New & Specialty Products

WIRE JOURNAL MAY 2010

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New & specialty products

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WIRE JOURNAL

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

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

CONTENTS

Volume 43 | Number 5 | May 2010

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26 New & specialty products . . . . . . . . .34

Fastener Update . . . . . . . . . 29 WAI News . . . . . . . . . . . . . . 30

This feature focuses on the mindset of three cable makers who share their thoughts on new and specialty products, as well as a look at one downstream growth area and observations from an industry analyst.

Chapter Corner . . . . . . . . . . 32 Technical Papers . . . . . . . 52-66

T ECHNICAL

Products/Media . . . . . . . . . . 68

Effect of drawing conditions in tandem pass drawing on drawn diameter Sonomi Shirasaki, Motoo Asakawa, Ryosuke Komami, and Yuichi Tanaka . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Classified . . . . . . . . . . . . . . 75 Career Opportunities . . . . . . 75 Advertisers’ Index . . . . . . . . 78

Next issue

SECTION

Development of high-strength steel wire products Tan Dianlong and Liu Lihua . . . . . . . . . . . . . . . . . . . .72 Aluminum wire rod produced with UPCAST® technology Juan Carlos Bodington and Matti Nordman . . . . . . . .78

June 2010 WJI • wire Düsseldorf wrapup • Ancillary Equipment/ Replacement Parts

Cover: A sampling of cable produced at U.S.-based Specialty Cable Corporation at its plant in Wallingford, Connecticut. To the left are reels of constant wattage heater cables used by the power generation and petroleum chemical industries and stacked high are spools of inner conductors used in satellite communication cables.

MAY 2010 | 3

INSIDE THIS ISSUE A TIMELY TRADITION

. .30

N EW &

SPECIALTY PRODUCTS

. . . .44

CONTENTS

MAINTAINING

Clockwinders gathered for a reunion dinner at the picturesque Rudding Park Hotel in Harrogate England, where the message was that, even as the industry contionues to evolve, there is value in maintaining a tradition with the WAI.

4 | WIRE JOURNAL INTERNATIONAL

Cable makers must always keep a focus on offering new products. Shown is a 5000 x view of Nexans’ new INFITTM insulation technology, developed specifically for fire-resistant cables. The company notes that, in the event of a fire, the insulation transforms into a tough ceramic shield that ensures a high level of fire resistance.

EDITORIAL WIRE JOURNAL

®

EDITORIAL

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

Report from Düsseldorf

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

The June issue of Wire Journal will have a wrapup of the wire Düsseldorf show in Germany, but here we can give you a short take on what happened April 12-16 at the Fairgrounds.

First, it was a most unusual week, what with the Poland president dying in a plane crash in Russia, an earthquake in China, turmoil in Bangkok and a volcano with an attitude in Iceland, but by the end of the show—and before just how much of an attitude the volcano had became painfully clear—it would be fair to say that there was a collective sigh of relief: the show had lived up to expectations.

It was important to the industry that the world’s largest wire and cable show not fail. It wasn’t expected to, but the economic events of the last two years have had to undermine the confidence of the most optimistic of exhibitors, especially as those same people had made a considerable investment in terms of resources and money. It was well known going in that the exhibitors would be there, for not to be there would be a sign of weakness that few suppliers would want to admit to, but what about the attendees?

It turned out that attendance was down some, but not much. A wrapup from the organizers, Messe Düsseldorf, pegged attendance at about 35,000, down some from the approximately 40,000 for the 2008 event, but more than enough to represent critical mass. What’s more important is that there was activity. Fewer attendees may also translate to more serious attendees, and a number of exhibitors said they appreciated that aspect. Still, it seems to be part of human nature that we want to see crowded aisles, although that’s not a reality any more for many trade shows.

While wire 2010 may not have matched the same highs as past shows, it was a good show, and about now one could say that, a good show, in some respects, is great news.

Mark Marselli Editor-in-chief

Senior Graphic Designer | Bill Branch Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing Services | Janice E. Swindells Graphic Artist | Adrienne E. Simpson Proofreader | Livia Jacobs Circulation Manager | Jan Valois Publications Advisory Board Antonio Ayala | J.J. Lowe, Mexico Ferruccio Bellina | TKT Group/President ACIMAF, Italy Malcom Michael | AWIA Australia Don Schollin | Q-S Technologies, USA Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA WAI Executive Committee Liaison Dane G. Armendariz | Henkel Corporation Technical Advisors John Drummond | Scotia Group R. M. Shemenski | RMS Consulting, Inc.

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel.

203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices.

Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2010 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700.

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

6 | WIRE JOURNAL INTERNATIONAL

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CALENDAR

CALENDAR May 12-13, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event will be co-located with The National Electrical Wire Processing Technology Expo and in conjunction with AWPA’s Long Products Supply Chain Symposium. Contact: WAI, tel. 203-4532777, www.wirenet.org.

May 12-13, 2010: The National Electrical Wire Processing Technology Expo Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event will be co-located with Wire Expo 2010. Contact: Jay Partington, Expo Productions, Inc., tel. 262-367-5500, www.expoproductionsinc.com.

Sept. 21-24, 2010: wire China 2010 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Oct. 18-20, 2010: WAI International Technical Conference Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities.

Contact: WAI, tel. 203-453-2777, www.wirenet.org.

Oct. 27-Nov. 3, 2010: K 2010 Düsseldorf, Germany. This event for the plastics and rubber industry will be held at the Düsseldorf Fairgrounds, Halls 1-17. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Nov. 7-10, 2010: 59th IWCS Conference™ Providence, Rhode Island, USA. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990.

Nov. 18-20, 2010: Wire & Cable India 2010 Mumbai, India. Organized by the Confederation of Indian Industry (CII), this event will be held at the Bombay Exhibition Centre in Goregaon. Contact: CII, tel. 91-2224931790, www.cii.in/.

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

June 19-23, 2011: JI Cable Versailles, France. This international conference on insulated power cables, which has multiple organizers and was last held in 2007, will present a comprehensive forum about power cables as well as exhibits. Contact: J1Cable 11, www.jicable.org. ■

W IRE ASSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; Internet www.wirenet.org.

May 12-13, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. See main listing.

June 10, 2010: New England Chapter dinner meeting Warwick, Rhode Island, USA. Bill Wall, vice president of marine operations at the offshore energy company Deepwater Wind, is the featured speaker for this education and networking event. His presentation will be, “Wired with wind – a new industry perspective on using offshore wind to generate power in the United States.”

June 21, 2010: WAI Midwest Chapter 8th Annual Golf Tournament West Chicago, Illinois, USA. The WAI Midwest Chapter will hold its 8th Annual Golf Tournament at the St. Andrews Golf & Country Club.

8 | WIRE JOURNAL INTERNATIONAL

Oct. 18-20, 2010: WAI International Technical Conference Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities.

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

May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. See main listing.

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INDUSTRY NEWS

INDUSTRY NEWS LS Cable wins Middle East contracts South Korea’s LS Cable reports that it has won multiple orders in the Middle East for extra-high-pressure cables for government-level electric power upgrade projects that together are valued at more than US$150 million.

A press release said that a contract from Bahrain calls for LS Cable to supply 220 kV level extra-high-pressure cables and binders across all regions “to meet the (country’s) rapidly growing demand for power with newly installed national infrastructure.” The contract, valued at US$120 million, is to be completed by next December, it said. The second contract, from Kuwait, will see LS Cable “supply and assist in the installation of a power transmission system promoted by the electric power administration of Kuwait.” That contract was valued at approximately US$34 million.

The release said that the contracts were won over strong competitors from Europe and Japan. “For these projects, LS Cable was selected from a group that included not only Saudi Cable, a highly influential regional player, but also other leading companies including JPS of Japan and Prysmian of Italy,” it said. It noted that the order includes gap conductors, which it said is significant as that market had previously been dominated by Japanese companies.

The gap conductors, it said, are capacity extension cables that produce high conductivity using super thermalresistant aluminum alloy as the conductor. “Without needing to add power transmission towers and lines, twice, the power can be transmitted simply by replacing the existing cable.”

Observed LS Cable Vice President Myeong-gyu Choi, “This is a valuable result achieved by systematic and organic harmony of a thorough market survey by local companies, customized marketing by business division and technological support by R&D. We will embark upon active entry into not only the Middle East, but also the North American and European markets in the future.”

SuperPower notes 10th anniversary, opens superconducting exhibit SuperPower, Inc. recently celebrated its 10-year anniversary with the opening of a new exhibit on superconductivity at the Schenectady Museum and Suits-Bueche Planetarium in Schenectady, New York.

A press release said that the exhibition details the company’s accomplishments, which include the successful scale-up of its second-generation (2G) hightemperature superconductor (HTS) wire production at SuperPower’s manufacturing facility in Schenectady; the world’s first in-grid demonstration of 2G HTS wire at the

SuperPower General Manager Art Kazanjian addresses guests at the opening of a new museum exhibit on superconductivity. Seated are New York Congressman Paul D. Tonko; Dr. Franklin Chang Diaz, CEO of Ad Astra Rocket Company; Debbie Haught, U.S. DOE; John Love, New York State Energy Research & Development Authority; and Steven Eckroad, Electric Power Research Institute.

Albany HTS Cable Project; development work in the superconducting fault current limiter (SFCL) device that improves power quality and grid reliability; the achievement of world-record magnetic field strengths in magnet coils; and ongoing efforts to demonstrate the technology in other fields.

“As our nation works to address the shortcomings of our utility infrastructure, the efforts underway at companies such as SuperPower are critical to providing new and improved methods of generating, transmitting and distributing the power we need to meet our daily needs at home, work and play,” said New York Congressman Paul D. Tonko. “Federal and state support of SuperPower’s work have enabled this success and we recognize that, with a period of continued support over the next few years, we can ensure U.S. leadership in the adoption and commercialization of the technology as well.”

CommScope to stop manufacturing in Omaha, will relocate production U.S.-based CommScope, Inc., announced that it plans to discontinue operations at its Connectivity Solutions Manufacturing, Inc. (CSMI) subsidiary in Omaha, Nebraska, relocating manufacturing to one or more existing CommScope facilities in North America, a move that will result in the loss of about 400 jobs.

“A combination of difficult circumstances, including

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

10 | WIRE JOURNAL INTERNATIONAL

Germany’s nkt cables acquires Australian cable distributor At its website, Germany’s nkt cables announced that it has acquired Aussa Power Products Ltd., an Australian cable distributor based in Brisbane, Queensland.

“Through this acquisition, nkt cables gets access to the Australian and surrounding markets, especially in the fields of medium-voltage cables, high-voltage cables and accessories,” said nkt cables group CEO Dion Metzemaekers. He added that nkt cables will also be able to perform high-voltage turn-key projects in the region, combining nkt’s industrial expertise and production resources in Europe and China with “the excellent

workforce and management of Aussa Power Products.”

The announcement noted that Aussa Power Products Ltd. has been a distributor for nkt cables, including medium-voltage cables from nkt cables’ factory in China and medium- and high-voltage accessories from nkt cables’ factories in Germany. It added that, besides having a highly competent sales force, the Australian company has a very capable high-voltage installation team.

McDermott subsidiary gets a project first in Asia Pacific market U.S.-based McDermott International, Inc. announced that its J. Ray McDermott, S.A. (J. Ray) subsidiary has been awarded its first Subsea Infrastructure, Umbilicals, Risers & Flowlines (SURF) project in the high-growth Asia Pacific market.

The milestone contract calls for J. Ray to supply PetroVietnam Exploration & Production with new production and export lines, and the umbilical and subsea cable, including the engineering and installation, a press release said. The project includes tie-in, testing and precommissioning of two 2.2 km flexible flowlines, replacement of two 2.3 km export flowlines and umbilical, installation of a subsea cable and 4.8 km of insulated flexible flowlines.

The offshore installation is expected to commence in the third quarter of 2011, the release said. The Dai Hung oilfield, operated by PVEP, is located in Block 05-1A, approximately 250 km offshore Vietnam, in a water depth of about 110 meters, it said.

General Cable Corporation likely to cut back New Zealand operations U.S.-based General Cable Corporation may make substantial cuts at its operations in New Zealand, where wire stories report that the union expects some 100 jobs to be cut.

The company, based in Christchurch, has declined to confirm those reports, the wire stories said, but its managing director, Chris Birkett, has been quoted as saying there would be a reduction in the workforce in 2011, although he indicated that he was not in a position to give a number at that time.

The subsidiary, which has about 350 employees at the plant and about 80 elsewhere, produces energy and communications cables and building wire-type products.

The New Zealand and Australian businesses are run from Christchurch.

According to the reports, the New Zealand activities of General Cable have not made money at an operating income level for the past two years due to factors such as margin pressure and volume reductions in some markets.

“I believe we have to take corrective action to have a

MAY 2010 | 11

INDUSTRY NEWS

facility underutilization, high labor costs, customers’ spending slowdown and their demand for lower-cost products, is causing CommScope to commit to alternative manufacturing options in order to satisfy customers while protecting the profitability of our business,” said CommScope President and CEO Eddie Edwards. “These actions are difficult yet unavoidable, and we regret the hardship on our employees.”

The company currently employs approximately 400 people in its CSMI subsidiary in Omaha, all of whom will be affected by the manufacturing relocation, the release said. Another 70 employees in non-manufacturing corporate functions, who currently are housed in the CSMI facility, are expected to relocate to a new Omaha location prior to the plant’s closing, it said.

The news follows a recent announcement from the company, a major supplier of infrastructure solutions for communications networks, that it would relocate cable production from its facility in Newton, North Carolina, a move that will result in the loss there of approximately 85 hourly and salaried employees. In January, CommScope had announced that it would analyze its options for the Omaha manufacturing facility.

“We are in the midst of a review of our global manufacturing footprint as we work to improve facility utilization, minimize cost and improve service to our global customers,” Edwards said. “As we transition production, we intend to ensure that customers continue receiving the superior service they have come to expect from CommScope.”

The release said that ComScope expects annualized pretax savings of approximately $18 million to $22 million upon completion of relocation and closure of the facility in late 2011. The company expects to incur total pretax restructuring costs of $45 million to $53 million to complete this facility relocation, including: employeerelated costs of $35 million to $40 million; impairment charges of $8 million to $10 million related to the Omaha facility; and equipment relocation costs of $2 million to $3 million, it said.

INDUSTRY NEWS

sustainable manufacturing presence. We need to change.

This is a response to that,” Birkett was quoted as saying.

On the positive side, Birkett said in the reports that plans call for a $5 million investment in the Christchurch plant, which would be reduced in scale, but would have its productivity improved and be made more responsiveness to market demand. The manufacture of some lower margin products made for the Australian market would be transferred to plants the company had in Asia, he said. “We have a multi-national company investing capital into New Zealand because we believe there is a sustainable future. That’s a very positive sign for manufacturing in New Zealand.”

Part of the transformation, the reports said, would involve consolidating two smaller sites in Christchurch into two larger manufacturing units in the city.

Tokusen on target to start production at Scottsburg facility in August Tokusen U.S.A. Inc. confirmed in late April that it is on schedule to commence wire production this August at a plant in Scottsburg, Indiana. A company official said that the schedule was still good and that there was nothing to add to the previously released information that was

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presented in Inside Indiana Business, which noted the following.

Tokusen U.S.A. plans to establish a wire manufacturing plant in Scottsburg that will create up to 134 jobs by 2012. The company is investing $24.5 million to purchase and equip a 300,000 sq-ft vacant facility in Scott County to manufacture sawing wire, which is used to slice silicon ingots for the solar energy industry. It plans to hire people for manufacturing, supervisory and clerical associates.

“The Tokusen Group, which operates wire manufacturing plants in Japan, China and the United States has been experiencing growing demand for sawing wire to support the growth in demand for solar panel manufacturing,” said Hiromi Kanai, chairman of Tokusen U.S.A. “Plans to expand the group’s production capacity have been under way for some time. With the help of the state, we were able to purchase and upgrade this existing facility to meet our production needs more economically than expansion of our other facilities.”

The Indiana Economic Development Corporation offered Tokusen up to $1.1 million in performance-based tax credits and up to $75,000 in training grants based on the company’s job creation plans. The city of Scottsburg

2 Marmon Group companies join together to form a single entity Hendrix Wire & Cable and the Kerite Company, which both manufacture utility cable products, have joined to

form a single entity called Marmon Utility LLC. “This change brings together two premier manufacturers who have served the utility industry for many decades,” a press release said. It added that the two underground divisions at both companies have also been integrated into a single business unit called MV Underground Cable.

The forming of the division of Hendrix and Kerite, respectively located in Milford, New Hampshire, and Seymour, Connecticut, will allow customers to have access to both TRXLP and EPR insulation on primary cables through the same sales channel, the release said. It noted that the deal “is a true integration that will combine the best of both underground cable units.” The division’s benchmark products are 15kV, 25kV, 35kV primary underground distribution cables.

Both Hendrix and Kerite are ISO 9001-certified and are member companies of The Marmon Group, an international association of more than 125 business units that operate independently within diverse business sectors. Member companies have collective revenues of $7 billion. The Marmon Group is owned by Berkshire Hathaway, Inc.

MAY 2010 | 13

INDUSTRY NEWS

will also provide additional property tax abatement.

“This is really a blessing for our city and Scott County for Tokusen to start this operation here,” said Scottsburg Mayor William Graham.

The Tokusen Group, based in Ono City, Japan, is a global supplier of specialty wire products for the automotive, medical and semiconductor manufacturing industries. Annual sales of steel cord and saw wire from its plant in Arkansas are in excess of $80 million.

Customers include automobile tire manufacturers such as Michelin, Continental, Yokohama, Toyo, Bridgestone and Cooper.

Tokusen U.S.A., Inc. operates out of a 400,000 sq-ft manufacturing plant in Conway, Arkansas. At its website, the company notes that the company has never had a force reduction or layoff at its Conway plant, and that the company has had nine plant expansions since locating there.

INDUSTRY NEWS

includes an analysis and forecast of SCS spending by 17 different vertical markets, such as healthcare, retail, manufacturing, finance/insurance services, etc. The A new report from U.S.-based FTM Consulting, Inc., analysis, it said, â&#x20AC;&#x153;combined federal government data projects that the structured cabling systems (SCS) market statistics for the individual industries (number of will grow at a compound average annual growth rate of employees, number of firms, etc.) with FTM Consultingâ&#x20AC;&#x2122;s 13.1% through 2015. vast database on the SCS market.â&#x20AC;?

A press release said that the report, â&#x20AC;&#x153;Vertical Market One study finding is that healthcare looks to be the Analysis of the Structured Cabling Systems Market,â&#x20AC;? leading vertical market customer for SCS products in 2010. The release noted that projected healthcare spending of $680.7 million would account for nearly 13% of the total 2010 SCS market. After healthcare, state government is the second largest sector, with an 11.8% share, followed by the retail sector, with an 11.6% share. The other two leading sectors include professional and technical services at an 8.7% share and manufacturing with an 8.4% share. These five vertical sectors, it noted, account for more than half the SCS market in 2010.

The study, the release said, includes projections for the same market share data for 2015 as well as vertical share data for UTP cabling and fiber cabling. â&#x20AC;&#x153;As a result, unique data, such as the leading vertical sector for fiber cable usage in 2010 and 2015, is provided in this study.â&#x20AC;?

