Spring & Fastener Equipment by Wire Journal International, Inc.

WIRE JOURNAL NOVEMBER 2008

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

Spring & Fastener Equipment

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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DOUBLE TWIST STRANDERS FOR THE STEEL INDUSTRY 4HE $OUBLE 4WIST 3TRANDER IS SPECIFICALLY DESIGNED FOR THE MANUFACTURE OF HIGH QUALITY STEEL STRANDS 4HE RANGE OF MACHINES ALLOWS THE USER TO PRODUCE UTILIZING THE DOUBLE TWIST PROCESS STRANDS FROM UP TO WIRES WITH WIRES FROM MM UP TO MM -ULTIPLE PAY OFF DESIGNS CAN BE PROVIDED WITH A FLEXIBLE DESIGN TO ADAPT TO THE SPECIFIC REQUIREMENT OF THE BOBBINS DIAMETER AND NUMBER OF BOBBINS 4HE STRAND IS FORMED BY TWO PRE TWISTERS WITH SEPARATE MOTORS AND DEVIATION

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WIRE JOURNAL

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

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

CONTENTS

Volume 41 | Number 11 | November 2008

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 24 People . . . . . . . . . . . . . . . . 28 Fiber Watch . . . . . . . . . . . . . 30

wire China wrapup . . . . . . . . . .42

Fastener Update . . . . . . . . . 32

Organizers of wire China say that the business climate remains good, with exhibitors reporting brisk activuity and many good contacts.

WAI News . . . . . . . . . . . . . . 36

Spring & Fastener Equipment

Chapter Corner . . . . . . . . . . 40

This feature presents a range of spring and fastener equipment as well as some thoughts on the sectors from the heads of CASMI and the Industrial Fasteners Institute.

. .44

Technical Papers . . . . . . . 60-77

T ECHNICAL P APERS Products/Media . . . . . . . . . . 78 Classified . . . . . . . . . . . . . . 83 Career Opportunities . . . . . . 83 Advertisers’ Index . . . . . . . . 86

Evaluation of motor winding insulation performance under pulse waveforms through electrical measurements Andrea Cavallini, Davide Fabiani, and Gian Carlo Montanari . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Effect of die semi-angle and multi-pass drawing on additional shear strain layer Kazuki Hosoda, Motoo Asakawa, Satoshi Kajino and Y. Maeda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Zinc-aluminum coating: management of Galfan® lines René Branders and Andrew Stacey . . . . . . . . . . . . . . . 74

Cover: A sampling of fasteners and springs. A range of the equipment used to manufacture such products is presented in this feature. See p. 44. Cover photo by Bill Branch.

NOVEMBER 2008 | 3

INSIDE THIS ISSUE CONTENTS

THE NEWS :

E UROLLS . . . .10

WIRE

Eurolls President Renato Raiz is interviewed by a local television station during the official opening of the new Cortinovis Machinery SpA building, which joins Team Meccanica SpA and Vitari SpA at the Italian company’s complex in Val Brembo, near Bergamo (Lombardy).

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C HINA

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. . . . . .42

wire China began with a splash of color at the opening ceremony. Some 30,000 people attended the combined wire and tube events at the Shanghai New International Expo Centre collectively saw 1,098 exhibitors showcase their newest technologies on 618,945 sq ft of exhibit space.

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EDITORIAL WIRE JOURNAL

EDITORIAL

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

Industry operating in a global economy: opportunity can come with a downside Up cycles and down cycles have long been a part of the wire and cable industry, and while the slow periods could be difficult, and painful, there was a certain predictability about them. A sense that the law of supply and demand would eventually even things out, especially in today’s global market, where there is always a hot region to pursue. After all, this is the 21st century, where the focus is on prosperity and a greater tomorrow, with many means to get there. Then again, that mindset might in part have led to the current situation. For all the heady pluses of operating in a global marketplace, it turns out that it can come along with some downsides. And they haven’t been pretty. Global problems have a way of grasping one and all, even though industry has little if anything to do with the recent crash of world stock markets. A staggering deployment of resources was made by financial leaders, a rare coming together, and optimism returned. Only the markets did not continue to respond as hoped. Credit was still hard to come by and the stock market further slipped, then plummeted, into the abyss, dragging along with it huge chunks of the investments of millions of people and emptying the credit well for business. What happens from here? There is no lack of experts ready to proclaim the future, even though they don’t agree with each other. There is no historical context for the current conditions because of the interwoven jigsaw puzzle of the world we live and work in. Meanwhile, companies must continue to plan and invest in their future. Wire and cable as a sector traditionally lags the economy, although some producers (think building wire, etc.) could tell you that the damage precipitated by bad mortgages has already hit home. The December feature in WJI will be looking at how companies plan to address the current fiscal conditions. If you have thoughts on what industry could or should do, please send them to us at editorial@wirenet.org and we will try to include them in the feature or at Wire Journal Extra.

Mark Marselli Editor-in-chief

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). Single copies: $6 in the U.S.; all other countries $7. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2008 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

CALENDAR

CALENDAR November 20-22, 2008: Wire & Cable India 2008 Mumbai, India. Contact: Cheryl Fernandes, Confederation of Indian Industry, tel. 91-22-24931790, ext. 470; fax 91-22-24939463; www.ciionline.org. April 25-30, 2009: Interwire 2009 Cleveland, Ohio, USA. To be held at the International Exposition Center (I-X Center), Interwire incorporates: Interwire Trade Exposition, the technical program and the WAI’s 79th Annual Convention. It addresses ferrous and nonferrous manufacturing, and electrical/data/voice segments as well as wire forming and related wire and wire products. May 12-15, 2009: wire Moscow Moscow, Russia. To be held at the Expo Centre Krasnya. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188; info@mdna.com, www.mdna.com. June 22-26, 2009: NPE 2009 Chicago, Illinois, USA. NPE2009, organized by The

8 | WIRE JOURNAL INTERNATIONAL

Society of the Plastics Industry, Inc. (SPI), NPE2009 will take place at Chicago’s McCormick Place. Contact: NPE 2009, www.npe.org. October 13-15, 2009: Wire Southeast Asia Bangkok, Thailand. To be held at the BITEC Exhibition Centre in Bangkok, this event, formerly known as wire Singapore, is organized by Messe Düsseldorf Asia Pte Ltd. Singapore. Contact: Messe Düsseldorf North America, tel. 312-781-5180; fax 312-781-5188; e-mail info@mdna.com; Internet www.mdna.com. Nov 8-11, 2009: 58th IWCS Conference™ Charlotte, North Carolina, USA. The IWCS will hold its annual event at the Charlotte Convention Center, Charlotte, NC, USA. Contact: IWCS, Internet www.iwcs.org, email phudak@iwcs.org; tel 732-389-0990. April 12-16, 2010: wire Düsseldorf Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180; e-mail info@mdna.com. ■

W IRE ASSOCIATION I NT’L E VENTS CALENDAR

For more information, contact the WAI, USA. Tel. 001-203453-2777; fax 001-203-453-8384; Internet www.wirenet.org.

November 11, 2008: Reconvene Providence, Rhode Island, USA. WAI will hold its second annual business meeting of the year at the Rhode Island Convention Center. March 3-5, 2009: Modern technologies and modelling of drawing and manufacturing processes of metal products Zakapone, Poland, Members of the WAI’s Poland Chapter are among the organizers of this event, which will present theoretical and practical research results. Contact: Dr. Sylwia Wiewiórowska, wiewior@mim. pcz.czest.pl, www.konferencja.mim.pcz.czest.pl. April 25-30, 2009: Interwire 2009 Cleveland, Ohio, USA. See main listing.

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NOVEMBER 2008 | 9

INDUSTRY NEWS

INDUSTRY NEWS El Sewedy Cables reports plans to build $150 million cable plant in Saudi Arabia El Sewedy Cables, one of the largest cable manufacturers in the world, recently announced the launch of its factory in Yanbu Industrial City, a venture that will represent an initial investment of $150 million. The factory, which will have a capacity of 34,000 tons of copper and aluminum for electrical cables and overhead transmission lines up to 500 KV, will be operational in the first quarter of 2009, said an article in The Saudi Gazette. The factory, it said, will contribute to meet the needs of both the Saudi as well as other Gulf Cooperation Council countries. El Sewedy Cables, based in Cairo, Egypt, is part of El Sewedy Cables Holding Company, which notes that it has more than 20 factories located in 10 countries in Africa, Asia and Europe. It exports its products to more than 110 countries in the Middle East and Africa (MENA), Europe, North America and Far East. Its operations include a new transformer factory that is described as the first-of-its-kind in the MENA region in terms of quality and quantity of production of power transformers and dry type transformers. For its new business in Saudi Arabia, the company has hired Afkar International “to promote its interests in the Kingdom by organizing four events in Riyadh, Dammam, Jeddah and Yanbu, among others,” the article said. It cited Walid Helmi, general manager of Afkar International, as explaining that one reason El Sewedy Cables decided to locate the factory in Yanbu was to tap the Saudi workforce. “El Sewedy Cables seeks from the beginning to recruit young talents from Saudi Arabia,” he said.

Eurolls opens new Cortinovis plant, 3 operations now in single complex For Eurolls Group President Renato Railz, the ceremony inaugurating the opening of its new Cortinovis Machinery, SpA, factory in Val Brembo, Italy—an accomplishment that brought together three key elements of the Eurolls Group— was the culmination of years of planning and hard work. In 2007, Cortinovis joined the Eurolls Group, an Italian entity that has both thrived and grown considerably in recent years. Other members of the Eurolls Group include the Eurolls Machinery Division, SpA, Team Meccanica, SpA, Vitari SpA, Teurema and Sictra Srl. Railz welcomed the more than 200 attendees, which included customers, trade association representatives, authorities and press, with a speech focused on what he called the “E” factor: enthusiasm. Enthusiasm, he explained, comes from a specific policy of friendly incorporations, enhancing the specific know-how and identity of each firm, but also optimizing productive and commercial activities by a group strategy.

Eurolls Group President Renato Railz speaking at the inauguration ceremony for the new Cortinovis Machinery, SpA plant. Seated (l-r) are Giampaolo Bozzetto, president of Cortinovis Machinery, SpA.; Federico Bussola, sales manager of Cortinovis Machinery, SpA; Tony DeRosa, president of Cortinovis Machinery America, Inc.; and Raul Pascoareli, president of Cortinovis do Brasil. “Today, technology, product innovation and after-sales service are undoubtedly the key words for success, but in these 21 early years of activity I realized that no project and goals can be achieved without a solid group of people around you. (That requires professionals) who are not just reliable and skilled, but also positive-thinking, enthusiastic people,” Railz said. He stressed that the achievements that have led to such growth for the Eurolls Group have come from a team effort by such people, people who bring an enthusiastic attitude to work each day as their normal course of business. “So it seems there is no need for celebrations, but I think that celebrations are always important if they can enhance and improve enthusiasm against new challenges,” Railz said. “The results prove that I am right: the three Eurolls Group companies (Cortinovis Machinery, SpA, Team Meccanica, SpA and Vitari SpA) now located in one industrial center, the industrial pole, are going to double the sales proceeds of 2007,” Railz said. “That is why I wanted this celebration day: to show how a period of general recession can be overcome by hard work and confidence in the future, turning worldwide and fast changes of the market into opportunities of new business.” Asked later for further comments on how he views the recent turmoil in the global finance and credit markets, Railz said that the conditions are unsettling, but that the situation

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

10 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

does not change his outlook. “This is a very unusual period, yes, but we will remain firm in our resolve. We planned for the years to come and the reasons we have done this have not changed.” The key is that the Eurolls Group, as it is now organized and located, is better positioned and better able to react to change in the industry, he said. Following the presentations and tours of the facility, attendees were taken by bus to the Castle of Cianezzo, where they enjoyed both a fine dinner and entertainment, a fitting end to a new beginning for the Eurolls Group.

Government support: Interwire 2009 For more details on the International Buyers Program to be offered for the time ever at Interwire, go to p. 36.

Alaska fiber project attains milestone U.S.-based Alaska Communications Systems Group, Inc., reported that it has completed a milestone in its major project to install its new undersea fiber optic cable from Alaska to Florence, Oregon. The cable network, known as the Alaska Oregon Network (AKORN), is now connected at landing points in both Alaska and Oregon, a wire report said. The cable that is laid from Anchorage to Florence was buried in Alaska waters and has come ashore in Florence on the Oregon coast, it said, adding that AKORN will be connected into existing terrestrial fiber routes to Portland, Oregon, and Seattle, Washington. The goal, it said, is for the system to be commercially ready by the first quarter of 2009.

The cable ship Tyco Resolute tied up in Homer, Alaska, where a segment of ACS fiber optic cable was offloaded.

The system, which includes both terrestrial and undersea elements, will have an ultimate capacity to transmit 64 10 G/bit wavelengths on each fiber pair for a total potential bandwidth of nearly 2.6 terabits, a previous company press release said. AKORN, which represents Alaska’s only geographically

NOVEMBER 2008 | 11

INDUSTRY NEWS

diverse undersea route, deploys four fiber pairs that will more than triple the existing bandwidth capacity in the state, the report said. The high-speed, high-performance cable will be continuously monitored and managed by dual Network Operations Control Centers in Alaska and the Lower 48, a security feature that no other telecom carrier in Alaska except ACS provides, it said. The total cost for the system, to include the undersea portions of the project to be managed and constructed by Tyco Telecommunications, will cost approximately $95 million, it said.

Niehoff GmbH building new plant for headquarters in Schwabach, Germany

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Germany’s Maschinenfabrik Niehoff GmbH & Co. KG, a global supplier of machinery for the wire and cable industry, has begun building a new headquarters in Schwabach near Nuremberg, a project that will cost approximately US$37 million, not including the cost for the property. “The upcoming headquarters relocation in Schwabach adds another contribution to the company’s capacity expansion,” a press release said. “This new investment aims at increasing the company’s competitiveness, which is no longer possible at its present site, and at reducing lead times especially in high demand conditions similar to current prevailing economic situations.”

