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WIRE JOURNAL

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

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

CONTENTS

Volume 42 | Number 5 | May 2009

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 20 People . . . . . . . . . . . . . . . . 22 Fiber Watch . . . . . . . . . . . . . 26 Fastener Update . . . . . . . . . 28

Perspectives: John Gross . . . . . . . .36 Manufacturers who use copper can—and should—take measures to avoid problems from volatile metal pricing.

Dies . . . . . . . . . . . . . . . . . . . . . .38 WAI News . . . . . . . . . . . . . . 30 Chapter Corner . . . . . . . . . . 34

Suppliers of dies discuss their technology and their perspectives about what they need to do in the current economy to provide value to their customers.

Technical Papers . . . . . . . 52-69 Products/Media . . . . . . . . . . 70 Classified . . . . . . . . . . . . . . 75 Career Opportunities . . . . . . 75 Advertisers’ Index . . . . . . . . 78

T ECHNICAL P APERS Analysis of the straightening of drawn wires using rollers by the Finite-Element Method (FEM) Kazunari Yoshida and Tsuyoshi Sugiyama . . . . . . . . . 52 Evaluation of hydrogen embrittlement susceptibility of PC wires Shingo Yamasaki, Seiki Nishida, Daisuke Hirakami and Toshimi Tarui . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Influence of surface texture and residual stresses on fatigue strength of wire rope Jan W. Pilarczyk, Bogdan Golis, Ryszard Budzik, Robert Kruzel and Marek Gała . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Cover: A die display from Woodburn Diamond Die. Die technology may not draw as much attention as capital equipment, but suppliers stress that manufacturers should not take this essential part of the wiredrawing process for granted. See p. 38.

MAY 2009 | 3

INSIDE THIS ISSUE NEWS

. . . . . . . . .11

CONTENTS

I NDUSTRY

Industry may have a far more pronounced global scope, but regional events still play an important role. One such gathering was the April 14 show put on by the New England Spring & Metalstamping Association (NESMA). The event drew nearly 500 attendees to the Aqua Turf Country Club in Plantsville, Connecticut.

4 | WIRE JOURNAL INTERNATIONAL

C HAPTER CORNER . . . . . . . .34 Life is about more than just work and fretting about a global recession that seems to be beyond anyone’s comprehension, and that’s more than reason enough for golfers to welcome both spring and a partial schedule of the annual golf tournaments for the WAI’s chapters. A day at the links with fresh air, refreshments, camaraderie and networking is just what the industry can use—even if that little white ball chooses not to be cooperative.

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EDITORIAL WIRE JOURNAL

EDITORIAL

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

Industry innovation part of global advances

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

The National Association of Manufacturers (USA) along with the Boston Consulting Group recently released the first International Innovation Index. The index measures governmental policies of 110 countries along with the following four factors that contribute significantly to innovation success: idea generation, structured processes, leadership and skilled workers. The full list of results and more details on the report can be found at nam.org/innovationreport. Like any competitive assessment, top finishes are the desired outcome and Singapore was considered the most successful in terms of innovation, followed by South Korea and Switzerland rounding out the top three. After scanning for the placement of my “home town team,” I saw that the U.S. had placed 8th. I next looked for China, the world leader in many categories, and found it in 27th place, and then for India, which hopes to surpass China, and found it at 46th place. While not surprised by any of the results, it is interesting to imagine how quickly China and India—both of which have established policies to facilitate innovation—will gain ground on the more developed nations. Both countries have the necessary ingredients to quickly find themselves in the top tier, with their expanding middle class, excellent science and mathematics educational foundations and growing cultures for innovation. Even more interesting will be to see the innovation that is generated as these countries unleash their growing resources in a wide range of areas, such as computer technology, appliances, automobiles, medical science and conservation. While all of us would like to see more innovation in our industry sector or region, the world is becoming more interconnected and the benefits of innovation are not exclusive to the countries attributed with the advances. As end-users are anxious for more choices in quests for alternative fuel vehicles or finding cures for cancer, the collective potential advances are unlimited, and the wire and cable sector will see its fair share of advances. That, in turn, will make its presence and contributions that much more important to society.

Steve Fetteroll WAI Executive Director

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2009 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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CALENDAR

CALENDAR May 12-15, 2009: wire Moscow Moscow, Russia. To be held at the Expo Centre Krasnya. Contact: Messe Düsseldorf North America, tel. 312781-5180; fax 312-781-5188; info@mdna.com; www.mdna.com. May 20-21, 2009: 9th Annual National Electrical Wire Processing Technology Expo Milwaukee, Wisconsin, USA. To be held in the Midwest Airlines Center, this event will include more than 100 exhibitors with products and services for the wire processing industry. Contact: NEWPTE, tel. 800-367-5520, www.electricalwireshow.com. June 7-9, 2009: 3rd World Wire & Cable Conference Rome, Italy. Organized by CRU, this event will bring together cable manufacturers, cable users, materials and equipment suppliers and financial institutions. Contact: CRU, tel. 44-20-7903-2350; fax 44-20-7837-0976; cruevents@crugroup.com; www.wireandcable09.com. June 22-26, 2009: NPE 2009 Chicago, Illinois, USA. NPE 2009, organized by The Society of the Plastics Industry, Inc. (SPI), NPE 2009

8 | WIRE JOURNAL INTERNATIONAL

will take place at Chicago’s McCormick Place. Contact: NPE 2009, www.npe.org. September 30-October 1, 2009: Electrical Manufacturing Coil Winding & Coating Expo Nashville, Tennessee, USA. This event is to be held at the Opryland Convention Center. Contact: Jo Thurman, tel. 619-435-3629; fax 619-435-3639; jothurman@emcw.org. October 13-15, 2009: Wire Southeast Asia Bangkok, Thailand. To be held at the BITEC Exhibition Centre in Bangkok, this event, formerly known as wire Singapore, is organized by Messe Düsseldorf Asia Pte Ltd., Singapore. Contact: Messe Düsseldorf North America, tel. 312-781-5180; fax 312-781-5188; info@mdna.com; www.mdna.com. October 24-27, 2009: Exhibition & Conference for Wire & Cable New Delhi, India. The 9th International Exhibition & Conference for Wire & Cable will present wire and cable, fasteners and springs and more at the Pragati Maidan. Contact: www.intechtradefairs.com.

Nov. 8-11, 2009: 58th IWCS Conference™ Charlotte, North Carolina, USA. Contact: IWCS, www.iwcs.org.; phudak@iwcs.org; tel 732-389-0990. April 12-16, 2010: wire Düsseldorf Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180; info@mdna.com. May 11-12, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event includes the WAI’s 80th Annual Convention, trade show and technical program. It will be co-located with The National Electrical Wire Processing Technology Expo. ■

W IRE ASSOCIATION INT’L E VENTS For more information, contact the WAI, USA. Tel. 001-203453-2777; fax 001-203-453-8384; Internet www.wirenet.org. June 3, 2009: WAI Webinar: Controlling Copper Costs This WAI webinar will focus on why companies need to control volatile copper prices and how to do it. See p. 30. June 15, 2009: 7th Annual WAI Midwest Chapter Golf Tournament West Chicago, Illinois, USA. The WAI Midwest Chapter returns to the St. Andrews Golf & Country Club for its annual golf outing. For more information, contact WAI’s Chip Marsh or call him at tel. 203-453-1748. Nov. 2, 2009: New Technology for Global Markets Istanbul, Turkey. See main listing. May 11-12, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. See main listing.

MAY 2009 | 9

CALENDAR

Nov. 2, 2009: New Technology for Global Markets Istanbul, Turkey. This biennial conference is jointly organized by the IWMA, CET, ACIMAF and the WAI. Prior conferences have been held in Bologna, Italy (2007), Prague, The Czech Republic (2005), and Stresa, Italy (2003). Contact: WAI, tel. 203-453-2777, www.wirenet.org..

INDUSTRY NEWS

INDUSTRY NEWS Leoni: story a familiar one for industry Germany’s Leoni reports that up to and including September 2008, the company’s sales and earnings were on target in key markets, with most production facilities at virtually full capacity. In a relatively short period, it noted that what still was a profitable year closed on a very troubling note. The company, which had landed several key projects and been bolstered by acquisitions, saw its employee base reach 53,500 as of September 2008, up from 36,855 as of the end of 2007. Beginning with its automotive business and later in other sectors, a press release said that Leoni saw “drastic decreases in demand unprecedented in terms of both their extent” and write-downs on copper inventory when prices fell more than half. The company began a cost-reduction program that included restricted spending on investment and assets and adjustment of production capacity. Temporary staff and employees on fixed-period contracts were reduced, working hours cut back and some 3,000 jobs were cut, mostly outside Germany. Looking forward, Leoni’s group-wide forecast for 2009 sees further harsh times. “Exactly how severe the decline in the markets affected by the global recession will be over the year as a whole is something that cannot, from today’s perspective, be reliably projected,” it said. “In the first two months of the new financial year, sales registered a 40 percent drop compared with the same period in the previous year.” In response, since 2009 it said that the company has shed 4,000 more jobs, dropping employment to some 46,000 people. Despite the extent of the downturn, the world’s largest wire and cable company projects that while there will be significant drop in demand for 2009 compared to 2008, there are hopes that it will “gradually and partially recover.” It notes that the company is well positioned to withstand the downturn, with acquisitions in growth areas such as the international wiring systems business of Russia’s Itelma and a 50 percent stake in the South Korean’s Daekyeung (wiring systems) as well as some key projects outside the auto sector.

SINOBRAS commissions new wire rod and bar mill at Brazil Siderúrgica Norte Brasil SA has commissioned a wire rod and bar mill with annual production of 250,000 metric tons supplied by SMS Meer. The plant, located in the district of Maraba, Para State, Brazil, includes eight cantilever and six housing-less stands in horizontal/vertical arrangement, a 10-stand wire rod block with new drive equipment, a loop laying head, a loop cooling conveyor, the complete coil transport facility, a high-

speed delivery system and a cooling bed with bundling and tying facilities. In addition to rebar, the plant will produce wire rod in coils from 5.5 mm to 12 mm.

Realignment for Marmon unit PMC Wire & Cable announced the realignment of its Manchester, New Hampshire-based operation to focus on the aerospace and defense industry. PMC, a manufacturer of airframe and specialty wire, and RSCC Military-Shipboard will combine to become RSCC Aerospace & Defense, a division of RSCC Wire & Cable, Inc., an announcement reported. It noted that Zane Daggett has been appointed vice president of sales and marketing for the aerospace and defense division. The company’s thermocouple products, also located in the Manchester facility, will retain the PMC brand, with Fran Shannis serving as vice president of sales and marketing, it said. “The new branding strengthens our presence and better defines the company’s capabilities and involvement in the specific market segment of aerospace and defense while allowing the PMC brand to remain focused in the thermocouple marketplace,” said President Timothy Grass. RSCC Aerospace & Defense is a Marmon Wire & Cable/Berkshire Hathaway company. Marmon Wire & Cable comprises more than 25 business units that manufacture electrical and electronic wire and cable for a wide range of industries.

Tenova’s Core Furnace Systems and LOI, Inc., combine operations Core Furnace Systems, part of the Tenova Group, and LOI Inc., the USA unit of Tenova LOI Italimpianti, reports that the two companies have combined their business operations. LOI, Inc., will be merged into and become another business unit of Core, along with Core’s existing metal making and furnace business units. LOI employees have moved to Core’s current Pittsburgh based headquarters near the Pittsburgh International Airport, it said. Core was acquired last year by the Tenova Group. The Tenova Group includes 30 companies based in five continents.

AMSC wins record deal from LS Cable American Superconductor Corporation announced at Hannover Fair 2009 that it has been awarded a contract from South Korea’s LS Cable Ltd. for approximately 80,000 meters (50 miles) of the company’s second generation (2G) high temperature superconductor (HTS) wire. A press release described the contract as the largest-ever such order for 2G HTS, which AMSC refers to as 344 superconductors. AMSC commissioned its proprietary 344 super-

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

10 | WIRE JOURNAL INTERNATIONAL

Business may have hit hard times, but one sector continued to be well represented at a biennial tabletop show held April 14 in a heartland of the U.S. spring industry. The single-day 2009 Table Top Trade Show, put on by the New England Spring & Metalstamping Association (NESMA), drew nearly 500 attendees to the Aqua Turf Country Club in Plantsville, Connecticut. The event, started in 1957, had been annually until it switched to a biennial format in 2007. Attendance numbers have dwindled from the high point in the late 1990s, when as many as a thousand people attended, but the Northeast spring manufacturers continue a generations-old legacy that stems back from the 1800s, when Bristol, Connecticut, was known as the spring capital of the world, the organizers note. “This is a very tight-knit group,” declared NESMA President Mark Leahy, national account manager for Connecticut Spring and Stamping, who said that the goal “is to promote our industry and provide a forum for spring makers and suppliers to meet.” He said that 90 percent or more of the manufacturing attendees come from a 20-mile radius of Bristol, which was home to Associated Spring, now part of the Barnes Group, from which many smaller spring companies were started by former employees. GEMCO Manufacturing’s Mark DiVenere, a third-generation springmaker who was a key organizer for the event, said the event continues to serve an important function. “That we drew what we did shows that despite the economy, we’ve got a great group of people here.” He pointed out that springmakers can compete yet remain friends as

Wafios Machinery Corp.’s Al Clement demonstrates the finer points of the Wafios FMU Superstar multi-axis CNC torsion spring machine to attendees at the April 14 NESMA show.

From l-r, Suzanne von Steiger, Richard Rae, Jr., and Richard Rae, Sr., all of ERA Wire, and Connecticut Spring and Stamping’s Mark Leahy. well as partners for special projects. Having 186 people stay for dinner following the show reflects how springmaking is both an occupation and a fraternity, he said. It was a casual event, and while every company had been hit to some degree by the economy, the atmosphere was positive. Attendees could also inspect equipment from five exhibitors (Wafios, SPX/Fenn, Orlimec, AIM and NIMSCO). Many suppliers were local, but one tabletop representative, A.I. Technology’s Terry Pettinger, said that he felt the event was worth the 11-hour drive from Detroit. “This is a large market for us,” he said, noting that his company has “a couple hundred pieces of machinery in the area.” Even if the spring industry is slow, there is value in seeing some of the people who are using the equipment and letting them know you are there, he explained. NESMA Board Member Richard Rae, Sr., who said that he has not missed a show, explained that the event remains special for the spring field because it provides a practical venue for the industry to meet. “There’s a lot of knowledge here,” he declared. The event also featured two technical presentations, one by Bob Iorio and Shannon Riotte from Gibbs Wire & Steel and one by Luke Zubek of the Spring Manufacturing Institute (SMI). Groups supporting the event included SMI and the Small Manufacturing Association (SMA). DiVenere also gave credit to efforts by the NESMA board, which also includes Secretary/Treasurer Cindy Scoville, Bristol Chamber of Commerce; Bill Lathrop, Colonial Han Dee Spring; Bob Iorio, Gibbs Wire & Steel; Art Funk, Fourslide Spring & Stamping; George Fournier, Acme Monaco Corp.; Scott Kirkpatrick, Radcliffe Wire, William Waseleski, Century Spring and Manny Tavares, Rowley Springs. For more about NESMA, go to www.nesma-usa.org.

MAY 2009 | 11

INDUSTRY NEWS

Regional approach works well for area with a legacy in spring making

INDUSTRY NEWS

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conductors pilot production line in late 2007. The company said that LS Cable will use the wire to manufacture a 22.9 kilovolt (kV) cable system that it will install in Korea Electric Power Corporation’s (KEPCO) commercial power delivery network near the city of Seoul in 2010. “With the ability to carry vast amounts of electricity in a small right of way, superconductor power cables will play a pivotal role in powering cities in Korea and around the world in the 21st century,” said Joon Hyung Cho, executive vice president of LS Cable’s Technology Development Group. “We see a billion-dollar opportunity for superconductor cable technology and believe our alliance with AMSC and KEPCO establishes a market leadership position for LS Cable.” The deal calls for AMSC to deliver the wire by the end of 2009 to LS Cable, which will strand the wire into a superconductor cable system capable of carrying 50 megawatts of power. The cable system, the release said, will be nearly a half-mile in length, making it the world’s longest distribution-voltage superconductor cable system. It is scheduled to be installed by the middle of 2010 and energized in one of Seoul’s largest satellite cities by the end of 2010, it said.

Belden to close plant, eliminate 45 jobs Belden, Inc., reported that it will close its manufacturing plant in Midlothian, Virginia, USA, by July, resulting in the elimination of 45 positions. The closing, the company reported, is part of its previously announced corporate restructuring effort. Last December, Belden announced plans to cut 1,800 jobs worldwide, or 20 percent of its work force, and consolidate some manufacturing operations. At the time, the company said those restructuring efforts would help save the company $30 million in 2009 and $50 million annually starting in 2011. Belden said that the Virginia facility’s products include connectors and components for industrial-automation applications, and that those products will be transferred to its plant in Tijuana, Mexico.

U.S. power transmission work underway Work has begun on a 35-mile-long power transmission system valued at approximately $600 million that is part of an overall $6 billion project that calls for approximately 2,000 miles of new transmission lines. The latest announcement, reports The Salt Lake Tribune, is for a segment of the overall project known as the “Populus to Terminal,” which will go from a new substation in southeastern Idaho, near Downey, to an existing substation near the Salt Lake City International Airport. The line, reports Transmission and Distribution World, is the first segment in the undertaking by PacifiCorp’s Energy Gateway. The goal, it said, is for the cables to be in-service by the end of 2010, supplying its two divisions, Rocky Mountain Power and Pacific Power, with the power it needs for their customers. The overall project calls for approximately 2,000 miles of new transmission lines to be completed by 2014 in Utah, Idaho, Wyoming and possibly Colorado, the articles noted.

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INDUSTRY NEWS

“We recognize that economic realities being what they are, we may have to make some adjustments to our construction plans, but those transmission lines still will need to be built,” said Dave Eskelsen, spokesman for Rocky Mountain Power, who was quoted as saying that, “There haven’t been any major additions to our transmission system since the 1980s.”

Rosendahl celebrates 50-year milestone This year, Austria’s Rosendahl Maschinen GmbH celebrates its 50th year in business, a hallmark that the company notes it achieved because of its fundamental values and belief in ongoing development and technological progress, which it outlined below. A part of the Knill Group, Rosendahl has evolved over its history to a global supplier of manufacturing technology for producing of power, automotive, RF-, datacom, coaxial and fiber optic cables. The company was founded in 1959 by Walter Rosendahl, whose ambition was to become a high-tech cable equipment manufacturer. His efforts led to the development in 1965 of the first extrusion line, technology that the company has continued to improve over the years. The next milestone was in 1971, when the company introduced SZ-stranding technology. Rosendahl expanded its product range to serve the evolv-

14 | WIRE JOURNAL INTERNATIONAL

ing market, with advances coming in foaming, fiber optic, RF welding and corrugation technology. In 1973, the company opened its facilities in Pischelsdorf, Austria, a larger site that enabled the company to increase its manufacturing capacity. It also expanded its offices and production facilities elsewhere in the world. In 1997, Rosendahl became a member of the globally active Knill Group, which Nextrom joined in 2005. Today, the group has become a leading global supplier of fiber and

wire and cable manufacturing solutions. Rosendahl has continued to spend considerable sums for R&D and its physical plants, investments that helped the development of its new ROEX Extruder Generation and the RX Crosshead Series. Today, the Knill Group operates in more than 100 countries, with offices in Austria, U.S., Russia, India and Hong Kong.

INDUSTRY NEWS

International Wire Group closes plants International Wire Group, Inc., announced that it would idle two plants, one in Jewett City, Connecticut, USA, and one in Littleton, New Hampshire, USA. A company statement attributed the closings to “continued weak customer demand in the aerospace and electronics/data communications markets in the first quarter of 2009 due to difficult general economic conditions.” It said that customers will be served by IWG’s 13 other U.S. facilities. International Wire acquired the Connecticut plant when it bought the U.S. assets and operations of Global Wire, Inc. As recently as a year ago, a local newspaper reported, the company had employed about 125 people.

