drum is small. 3. Twisting a wire before placing it in a drum is

TECHNICAL PAPERS

effective in reducing the residual twisting in the wire after it is removed from the drum.

References 1. K. Hayashi, T. Wada and M. Asakawa, Mechanism of the wire rotation during manufacturing processes, The Proceedings of the 42nd Japanese Joint conference for the Technology of Plasticity, 1991, pp. 169-172. 2. M. Asakawa, “Movement of the straightening process on the wire drawing,” Journal of the Japan Society for Technology of Plasticity, 39-447, 1998-4, pp. 48-51. 3. C. Sudo and M. Asakawa, “Formation and evaluation of the three dimensional curvature during sequence processing of wire,” Journal of the Japan Society for Technology of Plasticity, 31-352, 1990-5, pp. 658-663. 4. T. Fujita, “Kinking of the cables on the sea ground,” Journal of the Japan Society of Mechanical Engineers, 50-449, 1984, pp. 50-57. ■

Fig. 4:2. Relationship between equivalent strain and equivalent stress after uncoiling.

Kotaro Nishimura is a student in the School of Funda-mental Science and Engineering of Waseda University, Tokyo, Japan. Dr. Motoo Asakawa is a professor in the mechanical engineering department at Waseda’s School of Fundamental Science and Engineering. He came to the university 10 years ago from Sumitomo Metals Co. He has studied both the process engineering and materials engiNishimura Asakawa Kitazawa neering of the mechanical parts of cars, trains, aircraft, and construction and electric devices. He earned a doctoral degree in bar and rod rolling from Waseda in 1980. He is a Fundamental Science and Engineering. Akihisha recipient of Japan’s Okochi Memorial Prize, the Society Yokoyama is a graduate student in Waseda’s School of for Technology of Plasticity Prize, the Institute of Science and Engineering. This paper was presented at Metals Prize, and Iron & Steel Institute Prize. Masaki WAI’s International Technical Conference, Monterrey, Kitazawa is a student in the Waseda School of Mexico, October 2010.

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TECHNICAL PAPER Fabrication of biocompatible dental implant screw made of pure titanium A study found that it is possible to fabricate titanium screws by heading and rolling that do not contain elements of concernâ&#x20AC;&#x201D;such as cytotoxic vanadium and neurotoxic aluminumâ&#x20AC;&#x201D;and are able to be cold plastic worked. By Kazunari Yoshida, Yoshio Saiki, Chikahiro Ohkubo, Daisuke Kurihara, Tomoko Osada and Tadashi Tashima

Technological innovation and the development of new medical equipment have been used to realize highly advanced medical treatment. Materials used in medical and dental devices require high strength and resistance to corrosion and abrasion. Further, such devices must be nontoxic to biological bodies, that is, they must be nonallergenic while meeting the above requirements. Past studies by the authors have examined guide wires, orthodontic wires, microsprings, and stents formed from drawn wires and tubes, which are used in dental treatment. This study discusses the practicality of screws, with the research including the fabrication of dental implant screws made of pure titanium. Currently, titanium alloys (Ti-6Al4V) are used in dental implants. however, concerns have been raised about the fact that these alloys contain cytotoxic vanadium and neurotoxic aluminum. Another disadvantage of titanium alloys is that they are difficult for cold plastic working, and therefore they must be fabricated by

cutting, which is expensive. The dental implant screws were fabricated by heading and form rolling of pure titanium wires that were drawn to a predetermined diameter. The drawability, strength and dimensional accuracy of the obtained screws were determined.

Examined implant screw, materials and experimental method Examined implant screw and materials. Fig. 1 shows the structure of dental implant. In this study, the focus was on the screw (B in Fig.1) used for fixing an implant abutment. The dimensions of the screw are shown in Fig. 2. Pure titanium was used as a material, and three materials (Ti1, Ti2 and Ti3) with different Fe, N and O contents were prepared to examine screws with different strengths. Table 1 summarizes the chemical compositions of these materials.

Table 1. Chemical composition of tested Ti wire.

Fig. 1. Structure of dental implant1. 88 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS

Experimental methods. Implant screws were fabricated by the conventional processes, i.e., drawing, heading, and form rolling. See Fig. 3. Titanium wires were drawn using an ultrahard conical die with a half-angle of Îą=6o and a resin lubricant. They were formed by a double-header heading machine and rolled by a flat die rolling machine to fabricate the screws. A torsion test and a Vickers hardness test were carried out to measure the strength of the screws. The authors used Finite Element Method (FEM) analysis to examine how the screws were formed by heading and form rolling. The commercially available MARC was used as the FEM code.

Fig. 2. Schematic of titanium screw for fixing abutment.