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In attendance (l-r) at the groundbreaking ceremony for Niehoff’s new headquarters were: architect Arnd Willmann; Niehoff President Heinz Rockenhäuser; Schwabach Mayor Matthias Thürauf; Niehoff shareholder delegate Hans-Hermann Kroher; Dr. Michael Schwarzer (chairman of supervisory board); and town official Richard Schwager. More than 400 employees and 40 apprentices work for Niehoff in Germany, which worldwide has five subsidiaries and four representative and service offices with about 250 employees, the release said. It noted that 80 percent of current revenue is still generated at the company’s headquarters. The release said that the company held a groundbreaking ceremony in mid-September and that construction has begun for the first phase, which will see the building of a 183,000-

INDUSTRY NEWS

sq-ft of production area and 16,150 sq ft of production-related offices. The departments included in the first phase are the assembly, test stand, trials, shipping, paint shop and apprentices’ workshop, it said, adding that the cost for the first phase of the project is approximately US$37 million. The shop floors will feature workplaces designed for more

efficient organization of process flows and a savings for material handling and order processing as well as a state-ofthe-art paint finishing system, it said. “Dependent upon future business conditions, the company is planning a second phase of construction consisting of another (86,110 sq ft) production area,” the release said. It noted that Niehoff as a company has continuously invested in the development of new and innovative products and also in machinery, equipment and manufacturing and organizational methods. The company, it said, has also invested in its operations in the U.S. (2004), India (2006), the Czech Republic (2007) and Brazil (2008).

Coleman Cable to shift Oswego Wire work, cut 53 positions at plant Coleman Cable will shift production of some bare wire products from its Oswego Wire Inc. operation in Scriba, New York, to another plant, a decision that will result in the loss of 53 jobs. According to various wire reports, Coleman Cable made the announcement in mid-September to employees of Oswego Wire that the layoffs would take place by the end of the month. It will continue to operate the facility to service regional customers and to continue delivering specialty and multi-metallic wire constructions. The bare wire production will be shifted to the company’s operation at the Indiana plant of Copperfield LLC, which Coleman Cable bought in 2007. “We believe these changes will allow Coleman Cable to control costs in these challenging economic times while at the same time allow us to focus on and improve our manufacturing practices and customer service for our valuable Oswego Wire customer base” Coleman Cable Executive Vice President Richard Carr said. Per WAI’s Reference Guide listing, Oswego Wire, founded in 1987, also produces stainless steel wire, copper-clad steel wire, bronze wire cadmium copper wire and

14 | WIRE JOURNAL INTERNATIONAL

IISI changes name, notes new members

The International Iron and Steel Institute (IISI) announced that, effective immediately, its name has been changed to World Steel Association (worldsteel). Speaking at the organization’s 42nd Annual Conference in Washington DC, Director General Ian Christmas announced the reasons for the new name. “Since we were formed in 1967, the world for steel has substantially changed and so has this organization. We are now a truly global body, representing 18 of the An ISO 9001-2000 certiﬁed supplier world’s 20 largest steel companies, including six of the top 10 producers in China.” The new name, he THROUGH CUSTOMIZED SOLUTIONS explained, “provides a simple description of our role and Advanced technology for wire, tube and strip forming machines clarity to our purpose.” At the meeting, the organization also named its new officers: chairFX SER SERIES IES man, Lakshmi Mittal, chairman/CEO, ArcelorMittal; vice chairman, Ku-Taek Lee, chairman/CEO, POSCO; member, Paolo Rocca, NUMAC chairman/CEO, Techint Group; and member, John Surma, chairman/CEO, U. S. Steel. It also welcomed the following new member companies: Badische Stahlwerke GmbH; Deacero, S.A. de C.V; Laiwu Steel Group, Ltd.; and Metalloinvest Management Company; associate member, Jindal Steel & Power Limited; and affiliated members, Malaysian Iron & Steel Federation.

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INDUSTRY NEWS

bunched/stranded wire. The company, located off county Route 1, just east of the city of Oswego, will remain open with about 40 employees. “Given the choice between closing and downsizing, I’ll pick downsizing any day,” said L. Michael Treadwell, executive director of Operation Oswego County and secretary/treasurer of the Oswego County Industrial Development Agency.

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Bekaert notes changes in Latin America units NV Bekaert SA announced that it and its partners in Ecuador have agreed to create a holding company for their businesses in the northern part of Latin America, with Bekaert being the principal shareholder. A press release said that Bekaert has signed a memorandum of understanding with its Ecuadorean partners, represented by members of the Kohn family, to merge their interests in: Vicson, S.A. in Venezuela (currently 100% owned by Bekaert); Productora de Alambres Colombianos Proalco S.A. (Proalco) in Colombia (currently 87.5% shareholding by Bekaert and 12.5% by

INDUSTRY NEWS

the Partner); Ideal Alambrec S.A. in Ecuador (currently a 50/50 joint venture between Bekaert and the Partner); and Productos de Acero Cassadó S.A. (Prodac) in Peru (currently a 39.9% investment held 50/50 by Bekaert2 and the Partner). The merger will be effected by the establishment of a holding company in which the parties agreed that 80% of the shares involved will be held by Bekaert and the remaining 20% by the Partner, the release said. “Latin America is for Bekaert a growth market which is in full development. This agreement allows us to strengthen our strategic positions and to join the common interests of our operations in the region,” said Bekaert CEO Bert De Graeve in the release. Bekaert’s activities in Latin America go back to 1950, the release noted. “Today they represent almost 40% of combined sales by means of successful joint ventures and subsidiaries in Brazil, Chile, Colombia, Ecuador, Peru and Venezuela.”

New location in Wisconsin for AWC Allied Wire and Cable (AWC), a U.S. wire and cable distributor, has relocated its office and warehouse from Elkhorn, Wisconsin, to a larger 20,000 square-foot facility in Pewaukee, Wisconsin. The move, a press release said, will make it possible to

18 | WIRE JOURNAL INTERNATIONAL

provide customers with faster lead times for customers in the Midwest and Western states, add new machinery and employees and leave room for future expansion. “We are proud that we are moving to a larger facility. It is very exciting that in less than two years, we have outgrown the Elkhorn plant,” said Sales Manager Hans Nelson. The new location will have expanded value-added capacities, particularly striping and re-spooling, with more space and new or upgraded machinery, the release said. AWC’s corporate headquarters is located in Collegeville, Pennsylvania, with additional offices in New England, Florida, Tennessee, and South Carolina. The new facility is located at W233 N2870 Roundy Circle West, Pewaukee, WI, 53072, tel., 800-535-3271.

U.S. subsidiary of TELE-FONIKA rushes cable needed for Hurricane Ike relief TELE-FONIKA Cable Americas, the American subsidiary of Poland’s TELE-FONIKA Group, provided a rush delivery of power cables to Texas and Louisiana – two states that have suffered at the hands of Hurricane Ike. The delivery of the cables started on September 13, immediately after the receipt of the order for power cables by TF Cable Americas, a press release said, noting that Hurricane Ike destroyed or damaged many power lines,

INDUSTRY NEWS

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Power cable from TELE-FONIKA is shipped for emergency repairs in Texas and Louisiana. Photo courtesy of TELEFONIKA Cable Americas. especially in Texas and Louisiana. It noted that in 2005, in the aftermath of Hurricane Katrina, TELE-FONIKA Cable Americas delivered power cables to New Orleans within 24 hours of receipt of the order. With Hurricane Ike on the way, TELE-FONIKA began receiving urgent phone calls from its distributors who were responding to emergency requirements across the full range of end users, including FEMA, TELE-FONIKA Cable Americas President Mike Scheppach said. “Over the short time period we shipped over 1 million feet of cable all inclusive,” Scheppach said. “We expected that the realization of an imminent hurricane hit would have last minute product demands and we remained open during the weekend and later in the evening to respond. And although we shipped products to some customers several days in advance, most of the demand started coming in over the weekend and a day or so after hurricane landfall.” Tele-Fonika specializes in industrial cables, from 600V flexible cord to 2KV portable power cables, which are critical components for emergency power, pumps, lighting and more, Scheppach said.

Italian companies join forces to offer full welding wire equipment lines Represented by: LESMO MACHINERY AMERICA, INC Tel: int + (905) 761-6165 Fax: int + (905) 761-6168

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20 | WIRE JOURNAL INTERNATIONAL

SAMPSISTEMI and GCR Eurodraw announced that they have agreed to cooperate in the field of welding wire manufacturing equipment, making it possible for each supplier to offer a full range of machines and auxiliary equipment, an ability that is especially important for markets and projects in locations such as Russia and the Far East. GCR Eurodraw will produce the equipment for dry drawing, forming and coppering processes while SAMPSISTEMI will concentrate on wet drawing, pail-packing, winding and respooling systems, a press release said. It noted that all products will be compatible with the former

SAMPSISTEMI Sales Director Roberto Bazzani and GCR Eurodraw Managing Director Lorenzo Paolo Facchinelli. product lines of both companies, and that complete manufacturing lines will then be offered to the market under the joint brand SAMPSISTEMI-GCR Eurodraw. “Customers need not fear being left out in the rain; rather, they will benefit tremendously from the develop-

W. L. Gore joins Ethernet Alliance U.S.-based W. L. Gore & Associates, Inc., a developer and manufacturer of high performance cable assemblies, has joined the Ethernet Alliance, an industry group dedicated to the promotion of Ethernet technologies. A press release said that Gore will specifically play a

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INDUSTRY NEWS

ments we introduce on the new lines as a result of our combined experience in the field of welding wire manufacture,” GCR Eurodraw President Paolo Facchinelli said in the release. “SAMPSISTEMI and GCR Eurodraw will form the core of a new group of wire manufacturers, which will focus on process innovation whilst also improving the reliability and user-friendliness of existing wire manufacturing equipment.” “The product lines of GCR Eurodraw and SAMPSISTEMI complement each other ideally,” SAMPSISTEMI CEO Artemio Affaticati said in the release. “The R&D departments of both companies are already working together to build on each other’s experiences, and we are excited by the first results of this partnership. Besides the on-going improvement of existing products, we are also working on new releases so that customers will be able to benefit from our combined welding wire know-how as soon as possible.”

INDUSTRY NEWS

key role in the advancement of developing Ethernet copper cable interconnect technologies. “Currently this includes GORE™ SFP+ and QSFP Copper Cable Assemblies, which are ideal for the highperformance computing (HPC), enterprise networking and network storage markets and are well suited for emerging 10 GbE and 40 GbE applications,” the release said.

Oktoberfest draws 150 attendees The Rockford Oktoberfest, held Sept. 24-26 at Schlatter Inc.’s site in Rockord, Illinois, drew 150 attendees to the event, which presented technology from different companies.

New location for FMS USA FMS USA reports that it has moved to a new larger facility in Illinois, a change that it said stemmed from growth in demand in recent years for the company’s tension control and web guiding products that resulted in the move from Arlington Heights to Hoffman Estates. “This new facility not only accommodates our current needs, but provides flexibility for future growth of the organization,” said Joerg Inhelder, managing director of FMS Force Measuring Systems AG, parent corporation of FMS USA. In a press release, he said that the new facility, which houses sales, technical support and some manufacturing, will also maintain a large inventory of products for quick delivery to the North American marketplace. The office is located at 2155 Stonington Avenue, Suite 119, Hoffman Estates, IL 60169, tel. 847-519-4400; fmsusa@fms-technology.com.

Davis-Standard opens new office

Attendees take a close look at a Wafios system during Rockford Oktoberfest. The event saw demonstrations of wire and tube working machinery that included Pyromaitre stress relieving ovens, Witels-Albert roll straightening and guide rolls, Wafios spring making and wire and tube forming machine and Schlalter mesh welding lines.

AMSC ships superconductor wire American Superconductor Corporation (AMSC) announced that it has shipped approximately 17,000 meters (56,000 ft) of its proprietary second generation (2G) high-temperature superconductor (HTS) wire, branded as 344 superconductors, from the company’s manufacturing facility in Devens, Massachusetts. The cable, to be used for project HYDRA, represents the single largest shipment of 2G HTS wire by any company, a press release said. It noted that Project HYDRA, relies upon the development of new fault current limiting technology, is partially funded by the U.S. Department of Homeland Security (DHS) Science and Technology Directorate. AMSC’s Secure Super Grids™ (SSG) technology will be used in the power delivery network of Manhattan operated by Consolidated Edison Company of New York, Inc.

22 | WIRE JOURNAL INTERNATIONAL

U.S.-based Davis-Standard, LLC, reports that it has opened a new office in Gloucester, Massachusetts, that will be used by personnel representing both the extrusion and converting businesses of the company. Davis-Standard President and CEO Charles Buckley said in a press release that the new office will allow the company to increase its presence throughout the northeast and tap into the engineering and sales talents of the area. “Opening an office in Gloucester for experienced engineers and sales professionals is one more example of our ability to invest in future growth,” Buckley said. “In spite of the turmoil in the financial markets, we continue to grow through market share gains and continuous global expansion.” Wire and cable systems along with the Merritt brand will continue to be based out of the company’s headquarters in Pawcatuck, Connecticut, the release said. The new office is located at 7 Blackburn Center, Gloucester, MA 01930. For more information, contact Ken Sweet at ksweet@davis-standard.com, or tel. 978-381-0122.

RAD-CON relocates corporate offices U.S.-based RAD-CON, Inc., a manufacturer of industrial furnaces, has moved its corporate offices from Bay Village, Ohio, to nearby Lakewood. The new location, a press release said, is part of a refurbished industrial property managed by Omni Lakewood Corp. The space was configured to accommodate RADCON’s growing staff of engineers and programmers, as well as to consolidate its warehouse activities, it said, noting that “exports have been the main driver for company growth to steel industries throughout the world.” In addition to supplying bell-type batch annealing furnace equipment, RAD-CON provides design, installation and operational support of complete annealing facilities. Its equipment is manufactured primarily at affiliated companies in Cleveland, Ohio. ■

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ASIAN FOCUS Shaky U.S. finance markets could lead to bigger role for Asia leaders As world stock and credit markets continue to react to woeful financial conditions, some developing countries may be posed to replace long established leaders in the U.S. and Europe. An article in the Washington Post by Ariana Eunjung Cha said that the conditions shaking the U.S. and other countries have not shaken the confidence of some Asian countries. In her article, she cited one Shanghai investment manager as declaring that Wall Street’s reign as the world’s No. 1 financial hub is coming to an end. In the article, she quoted an investment manager at Guotai Asset Management, which oversees funds valued at about $5.1 billion, as saying that, despite the country’s inexperience in the financial sector, “China has a rare trump card: mountains of cash. It is inevitable that we will take the U.S.’s place as the world leader.” At the time the article was written, Cha noted that

Shanghai’s stock exchange had lost close to two-thirds of its value this year, but that China’s big banks “have escaped the credit catastrophe largely unscathed, and the economy continues to expand.” Venture capital, private equity and foreign direct investment are at all-time highs, she wrote. There are believers at other financial centers that they too are ready to take on a larger role in the overall financial picture as the financial systems react and settle into a new form. Tokyo, Cha wrote, has made it simpler for banks and insurance groups to operate. It has also done something that may appear to be small but does send a message: print securities documents in English. In Singapore, the government, which has massive sovereign wealth funds and has increased its private equity and other financial holdings in recent years, may invest further in distressed assets in the U.S., Cha wrote. Dubai, which has reaped the riches of the Middle East’s oil boom, has postured itself as the center of Islamic finance and its govern-

ment has declared that it wants to “develop the same stature as New York,” she wrote. There has been a flow of capital away from the U.S., Cha wrote. While New York City and London remain financial leaders, both of those, as well as Frankfurt and Paris, are no longer seen as clear-cut leaders. Instead, one study found that cities in Asia and the Middle East have attained a new status, she wrote. Her article cited Michael Mainelli, executive chairman of Z/Yen group, which carried out the survey, as pegging several cities as being likely to take over. “Dubai, Singapore, Shanghai and Mumbai, they are the probable leaders,” she said. Researchers, the article said, looked at factors including infrastructure, foreign direct investment, cost of living and the presence of a fair and just business environment. The article also cited Arkady Dvorkovich, a senior economic adviser, as saying that the U.S. financial crisis could benefit Moscow. “We are not naive. We’re not trying to say that Russia will substitute for the U.S. in the financial sense, but in certain niches, there’s a certain window of possibility for Russia to be a much more active player.” That statement, it should be noted, was made before the Russian stock market plunged even more dramatically than the U.S. market, and was closed for a period. At press time the story continues to evolve, but Cha wrote that however it turns out, China appears well poised to attain a larger role in world finances. “The United States may be grappling with its worst economic crisis since the Great Depression, but these are go-go days in China.”