ArcelorMittal delays timing, scope, for ambitious India projects Plans for ArcelorMittal, the world’s largest steel company, to commence steel production at proposed plants with 12 mmt of annual capacity at sites in Jharkhand and in Orissa, may be delayed two years from the originally proposed starting point and be only half the originally proposed size. An article in Steel Guru, citing Zeenews, quoted ArcelorMittal India CEO Vijay Bhatnagar as saying at a steel summit that, “Initially we were thinking of putting a six million metric ton per annum steel plant in phase one. We may now put up smaller plants. We could cut the size to 3 MTPA in each phase due to the slump in steel demand and other issues, including land acquisition problems in India. Investments could naturally come down in the same proportion.” He noted that the overall plan, which calls for 12 mmt annual capacity at each plant in Orissa and Jharkhand, has not been changed. The delays were attributed both to difficulties in land acquisition as well as the global recession. In other news, ArcelorMittal announced layoffs of 80 workers at its Hamilton wire plant in Canada. ArcelorMittal Hamilton East, formerly Stelwire, was described as a significant producer for the automotive and construction industries, sectors that have both seen heavy declines.

Rea Magnet to close second plant Rea Magnet Wire, which last December announced the closure of its plant in Las Cruces, New Mexico, plans to close one of its plants in Fort Wayne, Indiana, USA, where it will continue to maintain its corporate offices, after selling selected assets of its Diversified Products Division to Elektrisola of Boscawen, New Hampshire. The sale of selected assets includes specialty insulated fine and ultra-fine wire materials and products used by the microcoaxial cable industry. The company plans to consolidate remaining products of the Rea Diversified Products division into its other manufacturing plants, including the New Haven Avenue site, it said. According to multiple media reports, Rea Magnet will close its Pontiac Street plant, which a company statement said, “is no longer economically feasible to continue manufacturing operations at …”

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“This was an extremely difficult decision for us as it affects approximately 85 employees,” Rea CEO Chuck Fisher was cited as saying in the statement. The company will keep its corporate headquarters at Pontiac, which had been upgraded in 2006 and saw its corporate staff increased

by 20 positions following its purchase of Phelps Dodge Magnet Wire Co. Those assets include the former Phelps Dodge site at 4300 New Haven Ave., and another in Monterrey, Mexico.

Tata Communications to be active in West Africa Cable System India’s Tata Communication announced that it will be a participant in the new US$600 million West Africa Cable System (WACS) that it said will help the company expand its global presence and enhance its investments in the region. A press release said that Tata has joined a multinational consortium of telecom operators that recently signed up to be part of the project, which calls for a submarine fiber optic cable to link countries in Southern Africa, Western Africa and Europe, with international bandwidth of at least 3.84 terabits per second. Alcatel-Lucent Submarine Networks will supply the 14,000-km-long cable system with all associated landing points, which is expected to be ready for service by 2011. Other participants include Angola Telecom, Broadband Infraco, Cable &Wireless, MTN, Telecom Namibia, Portugal Telecom, Sotelco, Telkom SA, Togo Telecom and Vodacom. The planned landing points for the system include South Africa, Namibia, Angola, the Democratic Republic of the Congo, the Republic of Congo, Cameroon, Nigeria, Togo, Ghana, Cote d’Ivoire, Cape Verde, Canary Islands, Portugal and the U.K., the release said. It noted that the landings in Namibia, the DRC, the Republic of Congo and Togo will provide the first direct connections for these countries to the global submarine cable network. “We are very pleased to be participating in the West Africa Cable System,” said Byron Clatterbuck, senior vice president, global transmission services at Tata

16 | WIRE JOURNAL INTERNATIONAL

Q-S Technologies celebrates 25 years Q-S Technologies, Inc., a custom electrical and electronic wire and cable manufacturer based in Meriden, Connecticut, USA, recently celebrated 25 years in business. Led by co-founder and company President Donald D. Schollin, the Q-S team acknowledged the contribution of customers, vendors, staff and friends with a dinner at which Schollin thanked those who remained loyal to the company over the years. Among the highlights of the event was Schollin presenting a plaque recognizing the company’s first customer, who remains an active client to this day. “Over the years we’ve been through some times when we weren’t sure we could keep it going, yet here we are today celebrating this milestone,” said Schollin. “It’s with the help of the people in this room that we can mark this milestone occasion, and look forward to continuing to provide the best products and service that we can into the future.” Schollin credited the company’s more than two dozen

employees for making it possible to “provide engineered wire and cable solutions with a degree of personal attention, responsiveness, and flexibility rarely found in today’s competitive wire and cable industry.”

INDUSTRY NEWS

Communications. “The investment is another step for Tata Communications in bolstering its capabilities in the African market, and will enhance our service propositions together with our partner Neotel in bringing added diversity into South Africa.”

Some of the Q-S Technologies team with President Don Schollin and his wife, Betty, front and center.

Qatar Steel: recession not a factor yet The steel industry as a whole may be in a global slump, but Qatar Steel, which produces rebar and wire rod, reports that it has been quite busy because of local demand, to the point where it had to suspend exports late last year. “We have been producing at full capacity despite the pres-

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ent crisis,” Qatar Steel Marketing Manager Mohammed Al Saadi was quoted in Emirates Business 24/7 as saying at the Arab Steel Summit 2009. “The first quarter of 2009 has been really good. Sales have remained steady. In 2008, we had to restrict our exports to the neighboring market due to unexpected demand in Qatar. We have increased our production since January and have been sourcing raw materials to cater to the local demand. The good news is that from the beginning of this year we are producing full capacity at 130,000 metric tons per month,” he said in the article. “Currently we are satisfying the Qatar market and the additional capacity we inject into UAE, Bahrain and other countries in the region and export to Europe as well. The demand from Dubai has shrunk because of the financial crisis, but Abu Dhabi is going very strong,” Saadi said in the report. He said that the Arab market is faring well compared to the rest of the world. “Of course, the present crisis has affected everyone, but this region will be the first to recover. From the second quarter of 2010, we are expecting things to bounce back. We have several expansion plans, which we are analyzing and assessing. By 2010, we will make a decision on our future.” In addition to its new rebar facility, Qatar Steel’s other facility is an upgraded wire rod mill with an installed annual

capacity of 240,000 metric tons, the article said. At its website, the company notes that it was formed in 1974 as the first integrated steel plant in the Gulf, that commercial production commenced in 1978 and that the company became wholly owned by Industries Qatar in 2003.

SE Specialty Wire & Cable acquires assets of Performance Wire Rope SE Specialty Wire & Cable, LLC, announced that it has bought “the tangible assets” of Performance Wire Rope, dba Performance Line Hardware, a steel and steel alloy wire manufacturer in Clearwater, Florida, USA. The deal was made with Performance Wire’s secured creditor, BLN Capital Funding, LLC, with the plan being to relocate the assets to the SESWC manufacturing operation in Murrells Inlet, South Carolina. A joint statement released by James Stanton, operations manager of SESWC, LLC and Norman Lynn of BLN Capital Funding, LLC, said that, “This agreement results in the expansion and supplement of wire manufacturing capabilities from .018” through .375” diameter stranded multiwire constructions and business growth opportunities for diverse commercial specialty wire and cable markets in the U.S.”

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The World Steel Association reports that crude steel production in for the first quarter of 2009 for the 66 countries that report to it was 264 million metric tons (mmt), a drop of 22.8% from the same time a year ago. A press release said that production in North America dropped 52.1%, the EU was down 43.8% and Asia was down 8.9%, with China showing a slight increase of 1.4%. Individual results for production in March showed the U.S. down 52.7%, Germany down 49.8%, Japan down 46.7%, Italy down 42.7%, Brazil down 41.5%, Spain down 41.2% and South Korea down 21.2%. China, it said, showed a slight decrease for March at 0.3%. The World Steel Association (worldsteel), one of the largest industry associations in the world, reports that it represents approximately 180 steel producers (including 18 of the world’s 20 largest steel companies), national and regional steel industry associations, and steel research institutes. Its notes that its members produce around 85% of the world’s steel.

are relocating, Mexico City remains an important market for (Milacron), and a local network of service and technical support for all Milacron machinery technologies will remain in the area,” the release said. Milacron businesses include Uniloy, Extrusion, Ferromatik, U.S. Injection Machinery, SERVTEK and Cimcool. ■

Milacron opens Mexico operation Milacron announced that it has opened a new site, the Milacron Plastics Technology Center, in Queretaro, Mexico, which will provide local and expanded services to its customers in Mexico. A press release said the company, whose technology includes Cincinati Milacron extruders for wire and cable, has been active in Mexico for 25 years. The new larger technical center will enable it to better serve its customer base and offer more aftermarket services, it noted. “While the main operations

MAY 2009 | 19

INDUSTRY NEWS

Crude steel production figures for first quarter of 2009 reflect ailing economy

ASIAN FOCUS

ASIAN FOCUS Bekaert and Ansteel open steel cord production plant in Chongqing, China Belgium’s Bekaert and Ansteel, a global steel producer that is a leading producer in China, officially opened a new production plant for steel cord products in Chongqing, China. Ansteel and Bekaert entered into a strategic partnership in May 2008 and subsequently set up a 50/50 joint venture named Bekaert Ansteel Tire Cord (Chongqing) Co., Ltd., a press release said. It noted that the project, which saw the

“The Bekaert Ansteel joint venture here in Chongqing demonstrates our commitment to support the westward development objectives and actions of the Chinese Government, and further strengthens our position in China,” Buysse said. The Anshan Iron and Steel Group Corporation (www.ansteelgroup.com) was established in 1916 and has its headquarters in Anshan, Liaoning Province. It produces and sells steel products such as hot-rolled and cold-rolled sheet, galvanized steel sheet, color coating plates, silicon steel, wire rod and seamless steel pipes. These products are used in the automotive, construction and shipbuilding industries, in electrical appliances and in railroad construction and pipelines. Ansteel reports that in 2008 it produced more than 16 million metric tons of iron, over 16 million metric tons of steel and over 14 million metric tons of rolled steel. “The company’s goal is to be ranked in the Global 500 Forum by 2010 and become one of the most international and competitive steel companies,” a press release said.

Ramsarup Group opens new India plant At the official opening of the new Chongqing plant are, from l-r: Liu Weidong, vice director, CQ Economic Committee; Baron Buysse, chairman of Bekaert; Huang Qifan, executive vice mayor of Chongqing; Zhang Xiaogang, chairman of Ansteel; Ms. Laruelle, federal minister (Belgium); and Zhou Shaozheng, P.S. of Shuangqiao District. construction of the steel cord plant in Chongqing, represented an investment of about US$200 million, the work being done in phases. Chongqing, the release said, is rapidly transforming into a new automobile metropolis. “With the joint venture plant, Ansteel and Bekaert are responding to the rising local demand for steel cord products for tire reinforcement,” it said, adding that the plant currently retains 130 employees and will further grow in line with market demand. Those in attendance at the official ribbon cutting ceremony included Tong Xiaoping, vice mayor of Chongqing, Zhang Xiaogang, chairman of Ansteel, and Baron Buysse, chairman of Bekaert. “This new plant is a first step in our strategic partnership, and will open up new markets for Ansteel in partnership with Bekaert,” Zhang said. “I am confident that our partnership, that brings together the operational excellence and leadership position of both companies, will support China’s industrial growth.”

In February, India’s Ramsarup Group held the official opening of a new single-line Low Relaxed Prestressed Concrete (LRPC) steel wire plant in Durgapur, India, which is in the northeast section of the country and is considered a primary steel-producing center. The company notes it represents the first facility dedicated to production of LRPC wire in the country. The steel wire is to be used for a range of infrastructure projects. It reports that capacity is 30,000 metric tons of wire a year, which increases the group’s overall capacity to 300,000 metric tons (black and galvanized) of wire. Below, Ramsarup Group Chairman Ashish Jhunjhunwala discusses his outlook for this venture as well as the company with WJI. WJI: How does your company view this investment given the state of the world economy and that many companies are choosing to focus almost entirely on cutting their costs and investments? Jhunjhunwala: Our focus is mainly on the domestic markets which is still, if I may say so, “reasonably okay.” India will be spending approximately $500 billion towards infrastructure development in the next five years. This will include major developments of roads, rail tracks, ports, airports, metro rails, mono rails, etc. LRPC strands and single line LRPC has substantial use in all these projects. It is important to note that although India is producing approximately 1.6 million mt per year of wire, production of LRPC wire is hardly 100,000 mt per annum. Hence, we find suffi-

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

20 | WIRE JOURNAL INTERNATIONAL

ASIAN FOCUS

cient space for ourselves, even given the current state of the world economy. WJI: Do you believe that India’s economy will be better able to withstand the current conditions? Jhunjhunwala: While I do not believe that the Indian economy is decoupled from the rest of the world, only approximately 17% of India’s GDP is dependent on exports. With massive internal consumption and positive growth in GDP (approximately 5%), India is in a much better position to withstand the current global turmoil. WJI: Will you be able to operate your new plant at an efficiency rate that is costeffective? To what degree will Ramsarup Group its production be for domestic Chairman Ashish consumption versus exports? Jhunjhunwala. Jhunjhunwala: As mentioned above, our production will be largely dependent on our own consumption, and with expected fairly large expenditure by the Indian government towards infrastructure growth, we will able to run our plant at an efficient capacity. However, we will be not ignoring exports and are making full efforts to get our quality approved in the European Union, including certification of homologation and voluntary mark. We have already had inspection carried out by some of the authorities of the European Union. Moreover, we have also made some shipment to the Middle East and our quality has been approved by them. We want to be ready with all approvals so that once the situation improves in the West, we will able to market our product. WJI: How do you view your latest investment? We are extremely Jhunjhunwala: bullish about the We are extremely bullish about the long-term prospects long-term of our investment. prospects of our investment. The Ashish Jhunjhunwala Indian story is very much intact due to our world-class facilities, quality product, low cost, wide range of production, customer focused approach and experience in the wire line. We are very confident that the above investment will be very profitable. ■

MAY 2009 | 21

PEOPLE

PEOPLE RSCC Aerospace & Defense, formerly PMC Wire & Cable, has named Zane Daggett vice president of sales and marketing for aerospace and defense products. He heads the sales and marketing team for the New Hampshire facility, as well as the military/shipboard products in East Granby, Connecticut, USA. He will assume responsibility for managing the RSCC Aerospace & Defense sales team and help develop new business, further client relationships and introduce industry partnerships. Formerly vice president of sales and marketing at Hitachi Cable, he has 17 years of experience in the wire and cable industry and has been directly Zane Daggett involved in the development and management of marketing and strategic alliances, as well as new product launches, both domestically and internationally. Based in Manchester, New Hampshire, USA, RSCC Aerospace & Defense is a division of RSCC Wire & Cable, Inc.. Marmon Wire & Cable comprises more than 25 business units that

22 | WIRE JOURNAL INTERNATIONAL

manufacture electrical and electronic wire and cable for a wide range of industries. Liberty Wire & Cable announced the promotion of James Blumhardt to vice president of sales for the Eastern region, and the appointment of two A/V industry veterans, Kevin Peterman and Tom O’Hanlon, as commercial territory managers. Blumhardt has more than 27 years of experience in professional A/V, broadcast and systems integration, and the design-build industry. He will oversee Liberty’s Eastern Region sales team and consultants with Liberty’s connectivity solutions, products, and services. He will be based in Atlanta, Georgia, USA. Peterman and O’Hanlon will be responsible for managing all commercial dealer sales in their respective areas. Peterman, who will oversee the midAtlantic region, has more than 10 years of experience. O’Hanlon, who will oversee the Northeast region, has nearly 30 years of professional A/V experience. Based in Colorado Springs, Colorado, USA, Liberty Wire & Cable, a division of Communications Supply Corp. (CSC), sells wire and cable and related products primarily for audio/video and security applications.

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The Society of the Plastics Industry (SPI) will induct Ralph A. Noble, Robert Swain and Donald Witenhafer into the Plastics Hall of Fame during NPE 2009 this June. Noble is a graduate of the University of Toronto with a degree in chemical engineering and is a compounding innovator who pioneered the use of plasticizers for flexible vinyl and Ralph A. Noble crosslinked polyethylene for wire and cable. Swain has a degree in chemical engineering from Lafayette College and is a pioneer in the development of applications for polypropylene and the production of color masterbatches. Witenhafer has a Ph.D. in polymer science from Case Western Robert Swain University and is a polymer chemist whose inventions in PVC polymerization ended the threat of cancer caused by vinyl chloride emissions during resin production. Based in Washington, DC, USA, SPI is the plastics industry trade association representing the third largest manufacturing industry in Donald Witenhafer the United States. Jersey Strand and Cable, Inc., announced the hiring of Jerry Lowry as sales manager. Based in Phillipsburg, New

JUNE 2009

PEOPLE

Composite Technology Corporation (CTC) announced that its CTC Cable Corporation subsidiary has named Don Douglas as vice president of business development and Pat Avery as vice president of sales for North America. Based in Irvine, California, USA, CTC is a global provider of electric utility solutions.

E u r o pe a n outlook

Jersey, USA, Jersey Strand and Cable, Inc., manufactures small diameter wire and cable products. Geoff Hopwood has been named president of The European Fastener Distributor Association. He is chairman of U.K. importer/master distributor Owlett-Jaton and also serves as vice chairman of the British Association of Fastener Distributors. Dott. Bruno Trolano, managing director of Bossard Italy, was named the new vice president. He is serving as vice president of the Italian Fastener Distributor’s Association. The European Fastener Distributor Association is the European organization for specialized inventory-holding fastener distributors. The International Staple, Nail and Tool Association’s (ISANTA) Board of Directors has elected Guenther Kram chairman of its Board of Directors, Tom Green as vice chairman and Chris Miller as secretary/treasurer. Mark Hickok was reappointed chair of the legislative and legal advisory committee, Guenther Kram Pat Talano was appointed chair of the public relations committee and Winfred Grindle was named chair of the technology committee. Based in La Grange, Illinois, USA, ISANTA focuses on fastening recTom Green ommendations, product and safety standards for fasteners and fastening tools used in residential and commercial construction, remodeling, manufactured housing, furniture, vehicles, pallets and containers and Chris Miller other industrial markets. ■

C OMING N EXT M ONTH :

interwi

re•ife

wrapup

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E UROPEAN O UTLOOK & INTERWIRE • IFE W RAPUP

George R. Sublett of Louisville, Kentucky, USA, a Life Member of WAI and retired vice president of Beneke Wire Company, died Tuesday, November 18, 2008, in Jefferson County, Kentucky, at age 84. A WAI member for more than 44 years, Sublett was a native of Brownsboro (Madison County), Alabama. He was vice president of Beneke Wire Company in Louisville, Kentucky, after working as a metallurgical engineer for Reynolds Metals Company in Richmond, Virginia. He married Mary Margretta Felker in 1947, and the couple have four children. Besides his wife of 61 years, he is survived by his children, Margretta Wild, Suzanne Barnes, George C. Sublett and Patricia Hatcher; four brothers; three sisters; 11 grandchildren; and 15 great-grandchildren.

Norman A. Wilson, a retired mechanical engineer and Life Member of the WAI, died January 31, 2008 at age 88. He lived much of his life in his native Massachusetts. He graduated from Worcester Polytechnic Institute and in 1948, began his professional career with Morgan Construction Company in Worcester, Massachusetts, where he worked until his retirement in 1982. During World War II, he worked for Pratt and Whitney, designing jet engines. He held 13 U.S. patents, authored several technical papers, and held leadership positions in a variety of professional engineering organizations. Wilson is survived by his wife of 33 years, Jane Montague Wilson. He leaves two children from his first marriage, Meredith Sumner of Montpelier, Vermont, and Richard Wilson of Chevy Chase, Maryland; Jane’s children, Penelope Wood, Hamilton Wood and Carol Plumlee; and six grandchildren.

Russell L. Swartz, Jr., owner of Weartech International, Inc., a manufacturer of cobalt and nickel-base hardfacing and wear resistant alloys in Santa Fe Springs, California, USA, died February 13, 2009, at age 78. He is survived by his wife of 55 years, Theresa Swartz. The couple had three children: sons Russell L. Swartz III and Randolf L. Swartz; and a daughter, Theresa M. Swartz. Survivors also include four granddaughters.

Thomas L. Seal, a 30-year fastener industry veteran, died March 11, 2009, at age 57 in Westchester, Illinois, USA. At the time of his death, he was employed in sales at Arlington Fastener/Tuttle Manufacturing in Barrington, Illinois. He was a member of the Chicago Bolt, Nut & Screw Association, later called the Midwest Fastener Assoication. He is survived by his wife, Colleen, and two children, Erin and Kevin.

WIRE JOURNAL

DOUBLE FEATURE. European Outlook Will demand return in Europe for steel? Have cable manufacturers seen the decline in orders bottom out? WJI will provide commentary on those issues as well as outlooks from a range of European companies. Interwire • IFE Wrapup The return to Cleveland was not the follow-up to the 2007 event that the industry had hoped for, but few people were surprised about the low attendance numbers. If there is reason for optimism about the industry outlook, it comes from those who came as attendees, some of whom shared their thoughts with WJI.