The release added that the report addresses a wide range of topics, with some questions that are answered in the report including the following: What is the largest vertical market for UTP copper cables and fiber cables? How large is the SCS market for healthcare, retail or manufacturing? What will be the largest vertical market for fiber cables in 2015? Which are the primary vertical markets to target in the future? For the healthcare sector, how large is the SCS market â&#x20AC;˘ Ship Ship unassembled unasse ss s mbled re reels eels ee eels for LANs., for data centers, for â&#x20AC;˘ Save Sa S av av ve e on on freight ffrrei re ght costs costs os sts sts s VOIP? What will be the impact of â&#x20AC;˘ 14" and and 16" 16" ďŹ&#x201A;anges ďŹ&#x201A;anges s with w th 5" wi 5" barrels barrel barr rels emerging technologies (100 Gbps â&#x20AC;˘ Any Any y tra ttr traverse ra rav ave v rs se availab available av vailablle va e now, 1000 Gbps in the future) on â&#x20AC;˘ 10-second 10-se eccond assembly e ass sembly y wit w with th n th no o tools to oo ols the future SCS mark?

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14 | WIRE JOURNAL INTERNATIONAL

A recent article in TD World Transmission & Distribution World (tdworld.com) considered the outlook for utility poles for electricity distribution presented a range of perspectives about use of utility poles for that largely agreed that such poles (whether wood or otherwise) will be around, but it was most memorable for how it reflected that there can be a demand for a product that seems to make a lot of senseâ&#x20AC;&#x201D;until one factors the cost. Further, that sometimes even if you can get what you want it may not be exactly what you thought, and those ubiquitious poles someday may not be so bland.

One power company engineer said he believes use of underground cable delivery will increase, but most bulk power transfer from substations to load centers will continue to be by overhead lines on poles. Others said that while the concept of underground cable appeals, when it comes to actual projects, including for new communities, overhead lines often win because of the extra cost.

For transmission lines, the cost differential for Be it for power transmisburied versus overhead sion or distribution cable cable can cost 10 times lines, wooden poles are more, while it is less for likely to be employed for distribution although still years to come. substanially more than overhead, with prices varying greatly depending on the location and new versus replacement.

The article noted that even if a community wants to convert to buried power lines, those lines may well be overhead until they reach the borders where buried cable would begin, meaning that the buried section would still be vulnerable to overhead outages. Further, buried cable lines may have fewer outages, but those that do occur often last longer as repairs are more compex.

While more underground power lines may be used for new communities, poles are not going away. If anything, poles will get taller because rising power demand means they have to offer more. Already, there are pole extensions. What may happen, one contributor said, is that pole designs will change, anticipating new measures to prevent avian electrocutions and the accommodation of solar panels and antennas for wireless communication.

Power lines are likely to be a mode for developing countries, one expert observed, as overhead distribution remains the simplest and most cost-effective mode.

INDUSTRY NEWS

Utility poles are quite likely to be standing tall for many years to come

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MAY 2010 | 15

INDUSTRY NEWS

Sjogren expands presence in Europe U.S.-based Sjogren Industries, Inc., has expanded its sales territory throughout Western Europe through a partnership with P/A GmbH. A press release said that P/A GmbH, located in Ludwigsburg, Germany, and headed by Sales Manager Armin Losch, will represent Sjogren’s product lines, which include roll straighteners and replacement grooved rolls, wedge grip wire pullers, assemblies and replacement parts, permanent magnet brakes and clutches and roller guide units as well as stock parts for commonly used standard models.

The release said that P/A GmbH, founded in 2000, as an extension of U.S.-based P/A Industries Inc., a supplier to the press automation field of payoff, feeding, straightening and cutting equipment for strip and wire since 1953.

Thomas & Betts acquires supplier of cable protection U.S.-based Thomas & Betts Corporation (T&B) announced that it has agreed to acquire PMA AG, a privately held Swiss manufacturer of advanced cable protection systems, for approximately US$120 million.

“PMA is an excellent fit with our existing portfolio of leading industrial products,” said T&B Chairman and CEO Dominic J. Pileggi. He noted that PMA has strong relationships with leading global industrial OEMs and industrial distributors throughout Europe as well as in the Middle East and Asia, which will help T&B extend its access to those key, growing industrial markets.

PMA, which reported 2009 sales of about US$45 million, manufactures polyamide resin-based flexible conduit and fittings used in a broad variety of industrial applications to protect energy and data cables from external forces such as vibration, heat, fire, cold and tensile stress, the release said.

TELE-FONIKA reports contracts Poland’s TELE-FONIKA Kable reports that it has won two contracts, one from a Swedish energy company and the other a Polish coal mining business.

The first contract calls for TELE-FONIKA to supply Vattenfall AB, a Swedish energy company, with various types/sizes of low and medium voltage cables up to 30kV during 2010-201. The second contract calls for the company to supply Kompania Weglowa S.A,, described as the largest mining company in Europe, with cables and electrical power wires in 2010 for use in underground mine pits and in the above-ground area of mines. The deal, it said, is worth in excess of 11 million euros.

(Continued)

16 | WIRE JOURNAL INTERNATIONAL

INTERNATIONAL TECHNIC AL CONFERENCE

M O N R E Y SAVE THE DATE

Photos courtesy of the Monterrey Department of Tourism.

T E R 18-20 O CTOBER 2010 M ONTERREY, N.L. M EXICO | C ROWNE P L AZA H OTEL Wire and Cable Technical Program | Tabletop Exhibits | Networking

Venture to a place where wire and cable best practices and technological answers are much more than theory. And leave with ideas you can put into place immediately. Join WAI and educational sponsor ANTAAC for the 2010 International Technical Conference that will leave you both informed and inspired.

Learn more at www.wirenet.org or contact WAI’s educational director, Marc Murray at mmurray@wirenet.org; Tel.: 001-203-453-2777, ext. 121.

Conference organized by:

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Sweden’s Skaltek AB has won the Century International Quality ERA Award in recognition of its business leadership in Sweden. The award is based on the criteria of the QC100 quality model, implemented in over 100 countries, and is designed to recognize the prestige of outstanding companies, organizations, and businessmen in the business world. Skaltek, founded in 1973, specializes in creative approaches to advancing packaging technology. The award was highlighted by IDEAS B2B magazine, which featured company founder and Feneral Manager Öystein Skalleberg on its cover. ... U.K.-based Bridon International Ltd., a specialty wire rope manufacturer, reports that it will partner with Cosalt International, suppliers of safety equipment and inspection services.

Becoming Cosalt’s preferred U.K. wire rope supplier will enhance Bridon’s U.K. land and marine distribution reach, it said. Bridon provides steel ropes for the operational use of container cranes, tower cranes, mobile cranes, dockside cranes, and piling and dredging applications. ... The U.S. International Trade Commission will “re-hear” an AD investigation on wire rod from Trinidad and Tobago. The body announced that a federal court has ordered a second remand of its final determination regarding the antidumping duty investigation (No. 731-TA-961) of carbon and certain alloy steel wire rod from Trinidad and Tobago. The ITC had reached a negative finding. ... Trapeze Networks, a Belden brand, announced it has won a Wi-Fi Alliance 2009 Outstanding Leadership and Contribution award.

The Wi-Fi Alliance is an international non-profit organization with global marketing, technology and advocacy programs for Wi-Fi. ... SEA Wire and Cable, Inc. reports that it and JKM Manufacturing, Inc., are collaborating on lean manufacturing initiatives “to identify and eliminate waste in their collaborative and administrative processes, with the goal of improving responsiveness to customers’ needs and lowering costs.” ... Belgium’s NV Bekaert SA reports that it has

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MAY 2010 | 19

INDUSTRY NEWS

News briefs

INDUSTRY NEWS

completed the acquisition of two Bridgestone tire cord plants: BSSH, Huizhou (Guangdong Province, China) and BMI, Sardinia (Italy). As part of the transaction, Bekaert and Bridgestone have also entered into a long-term supply agreement of tire cord to Bridgestone. ... A product from U.S.-based Southwire Company, Proof Positive Copper with Trace ID Technology, was named the Grand Winner for the 18th Annual Georgia State University Marketing Awards for Excellence (MAX Awards). The technology is an identifiable, traceable bare copper product designed to provide proof of ownership to utilities and recyclers struggling with copper stolen from substations and warehouses. Further, it did not take long to prove its value. The company notes that during initial testing at a Georgia Power substation in Atlanta in early 2009, the copper was actually stolen. Within two weeks, A “Proof Positive” Southwire cable. the thieves

tried to recycle it, but employees at Schnitzer Southeast, the recycler, were able to identify the product and confirm the rightful utility owner. They notified law enforcement and the thieves were caught. ... Earlier this year, leaders from 10 global companies met in London to announce publicly the formation of the “Friends of the Supergrid” (FOSG). The new body was created “to progress policy towards the construction of a pan-European Offshore Supergrid.” Through the combination of their respective areas of expertise, the FOSG members have unique insight into the policies needed to create the Supergrid and have the capability to deliver it in practice, a press release said, noting that FOSG “combines companies in sectors that will deliver the High Voltage Direct Current (HVDC) infrastructure and related technology, together with companies that will develop, install, own and operate that infrastructure.” Founding members include 3E, AREVA T&D, DEME Blue Energy, Elia, Hochtief Construction AG, Mainstream Renewable Power, Parsons Brinckerhoff, Prysmian Cables & Systems, Siemens and Visser & Smit Marine Contracting. ■

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ASIAN FOCUS

ASIAN FOCUS Bekaert expands India presence ...

Belgium’s Bekaert N.V. further expanded its presence and technical capabilities in India with the opening of the Bekaert India Technical Center, which is located in Ranjangaon, near Pune.

HRH Prince Philippe (r) of Belgium was one of the dignitaries at the inauguration ceremonies.

“The progressive growth of our activities in India is a good illustration of the potential the country has to offer,” said Baron Paul Buysse, chairman of the Board of Directors of Bekaert. “With the creation of the technical center and the planned expansions of our current capacity, our Indian operations will play an increasingly important role within the global manufacturing platform of Bekaert.”

The Technical Center, a press release said, will support Bekaert’s customers in India with enhanced technical services in the form of product quality testing, technical assessments and related dedicated assistance.

The new Bekaert India Technical Center.

Among those in attendance for the event were HRH Prince Philippe of Belgium; Steven Vanackere, Belgian Deputy Prime Minister and Minister of Foreign Affairs and Institutional Reform; and Buysse. The delegation visited the plant in the framework of the Belgian Economic Mission to India, a press release said. Geert Roelens, Bekaert Group Executive Vice President Steelcord, said that the investment was an example of the company responding to increased demand for steel cord reinforcement solutions in India that stems from more demand for radial tires. “By providing technological support and a state-of-the-art testing facility tailored to local needs, we are ideally positioned to set up joint development programs with our customers,” he said.

The release said that Bekaert has been active since 1988 in India, where it operates its regional headquarters and three manufacturing plants (located in Pune, Ranjangaon and Lonand) with a workforce of more than 500 people. It noted that Bekaert produces a wide variety of steel cord and steel wire products in India, focusing “on the growing local needs of the automotive and construction markets as well as the textile and polymer industries.” In partnership with Mukand, Bekaert also produces stainless steel wire specialties, it said.

...while automotive moves to fast lane The automotive sector is a key customer to the wire and cable industry, and a recent news item on vehicles sales in India reflects the type of demand that led to Bekaert’s above cited investment.

According to wire reports, the Indian domestic auto industry was set to hit an all-time high sales figure of 12.2 million units in 2009-10, easily topping what had been the prior record of 10.1 million units in 2006-07. The growth represents more than 25% from the comparative period for 200809. Among the factors cited as fueling the strong showing were new launches, mostly in the compact car category, lower interest rates and a 4% reduction in excise duty that was part of the country’s fiscal stimulus.

Tata Motor President Rajiv Dube was quoted as saying in the reports that the results were especially impressive as the the growth over two years includes relatively flat performance in the first year. “If financing continues, as over 60% of the vehicles are purchased on finance, it is expected that the demand would be sustainable in the medium to long term though it may not be as high as this,” he said.

Another noteworthy element, the report said, was that the growth for 2009-10 is more than double what the industry had previously predicted. At the beginning of the financial year, the Society of Indian Automobile Manufacturers had predicted low single-digit growth for the sector. Later, the figure was revised to low double-digit growth following a spurt in sales during the festive months.

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

22 | WIRE JOURNAL INTERNATIONAL

Chinese cable-stayed bridge wins award The American Society of Civil Engineers has chosen the Sutong Bridge in China, the world’s longest cable-stayed bridge, as the winner of its 2010 outstanding civil engineering achievement award. The bridge, located in Nantong City, Jiangsu Province, spans the Yangtze River in China’s Jiangsu province, and has a main span measuring 1,088 meters, an article in the Daily Construction News reported. It noted that

China’s Sutong Bridge is the world’s longest cable-stayed bridge. Photo: Jiangsu Zhongtai Steel Structure Co., Ltd.

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the Sutong bridge represents the first cable-stayed bridge with a span that passes the 1,000 meter mark. The bridge also has two side-spans that are 300 meters, as well as four smaller cable spans. The article said that the bridge’s 577 meter long stayed cables were the longest ever manufactured.

China seeks to curb steel production As part of its efforts to control steel production, plans in China call for phasing out 100 million metric tons of “backward iron smelting capacity” in 2010 to 2011.

An article in Steel Guru cites, Jia Yinsong, an inspector from China Ministry of Industry and Information Technology Raw Materials and Industries division, as saying that said blast furnaces which are 300 cubic meters and below, and steel converters and electric furnaces which are 20 tons and below, will be eliminated by the end of 2010.

Furthermore, it said, blast furnaces which are 400 cubic meters and below, and steel converters and electric furnaces which are 30 tons and below, will also be eliminated by the end of 2011.

The goal, the article said, was to prevent unauthorized construction of iron and steel projects that create problems such as overcapacity, irrational industrial distribution, low concentration, and weak resource control, among others. ■

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MAY 2010 | 23

ASIAN FOCUS

ASIAN NEWS BRIEFS

PEOPLE

PEOPLE U.S.-based Guill Tool & Engineering, Inc., has named Stephen Blanche as the company’s sales manager for New England as well as New Jersey, New York and Pennsylvania. He had been national sales representative manager, and the move was made to help the company focus its new business efforts in its home region, with a focus on Stephen Blanche advanced medical and industrial tooling markets. He has more than 30 years of experience in sales and operations management, including serving as president of ETCO Cord Products, an electrical terminal manufacturer based in Warwick, Rhode Island. He has extensive experience with the Phillip Crosby Principles of Quality Management and holds six patents for electrical terminal products. He holds B.S. and M.A. degrees in technical education from Rhode Island College and the University of Rhode Island, respectively. Based in West Warwick, Rhode Island, USA, Guill Tool & Engineering, Inc., designs and manufactures extrusion tooling for applications that include wire and cable.

Kevin Slusarz has been named director of product development for U.S.-based Cable Components Group (CCG), responsible for the company’s research of high performance materials and fabrications using fluoropolymer resins and flame and smoke retardant compounds. He will also oversee the applied development of monofilaments, FluoroSpun® fluoropolymer Kevin Slusarz non-wovens and staple fibers, and FluoroFoam® chemically foamable perfluoropolymers and fluoropolymers. CCG’s staff of process engineers, technology consultants, technicians, and CAD design draftsman will report to Slusarz. He has 20 years of experience, including 17 years at Davis-Standard, where he held positions as a senior process consultant, process development engineer and senior process engineer.

Prior to that, he spent three years at Allied Signal, Inc. He holds B.S. and M.A. degrees in chemical engineering from Stevens Institute of Technology. Based in Pawcatuck, Connecticut, Cable Components Group (CCG) designs, engineers, and manufacturers high performance extruded products for the wire and cable, fiber optic and industrial non-woven markets.

AEI Cables has named Ian Watts as a project manager.

He will focus on developing cable design solutions for existing and prospective customers including specialists in the fire performance sector. He has 27 years of industry

24 | WIRE JOURNAL INTERNATIONAL

experience, working a wide range of cabling, including fiber optic, general wiring, data cabling and fire performance cable systems. Past employers include the former BICC Cables, Balfour Kilpatrick and Tyco Thermal Controls UK. Based in the U.K., and part of Paramount Communications Ltd., one of India’s largest cable manufacturers, AEI Cables is provides cabling solutions for sectors that include construction, defense, industrial, fire protection, mining, oil and gas, power and rail.

After a brief absence in 2009, Andrew Depue has rejoined JoeTools as sales engineer, responsible for management of special projects along with the expedition of production orders, quality control processes and product delivery and the company’s process engineering training program. He began with JoeTools in 2008 as inventory control manager, then in Andrew Depue 2009 became a sales associate for Cisco Chemicals in Charlotte, North Carolina. He is a graduate of The University of Georgia and served in the U.S. Marine Corp Reserves, including a year of active duty in Iraq. Based in Lilburn, Georgia, USA, JoeTools is a full service, design and manufacturing resource for crossheads, tips, dies, screws, barrels, breaker plates and accessories.

Rebecca Mertens, a sales assistant at the Wisconsin office of Allied Wire & Cable, has been promoted to a sales representative. She will be in-house, helping customers with the company’s full line of products. She began at Allied in February 2007 as a sales assistant. Based in Collegeville, Pennsylvania, Allied Wire & Cable is one of the largest privately owned Rebecca Mertens value-added manufacturers and distributors of electrical wire and cable products in the U.S., with offices in Florida, New Hampshire, South Carolina, Tennessee, Texas and Wisconsin, along with several warehouses across the country.

Bridon has announced the appointment of Jonathan Templeman as the company CEO. He was previously CEO with ESAB Global At Bridon, he will be asked to develop a strong vision and strategy that will provide a development framework for the company over the next five years as well as reinforce its brand and worldwide position. That is likely to include expanding the sales force, especially for the emerging markets, and strengthening the technical and customer service teams. Based in Doncaster, U.K., Bridon

Elgin Fastener Group has reached agreement with Carl Bailey to represent the company in the states of Colorado, Utah, Wyoming, Montana, and Idaho. He has 36 years of experience, with past employers including Hitachi, Makita, San Groban, Yamashima International and others.

He holds a degree in marketing from the University of Utah. Based in Carl Bailey Versailles, Indiana, USA, Elgin Fastener Group is composed of four domestic industrial fastener manufacturers (Ohio Rod Products, Leland Powell Fasteners, Chandler Products, Precision Screw and Bolt) with an engineering and international procurement division (Elgin Fasteners International) and a metal finishing company (Best Metal Finishing).

Nordson Corporation reported a number of executive appointments for its Adhesive Dispensing Systems Group.

George Porter, currently manager, market development & key accounts, will be promoted to vice president, North American adhesives sales and service, reporting to Peter Lambert, senior vice president, adhesive dispensing systems. David Titone, director of sales for Nordson EFD, will relocate to the Atlanta area and assume the position of director, business development and sales operations, reporting to Porter. John Schnarr, currently general manager at Nordson Canada Ltd., will be promoted to director, strategic marketing, relocating to the Atlanta area and reporting directly to Lambert. Alan Ramspeck, currently product line manager, will be promoted to manager, product management. Based in Westlake, Ohio, USA, Nordson Corporation is a global supplier of precision dispensing equipment.

Beta LaserMike has appointed V. Kumar as its country manager in India, operating out of the companyâ&#x20AC;&#x2122;s office in Gurgaon near New Delhi. He is charged with increasing awareness about the company and its products, increase sales, identify channel partners, conduct training programs and service existing customers. Based in Dayton, Ohio, USA, Beta LaserMike is a global supplier of testing and measuring technology. â&#x2013;

MAY 2010 | 25

PEOPLE

is a leading manufacturer of specialist wire and rope solutions. It was formed in 1924 from an amalgamation of wire rope producers, and was acquired by Melrose PLC, a specialist manufacturing investor, in 2008.