A personal touch for Beijing autos ... but drivers can’t get too carried away Beijing, the capital of China, is granting citizens a touch more freedom, one shared by drivers in many countries. According to Zinhau/COMTEX News Network, some car owners recently waited in line in Beijing for as long as 48 hours to get personalized license plates. Beijing had introduced “pick-your-own” license plates in 2002, but the program lasted for only 10 days before it reportedly came to a crashing halt after some 23,000 plates had been issued. Turns out that some of the issued plates were deemed both rude and crude, including “TMD,” representing the first letters in a common Chinese swear word, and others such as “SEX 001” and “FBI 007.” The Beijing Traffic Management Bureau says such picks will not be possible as the new system limits car owners freedom to only four digits and one English letter. Still, with some 400 plates were issued in two hours, it is a sign of a driven audience.

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

24 | WIRE JOURNAL INTERNATIONAL

ACL Cables to open rod plant in Sri Lanka ACL Cables, the largest cable company in Sri Lanka, plans to open a copper rod plant as part of its plan to become vertically integrated, reports Lanka Business Online. Plans call for the plant to produce roughly double the copper rod it needs for its four factories that manufacture cables, conductors and enameled wire, the report said. ACL Cables Managing Director Suren Madanayake was quoted as saying, “ACL has always been a stickler for getting the technical know-how right, and this time around too we have got technical support for our copper factory from expert foreign consultants. This copper plant is the natural sequence to our development process as we are a big importer of this product.” The article said that ACL Cables has more than 500 employees in Sri Lanka who produce for key export markets such as India, Australia, the Maldives, Bangladesh and African countries. It added that the company is seeking to develop other markets for their products. The company notes that via its advanced technology, it has “hugely expanded its operations both within and outside the country.”

Sterlite to supply fiber optics to BSNL India’s Sterlite Technologies Limited reports that it has received a contract from Bharat Sanchar Nigam Limited (BSNL), India to supply fiber optic cables with the highest density ever to be deployed in the country. The US$5 million contract is for Sterlite’s RIBBON-LITE ™ 288F ribbon fiber optic cables, which BSNL will initially install in about 100 city sites across India in the rapidly growing FTTx (fiber-to-the-“x”) applications sector, a press release said. This marks the first time that fiber optic cables higher than 144F will be deployed in India, the release said. Ribbon fiber optic cables, it noted, provide an efficient means to achieve high fiber density, as well as reducing the time per fiber required for installation, thus facilitating quick roll-out of a network. “Sterlite is the pioneer of ribbon fiber optic cables in India and has supplied more than 60% of the country’s requirements of these specialized cables since 2003.” Sterlite official K.S. Rao said that in 2008, “the number of broadband subscribers in India has grown by nearly 65% over that in 2007, and India is currently positioned as the 4th largest consumer of optical fiber in the world. ■

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NOVEMBER 2008 | 25

ASIAN FOCUS

ASIAN NEWS BRIEFS

C O N TA C T S COMMERCE A

WIRE, CABLE, AND FASTENERS

SAVE THE DATE FOR THE LARGEST WIRE, CABLE, AND FASTENER MARKETPLACE IN THE AMERICAS CONVENTION: APRIL 25-30, 2009 EXHIBITS: APRIL 27-30, 2009 I-X CENTER CLEVELAND, OHIO, USA

Meet Interwire—the gold standard in wire and cable trade events in the Americas—where inventory and equipment await a global destination. At Interwire more than 500 exhibiting companies will demonstrate how their supplies, merchandise, and machines can elevate your business operations to the next level. Interwire 2009 will be back at Cleveland, Ohio’s I-X Center and backed by the U.S. Department of Commerce’s International Buyer Program. We’ll all be focused on U.S. exports around the world. So when you land new contacts and partnerships at Interwire we’ll help ensure the goods you require are homeward bound. Whether it’s wire to Wales or an order for fence in the Outback, Interwire is a vast marketplace set on an international stage. Educational presentations and networking are another agreeable part of the deal.

The Commercial Service logo is a Registered trademark of the U.S. Department of Commerce, used with permission.

To learn more about the industry’s most anticipated business week in 2009, visit The Wire Association International, Inc. website at: http://www.wirenet.org/events/interwire

Supporting Sponsors:

Educational Alliances:

ORGANIZED BY: The Wire Association International, Inc.

INTERWIRE 2009 EXHIBITING COMPANIES as of October 2008 ABP Induction Ace Metal Inc. ACM AB - KSM AEB International Inc. AIM Inc. All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates Ametek Specialty Metal Products A. Appiani Srl Arcelor Mittal Aurum Chemicals Corp. AW Machinery LLC AWPA American Wire Producers Association AXIS Computer Systems Inc. Aztech Lubricants LLC B & H Tool Co. Inc. Balloffet Die Corp. Bao Zhang Galvanized Iron Wire Co., Ltd. Bartell Machinery Systems LLC Base Ten Consulting Inc. BCS Industries LLC Bekaert Corp. Besel Basim San Tic Ltd. Sti Beta LaserMike Beta Systems Srl BJ Holland Blachford Corp. Bongard Machines USA LLC Boockmann GmbH/The Slover Group Boxy SpA Breen Color Concentrates Inc. Brookfield Wire Co. Butt Welders USA Caballe SA Cable Consultants Corp. Canterbury Engineering Co. Carpenter Technology Corp. Carris Reels Inc. Cemanco LC Central Wire Industries Ltd. CeramTec AG CERSA-MCI Chin Pu Jir Enterprise Co. Ltd. Clifford Welding Systems (Pty.) Ltd. Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. CN Wire Corp. Coats North America. Cometo Snc Commission Brokers Inc. CommScope Condat Corp. Conductix Wampfler-Delachaux Conneaut Industries Inc. Continuus-Properzi SpA CoorsTek Cortinovis Machinery America Inc. CRU North America Inc. Dandong Decheng Chemical Co. Davis-Standard LLC Design & Engineering LLC

Die Quip Corp. Domeks Makine Ltd. Sti Donnelly Reels Dynamex Corp. E-Beam Services Inc. Ebner Furnaces Inc. Ebner Industrieofenbau ECD Inc. Engineered Control Systems Inc. Engineered Machinery Group Enkotec Co. Inc. ERA Wire Inc. Er-Bakir Elektrolitik Bakir Esteves Group Etna-Bechem Lubricants Ltd. Etna Products Inc. Eurobend SA Eurodraw Energy SpA Eurolls Group Eurowire Magazine George Evans Corp. EVG Inc. Fabritex Inc. Fenn Technologies FIB Belgium SA Fil-Tec Inc. Filtertech Inc. Fine International Corp. Fisk Alloy Wire Inc. FMS Force Measuring Systems AG FMS USA Inc. Fort Wayne Wire Die Inc. Frey Group LLC Frigeco Srl Frontier Composites & Castings Inc. FSP-One T. Fukase & Co. Ltd. Garg Sales Inc. Gauder SA Gavlick Machinery Corp. Gem Gravure Co. Inc. GEMCO Electrical GENCA Corp. Germ-Allcard (KP America) W. Gillies Technologies LLC Gimax Srl GMP-Slovakia Rudolf Grauer AG Guill Tool & Engineering Co. Hafner & Krullmann GmbH Vom Hagen & Funke GmbH Heacock Metal & Machine Co. Inc. Heany Industries Inc. Hearl Heaton Heatbath Corp. Henkel Corp. Heritage Wire Die Inc. Hezel GmbH & Co. KG Gebruder Hilgeland-Nutap GmbH Hofmann Ceramic GmbH Houghton International Inc. Howar Equipment Inc. Huestis Industrial Huettner Maschineenfabrik GmbH

ICE Wire Line Equipment Inc. IDEAL Welding Systems Ideal-Werk India Steel Works Ltd. Industrial Steel & Wire Co. Industrial Heating Magazine Inosym Ltd. InterWire Products Intras Ltd. Iowa Steel & Wire 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 Kemaite Optic & Electric Products Co. Ltd. Kinrei of America Klaus Jakob Messlechnik AG KMK GmbH Ernst Koch GmbH & Co. KG Albert Krenn Friedr Krollmann GmbH Kuhar Metallizing Co. Inc. Lamnea Bruk AB Lamnea Bruk USA Lang Vision (Shanghai) Cable Material Co. LaserLinc Inc. Laurel Wire Co. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. J.J. Lowe Associates Inc. M + E Macchine + Engineering Srl MacDermid Inc. Madem Reels USA Inc. Madem SA Magnetic Technologies Ltd. Magnus Equipment MAGPOWR Maillefer SA Mapre Belgium SA Mario Frigerio SpA Markem-Imaje USA Maschinenfabrik Niehoff Mathiasen Machinery Inc. William McCaskie Inc. Merritt Davis Metavan NV MFL USA Service Corp - Frigerio The MGS Group (MGS-Hall-Northampton) MGS Manufacturing - The MGS Group Micro Products Co. Microdia Mikrotek Machines Ltd. Morgan-Koch Corp. Mossberg Reel LLC /Boxy Group NEPTCO Inc. Nextrom Oy Niagara Composites Industries Inc. Niehoff Endex North America Inc.

Northampton Machinery Co. The MGS Group Northeast Steel Corp. Norwalk Innovation Inc. Numamerica/Numalliance Oklahoma Steel & Wire OM Frigerio OM Lesmo OMA USA Inc. OMCG North America Inc. OMCG SpA PA Industries Panchmahal Steel Ltd. Paramount Die Co. Inc. Parkway-Kew Corp. Pave Automation Design PEKUtech GmbH Phifer Wire Inc. Pioneer Machinery Co. Ltd. Pittsfield Plastics Eng. Inc. Plasmait GmbH Plasticolor/Woywod GmbH Polyone Pourtier SAS Power Sonics LLC Precision Die Technologies Inc. Premier Wire Die PrintSafe Process Control Corp. Properzi International Inc. Proton Products Ltd. PWT Ltd. QED Wire Lines Inc. Qinhuangdao Yanda-Guohai Stainless Steel Co. Ltd. Qual-Fab Inc. Queins & Co. GmbH Raajratna Stainless Wire (USA) Inc. Rad-Con Inc. Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Reelex Packaging Solutions Inc. Reel-O-Matic RichardsApex Inc. Rizzardi Rohmann LP Rosendahl Maschinen GmbH Rosendahl Nextrom Technologies Roteq Machinery Inc. Saarsteel Inc. SAMP SpA (SAMPSISTEMI) SAMP USA Inc. Sanxin Wire Die Inc. SARK-USA Inc. Sarkuysan SA H A Schlatter AG Schlatter Inc. Schnell (Wire System) SpA Schunk Graphite Technology Sealeze Setic SAS Shanghai Nanyang Shanghai Yingong Wire Products Equipment Co. Ltd.

Shijiazhuang Kingway Metal Products Co. Shuster-Mettler Corp. Sictra Srl SIKORA International Corp. Simpacks Singleton Reels Sirio Wire Srl Sjogren Industries Inc. Skaltek Inc. SKET Verseilmaschinenbau GmbH Sonoco Crellin Inc. Sonoco Products South Fence Machinery Ltd. Staku-Anlagenbau GmbH Steuler Anlagenbau GmbH & Co. KG August Strecker GmbH & Co. KG Summit City Enterprises T & T Marketing Inc. TAK Enterprises Inc. Talladega Machinery & Supply Taymer Industries Inc. Team Meccanica Srl Technical Marketing Services Teknor Apex Co. Tensor Machinery Ltd. Teurema Thermcraft Inc. Timco Inc. Troester GmbH & Co. KG Tubular Products Co. Tulsa Power LLC Unitek North America Inc. Uniwire International Ltd. Urbano Associates US Synthetic Wire Die Vandor Corporation Vitari SpA Vollmer America Inc. Wafios AG Wafios Machinery Corp. Wardwell Braiding Machine Co. Wardwell Italy SRL Watson Parts & Service Weber & Scher Mfg. Co. Inc. Wire & Cable Asia Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp. wire 2008/Messe D端sseldorf North America The Wire Association International Inc. Wire Journal International Wire Lab Co. Wire Machine Systems Inc. WireCo WorldGroup WireWorld Witels Albert USA Ltd. Woodburn Diamond Die Inc. World B.C. Co. Ltd. Worth Steel & Machinery Inc. Woywod Kunststoff Maschinen GmbH Wyrepak Industries Inc. Yield Management Corp. Zhejiang Minmetals Zumbach Electronics Corp.

PEOPLE

PEOPLE Singapore-Belden has named Koh Thian Guan as Vertical Manager of Networking for SouthEast Asia, responsible for the sales and GTM strategies of Belden’s structured cabling system solutions in SouthEast Asia. Guan has 25 years of experience in regional sales, managing channels and alliances. He has a B.S. degree in mechanical engineering from National University of Singapore. Singapore-Belden is part of Belden, Inc., a global supplier of cable technology for markets such as industrial automation, data centers, broadcast studios and aerospace. John Hubbard has joined Leland Powell Fasteners, Inc., as a project engineer, responsible for special fastener design, tooling design for cold forming equipment, applications engineering and standards management. He has 40 years of fastener engineering experience with Rockford Fastener, Rockford Headed Products, Camcar Corp. and Greenslade & Co. Leland Powell Fasteners, a member of the Elgin Fastener Group, specializes in small diameter special machine screws and tapping and thread forming screws.