INTERNATIONAL

Contact WJI’s Sales Team: Tel.: 001-203-453-2777 Bob Xeller E-mail: bxeller@wirenet.org Anna Bzowski E-mail: abzowski@wirenet.org

MAY 2009 | 25

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OBITUARIES

FIBER WATCH

FIBERWATCH SEACOM cable project on course

LEAF fiber optics mark milestone

Mauritius-registered private equity venture SEACOM Ltd. has signed up business worth about half its $700 million investment in an undersea telecommunications cable linking African countries with the rest of the world, published reports said. SEACOM president Brian Herlihy said the fiber-optic cable that will connect Kenya, Tanzania, Mozambique and other countries along the east and southern coast of Africa with India, Europe and the Middle East, is on course for completion and testing in June. “We have signed a healthy amount of presales, we are about there,” Business Daily Africa reported Herlihy as saying. He said demand for bandwidth in Tanzania and Mozambique was high, contrary to expectations that it would be low compared with Kenya or South Africa. Herlihy said SEACOM shareholders are actively pursuing opportunities in the West African market and were looking to install a cable in mid to late 2010. Kenya's government has been laying a terrestrial network of cables in readiness for the completion of the undersea cable, Business Daily Africa reported.

Corning Incorporated announced that it has sold more than 30 million kilometers of LEAF fiber optical fiber since introducing the product in 1998. As the backbone of many of the world's most advanced long-haul networks, LEAF fiber is the most widely deployed non-zero dispersion-shifted fiber (NZDSF) in the world. “LEAF fiber is a great example of Corning innovation,” said Martin J. Curran, senior vice president and general manager, Corning Optical Fiber. “The performance of this fiber is proven by its operation in more than 100 carrier networks worldwide.” Compared to other nonzero dispersion-shifted fibers, LEAF fiber allows higher levels of optical power to be transmitted while minimizing nonlinear impairments that can degrade transmission-system performance. It has low chromatic dispersion, which simplifies dispersion compensation and lowers the cost of network installation and operation for longhaul carriers. It has low-polarization-mode dispersion (PMD), which enables high-data-rate transmission. Corning Incorporated makes keystone components that enable high-technology systems for consumer electronics, mobile emissions control, telecommunications and life sciences.

FTTH Council: Tax incentives will boost economic growth, create jobs Adopting tax incentives for expanding next-generation broadband networks with direct fiber connections would ensure that Washington’s economic recovery package would create many jobs and extensive economic growth, according to a study released by the Fiber-to-the-Home Council. The study, prepared for the FTTH Council by the economic consulting firm Empiris LLC, found that enactment of tax incentives for the deployment of networks running fiber all the way to premises would generate more than 200,000 direct jobs in each of the next three years and increase economic output by more than US$100 billion. Increased broadband penetration from these proposals would indirectly generate another 360,000 new jobs. A copy of the full report can be downloaded at www.ftthcouncil.org. ■

26 | WIRE JOURNAL INTERNATIONAL

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FASTENER UPDATE

FASTENER UPDATE 2009 Stuttgart fastener fair exhibitor numbers reach record level Organizers of Fastener Fair Stuttgart 2009 said they expect exhibitor numbers to top 500, or 46 more than the previous show record of 435 exhibitors in 2007. Bucking what organizers describe as a “global trend” in which “well-established industry shows are postponing their events or holding them with reduced exhibitor numbers,” Fastener Fair Stuttgart is seeing measurable growth, said show organizer Jerry Ramsdale. Fastener Fair Stuttgart runs in Germany on October 7-8, 2009. It represents all aspects of the fastener and fixing market and brings together manufacturers, machine suppliers, wholesalers, distributors, importers, exporters and tool suppliers, in addition to trade associations and suppliers of services and related products, Ramsdale said. For more information, go to www.fastenerfair.com.

Fastener show passes in 2009, promises comeback in 2010 Citing the global economic crisis and downturn in the fastener industry, organizers of the 28th National Industrial Fastener Show/East 2009 have elected to cancel the May event, which was scheduled to be held in Columbus, Ohio, USA. The decision comes almost 30 years after the show first opened doors to members of the fastener industry. “We wanted to take unnecessary financial pressure off our loyal exhibitors and the many fastener distributors, importers, sales reps and others who attend the show,” said show manager Susan A. Hurley. Hurley noted that in the show’s history, this is the first time organizers decided to cancel the event. But confidence is high that 2010 will bring a recovered economy, a strong demand for fasteners, and a reason to once again platform the show as an effective marketplace, she added. “We are very confident about the 2010 show,” she said. “In 2009, we were not only dealing with the economy but we were also causing our exhibitors to have to choose between our show and the Chicago Fastener Tech TM 2009. Since the Fastener Tech show is only held every other year, it will not be a factor in 2010.” Exhibitors were disappointed at the announcement of the show’s cancellation, but “understood and appreciated that we took the burden of choosing between our show and the Chicago, Fastener Tech TM 2009 off their shoulders,” Hurley said. NIFS/East is scheduled for May 25-26, 2010, in Columbus, Ohio.

28 | WIRE JOURNAL INTERNATIONAL

For more information regarding the 2010 show or 2009 West Show in Las Vegas, call NIFS tel. 614-895-1279, info@fastenershows.com, www.fastenershows.com.

Atotech launches Taiwan tech center Atotech, a manufacturer of processes and equipment for the PCB industry and the decorative and functional electroplating industry, reports that it has kicked off a new, Taiwanbased Far East TechCenter, located at the Kaohsiung Environmental Science and Technology Park. The center, which opened in January 2009, specializes in corrosion protection with a focus on fastener applications, including new trends and technologies within the automotive industry and electrolytic corrosion protection and zinc flake coatings for fasteners, the company notes. Published reports say that Atotech plans to operate 14 centers globally by the end of 2009, including in Italy, the Czech Republic and India. The company explained that the operations serve as training grounds for Atotech employees, customers and OEMs, offering sample plating for new finishes and providing qualification runs for new processes and technologies, including equipment novelties. “Taiwan and especially the Kaohsiung region is known to show the highest density in fastener manufacturers worldwide,” said Atotech President Reinhard Schneider. “This is why we have chosen Kaohsiung County as the location for our new TechCenter, to be close to our customers and to best serve plating and coating companies in the region and throughout Taiwan and the Far East with our leading green technological solutions.” The Kaohsiung center is equipped with an automatic plating line for zinc, zinc alloys, phosphate pretreatment and Cr(VI)-free post-treatment processes including auxiliary equipment for environmental sound production, the company notes.

U.S. wire rod prices holding steady Steelguru.com reported that despite slow demand and mill capacity outages, domestic wire rod prices are steady. U.S. f.o.b. mill prices on industrial-quality low-carbon rod is holding at about US$640 a ton, almost equal to the February 2009 price. Buyers, however, predict that wire rod prices could go the way of scrap, and expect a drop as early as May. Foreign wire rod suppliers are quoting prices up to 11% lower than earlier this year.

U.S.-based Sealtight® Technology announced it has been awarded a contract to supply its Hi-Tech patented self-sealing fasteners to Lockheed Martin Missiles and Fire Control to support America’s next generation anti-missile system. The award will, after Phase I testing, result in a considerable ramp up in production at Sealtight, requiring the hiring of additional employees, reports said.

Interfast opens distribution facility, expects big demand from air, oil, gas In anticipation of strong demand from the aviation, oil and gas industries, Toronto, Canada-based global fastener distributor Interfast, Inc., announced that it is opening a distribution facility in Calgary, Alberta, Canada. Interfast Vice President of Sales and Marketing Conrad Lennert made the announcement at the Western Aircraft Maintenance Engineers Association 2009 annual symposium. “Our team of specialists has been working with Calgary area firms for years and we are delighted to open a regional distribution facility in response to increased business from airlines, manufacturers as well as aircraft maintenance repair and overhaul operations,” he said. Lennert said that the flagging economy is prompting organizations to examine ways they can improve their operational efficiencies, prompting a spike in interest in Interfast’s supply chain management expertise. Interfast has facilities across North America, in Vancouver, Toronto, Ottawa and Montreal (Canada), as well as Miami, Florida, and Cleveland, Ohio.

Mismarked bolts under investigation The Industry Fasteners Institute reported that the Fastener Industry Education Group released a March advisory regarding the shipment of mismarked Grade 5 bolts. This, FIEG

says, is a critical issue that could have legal implications for fastener suppliers and distributors. According to the report, FIEG announced that in 2008, Tycoons Worldwide Group, using the head mark TY, shipped to the US several orders of bolts identified as SAE J429 Grade 5 that do not conform to Grade 5 chemical requirements. US safety standards demand that SAE J429 Grade 5 bolts be manufactured using medium carbon steel containing a minimum of 0.28% carbon. The TY bolts were produced using steel containing just 0.15 to 0.25% carbon. The subject bolts meet the physical requirements of Grade 5.2, not Grade 5. US Customs reports that it has opened an investigation into the mismarked bolts. Although exact details were not known at press time, US Customs could prosecute importers and resellers of misrepresented products, FIEG said. FIEG urges distributors who bought the suspect bolts to quarantine all bolts that remain in inventory and obtain legal counsel to determine whether or not to sell the bolts and what action should be taken regarding notifying end users who have received them. Distributors should also contact suppliers to determine disposition of remaining inventory, it said.

Barnes Distribution doubles stainless steel fastener product line Barnes Distribution, North America, reports that it is expanding its product line by nearly 50 percent, adding more than 1,200 new items to its stocked inventory. New stainless steel items added to the product line include hex head cap screws, socket head cap screws, socket set screws, lock washers and machine screws in standard, fractional and metric sizes. The product expansion also introduces prepackaged product assortments organized in storage equipment to the company’s inventory. ■

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MAY 2009 | 29

FASTENER UPDATE

Sealtight, Lockheed enter contract

WAI NEWS

WAI

NEWS

June 3 WAI webinar to focus on managing price risks for copper Following the success of WAI’s second webinar, a March 26 presentation on lubrication by industry consultant David Gzesh, the Association has scheduled its third webinar for Monday, June 3, at 11 am. The program will focus on how companies can control risks related to the volatility of copper pricing. The program will start at 11 am Eastern Daylight Time and last about an hour. The webinar is free to WAI members. Details on how to access the program can be found on the home page of WAI’s website. The panelists will be Neville Crabbe, president, Leoni Wire, Inc., John Gross, president of J.E. Gross & Company, and Billy Harold, general manager, C.N. Wire Corporation. “We’re quite pleased that we were able to assemble such a good panel,” said WAI Executive Director Steve Fetteroll. “Each of the presenters will be able to present a unique perspective and anyone who draws copper should find this program of value.” Crabbe is president of Leoni Wire, Inc., part of Leoni USA and Leoni. Leoni Wire produces copper wire and strand as well as tin-plated, nickel-plated and silver-plated copper alloy wires and high flex products. Leoni is a global supplier of wires, cables and wiring systems as well as a provider of related development services. The group of companies, which is listed on the German MDAX, employs around 46,000 people in 35 countries and generated consolidated sales of approximately US$3.5 billion in 2008. Gross is president of J.E. Gross & Company, a metals management and consultancy firm established in 1987, and publisher of The Copper Journal, an industry newsletter that summarizes key fundamental, economic and financial indicators affecting the global metals market. Harold is general manager of CN Wire Corporation, established in 1998, a wholly owned subsidiary of ErBakir Elektrolitik Bakir Mamulleri A.S. (Er-Bakir) and the exclusive marketing and distributor company of c opper wire rod, bare copper wire, tin coated/stranded copper wire, bare/tin coated multiwire and bare/tin coated bunched wire manufactured by Er-Bakir located in Denizli, Turkey. As noted above, the program will focus on ways for companies to handle the volatile price of copper. The past several years have seen unprecedented price volatility for all commodities, with copper in particular subject to violent swings. In just the past nine months, copper soared to record highs, only to fall precipitously to multi-year lows. There are any number of factors contributing to these sudden reversals, including fundamental considerations, changes in foreign exchange rates, speculative influences, as well as the overall perception of future economic con-

30 | WIRE JOURNAL INTERNATIONAL

ditions. Many organizations feel they are at the mercy of the markets, with little or no control over metal prices, or the damaging impact upon their businesses. While no one can control the price of copper, this webinar is designed to identify and discuss the many tools available that can help companies manage price risk, and

WAI’s Chuck Szymaszek, l, and Marc Murray, oversee production of the Association’s second webinar on lubricants, presented March 26 by consultant David Gzesh.

enable an organization to maintain itself during turbulent times. The webinar is targeted toward operations and administrative management personnel involved in the purchasing process, managing inventory, or pricing of products, involving copper. “As our webinar program continues to expand, we’re glad to be able to keep adding new ideas to the mix,” said WAI Director of Education Marc Murray. “Our first presentation was on an economic topic, the second was technical. Now we’re trying our first discussion with more than one panelist. So we’re hoping to continue this trend of doing something a little different every time.” A total of 67 participants signed up for the webinar led by Gzesh, who has 30 years of experience developing and servicing metal-working lubricants. For the last 23 years, Gzesh has been with the various successors of the RH Miller Company, beginning with Pennwalt, Elf Atochem, Henkel and Condat, before becoming an industry consultant. Peak participation for the webinar was 48 people. Gzesh discussed basic wiredrawing lubrication principles and lubricant chemistry. During the session he fielded questions such as how to select an appropriate lubricant for high C steel rod drawn at low and high speeds, use of calcium lean versus sodium, and others. Details on how to access the June 3 copper webinar can be found at www.wirenet.org. Non-members can sign up for the webinar for $55. ■

Join WAI so that one day your day will be unified

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

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May 09 International Technical

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Locations and dates have been set for 3 WAI chapter golf tourneys The times and locations have been finalized for upcoming golf tournaments for WAI’s Midwest, Ohio Valley and Western chapters. Information about each of the events, including registration forms, can be found at the chapter homepage at www.wirenet.org. • The Midwest Chapter will return to the St. Andrews Golf & Country Club in West Chicago, Illinois, USA, on June 15, for its 7th Annual Golf Tournament. • The Ohio Valley Chapter will return to the Grantwood Golf Course in Solon, Ohio, USA, on August 7, 2009, for its 6th Annual Chapter Open. • The Western Chapter will move its event to the Los Verdes Golf Course in Rancho Palos Verdes, California, USA, on September 25, for its 9th Annual Wild West Shootout. Each of the events include a range of opportunities to win team and individual prizes as well as a reception and dinner following the round. Golfers may not claim the elusive $10,000 for acing a hole-in-one at the designated hole, but there definitely will be winners for contests that include the long-drive, closest-to-the-pin, most accurate drive and the

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popular putting contest. A range of sponsorship opportunities are offered to provide companies exposure, including signage and recognition in the tournament program as well as in the WJI wrap-up article. These include non-exclusive hole sponsorships as well as exclusive sponsorships for the different skills contests. Prize donations are also encouraged. For more information on any of the above events, contact WAI’s Chip Marsh at cmarsh@wirenet.org or call him at tel. 203453-1748. ■

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PERSPECTIVES

PERSPECTIVESS Copper: managing price risk Perspectives is an occasional section to present notable information about companies that may be directly or indirectly related to the wire and cable industry. If your company has information that it believes should be included, send an e-mail explaining why to editorial@wirenet.org.

Commodities have gone through unprecedented price volatility in recent years, and one product that has been subject to especially violent swings is copper, a staple of the wire and cable industry. In just the past nine months, copper has soared to record highs only to plummet to multi-year lows. That yo-yoing effect has put more than one company out of business and has figuratively changed the definition of inventory from “stock on hand” to “potential nightmare.” Why the sudden reversals? John E. Gross There is more than one factor, from fundamental considerations and changes in foreign exchange rates to speculative influences as well as our overall perception of future economic conditions. Thus, it comes as no surprise that many organizations feel that they are at the mercy of the markets, with little or no control over metal prices or the damaging impact upon their business. That may be true in that no one person or company can control the price of copper, but there are tools available that can help you manage price risk and prevent your business from becoming another statistic of turbulent times. The first step is to clearly define the risk your company faces. Is it the difference between the price you pay for metal and your selling price, or do you make the sale first and then buy the metal necessary to fill the order? Do you have to quote on a long-term project with firm metal prices and wait some period of time before learning that you were awarded the business? Or, is it the valuation of inventories that poses the risk? Each of these scenarios raises a different element of risk, but each one also has a solution to managing and controlling that risk. In the world of commodities, there are two terms of paramount importance that are all too often either confused, or misunderstood: hedging and speculating. The dictionary defines hedging as “protecting oneself from losses in market fluctuations with a counterbalancing transaction.” Speculating, on the other hand, is defined as “buying or selling in the expectation of profiting from market fluctuations.” Clearly, these are two very different

36 | WIRE JOURNAL INTERNATIONAL

approaches to the market, and should be treated as such. For our purposes here, the focus is on hedging and how it can work for you. The most basic form of hedging is to buy and sell a physical commodity like copper on a “back to back” basis. For example, a wire and cable manufacturer may agree with a customer that the base price of copper contained in a product will be the market price on a specific day. Correspondingly, the manufacturer will buy copper from their supplier on that same basis. Thus, there is neither a gain nor loss on the price of copper, and the margin that is built into the selling price is protected. In the normal course of business though, there are many other variables that may prevent such a transaction from occurring, thereby necessitating a different approach. Within North America, the vast majority of copper related transactions are based upon trading on the New York Commodity Exchange (Comex) with the official daily closing, or settlement price recognized as a benchmark for the industry. Futures markets such as Comex serve many purposes. First and foremost, it is the arena of price discovery, as buyers and sellers transact their business, with the resulting prices communicated to the market at large. The futures market is also the vehicle that enables one to offset, or hedge price risk exposure. For example, assume that a manufacturing company had the opportunity today to sell its product at a firm price, with delivery six months into the future, but had not yet purchased the copper to make the product. To avoid the risk of paying a potentially higher price when they purchase the physical copper, they could instead place an order to buy copper in the futures market as an offset to the sale. When the time comes to buy the physical metal, they would correspondingly sell the futures position. Thus, regardless of whether prices rose or fell, the profit on their product was protected. There is a cost for buying the futures, of course, but it is minimal, likely less than 12 percent of the total copper cost, and a company many find that it is well worth the elimination of the potential risk if prices spike. From another point of view, let’s take a look at a utility that is doing its planning and budgeting for the upcoming year. For planning purposes, the utility can look at prices for 2010 today, and see that for the full year, the average price of copper is about $1.75 per pound. The utility has a good estimate of its wire and cable requirements for 2010, as well as transformer and hardware needs. What it doesn’t know, however, is who it will be buying from, or precisely when it will be taking delivery. The one thing it does know is that it wants to stay within budget, and therefore must control future costs. To achieve this objective, the utility can buy, or lock in

Wild changes in copper prices in 2008 made for the best and worst of times for some wire and cable producers. copper prices on the futures market today for 2010, and be assured that its budget requirements will be met. When the time comes to place the orders for delivery and to agree with its suppliers on metal pricing, the futures market position will be sold at the then-current market price. Thus, the combination of the futures transaction, coupled with the physical purchase price, will comprise the total cost of copper, in line with expectations, regardless of where the price is in 2010. There are other scenarios where hedging can help. Companies typically must maintain some level of inven-

John E. Gross Editor/Publisher The Copper Journal Editorâ&#x20AC;&#x2122;s note: John E. Gross will be a panelist on a one-hour WAI webinar on June 3 that will focus on the risks of volatile copper prices and how companies can avoid them. See p. 30 for more details.

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MAY 2009 | 37

PERSPECTIVES

tory to support their business. During the first half of 2008, copper averaged $3.67 on Comex. Thus, many companies were holding inventories with historically high valuations. If management was concerned about a decline in prices, they had the opportunity to sell copper in the futures market, and thereby offset, or negate the potential of losses from falling prices. So, the reality is that while any company that buys copper canâ&#x20AC;&#x201D;and likely willâ&#x20AC;&#x201D;face risks from price swings, there are just as many solutions and tools available to mitigate the exposure. Doing nothing and hoping the market will work in your favor is not part of a prudent business plan. A cable manufacturer should focus on its business, not worrying about the copper market, which is why a well-planned hedging program is a valuable tool.

FEATURE

DIES I

n response to the harsh global business environment, many die suppliers say they are correcting excessive inventories, working to boost customer satisfaction and

cutting operating costs. Some say that the industry slowdown represents an opportunity to broaden their customer base and expand sales to existing customers with new products. Below, dies suppliers discuss how they are managing and why quality is a factor that never goes out of style.