FIBER WATCH

FIBER WATCH Survey: demand appears quite strong for gigabit-enabled fiber networks ...

A recent report from the Fiber-to-the-Home (FTTH) Council finds that gigabit-enhanced fiber has now been brought to more than 1.4 million homes in North America, which it notes represents about a quarter of all fiber-to-thehome connections on the continent.

A press release from the U.S. based organization said that the study, conducted by RVA Market Research, found that all-fiber networks are now available to 16 percent of homes in North America, with 5.8 million homes now receiving television, high-speed internet and/or phone service over these networks.

President of the FTTH Council, a non-profit organization of more than 200 companies and organizations dedicated to expanding the deployment of all-fiber, next-generation networks. “To continue to meet the rapidly growing bandwidth requirements for emerging applications and services, these companies know that they have to ‘future-proof’ their networks by running fiber all the way to the premises, and that’s why we are seeing all this activity.”

Savage said that Google’s plan to build gigabit FTTH networks in several cities has raised awareness of how many communities want to super-fast connections. At the same time, the survey results “show that many communities aren’t waiting and are instead taking matters into their own hands, sometimes through their local telephone or cable companies, and in some cases by operating their own FTTH network as a public utility,” he said.

... and these new fiber cables may help

A survey done for the FTTH Council predicts that demand for Fiber-to-the-Home in gigabit portions is likely to grow.

While a large portion of the FTTH deployment thus far has been due to Verizon’s $23 billion dollar investment in overbuilding its wireline service in many areas, the report noted that Fiber-to-the-Home is now being deployed by more than 750 service providers across North America, with most of those being small, independent telephone companies that are replacing their copper lines with end-to-end fiber in order to ensure their future competitiveness as broadband providers.

What may be even more noteworthy, the release said, is that the study found that more than 65 percent of small independent telephone companies that have not upgraded to FTTH said they would very likely do so in the future, with another 11 percent saying they were somewhat likely. More than 85 percent of those that have already deployed FTTH said they would be adding more direct fiber connections going forward.

“With Verizon approaching the end of its initial FiOS expansion, we are seeing a lot of small local exchange carriers in the U.S. who are ready to pick up the slack, along with some cable TV companies deploying RFoG and some larger Canadian companies going FTTH,” said Joe Savage,

26 | WIRE JOURNAL INTERNATIONAL

U.S.-based Intel announced that it plans to introduce new technology, called Light Peak, that would connect home electronic equipment with fiber-optic cables able to send data at 10 gigabits per second, speedy enough to transfer a full-length Blu-ray movie from one gadget to another in about 30 seconds.

A press release said that the new technology, which is being developed with other companies, will be able to operate 20 times faster than is possible with the USB connectors used on PCs today. Further, it said, a more advanced version of Light Peak is expected to transfer a Blu-ray movie in just three seconds. That capability, it said, will enable laptops and other electronic gear to be made thinner, while enabling consumers to hook up their gadgets at much greater distances and without cluttering their homes with the confusing array of cable types and sizes they are forced to use now.

“Our goal and expectation is that it’s the beginning of a new generation of cable connections,” Jason Ziller, an Intel director working on the concept, said in the release. The new technology will be something “everybody is going to want and need over the next 10 to 20 years,” he said.

The release explained that demand largely stems from the proliferation of electronic consumer products, from PCs, printers and scanners to smartphones, digital cameras and HDTVs. Because of the growing amount of video and other data being sent back and forth by these devices, the cables connecting them require faster and faster bandwidth, but electrical cables are approaching speed limits due to electromagnetic interference, which can disrupt what’s being transmitted, it said.

Because such interference often worsens as data are sent over longer distances, some cables now must be under 10 feet, which limits flexibility in hooking up gadgets, the release said. By contrast, fiber-optic cables are unhindered by electromagnetic interference, allowing those used in homes to be stretched more than 300 feet. ■

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WIRE & CABLE MANUFACTURING 10 ❏ Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) 40 ❏ Other Metal (Rod/Bar, Bare Wire, Both) 50 ❏ Electrical Wire & Cable (Insulated Wire) 53 ❏ Communications Wire & Cable (Insulated Wire) 55 ❏ Fiber Optics

FASTENERS, WIRE FORMING, FABRICATING 61 ❏ Fastener Manufacture 62 ❏ Four-Slide Forming 64 ❏ Hot and/or Cold Forming and Heading 66 ❏ Spring Manufacture 68 ❏ Wire Cloth Mesh Screening 69 ❏ Other Forming and Fabricating (Please specify)

WIRE END-USER 11 ❏ Appliance 12 ❏ Communications (Voice/Data) 13 ❏ Computer 14 ❏ Construction/Building 15 ❏ Electrical (Equipment/Components/Power) 16 ❏ Transportation/Vehicular 17 ❏ Wire Formed Durable Goods

SUPPLIER TO THE WIRE & CABLE INDUSTRY 72 ❏ Machinery 74 ❏ Process, Accessories, Materials

OTHER 80 ❏ Service Centers, Distributors & Warehouses 90 ❏ Consultants 92 ❏ Government, Library and allied

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10 ❏ General & Administrative Management 20 ❏ Engineering, Operations, Production

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May 2010 International Technical

Conference Proceedings

Chinese fastener show set for June The organizers of 2010 Fastener Expo Shanghai & the 1st Shanghai Auto Fastener Exhibition, scheduled for June 1619 at the Shanghai Everbright Exhibition Center (West Hall), say that the event presents a good opportunity for global buyers to learn more about the Chinese fastener industry as well as to visit the plants of some potential fastener and spring manufacturing suppliers.

As of press time, the event had more than 410 booths accounted for, while online registration of visitors had topped 5,000, a press release said. “All of them are focusing on fastener products, fastener technology. The booths selling will continue and the number of exhibitors is expected to increase a lot,” said Jin Tao, project manager of 2010 Fastener Expo Shanghai.

The Shanghai Everbright Exhibition Center will host the 2010 Fastener Expo Shanghai and the 1st Shanghai Auto Fastener Exhibition.

Under the guidance of the China General Machine Component Industry Association and sponsored by the China Fastener Industry Association/ChinaFastener.com, the event is organized by the Shanghai Ebseek Exhibition Co./Guangzhou Ebseek Information Co. Domestic supporters include: National Technical Committee Fasteners Standardization Administration; Hong Kong Screw & Fastener Council; Guangzhou Fastener Industry Association; Zhejiang Industrial Fastener Institute; Ningbo Fastener Association; Wenzhou Fastener Industry Association; Jiaxing Fasteners Import & Export Manufacturers Association; Haiyan Industrial Fastener Institute; Yongnian Fastener Association; Chongqing Fastener Association; Xingtai Fastener Association; the Shahe City General Machine Parts Office; and the Wenzhou Ouhai Fastener Industrial Association.

The event, the release said, will include fasteners such as bolts, screws, nuts, washers, rods, pins, circlips, rivets, DIY products and non-standard fasteners; auto fasteners; fastener equipment and auxiliary technology (forming machines, heading machines, rolling machines, checking machines,

twisting machines, pressing machines, soldering machines, tapping machines, heat-treating machines); fastener material (wire, strip, stamping sheet metal, stainless steel, copper and special alloy steels); mold and consumption goods; and fastener technology and service (patents, licensing services, software services, media, etc.).

The event is expected to have more than 700 standard booths, and to draw some 25,000 domestic visitors as well as 1,200 from overseas, the release said.

Contact: 2010 Fastener Expo Shanghai & the 1st Shanghai Auto Fastener Exhibition, at service@chinafastener.com, www.fastenerexpo.cn.

Black & Decker unit acquires Fastener Innovation Technology U.S.-based Emhart Teknologies, a Black & Decker Company that supplies fastening and assembly technologies, announced that it has acquired Fastener Innovation Technology, Inc. (FIT), a designer and manufacturer of critical, highly specialized aerospace fasteners based in Gardena, California.

FIT was described as manufacturer of aerospace threaded fasteners, including industry standard, customer-specific and proprietary designs for sophisticated applications. A press release said that the company has developed proprietary products in addition to special products for OEMs requiring unique fastening solutions.

“Combined with our Heli-Coil® initiatives and the 2008 purchase of Spiralock Corporation, bringing FIT under the Emhart brand enables us to integrate the finest aerospace fastener platforms into a single-source organization,” Emhart Teknologies President Michael A. Tyll said in the release.

“This acquisition allows us to better serve the aerospace, military and commercial aircraft industries where FIT enjoys a strong reputation among the world’s leading aerospace companies.”

FIT, the release said, has long-term customer relationships with Boeing, Honeywell, GE, Pratt & Whitney, Embraer, Bell and Gulfstream Aerospace Corp., based on its premium-quality products and appropriate certifications.

The company, it said, specializes in new high-strength materials such as steel alloys, titanium and super alloys.

“Production forecasted for both new and replacement aircraft through 2020 reflects the projected growth in global air traffic. The purchase of FIT positions Emhart Teknologies to further support this industry growth,” Tyll said.

The release said that Randy Aardema will lead FIT as General Manager. He recently joined Emhart from Acument Aerospace and previously was with Textron Fastening Systems.

Based in Shelton, Connecticut, Emhart Teknologies supplies unique assembly technologies from concept through installation. ■

MAY 2010 | 29

FASTENER UPDATE

FASTENER UPDATE

WAI NEWS

WAI

NEWS

Wire Foundation presents a travel scholarship for Interwire attendee The Wire Foundation recently awarded Jason Giebfried of Johnstown Wire Technologies with a Traveling Scholarship to attend the 2011 Interwire Trade Exposition.

that he was pleased with the intent behind the award. “The Wire Foundation is better known for awarding scholarships, but this is a good example of how its resources can provide very practical help,” he said.

A timely tradition continues to link the U.K. wire and cable industry and WAI On April 9, the Clockwinders held their biennial reunion dinner at the picturesque Rudding Park Hotel in Harrogate England, where Master of Ceremonies Nigel Lane expressed the importance of maintaining the tradition

From l-r, Johnstown Wire Technologies President Walter Robertson and Production Supervisor Jason Giebfried with WAI President Dane Armendariz and Wire Foundation Vice President John Bowles.

Giebfried is a production supervisor with responsibility for wiredrawing, cleaning house and bundling operations.

Johnstown Wire Technologies is a steel wire manufacturer serving a wide variety of markets including the cold heading and spring industry. The scholarship was presented to Giebfried by Wire Foundation Vice President John Bowles, Bowles Enterprises and WAI President Dane Armendariz, Henkel Corporation.

Bowles said that the Wire Foundation was impressed with Giebfried’s enthusiasm for the wire industry and his accomplishments to date in his young career. Armendariz added

The clockwinders who attended the April 9 Clockwinders Dinner included, standing l-r, Nigel Lane (2000), John Siddall (1970), Peter Siddall (1999), Peter Wilcock (1995), Ken Scott (2001), Stephen Rutherford (2003), Roger Matzen (1980) and Andrew Stacey (1994). Seated are Geoffrey Firth (1977), John Perry (2009) and Sandy Saunders (2008). Not in photo are Frank Fox (1978) and Darrell Fox (1992).

UPCOMING WIRE ASSOCIATION INTERNATIONAL/WAI CHAPTER EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org.

June 10, 2010: New England Chapter dinner meeting Warwick, Rhode Island, USA. This event will feature a presentation by Deepawater Wind’s Bill Wall on wind power. Contact: Chip Marsh, tel. 203-453-1748.

June 21, 2010: Midwest Chapter Golf Tourney West Chicago, Illinois, USA. The WAI Midwest Chapter’s 8th Annual Golf Tournament is at the St. Andrews Golf & Country Club. Contact: Chip Marsh, tel. 203-453-1748.

Oct. 18-20, 2010: WAI Mexico ITC Monterrey, Mexico. To be held at the Crowne Plaza

30 | WIRE JOURNAL INTERNATIONAL

Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities.

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

May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show and the Association’s 81st Annual Convention.

WAI’s President Dane Armendariz, his wife Karen and WAI’s Executive Director Steven Fetteroll.

The 2010 Clockwinding will be performed at WAI’s headquarters in Guilford, Connecticut, USA, by Kate Kendall of the Worshipful Company of Tin Plate Workers, alias Wire Workers on September 17, 2010. ■

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

Volunteer spotlight: WAI’s Member Relations Committee Membership is considered the lifeblood of any association, and the WAI is no exception to that axiom. The charge of the Member Relations Committee (MRC) is to help the Association manage its membership activities. It works with staff and other volunteers to identify recruitment and retention opportunities and to help develop strategies to ensure a solid membership base for the WAI internationally. It provides support to the chapter network as a means of membership and program growth for WAI, including volunteer development and identifying new chapter regions in which to expand the presence of WAI. “It’s our responsibility to help ensure that WAI is a viable organization with a membership that represents the diversity of the wire and cable industry,” said MRC Chairman Don Schollin of Q-S Technologies, Inc. “In addition to helping with recruitment and retention, one of the roles that we play is as a vehicle for input and feedback from the members, as well as nonmembers, on the programs and products offered by the association.”

Committee members have spent time in recent months contacting manufacturing companies to learn more about the issues they are facing and what needs they have that the association can help address. Some of this information is being used by the Education Committee to help plan upcoming Webinars on topics that range from practical operations practices to help on management issues.

Webinars are becoming a key feature of WAI membership, as all members have free access to both the live presentations as well as the archived ones.

“This committee is a great mix of veteran members along with some new blood which makes for good discussion in the meetings,” said WAI Director of Membership Chip Marsh, the committee’s staff liaison. “They definitely challenge each other, and the staff, to come up with

ways that help the individuals in the industry to better understand the value of WAI membership and to take advantage of the opportunities that are offered.”

WAI members are encouraged to recommend colleagues for membership in the association. Please contact any committee or staff member to sponsor a new member or to provide new ideas or feedback on WAI programs and products.

Don Schollin, chairman, WAI Member Relations Committee.

Committee Members Donald M. Dodge, Calmont Wire & Cable Paola D’Oria, Continuus-Properzi SpA Jaime Fuente, Condusal SA de CV Peter Funk, Talley Metals Ken Hardin, Southwire Co. Scott S. Higgins, Consultant John M. Kukalis, Henkel Corp.

Erik A. Macs, Fine International Corp.

Christine C. Matthias, Sonoco Molded Plastics Thomas Maxwell, Jr., Die Quip Corp.

Steven M. Montague, Leggett & Platt Wire Group Barry Mosemann, Sikora International Corp.

Lori Parent, Breen Color Concentrates Inc. Richard Pechie, Vollmer America Inc. Donald D. Schollin, Q-S Technologies Inc. (Chairman) Thomas J. Siedlarz, Plastic Equip. LLC Mark Spencer, W. Gillies Technologies LLC Andrew J. Stromer, Howar Equipment Boudewijn Vandromme, BWC Technologies Ltd. Stephen Vannais, Davis-Standard Corp.

Committee Liaisons Nick Nickoletopoulos, Sivaco Wire Group (Executive Committee Liaison) Charles H. (Chip) Marsh, WAI (Staff Liaison)

MAY 2010 | 31

WAI NEWS

as the industry continues to evolve.

The Clockwinding ceremony began in 1948 when the British wire industry presented an English long case clock, which requires annual winding, to the Wire Association in appreciation for cooperation during World War II. In attendance were 13 Clockwinders and their spouses as well as

CHAPTER CORNER

CHAPTER CORNER WAI New England Chapter to hear about wind power at June 10 meeting “Wired With Wind – a New Industry Perspective on Using Offshore Wind to Generate Power in the United States” is the topic of the next WAI New England Chapter Dinner Meeting on Thursday, June 10, 2010, at the Crowne Plaza Hotel in Warwick, Rhode Island. Bill Wall, Vice President of Marine Operations at the offshore energy company Deepwater Wind, is the featured speaker for this education and networking event.

Wall is responsible for offshore wind farm construction and marine operations, and has spent over 35 year in the marine construction and operations industry specializing in submarine cable systems both for power utilities and the telecom industry. His position prior to Deepwater Wind was as Business Development Manager for Caldwell Marine International where he completed a project for a major European offshore wind farm operator.

In his presentation, Wall will give attendees an overview of the offshore wind turbine concept and how it works, then focus more specifically on the impact offshore wind projects have on the wire and cable industry. He notes that a significant percentage of the cost of such a project is in cable and related supplies, and will discuss both the type and amount of product used as well as the technical aspects related to the project.

“The potential offered by offshore wind power generation and the role that the wire and cable industry can play in its delivery really attracted us to this topic,” said New England Chapter Education Committee Co-Chair Denise Coyle of Chromatics, Inc. “As the country focuses more on “green” sources of energy, the subject of offshore wind power presents itself as both new and potentially beneficial to our industry.”

The evening will begin at 5:30 p.m. with a networking reception followed at 6:30 by a buffet dinner and the presentation. The cost of the event is $60, discounted to $55 for WAI members and $45 for WAI Chapter members. The Crowne Plaza is offering attendees a $129 room rate in conjunction with the dinner for those who need to stay over.

Deadline for registration is Monday, June 7, 2010, and registration forms are available on the chapter webpage or by contacting WAI’s Chip Marsh, cmarsh@wirenet.org or tel.

203-453-1748.

Midwest Chapter to return June 21 to St. Andrews golf course in Illinois The WAI Midwest Chapter will hold its 8th Annual Golf Tournament, on Monday, June 21, at the St. Andrews Golf & Country Club in West Chicago, Illinois.

Last year, a total of 52 golfers took part in the scramble format tournament, where the team of Dane Armendariz, Michael Brewer and Dave Dohman of Henkel Corp., along

32 | WIRE JOURNAL INTERNATIONAL

The Midwest Chapter will return to the St. Andrews Golf & Country Club on June 21. with Michael Malwitz of Metal-Matic, Inc., turned in a tourney best score of 60.

“The 2009 Midwest Chapter outing was a huge success,” said then-Chapter President John Kukalis, Henkel Corp.

“There is no other way to put it. Everyone left with a gift and a smile on their face. There was a lot enthusiasm and the upbeat attitudes around the course allowed us to put aside the economic struggles for a day and just enjoy.”

The goal is to match that experience. The event includes a reception and dinner as well as the golf match itself and the various skills contests. Sponsorships are available to help fund the event, including opportunities for the $10,000 holein-one; Closest-to-the-Pin; long drive; most accurate drive; and the popular putting contest.

The tournament helps benefit the WAI Midwest Chapter Scholarship Fund which, with the Wire Foundation, provides two $1,000 scholarships annually. For more details, contact WAI’s Chip Marsh, tel. 203-453-1748, cmarsh@wirenet.org. ■

WAI

CONTACT INFO

Steven J. Fetteroll, executive director 203-453-2777 x 115, sfetteroll@wirenet.org David B. LaValley, treasurer 203-453-0593, dlavalley@wirenet.org Mark Marselli, editor-in-chief 203-453-2777 x 132, mmarselli@wirenet.org Charles H. (Chip) Marsh, membership director 203-453-1748, cmarsh@wirenet.org Marc Murray, education director 203-453-2777 x 121, mmurray@wirenet.org Janice Swindells, director of marketing services 203-453-2777 x 117, jswindells@wirenet.org Robert Xeller, director of sales 203-458-7578, bxeller@wirenet.org

FEATURE

New & specialty products

ow do new products come about? What makes specialty products special? WJI

H

plans to focus more on specific sectors and trends in future issues, but this story

focuses on the “big picture” thinking of company leaders. It presents comments from three manufacturers and an example of a development timeline for one new product.