28 | WIRE JOURNAL INTERNATIONAL

World Steel Association, formerly known as The International Iron and Steel Institute, named its new leaders at the organization’s 42nd Annual Conference in Washington DC. They include: chairman, Lakshmi Mittal, chairman/CEO, ArcelorMittal; vice chairman, KuTaek Lee, chairman/CEO, POSCO; member, Paolo Rocca, chairman/ Lakshmi Mittal CEO, Techint Group; and member, John Surma, chairman/CEO, U. S. Steel. Lenze-AC Tech has promoted Mark E. Baker to Vice President of Information Technology at its North American headquarters. He has more than 22 years of IT experience and holds a BS degree from the University of Minnesota and a CSS degree from Harvard University. Based in Uxbridge, Massachusetts, USA, it is a member of the Lenze Group, a global supplier of motion management technology. ■

William L. (Bill) Mathiasen, an industry veteran who founded Mathiasen Machinery, Inc., a supplier of used wire and cable equipment, died October 7 at age 77. Mathiasen was well known in the wire and cable industry, having worked in it for more than 40 years. He started out at Syncro Machinery, building new equipment at its location in Perth Amboy, New Jersey. He worked at Hudson Wire Company and Anaconda Wire and Cable. In 1973, he started selling used equipment at Gavlick Machinery Corp., where he rose to vice president of international sales. In 1983, he started Mathiasen Machinery, based out of his home in Connecticut. The growing company moved from a home operation in 1988 when the East Haddam warehouse and office location was purchased. Two of his three sons followed him in the William L. (Bill) family business. Mark joined the company as sales engineer in 1984, and in 1993, Michael came in as a sales engineer and Mark was promoted to vice president. Mathiasen A life member of the Wire Association International and a winner of the Charles D. Scott Distinguished Career Award from the Wire and Cable Manufacturers’ Alliance, William Mathiasen enjoyed traveling, meeting different people and experiencing different cultures. He retired in 1996 and his sons assumed daily operation of the company, Mark as president and Michael as vice president. Other survivors include his wife, Margaret George Mathiasen; son Bill Mathiasen and wife Sandy; daughter-in-law Debbie Mathiasen, Michael’s wife; daughter-in-law Susan Mathiasen, Mark’s wife; three daughters (Joanne Daxon, Judy Dallis and Diane Anderson) and their spouses; 14 grandchildren; five great-grandchildren and numerous nieces and nephews.

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NOVEMBER 2008 | 29

PEOPLE

OBITUARY

FIBER WATCH

FIBERWATCH Verizon: FiOS on fiber path to success There was no lack of doubters four years ago when Verizon announced its ambitious FiOS deployment, the goal being to offer optical fiber service to customers, but according a report by Saul Hansell in the The New York Times, the strategy may prove sound. As Hansell pointed out, there was a consensus that the copper wires used by telephone companies could not match the faster networks offered by the cable industry, but there was not a lot of support for laying fiber optic cable as the per customer cost for doing so was estimated at about $4,000. In his article, he said that there has been customer support for average bundle service prices that top $130 for Internet, TV and voice services. Of those homes “passed,” meaning that they can choose fiber service, 20 percent of those homes have signed up for FiOS (Fiber Optic Service) for video service, and 24 percent buy the Internet, which offers speeds up to five times faster than cable competitors, he said. In the article, Robert J. Barish, Verizon’s senior vice president and CFO of its wired communications division, was cited as saying, “I have yet to see a market where penetration has stopped growing.” Further, it noted that the compa-

30 | WIRE JOURNAL INTERNATIONAL

A Verizon fiber technician tests fiber-optic cabling that runs into a fiber service terminal on a pole. ny has reported that its cost to run the fiber through neighborhoods has fallen below $760 per home passed. While there are positive signs, because of the huge investment and alternatives, “it might be a decade before anyone really knows whether Verizon’s bet on FiOS is a smart

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NOVEMBER 2008 | 31

FIBER WATCH

two million FiOS Internet customers, up from 1.1 million investment in the future or a multibillion-dollar black hole,” last year. Hansell wrote. The article noted that Verizon did not Verizon has maintained that it will consider staying with its existing technolosave in the long run by deploying tech“... it might be a gy as voice telephone lines have continued nology now that will not need to be to decline (8.5 percent last year) and the upgraded. In contrast, AT&T has largely decade before anyone speed of the digital subscriber line (DSL) relied on getting more out of its copper really knows whether technology used to offer Internet service wires, but it “appears to have far less over copper wires has topped out at three capacity to deliver HDTV than FiOS,” Verizon’s bet on FiOS megabits a second for many customers. Hansell said. He observed that cable is a smart investment Still, some critics remain, including one companies are upgrading their Internet cited in the article who “concluded that speeds and digital offerings. Cable com- in the future or a Verizon would be $6 billion in the hole panies like Comcast and Time Warner multibillion-dollar when all was said and done.” have been successful in bundling black hole,” In a separate article in The New York Internet-based phone service with lots Times, Christopher Larsen of Credit Suisse of TV channels and high-speed Internet was cited as saying that if Verizon can service of 6 to 12 megabits a second. continue to get at least 20 percent of the potential customers FiOS offers current top Internet speeds of 50 megabits a to sign up for FiOS video, it will earn an acceptable profit. second and a large menu of video offerings, and Verizon’s The article also cited David Barden of Banc of America hopes are that its packages will allow it to leapfrog over its Securities, who suggested that the past investment should not cable rivals. Moreover, Verizon’s fiber network has the be viewed that way. In the article, he observed that while $6 capacity to add more data speed, video channels and other billion is a considerable sum, it “is almost lost in a company services without rewiring. that has annual revenue of nearly $100 billion and spends As of the end of the second quarter of 2008, Verizon $17 billion a year on capital improvements.” ■ reported that it had 1.4 million FiOS television customers, up from 515,000 a year ago. Verizon also noted that it had

FASTENER UPDATE

FASTENER UPDATE Boeing’s 787 Dreamliner is less of a “dream” for fastener manufacturers In case you missed it, the Boeing 787 Dreamliner, estimated to be worth $610 billion over 20 years at projected sales of 3,350 planes, may not necessarily be the stuff that dreams are made of, at least for fastener manufacturers. According to a Boeing fact sheet, the Dreamliner, which will come in three different sized models, will be made of 50 percent composite materials and 20 percent aluminum, versus 12 percent composites and 20 percent aluminum for the 777 model. The remaining materials for the 787 is titanium, 15 percent; steel, 10 percent; and other, 5 percent. Composite materials include glass, Kevlar, Spectra, Vectran and carbon fiber, which are held in shape by a hardened resin like epoxy or bismaleimide. Two items stand out in the fact sheet for the wire and cable industry. The composite barrel fuselage, which will now be made in one piece, “will eliminate: 40,000-50,000 fasteners, an 80-percent reduction in fasteners, compared to just (one) part for (the) composite,” and in addition will

32 | WIRE JOURNAL INTERNATIONAL

Boeing’s Dreamliner plane has been beset by delays that include a shortage of fasteners. eliminate 60 miles of electrical wire, it said. The results of the changes, it added, will make the plane 20 percent more fuel efficient than similarly sized airplanes as well as decrease emissions and reduce maintenance needs by 30 percent. The FBO Network took a closer look at the change in fasteners and reported the following: “By way of another comparison, a B-747-400 (the current model of Boeing’s jumbo jet, being replaced by the 747-8) uses more than

FASTENER UPDATE

six million identifiable parts. Half of these parts are fasteners such as rivets and screws. Three million fasteners? There are only 2.6 million blocks of stone in the Great Pyramid of Cheops in Egypt.” The article asked readers to imagine the weight of three million fasteners, the labor needed to drill three million holes, how many tungsten drill bits that would require and the potential for mistakes to be made that allow moisture in, leading to corrosion. “If you did not know that people could build such a complex structure as a B-747, you would wonder if it could be done at all.” In contrast, most of the 787’s composite elements are essentially “baked” together in a set of massive autoclaves. Using a process called “composite lay-up,” it is possible to tailor the size and thickness of various components to precise design specifications, which enables the 787 to be as much as 40 tons “lighter” than it would have been if constructed via traditional methods, it said.

Commerce Department finds against steel threaded rod from China The U.S. Department of Commerce announced its affirmative preliminary determination in the antidumping duty investigation on imports of steel threaded rod from China.

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Commerce said that producers/exporters from China have sold steel threaded rod in the U.S. at 77.85 to 206% below normal value. Respondents Jiaxing Brother Fastener Co., and Ningbo Yingzhou Foreign Trade Co., received preliminary dumping rates of 77.85 and 176.57%, respectively, a press release said. Nine Chinese exporters received a separate preliminary rate of 91.22%, with other exporters at 206%, it said. Steel threaded rod is commonly used in commercial construction. Commerce is currently scheduled to make its final determination in December 2008, the release said. The petitioner for this investigation is Vulcan Threaded Products Inc., from Pelham, Alabama.

Anixter completes WCWC buy U.S.-based Anixter International, Inc., reports that it has completed its purchase of World Class Wire & Cable, Inc., a valued-added distributor of electrical wire and cable based in Waukesha, Wisconsin. Anixter paid roughly $62 million in cash and assumed trade liabilities for all of the assets and operations of World Class, which has annualized sales of approximately $60 million, a press release said. Anixter is a global distributor of communication products, electrical and electronic wire and cable, fasteners and other small parts. ■

WAI

NEWS

WAI NEWS

Government support for Interwire 2009: how the IBP program works An announcement in the October WJI issue said that a program from the U.S. Dept. of Commerce (DOC) would provide global support and marketing as well as programming to help qualified U.S. exhibitors that want to take advantage of the International Buyers Program (IBP). Below, a government official and the head of a trade association that has been active in the program provide more details on how the IBP, a first for Interwire, will work for qualified exhibitors.

Commerce Department: there to support U.S. Interwire exhibitors Graylin W. Presbury, a Project Officer in the Trade Promotion Programs section of the U.S. & Foreign Commercial Service of the U.S. Department of Commerce, is working with the WAI on the International Buyers Program (IBP), discussed the program with WJI. WJI: What is the goal of the Commerce Department program to be offered at and through Interwire 2009? Presbury: The particular program being offered at Interwire 2009 is the International Buyer Program (IBP), which is designed to help U.S. exhibitors export or export better. Our U.S. & Foreign Commercial Service (US&FCS) network includes 107 U.S. Export Assistance Centers throughout the U.S. and more than 150 overseas offices, commonly referred to as “posts,” in 87 countries. Through the IBP program, under contract with the show organizer, we use our international network of embassies and consulates to promote the show abroad and recruit foreign buyers to attend the show. Most of these buyers will come in delegations and many of those delegations will be led by a foreign service national (FSN) working for the Commerce Department or maybe the State Department. The organizers prepare a U.S. Export Interest Directory for the IBP, so it’s important for U.S. exhibitors who want to export to sign up for it because it is both a foreign buyer recruitment tool and a matching making tool. At Interwire 2009, we will have an International Business Center (IBC) which is essentially a business lounge for the international buyers. There, they can use the Export Interest Directory and the show directory to help plan their trips to the show floor. We will also be available to counsel U.S. exhibitors regarding our export assistance programs and services. WJI: Why does the government do this? Presbury: In short, exporting, like domestic sales, requires production, which means workers or jobs. Exporting is good for our economy and the world economy. However, exporting can seem like a rather intimidat-

36 | WIRE JOURNAL INTERNATIONAL

The Commercial Service logo is a registered trademark of the U.S. Dept. of Commerce. Used with permission. ing endeavor, especially when you could just focus on domestic sales and not be concerned about language differences, exchange rates, foreign standards, getting paid, etc., things that you may be less concerned about with domestic sales. But for a successful exporter, exporting is well worth the risks. We are tasked with revealing opportunities, helping to make matches and facilitate business negotiations. We also offer advice on conducting business with foreign buyers by country and culture. When necessary, we recommend other agencies, like the Small Business Administration and the Export-Import Bank, to help with export financing or loan guarantees.

Want to be included in the IBP? To qualify for the International Buyers Program (IBP), a U.S. exhibitor has to export products that are at least 51 percent of U.S. origin. The value of intangibles, such as R&D costs and marketing, can be factored in. Companies that wish to take part must contact WAI (interwireibp@wirenet.org) no later than Dec. 8 to be included in the U.S. Export Interest Directory.

WJI: Can a company that is small, yet wants to export, be able to do so without having to add staff? Presbury: While it is possible, it is probably better to at least start with a person dedicated to international sales, and let the developing sales level be the driver behind just how much staff is needed. WJI: For exhibitors, is this a one-time help program? Are there other programs offered through the Commerce Department that can help? Presbury: While there could be some immediate sales or orders placed at the show, our activity at Interwire is best viewed as introductions that could lead to sales through follow-up and eventual negotiations. Of course, we’re going to make the U.S. exhibitor familiar with the U.S. Export Assistance Center near them to help with follow-up, and where an International Trade Specialist can assess the company’s export goals and readiness, and through our programs and services assist them in preparing for and in pursuing realistically attainable goals that grow in manageable increments.

Trade association CEO: IBP export program worked for our group One organization that has taken part in the International Buyers Program (IBP) multiple times is the Material Handling Industry of America (MHIA), the organizer of PROMAT. MHIA CEO John Nofsinger discussed the program recently with WJI. WJI: How did your organization first come to be part of the International Buyer Program? Nofsinger: PROMAT 2009 will be our 10th IBP participation, the first being held in 1989. The decision to apply was part of a broader strategy of internationalizing the event as well as better representing the globalization of the industry. With each cycle, we have seen progressive growth in both international attendance and exhibits. WJI: Has it worked out as well as you had hoped? Nofsinger: Actually, better. In our case, we also participate in eight or 10 international shows over a two-year cycle. IBP contacts as well as visitors to the Center (at the NOVEMBER 2008 | 37

WAI NEWS

WJI: Who are the people who will actually be making WJI: At Interwire, there will be presentations on contacts in other countries on behalf of exhibitors? How different programs: generally, what do they offer? Presbury: We are planning a presentation by the will they be able to know who would be a good person to Director of the Cleveland U.S. Export Assistance Center invite to Interwire? (USEAC). The plan is to have a brief overview of the Presbury: The foreign service nationals (FSNs), who US&FCS and then to talk about what the USEACs offer speak English as well as their home language, generally U.S. companies to assist them in becoming a successful focus on particular industries or regions of their country. exporter or to expand their export sales into new markets. While they will promote and recruit for an exhibition, it is Through the USEACs, we offer several programs and their choice as to whether they will lead a delegation and services designed to take a company from where it is in travel to the show. They will typically use the Export export sales and help it to get to where it wants to be. Interest Directory to help them with recruitment. The These services can range from helping to vet potential Commercial Sections of U.S. Embassies or Consulates foreign buyers, distributors or other potential business are usually open to meet with local business people who partners, to making appointments abroad to meet with want to import from or to represent U.S. firms. As a foreign business prospects at each result, the post or FSN may maintain a prospect’s home operations. Generally, list of companies by industry or prodthere is also a question and answer uct interest. The IBP program is period at the end. We are planning a Showtime pro... a benefit to both gram, coordinated by a few of our WJI: Is the IBP program for both domestic International Trade Specialists U.S. suppliers and U.S. suppliers and manufacturers? who will be at Interwire. Through manufacturers ... Presbury: The IBP program is really Showtime, at no cost, export-minded for trade show organizers who want to U.S. exhibitors can sign-up for brief interested in meeting increase their international attendance, (20-30 minutes) pre-scheduled appointpotential foreign which becomes a benefit to both U.S. ments to meet with the attending FSNs suppliers and manufacturers who are they have pre-selected, to learn about buyers. exhibiting at the show and are interestthose markets and to talk about their ed in meeting potential foreign buyers. product and export objectives for those countries. WJI: At Interwire, who can sit in on the presentations? Presbury: While the presentation is geared to U.S. WJI: Are there any indirect costs for this program for exhibitors, anyone may sit in. I suppose the only limit participants? would be space to accommodate the audience. It could be Presbury: Not that I can think of other than the time an a closed meeting, but that would best be achieved through exhibitor may be spending away from their booth, if they an appointment with a USEAC near them. don’t have someone else to attend to the booth.