WJI: Given the state of the economy, how has your role as an industry supplier changed? The state of the economy has forced us to become more aggressive in partnering with our customers to determine their immediate needs. It has also shown us the importance of diversifying the markets we direct our efforts towards. We are continually looking at ways we can service the customer better to increase sales. The economy has driven home how important lean manufacturing is as we strive to be more efficient in our usage and spending. Steve Marret, sales and marketing manager, Precision Die Technologies. With tighter economic times, wire producers are looking for better value—new ways to cut costs without sacrificing quality or production. Many wire producers seem more willing now, than ever before, to consider new technologies that deliver better economic results. This is a great discussion that helps the cus-

38 | WIRE JOURNAL INTERNATIONAL

tomer become more familiar and educated about the dies used in their processes. Joe Memmott, product manager, U.S. Synthetic Corp. Unstable economic conditions have highlighted the value that suppliers like Woodburn Diamond Die must offer to their customers. Never before have industry key success factors like quality, on-time delivery, and cost been so critical. Further, our role as business partners require that we be responsive to customer’s changing needs and proactive in helping them maximize the value of their tooling investment. Bill Schwehn, sales manager, Woodburn Diamond Die, Inc. Paramount Die was founded in 1968 by brothers Doug and Gil Sarver and is today the world’s largest producer of carbide wire dies for the ferrous wiredrawing industry. Paramount’s role in the wire industry has changed dramatically over the past sev-

We at Summit City Enterprises are a relatively new entry in the North American wire die business. We started Summit City in 1999 based on a business model which uses a combination of domestic and off-shore production facilities to allow quick response where needed and lowest cost where possible. We have enjoyed 10 consecutive years of record sales and/or earnings so we do not plan changes to that model as we go forward. Craig Martenson, principal, Summit City Enterprises. Customers in todayâ&#x20AC;&#x2122;s economy require just-in-time deliveries. They do not like to keep large inventories. Trying to be a service-driven supplier, we have had to maintain a partial finish die Paramount Die Company notes that it now stocks over 350,000 finished wire die inserts. eral years as the management and engineering staffs of wire companies have increasingly become leaner. With fewer staff to handle process development and supply management, Paramount has been called upon to fill the gap. Paramount routinely provides free on-site technical training and consulting to managers and operators alike. Paramount now stocks over 350,000 finished wire die inserts to meet the often next-day demands of its customers. As the trend toward leaner staffing continues to gather steam, a focus on service and responsiveness is essential for successful suppliers. Richard Sarver, president, Paramount Die Company. Sanxin views the current state of the economy as a huge opportunity with a large number of wire manufacturers, to assist in our primary roleâ&#x20AC;&#x201D;supply PCD and diamond dies with distinctly better price/performance. This is what we do. Our prices are obviously lower and we prove our performance, one step at a time, just like everybody else. Doug Thornton, president, Sanxin Wire Die, Inc. Our basic role as a wire die supplier has not changed with the state of the economy. We have always been about helping our customers improve their processes to reduce cost, improve quality, and survive in the increasingly difficult wire business. The things that have changed are the sense of urgency and the quick turnaround times required by our customers so they can meet

Cost cutting: asset or liability? Our customers are as focused on reducing cost in their manufacturing operations as they have ever been. We all know there are two ways to lower production costs: lower the purchase price of component parts or increase the efficiency and yield of the production process as a whole. Sometimes the actual result of purchasing a part at a lower cost is just the opposite of the intended result. For example, when that new part does not perform as well as the part it was replacing, or results in lower first pass yield, or prevents you from running that wire drawing machine at the speed it was intended to run. All of these situations result in higher costs, not lower. In the old days, buying a wiredrawing die was much simpler than it is today. The choices used to be simpleâ&#x20AC;&#x201D;tungsten carbide or natural diamond. Then polycrystalline diamond came along in various grain sizes, then single crystal Brad Scherer, vice president synthetic diamond. Today, there are multiple international operations, Fort manufacturers of each of Wayne Wire Die, Inc. these products along with new, unproven materials such as diamond film, diamondlike film and diamond-ceramic composite materials coming to market. Some of these may never become commercially viable, but others may serve the special needs of a particular market niche.

An assortment of dies from Esteves Group.

MAY 2009 | 39

FEATURE

the demands of their customers and gain business. Gary Kantz, sales director, Esteves Group.

blanking shelve for the times when shorter than normal deliveries are required. Jim Kasper, sales manager, Plan-E-Tech Industries, Inc.

FEATURE

Many wire mills are reducing staff and losing their most experienced personnel that deal with die purchases. These wire mills are relying more on the die vendors to make recommendations regarding die purchases. Vincent Griffin, sales and manufacturing manager, Premier Wire Die. Our role as a leader in the wire die industry has definitely changed over the past few years. Today we see ourselves more as solution providers rather than pure suppliers of a product. Companies are learning that the world is too complex today to try to keep up on everything yourself. They are finding that they have to find a supplier of whatever product they are purchasing, and that they can trust them to keep them up to date with the technological changes that are specific to their industry. In the

Dies from Fort Wayne Wire Die, Inc. past, our customers used to look at us simply as a supplier of a necessary tool needed to make wire. Today there is more of a partnership mentality or even expectation on the part of our customers, and we are there to fill that role. Brad Scherer, vice president, international operations, Fort Wayne Wire Die.

40 | WIRE JOURNAL INTERNATIONAL

The focus of the Ace American Wire Die Co., has always been creating a satisfying relationship with our customers. As the economy changes, our relationships with our customers have strengthened. We have always understood that our customers are a driving force behind our business success. Martha Thomen, sales manager, Ace American Wire Die. Imperial Wire Die Corp., provides the wire industry with tungsten carbide dies, (rough core and finished), polycrystalline diamond dies, natural diamond dies, unilap diamond powder and compounds. Recutting services are available for all round-wire dies. We have been in the wire die business for over 35 years and weathered many ups and downs brought about by the changing economy. We have made our adjustments to stay competitive without having to sacrifice quality and service to our customers. Marion Aiello, president/CEO, Imperial Wire Die Corp.

Clearly in these situations suppliers are subject to extraordinary pressure. The industry is not only asking for lower prices, but also for immediate deliveries of lower quantities. This reduces the possibilities of programming production and of achieving economies of scale, which then makes it very difficult to cut prices. Ferruccio Bellina, principal, TKT Group/Koner Spa. WJI: Do you spend more or less time visiting customers? Customers are looking for value, not just lowest price. They are working with fewer employees, reduced shifts, tighter scheduling in their shops, and shorter lead times to deliver to their customers. A fast and reliable response is a priorityâ&#x20AC;&#x201D;whether it is delivering the die quickly or answering their engineering questions. Customers are looking for service. As a customer, you want to know that the die you ordered will be made to your specifications and in a timely manner. As a customer, you want the assurance that if you need a die quickly, your supplier will respond quickly. We will do what it takes to get a die to a customer. We have driven to our material supplier (rather than waiting for standard shipping) so we could begin the manufacturing process immediately, and deliver the die to the customer the next day. Martha Thomen, Ace American Wire Die. (continued)

MAY 2009 | 41

FEATURE

With the current state of the economy, we donâ&#x20AC;&#x2122;t believe our role in the industry has changed in any way but for the better. These conditions have led us to take steps to improve and streamline our processes in ways that will have positive long-term benefits for us as well as our customers. Chris Hoffman, owner/manager, Heritage Wire Die, Inc.

We have had to make sacrifices, like most everyone else has, to deal with the loss of business resulting from the economic crisis. However, one thing we have not cut back on is communicating with and visiting our customers. If anything, we have had more frequent and in-depth communication with our customers during this trying time. Brad Scherer, Fort Wayne Wire Die. Sanxin is spending about the same amount of time as before directly in front of customers. We do not push customers into seeing us. We understand very well that many customers are fighting for their Sanxin representatives in Bejing. From l to r survival right now. are: Zhang Fan, production manager, Beijing They know when Sanxin; Wang Jiantuo, managing director and they are ready to chief engineer, Beijing Sanxin; Doug Thornton, talk about fixing president, Sanxin Wire Die; and Lee Thornton, their problems office manager, Sanxin Wire Die. with dies. Dies are only one part of the overall problem they face. Doug Thornton, Sanxin Wire Die, Inc. Given the difficult position our industry is in, we feel that personal visits to our customers are more important than ever for several reasons. Being on-site with your customer helps to increase understanding of the production process and results in a more informed and immediate response to challenges. Being able to suggest even seemingly minor improvements can increase efficiencies while reducing costs. Most of the personnel we deal with have had to accept responsibility for multiple positions in the production process due to staff reductions. This leaves them looking for experienced suppliers to lead them through the learning curve while they get acclimated to their new role. Subsequently, they look to us to assume more direct responsibility in keeping the die program efficient and effective. Bill Schwehn, Woodburn Diamond Die, Inc. Because of the increasing demands being placed on our customers, we are spending more time visiting them then in the past. Everyone seems to be willing to consider alternative ways of doing things, even when they have been running the same way for many years. As a result, we are building quite a portfolio of success stories that in many cases were previously thought not possible. Gary Kantz, Esteves Group. We strive to balance our visits and calls to customers at a level where we are maintaining good lines of communication and customer support with low-pressure expert advice. We keep in mind that many of the people in the industry have been given added duties or responsibilities due to personnel reductions and are wearing so many hats that interruption by vendors may be viewed differently than in the past. Chris Hoffman, Heritage Wire Die, Inc.

42 | WIRE JOURNAL INTERNATIONAL

FEATURE

Naturally the most recent downturn of the world economy has put even more pressure on us as a supplier. It is critical for us to be more of a partner to our customers, seeing their immediate needs, helping them cut corners, not just looking for that sale. Marion Aiello, Imperial Wire Die Corp. We spend more time with the customer. Our goal is not only to give the customer the product he or she needs, but to supply quality and service in the time it is needed. The customers are always willing to learn more ways to minimize inventory and cut costs. Steve Marret, Precision Die Technologies. We plan on spending more time visiting customers in the near future. In the past, due to our smaller size, we have not spent much time visiting individual customers or employed full-time salesmen on the road. We have used trade shows as an opportunity to meet our customers one-on-one. We will continue to do the trade shows and plan on adding more resources to visiting at least our local customers. We have also just redesigned our web page (www.plan-e-tech.com) to give our customers better access to information and speed up the inquiry process. Our customers are always willing to ask us about ways to save money and improve quality. Jim Kasper, Plan-E-Tech Industries, Inc.

Continuous Casting Technology

www.rautomead.com MAY 2009 | 43

FEATURE

The amount of travel has not changed. Wire mills are willing to listen if you have suggestions that will help reduce inventories and improve die deliveries. Vincent Griffin, Premier Wire Die. In the past, we have visited our customers routinely, but now are staying in close contact via e-mail, which seems to accommodate everybody’s limited time and schedule. Marion Aiello, Imperial Wire Die Corp. Moving far past the wire die piece of the process, Paramount offers recommendations on the complete drawing process from rod pre-treatment to drawing machine maintenance. Reduced administrative staffing and increased multi-tasking by management have led to a greater dependence on urgent response and next day deliveries. Richard Sarver, rsarver@paradie.com. The Summit City model strives to remain the lowest cost (and lowest price) supplier of world class dies in North America, so our advertising and travel budgets have been and will continue to be as low as practical. We always have and will continue to be ready to visit any customer or prospect who invites us. Craig Martenson, Summit City Enterprises. More time is spent visiting customers, mainly for the purpose of acquiring greater market share in order to compensate for the fall in consumption by existing customers. Clearly this is very difficult because nobody wants to lose their own share of the market. Ferruccio Bellina, TKT Group/Koner Spa. WJI: Are customers becoming even more focused on getting the lowest-cost dies available? This economy makes people anxious. They want to be

absolutely sure they are doing things in the most efficient and economical way possible. Today’s economy is not very forgiving for even small mistakes. So people have more questions today than they normally have. Secondly, with business volume down for most companies, people have more time on their hands now to look at and test new ideas and products that can make their operations more efficient. Brad Scherer, Fort Wayne Wire Die. Customers are being forced to make hard decisions in this business environment. Reducing the costs of die purchases is just one way they are trying to stay afloat, but they don’t seem willing to sacrifice quality A die from U.S. Synthetic Corp. just to cut their immediate tooling costs. They know that their value in the industry is based upon their ability to produce high-quality products at a low cost. Cheaper tooling doesn’t lower overall operating costs, if production and quality are sacrificed in the process. Joe Memmott, U.S. Synthetic Corp. In this terrible economic climate, the mills that buy new dies or die recut services have a rough time maintaining any profitability, never mind the levels of recent years. Two avenues to maintain profits—namely higher volume or higher prices—are

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44 | WIRE JOURNAL INTERNATIONAL

for all intents now dead ends. That leaves the third avenue, lowering costs, the only viable one. Craig Martenson, Summit City Enterprises.

Customers are indeed becoming even more focused on getting the lowest cost dies available. When people from one side of America to the other are looking more closely at how much they pay for their food, their clothes and their cars, it is right and proper that industry should also be looking more closely at the value provided by die makers. Note value, not just price, is the key word. Doug Thornton, Sanxin Wire Die, Inc. Price is definitely a selling point, but loyalty has played an important role. The lowest price die does not equal lower cost. Delivery, customs, communication difficulties and larger inven-

FEATURE

It seems in all aspects of manufacturing that adjustments are affecting both suppliers and customers. In today’s market, there are tighter controls of inventories, extreme pressures for timely deliveries and many other cost-cutting measures. There has been more scaling down of all personnel, and fewer people have more responsibilities and less time, if any, to spend with suppliers. Marion Aiello, Imperial Wire Die Corp.

Precision Die Technologies notes that its uses Conoptica technology for fast and accurate measurements of wiredrawing dies and other products.

tory because of lead times are all factors that play into the cost of the dies. If the dies don’t hold up well because of smaller stone size, breakage, inconsistency, out of spec., etc., this will spell extra costs associated with any down time. Is the best price truly the lowest price? Steve Marret, Precision Die Technologies.

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MAY 2009 | 45

FEATURE

We have seen many of our customers downsizing and sometimes eliminating their internal die shops. In response to greater demands, we have increased our die maintenance department. We are assuming the role of an internal die shop for many of our customers by maintaining their current die inventory. Martha Thomen, Ace American Wire Die. We believe that customers remain focused on maximizing the real value that is received for their investment in wire dies and related tooling. Customers are certainly conscious of the initial cost in new die purchases. However, informed buyers also give strong consideration to overall die life and quality to truly optimize die value. Personalized support from the die supplier is also a critical component in the purchase decision. Bill Schwehn, Woodburn Diamond Die, Inc. It is obvious that everyone, regardless of industry, is being more price-conscious. This is where things can get tricky, as the true total cost of an item seldom is based entirely on purchase price. Chris Hoffman, Heritage Wire Die, Inc. Value for your money is not always based on price alone. For instance, a lower priced die set that does not produce a high-quality part or parts and or has a shorter life span is probably not a good buy. The true value of a die lies in the equation of labor cost involved in set-up time plus the value added in quality parts produced divided by the die sets cost. One must also consider if the dies can be reworked or reground into a like-new set. Reworked dies give extra service life to your investment in the dies. Jim Kasper, Plan-E-Tech Industries, Inc. As has been said, customers are always seeking the lowest price, while their orders are smaller and less frequent. This means that customers not only want low prices but also immediate deliveries. Ferruccio Bellina, TKT Group/Koner Spa.

1 st

WJI: Why should a manufacturer not buy the lowest priced dies? Modern technology has divided die makers into two camps. Group A includes the die makers using high-tech instruments, such as those by Conoptica, to measure the parameters of the working profile of a die in ways not previously possible. The dies manufactured by Group A are now best described as a high tech commodity. Group B is the group, slightly lagging Group A, in which the advantages of high tech instrumentation and CNC tooling have not yet been seized upon. Their dies are also a commodity, but a commodity at a distinctly lower quality standard. Sanxin is in Group A, but also offers prices which are sharply lower than other die makers in this group. So, to answer the question with another question, why should a manufacturer pay more when better price/performance is readily available? Doug Thornton, Sanxin Wire Die, Inc. The lowest “priced” dies do not necessarily produce the lowest “cost” to manufacture. The low-priced die, if not optimal in either type or configuration for the process, can actually cost a customer many times the “savings” with increased process costs and downtime. This is often caused by a “lack” of service that usually accompanies the low priced dies. In some companies there is someone who is rewarded for buying the cheapest dies possible not realizing that they are costing their company dearly in operator frustration and poor or less than optimized manufacturing performance. It has become a corny cliché now, but the old slogan “pay me now or pay me later ” is really not so corny. Esteves Group offers manufacturers is 100 years of experience properly applying state-of-the-art technology to each customer’s unique processes. We have found ways to produce results for customers that have previously been considered and promoted as impossible by many in the wire die business. Enthusiasm for testing and experimentation rather

46 | WIRE JOURNAL INTERNATIONAL

Price is always a part of the equation in any sale, but most wire mills are looking for a vendor that can provide fair pricing, quick deliveries and offer die problem solutions. Vincent Griffin, Premier Wire Die. Thanks to the Internet and globalization, there are many lowpriced die suppliers on the market today. Some of them offer good value for the money. With others you get a low purchase price and a lot of headaches. We have lost business to low-priced suppliers but many of our former customers have come back after realizing higher production costs caused by fewer recuts, shorter die life or increased wire breaks far outweighed the relatively small savings they obtained from the original purchase. Remember, lower purchase price and lower cost do not always go hand in hand! Brad Scherer, Fort Wayne Wire Die. The true total cost of an item must include the following considerations: purchase price, quality, delivery, product durability, and, very importantly, the ability of the supplier to offer a legitimate knowledge base and customer support (in order to offer possible alternatives that will fit requirements without sacrificing value). What works well for one application does not necessarily work exactly the same for another. Our knowledge base is unique. Gillie started making dies in 1940, Otto (dad) in 1966, Chris in 1976, and I started in 1979—a total of 175 years of wire die manufacturing. In the last few years since Chris and I became the owners, and dad and uncle Gillie became consultants, it appears that some manufacturers have put more emphasis on short-term savings and less on long-term value. As an industry, we must strive to continually become more cost effective and productive to meet the challenges ahead. Chris Hoffman, Heritage Wire Die, Inc.

As long as Summit City provides dies and recut services which meet or exceed customer expectations, we see no reason that they should not take advantage of our lower prices. As more new accounts take advantage of our offerings, we hope that 2009 will con- Despite the ailing economy, Summit City tinue our stretch of Enterprises’“Die Guy” remains upbeat. record company performance. Craig Martenson, Summit City Enterprises. The lowest price dies are not always what the customer needs. If they want longevity, quality and a partner, the lowest price may not give them that. If they want service, convenience and on-time delivery, the lowest price may not give them that. If they want to surpass their customer’s expectations the lowest price may not give them that. So once again ask yourself, is the best price truly the lowest price? PDT offers different solutions to fit the customer’s needs. Leased dies can be one of those solutions. These are dies that you use and return. The savings can be as great as 50 to 80% versus a new die. This program is great for trial orders or short-term needs. Then there’s PDT’s inventory system, which is designed to save time and money. PDT’s customers need fast answers and faster solutions to meet their customer’s demands. While partnering with our customers we use our resources and knowledge to do whatever it takes to get the job done right, in the time that they need. As an ISO 9001/2000 certified die producer, our superior quality dies exceed the high-

FROM THE WOMB TO THE TOMB

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FEATURE

than relying on whis is considered “tried and true” has produced superior results for customers willing to partner with us. Improved performance is not only helping them survive in these down times, but will put them far ahead of their competition when things pick up in the future. Gary Kantz, Esteves Group.

SAVE

panoramic view of

MILWAUKEE

Wis.

taken from city hall tower

co-located with the National Electrical Wire Processing Technology Expo

MAY 11-12, 2010 | MILWAUKEE, WISCONSIN, USA The Home of Harley-Davidson

After more than 100 years, we’re getting closer to our neighborS.

cross town or across the country wire making and wire processing are two manufacturing sectors that have been linked by industrial proximity for years. Neighbors. One may be downtown, one downstream, but these groups share mutual interest.

Join us as two industry events—Wire Expo and the National Electric Wire Processing Technology Expo—share residence in Milwaukee, Wisconsin, for exhibitions that will run side by side making cross-over admission open to all who register.

History shows many ways to assemble groups. Sometimes into regions, neighborhoods, or sales territories and—from a finished wire perspective—many times into cable assemblies, cord sets, and wiring harnesses.