Fig. 3. Fabrication method of screws by metal forming.

Fig. 4. Total content of Fe, N, and O, tensile strength, breaking strain.

Fig. 5. Drawing limit of pure titanium wires with different total contents of Fe, N and O.

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Results and discussion

Fig. 6. Relationship between hardness and total reduction.

Fig. 7. Formability of wires with different total contents of Fe, N and O.

Fig. 8. A well-formed screw produced during the study.

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Mechanical properties of mother wire. Fig. 4 shows the measured tensile strength (T.S) and breaking strain (εb) obtained in a tensile test on the three types of pure titanium wire shown in Table 1. In the figure, the abscissa represents the total content of Fe, N and O, and the left and right ordinates represent T.S and εb, respectively. T.S increased and εb decreased with increasing total content of Fe, N, and O in the material. It is known that a higher εb generally indicates higher drawability. Therefore, Ti1 is expected to have the highest drawability. Drawing limit. The three types of pure titanium wire with different total contents of Fe, N, and O were drawn using an ultrahard conical die with a half-angle of α=6o and a diamond die, and their drawing limits were determined. The results are shown in Fig. 5. The upper limits of total reduction Rt (drawing limit) of Ti1, Ti2 and Ti3 were 97, 96.4 and 91.9%, respectively. As described above, there is a correlation between the drawing limit and the value of εb for the mother wire. Fig. 6 shows the relationship between the Vickers hardness (HV) and Rt for the Ti1 drawn wire. The hardness for a Ti-6Al-4V alloy drawn wire is also shown for reference. The pure titanium wire hardens during drawing, although it is clearly softer than the alloy wire. Fabrication of screws. Fig. 2 shows the dimensions for the fabricated pure titanium screws that were produced by the conventional heading and form rolling processes using the three types of pure titanium wire. No problems were encountered in the fabrication of Ti1 in terms of the dimensional accuracy, crack formation and surface roughness, whereas Ti2 and Ti3 exhibited some defects, as shown in Fig. 7. Ti1, with high drawability, exhibited the highest workability during the fabrication of the screws. In contrast, for the wires that exhibited the greatest hardening during drawing, cracks developed in forming a recess in the screw head during the heading process. Fig. 8 shows a well-formed screw obtained in this experiment. The three types of material were subjected to form rolling to produce the screw threads. No cracks developed in any of the screws, and they had a good shape. Among them, Ti1 exhibited the highest screw thread

TECHNICAL PAPERS Fig. 9. Comparison of different types of pure titanium wire after form rolling.

formability. Similar results were obtained in the FEM analysis. See Fig. 9. Torsional strength of screw. Different types of Ti1 mother wire were made by changing the Vickers hardness near the surface from approximately 120 to 200 HV. These wires were subjected to heading and form rolling to form screws, and their torsional strengths were measured. Fig. 10 shows the relationship between the torsional strength and the hardness of the mother wires. The torsional strength of the screw increases with increasing hardness of the mother wire. According to the experimental results, when the torsional strength (TB) exceeds a certain value, it can be approximated as TB=0.097HV+16.6 [Ncm]

Fig. 10. Relationship between torsional strength and hardness of screw.

Eq. (1)

The torsional strengths of conventional screws made of a titanium alloy (Ti-6Al-4V) and a steel (SWCH16A) are shown in Fig. 11. Pure titanium dental implant screws have a torsional strength of 36 Ncm, which is sufficient to endure the tightening at a torque of 20 Ncm applied in medical situations. Furthermore, Fig. 13 indicates that the screws have higher robustness to impact than conventional screws obtained by cutting.

Conclusions The fabrication of biocompatible pure titanium dental implant screws was studied, and the following results were obtained. â&#x20AC;˘ Dental implant screws were successfully fabricated by drawing, heading and form rolling. â&#x20AC;˘ The smaller the total amount of Fe, N and O in the material, the higher the drawing limit.

Fig. 11. Comparison of strength among different materials.

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One of the materials used in this study had a high drawing limit of 97%. • Similarly to the drawing limit, the workability during heading and form rolling was also affected by the total amount of Fe, N, and O in the material. • The fabricated screws were found to have a torsional strength sufficient for them to be used in practice. The torsional strength was positively correlated with the hardness of the mother wire.