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

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NOTE: All checks must be in U.S. Dollars drawn on a U.S. bank. Credit card payments are preferred for members from outside the U.S. and Canada. If a check or credit card is not used, a wire transfer may be sent in U.S. dollars. For instructions, contact the WAI Membership Department at membership@wirenet.org or by phone at (001) 203-453-2777. Your membership dues may be deductible as an ordinary and necessary business expense, not as a charitable contribution. Membership in The Wire Association International, Inc. is held by the individual, not the company, and is continuous unless cancelled in writing. Membership is not transferable. Dues are non-refundable and are billed annually based upon the member’s anniversary date. Annual dues are set by the WAI Board of Directors, and are subject to change.

November 08

International Technical

Conference Proceedings

WJI: What kind of feedback have you had from exhibitors at your show that took part in the IBP? Nofsinger: Very positive. Results have ranged from project-specific to regional manufacturing/distribution partnerships as well as outsourcing opportunities. WJI: Can you cite an example or two of exhibitors that have beneMaterial Handling fitted from the IBP? Industry of America CEO Nofsinger: There are John Nofsinger. many. A controls manufacturer leveraged relationships with IBP visitors to establish a base of operations in China; a major consulting company found a Chinese part-

ner to offer in-country services to its USA customers looking to China; numerous companies have won export orders with even more locating sources of supply. WJI: Does a company need to The process is pretty have a big staff to take advantage of straightforward for this? Are there qualified exhibitors. hidden costs or time-consuming As for response/ procedures? followup ... a Nofsinger: The process is pretty champion needs straightforward to be identified ... for qualified exhibitors. As for response/followup of domestic visits, a champion needs to be identified for the international visitor at the show as well as the numerous contacts that can follow. Language, rules and distance will make the management of the international contacts a bit higher maintenance. ■

Two believers in other DOC programs The IBP program discussed above is one service offered by the U.S. Commerce Department, but other DOC programs exist that can help companies export. Below, one supplier and one manufacturer provide their thoughts on this venue. “There is no way I could have found the wire mills and set up eight appointments over two days in the Czech Republic (without the help of the DOC). They even provided translators,” said Die Quip President Tom Maxwell, Jr., who has been active in “the Gold Key program” for several years. He said that via the program, he has been able to go to another country and meet with qualified customers he otherwise would never have met, and on a very cost-effective basis. “It takes work but it’s definitely worth the effort.” Mount Joy Wire President Tom Duff said that he was unaware of DOC programs until he found out via word-ofmouth. Today, he is a big believer. “The first time for us was last year in Düsseldorf and we were very pleased with the results,” he said. He also took part in the DOC’s Gold Key Program, the goal being to increase exports for his company’s oil-tempered, high-carbon steel wire. Through the program, he said, he was able to find several reliable traders. The results have already been tangible and Mount Joy is on its way to making its goal of making exports represent 20 percent of its revenues by 2010, he said. The Gold Key program will be among those to be presented at Interwire.

At the Die Quip Corp tabletop at the WAI’s International Technical Conference in Prague in 2005, an attendee (seated, middle) speaks with Die Quip President Tom Maxwell, Jr., (seated, right). Seated next to the attendee is Klara Svetecka of the U.S. Commerce Department, and standing is Die Quip rep Hans Heppner. Maxwell said the Commerce Deptartment’s advance work helped him arrange a busy schedule during the conference.

NOVEMBER 2008 | 39

WAI NEWS

show) have opened many doors for both MHIA and members throughout the world.

CHAPTER CORNER

CHAPTER CORNER Speaker assures chapter that ‘green’ energy approach can be win-win deal The WAI New England Chapter drew 45 members and guests to the Old Sturbridge Village in Sturbridge, Massachusetts on Thursday, October 9, 2008 for a memorable—bordering, one could say, on “electrifying”— presentation on “Energy Independence.” Attendees gained insight into the process and issues that a Connecticut manufacturing facility went through that led to their installation of 1,700 solar panels on one of their manufacturing facilities, resulting in an approximately 20% reduction in energy costs there. Sharing this experience was Leighton Lee IV, facilities manager of the Lee Company, who led the company’s efforts in this matter. Lee gave attendees a quick “Energy 101” lesson into the various activities that companies need to do before deciding to take on a project of this matter. An item that he emphasized was the need to really understand a facility’s current electricity usage, stating that, “the electric bill does not show you your usage.” He combined technical and practical information with the attendees to give them

40 | WIRE JOURNAL INTERNATIONAL

New England Chapter Education Chair Denise Coyle, President Paul McDermott and Lee Company’s Leighton Lee IV, who spoke about renewable energy and business at the chapter’s October 9 meeting. a sense of the full scope of issues that were faced in the process. One of the points that he made was that the renewable energy benefit was the by-product of a process

NOVEMBER 2008 | 41

CHAPTER CORNER

into a process that may help their operations costs.” that was begun to consider ways to reduce energy costs. One attendee who felt that the program was beneficial Lee discussed the opportunities for grants from both was Quirk Wire President Dave Thibodeau. “It was defigovernmental and utility sources, showing that the grants nitely worthwhile. This was amazing in a that they were able to acquire way because what his company did was help reduce the cost of the undergo a project that was so extensive project significantly, to the “It was definitely worththat few people would ever consider doing point that they will see paywhile. This was amazing it. He spent a year and a half or two and back in about two years. Of in a way because what he summarized it in 45 minutes. You course, he said, the tradeoff wouldn’t think trying to cut an electric is the added reporting and his company did was bill would be worth all the work but he other requirements that go undergo a project that showed how after rebates, it was very along with acquiring the cost-effective.” grant monies. was so extensive that Thibodeau added that he had gone into “As renewable energy and few people would ever the presentation with mixed feelings but going green become more consider doing it.” left thinking that it might make sense. prominent in the current manufacturing environment, “The way Lee described it, he was able to — Dave Thibodeau achieve all this without disrupting producwe wanted to offer an educaQuirk Wire tion,” he said. tional program that gave our A read-only version of the presentation members more exposure in will be made available on the chapter those areas,” said Chapter webpage. The Chapter’s next event will be their 15th Education Committee Chair Denise Coyle. “Making the Annual Meeting on Thursday, January 29, 2009, at the connection with Leighton Lee was a way to have him share their experience and give our members some insight Mohegan Sun Conference Center. ■

FEATURE

wire China

combined wire and tube events fare well in Shanghai Organizers report that the recent concurrent staging of wire China 2008 at the Shanghai New International Expo Centre with a sister tube event proved to be a good experience for both industry sectors. The largest wire and tube trade fairs in Asia were jointly organized by Messe Düsseldorf China Ltd., the Shanghai Electric Cable Research Institute and the Metallurgical Council of the China Council for the Promotion of International Trade. In a press release, they reported that wire China, The All China - International Wire & Cable Industry Trade Fair and Tube China 2008, The All China - International Tube & Pipe Industry Trade Fair, collectively saw 1,098 exhibitors showcase their newest technologies on 618,945 sq ft of exhibit space to more than 30,000 visitors. “The shows closed … with satisfied exhibitors and visitors, filled order books and an encouraging outlook for good post show business,” the release said. Both events were supported by Messe Düsseldorf, which puts on the world’s largest wire and cable event every other year in Germany, as well as numerous national and international associations, including the Wire and

Business was described as brisk at wire China. Photo courtesy of Messe Düsseldorf.

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Organizers said that more than 30,000 people attended the combined wire and tube events. Photo courtesy of Messe Düsseldorf.

Cable Industry Suppliers Association (WCISA). Exhibitors at the event, which preceded the recent shakeup in the world’s financial and credit markets, said that activity was good and that there were no warning signs that all was not well. “We did not feel any sense of the financial concerns,” said Luis Morancho, C.M. Caballe, S.A. “Our conclusion about the Shanghai exhibition is that there was an increase in the number of foreign visitors, mainly from India and from Europe. Our thought is that these foreign visitors are looking for cheaper machines from the Chinese manufacturers, what is not good for us. However, our business in China is good at this time (in 2008 it will represent a 25% of our annual turnover) but only with machines that there are no local manufacturers.” “We were quite happy with the recent wire China show,” said Ralf Wallmeyer, IDEAL-WERK. “The organization was in accordance to our expectation and, to be honest, the number and quality of visitors exceeded our expectations.”

WAI’s Anand Bhagwat, left looking forward, was kept busy at the WAI booth.

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“For Gimax, the show was very good. We had a very large number of Chinese visitors and in particular Indian visitors; what we appreciated a lot was the fact that many of the visitors were customers or potential customers that we invited personally,” said Enrico Romagnolo, Gimax Srl. “The first two days in particular, we were kept very busy, and then it slowed down. The show exceeded our expectations to the point that we will be booking a much larger booth next time and we will certainly have some machinery there.” Romagnolo said there were no signs of financial concerns. “We got numerous requests for proposals both from Chinese and Indians. There were no specific comments about cutbacks in expenditure, on the contrary, I had the impression things were moving along quite well.” The WAI was among the exhibitors. Anand Bhagwat, who heads the Association’s subsidiary in India, said that the majority of his visitors were from China and India, reflecting still robust Chinese and Indian economies. “WAI received a very good response from the visitors. The general interest from Chinese visitors was for Interwire, our books and publications and membership. The membership has a complicated twist regarding dues structure, something we will have to further explore.” The wire and tube events featured country group exhibits from Austria, Great Britain, France, Germany, Italy, Korea, Spain, the U.S. and Taiwan, the release said. It noted that two special showcases (“Chemical” and “Spring & Fastener”) experienced rapid growth, with the

Spain’s Caballe was among the exhibitors at wire China.

number of companies taking part in “Chemical” exhibit doubling compared to the 2006 event. Attendees at both trade fairs included delegations from India, Iran, Japan, Korea, Malaysia, Taiwan, Thailand and Vietnam, the release said, adding that there were also delegations from numerous provinces and regions from mainland China. Attendees, it said, gave wire and Tube China 2008 good ratings. “The exhibitors were pleased with their participation in wire and Tube China 2008 and praised the excellent business talks with the attendees, their level of decision-making authority and high international ratio,” the release said. The events included forums, conferences and technical seminars, with one highlight the 2008 China Wire & Cable Industry Conference, which addressed “Sense, Concept, Sustainable Development.” “wire and Tube China have grown considerably during recent years and become the leading wire and tube trade fairs in Asia,” the release said. It observed that “the prosperous Chinese market was certainly helpful in this development,” noting that production volume of Chinese wire and cable accounts for 20% of the global market, with an annual growth rate of 10%. The next staging of wire and Tube China will be in September 2010 in Shanghai. Contact Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. ■

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Spring & Fastener Equipment

his feature presents information on a range of spring and fastener equipment from suppliers, including some systems presented recently at Spring World. It

also includes observations about the two fields from heads of two industry organizations: the Chicago Association of Spring Manufacturers, Inc. (CASMI), the sponsor of SpringWorld 2008, and the Industrial Fasteners Institute (IFI).

Springs Bennett Mahler Ltd./NIMSCO At Spring World, U.K.-based Bennett Mahler Limited represented in North America by NIMSCO, displayed its MC-25 servo-driven spring coiling lathe for the first time. The system offers the company’s largest processing sizes, able to work wire with a maximum wire diameter of 1.000 in. hard wire/1.250 in. annealed wire (the ultra large springs can be used for applications such as trains). As with six other smaller Bennett Mahler models in the machine range, the system is able to accurately coil wire diameters down to 0.200 in. Thus, the Maxicoil MC series can produce extremely accurate and repeatable springs for end uses such as aerospace and performance racing cars as well as those made by general spring making factories. The company’s innovative software not only allows springs to be set up very easily and quickly, thereby minimizing the amount of material used, it also greatly “de-skills” the spring-making process by assuring squareness of the spring ends, control over the transition coils and the amount of initial tension to

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The MC-25 spring coiling lathe from Bennett Mahler Ltd., represented in North America by NIMSCO. be controlled from the keyboard. Bennett Mahler also manufactures a complete range of spring end grinding machines. Springs made on the larger Bennett Maxicoil MC machines can then be ground on the Bennett DHG-660 single-end, dry

Fenn Division/SPX Precision Components The U.S.-based Fenn Division of SPX Precision Components offers CNC multi-axes spring former machines that represent revolutionary 12-axes spring/wire forming performance in an easy-to-use system that offers high speeds and accuracy. The CMM-12-260RWmodel, which was shown at the recent CASMI event, features: free-arm technology; window screen operation; servo-driven slides; a servo spinner tool; intuitive graphics user interface based on Windows with a “crash free” characteristic; and standard

A 12-axes CMM model, shown at Spring World, offered by the Fenn Division of SPX Precision Components. bells and whistles such as rotary wire, rotary quill, spinner and eight forming blades. The CMM-12-260RW model can process wire from .016 in. to .080 in. Maximum wire feed speed is 328 feet per min and minimum wire feed is .0004 in. The system comes with an industrial grade computer and a flat LCD display with software that can store more than 2,000 runs. Contact: Nelson Ferguson, Fenn Division/SPX Precision Components, nelson.ferguson@fenn.spx.com.