It takes a village. So if you want to develop your career in a community of like-minded industry professionals visit us at Wisconsin’s Midwest Airlines Center, May 11-12, 2010 where we’ll be celebrating the 20th anniversary of Wire Expo with new friends and great neighbors. Make it a point to drop in.

For 2010 we’ve planned a new group to show a panoramic view of the industry and provide the most current solutions available from exhibitors and educators.

For exhibiting information e-mail WAI sales at bxeller@wirenet.org or abzowski@wirenet.org. Find upcoming show details online at: www.wirenet.org.

Typically there are two approaches to lowering costs: buy cheaper tools that deliver shorter production life, or find better tools that deliver longer production life. Manufacturers should be looking for better value, not just lower prices. For example, a tool that costs a dollar and only lasts one month is not a better value than a tool that costs two dollars and lasts an entire year. For wire drawing dies, the quality of the PCD correlates directly with the life expectancy of the tool. Customer feedback and test data shows that US Synthetic PCD drawing dies last longer than other PCD drawing dies. The overall production value and total cost of ownership of USS PCD dies is better than other options on the market. As the only PCD wire die manufacturer that presses its own specialized material, we can deliver additional value to our customers by tailoring the right blend of material to achieve the best possible results for each customer. Under the current economic clouds, now is the time to look for value. Joe Memmott, U.S. Synthetic Corp. One of our responsibilities towards our customers is trying to present them with the best price possible for our quality dies. It is a very competitive market and there is always a cheaper die out there, but does cheaper replace quality? All our customers know that our experienced sales and manufacturing team will provide continuous customer support well past the shipping date of an order. We are a small enough company to give individual service and large enough to accommodate most wire mills requests. This extreme slow market is testing all of our patience. We need to focus on our relationship with our customers and together, weather this economic storm. Marion Aiello, Imperial Wire Die Corp. There is more to a die than price. As a customer, you want a supplier who will partner with you to meet your many business requirements. Ace American’s customers have grown to expect a

high level of service quality. Our manufacturing process encompasses over 50 years of die making experience. We have manufactured some unusual configurations. For example, customers have material “on the floor” that does not match well to the jobs they need to run. But they don’t want the extra inventory just sitting around. Our engineering department has worked with them to create a die that will let them use that material. Our customers depend on our technical advice and expertise. Martha Thomen, Ace American Wire Die. One should not buy the lowest price dies if the more expensive dies lower your overall costs with longer die life and faster setup times. Plan-E-Tech Industries Inc., produces its Planetary Nail Thread Rolling dies out of high-quality tool steels to give extended life. Our nail dies are also sold in matched sets of

Dies from Plan-E-Tech Industries, Inc.

rings and shoes with the thread form of the ring and shoe(s) within .002, which greatly reduces set up times. Plan-E-Tech Industries has over 20 years experience in manufacturing cylindrical thread rolling dies for the bolt manufacturing industry. We make those dies from high-quality tool steels to the tightest tolerances. Our dies produce high-quality threads in the finished

MAY 2009 | 49

FEATURE

est industry standards that assure consistent and reliable performance. All of these things coupled with our 100% guarantee are the best way we can add value to our customers for their manufacturing needs. Steve Marret, Precision Die Technologies.

FEATURE

product and give the user long die life. We also have a stocking program that reduces inventory costs and allows for just-in-time delivery. We also rework/regrind used dies that lowers the customers overall die costs. Jim Kasper, Plan-E-Tech Industries, Inc. The lowest price doesn’t always represent the best value. Most companies are reducing die inventories and delaying die purchase until they receive a wire order that forces them to make the purchase. Most orders we receive are rush orders and our ability to deliver in days, not weeks, is the new standard by which we are measured. Competitive pricing is expected in these economic conditions. Vincent Griffin, Premier Wire Die. There is no doubt on our part that even if costs and operating margins are cut to the minimum, below a certain price level there is no other choice but to reduce the overall quality of the product: no one can perform miracles. That is why we have let orders go where the price level is too low for us to be able to maintain our standards of quality. Ferruccio Bellina, TKT Group/Koner Spa. The reasons for not buying dies strictly based on initial cost are as relevant today as ever. Woodburn works hard to be as competitive as possible with products, but ultimately the pricing is built around the customer and the demands of their drawing program. Over the years we have evolved into a business of customized solutions as every customer has specific product needs. We work with them to design their die programs accordingly. Sometimes a very low-cost die will fit the specific need and other times a more complex program will require a more technically advanced die program with higher costs involved. In today’s global economy, there will always be someone there to sell the die cheaper than someone else. However, the ability to service customers following sales and being there to help them meet daily demands on the production floor results in a value that transcends the actual cost of the product supplied. Bill Schwehn, Woodburn Diamond Die, Inc. ■

Contact information Ace American Wire Die Martha Thomen, sales manager aawiredie@aol.com www.aawiredie.com Esteves Group Gary Kantz, sales director gkantz@estevesgroup.us.com www.esteves-dwd.com

50 | WIRE JOURNAL INTERNATIONAL

Fort Wayne Wire Die, Inc. Brad Scherer, vice president, international operations bscherer@fwwd.com www.fwwd.com Heritage Wire Die, Inc. Chris Hoffman, owner, heritage.wiredie@verizon.net Imperial Wire Die Corp. Marion Aiello, president/CEO imperialw@aol.com www.imperialwiredie.com Koner Spa/TKT Group Ferruccio Bellina, principal tkt@tktgroup.it; www.tktgroup.com Paramount Die Company Richard Sarver, president, sarver@paradie.com www.paradie.com Plan-E-Tech Industries, Inc. Jim Kasper, sales manager jkasper@on-b.com www.plan-e-tech.com Precision Die Technologies Steve Marret, sales and marketing manager stevem@pdtinc.com, www.pdtinc.com Premier Wire Die Vincent Griffin, premierwiredie@cox.net., www.premierwiredie.com Sanxin Wire Die, Inc. Doug Thornton, president admin@sanxinamerica.com www. sanxinamerica.com Summit City Enterprises Craig Martenson, principal summittdie@aol.com www.summitdie.com U.S. Synthetic Wire Die Joe Memmott, product manager wiredie@ussynthetic.com www.usswiredie.com Woodburn Diamond Die, Inc. Bill Schwehn, sales manager bschwehn@woodburndd.com www.woodburndd.com

R D

E E

S V

E L

A O

R M

C E

H N

AND IMPORTANT PAPERS Some of the most important documents in the wire and cable industry are the technical papers presented at Wire Association International conventions. But many authors lack the proper funding needed to travel for speaking opportunities, which means that even the most world-wise ideas could stay packed away somewhere without a destination.

You’ve done your research. And we’ve developed a plan to help give your ideas wings. Don’t delay. Contact The Wire Foundation today to inquire about available funds for educational travel. You may just find that you’ve arrived.

The Wire Foundation, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 | Telephone: 203-453-2777

E DA L Analysis of the N ER N I W straightening of drawn AWA R wires using rollers by the Finite-Element Method (FEM)

TECHNICAL PAPERS

TECHNICAL PAPER

Roller position, diameter and change in pitch were examined to determine the optimum straightening conditions. By Kazunari Yoshida and Tsuyoshi Sugiyama

A high precision of straightness is demanded today for drawn wire, which has placed more value on the ability of machines to be able to provide such wire1,2. Wire straightening is done by automatic equipment that uses rollers. The straightening process uses a roller leveller, and wire is passed between the rollers in a zigzag arrangement to improve the straightness by repeatedly applying the bending processes3. The authors have previously reported on the straightening of drawn ultrafine wires4. The process is effective for improving the straightness of ultrafine wire and the costs related to this are low. While the equipment costs are not high, straightening wire during the fabrication process is much more expensive. Stable straightening is necessary and expected, but the basis for this has not yet been established as there are few theoretical guidelines and manufacturers must rely on the experience of on-site engineers5-7.

Fig. 1. Analysis model of roller straightening.

52 | WIRE JOURNAL INTERNATIONAL

The purpose of this study is to clarify the optimum straightening conditions, when using rollers, by Finite-Element Method (FEM) analysis under various straightening conditions. In particular, the position of rollers, roller diameter, and roller pitch were examined to determine the effect of these factors on the improvement of wire straightness.

Simulation Model Analysis conditions. The software used for the FEM analysis of wire straightening using roller leveller is MSC Marc2005 r3, a commercially available product . The model is a system with nine rollers to process a test wire that initially has curvature. The analysis model is shown in Fig. 1. The diameter and curvature of the wire to be straightened are 2 mm and 0.00174, respectively, and the diameter and pitch of

Fig. 2. Basic roller arrangement.

TECHNICAL PAPERS Fig. 3. Straightening using an inclined-roller arrangement.

the rollers are 60 mm and 35 mm. The rollers have a groove on their circumference that is semicircular with a diameter of 3 mm. In this analysis, friction between the rollers and the wire is not considered. The straightness of the wire after straightening is evaluated from the magnitude of curvature of the processed wire. Change in roller pitch and roller diameter. It is considered that the roller position directly affects the straightness of the wire after straightening. However, in the case of changing the positions of the nine rollers, many combinations of positions should be examined. It is difficult to obtain wire with stable straightness when a complicated roller arrangement is adopted. In addition, a complicated roller arrangement leads to an increase in the time required for setting up the system and in processing costs. FEM analyses are carried out with only roller pitch L or

roller diameter D being changed for the roller arrangements, to examine the effects of L and D on the straightening performance. Change in roller position. In this study, FEM analyses are carried out for the following two roller arrangements: an even roller arrangement (see Fig. 2) where all rollers induce the same amount of flexure (the roller position is indicated by the parameter h) and an inclined roller arrangement, where the roller position is successively elevated by a constant amount H as the wire approaches the final roller such that the flexure is minimum at the final roller. A comparison of the two methods is shown in Fig. 3.

Results and discussion Straightening with various roller pitches. In the abovedescribed task, FEM analysis was carried with D and L

Fig. 5. Distributions of equivalent strain depending on various roller pitch. Fig. 4. Effect of straightening for various roller pitches.

MAY 2009 | 53

TECHNICAL PAPERS Fig. 6. Effect of straightening depending on various rollers.

Fig. 7. Distributions of equivalent strain depending on various roller diameter.

constant at 60 mm and 35 mm, respectively. To examine the effect of L on wire straightness, L was changed as 32.5, 35, 40, and 50 mm. The change in L is related to the amount of roller roll-up . See Fig. 3. With increasing L, straightness tends to be improved; however, with a large H of 0.8 mm, the effect of L on straightness is small. See Fig. 4. Fig. 5 shows the distribution of residual equivalent strain for wire subjected to straightening with h = 3.5 mm, H = 0 mm and L = 35, 40 and 50 mm. As L increases, the bending strain of the wire decreases, as does residual equivalent strain. Straightening with various roller diameters. Fig. 6 shows the

effect of D on straightness when D is 40, 50, 60 and 70 mm. For all D, L was constant at 40 mm. Similar to the analysis described above, straightening with the inclined roller arrangement was adopted. The roller leveler proceeds, continuously providing bending deformation to the wire. Therefore, it is considered that with increasing D, bending deformation applied to the wire from the roller becomes smaller. However, in this study, the effect of D on bending deformation was small. This is because the amount of â&#x20AC;&#x153;roll-upâ&#x20AC;? of the roller changes as D changes due to the use of fixed L. Also, similar to the previous analysis, the effect of D decreases as H increases.

Fig. 8. Curvature of wire straightened using even roller arrangement.

Fig. 9. Axial strain of wire straightened using even roller arrangement.

54 | WIRE JOURNAL INTERNATIONAL

decreases successively with increasing H, where H is 0, 0.2, 0.4, 0.6 or 0.8. The straightness of the wire after straightening is investigated for each H value (Fig.10). With the inclined roller arrangement, K decreases. When the inclination angle of the roller is increased, the straightness of the wire improves and an almost perfectly straight wire can be obtained. Fig. 11 shows the relationship between N and the axial strain when straightening with the inclined-roller arrangement done with H = 0.8 mm, the point at which the best straightness was obtained. As the straightening process proceeds, axial strain decreases. At the final stage of straightening, the axial strain is extremely small. It is judged that decreasing h as straightening progresses is important for achieving wires with high straightness. On the basis of the above findings, it was confirmed that straightening with the inclined roller arrangement can effectively suppress axial strain in the wire and can yield highly straight wires.

Fig. 10. Curvature of wire straightened using inclined roller arrangement.

Fig. 11. Axial strain of wire straightened using inclined roller arrangement.

Conclusion â&#x20AC;˘ When L is large, the straightness of the wire tends to improve; however, with a large H of 0.8 mm using the inclinedroller arrangement, the effect of L on straightness is small. â&#x20AC;˘ The effect of D on wire straightness is small. This is because the amount of roll-up of the roller changes as D changes due to the use of fixed L. â&#x20AC;˘ For straightening using the even-roller arrangement, when h is too large, the straightness of the wire improves but only slightly. As h decreases, straightness improves; however, the level of straightness is not satisfactory compared with the level demanded on the market.

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TECHNICAL PAPERS

Fig. 7 shows the distribution of residual equivalent strain of the wire subjected to straightening with h = 3.5 mm, H = 0 mm, L = 40 mm and D = 40, 50 and 70 mm. As explained above, even when D varies, the change in the distribution of equivalent strain is limited. Straightening using even-roller arrangement. Wire with a diameter of 2 mm and curvature of 0.00174 was subjected to straightening using the roller in the even-roller arrangement to examine the straightness of the wire after straightening. Curvature K, which is an indicator of the straightness of the processed wire, and axial strain, which is applied to the wire from each roller, were examined by changing h in the range of 1 mm and 3.5 mm. Fig. 8 shows the relationship between h and K. When h is too large, the straightness of the wire improves but only slightly. As h decreases, straightness improves further; however, the level of straightness is not satisfactory compared with the level demanded on the market. Fig. 9 shows the relationship between roller number (N) and the axial strain applied at the position of each roller when straightening is carried out with h = 3.5 mm. The wire is subjected alternately to tension and compression. The axial strain is almost a constant value, except at the first and last rollers, because the value of h was the same for all rollers. Straightening using an inclined-roller arrangement. Manufacturing sites require a simple roller-straightening method that produces straighter wire. Therefore, the authors examined straightening using an inclined-roller arrangement. Using the same wire as previously described, straightening was performed using the inclined-roller arrangement with h = 3.5 mm for the first upper roller. For subsequent rollers, h

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• For straightening using the inclined roller arrangement, the curvature of the obtained wire decreases. When the inclination angle of the roller is increased, the straightness of the wire improves and an almost perfectly straight wire can be obtained.

References 1. Y. Onoda, T. Yanagihashi, T. Hama and M. Asakawa, Advanced Technology of Plasticity 2002, Proceedings of the 7th ICTP, 2002, pp. 625-630. 2. K. Li, C. Chen and S. Yang: Journal of Materials Processing Technology, 94, 1999, pp. 157-166. 3. Japan Society for Technology of Plasticity, “Straightening of Metal Products –Technology to Straighten Sheet, Tube and Others,” 1992, pp. 29-63, Korona-sha. 4. K. Yoshida, K. Sato, T. Yamashita, H. Sato, E. Matsunaga and D. Kato, Tension straightening of a drawn superfine wire, Wire Journal International, May 2007, pp. 46-50. 5. K. Park and S. Hwang, ISIJ International, Vol. 42-9, 2002, pp. 990-999. 6. H. Suzuki, J. Araki and N. Yamamoto, Journal of the Japan Society for Technology of Plasticity, Vol. 15-156, 19741, pp. 35-42. 7. Y. Onoda, T. Yanagihashi, T. Hama and M. Asakawa, Advanced Technology of Plasticity 2002, Proceedings of the 7th ICTP, 2002, pp. 625-630. ■

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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 prizewinning 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 and 2004. Tsuyoshi Sugiyama is a graduate student at Tokai. This paper, which was presented at WAI’s 78th Annual Convention, Pittsburgh, Pennsylvania, USA, June 2008, won the Horace Pops Medal Award for the best paper in the General Division

Yoshida

Sugiyama

TECHNICAL PAPERS

TECHNICAL PAPER Evaluation of hydrogen embrittlement susceptibility of PC wires This study found that one of the key factors in the industry standard FIP test was the relationship between diffusible hydrogen concentration and the dipping time for the test materials. By Shingo Yamasaki, Seiki Nishida, Daisuke Hirakami and Toshimi Tarui

The requirements for high-strength steels including prestressed concrete (PC) wires, has risen to reduce the cost and time associated with its use for construction. One of the critical factors affecting steel strength is hydrogen embrittlement; as it increases, as does the strength of a steel. For decades, much effort has been paid to investigate the mechanism and the procedure of hydrogen embrittlement of steels. One finding is that diffusible hydrogen causes fracture of steels. Recently, some methods using diffusible hydrogen concentration in steels to evaluate hydrogen embrittlement susceptibility of steel parts, e.g. fasteners, have been presented1. Hydrogen embrittlement susceptibility of PC wires has also been evaluated by the Federal International Prestressed Concrete (FIP) test method, which is known as the FIP test. In this method, the fracture time is the criterion for evaluation, and test conditions, e.g., the temperature and concentration of test solutions, the applied stress and the minimum dimension of a test cell are suggested. Among these factors, the diameter of a test cell is capably different among research laboratories. However, the

Table 1. Chemical composition of the test wire.

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diameter of a cellâ&#x20AC;&#x201D;in other words, the amount of a test solution per unit surface area of a test specimenâ&#x20AC;&#x201D; influences the behavior of hydrogen absorption into steels. The influence of the solution temperature on hydrogen absorption is not clear. In this study, the effects of the temperature and quantity of FIP test solutions on the absorbed hydrogen concentration in specimens were investigated.

Experimental method Tables 1 and 2 show the chemical composition and mechanical properties of the test wire, respectively. The FIP test condition is suggested in FIP special report SR88/1. Table 3 shows the test conditions. In the FIP test, the temperature, quantity and concentration of a test solution are considered to be the dominant factors of hydrogen absorption into steel wires. This work focused on the influences of the temperature and quantity of FIP test solution on the absorbed hydrogen concentration. Wire specimens with a length of 50 mm were dipped into 20 mass percent of ammonium thiocyanate solution with

Table 2. Mechanical properties of the test wire.

different conditions to charge hydrogen. Table 4 shows the conditions of dipping tests. The temperature of a test solution was from 40 to 60°C and the amount of a test solution was from 65 to 1000 cm3. Dipping time was from 5 to 100 h. After dipping tests, hydrogen concentration measurements described below were carried out immediately. In addition, some of the specimens dipped into FIP test solutions at 50°C were held at room temperature for 1 to 5 days and hydrogen concentration measurements were then carried out to identify the diffusible hydrogen. Hydrogen concentration measurement. The absorbed hydrogen concentration into specimen was analyzed through programmed temperature analysis using a gas chromatograph. Fig. 1 shows a schematic of this apparatus. A specimen was put in the quartz tube and the air was purged by Ar gas. The specimen was then heated from room temperature to 600°C at a constant programmed rate of 100°C h-1 in Ar gas. Hydrogen absorbed in the specimen was evolved by heating and carried by Ar gas to the gas chromatograph detector. A curve of hydrogen evolution rate against temperatures was then obtained. A hydrogen evolution rate curve shows some peaks corresponding to the trapping energy of hydrogen2. The area-integrated values of these peaks were then taken as the trapped hydrogen concentration.

Fig. 1. Schematic of hydrogen measurement apparatus.

TECHNICAL PAPERS

Table 3. FIP test conditions.

Table 4. Dipping test conditions.

Results and discussion Hydrogen evolution rate curves. The evolution rate curves of hydrogen from specimens before and after dipping into a test solution are shown in Fig. 2. Since the peaks of hydrogen at about 100°C and 300°C did not exist before dipping, hydrogen of these peaks was absorbed through the dipping test. Fig. 3 shows the hydrogen evolution rate curves from specimens dipped into FIP test solutions of 50°C, 1000 cm3 for 25 h and then held at room temperature for several days. The peak at 100°C decreased with the holding time in room temperature whereas the peak at 300°C was stable. It is therefore considered that hydrogen of the peaks at 100°C is diffusible. It has been reported that diffusible hydrogen causes embrittlement of steels; as diffusible hydrogen concentration becomes higher, fracture time of steel becomes shorter, as shown in Fig. 41. However, at a peak of 300°C, hydrogen is trapped steadily at some trapping sites. Fig. 5 shows the evolution rate

Fig. 2. Evolution rate curves of hydrogen from specimens before and after dipping into FIP test solutions at 50°C.