3. The Fasteners Institute of Japan, “New Introduction to Screws,” 1980, pp. 26-38, 207-220. 4. H. Sano, “Revision Machine Material,” Kyoritsu Pub., Inc., 1983, pp 1-10. 5. MJ Donachie, Jr., “Titanium Technical Guide From the Foundation to Business,” Uchida Rokakuho Publishing, 1993, pp. 161-192. 6. Titanium Association: “Processing technology of titanium,” Nikkan Kogyo Shimbun, 1992, pp. 9-18. ■

References 1. Y. Akagawa, “Easy-to-Understand Oral Implantology,” Ishiyaku Pub., Inc., 2005, pp.10-40. 2. Kazuya Yoshida, “Basis of Plastic Working,” Sangyo-Tosho Publishing, 1988, pp. 64-72.

Yoshida

Saiki

Ohkubo

Kazunari Yoshida is a professor of precision mechanics at the school of engineering at Tokai University, Japan. He researches wiredrawing, extrusion and forging processes and has served as a member of the steering committee for Japanese Wire Drawing. He holds a Ph.D. degree in engineering. He authored a prize-winning paper for the Japan Society for Technology of Plasticity in 1984 and won medal awards from the Wire Association International for the best paper in the nonferrous division in 1999, 2001, 2003,

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Kurihara

Osada

Tashima

and 2004, and in the general division in 2008 and 2009. Yoshio Saiki is a graduate student at Tokai. Chikahiro Ohkubo, Daisuke Kurihara and Tomoko Osada are from the Tsurumi University School of Dental Medicine, Yokohama, Japan. Tadashi Tashima represents Union Semitsu Co. Ltd., Aiko-Gun, Japan. This paper was presented at WAI’s 80th Annual Convention, Milwaukee, Wisconsin, USA, May 2010.

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Organizers ACIMAF—Associazione Costruttori Italiani Mecchine per Filo — Italy CET — Comité Européen de la Tréfilerie — France IWCEA — International Wire & Cable Exhibitors Association IWMA — International Wire & Machinery Association WAI — The Wire Association International, Inc. The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

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PRODUCTS & MEDIA PROD DUCTS Powder coating machines provides dust-free powdering of cables Exhibited at Interwire by Amaral Automation, the Rolf Schlicht electrostatic powder coating machine model RSC, form Germany’s Rolf Schlicht GmbH, was designed for an even, fine dosing and absolutely dust free powdering of cables, wires, hoses, profiles with powders that include talc, stearate, lac powder, swellable powder, etc. The electrostatic charging of the powder provides for strong adhesive power on the product and even coating, a press release said. It noted that the electrostatic charge ensures that powder will not fall from the substrate after leaving the dusting chamber. Depending upon the extrusion speed and product diameter one to four powder guns may be used, it added. Optimal adjustment of the powder quantity is done by controlling the power of the electrostatic charge from 0-100 kV, the release said. The speed of the dust cloud may be adjusted for optimal coverage. The system has a fully automatic and maintenance-free filter system that is constantly cleaned by a special process. “Thanks to this filter system, a strong and constant vacuum is generated in the machine, so that powder will not escape into the atmosphere. Inlet and outlet openings of the dusting chamber do not have to be sealed by brushes, etc.” For tight areas, a free-standing dusting chamber can be used that is connected to a remote machine by hoses, the release said. For extremely fine powdering of slowly running products, an optional fine dosing device can make sure that only a breath of powder is transported to the guns. Contact: Rolf Schlicht GmbH, info@schlicht-gmbh.de, www.schlicht-gmbh.de; In North America, Amaral Automation, insidesales@amaralautomation.com.

Buttwelder serves ‘in between’ sizes At Interwire, Germany’s August Strecker GmbH & Co. KG, which has more than 75 years in manufacturing electric as well as cold pressure buttwelding machines, introduced a new machine, type 1b. A press release said that the new model is meant to

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serve as an “in between” model that is larger than its well-known table-top unit, 1a, and its larger movable unit, type 2a. The new model, it said, was designed to be a price-worthy alternative for customers that need to cover such a welding range. Specifically, the type 1b model has a working range for nonalloy steel of .160 in. to .550 in (4 mm to 14 mm), alloyed steel from .160 in. to .390 in. (4 mm to 10 mm), copper wire from .120 in. to .315 in. (3 mm to 8 mm), brass wire from .120 in. to .390 in. (3 mm to 10 mm) and aluminum wire from .160 in. to .390 in. (4 mm to 10 mm), it said. In addition to its lines of cold-pressure buttwelders, the company also offers conventional resistance pressure welders for solid wires of all kinds, electric dual upset welders with auto-deburring for ferrous and nonferrous material, strand and cable buttwelders (with or without tubes), machines for electrical parting as well as buttwelding of steel strands or steel cord, buttwelders or spotwelders or lapwelders for all kinds of strip material, and battery-operated welding or parting guns with independent power supply fed off the line. Contact: Sigrun Mobus, August Strecker GmbH & Co. KG, sales@strecker-limburg.de, www.strecker-limburg.de.