Huei Shang Industrial Co., Ltd./FSI Taiwan’s Huei Shang Industrial Co., Ltd., represented in North America by Forming Systems Inc. (FSI), displayed one of its CF series of spring coilers at Spring World. The line features computer-controlled servo

The spring sector outlook WJI posed some questions about the outlook for the spring sector to Tom Renk, executive vice president, Chicago Association of Spring Manufacturers, Inc. (CASMI), the organizer of Spring World.

WJI: U.S. fiscal concerns have increasingly been felt around the world: has this impact been felt yet by spring manufacturers? Renk: Dealing with the economic downturn has been one of the primary challenges for the CASMI springmaking membership. Since manufacturing in general has been adversely affected, the springmakers that supply parts have been affected as well. This, coupled with the (unstable) U.S. dollar, has impacted some of our members more than others. The housing, automotive and appliance industries have slowed dramatically and spring orders have fallen off in these product segments. A number of companies have cut back on three shifts to double shifts, and some have gone back to just a single shift. I recently heard of one Tom Renk manufacturer that reduced the company’s work week to just three long work days to maintain better machinery and staff efficiencies and lessen building costs. That’s the downside. At the same time, this situation is actually offering some advantages to companies with the ability to offer spring products for the export marketplace. The agriculture, construction, aerospace and defense industries have experienced good growth and springmakers serving those industries have seen a rise in production. WJI: Do you see overall conditions getting better or worse for the spring sector? Renk: In talking with spring manufacturers, they’re generally saying that they are definitely in a down cycle and they expect manufacturing to continue to slow down. The bottom of the cycle will be dictated by the public's willingness to again shop and purchase hard goods. Once they have the confidence to buy, then everything will start to grow. For example, people are not buying major expenditure hard goods because they are more concerned about necessities. Without cars and machinery being purchased, hundreds of parts manufacturers and supplier companies are idled as they have fewer orders. Until the consumer signals they have confidence, there will be no up-turn. Will it get better? That has yet to be determined, but manufacturers are optimistic that we will be going into a recovery cycle, even if it is not as soon as we would like it. WJI: What are the most significant challenges that spring manufacturers face now? Are these likely to be any

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spring grinding machine or, alternatively, on the new watercooled version, the Bennett WHG-660. Both machines have a 26-in.-diameter grinding wheel, which in-feeds while springs that are clamped in two separate tooling stations oscillate horizontally across the grinding wheel. These machines ensure that springs are ground to the highest possible squareness tolerances, are extremely simple to set up, and are very efficient spring grinding machines. Contact: Bennett Mahler Limited, sales@bennettmahler.com, www.bennettmahler.com. In North America, Jerry Jacques or Jerry Ashdown, NIMSCO, info@nimsco.com, www.nimsco.com.

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more or less difficult to surmount than prior down periods? Renk: The challenge of competing in the global marketplace is high on the list. Import parts are taking away market share here and abroad and that translates into lower sales volume. Other challenges include raw material shortages and (unstable) material prices. For years, spring manufacturers have been asked to provide spring parts on a Just In Time basis. This allowed spring manufacturers to make the spring parts in huge runs, thus maximizing the effectiveness of both equipment and personnel to hold down costs. They then warehoused the product until it was needed, often shipping parts on a weekly or monthly basis. With manufacturing slowing down, the call for these spring components has slowed down and inventories are stacking up. That means normal production schedules are changed because there are already springs waiting to be shipped. Another element is the importance of lean manufacturing. Trying to do more with less and, in general, learning to do things in a more intelligent manner, has become increasingly important for springmakers. Companies are looking to save money any way Companies are they can so they don’t have to looking to save pass along price money any way they increases to their end users. Our can so they don’t spring manufachave to pass along turers have lost price increases to market share to overseas spring their end users. makers, due to the weakness of the dollar, although this is a plus in the export markets. We are also seeing more of these foreign springs failing to hold up to the stresses they are designed for. That lack of quality in some overseas spring products are bringing the production back to America so they can get the quality back. WJI: In such a timeframe, many companies make containing expenses the top priority: From a long-term perspective, is this the best approach? Renk: Reduction of expenses is the first defense against slow times so you don’t have to downsize staff. But after you have reduced expenses as much as possible you have to look at staff reductions if you can’t keep them busy. The problem there is that once you lose talented people to staff reductions, a company is handicapping its return to normalcy because new hiring and training will have to take place.

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The HTC60CF spring coiler from Huei Shang Industrial Co., Ltd., shown at Spring World and offered in North America by Forming Systems Inc. motors, cam-less operation for quick and easy setup, standard spring shapes pre-programmed in computer CPU for easy setup and computer-controlled mandrel in/out movement, with standard features including O.D. control, rotating cut and straight cut-capability. The system, which has on-screen diagnostics that show alarm status and whether corrective action is needed, works on a continuous rotation mode to ensure high-speed production capacity and uses a micro pulse hand wheels for easy set-up and programming for either the manual or auto mode. Optional features include: safety guard, torsion attachment, spring length gauge and long spring guide. The HTC60CF model, shown at Spring World, can process wire from 2.2 mm to 6.0 mm at a maximum rate of 130 pieces a minute. Contact: Huei Shang Industrial Co., Ltd., sales@hsiwww.com, www.hsiwww.com. In North America, Tim Weber, Forming Systems Inc., info@formingsystemsinc.com, www.formingsystemsinc.com.

Itaya Engineering Ltd./A.I. Technology Japan’s Itaya Engineering Ltd., represented in North America by A. I. Technology, Inc., offers a wide range of spring making equipment, but it would like to focus here on an important element of better spring production: process control. Faster! Faster! Faster! That was the mantra of the 1990s. Everyone wanted machines to go faster! Faster! Faster! After all, a tenth of a second saved per part would shave off almost 28 hours on a million piece run. Machines today routinely run from three to 10 times faster than their predecessors. However, one must carefully monitor the parts for quality purposes. Itaya Engineering Ltd. developed the first statistical process controller to monitor the free length of compression springs. These units were often adapted to other types of machines. Now customers need to control free length, diameter and angular relation. Responding to these needs, Itaya developed the SCD-7. The SCD-7 is still a

The SCD-7 capacitance sensor from Itaya Engineering, which was among the exhibitors at Spring World. springs, total springs, ratio of good to bad, histogram, statistic data and more are all saved on USB flash memory. This flash memory can be taken from the unit and printed on a PC off-sight of the machine. The SCD-7 is used extensively in "lights out" operations. With the capability to correct parts based on the parameters that the user decides on, each SCD-7 is unique to that operation. The ability to customize the machine to suit your needs is invaluable. The SCD-7 Image Sensor System uses a CCD device to capture the image of a spring at the trigger point you decide upon. The calculations are performed in 20 milliseconds. So even if you are running high volume at high rates of speed, you can still use the image system to monitor your parts. Inspection and correction in a lights-out atmosphere, now that's productivity! Visit our website for specific spring equipment models. Contact: Itaya Engineering Ltd., www.itaya.co.jp. In North America, Carl Atwater, A. I. Technology, Inc., catwater@aitechnology.us, www.aitechnology.us.

springs and wire forms without wire hitting other tools, bend wire in both directions with a round center pin and make multiple bends in the front leg after body coils are made. The HX machine comes with eight individual servo slides, rotary wire, rotary quill, moving wire line and wire feed axes. Additional An HX series spring and wire former axes include up to former from Nucoil Industries that two twin servo was shown at Spring World. spinners with rotating center pins, two regular servo spinners, a servo rotary tool holder to control initial tension and make double torsion springs, and a servo cutter for large wire. Using high-speed digital servos from Austria, the HX machines run all 21 servo motors with high-speed and precision, without using homing sensors or limit switches. The HX-35 model can process wire from 1.0 to 3.5 mm while the HX-60 model can process wire from 3.0 mm to 6.0 mm. Accessories include a tool set, laser probes, an FU-series inverter payoff reels and more. Contact: Nucoil Industries, Inc., sales@nucoil.com, www.nucoil.com.

Shinko Machinery Co., Ltd. At Spring World, Japanâ&#x20AC;&#x2122;s Shinko Machinery Co., Ltd., displayed a TF series spring maker that was designed to produce springs to precisel specifications. The TF-23S model can process wire from 0.6 mm to 2.6 mm at a maxi-

Nucoil Industries, Inc. At Spring World, U.S.-based Nucoil Industries, Inc., displayed its HX-series of spring and wire-forming machines that feature a moving wire line for more capability and versatility. The 21 axes design is an engineering marvel as the wire, feed box and quill not only rotate, they move up and down, left and right, in and out, up to 6.3 inches in all directions. Springs and wire forms that were impossible to make before are now easy. One can shift the wire line to bend long

At Spring World, Takashi Takumi, president of Shinko Machinery Co., Ltd., with a TF series spring system.

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non-contact capacitance sensor for free length. At the same time, it can be converted into an image system with the addition of a vision board and camera. The SCD-7 is capable of taking three views of a spring, monitoring the three previously cited criteria (free length, diameter and angular relation) with a single camera. And the most important part is that the Itaya SCD-7 can make corrections to the axis that is controlling the free length, diameter or position. The free length graph, good springs, bad

esteves group

the global die company

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er is 60/55 pieces per min. The system, which has a retractable arbor, can do straight cuts and swing cuts, with twist cuts possible depending on condition. Contact: SIMCO Spring Machinery Company, simco@simcotw.com, www.simcotw.com. In North America, Michael Shapiro, Gibraltar Corp., tel. 847-769-2089, mshapiro@gibraltar8.com.

Simplex Rapid/NIMSCO Italy’s Simplex Rapid, represented in North America by NIMSCO, displayed its MC 70 spring coiler at Spring World. The system, designed especially to produce compression springs with complex pitch and shape variations, can process wire from 1.5 mm to 7 mm at maximum feed rates of 130 m/min and produce a spring with a maximum outside diameter of 120 mm. It has two pivoting finger holding plates controlled by four CNC independent axes for instantaneous changeover of the coiling direction. High-resolution digital transducers result in precise repeatability of the axes. The system comes as standard with 11 axes, but it can also be ordered with a new patented system for pre-tension control that comes with 13 axes. The system includes the Simplex Rapid Program Generator (SPG), Simplex Rapid Graphic Programming (SGP) and motion control technology. Programming is easy and quick due to the innovative software (SPS/SGP) that has 2D and 3D functions. The spring coiler has an integrated VIDECAMERA system for spring free length and diameter measurement (optional); RH/LH coiling configuration changes made by software, so mechanical adjustment is required; and a quick cutting system, also controlled by software, for standard cuts, rotary cuts, twist cuts and flying cuts. The machine can be connected to a computer LAN network. The spring coiler has 11 motors: two for feed, four for diameter, two for cut/pitch, one for horizontal pitch and two for mandrels (one for vertical and one for retraction). The system has a motorized device for spring preload control during the coiling

cycle, optional technology that is part of the company’s international patent. The motion control technology reduces positioning errors to provide “unimaginable accuracy.” It optimizes synchronized movements to eliminate idle times. A second model, the MC 50, can process wire from 1.0 to 5.0 mm at speeds to 130 m/min with a maximum outside spring diameter of 80 mm. Contact: Simplex Rapid, www.simplexrapid.it. In North America, Jerry Ashdown, NIMSCO, info@nimsco.com, www.nimsco.com.

Wafios AG At wire 2008, Germany’s Wafios AG introduced its new FMK series, which is meant to be both an economical alternative and a companion machine to the company’s highly versatile FMU series machines. Many parts now made on well-equipped FMU machines can be produced on the simpler and lower cost FMK. Programming procedures for the two series are nearly identical, but the newer FMK has certain programming features not present on the FMU. Operators trained on the FMU will have no difficulty operating the FMK. The new series consists of two models (FMK 2 and FMK 3) that cover a wire diameter range of .023-.126 in. high-tensile spring wire. The basic design feature that sets the FMK apart is the use of Cartesian tables to provide bending motion for the forming tools. Only two axes are used to drive the two layered tables into relative positions around the quill, thereby positioning the forming tools that are fixed to the topmost table. This system reduces the cost of the machine by providing extensive bending capability from the two CNC axes. Fixed tools and both single- and doubleAn FMK series torsion spring axes, rotary-bending coiling machine from Wafios AG. tools can be used. It is also possible to use laser sensors for accurate positioning and production monitoring. Contact: Wafios AG, www.wafios.de. In North America, Don Fisher, Wafios Machinery Corp., dfisher@wafios.us, www.wafios.us.

Winston Tech Industrial Group/RK Trading

The MC 70 spring coiler from Italy’s Simplex Rapid, represented in North America by NIMSCO.

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At Spring World, RK Trading Company displayed an all-servo hybrid machine from Taiwan’s Winston Tech Industrial Group that it described as unique in the industry for its flexibility. The camless system features a 16axes, PC-based CNC with a 3D spinner unit and sliding work platform that makes it feasible to create any springs

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and wire forms. The system is offered in four models: the CSX-35T, for processing wire from 1.0 to 3.5 mm; the CSX-20T, for sizes 0.4 mm to 2.6 mm; the CSX-50T W/EA station, for sizes from 2.20 mm to 5.0 mm; and the CSX-80T (pictured), for sizes from 3.0 to 8.0 mm. The CSX-80T has an innovative design that simplifies setup and provides further versatility. It has a sliding work platform and three-dimensional top spinner unit. A specially designed operator interface provides an intuitive way to generate part programs, made easier to run via a graphical representation of the actual axes and the table entries. A TEACH function makes it easier than ever to create a program and a TEST mode permits control of program execution by hand. The system has auto detection of abnormal/error conditions and is able to warn of potential problems such as wire feed failure, servo motor alarms, axis over travel, “open door” and more. The tool management function keeps track of setup information for a given spring, while product management provides information for each production job. Contact: Winston Tech Industrial Group, www.winsrtech.com.tw. In North America, Robert Meyer, RK Trading Company, tel. 847-640-9771, rktrading@sbcglobal.net.

Winston Tech Industrial Group’s CSX-80T all-servo hybrid, offered in North America by RK Trading Company.

Fasteners FEATURE

Aachener Maschinenbau (AMBA) Germany’s Aachener Maschinenbau (AMBA), a manufacturer of cold forming and rod heading equipment for very long parts represented in the U.S. by Barbarotto International Machinery, proudly reports that it has completed its largest long bolt maker ever built. Completed in August 2008, its system, model BM-10-800, is approximately 10 meters long, and at nearly 32,000 kg, is a heavyweight. It is equipped with three heading stations and a pointing unit and includes two flat-die thread rolling units, instead of the standard single unit. So, in addition to the usual thread rolling operation on the end of the part, a second thread under the head can be included in the production process. All operations are done in line, and the integrated turning units and horizontal transport conveyor system will turn the bolt around twice during production. The new BM 10 - 800 will produce bolts from 150 to 800 mm long, and will process wire up to 10

The model BM-10-800 bolt maker from AMBA, represented in the U.S. by Barbarotto International Machinery. mm diameter at 80 to 90 parts per minute. AMBA’s BM series of automatic machines are capable of producing long screws and bolts (head and thread) from coil, in one pass, and include standard features such as wire feed & cutoff to exact length, pre-heading, finish heading, and thread rolling. Standard size models range from ¼ in. – 3/8 in. thread diameter, and from 4 in. – 32 in. part lengths. Other options for the series include extruding station, magazine feed, induction heating units and more. Contact: AMBA, www.amba.ac. In North America, Fred Barbarotto, Barbarotto International Machinery, www. barbarottomachinery.com.