It also includes a look at demand for one cable product beyond its traditional core use as well as observations from an industry analyst.

Leoni Group: company is innovative and driven beyond the automotive sector Germany’s Leoni AG is best known for the automotive sector, but about a third of its wire, cable and wiring systems business is outside that area. The Leoni Group as a whole has some 50,000 employees and annual revenues topping US$3 billion. The Conductors & Copper Solutions Business Group has about 600 employees at six plants (three in Germany, one in China, one in England and one in the U.S.) that manufacture a wide range of wire, some of which is used for special cables and heating systems, round stranded copper flexible and braided copper tapes and other special products, its “Sun Wire” product for solar energy being among its newest. Markus Thoma, a managing director of Leoni Draht GmbH, and senior vice president for the Conductors & Copper Solutions Business Group, spoke to WJI about how his division approaches product development.

WJI: How does your division decide when to update existing products and how long does this process take?

Thoma: Our day-to-day customers tell us what they need through our our sales and technical staff in the field.

It can be as simple as changing the outside diameter or the lay length. We call such work “renovation” rather than innovation. We probably do more than 300 such changes a year, and while we are responsible for some, in most

34 | WIRE JOURNAL INTERNATIONAL

cases they are motivated by customer requests. These are not so difficult, and the average time from getting a request to presenting a sample can be two to eight weeks, with a customer’s approval often from four to 12 weeks.

WJI: What about new products? How important are they and what aspects do you consider?

Thoma: New products are crucial to secure economic success of our company. Since all products are subject to a specific lifecycle, they will come to an end sometime.

That’s why new products need to replace them and bridge

Leoni AG’s Markus Thoma displays the company’s “Sun Wire” at wire 2010.

WJI: Ultimately, how are decisions made? Is this strictly a matter of numbers?

Thoma: We are very much engineering-driven, and engineers love to plan ahead, and that’s one of the big differences between renovation, which comes from people in the field who have to take care of fires every day, and innovation, which is all about planning ahead. There will always be a need to take risks, but careful planning is the key to success.

WJI: What percentage of new product concepts turn to reality? And, from concept to commercial production, how much different may the actual product to market be from what was initially considered?

Thoma: For every 10 products in the innovation funnel, we usually end up with one or two products. As for how a proposed product may evolve, we usually stick quite closely to the original concept. The reason is that we do extensive research and precise plannings. Of course, the degree of modification also depends on how accurate the

Integer Research: product perspective U.K.-based Integer Research provides a range of industry reports as well as independent and confidential research and consultancy about the global wire and cable industry. Below, director Philip Radbourne discusses the role and potential for new and specialty products.

WJI: Looking at the wire and cable industry as a whole, how much production is for what is considered special products versus commodity products?

Radbourne: The cable market is made up of a range of wire and cable products. In 2009 the total industry was worth around US$107 billion, down from US$157 billion in 2008. You can see that copper and aluminum prices played a major part here in the total value of the industry.

You can break these down into a number of categories, power cable, building wire, magnet wire – which may be commodity products, although at some point in the past, they would have been, or might have been a specialty cable, designed for a specific customer in mind.

A large share of the total industry is commodity cable, Philip Radbourne with thousands of smaller producers in China and the rest of Asia, but elsewhere, there are producers of commodity wire and cable, but also production of a large deal of more specialized and even specialty wire and cable.

This tells you that in some sectors, notably building wire, low voltage power cable and even enamelled/magnet wire—where the cable or wire product is well covered by international or harmonised standards— the product is going to be bought on price, with some element of delivery. Quality is a given, but even here there are problems with poor quality cable, coming in from some countries, where trading standards agencies are weaker. It is something that the Chinese and Turkish cable makers are keen to crack down on too.

WJI: How do you define specialty products? Do they necessarily overlap new products, and if not, what is the difference?

Radbourne: I think if you ask a number of people in the cable sector what they define as “specialty,” they will give a number of varying answers. I think one key determinant of a specialty product is that it has either a recent design history or a specific end-use that is customerbased, with specialty or specific requirements in the cable design. Some new products, such as NZ-DSF fiber

MAY 2010 | 35

FEATURE

the gap. In the best of cases, the overall product portfolio keeps growing. When planning innovations, we mainly consider feasibility, profitability and sustainibility. We are not focusing on short-term effects, but rather try to enlarge our market-share in existing markets or to pursue new markets.

Real development of new products comes from the international management team. We meet twice a year and decide which products to pursue and where. We choose from two to six development projects a year. In most cases, they are motivated by strategic positioning, market research, mega trends analysis or individual customer demand.

Specifically, the sales department/director considers the potential profitability of the new product; its potential volume; the threat for existing products losing market share if we do not pursue this product, the opportunity it may provide us to supply the new product to other customers; and the importance of the customer who initially requested this direction. We have to consider not just what we can sell tomorrow, but how that market will look in four or five or six years. It could take 16 to 18 months to provide samples for customers, and approvals could take up to two years, so you have to be able to look at the market and have a perception of how it will grow. The cost of the investment must also be considered.

We also have to decide where a project will be done.

If there is a lot of R&D work involved, that is normally done in Germany, but that is not necessarily so. Our headquarters is not a monopoly of innovation. For instance, some wire products are for cables that are used more in the U.S. than in Europe, so it makes sense to have that work done there. Also, some innovation is not about a product itself. For instance, we can consider if we can do annealing differently or some element of a process, or both. We put this all together in our planning.

FEATURE

cable or even copper telecom cables using DSL technology are defined by development in technology. Even the development of double copper screened coaxial cable for HD SATV systems, is really just a more expensive version of an existing design.

WJI: Are specialty/new products inherently more profitable, or is it possible that the start-up cost/R&D requirements and competition can make it hard for companies to make a profit in even a “hot” sector, such as power transmission cables?

Radbourne: Specialty products should be more profitable, given that an end-user should be willing to pay more for their cable, given that they have specific or tougher requirements than the minimum standards. Yet, profitability also depends not only on unit price of cable, but also selling costs. If the costs of winning that really good specialty cable order are added to high selling costs, then profitability might not be that high.

We often see that there are some producers that make good margins, but that really is because they are really good at cable making and innovative and efficient at serving their customers, whatever the product mix.

WJI: What percentage of cable companies do you believe compete in specialty products?

Radbourne: As a percentage of total cablemakers it is less than 10%. There are always a number of smaller building wire producers in many markets, which skew the sample away from specialty. In other markets, which have consolidated, you have some larger players, such as Southwire in the U.S., and Wilms in Europe, which are very lean operations, selling mostly commodity type products. But even here both companies also innovate and produce new products to very high standards.

WJI: Has the specialty cable market been fairly constant or do you see it becoming increasingly important?

Radbourne: As a share of the market, specialty has become a smaller part of the industry in recent years, as we have seen the take-off in demand from the Middle East and China, and now other parts of Asia.

We do however see many of the leading North American, Western European, Japanese, South Korean and Taiwanese cable makers moving into China, where they are able to serve this small but developing market in China for specialty cable. You are also beginning to see a number of key Chinese cable makers emerge – such as Far East Holdings, that are also producing a range of sophisticated cables. There are even producers of submarine power cable in China, shipboard cable, and cable producers that are running E-beam machines, cross linking electronic cable and power cable for military and even nuclear power cable applications.

36 | WIRE JOURNAL INTERNATIONAL

customer’s specifications and demands are. That’s why we stay in close contact with him as early as possible.

WJI: Can you provide an example of one product that has gone through this process?

Thoma: Our Sun Wire product, which was introduced at wire Düsseldorf, is a good example. This product collects the electrons on the photovoltaic solar wafers. It is a flat copper wire that is both environmentally and ecologically friendly, going through a responsive dip-plating process without any toxic flux. The base material is CuETP or Cu-OF; it comes in thicknesses from 0.08 to 0.40 mm and in widths of 1.2 to 5.0 mm. It has extremely high elongation (> 25%) and low yield strength (< 80 N/mm²).

The solar energy market is very strong and in our Business Group we first began planning for this industry in 2007, including market research, technical feasibility studies and product development. The pure development process started mid-2009 and was already completed in March 2010. By the way, it was performed in accordance with ISO TS 16949. The timetable for our new Sun Wire product (see opposite page) shows just how many steps can be involved. A few other examples are highly sophisticated conductors that have a 2 μm silver plating that prevent “red plague” effects, nickel-plated CCA aircraft ropes, and water-blocking strands using swellable yarn fillers that have exceptional resistance to water seepage.

WJI: Has the current weak economy impacted your new products introduction?

Thoma: A company can choose to save expenses not directly related to actual sales by reducing Research & Development investment and cutting development staff.

Leoni, however, has chosen to intensify the company’s development activities by challenging the existing R&D staff to provide strong results by being more effective within the parameters of a reduced budget. It would be simple to save money by reducing any investment in new equipment/assets, but Leoni has continued investment in new technologies, such as an environmentally friendly dip-plating process. We believe in investing where it makes sense for our customers and our long-term success.

WJI: Is there anything else you would like to note about the role of new product development?

Thoma: On the one hand, every development process implies an economic risk, because you can never be 100 percent sure about the future market penetration of your new product. On the other hand, innovation is necessary in order to comply with the needs of evolving or emerging sales areas. We consider continuous development, focused both on customer and future market requirements, to be key to success for our company. When we see new opportunities, we try to minimize risks with the help of extensive research and analysis before going into product development. In the past, this strategy has worked out very well.

FEATURE NR. 1 2 3

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Timeline for sun wire development. Extensive market demand forced the Leoni AG team to accelerate the development phase for its â&#x20AC;&#x153;sun wireâ&#x20AC;? product. This effort was possible due to the transfer of existing company knowledge, which included flat rolling that had been developed for extruded flat cables (exFCâ&#x201E;˘) and Leoniâ&#x20AC;&#x2122;s experience in hot-dip tinning. That, along with an intensive feasibility study of the process, supported a well-educated and motivated development team tasked with this project. The core team, which included two engineers, one technician and one sales representative, were supported by central services, such as quality management. This team effort resulted in the product being successfully completed on a â&#x20AC;&#x153;rushâ&#x20AC;? schedule.

MAY 2010 | 37

FEATURE

Specialty Cable Corp.: out of the ordinary is very ordinary for this U.S. cable maker Based in Wallingford, Connecticut, USA, Specialty Cable Corporation (SCC) focuses on special products, designing and manufacturing cables for demanding customers who may have needs for cables that can withstand temperatures from -150°C to more than 1400°C. The company, a former Pirelli Special Cables Division, has some 60 employees who produce cables for end uses as diverse as aircraft engine control systems to delicate wires for fetal heart monitors, using materials from ceramics and kapton to mica and fluoropolymers. As company CEO Kim Bowen explained, “Our products absolutely cannot fail.” Jim Streifel, vice president of sales and marketing, spoke to WJI about their operations and the need for specialty products.

WJI: How has your field most changed over the years, especially in terms of how you work with customers in product development?

Streifel: Customer partnership is very important to us.

It enables us to anticipate and satisfy their needs. If we understand their product needs, we can help in assuring their new product development is a success and meets all very long from order to shipment. This used to be accept-

sizes range: 0.827”- 0.001” quantities: from 10ft profile: any shape resistance wire: all materials

Specialty Cable Corporation Vice President of Sales and Marketing Jim Streifel (l) and CEO Kim Bowen. able, but with the increase in technology, whether it is in communication, MRP systems, to manufacturing equipment and/or transportation, customer requirements are now more demanding.

WJI: Do specialty products evolve over the years to a commodity status, or are they simply phased out, replaced by different designs?

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38 | WIRE JOURNAL INTERNATIONAL

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FEATURE

Streifel: All of the above. As the products are used in more applications and quantities produced increase in volume, the processes and setups become more standardized. This, depending on the product, will increase efficiencies and eliminate the many variables that come with the constant change in flow of products. Many are phased out, but repair and maintenance of end customer products will make those “phased out” products pop up again, sometimes with updated revisions, but still similar in design. And lastly, sometimes they are replaced with totally different designs. As technology changes, the wires to connect those new products also change. We are constantly manipulating current cable constructions and adapting those constructions to meet the requirements for new applications as they arise.

WJI: What kinds of markets are you active in, and what makes them special?

Streifel: We’re in markets that include some you probably have never heard of. We sell a range of products for the military, for medical, the nuclear industry and aerospace and more. One example of an unusual product we make is our “dog bone” cable, which is used for grain elevators. As you might guess, this is a limited market, and as far as we know we’re the only supplier in the U.S.

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Production of the “dog bone” cable at Specialty Cable. who offers this. The cable construction at first glance looks relatively simple to make. This could not be further from the truth. The cable is constructed with a special high-strength conductor that is manufactured exclusively for our use. The extrusion process requires special tooling. The insulating material is a high-temperature fluoropolymer that can only be run at a very slow speed requiring constant supervision.

WJI: How many such products might you offer at any given time? Are some (or all?) offered as unique products intended for a single customer?

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WJI: Does your focus inherently require much more highly skilled employees than commodity products?

Streifel: Yes. With specialty products, there are many unique products for specific customer designs, but there also many different variations of similar products. Every variation requires different materials, setups, tooling, run speeds, etc. Our employees are what make Specialty Cable “special.” We’ve had employees come to us with a commodity background, and more times than not, they didn’t last. The commodity business has a much different pace than in the specialty product environment. Our employees need to continually adapt to the ever-changing products and processes. They do a wonderful job in keep-

ing with our high quality of workmanship and continue with our high customer satisfaction.

WJI: How is your operation most different from one that provides commodity products?

Streifel: Well, one thing you won’t see much of here is finished product in inventory, because aside from a few staple products that we can expect to get repeat orders on, you can’t stockpile inventory because it may be outmoded next month. But at the same time, we probably keep more wire for use for future products because we can’t get caught with an order for a cable that requires a special conductor or material that could take weeks to get. We have to be able to react fast. The other thing is that every day at Specialty Cable truly is a new day, because we never know what we’re going to be asked to do. We are continually asked to think outside the box when approached by our customers with new and challenging cable requirements.

WJI: How long might it take for a new product to go from concept to design to prototype to field test to fullfledged production? How much might the final product vary from the original design?

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Streifel: Hundreds. Many are offered as unique products intended for single customers, but many are specialty products that are used in specific applications in specific industries, but are used by many different customers within that industry. We doubled our investment in equipment last year and we’ve been able to adapt some of our existing equipment so that we can do some things here that other companies cannot. In fact, we do work for other cable companies that are not able to process certain attributes, such as removing “memory” from a cable.

FEATURE

Streifel: Depending on the product type, customer information and participation, this could take between two weeks to over one year. The customers’ final end product will dictate the design of ours, not only in electrical properties, but also in dimensions and selection of materials to be used in the design. Our engineers, sales and manufacturing staff work closely together in all new product development projects to ensure their passing internal quality tests and their success in the field.

WJI: Is there any single product you’ve made that stands out?

Streifel: There certainly is, and that’s a cable we were asked to make because of 9/11. It turned out the rescue workers dispatched to the attack were having trouble communicating at the site because of cross-talk. There were many different rescue departments dispatched to the scene that normally would not have been working together, and they had problems identifying their individual instructions because the frequencies used by all the energy responders were not unique to each department. Many of the rescuers had to distinguish their instructions from various first responders, police, fire, etc. This inevitably added to the confusion of the 911 tragedy.

You might think that there’s already cable that could fill that need, but the problem was that the cable needed to be

42 | WIRE JOURNAL INTERNATIONAL

able to withstand high temperatures, have a long flex life, be able to isolate the signal and be small in size. We were able to develop a cable that provides exceptional flexibility by using a special alloy conductor used mainly in the robotics field. We insulated and jacketed the cable with extruded high-temperature materials A finished transducer that were also flexible. We were also able to construct the cable and an unfinished cable in such a way that it iso- one used for the 911 communication cable. lated the signal thereby eliminating any cross-talk. The cable is now in use throughout the U.S and now when rescuers from different departments are required to work together, they can communicate clearly with each other.

This was an example of our company performing at its best. Our design team came up with a creative solution, purchasing located the materials and had them delivered immediately, and production made them quickly. This truly was a company-wide effort and we are all very proud at Specialty Cable at being able to contribute.

Based in France, Nexans, a worldwide leader in the cable industry, has an industrial presence in 39 countries and commercial activities worldwide. It is active in infrastructure, industry, building and LAN sectors, employing nearly 23,000 people. It notes that its wide range of technology resulted in 2009 revenues of 5 billion euros. A key to continued success is the ability to provide solutions that meet the needs of a changing industry. Below, Nexans Technical Corporate Vice President Patrick Barth discusses his group’s approach to innovation and development, including how it has evolved in recent years.

WJI: How does Nexans approach product innovation and development?

Barth: Innovation at Nexans is a continuous process, which is not focused only on new applications and products. In fact, the company has had to reinvent itself a few times over recent years, to address its markets (after the collapse of telecoms), change of structure (after the separation from Alcatel), or evolution of its geographical footprint (it is today much less European-centric than it was a few years ago). A very important field of innovation, although invisible from the outside, is production, and

production methods. These fields are mentioned here because they interact with the product innovation.

Technical innovation, and development in general, is led at three levels by Nexans.

Basic research, process and material developments. These Nexans Technical Corporate Vice are done in President Patrick Barth.

Nexans Research Centers. The main Research Centers are located in Lyon (France), Nürnberg (Germany) and Lens (France), this last one specializing in metallurgy. New Research Centers are to be opened in Asia. These Centers are preparing the technolo-

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Nexans: innovation and development remains keys to continued success

FEATURE

gy platforms necessary for the Group’s development. A recent example of the technology out of these Research Centers is the INFIT™ insulation material technology for fire-resistant cables that was recently launched on a commercial basis. INFIT™ combines exceptional strength with flexibility, and thanks to advanced materials technology applied at the nanostructure level, when the plastic insulation burns it hardens to form a protective shield that maintains the insulation properties. It is worth noting that the basic Nexans patents for this technology are already several years old. In terms of the number of innovation projects, the Research Centers are running several dozen programs simultaneously, of which on average one or two in a year will lead to practical applications.

The Research Centers also host application centers, where cables can be tested in simulated actual conditions.

For example, Lyon hosts a handling application center, for cables for cranes and gantries, and Nürnberg an automation application center for cables for industrial robots. This gives them a closer view of the actual constraints the cables face in their daily use. Around 60 patents are registered each year by Nexans.

44 | WIRE JOURNAL INTERNATIONAL

Application R&D. Using either technology created by the above platforms or having a need that has widespread importance to multiple units of Nexans, joint effort projects are done by the Research Centers and the units, or between units, under the supervision of Corporate Technical Management. These developments are handled as corporate projects, with a project leader from one of the participating units, or from a Research Center. There are about 30 projects now running, each one targeting a new product, or product family. These projects are the normal path for major product innovations. Their duration is two or three years on average.

Direct customer-driven innovation. This part of development is normally performed by the individual Nexans units. It is essential to perform these developments with the best possible reactivity, and this is best achieved by the units themselves, since they have the closest customer contact, hand in hand with the Research Centers. Efforts range from specific made-to-order products for a specific customer’s need to a new product range that will then be produced by several other units. Around a hundred are run simultaneously and the development duration is very often determined by the required qualification testing.

WJI: How have current economic conditions affected your approach?