Testing system uses 2 technologies for inspecting titanium rod and bars U.S.-based Magnetic Analysis Corporation (MAC) supplies multi-test eddy current/ultrasonic systems to inspect small diameter bars and rods, including a system to test titanium rods and bars (2.54 mm to 31.75 mm). A press release said that the systems can meet test criteria

Enhanced PTFE cables maximize longevity, avoid particle problems U.S.-based W.L. Gore & Associates reports that it has continued to enhance its engineered PTFE (polytetrafluoroethylene) technology for use in flat and round cables, making them ideal for demanding, extreme environments such as semiconductor manufacturing, aerospace and industrial applications. A press release said that Gore’s customized materials and unique cable designs have resulted in products that minimize particulation and outgassing while maximizing longevity, a combination of qualities it said is not found in any other cable technology. The low coefficient of friction and excellent tear resistance of Gore’s expanded PTFE composite jacket material enable its high flex cables to maintain excellent signal integrity while the flexible material also allows the flat cables to be stacked on top of each other without needing dividers and shelves, reducing the overall size and weight of the cable system, it said. Unlike flat cables with jackets made of extruded materials such as silicone and polyurethane, GORE® High Flex Flat Cables’ extremely low coefficient of friction does not create particles, a crucial advantage in cleanroom environments, the release said. The technology is offered in several cable solutions. Contact: W.L. Gore & Associates, www.gore.com/electronics.

process singlecore wires, twin leads, twisted pair, multi-conductors, shielded and ribbon cables up to around 6 mm outside diameter or 100 mm wide for ribbon. A press release said that the SIENNA 700 range has been designed for precision-critical applications, including medical device manufacture, such as for ultrasound cable assemblies and medical probes. It encompasses a number of technological performance enhancements over the existing range of laser wire stripping products, such as increased optical motion of up to 250 mm per second, or 10 inches per second, which is five times faster than previous SIENNA models, it said. Strip position accuracy has also been enhanced offering accuracies of +/-0.2 mm, and a high level repeatability in terms of strip quality, it said. The model has a new touch-screen HMI (HumanMachine Interface) for easy programming of power,

New line of wire strippers offered U.S.-based Spectrum Technologies has launched the SIENNA 700 series, the company’s new top-of-the-range, high speed, high-specification laser wire strippers that can

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AMS-2631B, Class AA for the ultrasonic test (aerospace specifications), and typical eddy current inspection standards for the eddy current test. “By combining eddy current and ultrasonic technology, superior test results can be obtained as each technique detects the conditions that it is best suited to find,” it said. The titanium test system uses Echomac® FD-4 ultrasonic test electronics and a rotary to detect surface and near-surface defects such as seams, spiral seams and light cracks as well as inclusions and deep voids, while the MultiMac® eddy current instrument and test coil detects some very small surface seams or pitting that are poor reflectors of sound, it said. Contact: Jean Gould, Magnetic Analysis Corporation, tel. 914-530-2000, jgould@mac-ndt.com, www.mac-ndt.com.

PRODUCTS & MEDIA

speed, depth of focus and pattern combinations, with high-precision control software that enables interpolated movements permitting stripping of complex patterns such as diagonals and curves, the release said. It added that the SIENNA 720SR is included in the new range with single and dual axes of movement, designed for cutting metallic shields on delicate microcoax assemblies. Contact: Spectrum Technologies. sales@spectrumtech.com, www.spectrumtech.com.

Rod welder is very energy efficient The EP500 electro/pneumatic rod welder from U.K.based Pressure Welding Machineries (PWM), shown at the Amaral Automation booth at Interwire 2011, has been one of the company’s best-selling machines. PWM notes that the EP500 model offers wire and cable manufacturers a cleaner, ‘greener’ and more economical method of joining large nonferrous rod sections than electrical butt welding. The system, which can weld copper rod up to 12.50 mm (.492 in.) in diameter and aluminum rod up to 15 mm (.590 in.) in diameter, is extremely energy efficient to operate, it said. The systems are precision-engineered in PWM’s U.K. workshops to meet strict quality standards, the company reports. It said that the EP500 “guarantees strong reliable welds every time, reducing materials wastage to a minimum.” Further, no set-up time is required, and no heat, flux or fillers are required, and the cold weld process does not generate any dangerous or unpleasant fumes, it said. The EP500 is quiet, safe and easy to operate, and the weld cycle is

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completed in one minute, with automatic de-flashing on completion. Contact: PWM, www.pwmltd.com, pwm@btinternet.com; and in North America, Amaral Automation Associates, tel. 401-4050755, insidesales@amaralautomation.com, www.amaralautomation.com.