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TECHNICAL PAPERS Fig. 3. Hydrogen evolution rate curves from the specimens dipped into 1000 cm3, 50°C FIP test solutions for 25 h and kept at room temperature for several days.

curves of hydrogen from dipped specimens machined from a rod and a drawn wire. Hydrogen at the 300°C peak is considered to be trapped at the dislocations introduced into steels by drawing, since the peak at 300°C was measured only from the specimen cut out from a drawn wire. It has

Fig. 5. Hydrogen evolution rate curves from dipped specimens machined from a rod and a drawn wire.

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Fig. 4. Relationship between diffusible hydrogen concentration and fracture time under constant load using notched specimens machined from martensitic steels1.

been reported that hydrogen at the 300°C peak is trapped steadily and does not cause embrittlement3. Diffusible hydrogen means hydrogen that evolved below 225°C using the test equipment with a heating rate of 100°C h-1, as shown in Figs. 2 and 3. Influences of the test solution temperature and dipping time on the diffusible hydrogen concentration. Fig. 6 shows the relationship between the diffusible hydrogen concentration and dipping time into FIP test solutions at 40°C, 50°C and 60°C. The solution amount was 120 cm3. As shown in Fig. 6, the diffusible hydrogen concentration showed the maximum (3.75 mass ppm) at 25 h was consistent up to 100 h. At 60°C, however, hydrogen absorption was accelerated and the diffusible hydrogen concentration showed the maximum (4.4 mass ppm) at 10 h. However, after reaching the maximum, the diffusible hydrogen concentration decreased with dipping time and it was 1.7 mass ppm at 100 h. Although the reason has not been verified in this research, it is considered that the chemical reaction which generates hydrogen accompanying an increase of pH value was accelerated in higher temperature. At 50°C, the diffusible hydrogen concentration showed the maximum (4.2 mass ppm) at 25 h and decrease to 3.2 mass ppm at 100 h. Influences of the test solution amount and dipping time on the diffusible hydrogen concentration. To evaluate the influence of the solution amount, dipping tests were performed by changing the amount of a test solution per unit surface area, represented as Rsol. The temperature of a test solution was controlled at 50+1°C during a dipping test. Fig. 7 shows the relationship between the diffusible

TECHNICAL PAPERS Fig. 6. Relationship between the diffusible hydrogen concentration and dipping time in FIP test solutions at different temperatures.

hydrogen concentration and dipping time at various Rsol. The diffusible hydrogen concentration is dominated by dipping time and Rsol. For example, for Rsol = 6.5 cm3/cm2, the diffusible hydrogen concentration showed the maximum value of 4.1 mass ppm at a dipping time of 10 h and decreased to 3.0 mass ppm at 100 h, likely because of an increase of pH value. On the other hand, for Rsol = 100 cm3/cm2, the diffusible hydrogen concentration showed the maximum value of 4.5 mass ppm at a dipping time of 25 h and decreased to 3.9 mass ppm at 100 h. It is therefore considered that Rsol of over 50 cm3/cm2 is appropriate to keep diffusible hydrogen concentration consistently during test duration. Hydrogen absorption in FIP test solution is accelerated with the increase of drawing strain4. Lifetime in FIP test. It has been reported that the lifetime in FIP test strongly depends upon the tensile strength of wire5. According to this report, the lifetime of 1800 MPa class wires is 5 to 20 h, at which time the diffusible hydrogen concentration reaches the maximum from Fig. 7. It is therefore considered that the influence of Rsol on the lifetime is small. On the other hand, the lifetime of 1700 MPa wire is 20 to 50 h at which time the diffusible hydrogen concentration varies depending on Rsol from Fig. 7. It is therefore considered that the influence of Rsol on the lifetime is significant. For example, in FIP test using 1700 MPa class wire and applied stress of 70% of tensile strength, the average lifetime was 30 h for Rsol =55 cm3/cm2, whereas the lifetime was over 100 h for Rsol =12 cm3/cm2.

Fig. 7. Relationship between the diffusible hydrogen concentration and dipping time at various Rsol.

Conclusions To evaluate the hydrogen embrittlement susceptibility of PC wires by clarifying the dominant factors of FIP test, the absorbed hydrogen concentration into wires in FIP test solutions have been investigated. The conclusions are summarized as follows: • Evolution rate curves of charged hydrogen in wires were obtained using programmed temperature analysis. The curves showed characteristic two peaks at around 100°C and 300°C with a heating rate of 100°C h-1. The former is considered to be diffusible hydrogen which causes embrittlement of wires and the latter is to be non-diffusible hydrogen which is trapped at dislocations introduced into wires by drawing. • Diffusible hydrogen concentration charged in ammonium thiocyanate solution was dominated by the solution temperature and solution amount, which was represented by Rsol, and dipping time in a solution. At high temperature (50 to 60°C, Rsol =12 cm3/cm2 ), hydrogen charging was accelerate, the diffusible hydrogen concentration therefore reached at the maximum value in shorter time. Diffusible hydrogen, however, decreased after reaching at the maximum value, probably because of an increase of pH value. At lower temperature (40°C), the diffusible hydrogen concentration showed the maximum at dipping time of 25 h, and was almost constant for 100 h. At 50°C, diffusible hydrogen concentration shows the maximum at 10 to 25 h at Rsol=6.5 to 100 cm3/cm2. The maximum value of diffusible hydrogen concentration increased with Rsol value. Diffusible hydrogen then

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decreases with an increase of dipping time. This decrease of hydrogen concentration is larger for small Rsol value. It is therefore considered that the lifetime in FIP test of 1700 MPa class wire depends on the Rsol value. • To obtain rational data in FIP test, the temperature and Rsol must be controlled carefully. Quantitative analysis of diffusible hydrogen is important to analyze and understand the FIP test results.

References 1. S. Yamasaki and T. Takahashi, Tetsu-to-hagane, 83, 1997, 454. 2. H.G. Lee and J. Y. Lee, Acta Metall., 32, 1984, 131. 3. K. Takai, T. Watanuki and A. Nozue, CAMP-ISIJ, 9, 2001, 644. 4. K. Takai, G. Yamauchi, M. Nakamura and M. Nagumo, Journal of JIM, 62, 1998, 267. 5. U. Nurnberger, Otto-Graf-Journal, 9, 1998, p. 218. ■

Shingo Yamasaki received his Ph.D. in metallurgy from University of Cambridge in 2004 and is currently a senior researcher at Kimitsu R & D Lab, Nippon Steel Corp., Japan. He has been involved in research programs of high-carbon steel rods for high-strength wires. Seiki Nishida joined Nippon Steel Corporation in 1986, and is currently chief researcher at Kimitsu R & D Lab., Nippon Steel Corp. Daisuke Hirakami completed the metallurgical master’s course at Kyushu University in 1994. Since joining Nippon Steel Corporation in 1994, he has been engaged in the metallurgic study of rails, highstrength bars steel and highstrength wire. Toshimi Tarui received a master’s degree in metallurgy from Hokkaido University in 1981. Since joining Nippon Steel Corporation in 1981, he has been involved in various research programs in the fields of metallurgy and processing of high-carbon steel wire rods for high-strength wires. This paper was presented at WAI’s 78th Annual Convention, Pittsburgh, Pennsylvania, USA, June 2008.

Yamasaki

Nishida

Hirakami

Tarui

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Influence of surface texture and residual stresses on fatigue strength of wire rope It was found that the hot zinc coating process reduces the fatigue strength of rope made from steel wires. By Jan W. Pilarczyk, Bogdan Golis, Ryszard Budzik, Robert Kruzel and Marek GaĹ&#x201A;a

Fatigue strength of steel rope is related to many factors such as steel grade, rope construction, type of load and the mechanical properties of wires. Experience has shown that the mechanical properties of wire have the most significant influence on the fatigue strength of wire rope. The fatigue strength of wire depends on the parameters of the drawing process as well as the type of applied protection coatings. Due to economical and technical reasons, zinc is the most commonly used coating. The rate of zinc corrosion is about 15 to 20 times less than the rate of the steel corrosion. Further, there is no shortage of zinc as there are large amounts of it that can be sourced. Finally, the technology of covering wires with a zinc coating is relatively simple, all of which explains its widespread use.

Factors that effect wire fatigue strength Fatigue strength of wires is one of the fundamental criteria used to estimate their quality in wire rope. It depends on material properties in the core as well as on the state of the surface layers of the wires. Parameters of drawing such as die geometry, drawing method, draw speed and a value and schedule of reductions all have an effect on the properties of the core as well as on properties of the surface layer and, finally, the fatigue durability of wires after drawing. Many works about those factors have been published. In the work1 it has been found that with the increase of single reduction from 23 to 32% and a total reduction from 60 to 85%, a small decrease of fatigue strength of rope wires has been observed. Muskalski et al2 has found that the fatigue

Table 1. Chemical composition of test materials.

Fig. 1. Methods of improvement of fatigue strength limit Zgo of steel wires12. Table 2. Mechanical properties of test materials. MAY 2009 | 63

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Table 3. Values of single and total reductions in subsequent draws for the test wires. Fig. 2. A schematic showing the production process for the test materials.

Eq. (1) strength of wire rope drawn in one direction is higher than the fatigue strength of wire drawn with a change of drawing direction in subsequent draws. In cited works it also has been proven that a decrease of a die angle has resulted in the increase of the fatigue strength of wires. In works3-5 it has been found that hydrodynamic drawing of rope wire improves their structure and texture, lowers longitudinal residual stresses and results in significantly higher fatigue strength for wire ropes compared to those manufactured by conventional drawing methods. Pomp and Duckwitz6 have found that for a steel with a carbon content of 0.43 %, the ratio of the fatigue strength limit to the wire tensile strength decreases from 0.7 at total reduction of 44 % to 0.25 at a total reduction of 90%. Gill and Goodacre7 have obtained similar relationships and additionally found that decarburization of the surface layer of wires as well as its roughness significantly effects the fatigue strength of wires. A decrease of decarburization and roughness increased their fatigue strength. Krasilnikov8 has stated that removing tensile residual stresses in the surface layer of a wire by means of a lowtemperature thermal treatment increases the fantigue strength of the wire. Kobayashi9 found that wire fatigue strength is dependent on non-uniformity of plastic strain distribution on the cross section of the wire resulting from the wiredrawing process, which creates a higher tensile strength and hardness of the surface layer than of the wire core. In a series of works, Verpoest et al 10-12 have proposed a new definition of the fatigue strength of wires in which they quantitatively take into account the effect of material properties and the state of the surface layer in the form of an equation:

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where:

ΔKth = factor of stress intensity; α = geometrical coefficient; a = notch depth.

According to Verpoest12, every wire surface defect can be treated as a semi-elliptic crack characterized by depth “a” and width “2c” (or by geometrical coefficient a/c). For a calculation of the stress intensity factor for every surface defect it is necessary to first calculate the geometrical coefficient on the base of the equation elaborated by Newman13:

Eq. (2) Verpoest has proved12 that 50% of wire fatigue cracks that occur during tests have begun in the points of contacts of the two longitudinal grooves on the wire surface, 25% have started on the broken martensite particles and 25% on inclusions or surface valleys. According to the model presented in the work12, fatigue durability can be improved by the increase of the stress intensity factor and a decrease of the defect depth; it also can be realized by the increase of the values of geometrical coefficient a/c (see Fig. 1). On the base of his model, Verpoest found that tensile longitudinal residual stresses, even if they are present in the thin surface layer, increase the value of the stress intensity factor according to the following equation12:

TECHNICAL PAPERS

Eq. (3)

From this equation it is obvious that in testing wires that have residual stresses at the surface, smaller amplitude stresses are necessary to reach value ΔKth and start development of the fracture from existing defects. On the basis of the Verpoest work, the value of the stress intensity factor can be estimated for wires with a diameter from 1.5 to 2.0 mm and the tensile strength in the range from 1300 to 2200 MPa from the following equation:

Eq. (4) Table 4. The average values of tensile strength Rm and fatigue strength limit Zgo of wires from steels D55, D65 and D80 uncoated and zinc-coated electrolytic process and a hot-bath process.

Experimental determination of the stress intensity factor is very complicated. In the literature there is a lack of comprehensive works concerned with the effect of the methods of zinc coating (electrolytic or hot bath) on the fatigue strength of rope wire. The wires) have been also proposed. Wires with diameters from works of Hempel and Horstmann14 found that a zinc coat1.5 to 2.4 mm made from steel with carbon content in the ing in a hot bath has a small effect on the fatigue strength range 0.56 – 0.79 % were considered. for wires with a tensile strength lower than 1000 MPa but for wires with higher strength this effect is remarkably. Materials and experimental According to Koziol and Zawislak15 the tensile strength procedures of wire after a hot-bath zinc coating decreases from 4 to 6% for wires with a low-carbon content and 8-12% for Tables 1 and 2 show the chemical compositions of the wires with a higher carbon content. For those wires, steel types used in this work and the mechanical properties according to Steininger15, a decrease of the tensile strength of the wires after patenting. Wire was drawn to 4.2 mm can be even 15%. from steel grade D55, to 3.1 mm from steel grade D65 and Investigations carried out by Hooker and Almen and 3.8, 4.4, 4.6 and 4.8 mm wire from steel grade D80. Table cited in the references16 have proved that zinc coatings on 2 shows the mean values (from five specimens) tensile the wires lower their fatigue strength about 40%. strength Rm, yield strength R0.2, number of twists Lt and Kowalczyk et al17 has stated that for uncoated wires—2.1 number of bends Lb.. mm from steel D55 with a tensile strength 1600 MPa and the fatigue strength 460 MPa determined in a rotational beam test— an electrolytic zinc coating has resulted in a decrease of the fatigue strength to the value of 443 MPa and a hot-bath zinc coating decreased this strength to the value 232 MPa. In the work19, the relationships among the fatigue strength of zinc-coated and uncoated wires determined in the rotational beam tests and the tensile strength of those wires have been determined. In cited work empirical equations relating the fatigue Table 5. Percentage variations of tensile strength Rm and fatigue limit versus chemical compositions of strength limit Zgo in result of zinc coating in comparisons with steels, wire diameter before and after data for uncoated wires. patenting (for zinc coated and uncoated

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For calculation of the average values of fatigue strength limit the following equation was used21, 22:

Eq. (5)

where:

Fig. 3. Percentage variations of tensile strength ΔRm, fatigue strength ΔZgo and ΔRm/Zgo in result of zinc coating (galvanized E and hot galvanized H) as compared with data for uncoated wires.

Fig. 2 shows the scheme of investigations planned in this work. As can be seen from this figure, after drawing, wires with diameters of 1.5; 1.7 and 1.8 mm were subjected to two different process of zinc coating, namely a hot bath and an electrolytic one. After zinc coating, wires were tested to determine their fatigue strength and tensile strength, number of twists and number of bends. Similar tests were performed for uncoated wires with the same diameters as zinc coated wires for a comparison. Fig. 2. shows the process that was used for the tests, which included the patenting of the steel grades in a lead bath, followed by pickling, drawing by a bull-block machine (JP 600) using dies with a 12° die angle and a natrium soap powder as a lubricant. Table 3 shows the values of single and total reductions in subsequent draws for the test wires.

σ a = value of the bending stress at which the break occurs; n = frequency of breaks occurring; ni = frequency of breaks occurring at subsequent levels (i= 0, 1, 2, ……q).

A “+” sign in Eq. (5) is used when breaks have not occurred and a “-” is for when a break has occurred. A standard deviation of the fatigue limit can be estimated from the following equation21, 22:

Eq. (6)

For measurements of longitudinal residual stresses σz a stand for reversible electrochemical pickling was used and procedure, both of which were described in the work22. The total length of the specimens was equal to 570 mm and the etched length was 450 mm; a change of a current direction was done every 5 s. In the tests, the relationships of specimens’ elongation versus etching period, initial and final wire diameters, initial etched length and Young modulus were input data for calculation of residual stresses from Wysoczin equation18:

Test procedure Fatigue tests of drawn wires (zinc-coated and uncoated) were done with a Pul Drabi Schenck rotational beam tester for wire from 0.5 to 4.0 mm. The level of bending stresses is adjusted by selection of axial force P and arrow of deflection. A fatigue strength limit Zgo has been determined by the so-called staircase method (up and down) in which the minimum number of tested specimen is about 4020. In this method, when at a selected stress level the first specimen breaks, the next one is tested at a lower stress level, but if the first specimen will not break at the mentioned stress level the next one is tested at a higher stress level. The number of cycles during this test that specimens should sustain is equal to 2 x 106. The advantage of this method is an arrangement of test results around real value of the fatigue limit, but the disadvantage is that it is time consuming, about 20 hours for one specimen.

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Eq. (7)

where: r = radius of specimen during etching, Δl = function determining relationship of elongation versus radius r. Experimental data were approximated with a function:

Eq. (8)

where: a,b = constants, R = initial wire diameter.

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Roughness measurements were performed with profilographometer Form Talysurf in longitudinal and circumferential directions. In longitudinal measurements cut off was equal 0.8 mm and in circumferential 0.25 mm. From many parameters that can be determined with Form Talysurf the following were determined: Ra

= average arithmetic deviation from the mean line of the profile; Rtm = average maximal height of the profile; S = average spacing of local peaks of the profile. Those parameters of the roughness profile were used for calculation of the fatigue strength according to Verpoest model and geometrical coefficient of the profile.

Research results

Table 6. Average values of fatigue limit, tensile strength, residual stress and roughness parameters.

Table 4 shows the average values of tensile strength Rm and fatigue strength limit Zgo of wires from steels D55, D65 and D80 uncoated and zinc-coated electrolytic process and a as well as the average values of surface roughness paramehot-bath process. ters such as Ra, Rtm and S. From the data of this table it can From the data in Table 4 it can be stated that process of be stated that for all three tested steels the zinc-coated wires zinc coating has resulted in a decrease of tensile strength have exhibited lower values of the fatigue strength comand fatigue strength but much higher effect has the process pared to those of uncoated wires. It results from the sum of the hot zinc coating comparing with electrolytic zinc interaction of the worsening of the surface roughness, lowcoating. It also effect for all tested steel grades for a ering of the residual stresses and variation of the values of decrease of the ratio of Rm/Zgo â&#x20AC;&#x201C; also in that case a higher the stress intensity factor. drop values of this ratio was observed after the hot bath zinc coating as compared with the electrolytic process. Based on data from Table 4, percentage variations of above-mentioned parameters were calculated and placed in Table 5 and in Fig. 3. These data show that hot galvanizing has decreased the tensile strength of wires from 4.48% to 6.51% but a greater influence was seen on the fatigue strength of wires, lowering their values as compared with data for uncoated wires from 12.2 to 14.8%. It can be stated that an average decrease of fatigue strength Zgo is more than two times higher than an average decrease of tensile strength Rm. On the basis of the data of Table 5, it also can be found that the influence of hot galvanizing on fatigue strength is less pronounced for steel wire that has a higher carbon content. For steel D55 the values of the ratio Rm/Zgo is equal at 11.5 %, but for steel D80 it is only -7. %. Table 7. Increments of fatigue strength limit related to Table 6 shows the average values of longiparameters effecting on fatigue durability (comparison with tudinal residual stresses Rz at the wireâ&#x20AC;&#x2122;s data for uncoated wires). surface for wires from different steel grades

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Conclusions Eq. (9)

where: ZU = Zgo of uncoated wires, ZE = Zgo of wires coated in hot galvanizing, ZH = Zgo of wires coated in galvanizing.

Eq. (10)

Eq. (11)

Eq. (12)

Eq. (13)

Eq. (14)

Similar equations were used for hot galvanized wires. Using values of data placed in Table 6 and Eqs. 9-14, calculations were performed for determination of the increments of the fatigue strength related to all parameters effecting the fatigue strength of considered steels and zinc coating methods. Results of calculations of those increments in comparison to values of analyzed parameters of uncoated wires are placed in Table 7. These data show that the most pronounced effect, a decrease of the fatigue strength of zinccoated wires as compared with to that for uncoated wires, can be seen in the wire surface roughness, especially the increase of a defect depth and variations of the geometrical coefficient of the surface profile. In the case of hot-zinc galvanizing, it is compensated by an increase of fatigue strength that results in a decrease of residual stresses and an increase of values of stress intensity factor. A good agreement was found between the estimation of the sum of the effect of analyzed parameters on fatigue strength and determined experimentally, especially for hot galvanized wires. Calculations presented in this work have only illustrative character and for real determination of the effect of surface roughness on the fatigue strength it is necessary for every specimen to measure a depth and the shape of the defect (notch) which has been the reason of the fracture.