Barth: Nexans has taken the deliberate decision to

maintain R&D activity at a constant level, in spite of the overall activity reduction caused by the economic crisis.

Since the R&D activity is the guarantor of the company's future, it was considered important to maintain a serene approach to development. Probably the main impact of the crisis has been to change our market priorities. It is clear that some markets which required large R&D efforts are now totally depressed. A refocusing has therefore occurred. Except for this, the crisis has also offered more freedom to be creative. Some customers who would not have accepted change are now more open to innovative and more cost competitive solutions. Total cost of ownership has now become a well-known and well-understood criterion.

WJI: What about the evolution of the industry’s ever “greener” focus?

Barth: New major trends have appeared over the past few years. Although they have had no significant impact yet on our business, sustainability, eco-friendliness, social responsibility, bio-products, are now an integral part of Nexans’ set of criteria for the launch of new programs or platforms. What has already had a major impact on markets, and therefore on developments, is the emergence of renewable energy. Photovoltaics, windmills, sea energy,

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MAY 2010 | 45

FEATURE

WJI: How do you decide which products to pursue?

Barth: The drivers of development are quite different for the three above levels. For basic R&D, the drivers are a technology watch, material evolution and long-term trends. For example, development of carbon nanotubes or superconductors is followed very closely. A good part of this R&D operates in “TechnoOne example of Nexans’ R&D push” mode, offerresults is its DuoTrack® product, a ing new and better hybrid railway infrastructure cable solutions to units (fiber and copper) designed to be for known problems installed directly on the track. It with no satisfactory, has been selected and completely or too costly soluqualified by Deutsche Bahn to tions. For corporate carry signaling, local and long projects, a close distance communications. cooperation between R&D and marketing determines what the market needs as opposed to the needs of individual customers. A typical example is Nexans’ work on “smart grids.” This is where implicit needs are also addressed. But, as one would expect, direct requirements by customers drive most of the development effort at Nexans, mostly at the unit level, but if the problem cannot be solved there, at project, or Corporate R&D level.

Some significant changes have occurred over the recent years in how these elements work. Probably the most visible one is the change in approach by our main customers. In recent years, they have changed from specifiers to open-market customers. In other words, they used to have very powerful R&D centers specifying products, so they knew what they needed down to the finest detail. All suppliers were then asked to supply fully interchangeable products to the customer’s specification. Today, the R&D is mostly done by the suppliers, even if a successful development will then be opened to competition. Nearly all major customers are now operating in this mode for their new products. This has forced suppliers to boost their R&D activity and improve their qualification labs, but it has also made it possible for them to be much more creative.

Company contacts

FEATURE

Integer Research www.integer-research.com Leoni AG www.leoni.com Nexans www.nexans.com Specialty Cable Corporation www.specialty-cable.com Tom Rossi Pivoteur Solutions www.pivoteur.com & Solutions by Design www.solutionsbydesign.biz

and micro power plants have required a completely new range of products, with in particular a completely new range of properties (flexibility; cold-hot behavior in extreme temperatures, both hot and cold; lifetime, etc.), resulting for example in the development of the complete WINDLINK® range of cables for wind turbines.

More than ever before, Nexans is a worldwide leader, and has therefore a much broader view on the markets and their evolution. While this does not necessarily have an impact on the products (typically local products, produced locally for the local customers), it allows Nexans a much better understanding of the trends, and the opportunity to reuse technologies for very different, and sometimes completely unrelated products.

WJI: Does Nexans rely on its own resources or does it take advantage of external R&D? Barth: At the basic R&D level, cooperation is quite common with—but not limited to—academia. Nexans’ R&D centers work with numerous universities in Europe, Asia, the Americas and Australia. We are also part of multi-company projects, such as European projects.

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WJI: What about local versus global development?

Nexans has for a large part escaped the commoditization that has hit so many markets, because it remains a local company wherever it is active. Most of the products are local, and the responsibility of the units for the devel-

opments needed by their customers really make “act local” an integral part of our company culture. For example, our unit in Chile has developed a luminescent cable for a mining customer. Many similar innovations are not publicized as they should be. But an exchange of best practices and know-how within the technical community of Nexans is actively promoted, and is the main advantage of a large group like Nexans (as well as the “think global” part of the motto). The wide availability of innovative products, in many cases already qualified and debugged for years in other countries, is of course a significant advantage for our customers, and an important element to avoid commoditization.

A few of these successes include ICEFLEX®, a shipping cable designed to stay flexible in ultra-cold Arctic conditions (down to -50°C) where conventional cables become so stiff and brittle that they can snap like carrots as well as the LIPA project in the U.S. to install the world’s first superconductor power cable to operate at grid transmission voltage (138 kV) or superconducting fault current limiters (SFCLs) (both world records). (continued on p. 50)

MAY 2010 | 47

FEATURE

Nexans has also entered several international joint-ventures, for contracts, such as LIPA (Long Island Power Authority) with AMSC (American Superconductor Corporation) or for other industrial ventures, such as with Polycab in India, or Sumitomo for optical cables (Opticable) in Belgium.

However, Nexans recognizes at the same time the ever increasing importance of intellectual property. A reinforced Intellectual Property policy has been put in place over the recent years, which has resulted in Nexans filing more and higher quality patents, a reinforced patent watch (both to avoid infringing on competitors’ patents, and to discover infringement on Nexans’), and in general a better awareness of the impact of intellectual property.

But this has not prevented Nexans from taking or granting licenses when fitting to the operational strategy.

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

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

INTERWIRE 2011 IS ALIVE WITH POSSIBILITIES. IT IS RENEWED, INVIGORATED, AND TAKING A NEW TACK. WHO’S AT THE HELM? Senior executives from more than 25 key corporations are skillfully guiding major changes to the show. Their interest in Interwire—the largest wire and cable marketplace in the Americas— is resolute. Interwire affects their business and is clearly worth their personal time.

The result is a series of carefully considered and nimbly integrated transformations to better Interwire.

WHAT’S DIFFERENT? Location: Atlanta, Georgia.

Relocated and familiar, Interwire returns to the city of its origin where it was introduced in 1981.

Compact: 3 full days of exhibits.

Interwire 2011 offers a concentrated show schedule.

More operating equipment.

Interwire is a machinery show. Visitors can count on more operational equipment in 2011.

Renewed energy.

Exhibitor participation is on the upswing showing a 14% increase between the 2007 and 2009 events. Networking opportunities, ranked as the #1 reason to attend the show, will be part of the landscape. Expect to see production solution demonstrations and other attendance-building activities on the exhibit floor.

Special industry theme days to be announced.

Look for presentations, technical papers, and executive discussions to orbit around these central themes: Energy | Environmental | Safety Issues Metals | Materials | Machines Best Practices | Operational Excellence Fully supported.

Show management continues to work with allied organizations, supporting sponsors, and educational supporters to interest a growing number of international participants in the show. Event news is communicated to Wire Journal International readers in 108 countries worldwide.

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

Ed Kozlowski, Senior Design Engineer W.L. Gore & Associates

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

INTERWIRE 2011 EXHIBITING COMPANIES — AS OF APRIL 2010 Filtertech Inc. Fine International Corp.

Fisk Alloy Conductors Flymca Flyro FMS USA Inc./FMS AG Foerster Instruments Inc. Fort Wayne Wire Die Inc. Fortune Machinery Frontier Composites & Castings Inc. Fushi Copperweld Garg Sales Co. Ltd. Gauder & Co. Gauder Group Inc. Gavlick Machinery Corp.

GCR Eurodraw SpA Gem Gravure Co. Inc. Genca/Canterbury Engineering W. Gillies Technologies Gimax SRL Guill Tool & Engineering Co. V. Hagen & Funke Heacock Metal & Machine Co. Inc. Heany Industries Inc. Heatbath Corp.

Henrich Maschinenfabrik GmbH Heritage Wire Die Inc. Huestis Industrial Huettner Maschinenfabrik GmbH ICE Wire Line Equipment Inc. IDEAL Welding Systems Ideal-Werk INHOL LLC Inosym Intras Ltd. Italian Trade Commission ITO-SIN (Deyang) Wire & Cable Equipment Co. Ltd. IWE Spools & Handling GmbH IWG High Performance Conductors Inc. IWMA - International Wire & Machinery Association JMS Machinery Joe Tools Kalmark Ltd. Kieselstein GmbH Ernest Koch GmbH & Co. KG Albert Krenn Friedrich Krollman GmbH & Co. KG Lamnea Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. OM Lesmo Lesmo Machinery America Inc. Lloyd & Bouvier Inc. J.J. Lowe Associates LUKAS Anlagenbau GmbH M + E Macchine + Engineering

Madem Reels USA Inc./ Madem SA Magnetic Technologies Ltd. Maillefer SA Mapre Belgium SA Merritt Davis MFL USA Service Corp. Frigerio The MGS Group (MGS-HallNorthampton) MGS Manufacturing Inc. Micro Products Co. Microdia USA Millennium Steel & Wire Inc. Morgan-Koch Corp.

Mountville Rubber Co. MPI Machines Ltd. NEPTCO Inc. Nextrom Oy Niehoff Endex North America Inc. NUMALLIANCE Oklahoma Steel & Wire OMA SRL OMA USA Inc. Paramount Die Co. Parkway-Kew Corp.

Phifer Wire Inc. Pioneer Machinery Co. Ltd. Pittsburg Carbide Die Co. Pittsfield Plastics Eng. Inc. Plymouth Wire Reels Pourtier - Gauder Group Precision Die Technologies Inc. Premier Wire Die Properzi International Inc. Proton Products QED Wire Lines Inc. Queins & Co. GmbH Raajratna Metal Industries Ltd. RAD-CON Inc. Radyne Corp.

Rainbow Rubber & Plastics Rautomead Ltd. Reel-O-Matic RichardsApex Inc. Rizzardi Rosdendahl GmbH Rosendahl Nextrom Technologies Roteq Machinery Inc. Saarsteel Inc. SAMP SpA SAMP USA Inc. SAMPSISTEMI Schlatter Inc. Schunk Graphite Tech Setic SAS Sictra Srl SIKORA International Corp.

SIMPACKS Sirio Wire Srl Sjogren Industries Inc. Skaltek Inc.

SKET Verseilmaschinenbau GmbH Sonoco Reels Spirka Schnellflechter GmbH SPX Precision Components FENN Division STAKU-Anlagenbau GmbH Stema/Pedax Stolberger Inc. (dba Wardwell Braiding Co.) Stolberger KMB Maschinenfabrik GmbH T & T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Team Meccanica Srl Teknikor Teknor Apex Co. Tensor Machinery Ltd. Teurema Thermcraft Inc. Traxit North America LLC Paul Troester Maschinenfabrik Tubular Products Co. Tulsa Power Inc. United Wire Uniwire International Ltd. US Reel US Synthetic Wire Die Vandor Corp.

Vitari SpA Vollmer America Inc. Wafios Machinery Corp.

WAI Connection WCISA - Wire and Cable Industry Suppliers Association Weber & Scher Mfg. Co. Inc. Windak Inc. Wire & Cable Asia Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp. wire 2012/Messe Düsseldorf North America The Wire Association International, Inc. WIRE BULLETIN Wire Forming Technology Wire Journal International Wire Lab Co. Wire Machine Systems Inc. WireCo WorldGroup WiTechs Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Wyrepak Industries Inc. Ya Sih Technology Yield Management Corp.

Zeus Inc. Zumbach Electronic AG Zumbach Electronics Corp.

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

A. Appiani Ace Metal Inc. AFL AIM Inc. Ajax Turner All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American Kuhne AW Machinery LLC Axjo Plastic AB Aztech Lubricants LLC B & H Tool Co. Inc. Balloffet Die Corp.

Bartell Machinery Systems LLC/ Ceeco Machinery Bekaert Corp.

Bergandi Machinery Co. Besel Basim San Tic Ltd. Sti. Beta LaserMike Blachford Corp.

Butt Welders USA Caballe SA Cable Consultants Corp.

Carris Reels Inc. Cemanco LC Chase Coating and Laminating Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. CN Wire Corp./Er Bakir Comapac Wire Machinery Srl Cometo SNC Commission Brokers Inc. Condat Corp.

Conneaut Industries Inc. Continuus-Properzi SpA Cortinovis Machinery America Inc. CRU North America Inc. Daloo Machinery Davis-Standard LLC Dem Costruzioni Speciali Srl Die Quip Corp.

Domeks Makine Ltd. Sti Dynamex Corp.

EJP Maschinen GmbH Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Esteves Group USA Etna Products Inc. Etna-Beechem Lubricants Ltd. Eurodraw Energy SpA Eurolls Group Srl EuroWire Magazine George Evans Corp.

EVG Inc. Fabritex Inc. FIB Belgium SA

FEATURE

Active Optical Cables: an emerging growth market that could change the downstream Tom Rossi believes that few cable industry segments are poised to expand as rapidly as Active Optical Cables (AOC) the next five years. That potential was cited in his report, “AOC 2010 Market Report,” which was published by IGI Group of Boston, Massachusetts (www.igigroup.com). Below, he explains what AOC is and how the market is evolving, which he notes should be of interest to cable manufacturers because this downstream trend can pose more competition for copper cables.

What exactly is an “active optical cable” and why should the average consumer care about this technology?

Simply put, an AOC provides a direct replacement for copper cables connecting one or more pieces of electronic equipment, using industry standard electrical interfaces.

This extremely powerful technology helps designers and users tap into the many benefits of optical data communications (higher speeds, thinner, lighter, and more flexible cables) while reaching connection lengths far greater than possible with copper-based cabling systems at today’s higher data rates.

AOC is a direct competitor for higher-performance specialty copper cables (multi-coax, TwinAx, etc.) in that it offers to make the same inter-equipment connections with far smaller geometries (cross-sections) and better performance (lower bit-error rates) with a lighter and far more flexible (read: easier to install) cable. Traditional fiber cables place the optoelectronic transceiver function inside the equipment chassis on either end, making them more customized for fiber and more expensive to produce) whereas AOC places the opto transceivers inside the cable ends themselves.

One can certainly claim AOC is intended for shorter distances (< 500 m) than more traditional long-haul telecom (up to hundreds of kms), but one can also claim that AOCs are far more effective in the 10-100 m range than an equivalent copper cable, especially if the copper-only cables need expensive switches, hubs, or cable amplifiers and repeaters to make that same connection length operational, as the AOC does not need any of the expensive cable extenders required by the copper cable installations.

Several mainstream cable and connector companies are looking to AOCs as a means of boosting their average product margins and providing some defensive positioning for their other copper-based business. As the AOC business grows another order of magnitude (with commensurate reduction in AOC materials and production costs) over the next five years, you will undoubtedly see more and more cable suppliers re-evaluate their position on AOCs and optical cables in general.

AOCs first started appearing in supercomputers and data centers using electrical interfaces such as InfiniBand and 10 Gigabit Ethernet over the past three-five years.

They offered system designers the opportunity to build larger cluster configurations with their longer reach (up to

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100 meters and longer) without the expense of expensive routers, repeaters and switches necessary with pure copper cabling systems. As an added benefit, they offered significant power savings towards the operation of the cooling systems used by these types of applications.

An active optical cable takes a standard electrical interface such as the ones previously mentioned, and converts the signals into the optical domain for transmission across the length of the fiber cable, then converts the signals back into the electrical domain on the far end of the optical cable. System installers apply these cables in the same manner as copper cables, but without all the bulk associated with the older copper technology. Mixed configurations are possible, as the system builders can employ copper cables for shorter distances (1-5 meters), while using AOC for greater reach.

AOCs are starting to appear in consumer-based applications as data rates are reaching beyond 5 gigabits per second. As data rates continue to grow, copper cables continue to grow larger in diameter and heavier in bulk, as cable designers are forced to employ larger gauge wiring to support these newer speeds. In some cases, the

A simplified block diagram showing an active optical cable block diagram. Image courtesy Zarlink Corporation (www.zarlink.com). standards bodies surrounding several key interfaces such as USB, HDMI and DisplayPort are now suggesting shorter allowable distances for copper cable versions, in some cases only two meters.

There are some simple reasons why consumers are expected to choose AOCs over less expensive and shorter copper cables. AOCs can be more easily coiled for those mobile users who do not want to crowd their briefcase or backpack with thicker and heavier copper cables. Besides, who wants to carry a cable that is heavier than the device they intend to connect with, such as a 3-ounce MP3 player or an 8-ounce HD video camera?

Active optical cables can technically support any electrical data transmission interface. From a practical perspective only the higher volume interfaces (such as USB 3.0 used in personal computers and HDMI as used by HDTV and BluRay players) are likely to get supported, due to the design and product costs surrounding AOC implementation.

Since a similar set of electrical and optical components are used for commercial and consumer grade AOCs, both market segments co-exist in a symbiotic fashion. Readers

A ZLynx cable from Zarlink Corporation, which offers plug-and-play AOC cables specifically designed for connection to industry-standard 4-wide I/O electrical highspeed powered CX4/IB ports. Image courtesy Zarlink Corporation (www.zarlink.com). who wish to understand a greater level of detail within the AOC ecosystem can find further information in the report cited in the introduction. The AOC 2010 Market Report provides an excellent breakdown of each major

About the Author: Tom Rossi is president of U.S.-based Solutions By Design, a technology consulting business based in the heart of Californiaâ&#x20AC;&#x2122;s Silicon Valley. He holds two electrical engineering degrees from Cornell University and has more than 30 years of experience with Intel Corp. He is well known in the high technology industry, both as the author of the Active Optical Cable 2010 Market Report and as the author of several technical articles that have been published in industry publications.

He is also the founder and principal software developer for Pivoteur Solutions, a software startup company, whose flagship product, DataCube Pivoteur, was used to manage the database and build the collection of 140+ charts and data tables found inside the AOC Market Reports. Further information about the power of real-time data cube generation and pivot report dashboard updates can be found at www.pivoteur.com. â&#x2013;

MAY 2010 | 51

FEATURE

electrical interface expected to be used by AOCs over the next five years. This 200+ page report illustrates the number of cables by interface across the various application types, and provides details on the number of connectors and aggregate cable lengths as well. Readers who wish to stay in touch with the rapidly changing AOC landscape are also encouraged to obtain and read the AOC Quarterly Update service, also provided by IGI Group of Boston.

TECHNICAL PAPERS

TECHNICAL PAPER Effect of drawing conditions in tandem pass drawing on drawn diameter While tandem pass drawing is effective at reducing residual strength, it can be difficult to control diameter change. One finding in this research was that applying a low approach semi-angle in the second die is an effective method to reduce diameter variance.

By Sonomi Shirasaki, Motoo Asakawa, Ryosuke Komami, and Yuichi Tanaka

High-quality drawn bars and wires are increasingly required for automobile components and office equipment, which demand high dimensional accuracy in the range of 0% to +0.17% of the drawn diameter. However, the drawn diameter can become thicker or thinner than the die diameter, resulting in variances that can exceed specifications.

It is necessary to investigate the factors that cause diameter variance. Tandem pass drawing is expected to reduce residual stress and improve die life by generating back-ten-

sion between the dies1-3. However it is difficult to predict diameter variances caused by changing the back-tension and the mechanical properties after drawing4,5.

The aim of this paper is to investigate the effects of the allocated reduction, the total reduction and the approach semi-angle of the second pass on the drawn diameter.

Finally, a method of reducing diameter variance resulting from tandem pass drawing is proposed.

Ď&#x192; Ď&#x192; Table 1. Chemical composition.

Table 2. Mechanical properties.