Line of keyed color-coded LC connectors has been introduced U.S.-based Optical Cable Corporation (OCC®) has introduced new keyed LC connectors to its Limited Axcess™ product line, which offers limited accessibility to networks through a physically restrictive cross connect system. A press release said that the company’s Limited Axcess LC fiber optic connectors enable network administrators to easily segregate networks for security or confidentiality concerns, making them secure network and military applications. The LAX-series adapter plates and patch cables are available in 12 keyed color-coded options that limit unauthorized access to network ports, it said, adding that all LAX adapter plates are accepted in any of OCC’s fiber optic enclosures and that they can even be pre-terminated for easy plug and play installations. All adapter and connectors are of single-mode quality and covered by the standard OCC 15 year product assurance warranty, it said. The release said that the technology, previously avail-

More ergonomics, easier access are offered for pallet handling U.S.-based Southworth Products Corp., notes that it has redesigned its “time-tested” PalletPal Level Loader, using a smaller base that it said makes loading and unloading pallets faster, safer, and easier because it lets the user step even closer to the unit’s platform, for the best access to palletized loads. A press release said that the PalletPal, introduced in the U.S. more than 25 years ago, “virtually eliminates the productivity-robbing, injury-producing bending, lifting, reaching, and stretching common to pallet-loading applications.” It said that heavy-duty springs automatically lower or raise a pallet as weight is added or removed, maintaining the top layer of stacked containers at a convenient height, while the turntable ring (or optional turntable platform) at the top of the PalletPal allows the user to spin the load so the operator can stand in the same spot throughout the loading or unloading process. The unit is economical, requires no power and is virtually maintenance-free, it said, able to handle loads from 400 to 4,500 lb, depending on which of five spring packages is chosen by the customer (based on the anticipated weight and height of a fully loaded pallet). Contact: Southworth Products Corp., tel. 207-

878-0700, salesinfo@southworthproducts.com, www.southworthproducts.com.

These electrical connectors were made to stick together U.S.-based ETCO Incorporated has introduced a line of electrical connectors for appliances and instruments that it said cannot pull apart, as well as for connectors for spark plugs that feature a vibration-resistant retention clip.

Continuous Casting Technology

Advancing Metals Technology

www.rautomead.com

Rautomead Limited PO Box 100, Dundee, DD1 9QY Scotland, UK

Tel: +44 (0)1382 622341 Fax: +44 (0)1382 622941 email: sales@rautomead.com

Rautomead Limited PO Box 100, Dundee, DD1 9QY Scotland, UK

Tel: +44 (0)1382 622341 Fax: +44 (0)1382 622941 email: sales@rautomead.com

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able only as a keyed copper solution, are now included in the OCC Limited Axcess product set. Contact: Optical Cable Corporation (OCC®), www.occfiber.com.

PRODUCTS & MEDIA

A press release said that the ETCO high-retention electrical connectors are offered in two styles: the FlatSnap® Connector, which features a unisex design with a positive locking mechanism that connects with a simple pushpull motion, clicks into place, and cannot pull apart; and the spark plug terminal featuring a spring clip which connects with a tactile feel and seats for a reliable connection. The connectors are supplied on a carrier strip for automated assembly equipment. They are available in 0.032 in. x 0.250 in. and other sizes, and are made from nickel-plated steel and various high temperature alloys, it said, adding that the spark plug terminals and clips are offered in various types of steel. Contact: ETCO Incorporated, tel. 941-756-6426, www.etco.com.

MEDIAA On-line flat cable configurator can design custom products U.S.-based Cicoil, a manufacturer of extruded, siliconejacketed flat cable, has launched a new web application that allows users to design their own custom cable online. A press release said that the Cable Configurator web application features drag and drop simplicity to design any flat cable up to widths of 3.75 in., and get an immediate drawing and quote. Immediately after constructing a flat cable design, users receive an engineering drawing

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and a price quotation, and once an order is placed, Cicoil promises to ship any custom cable within one week, it said. The cables can be constructed of many elements, including shielded power conductors, shielded signal conductors, video and coax wires, tubing for fluids or gases, and other design elements, such as Cicoil’s patented StripMount™ fastening strip, it said. Any of these elements, it said, can be combined in a flat cable, which means that millions of flat cable designs are available for immediate production and delivery. The company’s silicon-coated flat cables are designed to provide high flexibility, extremely long life and to be able to withstand temperature extremes from -65 degrees to +260°C. “This exciting tool takes flat cable design to the next level, as our customers now have the power to design a custom flat cable with a few simple clicks of a mouse,” said Cicoil President Howard Lind. Contact: Cicoil, www.cicoil.com.