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The process of galvanizing and hot galvanizing of wires results in lowering of tensile strength and fatigue strength compared to those properties for uncoated wires made of plain carbon steel with a carbon content in the range 0.5 to 0.8% The hot-zinc galvanizing process decreases the tensile and fatigue strength of wire to a higher degree than galvanizing as compared with values of mentioned properties for uncoated wires. Those average decreases are respectively equal to 5% for the tensile strength and 15% for fatigue strength. A model developed by Verpoest allows for a quantitative estimation of the effect of residual stresses, depth and shape of surface profile of wires and stress intensity factor on the fatigue strength of the wires. A remarkable decrease of the fatigue strength of zinccoated wires as compared with this strength for uncoated wires in spite of advantageous effect of a decrease of residual stresses and increase of stress intensity values for former wires on their fatigue strength is concerned with the sum of negative effects from the increase of a depth of the defect and geometrical coefficient of the surface profile.

References 1. L.W. D orodnych and W.S. M archenkow, Koliczestwiennaja ocienka wlijenija tiechnologij izgotowlienija kanatnoj prowoloki na jego wynosliwost, Stalnyje Kanaty No. 4, 1967, p. 344. 2. Z. Muskalski, “Influence of direction of drawing on fatigue strength of high –carbon steel wires,” Wire Journal International, December 2003, p. 61. 3. J.W. Pilarczyk, “Hydrodynamic drawing effects on wire ASTRO characteristics,” Wire Journal International, September 1997, p. 70. 4. B. Golis, J.W. Pilarczyk, Z. Bła ejowski and E. Filipczyk, “Drawing practice of steel wires with pressure dies,” Wire Journal International, April 1997, p. 54. 5. J.W. Pilarczyk, M. Pietrzyk, H. Dyja and B.Golis, “FEM analysis of metal flow in hydrodynamic drawing of steel wires,” Wire Journal International, November 1997, p. 760. 6. A. Pomp and C.A. Duckwitz, Dauerprufungen unter wechselnden Zugbeanspruchungen an Stahl-drahten. Mitteilungen aus dem Keiser Wilhelm-Institut, XIII, p. 79. 7. E.T. Gill and R. Goodacre, “Some aspects of fatique properties of patented steel wires,” J. Iron and Steel Inst., No. 130, 1934, p. 293 8. L.A. Krasilnikow, “Residual stresses in cold drawn and tempered steel wire and its fatigue strength,” Stal, No. 6, p. 492. 9. S. Kobayashi, “The effect of work hardening and residual stresses on the fatigue strength of steel wire,” J. Soc. Mater. Sci., Japan No. 22, 1973, p. 962. 10. I. Verpoest, “The fatigue threshold, the surface conditions and the fatigue limit of steel wire,” Ph.D. thesis, KU

Jan W. Pilarczyk is a professor in the Department of Materials Processing Technology and Applied Physics at Czestochowa University of Technology (CUT), Poland. He works on the development of new technology for wire drawing and metal products. He is the author or co-author of more than 170 papers and is president of the Poland Chapter of WAI. Bogdan Golis is professor of plastic working in the Dept. of Materials Processing Technology and Applied Physics at CUT. He joined the university in 1987 and previously worked in Poland’s Central Laboratory for Metals Products in Zabrze. He has more than 40 years of experience in the wire and rope industry. He is the author or co-author of more than 200 papers. Ryszard Budzik is an associate professor and head of Chair of Management and Logistics at CUT. He has practical experience in metallurgy, management, and evaluation of industrial enterprises. He is the author or co-author of more than 150 papers. Robert Kruzel is an assistant professor in the department of materials processing technology and applied physics at CUT. He has authored or co-authored more than 70 papers. Marek Gala is an assistant professor in the Institute of Industrial Electrotechnic at CUT, at which he earned a Ph.D in 2007. He is the author or co-author of more than 20 papers related to quality of electrical energy and application of artifical neural networks in modelling of different devices. This paper was presented at WAI’s International Technical Conference, Monterrey, Mexico, October 2008.

17. J. Kowalczyk, et al, Wytrzymało zm czeniowa drutów stalowych ocynkowanych elektrolitycznie i cieplnie, Biuletyn Techniczny ZPW M, No. 1, 1973, in Polish. 18. J.W. Pilarczyk, Analiza przyczyn zmian własno ci drutow ci gnionych konwencjonalnie i w ci gadłach ci nieniowych. Monography, Czestochowa University of Technology, 1996 (in Polish). 19. B. G olis, E. F ilipczyk, J.W. Pilarczyk and Z . Bła ejowski, “Fatigue strength rope wires,” European Technical Conference Proceedings, Brugge, May 1995, p. 16. 20. T. Yokobori, “The strength, fracture and fatigue of materials,” Groningen. P. Noordhoff, 1965. 21. Z. D yl g and Z. O rło, Wytrzymało zm czeniowa materiałów. W NT, Warszawa, 1962. (in Polish). 22. J.W. Pilarczyk, W pływ warunków ci gnienia na własno ci mechaniczne, technologiczne oraz stan warstwy wierzchniej drutów ze stali D 65. Ph.D. thesis, Czestochowa University of Technology, 1978 (in Polish). ■

Pilarczyk, Budzik and Golis

Kruzel

Gala

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Leuven, 1982. 11. I. Verpoest, E. Aernoudt, A. Deruyttere and M. Neyrinck, “An improved a.c. potential drop method for detecting surface microcracks during fatigue tests of unnotched specimens,” Fatigue of Eng. Mat. Structure, No. 3, p. 203. 12. I. Verpoest, “The fatigue threshold, the surface condition, and the fatigue limit of steel wire,” Academiae Analecta, AWLSK, Klasse der Wetenschapper, Jaargan 46, 1986, No. 4. 13. J.C. Newman, “A review and assessment of the stressintensity factors for surface cracks,” ASTM-STP 687, J.B. Chang, ed.. 1979, p. 16. 14. M. Hempel and D. Horstman, Einfluss der Feuerverzinens auf die Dauerfestigkeit von Stahldrahten, Arch. Eisenhuttenw, 1971, No. 12. 15. K. Kozieł and C. Z awi lak, Cynkowanie drutu stalowego. Wydawnictwo l sk, Katowice, 1965, in Polish. 16. Praca zbiorowa, Zm czenie metal,. W NT Warszawa, 1962 (in Polish).

PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS Zinc-calcium phosphate process offers users one-pass ease Germany-based Staku—Anlagenbau GmbH and U.S.based Wire Machine Systems announced the development of Staku-Ephos-technology, a continuous electrolytic zinc-calcium phosphating process used for coating of cold heading and steel wire material. A press release said that the in-line production enables the user to perform the de-scaling and phosphating process in one pass. Optimum cold-forming and drawing results are obained by the 100% coverage of wire surface and the fine crystalline structure of the electrolytically deposited zinc-phos layer (coating weights between 6 and 10g/m²), it said. In general, all wire diameters from 3 to 20 mm can be operated with drawing speeds of about 60m/min, it said, adding that cleaning and coating with the Ephos technology is used on de-scaled and annealed wire rod, pre-drawn, annealed and patented steel wire. De-scaling of the wire rod can be done by in-line shot blasting or a combination of mechanical bend de-scaling and electrolytic pickling system, it said. Contact: Staku Anlagenbau GmbH, tel. 49-6404-20 31, info@staku-gmbh.de; or Wire Machine Systems, tel. 260-483-9269, sales@wire-machine.com.

Wire measuring system heads off structural return loss failure U.S.-based Beta LaserMike announced the release of its SRL Pro, a length measurement system that allows detection of periodic variations in wire diameter, insulation diameter and capacitance. Ensuring that category and coaxial cable meets Structural Return Loss (SRL) performance specifications is essential, and off-line testing is one way to determine whether the wire is made properly, but can end up being costly when the cable fails, a press release said. These cyclical variations cause impedance variations on finished cable, causing SRL failure, it added. SRL Pro is equipped with eight analog input channels, it said. It can perform Fast Fourier Transform (FFT) on any sensor with analog output, such as Beta LaserMike’s LaserSpeed gauge, tension gauge, accelerometer, temper-

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ature gauge, current sensor to detect variations in extruder screw driver, it said, adding that it can also predict SRL performance of the finished cable. SRL Pro is equipped with up to 13 graphs per channel, simultaneous displaying of multiple channels in the same graph, warning and reject tolerance setting for external alarm, spectrographs for trending FFT and SRL for the entire reel and more. Contact: Beta LaserMike USA, tel. 937-233-9935, www.betalasermike.com.

Automatic spool winding line doubles normal machine output Italy-based PS Costruzioni Meccaniche Srl announced the release of its new, improved double-head fully automatic spool winding line. The PS 200/6/B allows operators to double normal machine output due to the design of two winding heads that work at the same time. It can accommodate approximately 200 cardboard, aluminum, plastic, plywood and wooden spools, with a spool diameter range from 100 to 200 mm and flange from 50 to 190 mm, a press release said. It can produce more than four spools of 100 m per minute, and the wire guide comes with CNC digital technology and CNC software, it said, adding that upon request, an in-line cable diameter detector can be included, which can correct any cable diameter modification in real time. Contact: PS Costruzioni Meccaniche Srl, tel. 39-039-6898763; ps@pscostruzioni.com; www.pscostruzioni.com.

Photovoltaic-rated solar cable holds up under stress U.S.-based USA Wire & Cable, Inc., announced the launch of USA Solar Cable, the first photovoltaic-rated cable for the solar energy industry. The cable will be used to wire hundreds of photovoltaic panels to the electrical collection system on utility-scale solar energy projects and is designed to withstand longterm exposure to extreme conditions, a press release said. The jacket is lead-free, halogen-free, limited smoke producing, flame retardant and environmentally friendly, and in fire, the cable will not emit harmful gases, smoke

Low-loss radio coaxial cables boost frequency bandwidths U.S.-based Coleman Cable, Inc., introduced the SignaWave™ brand of high-performance, American-made, low-loss 50 Ohm radio frequency coaxial cables. According to a press release, the cables offer superior performance and loss characteristics over higher frequency bandwidths than the traditional military-type 50 Ohm coaxial cables, RG58, RG213, RG223, RG214 and RG217. The cables are predominantly used in land mobile radio communications, but have also evolved for use in Wi-Fi Networks, broadband, satellite antennas, mobile phone, terrestrial microwave, military, air traffic control, medical, and RFID antennas, with new applications and challenges for low-loss 50 Ohm cables arising all the time, it said.

According to Tony Gabriel, director of engineering at Coleman Cable, “the Signa-Wave coaxial cables are manufactured in accordance and meet these military standards for superior electrical performance.” Contact: Coleman Cable Inc., www.colemancable.com.

Pivoting laser micrometer fixture boosts non-circular measuring U.S.-based LaserLinc announced the release of the ProfileVu, a micrometer fixture that pivots up to 180 degrees to allow for continuous inspection. According to a press release, the system is ideal for use in finding width and thickness of non-circular products such as flat wire and for locating thick and thin sections of extruded material and other die-formed products. Users can mount one or two LaserLinc laser micrometers to the ProfileVu; using three-axis micrometers (providing six-axis of inspection), the angle of rotation and the cycle-time required to identify the dimensions of interest are significantly reduced, it said. Combined with a Quadrature encoder, the system can correlate diameter (or other laser scanner measurement) with the angle of measurement, giving an accurate picture of the product, it said.

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PRODUCTS & MEDIA

or hydrochloric acid when exposed to water, it added. It also noted that the cable conforms to UL’s photovoltaic technical brief and specification UL 4703. The cable can be used with transformerless inverter systems and has lower SIC or energy loss, it said. Contact: USA Wire & Cable, Inc., tel. 800-880-9473, www.usawire-cable.com.

PRODUCTS & MEDIA

Contact: LaserLinc, tel. 937-318-2440; 888-707-4852; www.laserlinc.com.

12-point bolts offered in a range of materials and finishes U.S.-based SPS Technologies announced the release of its line of 12-point bolts in a variety of materials and finishes available in sizes from #6 to 1-3/4” diameters. According to a press release, the bolts can be ordered in AEREX® 350, MP35N®, MP159®, TITAN® 160 and 180, Alloy 718, WASPALOY®, Alloy Steels, CRES materials, H-11 and A286. Available finishes include cadmium, nickelcadmium, no finish, silver and passivated, it said. Tensile bolts with this head configuration are available with strength levels up to 260 KSI ultimate tensile strength, and shear bolts are offered in strength levels up to 160 KSI shear strength, depending on choice of material, it said. Contact: SPS Technologies, tel. 215-572-3308, www.spstech.com/aero.

Portable power cables available in a wide variety of colors U.S.-based General Cable announced that it has added more color to its Portable Cord line with Carol® Brand Super Vu-Tron® Type W Extra-Flex cables, now in bright colors and available in stock or by special order. According to a press release, customers can now choose from gray, blue, green, orange, yellow, red, or standard black, all made with Super Vu-Tron’s unique construction features, which provide durability, toughness and flexibility, all withstanding harsh sunlight, severe weather and other environmental conditions. The Super Vu-Tron Type W Extra-Flex portable power cable is designed for temporary power cable identification and tracking while on location, it explained. Initial stocking for the portable power cable in colors is available for General Cable’s 4/0 size offering, but other sizes are also available with low minimum-run requirements, and the standard black is available in-stock in a

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wide range of standard sizes, it said. Contact: General Cable, 859-572-8506, www.GeneralCable.com.

High-performance synchronous drives reduce costly downtime U.S.-based Altra Industrial Motion announced the release of its TB Wood’s Synchronous Plus™ drives featuring a dual sprocket design that includes both metric and standard-tapped holes coupled with a high-capacity Synchronous Plus belt. The Synchronous Plus drive delivers 50% more horsepower capacity than standard construction, hightorque drives, a press release said, adding that the design allows for the use of smaller, lighter weight sprockets which, in many sizes, are drilled for both inch and metric hardware. The belt features helically-wound, strong fiberglass cords that are chemically treated and designed to assure superior length stability, maximum flexibility and high tensile strength for shock loads, it said. Because they need no lubrication, the drives are ideal in applications where maintenance is difficult or where downtime could prove expensive, it added. Contact: Altra Industrial Motion, tel. 815-3896227; david.brooksbank@altramotion.com; www.AltraMotion.com.

Tie rod length and clevis calculator simplify applications ratings U.S.-based Portland Bolt & Manufacturing Company announced its tie rod length and clevis calculator for use in construction and structural steel applications. The device allows users to enter the overall tie rod assembly length and diameter to determine individual rod dimensions and the appropriate clevis size, a press release said. It quickly estimates rod lengths for three different tie rod configurations, whether the assembly is a standard two clevis rod or clevises with a turnbuckle and different rod lengths, it said. It determines accurate lengths for tie rods when given pin-to-pin dimensions, but also ensures the proper clevis number is being used for a specific rod diameter, it noted, adding that

Fluoropolymer masterbatches simplify wire color-coding U.S.-based RTP Company announced it has commercialized a line of melt processable fluoropolymer (MPFP) color masterbatches for the wire and cable industry that provide an easy-to-use solution for coloring complex MPFP resins used as plenum space jacketing materials. Available in 10 common wire and cable industry colorcoding formulations matched to Munsell and RAL standards, the MPFP color masterbatches are initially available in fluorinated ethylene propylene (FEP) and polyvinylidene fluoride (PVDF) resin systems that are expandable to include other MPFP resins, a press release said. They make color-coding wire and cable jacketing

materials easy for processors to use with low 3% letdown ratios and excellent dispersion and maintains the inherent flame retardancy and low smoke emissions that allow fluoropolymers to be used as a jacketing material for plenum spaces, it said. Additionally, custom color matches and engineered compounds using MPFP resins are possible to meet specific application requirements, and RTP Company also offers thermoplastic elastomer, EMI shielding, and flame retardant product lines for wire and cable industry applications and connected devices, it said. Contact: RTP Company, tel. 800-433-4787 or 507-454-6900, www.rtpcompany.com.

‘Green’ audio-video cables designed specifically for classroom use U.S.-based Liberty Wire & Cable has introduced EDULinx Classroom Solutions™ to provide school districts with the easiest, most efficient solutions for the audio/video modernization of K-12 classrooms, especially those suited for desktop or laptop computer use. EDULinx Classroom Solutions combine the performance of Liberty’s patented multi-pin connector cables with PanelCrafters™ wall plates, a press release said. It is

Sjogren Tensile Testing Wedge Grips

• Manufactured with a proprietary tooth pattern for superior grip and longevity. • A variety of sizes and styles to be used with Baldwin/Satec, Instron, and Tinius Olsen tensile testing equipment. • Custom manufacturing available. • Lifetime return guarantee on defective material or workmanship, and a 30-day no-risk warranty. For more information visit www.sjogren.com. Sjogren Industries, Inc. Tel: 1-508-987-3206 Fax: 1-508-987-1965 www.sjogren.com

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although it does not use complex mathematical formulas to determine the rod lengths, it performs calculations quickly, removes the possibility of mathematical errors, and eliminates the need for technical insight necessary to accurately determine proper rod lengths. Portland Bolt manufactures tie rods in diameters from 1/2 through 4” and provides the clevises and turnbuckles as a complete package, it said. Contact: Portland Bolt & Manufacturing Company, tel. 503-227-5488, www.portlandbolt.com.

PRODUCTS & MEDIA

designed to deliver years of reliable service, even in the harshest environments, and across the entire spectrum of K-12 facilities, including classrooms, multi-use rooms, teacher lounges, student counseling centers, libraries, gymnasiums, cafeterias, and performance areas, it said. The smaller diameter of the EDULinx connectors allows it to be easily installed in either a surface-mounted conduit or an in-wall box-and-conduit environment, it said, adding that the cables comply with the Restriction on Hazardous Substances (RoHS) directive. Contact: Liberty Wire & Cable, tel. 860-542-1234, emlye@jbstanton.com.

System brightens copper finish U.S.-based Radyne Corp. announced its new oxygenfree copper wire bright annealing system. According to a press release, it maintains the highest quality surface finish and interior strength for copper wire by eliminating traces of alkali, minimizing carbon deposition and stress relieving. The system anneals copper wire from 0.102 to 0.258” in diameter and up to 700ft/min., and the power supply used for this application is a newly designed TFN induction power source, it said. Contact: Radyne Corp., sales@radyne.com, www.radyne.com.

Small-diameter strand and cable suited for use in medical devices Jersey Strand and Cable announced that it now provides a unique manufacturing ability for small-diameter strand and cable for medical devices such as guide wires and snares for endoscopic tools. Jersey Strand and Cable’s miniature cables can be produced using type 304, 316 or other grades of stainless steel, a press release said. The equipment can produce strand and cable using a wide variety of materials from stainless steel to high carbon steel to manmade materials, it said. Contact: Jersey Strand and Cable Inc., tel. 908-213-9350; sales@jerseystrandandcable.com; www.jerseystrandandcable.com/c-products.html

Indoor wall mount panel supports range of PON-based applications U.S.-based Clearfield, Inc., announced the introduction of its PON in a Box. The FieldSmart Fiber Delivery Point (FDP) Indoor Wall Mount Panel teams 144 ports of fiber connectivity with up to four splitters in a compact 24 by 26 by 8” footprint, a press release said. Ring-cut capable, it is designed for the deployment of PON-based FTTH networks in a multi-dwelling unit, allowing for 12 to 144 ports of connectivity from a single deployment point, it said. Keeping with Clearfield’s design modularity, the mount panel is also stackable, allowing for 288-port availability,

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and the solution supports configurations for deploying flat drop cable to the customer dwelling unit, it said. The cassette ensures that all the basic principles of fiber management are satisfied without exposure to environmental hazards or human interaction and integrated cassette components support any application or fiber type desired, it said. Contact: Clearfield, Inc., tel. 800-422-2537; sales@clfd.net; www.ClearfieldConnection.com.

MEDIA Website offers wide array of support U.S.-based B&H Tool Company announced the launch of its new website, www.bhtool.com, offering engineering, production and technical support for companies that use extrusion tooling including adjustable center, fixed center, multi-layer crossheads, and in-line die assemblies. According to a press release, the website includes tips for reducing set-up times and strategies for scrap and meeting production goals, such as lower head pressure and faster line speeds. It has two calculators to determine the right tooling dimensions for a specific extrusion, or to test an existing tool set for balance, a DDR/DRB calculator for draw-down ratios and balances and a tooling calculator for die and tip sizes, it said. Contact: B&H Tool Company, tel. 760-471-8949; pneville@bhtool.com; www.bhtool.com.