Fig. 1. Experimental drawing method using tensile testing machine.

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TECHNICAL PAPERS

Experimental methods AISI 1045 (0.45% plain carbon steel) was used in this study. Table 1 shows the chemical composition of the material and Table 2 shows the mechanical properties.

The effects of the allocated reduction and the total reduction on the drawn diameter were investigated. Changing the allocated reduction changed back-tension and residual stress after drawing.

Changing the total reduction changed back-tension, residual stress and mechanical properties after drawing. Therefore, it is thought that the drawn diameter was greatly affected by the allocated reduction and the total reduction.

Fig. 1 and Table 3 show the experimental conditions. The die diameter in the second pass (D2 = 12 mm) was constant in all cases. The total reduction Re was changed by changing the bar diameter before drawing (d0). The first die diameter D1 was changed in order to change the allocated reduction.

In the case of a total reduction of Re = 10%, the drawing tests were carried out from Case 1 to Case 5. The Re = 20% total reduction drawing tests were carried out from Case 1 to Case 7. The Re = 30% total reduction drawing tests were carried out from Case 1 to Case 9. All drawing tests were carried out with a universal tester and at an 80 mm/min drawing velocity.

The die geometry is shown in Fig. 2 and Table 4.

The approach semi-angle α of the first and second die was 7°, the bearing length L was 5 mm, and boundary R between the approach zone and the bearing zone was negligible.

Fig. 2. Schematic of die geometry.

Table 3. Experimental conditions.

a

Table 4. Die condition.

Fig. 3. Relationship between the second pass reduction Re2 and the diameter thickening ratio η.

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TECHNICAL PAPERS

Results and discussion Fig. 3 shows the relationship between the second pass reduction Re2 and the diameter-thickening ratio η. Here the diameter thickening ratio η was defined as the thickening percentage of drawn diameter based on the die diameter of the second die D2. The diameter thickening ratio η was calculated from Eq. (1).

η

Fig. 4. Measurement results of longitudinal diameter under changing total reduction.

σz

σz σz

σz

Fig. 5. Axial stress at bearing zone.

Fig. 6. Result of axial residual stress by Heyn-Bauer method.

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x

Eq. (1)

where D2 is the die diameter in the second pass and d is the drawn diameter. When the diameter thickening ratio η is positive, the drawn diameter is thicker than the die diameter, and when the ratio η is negative, the drawn diameter is thinner than the die diameter.

The diameter thickening ratio η was low as the total reduction Re was high. For total reduction Re = 10%, the drawn diameter was thicker than diameter under every second pass reduction Re2. However, for total reduction Re = 20% and 30%, the drawn diameter was thinner than the die diameter.

The diameter thickening ratio η had a minimum at the second pass reduction in the 5% to 10% range.

The bar diameter was experimentally measured with a laser micrometer with repeat accuracy of ±0.105 μm. Drawing was stopped halfway, the bar was drawn out backward and the diameter was measured near boundary R (X = 0). Fig. 4 shows the comparison between the bar diameter near boundary R and total reduction under second pass reduction was Re2 = 7.84%. The bar during drawing shows without touching the bearing zone in the case of Re = 20%, 30%. The bar during drawing seems to touch the bearing zone in Re = 10%. However, the unloading elastic recovery value was calculated at about 5 m. In addition, the die shape was displaced by the pressure during drawing.

Actually, the bar during drawing touched the bearing zone in these conditions.

The investigation of the diameter change mechanism focused on the stress state of the bar at exit of boundary R. To make the phenomenon clear, we only the effect of axial stress conditions on the diameter variance were considered.

σ

σ

TECHNICAL PAPERS

σz

Fig. 5 shows the axial stress at the bearing zone. It is believed that a phenomenon termed “undershoot” is one of the factors that caused the diameter variance6. The bar begins to separate from the die at the exit of boundary R during drawing.

The surface axial stress of bar is highly tensile at the bearing zone during drawing. This phenomenon is thought to be the result of two factors: the axial residual stress at the surface of the bar is tensile and the axial residual stress at the center of the bar is compressive beyond boundary R. In addition, the drawn bar uniformly generates the drawing stress in the radial direction.

As a result, the axial stress at the surface exceeds the yield stress. Therefore undershoot is a plastic deformation at surface of the bar beyond boundary R. Here, the undershoot prediction formula Index is defined as Eq. (2)

Fig. 7. Relationship between second pass reduction Re2 and surface axial residual stress σz.

Eq. (2)

where σz is the surface axial residual stress, σt is the drawing stress, and σY is the yield stress of the drawn bar.

It is thought that a higher Index generates a larger undershoot. It is necessary for using the Index that the surface axial residual stress σz and the total drawing stress σt are measured. The surface axial residual stress σz was measured by the Heyn-Bauer method7. Fig. 6 shows the result of axial residual stress at Re2 = 7.84% by this method, which can measure the distribution of axial residual stress.

Fig. 7 shows the relationship between the second pass reduction Re2 and the surface axial residual stress σz. The surface axial residual stress had a minimum value when the second pass reduction Re2 was in the 5 to 10% range.

The surface axial residual stress was slightly high when the total reduction Re was low.

Fig. 8 shows the relationship between the second pass reduction Re2 and the total drawing stress σt. The total drawing stress σt was high when the total reduction Re was high. The second pass reduction Re2 was not related to the total drawing stress σt.

Fig. 9 shows the relationship between the Index and the diameter thickening ratio η. The diameter thickening ratio η greatly decreased when the Index exceeded a defined value. This value is defined as the undershoot limit.

Therefore, it is clear that plastic deformation at the surface of the bar was caused by high tensile axial stress at the surface. The Index was at the

σt

σ

Fig. 8. Relationship between the second pass reduction Re2 and the total drawing stress σt.

Fig. 9. Relationship between Index and the diameter thickening ratio η.

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TECHNICAL PAPERS

maximum when the diameter thickening ratio η was at the minimum. The Index was high when the total reduction was high.

Method of reducing diameter variance

σz

Fig. 10. Relationship between the second pass reduction Re2 and the diameter thickening ratio η.

σt

Fig. 11. Relationship between the second pass reduction Re2 and the surface axial residual stress σz .

Fig. 12. Relationship between the second pass reduction Re2 and the total drawing stress σt.

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The drawing test was carried out by changing the approach semi-angle α in the second die. As it became lower, the residual stress after drawing decreased.

Therefore, applying a low approach semi-angle in the second die could well be an essential method of reducing diameter change.

The approach semi-angle α in the second die was changed from 4° to 13° to change the surface axial residual stress σz. The total reduction of Re was 20%.

The approach semi-angle in the first die was 7°. The other die conditions, except for the approach semi-angle in the second die, were same as in the previous experiment.

Fig. 10 shows the relationship between the second pass reduction Re2 and the diameter thickening ratio η. The diameter variance decreased when the approach semi-angle in the second die was lower. Here, the diameter variation Δη is defined as the difference between the maximum diameter and the minimum diameter. When the approach semi-angle α in the second die was 4°, the diameter variation Δη was 0.107%. When the approach semi-angle α in second die was 13°, the diameter variation Δη was 0.623%. Applying a low approach semiangle in the second die is an essential method of reducing diameter change. In order to investigate this phenomenon, the axial residual stress and drawing stress were measured.

Fig. 11 shows the relationship between the second pass reduction Re2 and the surface axial residual stress σz. The surface axial residual stress σz decreased as the approach semi-angle α in the second die become lower. Even more than the second pass reduction Re2 = 5%, the surface axial residual stress greatly decreased when the approach semi-angle α = 4°.

Fig. 12 shows the relationship between the second pass reduction Re2 and the total drawing stress σt. The total drawing

Conclusion To investigate the effect of the drawing conditions in tandem pass drawing on the drawn diameter, the total reduction, the allocated reduction, and the approach semi-angle were changed. The results were as follows.

(1) The diameter thickening ratio η had a minimum value regardless of total reduction when the second pass reduction Re2 was from 5% to 10 % range.

(2) The diameter thickening ratio η was low as the total reduction Re was high.

(3) The undershoot was greatly affected by the axial residual stress and drawing stress. The undershoot easily generated under high axial residual stress at the surface and high drawing stress.

(4) Applying a low approach semi-angle in second die is an effective method to reduce the diameter variance.

Shirasaki

Asakawa

Sonomi Shirasaki is a student in the School of Fundamental Science and Engineering of Waseda University, Tokyo, Japan. Dr. Motoo Asakawa is a professor in the mechanical engineering department at the School of Fundamental Science and Engineering of Waseda. He came to the university 10 years ago from Sumitomo Metals Co. He has studied both the process engineering and materials engineering of the mechanical parts of cars, trains, aircraft, and construction and electric devices. He earned a doctoral degree in bar and rod rolling from Waseda in 1980. He is a recipient of

References 1. J.G. Wistreich, “Back pull in Wire Drawing,” Journal of the Iron and Steel Institute, November 1947.

2. K. Yoshida, “Effect of back tension and drawing direction on wire properties in copper wire drawing,” Wire Journal International, February, 2002, pp. 110-115.

3. T. Kuboki:, “Influence of back-tension on effect of skin pass in minimizing residual stress levels after rod drawing,” Ironmaking and Steelmaking, Vol. 28 Part 2, 2001, pp. 117-121.

4. Y. Tanaka, Effect of mechanical properties on diameter of drawn steel materials, Wire Association International, 2008 Proceedings.

5. H. Kubota, “Effect of Back-Tension in Drawing on Diameter of Bar and Wire,” Wire Association International, Wire Expo 2006, Proceedings, pp. 112-123.

6. M. Akiyama, “Influence of work hardening ratio of parent tube on undershooting phenomenon in cold tube extrusion,” Ironmaking and Steelmaking, Vol. 34 Part 4, 2007, pp. 360-368.

7. W. Sasaki, “Effect of die approach geometry and bearing length on residual stress after bar drawing,” Wire Journal International, November, 2002, pp. 68-72. ■

Komami

Tanaka

Japan’s Okochi Memorial Prize, the Society for Technology of Plasticity Prize, the Institute of Metals Prize, and Iron & Steel Institute Prize. Ryosuke Komami is a graduate student in the School of Fundamental Science and Engineering at Waseda.

Yuichi Tanaka is a student in the Department of Applied Mechanics and Aerospace Engineering at Waseda’s School of Fundamental Science and Engineering. This paper was presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, April 2009.

MAY 2010 | 57

TECHNICAL PAPERS

stress σt was approximately 300 MPa regardless of the approach semi-angle α in the second die and the second pass reduction Re2.

In summary, a decrease in the Index was caused by applying a low approach semi-angle α in the second die in the result of the surface axial residual stress σz and the total drawing stress σt. As a result, the diameter variance could be controlled. Applying a low approach-semi angle α in the second die was an effective method to reduce diameter variance.

TECHNICAL PAPERS

TECHNICAL PAPER Development of high-strength steel wire products It is possible to manufacture steel wire to meet increasingly higher requirements for products such as wire ropes, but the key may be not so much the technique used to produce high-strength steel wire as it is the management of the process.

By Tan Dianlong and Liu Lihua

Significant development of weight reduction in steel structure has been made in the past years in markets such as automobiles, large ships, engineering machineries and steel bar reinforced constructions. But for steel rod used for wire or rope, no substantial progress has been made in decades, mainly due to metallurgy conditions and the limits of rope making techniques. High-carbon or Mn-alloyed steel has been used for many years in steel wire or rope manufacture. Further, little research was conducted compared to that for sheet, plate and reinforced bar steels1.

The strength of steel wire has risen, even up to 4500MPa. This should be attributed to the improvement of metallurgy and the drawing process. The required strength for steel ropes in a newly revised specification (China) was

increased to a higher grade, for example, with 1960 MPa becoming the highest level.

Requirements have appeared in recent years for lighter steel ropes. That lead to the improvement of the overlay process for manufacturing higher strength wires, reducing the weight of steel ropes while keeping the same load level.

In China, some steel makers have been engaged in developing new steel grades for higher strength.

Fig. 1 shows that if wire strength increases from 1870 MPa to 2460 MPa, the rope diameter will be reduced from 10 mm to 8.72 mm, the weight for 100 meters will be reduced from 38.7 Kg to 29.4 Kg. That equals a 24% reduction in weight. In fact, many steel rope makers are capable of making such strength level products, but this

Fig. 1. Relationship between weight reduction and wire strength for a 10 mm wire rope with a 6Ă&#x2014;7+IWS structure. Breaking load is supposed to be 67.1KN.

Fig. 2. Effect of carbon content on tensile strength in steel with and without 0.2%Cr.

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TECHNICAL PAPERS Fig. 3. Effect of carbon content on area reduction in the steels with and without 0.2%Cr.

Fig. 4. Effect of Cr content on tensile strength.

requires a well managed system. Specifically, chemical composition and microstructure must be optimized to obtain the wire with strength level above 2500 MPa through 3000 MPa. If wires are to be stranded, wire toughness must also be considered, especially for the steel wires with a strength level over 3000 MPa. Reducing steel rope weight by increasing wire strength is desireable in different areas, leading to a lower cost in transportation, storage and windless usage, as well as saving iron and steel resources.

Adding high content carbon or alloying. Higher carbon content such as 0.9%wt carbon, combined with higher

compressing ratio, can well increase wire strength. This may be the way to achieve the strength level over 3500 MPa. Some research has shown that ultra-high carbon can be used for high strength, i.e. carbon content from 1% to 1.2%. Such high-carbon steel has been considered to be brittle and cannot be used for demanding applications.

Nevertheless, recent research shows that such high-carbon steel can achieve high strength with good toughness if well heat-treated. Some patents show that tensile strength as high as 1300MPa with elongation of 18.5% is possible.

Microalloying has become popular. Chromium and vanadium alloying combined with the addition of higher content of silicon and manganese are often used for obtaining high strength. Cr will move the CCT curve right,

Fig. 5. Effect of Cr on area reduction in 0.82% carbon steel.

Fig. 6. Dependence of tensile strength on compression ratio and carbon content.

The approaches to achieve high strength

MAY 2010 | 59

TECHNICAL PAPERS Fig. 7. The trend of tensile strength with the variation of compression ratio in a 0.9%wt carbon steel.

Fig. 8. Relationship between compression ratio and drawing force.

reducing the amount of pro-eutectoid ferrite and increase the amount of fine sorbite. This may lead to a 100 MPa increase2. Some research indicated that a Cr addition can also make sorbite more homogeneous2-3. Fig. 2-5 shows the effect of Cr addition on mechanical properties.

Use of silicon has been limited because it may cause brittleness, but Japanese researchers used about 0.9%wt Si for 4000 MPa high-strength wires. This indicates that conventional alloying or microalloying system should be reconsidered.

High-compression ratio. A high-compression ratio is possible because the steel industry is well developed.

Domestic middle carbon wire rods can be cold drawn at a compression ratio of nearly 98% and some high carbon wire rods can be drawn at a compression ratio about 95%.

High-carbon content and a large compression ratio are needed for high strength as shown in Fig. 64.

Most data about the relation between the strength and compression ratio are based on the experiments at a compression ratio less than 90%. In fact, the increasing

trend of strength at the ratio larger than 90% is different from that of less than 90%, as shown as in Fig. 7. With an improved metallurgical process, a larger compression becomes possible. Therefore, the deformation mechanism of steel wire rod under large compression will be reconsidered for use.

Finer pearlite microstructure. Traditionally a middle-sized pearlitic cluster microstructure is sought as this is considered to be easier to cold draw. Recent research indicates that a finer microstructure can produce a better combination of high strength and toughness, as shown in Table 1.

With increased initial strength, the drawing and stranding equipment must also be changed for the wiredrawing. Fig. 8 shows the relationship between drawing force and wire strength. It should be noted that the compression ratio must be well controlled because the variation of strength becomes bigger at large compression.

Some issues in practice. Analysis on imported high-quality wire ropes shows that higher level wires were used for a lower level wire rope, for instance, 1870 MPa or 1960

Table 2. Comparison of composition variation between different steel makers.

Table 1. Mechanical properties in different processes.

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TECHNICAL PAPERS

MPa wires were used to manufacture 1770 MPa wire rope5.

Some researchers6-8 pointed out that uniform wire properties, homogenous composition, and even stranding and proper construction, are the main issues for manufacturing high quality wire ropes. These issues represent the management problems, not technique issues.

Table 2 shows that carbon control is different between steel makers. It also can be seen that such steel makers provide the most stable and homogenous wire rods.

Further, inclusion control is a very important issue that has been well improved in recent years by steel makers.

Some research on gas control and nonmetallic inclusion matching has led to great progress9-10. All this research and practice has made it possible for large compression ratio drawing and high speed stranding.

Summary The possibility for manufacturing high-quality wire rope has been discussed. High-strength wires or wire rope is considered to be possible in China, with the development of metallurgic techniques, but such production must be well managed by steel makers, wire rope makers and research institutes. More studies are needed that consider elements such as the control of homogeneity, severe deformation, sorbite refining and nonmetallic inclusions.

References 1. D. Baochang, New Techniques in Production of Key Wires and Ropes, Metallurgical Industry Press, Oct. 1984.

2. F. Yunli and Y. Haili, “Effect of microalloying on the microstructure and properties of high carbon steel wire rods, iron steel vanadium titanium,” Dec. 2003, p. 31.

3.Y. Liqun and H. Yixin, Steel Rolling, June 2001, Vol. 18 (3).

4. L. Zhishen, Production of Steel Wires, Steel Wires Products Information Net of Metallurgy Ministry, p. 41.

5. C. Guozhouand W. Min, “Quality analysis on the steel wire rope used for Port Derrick,” Metal Products, Dec. 2002, p. 44.

6. Z. WeiPing, Localization of Wire Ropes Used for Large Wells. Metal Products, Dec. 2000, p. 49.

7. F. Quanzhen, Quality Differences of wire ropes used for wells between local and imported products, Metal Products, Oct. 2001, p. 17.

8. C. Guangliang and J. Enzhi, Analysis on quality instability of local wire rope products, Metal Products, Oct. 2007, p. 21.

9. Kobe Steel, Patent, Manufacture Process of Steel Wire Rods with Good Drawability and High Performance, CN1928142, Sept. 4, 2006.

10. Nippon Steel, Patent, High Carbon Steel Rods with Good Drawability and High Performance, PCT/JP00/03977, June 16, 2000. ■

Dianlong

Lihua

Dianlong Tan is director of the Fasten Technology Center, Fasten Group, China, where he is a senior engineer in new materials development. He earned his Ph.d in Materials Science at Beijing University of Science & Technology in 1996. His working focuses on steel wire and wire rope development. Lihua Liu is vice president and chief engineer of Fasten Group Company. He is also a professor of Harbin Institute of Technology, where he was awarded his Ph.D in materials science in 2003. He has been engaged in wire and wire rope field for more than 20 years, and has interests in other new materials. This paper was presented at WAI’s International Technical Conference, Istanbul. Turkey, November 2009.

MAY 2010 | 61

TECHNICAL PAPERS

TECHNICAL PAPER Aluminum wire rod produced with UPCAST® technology Developmental efforts to use UPCAST® technology to produce aluminum rod for electrical applications to sizes smaller than 0.2 mm has led to encouraging results that merit further research.

By Juan Carlos Bodington and Matti Nordman

Aluminum is a young metal, having only been produced commercially for 155 years. Despite the fact that copper, lead and tin have been in use for thousands of years, today more aluminum is produced than all other nonferrous metals combined. Its unique combination of properties makes it suitable for many applications. It has become the world’s second most used metal after steel. Annual primary production of aluminum in 2006 was around 34 million metric tons (mmt) and recycled production around 16 mmt.