Website features product gallery U.S.-based C&M Corporation, a vertically integrated manufacturer of bulk cable, coil cords, and cable assemblies, has added an OD Calculator to its suite of websitebased design tools. A press release said that the calculator is designed to support the development of standard multi-conductor cables where all the components are similar in size, or composite cables which feature components of different dimensions. The calculator provides a selection of various shielding options and accepts the user’s choice of jacketing thicknesses before providing an estimate of the finished cable’s OD, it said, noting that the tool can also be used to estimate the OD of cable cores. The OD Calculator is available via a link on C&M’s home page marquee or through the “Resources” tab. “Our goal after reviewing the other internet options available to cable engineers was to provide a design tool that was more accurate and more robust than what we were able to find during our competitive benchmarking, while at the same time maximizing the ease of use for our visitors,” said C&M Marketing Communications Manager Mike Levesque. “I believe we were able to accomplish our objective and have provided a very unique design tool.” Contact: C&M Corporation, tel. 860-774-4812, www.cmcorporation.com. ■

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking positions are entitled to free “Position Wanted” classified ads. Limit: one ad per issue, three ads per year. This benefit is not transferable to nonmembers or to companies. CLASSIFIED AD RATES: • $1.30 per word for WJI and on-line classifieds at wirenet.org (20-word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category. BLIND BOX INFO: Responses to Blind Box ads should be addressed to: Wire Journal International, Box number (as it

CAREER OPPORTUNITIES WIRE OPERATORS WANTED. Experienced in Copper wire fabricating on bunchers, multiwire machines, rod breakdown or bobbin winders. Excellent work environment with competitive pay plus health Care benefits. Please send resume to SARK Wire Corp. 120 Industrial Park

appears in print or on-line), P.O. Box 578, Guilford, CT 06437-0578 USA. PAYMENT POLICY: All ads must be pre-paid. DEADLINES: Copy is due a full month in advance, i.e., it must be received by March 1 for publication in the April issue. Classifieds booked on-line, run for at least one-month on-line, from the date of booking. Wire Journal International “Print classifieds” booked on-line as an “add-on” to an “online classified” booking will run in the next available issue.

Road, Albany, NY 12206 OR send an e-mail to vpresident@sark-usa.com OR fax to (518) 453 4166. S A L E S R E P R E S E N TAT I V E S NEEDED. Wire manufacturer looking for Sales Representatives. We specialize in flat, square and shaped wire manufactured in stainless steels, carbon steels, nickel bases, copper bases, and

aluminum. The following states are desired: TX, IN, OH, MI, WV, VA, TN, &, KY. Please contact Bob Swanson at tel. 800-840-9481.

PERSONNEL SERVICES “LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire

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

SALE 1 - NEW ENGLAND BUTT 24-Carrier Model CB-1 Cable Braider 7 - WARDWELL 12-Carrier Braiders 1 - OMA 24-Carrier Braider, Type 24/1 104 w/Payoff and Take-up 2 - OMA 24-Carrier Braiders, Type 24+24/140TCH/EORIZ, 1996 w/Capstans 1 - SPIRKA 24-Carrier Braider, Model 24N4, 1990 1 - SPIRKA 16-Carrier Braider, 500mm Take-up and Payoff 1 - NEB 12-C #2 Braider, Long Legs, Motor 1 - NEB 16-C #2 Braider, Long Legs, Motor 1 - EDMANDS 18-Wire, 6+12, 16” Planetary Cabler Line 2 - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 1 - MGS 50” Continuous Belt Caterpuller, Model LC50.4D-LH 1 - DAVIS STANDARD 4.5” 24:1 L/D Extruder 1 - DAVIS STANDARD 2.5” 24:1 L/D Nylon Extruder, Model 250SII 1 - D/S 2.5” 24:1 L/D Hi-Temp Extrusion Line 1 - D/S 2” 30:1 L/D Hi-Temp Extruder 1 - ENTWISTLE 2” 24:1 L/D Extruder, Model TFII-2000-24 1 - HALL 60” Drag Payoff, 1997 1 - SKALTEK 1600mm, Model A16-4K, Motorized 1 - ROSENDAHL 630mm Parallel Axis Dual Reel Take-up, never used 1 - NOKIA Model EKP50 Parallel Axis Dual Reel, 1997