Chun Zu Machinery Taiwan’s Chun Zu Machinery, represented in North America by Quality Rebuilding Corporation, supplies the fastener manufacturing industry with the latest designs in cold heading and thread rolling machines. Chun Zu con-

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A CBP multi-die parts former from Chun Zu Machinery, represented in North America by Quality Rebuilding Corporation. centrates on producing larger and longer multi-die, affordable parts forming equipment. One example of this type of equipment is the new Chun Zu CBP series of multi-die parts formers that are supplied with both straight across (I.F.O.) and universal transfer systems. Air clutch brake systems ensure that the mainslides always stop at rear position. The positive knock-out cams on the punch sides of these machines have been computer designed for maximum simplicity and precision. Additional CBP Series machine features include automatic digital control checking devices and nut-type 180-rotated cassettes and bolt-type grippers. Specs for the CBP206 model are: max. cut-off diameter: 30 mm (1.2"); number of dies: six; and max. kickout length: 220 mm (8.7"). For the CBP-276 model: max. cut-off diameter: 41 mm (1.6"); number of dies: six; and max. kickout length: 280 mm (11.0"). Chun Zu also manufactures flat die inclined thread rolling equipment in die sizes ranging from #0 to #70. This equipment is offered with options such as numbered adjustment calipers, easily removed rail cover sections, sound proof covers, vibratory feeders and elevator hopper feed systems. The DPR series of flat die thread rolling machines features a simple machine design and low operating noise. Hard metal and phosphor-bronze bearings are set on the sliding surfaces between the main slide and bed frame and require adjustment only after years of operation. Forward and backward push buttons along with a foot brake enable rapid setups. Contact: Chun Zu Machinery, www.chunzu.com.tw. In North America, Quality Rebuilding Corp., www.qualityrebuilding.com.

National Machinery LLC LeanFX is a new FORMAX® from National Machinery LLC. Designed to appeal to the standard segment of the fastener market, where cost and speed are critical, LeanFX10 is a four die FORMAX with no quick change features. LeanFX starts with high quality FORMAX features and components, such as linear feed, zero clearance heading slide and straight across transfer. The bed frame

The fastener sector outlook

The LeanFX10 FORMAX® system from National Machinery LLC. is the same proven construction as on all FORMAX. The machine is based on simplicity, so options are minimal. Feed and kickout adjustments, as well as lifting of the transfer, are done manually. All aspects contribute to a global machine that can produce high quality M10 fasteners faster than any cold former on the market. To further reduce costs, LeanFX is assembled at NMGT, National’s new, wholly owned facility in Suzhou, China. NMGT utilizes the latest in machine tools, inspection, assembly and test practices. Various National Machinery experts in engineering, machining, assembly and quality are stationed at NMGT to ensure “national” quality of any product. Procedures for assembly, testing, and customer support are the same as done in Tiffin. Contact: National Machinery LLC, Jerry Bupp, jbupp@ nationalmachinery.com, www.nationalmachinery.com.

Reed Machinery, Inc. The Hartford™ line of high-speed flat die thread rollers offered by U.S.-based Reed Machinery, Inc., has been redesigned to incorporate new features and technologies previously unavailable. Reed engineers’ objective was to utilize the proven hardy, reliable reputation of the Hartford machine as a familiar platform while improving productivity and ease of use. Design concepts from their 2000 ppm planetary machine starter were employed in the Hartford’s Precision Plus™ starter mechanism with improved blank control for more precise feeding. Other improvements, available as options, include PLC controls for ease of use and a variable speed drive for optimum, precise speed control. For faster initial setups or changeovers, the new Hartford has available push button track and bowl height adjustment as well as push button, positive hydraulic die-clamping. Another unique upgrade is the new stationary die block with built-in adjustment for taper, eliminating the need for shimming or other time consuming adjustments. For jobs that were formerly prone to part rollbacks, there is a new mechanical kickoff that sweeps parts away from the threading dies eliminating the possibility of the rolled part being returned on the return stroke of the dies. As with other Reed machines the

WJI: U.S. fiscal concerns have increasingly been felt around the world: has this impact been felt yet by fastener manufacturers? Harris: The current U.S. and spreading world economic crises is being felt by fastener manufacturers to varying degrees depending on what sector they serve. In the automotive sector, we have seen a build projection of over 15M units fall to a current projection of probably less than 13M units. That’s a lot of lost business, compounded by the change in the percentage supplied by the Detroit-three versus the “New Domestics,” as they largely import or purchase their fasteners from Japanese-owned facilities here. That is compounded by the average weight of the steel fasteners going into a vehicle being drastically reduced from 300 lbin an FRob Harris 150 to 100 lbin a mid-sized car to now 30 lb in a Focus! A lot of the industry’s customers have gone Chapter 11 or may do so, are so starved for cash that they won’t deal with drastic raw materials cost increases and that they have all adopted outsourcing strategies that are now having to be seriously re-looked as the price of transportation and Chinese wages escalate at a spiraling rate. But, chaos can be good, as those who are ahead of the power curve will become stronger by becoming faster and leaner. Our feelings are that you’ll start to see some stability returning, probably not until 2010, and some regionalization of production: North America supplying North America, the EU and Eastern Europe supplying Europe and Asia supplying Asia. In the aerospace sector, we have the strike at Boeing disrupting aircraft shipments, allowing some catch up and clean up in the supply and production chains. If it really is a long stoppage, then there will be fastener production slowdowns and maybe shutdowns. Long term though, the backlog of demand for fuel-efficient, properly sized planes will not abate and now stands at about 36,000 commercial aircraft by 2025. Add military and space sales on top of that. In the industrial products sector, it depends who you supply. The housing market is hurting appliance and home building products of all types, Caterpillar is having a record year, farm implement is generally good, furniture almost disappeared from the U.S. but we’re seeing returns now. In general, this sector is OK to good, not great. Sales in dollars are actually looking very good, but that’s because they are able to pass through steel and energy cost increases, but I expect the tonnage shipped is actually down.

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WJI posed some questions about the outlook for the fastener market to Robert J. Harris, managing director, Industrial Fasteners Institute.

FEATURE

WJI: The industry has undergone down cycles before: has it entered one? Harris: The industries’ cycles vary by segment and very much based on traditional economic cycles. We follow the U.S. Industrial Production curve which matches to GDP. We don’t see conditions improving until 2010 and probably worsening somewhat before that. WJI: What are the most significant challenges for fastener manufacturers now? Harris: Challenges are the economy, raw material and energy costs, access to capital and cash, government regulations, stupid U.S. trade and tax policies, Asian currency manipulation and a government that takes a largely adversarial rather then partnering position with respect to manufacturing and business in general in the U.S. WJI: In such a timeframe, many companies make containing expenses the top priority: From a long-term perspective, is this the best approach? Harris: Cost cutting is always the usually necessary, but often knee-jerk reaction. Strategizing and organizing to keep your top performing people, leaning down the organization by stopping doing what wasn’t contributing to the bottom line performance of the company while keeping your people challenged and fulfilled, and making sure you are focused on effectiveness (doing the right thing) before dealing with efficiency (doing the thing right) is the opportunity tough times offer. Those that do, elevate themselves to world class organizations capable of competing with anyone anywhere. ■

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Hartford thread rollers are available with the IntelligentOne™ Smart Machine Tool System, the patented RFID technology which allows the machine to read and write data to the thread rolling dies. The Hartford machine reads the dies when installed to ensure the right dies for the job are being used and then writes the usage to the dies so that they can provide information about their tool life even while in inventory. Because Reed engineers utilized the proven, rugged Hartford platform for the new model, many of A Hartford™ line of high speed flat die these new thread rollers offered by U.S.-based features are available as Reed Machinery. Inc. retrofit kits to upgrade older machines in the field. Reed technicians can retrofit machines on site or, users can do so themselves. Contact: Reed Machinery, Inc., Jim Flanagan, jflanagan@reed-machinery.com, www.reed-machinery.com.

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Talleres Saspi, S.A.

Videx Machine Engineering Ltd.

Spainâ&#x20AC;&#x2122;s Talleres Saspi, S.A., represented in North America by Cinco Industries, Inc., offers a complete line of flat die thread rollers from #0 through #70 high-speed thread rollers as well as a complete line of rotary thread rollers through 12 mm diameter. All machines can be supplied with high-speed washer assembly units. They offer separate washer assembly units that can be mounted on other makes of thread rollers or a complete self-contained washer assembly unit can be placed behind most existing thread rollers. All Saspi machines come with a touch screen control and standard motorized controls to raise and lower feed rails and vibratory feeder. They also offer optional complete touch screen setup, which includes hydraulic clamping of die block, hydraulic clamping of dies and opening and closing of feed rails for a complete wrench-free setup of the machine. Job numbers can be stored into the memory and recalled so the operator simply types in the job number from the touch screen key pad and all rail adjustments are moved by servo motors (height and width) to the original set up. Also, Saspi has added an automatic eccentric option avail- A die thread roller from Talleres Saspi, able on their S.A., represented in North America by thread rollers Cinco Industries, Inc.. for matching the dies, which is also controlled through the touch screen as well as a process monitor integrated into the touch screen as well. The touch screen and process monitor can also be viewed from a remote location. Saspi recently designed and built a new form roller to run products such as ball studs or parts which were previously shaved. The machine is built on a #40 size frame with a #60 die size. All movements are controlled by the touch screen control panel including movement of the transfer and starter finger and rail heights and widths. The machine will roll parts from 5 to 16 mm diameter with lengths up to 200 mm. Speeds are from 30 to 120 ppm. Total weight of this machine is 23,500 lb. Saspi also builds a complete line of high-speed shave pointers that can be run independent or mounted onto our thread rollers. Contact: Talleres Saspi, S.A., www.saspi.es. In North America, Cinco Industries, Inc., Ray Sullivan, bisc@optonline.net, www.cinco-ind.com.

Israelâ&#x20AC;&#x2122;s Videx Machine Engineering Ltd., represented in North America by Barbarotto International Machinery, notes that its VA-20/20-ESS double-spin thread roller can roll parts above and below the shoulder, with the threads being different or similar to each other. In any case however, the two rolling heads are independently set and matched, eliminating any influence of one rolling operation on the other, and enabling the use of simple and more economical thread rolling dies. The two threads are rolled one after the other. The blanks accumulate in a magazine after the first rolling station and enter the second station already oriented, assuring no mix between blanks and no thread damage. The advantages of the new dual-head thread rollers include: independent adjustment that assures a better quality of each rolled operation, which also helps to better control the separate operations and the tooling used; a higher production speed as the second operation does not slow down the machine; less handling, which eliminates the possibility of mixing parts, such as heat treated parts with non heat-treated parts; it permits rolling with inexpensive tooling, while having complete control of the quality of each rolling operation; and when a tool has to be replaced, it can be done in minutes. Both thread rolling stations are equipped with controlled thread rolling start, hydraulic camping of the thread rolling dies, zero-taper mechanism for parallel threads and micrometric thread pressure screws. Other standard features include AC speed controller, automatic air shut-off and dual operator control panel on both sides of the machine for convenient and safe operation and for easy set-up of the feeder. This technology prevents handling problems and some quality issues encountered in a tradtional process. Videx Ltd., videx@videx.co.il, www.videx.co.il. In North America, Fred Barbarotto, Barbarotto International Machinery, www. barbarottomachinery.com

56 | WIRE JOURNAL INTERNATIONAL

The VA-20/20-ESS double-spin thread roller Videx Machine Engineering Ltd., represented in North America by Barbarotto International Machinery.

Germany’s Wafios GmbH report the new development of the Hilgeland high speed, two-die, three-blow header, model CF2N, for processing wire at 600 N/mm² max. 10 mm, at speeds to more than 200 parts/min for the production of short precision parts that provides a wide range of applications and has the advantage of short set-up time. The CF2N exerts the double blow either on the first or on the second die. The parts are conveyed by a cross transport and gripper fingers. In the case of extremely short parts, transport without gripper fingers is possible. The machine is equipped with two separately adjustable die ejectors. The adjustment of the first ejector enables the synchronous movement with the retreating header slide in order to transfer short parts, by means of finger less transfer. Additionally, the second ejector can be adjusted for the trimming operation. The system features: double blow either on first or second die; transport of parts by means of gripper fingers; short parts can be transported without gripper fingers; trim station; resetting device; linear feed without wire stop, ejection of parts separated from ejection of burrs; closed cutting-off shear; punch ejector stroke up to 40 mm; sound protection hood with sliding doors; separate pressure adjustment for each punch; stripping-off device for hollow parts; short set-up times due to

FEATURE

Wafios GmbH

A schematic of Wafios GmbH’s CF2N header. easy wire entry; hydraulic release of cam clamping; short operating steps; and further automation possible via servo motors. Contact: Wafios AG, sales@wafios-umformtechnik.de. In North America, Don Fisher, Wafios Machinery Corp., dfisher@wafios.us, www.wafios.us or for U.S./Canada, BW Group Inc., sales@bwgroupinc.com, www.bwgroupinc.com.

Warren Division/ Jerhen Industries, Inc. The U.S.-based Warren Division of Jerhen Industries, Inc., produces Warren flat-die thread rollers, which are among the finest U.S. made rollers on the market today.