The total of some 50 mmt compares with 17 mmt of copper, 8 mmt of lead and 0.4 mmt of tin1.

Electrical applications of aluminum primarily exploit the

very good electrical conductivity (low resistivity) of the bulk metal, and its low cost and density. Good mechanical strength, corrosion resistance and thermal conductivity are also important characteristics.

Aluminum competes strongly as a low-cost electrical conductor. Both pure aluminum rod and alloy rod are produced to feed the demanding wire and cable industry.

Typical electrical applications include: bare conductors (AAAC, AAC, ACAR, ACSR, AACSR, GTACSR); insulated conductors (building wire, service drop, underground feeders, covered line wire); and magnet wire.

Aluminum wire rod for electrical purposes is typically

Fig. 1. Simplified schematic diagram of UPCAST® process key elements.

Fig. 2. UPCAST® “process triangle.”

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TECHNICAL PAPERS

manufactured to a 9.5 mm diameter using the moving molds process (mainly casting wheel and band). However, the intrinsic existence of inclusions—mainly aluminum and magnesium oxides—and/or alloying element segregation associated to the process put a practical limit to its drawability at around 0.2 mm diameter.

To break this limit a new casting process should minimize segregation and inclusions, while having a smaller environmental signature (being less energy consuming and producing less emissions or by-products). It should also be flexible in terms of production rate while having a low production cost. These ideas, supported by requests from many UPCAST® users, kicked off the R&D project whose preliminary results are presented in this paper.

UPCAST® in ‘a nut shell’

Table 1. Comparison of some Al and Cu physical properties.

The UPCAST process was invented by Finland’s Outokumpu Oy in late 1960s, and ever since, this technology based on the submerged die casting technique, has evolved into very sophisticated computer controlled automatic casting systems for copper and a number of alloys.

Fig.1, a simplified schematic of the process key elements shows the casting die, the bottom part of cooler (watercooled copper jacket) where the die is inserted, the traction shaft and the pinch roller. The solidification front and relative melt level are also shown. The casting process starts with the insertion of a steel “fishing” rod with a detachable copper or steel tip (bait). Upon its insertion, the melt solidifies against the bait and the fishing rod is pulled up in strokes by the withdrawal machine traction shaft and pinch rolls. When the cast rod passes the withdrawal machine, the fishing rod is removed and the bait is cut away. From this moment, the process is self maintained, and produces rod that is usually coiled in racks2.

The most relevant UPCAST copper casting process variables can be represented as a triangle that is fed on one side by suitable quality raw material that exits the other side as

Table 2. Chemistry of rod sample.

Fig. 3. Transversal view, 9.5 mm rod.

Fig. 4. Longitudinal view, 9.5 mm rod.

Fig. 5. Longitudinal section, 5.63 mm.

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HCOF rod. (See Fig. 2.) This representation highlights the relationship between the process variables, namely casting speed, metallostatic pressure, heat exchange, withdrawal stroke form, oxygen concentration and hydrogen concentration, in such a way that fluctuations in one or more of them may affect the process stability and as a consequence the end product quality2.

Differences between copper and aluminum Copper and aluminum are quite similar metals in some instances, but quite dissimilar in others. Table 1 contrasts some of their more important physical properties.

Even though copper and its alloys has been cast upwards commercially since 1971—the year when the first UPCAST unit went into operation—aluminum represented a completely new challenge, and adapting the process to this new material required taking into consideration the property differences between the two elements, such as: • Extracting the heat from the solidifying core of the aluminum rod becomes more difficult as its thermal conductivity is about half that of copper.

• As aluminum linear expansion is 50% higher than that of copper, the solidified shell will depart faster and farther away from the cooling surface in the die or cooler, decreasing the effective heat exchange rate.

• The specific heat capacity of Al is almost 2.5 times that of copper, and the heat of fusion is almost double.

However, when considering the energy accumulated as heat per unit of volume in the solidifying metal to be taken away to go from molten to 75% of melting temperature, copper takes the lead, as its rate is 1.9 times higher than that for aluminum. Thus, the casting speed of aluminum compared to that of copper is limited more by the metallostatic pressure and the effective heat exchange rate than by the amount of energy to be removed.

• The metallostatic pressure directly depends on the material density and the casting die submersion depth. In order to compensate for the lower density, the aluminum casting cooler should be approximately three times deeper than when casting copper.

• From the chemical side, aluminum is a very reactive element, contrasting with the more passive behavior of copper, so special considerations are needed when choosing casting die material. This choice was also influenced by the wetting angle of aluminum on different substrates.

• Hydrogen is the only soluble gas in aluminum. It has a big difference in solubility between the molten and solid phases, which represents a major problem for casting as the rejected gas has no way to escape, which can cause macroporosity.

Upcasting aluminum

Fig. 6. Longitudinal section, 2.99 mm.

Fig. 7. Longitudinal section, 2.04 mm.

64 | WIRE JOURNAL INTERNATIONAL

UPCAST OY’s R&D team arranged a rather simple setup for the development experiments. Components included: a 750 Kg (Al) coreless induction furnace (as melting/alloying furnace); a 250 Kg (Al) resistor crucible furnace (as casting furnace); a single-strand withdrawal machine with servo-drive system; modified UPCAST primary coolers (to fit 9.5 mm dies); a standard UPCAST coiler and speed control device; standard personal safety equipment; and standard foundry tools.

No degassing or filtering devices were used. The lack of degassing was partly compensated for by keeping the molten metal at a rather low temperature for at least 24 hours prior to casting. Cooling water flow and temperature were tightly controlled.

Aluminum raw material came from extrusion press matching the 1350 alloy chemistry. No extra grain refiners were added. However, the level of two impurities was found to be quite high. (See Table 2.) The chromium concentration was six times more than allowed and the iron was 25% more than the allowable maximum. Neither sample met the required minimum aluminum content. As chromium is especially harmful in aluminum in terms of electical conductivity, it was obvious that cast rod with such a chemical analysis would inevitably have a low conductivity value. This however was not considered as a major drawback at this early stage where the primary goal

Casting and drawing results and discussion The first results were rather discouraging. The longest pieces of cast 9.5 mm rod were no more than a few meters.

Those results triggered a deeper research into die materials and led to many adjustments in cooling parameters and withdrawal strokes.

At the current stage, it is possible to cast more than 1000 Kg per die. Rod grain structure is typical “as cast,” with large columnar grains. There is very little segregation and microporosity due to negligible shrinkage. (See Figs. 3-4.)

However, the surface visual aspect deteriorates rather quickly after some two hours of casting, but remains stable (rough) for the remaining casting process. Later, this visual quality of the rod surface showed no effect on drawing.

Drawing tests were initially performed in a lab drawing bench using from 20 to 35 % area reduction per die. The rod was easily drawn down to 1.2 mm, and the roughness completely disappeared at 5.6 mm dia. (See Figs. 5-7.)

Due to the melt chemistry, the electrical conductivity values were expected to be low, as indeed was the case (52% IACS in 9.5 mm rod)3. However, the excess chromium alone accounts for a 6-7 % IACS unit drop in electrical conductivity. An interesting and totally unexpected finding was that conductivity increased with area reduction. (See Table 3.)

The R&D team has theorized about this latter phenomenon and several reasons have been proffered: • Inverse segregation: accumulation of phases rich in Cr/Fe on the rod surface. This would increase the contact resistance. This accumulation would be diluted as the rod/wire is drawn down. At the time of publication some

Table 3. Conductivity, elongation and tensile strength versus area reduction.

tests have been prepared by “scalping” some of the contact area on the rod with the testing bridge.

• Low solubility elements. These elements, “entrapped” in the grains, could precipitate during drawing due to the punctual increase of temperature.

• Formation of metastable compounds/phases due to the initially fast cooling. These phases may form crystals that are initially coherent with the Al matrix, reducing the conductivity. When they become stable (transformation triggered by deformation or heat) the structure may become incoherent with Al matrix, so conductivity increases.

From a mechanical point of view, rod Rm showed values in the high end of temper O or the lower end of H12 1350 aluminum, possibly due to the high concentration of Cr and Fe. Elongation values were very good as well as work hardening behavior.

A key process ability test was performed at the Riihimäki plant of Reka Kaapeli Oy, a Finnish cable producer, where a 1-metric-ton coil was drawn to 3.13 mm. See Fig. 7. The wire was shaped trapezoidal with dies and three compacted 120 sq mm cable units were assembled. See Fig. 8. The cable construction type was an underground feeder, 3 x 120 + 35, for medium voltage (12/20 (24)Kv).

Although the rod experienced a number of cuts during the breakdown phase, the further behavior of the drawn wire was excellent. The cuts are probably related to inadequate melt quality induced by the simple and imperfect furnace configuration, but finding optimum drawing parameters for the breakdown machine to better suit the “as cast” characteristics of the rod can also play a marked role in reaching acceptable breakdown performance. These issues will be tackled as the project proceeds.

Fig. 8. UPCAST® aluminum rod coil being drawn at Reka Kaapeli Oy. MAY 2010 | 65

TECHNICAL PAPERS

was to determine the overall “upcastability” of aluminum by testing different die materials, withdrawal stroke forms, cooling parameters and casting speeds.

TECHNICAL PAPERS Fig. 9. Compacted unit for AHXA-WMK cable produced from UPCAST® aluminum rod

Conclusions It was found that aluminum rod can be cast upwards with UPCAST technology. However, the process needs to be further refined to attain a higher productivity level.

The bench drawability was found to be very good, but industrial level tests showed inadequate results in rod breakdown, possibly triggered by melt quality issues and/or adjustments of drawing parameters.

Wire behavior after rod breakdown was found to be excellent in terms of ductility, twisting and compacting.

Cooperation with specialized companies may be sought to ensure a suitable quality melt (ruling out melt related problems), facilitating the testing of the casting system with a larger range of aluminum alloys as well as rod diameters.

Acknowledgements The authors want to thank Matti Santala, Outotec Research Oy, Finland; Timo Välimäki; Luvata Pori Oy, Finland; Pasi Lindholm, Reka Kaapeli Oy, Finland; Heikki Thurman, Reka Kaapeli Oy, Finland; and Arturo Gamboa, MADECO, Chile, for their very valuable contribution.

References 1. International Aluminum Institute. Web page.

2. J.C. Bodington, “Manufacturing highest quality rod for the production of smallest size wires,” Problem solving in Wire & Cable Manufacture & Processing, IWMA Educational Seminar, 2001, Singapore.

3. ASM International (Editor), 1998, ASM Specialty Handbook: Aluminum and Aluminum Alloys, 4th Edition.

66 | WIRE JOURNAL INTERNATIONAL

Bodington

Nordman

Juan Carlos Bodington is technical advisor and part of the R&D team for UPCAST OY, which was formed from Outokumpu Castform Oy in 2006 and is based in Pori, Finland. Responsible for commissionings and technical service, he joined the company in 2006. He has worked in the wire industry since 1987 for companies that include Outokokumpu, which he worked in the technical area, Phelps Dodge, Alcatel and Kabelmetal Indonesia. He holds a degree in electrical engineering from Simon Bolivar University, Caracas, Venezuela.

Matti Nordman is the marketing manager for UPCAST OY. In 1994, he joined the sales team of Outokumpu Castform Oy, which transformed into UPCAST OY in 2006. He holds an MSc degree in aeronautical engineering from Finland’s Helsinki University of Technology.

After graduating in 1980, he went to work within the Finnish aircraft industry in various positions, including marketing and sales. This paper was presented at WAI’s International Technical Conference, Istanbul, Turkey, November 2009.

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PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS Masterbatch is a master ‘anti-ants’ solution for PVC cable protection Swiss-based Clariant Masterbatches announced that it has introduced an anti-termite masterbatch for PVC wire and cable applications that has shown great results for customers in the Middle East.

A press release said that while termites may be best known for attacking wood, they are also known to chew on underground cables with outer jackets made of PVC and sometimes polyethylene. One common solution has been to apply an insecticidal oil to PVC pellets or granules, but that can be a messy and ineffective solution as well as one that uses materials that are considered hazardous, it said.

In contrast, the Clariant Masterbatches solution, marketed under the CESA®-antimicro brand, incorporates an EPA-registered pesticide with a PVC carrier that is added during the wirejacketing process simply by adding it into the material stream at the extruder feedthroat, the release said. This, it noted, eliminates the need to maintain a stock of oil-treated PVC along with the untreated compound, so inventory costs are reduced.

The company also offers a “universal” masterbatch formulated with a carrier resin that is compatible with polyolefins as well as a multipurpose “combibatch” that adds other additives (like UV stabilizers) and color into a single concentrate, the release said. A 1% addition rate is recommended for both masterbatches, which it noted have been effective against flies, cockroaches, fleas and bedbugs.

Contact: Clariant Masterbatches, www.clariant.masterbatches.com.

Systems offer ‘new age’ of precision Germany’s Sikora AG, represented in the U.S. by Sikora International Corp., announced that its LASER Series 6000 line opens up a new age of precision diameter measurement that includes a number of technical innovations that result in even higher precision and reliability.

The series includes the LASER 6020 XY for diameters from 0.25 to 20 mm, LASER 6040 XY for diameters from 0.5 to 40 mm and the LASER 6080 XY for products from 1 to 80 mm. A press release said that the improvements in the LASER Series 6000 effectively improve production

68 | WIRE JOURNAL INTERNATIONAL

line efficiency. The most significant development, it said, is that the system now operates at 2,500 measurements per second, with extremely high single-value precision that results in cable diameter with outstanding repeatability and accuracy.

Other practical improvements, the release said, include increasing the size of the gauge opening to twice as large as the measuring range to ensure an easy and safe cable feed through, and adding a pluggable universal interface module for all connections integrated directly into the gauge head. Another outstanding feature, this one carried over from the larger LASER Series 2000 gauges, is a swivelhead gauge design that allows the gauge head to be easily moved up, out of the extrusion line. The measuring axes are arranged in such a way that the gauge is open at the bottom to prevent dirt and water from falling into the measuring area.

Contact: Sikora International Corp., tel. 770-486-1233, sales@sikora-usa.com, www.sikora-usa.com.

10G cable has very small diameter U.S.-based Berk-Tek, a Nexans Company, announced that it has the introduced a 10G Limited Distance (LD) UTP cable with a diameter of .265 in., which it said represents a significant reduction in cable diameter compared to existing Cat. 6A UTP cables.

The .265 in. diameter Berk-Tek 10G LD cable is 15% smaller than LANmark-10G2, which can save up to 50% in conduit space, a press release said, noting that this reduces pathway constriction and facilitates improved air circulation, resulting in lower cooling costs and a reduction in energy consumption. The cable, it said, is designed to support IEEE 802.3an 10GBASE-T to a maximum distance of 60 meters, specifically in high-density applications such as data centers. The biggest challenge for UTP cables for 10 Gigabit applications, is the elimination of alien crosstalk.

To counter that, the new 10G LD cable incorporates several design innovations used in Berk-Tek’s LANmark-10G2 Cat. 6A cable, which it noted is one of the smallest in the industry.

The result is that the new Berk-Tek 10G LD cable meets all IEEE 802.3an channel performance requirements when terminated with Cat. 6A connectivity (four connectors to

Riser cable is halogen-free U.S.-based General Cable reports that it has added halogen-free riser cables to its GenSPEED® product line. The UL-rated Cat. 6 and 5e riser cables, known as 17 FREE™ cables, will be offered at competitive pricing and feature substantiated green properties.

A press release explained that the product name refers to Group 17 of the Periodic Table, which includes materials such as any chlorine, fluorine, bromine and iodine. The revolutionary 17 FREE line of GenSPEED Riser cables does not contain any of those elements, thereby “reducing the overall toxicity of the cable and truly resulting in a more environmentally friendly ‘green’ product,” it said.

The release noted that the U.S. Green Building Council has introduced LEED Pilot Credit 2, which is a credit geared to reducing the release of persistent bio-accumulative toxic chemicals (PBTs) associated with the life cycle of building materials, including electrical wiring and cable jacketing. “Based on this LEED credit and earlier requests for green products, General Cable’s GenSPEED wire wizards closely examined the jacket of its Cat. 5e and 6 cables and successfully engineered this 17 FREE halogen-free riser cable version,” it said. “Our 17 FREE product line is a great example of turning end-user feedback into reality,” said Bob Kenny, Vice President and General Manager, General Cable Communications Cables. “As part of this commitment, we continue to find innovative ways to exceed the requirements of our customers.

Contact: General Cable Corporation, www.generalcable.com.

In-line measuring system can process a wide range of products/materials Zumbach Electronics Corporation reports that the SIMAC 63, the company’s latest model for surface inspection, uses image processing with a scan rate up to 35,000 scans/second.

A press release, which said that the design was focused to achieve the best price/performance ratio for cables (2 mm to 50 mm) as well as tubes, hoses, etc., and products made of other materials, such as plastic and rubber, noted the following. The SIMAC 63 has a measuring field of 63 mm and uses LED lighting to measure products from approximately 2 to 50 mm. The unit meets market demands for a compact, durable and costeffective system, providing: increased product quality for higher customer satisfaction; an easy-to-use unit, with a graphical user interface (GUI) of the latest generation; a very compact design; and a modular base, extensible with various options that make it possible to see surface faults down to 100 μm; length related scanning and fault definition; and more.

Contact: Zumbach Electronics Corporation, tel. 912241-7080, sales@zumbach.com, www.zumbach.com.

Clad metal wire composites can meet critical property and design demands U.S.-based Anomet Products, Inc., reports that it offers custom-engineered, clad metal wire composites that combine two or more metals or alloys to achieve specific properties and meet critical design requirements.

A press release said that the composites are metallurgically bonded together to provide higher quality than electroplating and allow designers to combine the properties of several different materials to suit their application.

Creating one wire that provides improved properties versus the individual metals by themselves, clad metal wire can feature attributes such as greater tensile strength or conductivity and higher corrosion- and wear-resistance, it said.

The composite wires act as a highly flexible and formable system, and will not break, flake, or blister when bent or twisted, the release said. The company’s precious metals, alloys and core metals, it said, can be combined to meet requirements for: high strength, high conductivity, biocompatibility, radiopacity, corrosion- and contactMAY 2010 | 69

PRODUCTS & MEDIA

60 meters and two connectors down to a seven-meter channel), the release said. The cable also meets TIA-568C.2 internal requirements for Cat. 6A component compliance (500 MHz) at these distances, it said.

“We are finding that many 10GBASE-T implementations do not require full 100 meter channels,” notes Todd Harpel, Director of Marketing for Berk-Tek. “This cable provides an extremely small cross-sectional area to optimize pathway fill in high density installations like data centers and high performance computing operations,” he adds.

Contact: Berk-Tek, tel. 717-354-6200, berktek.info@nexans.com, www.nexans.us/eservice/USen_US/navigate_182226_277_2432/Berk_Tek.html.

PRODUCTS & MEDIA

resistance, shape memory, ductility, formability and cost reduction. Typical finished wire sizes range from 0.002 in. to 0.125 in.

Contact: Anomet Products, Inc., tel. 508-842-3069, dlambert@anometproducts.com, www.anometproducts.com.

Precision wire cutters can handle a wide range of tasks for industry A full line of precision cutters from U.S.-based Xuron Corp. have by-pass shear cutting action that makes them able to handle a wide range of assembly, production and field-service tasks.