Online copper study spotlights industry forecasts through 2030 CRU announced the release of its updated study, “2009 Copper Long-Term Outlook” that provides detailed analysis of over 80 major existing and future copper mines and extensive industry forecasts through the end of 2030. According to a press release, the study features: a copper mine profile analysis that covers more than 12 million tons of potential production from more than 80 major existing and potential projects around the globe; extensive regional and country forecasts that examine when global demand will recover and how China will be affected; and long-run marginal costs through 2030, which breaks down variables for the LRMC and future operating costs. The study can be ordered online at www.clientfiles.msgfocus.com. Contact: CRU Group, copper@crugroup.com, www.cruonline.crugroup.com. ■

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking employment positions are entitled to FREE “Position Wanted” classified ads. Limit: one ad per issue, maximum three ads per year. This WAI membership benefit is not transferable to nonmembers or to companies. CLASSIFIED AD RATES: • $1.30 per word for Wire Journal International 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: Blind box numbers assure the confidentiality of the advertiser in both the WJI and the on-line publication. Responses are mailed out within two business

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

CAREER OPPORTUNITIES

PERSONNEL SERVICES

INDUSTRIAL MAINTENANCE FOREMAN. Electrical wire factory in Houston, TX has an immediate opening for a career-minded industrial maintenance foreman. Qualifications include: experience in drawing, stranding, and extrusion. Individual will work to maintain production and quality through preventative maintenance and repair. EEOC employer. Please forward resume to Blind Box 5-1.

“LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors, managers and executives. For corporations we provide recruitment, outplacement, and salary assessment functions. For the professional exploring a new opportunity, we provide career evaluation and guidance. Our services are performed in absolute confidence. Contact: E-mail Peter Carino at pcarino@wireresources.com or Jack Cutler at jcutler@wireresources.com, w w w. w i r e r e s o u r c e s . c o m . Wi re

SALES REPRESENTATIVE. Traxit North America is looking for a sales representative to become part of the TRAXIT sales team in the following areas: Illinois, Wisconsin and Indiana. Sales will include dry and wet drawing lubricants, precoats and other wire products. Compensation is negotiable. Also, looking for straight commission sales in all areas of the USA. Please send resume to: Traxit North America, P.O. Box 381465, Memphis, TN 38138 or e-mail to tnamanf@bellsouth.net.

Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE. DIES MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904-388-3654. APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural & PCD DIAMOND DIES. Fair prices & excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@wmconnect.com.

EXTRUDER OPERATOR. Southwest Florida Wire Company is in need of an extruder operator with 2-5 years wire experience. Competitive wage and benefit package will be offered to the right individual. Please contact rferris@pelicanwire.com Serving the non-ferrous and ferrous industries since 1983

MAY 2009 | 75

CLASSIFIEDS

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

BLIND BOX? YES____ NO ____

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

DIAMOND & CARBIDE DIES: PRICED TO MOVE! Take advantage of discounted pricing on new, used and recut diamond and carbide dies in standard case sizes: 2, 5, and 6. For quality dies with competitive pricing, contact Ida Pardo at info@knottco.com or by phone at 617-519-3303.

MACHINERY

MEDIA

WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment. Tel. 727-863-4700 or by e-mail: urbassoc@ verizon.net.

ELECTRICAL WIRE HANDBOOK. Focusing on the special needs of the insulated wire and cable industry, this three softcover book set examines materials, equipment, and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire, and other applications. The original version remains available while the revised Electrical Wire Handbook is divided into three separate handbooks: Part 1 Wire and Cable Production Materials, Part 2 - Wire and Cable Production Processes, and Part 3 - Types of Cables. While the updated handbook includes the latest information available, this new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. The handbooks provide basic information to those people working in the wire and cable industry. Produced by the WAI’s Electrical Management Committee, these books are intended to serve as a valuable reference tool for members of the industry to help keep up with today’s rapidly changing technology. List Price: $99, WAI Member Price: $59. To purchase, go to wirenet.org and click on The WAI Bookstore.

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

FOR SALE

1 - NEB 64-Carrier CB-1 Cabler Braider 1 - NEB 72-Carrier B10-72 Braider, Capstan, Motor 1 - NEB 32-Carrier B10-32 Braider, Capstan, Motor 2 - STEEGER 16-C Braiders 1 - WATSON 36” Rotating Cabler Line 1 - NORTHAMPTON ST1000 Cabler, 1999 1 - CEECO 6-Bobbin 60” Closer w/Caterpuller, Take-up 2 - MGS Model LC50.4 Caterpuller Capstans 1 - DAVIS ELECTRIC Model CAT-TRAK 22 Caterpuller Capstan 1 - VITECK 24” Horizontal Belt Wrap Capstan 1 - NIEHOFF M15 Wire Drawer, Annealer, SG45 Spooler 4 - D/S 3.5” 24:1 L/D Extruders 1 - D/S 3” 24:1 L/D Extruder 1 - D/S 2.5” 24:1 L/D Nylon Extruder 1 - D/S 2” 30:1 L/D Hi-Temp Extrusion Line

1 - HALL 36” Motorized Payoff w/Model 4F15 Dancer 2 - TULSA 24” Motorized Shaftless Payoffs, Model HSPO-1, 12/02 1 - NEXTROM 1000mm Rotating Take-up w/Group Twinner 1 - ENTWISTLE 36” Dual Reel Take-up, Model THE 24/36 4 - D/S 30” Dual Reel Take-ups 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 4 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-ups 1 - CLIPPER Model SP16 Dual Spooler 1 - HALL 48” Shaftless Take-up 2 - TEC Model 24STC Hi-Speed Twisters, rated 1300rpm w/2-Wire Payoffs 1 - RAYMOND 3000lb Stacker Forklift 41 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels

Contact: Martin Kenner

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

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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.

THE BOOK OF WIRE & CABLE TERMS. This 350-page book is an indispensable publication covering both ferrous and nonferrous terminology. Price $75, $50 for WAI members, plus shipping. WIRE BREAKS, by Horace Pops and Julie Steininger. 2003, 49 pages. Breakage of copper, steel, or aluminum wire is one of the most common and costly problems facing the wire industry today. To help minimize the number

of breaks, drawing personnel must first be able to recognize and identify the type and cause of material failure. With this need in mind, the following reference manual was prepared. It contains pictures of the most frequent examples of broken wires found in the wire mill and at the customer’s facility. Although some of these photographs were taken with a scanning electron microscope, adequate visual examination of the broken ends can be made in the plant using either a magnifying glass or a low power stereomicroscope. Many pictures of cross-sections are included that were obtained in the laboratory using metallographic techniques The photomicrographs provide supplemental information that helps to explain the nature of the wire breaks. List Price: $15, WAI Member Price: $10. To purchase, go to wirenet.org and click on The WAI Bookstore.

INTRODUCTION TO EXTRUSION SET (DVD). This video series (total running time of 1 hr., 45 min.) by extrusion expert Tom Black includes Part 1, Materials & Equipment (50 min.), and Part 2, Extrusion Processing (55 min). List Price: $425, WAI Member Price: $325. To purchase, go to wirenet.org and click on The WAI Bookstore. ANNEALING: PARTS 1-3. This three-part video set presents information from industry expert Dr. Horace Pops. The set includes: Annealing Part 1: Principles of Annealing (28 min.); Annealing, Part 2: Annealing of Copper and Aluminum Wire (31 min.); and Annealing, Part 3: Annealing Problems (37 min.). The set can be ordered for $285, $225 for WAI members, plus shipping, or by individual parts for $95, $75 for WAI members, plus shipping. To order, go to wirenet.org and click on the WAI Store. ■

WIRE MACHINE SYSTEMS, INC. GAVLICK MACHINERY CORPORATION

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

Largest Inventory & Listing of Used Ferrous Wire Machinery BULLBLOCKS: • Vaughn #18 Bullblock; 30"x125hp; 1"start; late model controls-excellent • Vaughn #19 Bullblock; 30"x65/75hp; start .625" • Vaughn #22 double deck; 22/30” x 125/150HP DC; start .415” H.C.; 200/800 FPM • Vaughn #19; 30” x 60/80 HP; start .625”; 157/628 FPM • Vaughn #13 double deck; 18”/24” x 40/50 HP; start .312” • Vaughn #10; 26” x 40HP DC; 278-834 FPM; Eurotherm electrical controls WIRE DRAWERS: • (6) FE In-Line Model DTH-2020-105-24 Wire Drawers; max. wire .250"; 24" blocks; 20HP; (5) @ 112FPM, (1) @ 170FPM • Tecno Impianti 8 block; inlet 7mm, outlet 2.1mm; 560mm block dia; 25M/sec.; twin payoffs; descaler; spooler; electrics; 1990 • (2) Vaughn 5/6 HRM; start .280” S.S.; 26” x 40/50/69HP; 30” deadblock • Vaughn 7/8 HIVX; start .220”, finish .069”; 45/33 HP; 1000/3160 FPM • (2) Vaughn 5/6 HRS; start .220”; 16”-20”-24” x 50HP blocks; payoff, descaler, 24” x 50HP deadblock STRAIGHT & CUT MACHINES: • Lewis 2SV5-189-3; .062"-.312"; 3' runout; 65250FPM

• Lewis 2CV4; .062"-.250"; 3' runout; 65-200 FPM • Lewis 8-F’s; .157”-.375”; (1) 9’, (2) 12’ runout; 3 avail. • Lewis 9-F; .250”-.500”; 18’ runout • Lewis 10-F; .375”-.625”; 18’ runout MESH WELDERS FENCE: • Hurricane Hinge Joint Fence Machine model HJL55"; 11 line wires, 6"-12" stay; completely rebuilt • EVG GZN/85; 90"max. width; 85"max weld width; 1,2,3,4,6,8 line spacing; cross wire 1/2" up to 4"; wire dia. 1.4-3.8mm; slitter; nibbler; coiler for rolls; excellent NAIL MACHINES: • (4) Enkotec's NA-03-HD • (1) Enkotec NA-05-SH • Wafios N-100; .087”-.149”; .512”-4” length; 430 NPM • Wafios N-140; .122”-.181”; .512”-5.5” length; 370 NPM SPOOLERS: • Hall; 20"-30"; traverse, 1000 lb. cap; 5002500FPM • (2) 30" traverse base; 16" traverse; (4) 280FPM, 5HP EC motors • (3) Electro Power 30”x11”trav.; 1000lb. cap. MISCELLANEOUS: • Large inventory of deadblocks, pointers, butt welders, turksheads

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

VISIT WWW.GAVLICK.COM TO SEE OUR COMPLETE LISTINGS

and IN Equipment for the x FAX (260) 484-0515 6032A Highview Dr.Machines x FORT WAYNE, 46818 x (260) 483-9269 e-mail: sales@wire-machine.com www.wire-machine.com Wire and Cable Industry SHOT BLASTER • No. 1001 EJP-TOSCA COIL SHOT BLASTER TSVM 5000, Yr. 1996, working range 5.5 – 35 mm, Coil weight max. 2.500 kg • No. 1003 PANGBORN IN-LINE SHOT BLASTER Type ES-1972-5, Yr. 1998, working range 5.5 – 35 mm, operating speed 120m/min. max. • No. 1004 EJP-TOSCA SINGLE BAR BLASTER, Capable to shotblast round, hexagon and square bars and billets up to 160x160 mm. Complete system with loading table, entry conveyor, Shot blaster, exit conveyor, collecting pocket. Yr. 1998, like new, nearly never used. COMBINED DRAWING MACHINES • No. 1005 SCHUMAG KZ-RP 0B, Yr. 1985, working range 3 – 8 mm, max. speed 80m/min with SIEMENS PLC S5 control (1377) • No. 1006 SCHUMAG KZ-RP IB/5, fully reconditioned, Yr. 1990, working range 5 – 16 mm, max. speed 100m/min, latest Schumag design with hydraulic impact shear (1378) • No. 1008 SCHUMAG KZ-RP IIB, Building year 1976, working range 10 – 28 mm, max. speed 60m/min with DANIELI 2-RollStraightener, Yr. 1988, (1383) • No. 1022 SCHUMAG KZ-RP I, Yr. 1960, working range 4 – 13 mm, max. speed 42m/min • No. 1024 SCHUMAG KZ-RP IIB, fully reconditioned, Yr. 1971, working range 10 – 28 mm (30mm tubes), speed 7,5/15/20

m/min, 30/40/60 m/min. With IMPES pushpointer Yr. 1985. Cams, drawing carriages and shear have been reconditioned in 2000. STRAIGHTENING MACHINES • No. 1009SCHUMAG Pre-Straightener (horizontal & vertical), size IB/5, Yr. 1982, working range 5 – 18mm • No. 1010 EJP 2-ROLL-STRAIGHTENER SP 6-22, Yr. 2002, working range 6 – 22 mm, working speed 100 m/min. max. • No. 1012 KIESERLING 9-ROLL-BAR & TUBE-STRAIGHTENER WRUN I, Yr. 1974, working range 10 – 50mm, max. speed 40 m/min (1407) DRAW BENCHES • No. 1015 OTT DRAW BENCH Yr. 1974 completely rebuild in 1993, drawing force 50 tons, working range max. 85 mm, drawing length max. 12 m, speed stepless adjustable up to 30 m/min, currently single bench with push-pointer, but was originally triple bench and can be changed back easily (1400) CHAMFERING MACHINES • No. 1027 WAFIOS CHAMFERING MACHINE Type EB 728, Yr. 1977, working range 8 – 34 mm rounds, 10 – 27 hex., bar length 3 – 6 m max, 30 bars/min.

OFFERED BY:

MAY 2009 | 77

CLASSIFIEDS

FERROUS WIRE HANDBOOK. The most recent in a series of handbooks published by WAI, this comprehensive hard-cover book is a new, definitive industry resource for ferrous wire written by members of the Association and edited by former WAI President Robert M. Shemenski. List Price is $235, $195 for WAI members. To purchase, go to wirenet.org and click on The WAI Bookstore.

ADVERTISERS’ INDEX

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

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

A. Appiani/Lesmo Machinery America Inc . . . . . . . . . . . . . . . .26

HTC/Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . . . . .29

Alloy Wire International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Amaral Automation Associates . . . . . . . . . . . . . . . . . . . . . . . . .47

IDEAL Welding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Joe-Tools Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Balloffet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Lamnea Bruk USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

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

Lesmo Machinery America Inc/Appiani . . . . . . . . . . . . . . . . . .26

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . .42

Lesmo Machinery America Inc/HTC . . . . . . . . . . . . . . . . . . . . .29

CRU North America Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

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

Madem SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Cometo/Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . .71

Manner Plastics LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Markem-Imaje USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Durant Tool Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Esteves Group USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Metavan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Eurolls Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

Fort Wayne Wire Die Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Gauder SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Gavlick Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . . . . . .43

Howar Equipment Inc/Metavan . . . . . . . . . . . . . . . . . . . . . . . . .37

PS Costruzioni Meccaniche Srl . . . . . . . . . . . . . . . . . . . . . . . . .41

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

78 | 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

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

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

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Rautomead Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Wyrepak Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

RF Wire/Wheeler Industrial Corp. . . . . . . . . . . . . . . . . . . . . . . .18

Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . . . . . .Cover 4

Sanxin Wire Die, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Sikora International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

WIRE ASSOCIATION INTERNATIONAL ADS

Staku Anlagenbau GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-32

Summit City Enterprises Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Wire Expo 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . . . . . . .4

Wire Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Tubular Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

WAI ITC: Turkey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . .79 Wire Machine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

PLEASE VISIT US AT WIRE RUSSIA BOOTH #FOB39 RECENT PURCHASES — INVENTORY HIGHLIGHTS EXPL347 - 2 ½”DAVIS. STD/ SAMP Tandem line, Yr 2005. SAMP Wire Drawer/ Annealer, Davis 2 ½” 24:1 and 1 ¼” 30:1 extruders, Zumbach USYS 8000 FFT process monitoring system, 630mm SAMP ACDT-63 parallel axis dual shaftless takeup. 2500 mpm. EXPL304 Rosendahl Skin-Foam-Skin Insulation Line, 2000. Henrich Annealer, Preheater, 60/45/30mm extruders w/gas injection, Multi capstan, Rosendahl DIN500 Dual Take up. EXPL319 (2) DeAngeli/Samp 45mm Hi Temp Lines with Zumbach Preheater, SS multipass Capstan, 560mm Dual Parallel Axis Take ups. EXPL310 1 1/2” 24:1 D.Std. Extruding Line w/24” B.W. Capstan, PA-16 Clipper Dual Take-up, Beta MCS 120 Preheater, Yr. Mfg. 1996. EXPL252 3 1/2” D.Std. 24:1 Therm II Jktng Line w/2 Skaltek 50” Payoffs, (2) 40” Take-ups, 60” MGS Caterpuller, Accumulator EXPL253 3 1/2” D.Std. 24:1 Therm II Jktng Line w/(2) Skaltek 50” Payoffs, (2) Hall 40” Take-up, Accumulators, Dual 30” Capstan EXPL327 3 1/2” D. Std Thermatic II Extrusion Line w/84” Bartell Payoff, MGS 50” Belt Cat., (2) Royle 96” Take-ups. EXPL260 3 1/2”/ 2” 24:1 Tandem Wire Drawing/Insulating Line w/Samp TRB-2 Draw/Anneal/Preheat, Viteck Multipass Capstan, Clipper PS-24HS Take-up EXPL325 4 1/2” Luigi Jktng Line w/2) 60” Belt Caterpullers, 96” Portal P/O, T/U, 30” multipass capstan. CBR1030 - 600mm TEC Double twist twinner with back twist payoffs. Model BTTW-600E, 2500 TPM. Yr. 2000 CBR998 (8) Setic 630mm PA630i D.T. Twinners, Yr. 1998.

CBR986 (2) 30” Entwistle SC-30 S.T. Cablers. CBR995/CBR989 630mm MGS & TEC D.T. Twinners, NMC 800mm D.T. CBR996 24” TEC Double Twist Twinner. CBR923 1.25m Pourtier Drum Twisting Line, w/12 630mm Neutralizers, tapers, cat, 1.25m rot. Payoff, Yr. Mfg. 1993 CBR948 48” TEC Drum Twister w/(2) Conc. Tapers. CBR957 48” Cook S.T. Buncher, BH-48, Conc. Taper, Still Installed. CBR778 48” Ent. Single Twist Closer, STC-48. CBR712 36” Cook S.T. Buncher, BH-36. CBR953 1.0m Setic D.T buncher, Model T1085. CBR927 560mm Watson/Kinrei Double Twist Twinner, NB-560, 1998. CBR888.1 800mm Setic D.T. Twinner, Yr. Mfg. 199.7 CLR197 20” Reelex Windings Single Coiler, D750. TKU1021 30” D.StD Clipper Dual Parallel Axis Shaft Type, PA-30. TKU1106 50” Clipper Dual Parallel Axis Take up, PS-50. TKU1057 96” Bartell S/l Take-up. TKU943.2 84” Bartell S/L Take up, SLTU-84. WRD837 (4) Niehoff M30 Intermediate Wire Drawing w/VG_30 annealer, 75 kw DC motor, controls. WRD835 16” Endex Drop Coiler. BRD292 16C Wardwell Braider, on Wire. Dratex 1615. Yr. Mfg. 1999. (Qty 2). BRD230 16C Wardwell Braider, on wire, 36” 24C frames. BRD305 16C Wardwell Braider, on Wire. Rebuilt.

MAY 2009 | 79

ADVERTISERS’ INDEX

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

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

T E C H N I C A L

C O N F E R E N C E

New Technology

for Global Markets TWO DAYS. TWO CONTINENTS. ONE STOP. Take a look at developing industries in the wire and cable sectors as you join colleagues, presenters, and exhibitors at this educational conference and marketplace 2-3 November 2009.

SAVE THE DATE:

2-3 NOVEMBER 2009 | ISTANBUL, TURKEY

EXHIBITORS NOTE:

Set in Istanbul, Turkey—one of the largest cities in Europe, which is also the only metropolis situated on two continents—the event is next in the series of anticipated conferences by the WAI, ACIMAF, CET, and IWMA sponsors designed to surface big ideas and relevant dialogue.

TABLETOP SPACE AVAILABLE FROM € 630. Details and registration information are forthcoming online at: www.wirenet.org or www.iwma.org.

For more information contact: Marc Murray, Director of Education, The Wire Association International, Inc., 1570 Boston Post Rd., P.O. Box 578, Guilford, CT 06437-0578 USA, Tel.: (001) 203-453-2777 ext. 121, Fax: (001) 203-453-8384, E-mail: mmurray@wirenet.org.

Conference organized by: Associazione Costruttori Italiani Macchine Per Filo

C.E.T.

Comité Européen de la Tréfilerie

International Wire & Machinery Association

The Wire Association International, Inc.

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