1 - SPHEREX 18” Dual Reel Take-up, refurbished 1 - CLIPPER Model SP16 Dual Spooler 1 - HALL 10” Dual Spooler/Coiler w/36” Powered Payoff and Dancer 1 - REEL-O-MATIC Model PRR1 Rim Drive Powered Reel Roller 1 - REEL-O-MATIC Model RD-5 Rim Drive Take-up w/Coiling Head 1 - TEC Model DTC630 D.T. Twister 1 - ENTWISTLE 4-Wire 24” D.T. Twister, Model 4WDT 1 - FINE Preheater, Model IP4000-180-1 1 - ARTOS Model MTX-5 Wire Processing Machine 1 - EUBANKS Model 9800-03 Cut & Strip Machine 1 - SCHLEUNIGER EcoStrip 9300 Cut & Strip Machine 1 - SCHLEUNIGER JS8300 Jacket Stripper 1 - SCHLEUNIGER US 2015 UniStrip Stripper 1 - SCHLEUNIGER US 2500 UniStrip Stripper 1 - IDEAL 940 Bench Stripper (now ARTOS 45-940)\ 1 - CARPENTER 3-Head Stripper, Model 74-C 3 - CARPENTER Strippers, Model 70-B 1 - MICRODIA Crosshead, Model M9000/10XFL 1 - BOXY Reel Tilting Unit for 60” Reels, 2003 1 - CONAIR Model SC-15 Carousel Dryer 1 - CONAIR FRANKLIN Model CS-101Carousel Computerized Dryer 1 - UNADYN Model BD Mini Dryer

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

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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”)

& Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors and managers. Contact: E-mail Peter Carino at pcarino@wireresources.com or e-mail Jack Cutler at jcutler@

wireresources.com, or visit the Wire Resources company website at www.wireresources.com. Wire Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, color-o-meters and pointers). Tel: 727863-4700 or by e-mail, please send to urbassoc@verizon.net.

INVESTMENT OPPORTUNITY OPPORTUNITY FOR INVESTMENT. Big wire rope producer in the Center of Europe seeks a Partner who can invest in Wire Drawing Equipment at our existing wire rope factory. Contact Blind Box: 5-1.

PURGING COMPOUNDS AMERICA’S OLDEST SUPPLIER. Since 1948, we’ve supplied millions of pounds so we know a little bit about JIT deliveries an customer satisfaction. We sell for less because our costs are less. BUY SMART - WE DO. Alan Plastics Co., Inc. PH: (781) 828-0700. FX: (781) 828-2087. Contact: E-mail: alphas@aol.com, www.alplastic.com

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

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. 904388-3654. APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ wmconnect.com. AJEX & TURNER WIRE DIES CO. The company offers a wide range of PCD/ND/ Carbide Dies, Extrusion Tools, Die Polishing Machines, Ceramic & Diamond Tools. www.ajexturner.com. Send inquiries to either ajexturner@ gmail. com or to sales@ajexturner.com. A-53, G.T. Karnal Road, Delhi-33 India. Ph: 00919811078882 (Ravi Bansal). SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service. 60+ years of quality products and service to the wire industry. Contact Bill Drumm at 1-800-332-0747, or E-Mail at sales@sancliff.com.

MEDIA FERROUS WIRE HANDBOOK. This comprehensive hard-cover book is a definitive industry resource for ferrous

included in the handbook. List Price is $235, $195 for WAI members. THE BOOK OF WIRE & CABLE TERMS. Learn the A to Zs of wire and cable with this essential reference source. Presented in a clear, practical manner over 350 pages, The Book of Wire & Cable Terms covers both ferrous and nonferrous terminology. More than 5,000 entries are offered. List Price: $75, $50 for WAI members. Ships in one to two business days. ELECTRICAL WIRE HANDBOOK SET. Focusing on the special needs of the insulated wire and cable industry, these books examine materials, equipment, and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication

cables, magnet wire, heater wire, and other applications. The original version remains available while the revised Electrical Wire Handbook is divided into three separate handbooks: Part 1 Wire and Cable Production Materials, Part 2 - Wire and Cable Production Processes, and Part 3 - Types of Cables. While the updated handbook includes the latest information available, this new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. The intent of these handbooks is to provide basic but meaningful information to those people working in the wire and cable industry-especially those who are new to the field. Price $99, $59 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

LIVE ON-SITE & WEBCAST AUCTION Surplus Equipment from Continuing Operations of: WINDSOR MACHINE GROUP

AUCTION: Wednesday, August 3, 2011 at 10:00am EDT LOCATION: 178 London Rd Thamesville, ONT N0P 2K0 Canada (1-1/2 hours from Detroit, MI)