A press release said that the Xuron® precision cutters are manufactured from high-carbon steel with a glareeliminating black finish, have soft rubber hand grips, Light Touch™ return springs, and feature patented MicroShear® by-pass shear cutting. The cutters are designed for specific tasks and environments, including models with a thin profile cutting head for high density areas, tapered and angled heads, serrated heads for cutting Kevlar® fibers, fine pointed blades for slitting cable jacketing, a hard wire shear with retaining clamps, and many more, it said.

The cutters can process soft wire up to 16 AWG, PC board and SMT work with cutting capacity to 18 AWG in tight spaces, vertical cutting with a 55° angled head, cable tie cutting with an unrestricted cutting surface, and extra tapered tips for plastics de-gating, the release said.

Contact: Xuron Corporation, tel. 207-283-1401, arobey@xuron.com, www.xuron.com.

Stripper can process magnet and enameled wire despite film insultation U.S.-based Eraser Company reports that its model DCFV1 magnet and enamel wire stripper can process round magnet and enamel wires with any type of film insulation.

A press release said that the strippers can process wires that have Formvar, nylon, polythermaleze and varnish. The DCFV1 hand piece, it said, contains its own internal dust collection system, which operates when the switch is depressed. The variable speed power unit controls the speed and the insulation is cleanly removed without harming the wire conductor, it said. The tool was described as ideal for the production and repair stripping of armatures, coils, chokes, transformers, relays, solenoids and more.

70 | WIRE JOURNAL INTERNATIONAL

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

Tools ideal for splicing wire ropes U.S.-based Nicopress® Products has introduced a series of lithium ion battery-powered tools for splicing wire rope with Nicopress sleeves and dies.

A press release said that three models provide operator convenience and speed while their compact size permits use in confined areas where traditional compression tools cannot easily be used for wire rope splicing. The batterypowered models can process wire rope from 3/64 to ½ in. diameters, able to do about 65 crimps to a charge, it said, adding that a variety of die sizes and styles are available to accommodate Nicopress sleeves, making them appropriate for all rigging applications. Each tool comes with two lithium ion batteries, A/C battery charger and molded carrying case.

Nicopress Products is a division of The National Telephone Supply Company, which notes that it has manufactured products for the utility market since 1901 and wire rope products for more than 70 years.

Contact: The National Telephone Supply Company, tel. 216-361-0221, sales@nicopress.com, www.nicopress.com.

MEDIA Specific benefits of shielded network cabling is now featured on-line U.S.-based Siemon, a global supplier of network cabling solutions, announced that it has launched a new online resource to provide IT network and data center professionals with clear facts on shielded network cabling systems such as Cat. 6A F/UTP and Cat. 7A S/FTP solutions.

A press release said that the site (www.siemon.com/ shielded) focuses on key network infrastructure issues such as 10Gb/s performance requirements, noise resistance, installation considerations, cost savings and futureproofing as well as an easily navigated portal to Siemon’s library of in-depth resources. “From a simple, one-page list of key shielded cabling benefits, advantages and myths, users can access instructional videos, whitepapers, customer case studies and more,” it said. Topics, it noted, included: shielded cabling market drivers; performance

Website has been designed to offer a greater level of customer service U.S.-based Maxcess International reports that it has unveiled a new website with simplified navigation as well as â&#x20AC;&#x153;live chat,â&#x20AC;? all meant to make it easier for people to get answers, request a quote, or simply find product specifications about the companyâ&#x20AC;&#x2122;s winding, slitting, inspection and tension control technology.

The site structure provides easy access to popular content, with all product data, related videos, articles and support documents found in a single location (each product page), as well as related products to help the user quickly select components and systems that will improve their application, a press release said. A â&#x20AC;&#x2DC;quick quoteâ&#x20AC;&#x2122; function allows users to initiate a request for product pricing with-

out a separate e-mail or phone call, it noted.

The new â&#x20AC;&#x2DC;Ask Maxâ&#x20AC;&#x2122; live chat feature allows immediate access to a Fife, MAGPOWR or Tidland customer service representative to help find answers quickly, the release said, adding that user accounts enable visitors to return products for service and manage an online profile to receive updates on training opportunities and new technology from one or all brands.

The companuy notes that its Fife, MAGPOWR and Tidland businesses make Maxcess International a single resource for the latest technology in guiding, winding, slitting, inspection and tension control. Together, these brands deliver over 180 years combined experience in challenging applications and a unique perspective of how their products impact an entire production line.

Contact: Maxcess International, www.maxcessintl.com.

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PRODUCTS & MEDIA

headroom; termination speed; installation practices; grounding and bonding; electromagnetic interference considerations; alien crosstalk resistance; PoE and PoE Plus heat generation issues; security considerations; and cable sharing as high density work area solution.

Contact: Siemon, tel. 860-945-4380, www.siemon.com.

PRODUCTS & MEDIA

Website features streaming video U.S.-based Maguire Products, Inc., notes that it has posted streaming videos of its latest auxiliary equipment innovations to its website (www.maguire.com) as part of enhancements to the company’s website, which it said now provides comprehensive technical information on every model of Maguire® equipment and software.

A press release said that the videos provide demonstrations by a Maguire expert, one of whom is company President Steve Maguire, the chief inventor and designer.

Video topics include: Purging Recovery System, latest innovation by Maguire: the first size-reduction system for routine reclamation of purgings; The Sweeper™, a simple device that empties bulk containers without operator intervention, leaving less than a handful of resin pellets behind; LPD™ Resin Dryer, the only vacuum dryer for plastics processors, requiring (in comparison with desiccant units) as little as 20% of the energy and one-sixth of the time to dry properly; MicroPlus™Blender, with removable hoppers, a corner valve for regrind, and pneumatic lifters that automatically raise hopper lids on which loaders are mounted; GVL Motor Loader, a self-contained unit with

onboard motor, see-through body, and a discharge area designed for bridge-free, free-flowing evacuation; Touchscreen Blender Controller with the same intuitive access as Maguire’s well-known “thumbwheel” controller, plus fast response to inputs and special capabilities for critical jobs; and Gravimetric Feeder, the first low-cost gravimetric unit for metering color into the processing machine, providing accuracy and accountability unachievable with volumetric feeders.

Founded in 1977 and a global technology supplier in material management systems for plastics molding, extrusion, and compounding, Maguire is based in Aston, Pennsylvania, and has five production facilities in Aston and in Smithfield, Rhode Island.

Contact: Maguire Products, Inc., www.maguire.com. ■

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Company profiles are revealed as customers identify the products they want to buy; and new prospects pinpoint suppliers to contact.

wire • cable • supplies • equipment

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

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

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

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

PAYMENT POLICY: All ads must be pre-paid.

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

CAREER OPPORTUNITIES ENGINEER. Champlain Cable Corporation is actively seeking a Materials Development Engineer.

The successful candidate will be responsible for the development of wire & cable products and polymer compounds, cable extrusion processes, product analysis, writing technical reports, customer support, product specification review and writing, and project management for the R&D Department. He/she will interact with manufacturing to transfer new technologies from laboratory scale to production; support marketing and sales with product knowledge, samples, technical data, written reports, and presentations; participate in industrial committees such as SAE and ISO. • Minimum of a BS degree in an appropriate field, Chemistry, Chemical Engineering, Polymers or Materials Science.

• Three plus years of industrial experience, with preference to the wire and cable industry.

• Compound development expertise.

• Ability to perform hands on laboratory work.

• Knowledge and/or experience with polymeric materials.

• Excellent analytical abilities, and written and oral communication.

• Knowledge of QA/ISO processes.

Apply online by emailing resume,

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.

cover letter, and salary requirements to hr@champcable.com PROCESS ENGINEERS. Carlisle Interconnect Technologies (formerly Tensolite Company) is actively seeking three (3) Process/Product Development Engineers. Essential responsibilities include a hands-on approach to creating standard operat-

ing procedures and work instructions for cable manufacturing, development of new wire and cable products, develop solutions leading to the implementation of corrective actions, provide equipment performance specifications, and coordination/implementation of projects contributing substantially to plant profitability.

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

FOR SALE

1 - HALL Vertical Accumulator, 15” O.D. Sheaves, 500’ accum., ‘97 4 - NEB 64-Carrier (1), 48-Carrier (3) Type CB-1 Cable Braiders 2 - WARDWELL 24-C Speedmaster Braiders 7 - WARDWELL 12-Carrier Braiders 10 - NEB 12-C, 16-C, 44-C, 96-C #2 Braiders 1 - WATSON 36” Rotating Cabler Line 4 - NORTHAMPTON 800mm (1), 630mm (3) D.T. Twisters 2 - NEW ENGLAND BUTT Model C58 12-Wire 8” Vertical Planetary Cablers 2 - NEW ENGLAND BUTT Model C58 6-Wire 6” Vertical Planetary Cablers 1 - CEECO 6-Bobbin 60” Closer w/Caterpuller, Take-up 1 - DAVIS ELECTRIC Model CAT-TRAK 22 Caterpuller Capstan 1 - VITECK 24” Horizontal Belt Wrap Capstan 3 - D/S 3.5”, 2.5” 24:1 L/D Extruders 2 - D/S 2.5” 24:1 L/D, 2” 30:1 L/D Hi-Temp Extrusion Lines 1 - D/S / KILLION Model KL100 Extruder, 24:1 L/D, 2001 2 - TULSA 24” Motorized Shaftless Payoffs, Model HSPO-1, 12/02 3 - MGS 18-Bay 10” Tubular Stranders 1 - BARTELL 12-Bay B62 Tubular Strander

5 - D/S 36” (1), 30” (4) Dual Reel Take-ups 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 5 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-ups 1 - CLIPPER Model SP16 Dual Spooler 1 - DAVIS ELECTRIC Model CRS30 Respooler 1 - WATSON/AFA 96” Rewind Line, 10,000lb reel weight max 2 - TEC Model 24STC Hi-Speed Twisters, rated 1300rpm w/2-Wire Payoffs 41 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels 1 - KOMAX Gamma 333 Cut & Strip 1 - AUTOMATED PACKAGING SYSTEMS Bagger, Model H-100E Legend 2 - EUBANKS Model 8000, 9800 1 - EUBANKS Model 4000-04 Cutter & Stripper w/HUESTIS 36” Payoff 1 - AUTOJECTOR HCS-40 Injection Molding Machine 1 - KIRSTEN Stripper/Crimper, Model K750 10 - SCHLEUNIGER MP257, 2015, OS9100, OS9400, PS9500, PS9500RS 8 - AMP K, ELT Presses 10 - ARLINK Work Benches 15 - A-Frame Work Stations 1 - MIYACHI Laser Welder

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

MAY 2010 | 75

CLASSIFIEDS

CLASSIFIEDS

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”)

• BS in engineering discipline preferred. Associates degree with at least 3 years of engineering experience in wire and cable industry considered. Aerospace data bus, highfrequency coax, or high-voltage wire and cable experience preferred.

• Excellent written and verbal communication skills.

• Experience with data acquisition hardware and/or software a plus.

• Proficient with Microsoft Office tools.

• Ability to build and work within teams.

• Ability to work within cross-functional environment to gain consensus and cooperation.

• Understanding of electrical signal or power transmission principles and relationship to product characteristics preferred.

• Experience with CAD software preferred.

• Project management training a plus.

Apply via email by sending resume and salary requirements to Teresa.tezack@carlisleit.com.

DESIGN ENGINEER. Carlisle Interconnect Technologies (formerly Tensolite Company) is actively seeking a Product Design Engineer.

Essential responsibilities include working on design and costing for product manufacturability, product development and productivity improvements.

• BS in engineering discipline preferred. Associates degree with at least 3 years of design engineering experience in wire and cable industry considered.

• Excellent written and verbal communication skills.

• Proficient with Microsoft Office

Serving the non-ferrous and ferrous industries since 1983

76 | WIRE JOURNAL INTERNATIONAL

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.

tools.

• Ability to work within cross-functional environment to gain consensus and cooperation.

• Understanding of electrical signal and/or power transmission principles and relationship to product characteristics preferred.

• Ability to handle multiple tasks.

Apply via email by sending resume and salary requirements to Teresa.tezack@carlisleit.com.

PERSONNEL SERVICES “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, or visit the Wire Resources website at w w w. w i r e r e s o u r c e s . c o m . Wi re Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE.

APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ wmconnect.com.

SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service.

60+ years of quality products and service to the wire industry. Contact Bill Drumm at 1-800-332-0747, or E-Mail at sales@sancliff.com.

AJEX & TURNER WIRE DIES CO. offers a wide range of PCD/ND/ Carbide Dies, Extrusion Tools, Die Polishing Machines, Ceramic & Diamond Tools. www.ajexturner.com.

Send inquiries to ajexturner@ gmail.com/sales@ajexturner.com A53, G.T. Karnal Road, Delhi-33 India.

Ph: 0091-9811078882 (Ravi Bansal).

MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904-388-3654.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & Non-ferrous; Marldon Rolling Ring Traverses) and Used Wire & Cable Equipment.

Available (Cleaned, painted & checked operational) Buttwelders: Micro Models E1S, J4S, J5S, J6S, THD, J45C, GP-0 and AD-5. Coldwelders: Koldweld Models KBM-5 & KBM-9.

Babcock Models CBW-2, CBW-10 &

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

CBW-20. Printers: Gillies Models GS500 & GS100HD. Roll Pointers: Morgan Models #250 and Hand Operated. Inquire on other used equipment. Please contact by telephone at #727-863-4700 or by e-mail at urbassoc@verizon.net.

MEDIA MEDIA ELECTRICAL WIRE HANDBOOK. This three soft-cover 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 more. List Price: $99, WAI Member Price: $59. To purchase, go to wirenet.org and click on The WAI Bookstore.E■

WAI moves information The Wire Association International (WAI), Inc., delivers The WAI Connection, its comprehensive online newsletter, to our members twice each month.

Featuring the latest WAI, Chapter, and industry news—as well as late-breaking event and people items—it’s a great way to stay informed about the industry.

But if we don’t have your most current e-mail address, we’re both missing Connections! A quick e-mail message is all it takes to help us deliver The WAI Connection directly to you. But without your update, you may miss out.

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

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

Enlighten us with your updated e-mail address today!

The WAI Connection is an online publication of The Wire Association International, Inc.

MAY 2010 | 77

CLASSIFIEDS

DIES

ADVERTISERS’ INDEX

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

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

Ace Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Alloy Wire International Ltd . . . . . . . . . . . . . . . . . . . . . . . .38

Howar Equipment Inc/ACM . . . . . . . . . . . . . . . . . . . . . . . .16

Alumoclad de Mexico SA de CV . . . . . . . . . . . . . . . . . . . .33

Howar Equipment Inc Unitek . . . . . . . . . . . . . . . . . . . . . . .47

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .72

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23, 40

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

IWMA Educational Trust Fund . . . . . . . . . . . . . . . . . . . . . .80

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .44

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

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

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

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .75

Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . .76

Elof Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Eurolls SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .14

Flymca & Flyrd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Power Sonics LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .45

WIRE JOURNAL

®

INTERNATIONAL

DRAWING LINES

TO CAPITAL EQUIPMENT.

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

JULY 2010 | EQUIPMENT: PART 1 Part 1 of this two-part feature will showcase some of the newest technology and machinery displayed at wire Düsseldorf. If you sell machinery for wire and cable making, make plans to advertise today.

Also: Wire Expo Wrapup Contact the WJI Sales Team to reserve your space today.

Bob Xeller | ext. 119 | bxeller@wirenet.org or Anna Bzowski | ext. 126 | abzowski@wirenet.org

78 | WIRE JOURNAL INTERNATIONAL

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

Rockford Manufacturing Group Inc . . . . . . . . . . . . . . . . . .51 Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

WIRE ASSOCIATION INTERNATIONAL ADS

SAMP USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41, 43

WAI Monterrey ITC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Sealeze A Unit of Jason Inc . . . . . . . . . . . . . . . . . . . . . . . .17

Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27-28

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

Interwire 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48-49

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

WAI webinars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

SuperPower Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

WAI Reference Guide/Virtual Trade Show . . . . . . . . . . . . .74

Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . .42 Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Tubular Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 US Synthetic Wire Die . . . . . . . . . . . . . . . . . . . . . . . .Cover 2 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .79 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .72 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 4

Next issue

June 2010 WJI • wire Düsseldorf wrapup • Ancillary Equipment/ Replacement Parts

Wire Expo:

Milwaukee May 12-13.

Booth Number: 218 WAREHOUSE SPACE AVAILABLE: PAWTUCKET, RI - ATTLEBORO, MA - MORVEN, NC - BONHAM TX

RECENT PURCHASES — INVENTORY HIGHLIGHTS BRAIDERS: WARDWELL 16C/24C Wire/Textile Braiders (500+) New Speedmaster 150 Heads (30.)

BRAIDERS: SPIRKA 16C/24C OMA Hi Tech 16C/24C, NEB, TMW Braiders EXTRUDERS: DAVIS STD. 1 ¼”, 1 ½”, 2”, 2 ½”, 3 ½”, 4 ½”, 6” 24:1 Air cooled Extruders DUAL TAKE UPS: CLIPPER PA-16, PA-24, PA-30, PS-24, PS36, PS-50 Dual Parallel Axis.

CBR983 WATSON/NEB 61 Wire 22” Rigid Strander EXPL351 NEXTROM 80 mm 24:1 Ext Line w 500mm Split Capstan, S.S. trough, 1200 mm BCA-12 Belt Cat (New). Yr Mfg 1999.

CBR1050 DYNAMEX 30” S.Twist Cabler w Controls, Yr Mfg 2000 CLR220 REELEX D1500 Dual coiler w/controls Yr Mfg 1999.

CBR1049 (3) LESMO 760 mm D.T. Bunchers, Yr. 1998, w/Siemens PLC & Simoreg Drive / Mistubushi A500 drive.

CBR984 WATSON 19 wire 22” Planetary cabling line (still installed)

WRD831/WRD678 SAMP 8 wire MT8.2.4.21 drawing machine/SAMP 14 wire MLS/5.T.14 CBR957 COOK 48” BH-48 ST. Cabler (still installed). Cook BH36, BH-30, BH-24, BH-22, BH-16 TKU1149 NEXTROM Take ups EKP-63 Yr. 2000 Never used/(4) EKP 50, Yr. 1998, TKU1118-1121/EKP-5, Yr. 2001 (2) WRD890 (3) SAMP TR2TP Wire Drawing/Annealing /Preheating Yr. 2000 Never Used.

CBR998 (8) SETIC 630mm PA630i D.T. Twinners, 1998.

CBR1000 84” CABALLE/KALMAR/POURTIER Drum Twisting Line, 1990’s.

CBR995/CBR989 630mm MGS & TEC, D.T. Twinners.

MGS/BARTELL Payoffs: 60”, 72”, 84”, 96”. Take ups 60”, 72”, 84” 96” (some rebuilt) RWD359 2.6m SKALTEK Rewind Line. A264K P/O, S60/L100 line controls., meas. mach. Guide roller assy. U26T T/U.

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

MAY 2010 | 79

ADVERTISERS’ INDEX

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

EDUCATIONAL TRUST FUND SCHOLARSHIPS

Walter Niehoff scholarships are worth up to $24,000 over two years to an individual trainee, student or apprentice engaged in study, research or training activities related to the wire, cable or wire product industries. Awards can also be made to industry institutions or establishments that offer training in the wire and cable sector.

THE IWMA EDUCATIONAL TRUST FUND â&#x20AC;&#x201C; MAKING LEARNING PAY TODAY FOR THE TECHNOLOGY OF TOMORROW

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