PREVIEW: Mon., August 1st & Tues., August 2nd or by Appointment

World-Renowned Manufacturer of Automotive Muffler Hangers, Seat Rods, Long-Headed Rods, Bent Wire Forms WIRE MACHINERY: (6) Refflinghaus Automatic Wire Benders 3/8 thru 5/8", (1) OMAS Mdl. CEB-110 4 Axis CNC Wire Forming Machine. Lewis Mdl. 10-FA, Lewis Mdl. 9-FA, (9) FE In Line Wire Drawers 40-hp, 110 fpm. (8) RMG In-Line Wire Drawers 25 - 60 hp, up to 250 fpm. (8) Ajax type, In-Line Hitch Feed Wire Drawers, (15) Custom Vertical Hyd. Benders (10) Custom Air Benders, w/flexible slide positions. COLD HEADERS: Waterbury Rod Headers (1) Mdl. #44 DSOD, (2) Mdl. #33 DSOD, (1) Mdl. #11 DSOD, Manville #3 DSOD. (2) 9/16 x 7" Mekifasa (Fide) Mdl. EF-L-180 Long Stroke Solid Die, 1" Ryazan, Mdl. BP-1131 3-Die Hot Upsetter (NEW). KNUCKLE JOINT PRESSES: 150 ton Bliss, 200 ton Clearing, 400 ton Toledo, 400 ton Minster, 600 ton Clearing, 600 ton Minster • OBI PRESSES: 20 ton L&J, 35 ton Niagra, 50 ton V&O, 60 ton Bliss • ECCENTRIC PRESSES: (10) VSS (TOR) Mdl. LE-160-C, 160 Ton (3) SURFACE ENGINEERING WIRE IN-LINE POLISHING MACHINES COMPLETE TOOL ROOM: Vertical Milling Machines, Vert. Band Saws, Horizontal Band Saws, Welders, Surface Grinders, Lathes, Drilling Machines, Radial Arm Drills, Pick and Place Robots, Air Compressors, Forklifts & Much More!

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wire written by WAI members and edited by former WAI President Robert M. Shemenski, this 1,168 page hard-cover book was published in 2008. It is a modern-day reference tool for those working directly in the steel wire or manufacturing, engineering, or operations sectors of the industry. The 36 chapters cover a broad range of topics, including equipment types, processes and specialty applications of steel wire manufacturing. Specific subjects that are discussed include continuous casting; controlled rod cooling; rod defects; pickling and coating; descaling; deformation in cold drawing; wiredrawing theory, machinery, and finishing equipment; lubrication; heat treatment; stress relief; annealing; oil tempering; patenting; corrosion; galvanizing; statistical process control; bridge rope and strand; and nails, barbed wire, mechanical springs. Appendices and a complete index are

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX ADVERTISER ..............PAGE Amacoil Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3 Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .54 Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Bogimac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .57 Cable Consultants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cemanco LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58, 97 Cimteq . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .99 Esteves Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Foerster Instruments Inc . . . . . . . . . . . . . . . . . . . . . . . . . .59 Force Measuring Systems (FMS) . . . . . . . . . . . . . . . . . . .16 T Fukase & Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Fushi Copperweld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Gauder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 GBC Techologies Inc./Filowire, Inc . . . . . . . . . . . . . . . . . .61 GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 v. Hagen & Funke GmbH, . . . . . . . . . . . . . . . . . . . . . . . . . .69 Howar Equipment Inc/Unitek . . . . . . . . . . . . . . . . . . . . . . .64 Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19, 51 Inhol BV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Kiswire Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

102 | WIRE JOURNAL INTERNATIONAL

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

Koswire Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Power Sonics LLC/Magnus Equipment . . . . . . . . . . . . . .45

KP America Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .95

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Properzi International . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

LaserLinc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Leibinger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Rautomead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . . . . .13

Reel-O-Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Locton Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Reelex Packaging Solutions Inc . . . . . . . . . . . . . . . . . . . . .5

Magnetic Analysis Corporation (MAC) . . . . . . . . . . . . . . .35

Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Messe Düsseldorf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

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

NIMSCO LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

NUMALLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Talladega Machinery & Supply Co . . . . . . . . . . . . . . . . . .27

Paramount Die Co./WiTechs . . . . . . . . . . . . . . . . . . . . . . .31

Tubular Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

JUNE 2011 | 103

ADVERTISERS’ INDEX

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

ADVERTISERS’ INDEX

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

August 2011 WJI

Unience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2 Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Windsor/Bid It Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . .103 Witels Albert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

• Brazil outlook and preview of Tubotech • CabWire/ITC preview Düsseldorf, Germany • Wrapup: wire Southeast Asia

Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . . .9

Advertising Deadline: July 1, 2011 Wyrepak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 4

WIRE ASSOCIATION INTERNATIONAL ADS WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 CabWire/WAI ITC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

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

NORTH AMERICA

EUROPE

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

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

104 | WIRE JOURNAL INTERNATIONAL

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

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

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