NOVEMBER 2008 | 57

FEATURE

The rollers feature time-proven, four axes setup adjustment systems that eliminate the guess work for operators during the setup procedure. Each axis adjustment is independently gauged for a reliable, close tolerance setup, time and time again. The system’s simplicity is the key to more positive setups and less operator error. An exclusive feed stop-feed trigger system ensures a controlled skidfree start for parts and controls blank forces at the rail tip, ensuring that only one part at a time enters the die area. To eliminate the possibility of damage from “rollback” during high-speed operation, the swing-away keeper assures complete control and alignment of the blanks as they enter the die. Should a rollback occur, the swingaway keeper is designed to automatically retract, preventing damage to your tooling and contains the balance of the blanks in the rail system. All models are provided with the company’s proven feed rail height adjustment system to speed the set-up process. The feed systems are custom designed/fabricated at Jerhen Industries, which offers a full range of service parts and dedicated customer service and support network. The models range from #000 .027” (.7 mm) thru #30 .500” (12.70 mm) in part diameter and .125” (3.17 mm) to 6” (152 mm) in length. An exclusive “flip-top” rail system is designed using a special adjustment mechanism that allows the operator to

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quickly and accurately adjust the blank head clearance at both ends of the feed rails and release any foreign blanks A Warren flat-die thread roller. which may impede feeding. The unique use of a 45-degree insertion angle allows very high production speeds while maintaining absolute precision and blank control. As a result, Warren thread rollers eliminate “blank skid” during startup, which is common with other thread rollers. Contact: Jerhen Industries, Inc., Warren Division., salesinfo@jerhen.com, www.jerhen.com. ■

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Evaluation of motor winding insulation performance under pulse waveforms through electrical measurements

LV E R ATE C I F I T CER AWA R

TECHNICAL PAPERS

TECHNICAL PAPER

Peak-to-peak voltage and pulse repetition frequency were found to be the main factors accelerating the aging of wire insulation, with partial discharge activity playing a key role especially for organic insulated motors. By Andrea Cavallini, Davide Fabiani, and Gian Carlo Montanari

The speed and power control of low voltage (LV) and medium voltage (MV) ac-rotating machines today is tuned by means of electronic voltage converters that generate pulse-like voltage waveforms. Appropriate switching techniques are implemented by these converters to create motor supplyvoltage free of low-order harmonics that could otherwise be

responsible for torque and speed oscillations. The cancellation of low-order harmonics is achieved, however, at the cost of generating high-order harmonics. Pulse Width Modulation (PWM) is a commonly used such switching technique. The kinds of waveforms generated, however, are the ones most responsible for insulation failures of motor magnet wires with

Fig. 1. Examples of a random wound: (a) form wound; (b) winding design. Different insulation systems are also indicated.

Fig. 2. Example of voltage waveforms (phase-to-phase) recorded at the terminals of a voltage-converter fed motor.

60 | WIRE JOURNAL INTERNATIONAL

Electrical insulation stress Fig. 1 shows a sketch of the two main winding typologies for rotating machines, i.e., random wound and form wound, together to the main insulation systems (ground, interturn and

Fig. 3. Overvoltage factor at the motor terminals in relative value of voltage amplitude at the inverter output.

stress-grading insulation)7,8. It must be pointed out that the difference between the turn-to-ground voltage of two adjacent turns belonging to a coil of the winding represents the electrical stress affecting the interturn insulation. In random-wound (Fig. 1a) machines coils consist of magnet-wires wound in a random way. This is suitable for low-voltage motors that have a small interturn stress (like motors fed by sinusoidal supply). If interturn stress is significantly higher, as it occurs for MV rotating machines, form-wound windings are needed (Fig. 1b). In this case, electrically adjacent turns are also gemotrically adjacent, in order to have the smallest voltage drop possible and, thus, minimize the stress between turns. The voltage waveform generated by a PWM AC/AC converter consists of a series of pulses of the same amplitude with very high rise fronts (up to 50 kV/Âľs), width modulated according to a sinusoidal law with an high-frequency carrier (up to 5 and 50 kHz, for MV and LV motors, respectively), and a low-frequency modulating which depends on the motor speed. Fig. 2 sketches the phase-to-phase voltage waveforms at motor terminals. The waveform is constituted by a sequence of unipolar pulses whose number is linked to the high-frequency carrier of the AC/AC converter, while the (low) frequency pulse polarity reversal is related to the desired motor speed. Significant overvoltages present at the motor terminals are due to wave reflections associated with impedance mismatch between motor and connection cables. The amplitude of these peaks depends on the cable length and the rise time of the waveform5-8. Fig. 3 reports the overvoltage factor as a function of the cable length, lC, for four different rise times, tr, of the pulse voltage. The overvoltage factor is given by the amplitude of the voltage peak, UP, at the motor terminals related to the amplitude of the voltage at the inverter output, Ua. As can be seen in Fig. 3, the shorter the rise time, the larger the amplitude of the overvoltage for a given cable length. Increasing

Fig. 4. Examples of data reported in Weibull plot together with the relevant Weibull graphs. Life tests performed at V=2500 V (rms value), 10 kHz unipolar and bipolar square waves. Insulation #A. NOVEMBER 2008 | 61

TECHNICAL PAPERS

respect to conventional operation at power frequency. These failures have been associated with inception or increase of partial discharge (PD) activity between coil turns1-5, so motors designed to operate below partial discharge inception voltage (PDIV), as LV machines insulated by organic materials, can actually experience significant PD activities during operation. PD activity is usually originated by electrical stress enhancement in motor winding insulation, which itself is caused by both converter-motor setup and motor design. Converter solid-state components give rise to overvoltages and ringings which affect voltage waveform applied to the motor terminals. However, steep-fronted waveforms can remarkably enhance the interturn stress of the first coils of a motor winding, especially in random-wound motors5,6. The weak resistance to PD exhibited by magnet-wire organic insulating materials (e.g., poly-amide-imide) pushed motor manufactures to develop new insulating materials (organic/inorganic) for magnet wires known as â&#x20AC;&#x153;corona-resistant,â&#x20AC;? that are specifically designed for converter-fed motors, showing improved endurance to PD activity. Several research groups are analyzing the detrimental effect of voltage converter waveforms on reliability of insulation (standard and corona resistant) of electrical motors1-5. These works give a contribution for the preparation of new IEC standards7-10, which provide techniques for evaluating the endurance of insulation systems that are candidates to be used in electrical motors controlled by electronic power converters. In the following, a summary of the main outcomes regarding this topic are presented.

TECHNICAL PAPERS

cable length, large overvoltage factor values occur even with longer voltage rise times. For example, if tr = 50 ns and the cable length is about 5 m or more, the amplitude of the overvoltage may became two times the maximum voltage of the DC bus, while if tr = 1 µs, the same overvoltage is reached if the cable is longer than 100 m. According to Fig. 3, a critical length of the cable (function of rise time) above which the maximum overvoltage is reached can be defined. Moreover, the steep voltage rise front of the square waveform can cause an uneven voltage distribution along the motor windings. As an example, form-wound motors are designed so that the voltage drop across a turn is generally <25V under 50 Hz sinusoidal supply, while it can be considerably higher in the presence of square waves. In random-wound motors, two adjacent turns can experience the whole phase-to-ground voltage (worst case). Large overvoltages and uneven potential distribution can contribute together to the magnification of the electrical stress at the winding insulation. In particular: • between conductors of different phases; • between a conductor and ground; and • between adjacent turns, generally in the line-end coil. In some conditions, the voltage amplitude can be so high to exceed the partial discharge inception voltage (PDIV), so that insulation degradation may be largely accelerated, especially in the line-end turns. The overshoots may contribute, however, to degradation acceleration of insulating materials even in the absence of PD, because they constitute an additional stress accelerating intrinsic aging, e.g., producing and/or enlarging micro-cavities in the material due to local electromechanical energy storage and electrical fatigue5. Summarizing, the inception/enhancement of PD activity, normally absent or having relatively small amplitude under

50 Hz sinusoidal supply, is observed to be the main factor accelerating insulation degradation, leading to premature failures of motors fed by voltage converter waveforms. Therefore, experimental techniques, e.g., PD measurements and endurance tests, are needed to asses the quality of insulation to be used in converter-fed rotating machines.

Fig. 5. Life test results and life lines for tests in the presence of PD for sinusoidal (50 Hz and 10 kHz) and square wave (unipolar and bi-polar) at 10 kHz. The values of the voltage endurance coefficient (VEC) are also indicated. Materials #A and #B.

Fig. 6. PDIV as a function of waveshape and frequency for twisted pair samples (A) and complete stators (B).

62 | WIRE JOURNAL INTERNATIONAL

Experiments Test procedures for life tests and PD measurements. Different kinds of specimens can be used for experimental tests: • twisted pairs (two enameled wires wound in a standardized way11); • motorettes (special test model used for the evaluation of the electrical insulation systems of random-wound windings)7,8;

Eq. (1)

Fig. 7. PDIV as a function of square waveform rise time for stator motor samples.

where tF is failure time, α is scale parameter (corresponding to 63.2% of failure probability) and β is shape parameter (the inverse of β is proportional to sample variance). An example of Weibull plot is shown in Fig. 4, where the experimental points, the line representing the Weibull distribution (Eq. (3)) and the 95% confidence bounds are reported relevant to two life tests performed with different stress waveforms (unipolar and bipolar square waves). The least squares method was used to obtain the regression line parameters and the estimates of α and β, while the confidence intervals are calculated by the Monte Carlo method. An Inverse Power Model (IPM) was employed to fit the 63.2% failure times (α) at different stress values. The slope of the regression life line obtained is inversely proportional to the so-called voltage endurance coefficient, VEC4. The IPM is given by: Eq. (2) where tF is the failure time at the applied voltage V, k and N (VEC value) are parameters of the model. The specimens for PD measurements consist of low voltage 0.2 kW three-phase ac-motor stators. In order to measure the PD inception voltage (PDIV) in the turn insulation system the supply was connected with one line terminal of the open-star windings, while the other two terminals were grounded9. PDIV was evaluated increasing the voltage amplitude with a slope of 2 kV/min until a stable PD activity is measured. First, PD measurements were performed under sinusoidal waveforms at different frequencies (50–500Hz), then, PD activity was evaluated under unipolar and bipolar square waveforms, with the purpose of inferring the effect of frequency (up to 10 kHz) and waveshape on PDIV.

Fig. 8. Example of two life-lines at different frequencies f1 and f2.

NOVEMBER 2008 | 63

TECHNICAL PAPERS

• formettes (test model reproducing form-wound windings)8; and • complete motor stators. The test objects here used for life tests consist of twisted pairs, whose low cost allows to carry out tests on a sample of several specimens. Life tests were carried out on two kinds of enameled wire insulation, one organic, #A, i.e. the same used traditionally for 50 Hz motors, and the other, #B, containing inorganic oxide additives specifically designed for better withstanding PD activity. Preliminary sinusoidal life tests at 50 Hz were performed to be used as reference for the tested materials. Then, life tests with 10 kHz sinusoidal and square (unipolar and bipolar) waves were carried out to analyze the effect of frequency increase and of pulse waveforms on aging acceleration. The duty cycle of the square waves was 50% and the rate of voltage rise about 1 kV/μs. The life tests were carried out at three or four levels of constant electric field, room temperature in the presence of PD activity in order to understand the effect of PD on aging acceleration with different voltage waveforms. The values of test fields were large enough to accelerate the breakdown process, in order to reduce test times, without changing, however, the degradation mechanism with respect to the one expected at lower fields10. Samples of five specimens were used at each test stress, waiting for the breakdown of all the specimens. Failure times were recorded for each specimen and statistically processed through Weibull probability distribution, that is:

TECHNICAL PAPERS

Square waveforms were obtained by means of TechImp TechSquare 4000B. Unipolar and bipolar waveforms can be generated having amplitude up to 4 kV peak-to-peak, frequency ranging from 0 to 20 kHz and rate of voltage rise up to 75 kV/µs (i.e., minimum rise time 30 ns). Partial discharges are detected by means of TechImp PD Solver system, opportunely modified for measurements under square wave voltages5. The PD signal is picked up from an UWB antenna probe connected with a high-pass filter for the attenuation of switching surge disturbances. Test results. The life points and lines of twisted pair samples obtained at different frequencies and waveshape (sinusoidal, unipolar and bipolar square waves) in the presence of PD, are reported in Fig. 5. As can be seen, #A exhibits the worst life performance (very short failure times and small VEC) at 10 kHz while corona-resistant material, #B, behaves better than #A, even if the failure times are shorter than those obtained at 50 Hz. PDIV (voltage peak-to-peak value) was then measured under different supply conditions on a twisted-pair sample (Fig. 6a) and a motor stator (Fig. 6b), insulated by organic materials. The samples were subjected to 50 and 500 Hz sinusoidal voltage, as well as unipolar and bipolar square waveforms with different frequency levels, 50, 500, 1000 and 10000 Hz. After that, the rise time of voltage (bipolar square waveform at frequency of 10 kHz) was varied from 50 to 1000 ns and PDIV was measured again only on the stator motor (Fig. 7). It can be observed that the supply waveform does not significantly affect PDIV for twisted-pair sample (as can be expected, due to the purely capacitive behavior of the twisted pair itself), while a remarkable decrease of PDIV can be seen with square wave supply for motor stator, particularly for the lowest values of the voltage rise time. This behavior will be explained clearly in the next section.

Discussion The effect of PD activity with frequency increase is highlighted by Fig. 5 for the tested materials. Partial discharge activity at 10 kHz strongly reduces the expected life and the voltage endurance for organic material #A with respect to 50

Table 1. Contribution to electrical aging by 1 kHz impulses from a 3-level converter as a percentage of the aging from the 50 Hz fundamental voltage for different values of the voltage endurance coefficient, n.

64 | WIRE JOURNAL INTERNATIONAL

Hz sinusoidal (VEC decreases strongly from 6.4 to 3.8). Corona resistant enamelled wire #B, on the contrary, lasts much longer than #A and shows a better voltage endurance. In particular, the endurance coefficient of #B decreases slightly with frequency (from 7.1 to 5.9), thus confirming the good life performance of corona resistance materials at high frequency. Moreover, life reduction of material #B due to frequency increase stands about in the inverse ratio between frequencies. Another interesting result which can be obtained from the life data of Fig. 7 is that, if plotted as a function of peak-topeak voltage, failure times relevant to different voltage waveforms (sinusoidal, unipolar and bipolar squarewave), at the same frequency, fit quite well the same straight line4,5. This shows that the most important stressing factor, at a fixed frequency, is the voltage amplitude (from negative to positive value), rather than the kind of waveform (square or sinusoidal). This is true at least at rather low values of slew rate, as those employed in the life tests here presented (maximum value ≈ 1 kV/μs). If the slew rate is larger than 10 kV/μs a significant effect of rise time on aging is observed3,5. The kind of waveshape (square bipolar/unipolar, sinusoidal) seems to affect significantly PDIV measurements on motor stators rather than on twisted pairs (see Fig. 6). This can be associated with the voltage distribution along the winding. In twisted pairs, in fact, the voltage drop between specimen turns (Fig. 6a) is about the same for any turn. In case of randomwound motor stator, on the contrary, the voltage distribution between turns depends on the supply voltage waveform and on the winding morphology. As already mentioned, the smaller the rise time, the larger the voltage drop along the first turns, so that if two adjacent turns belong to different coils, a large potential can stress the interturn insulation, leading to a smaller PDIV than in sinusoidal case. This is confirmed also by the tests on motor stator carried out at different rise time of the square waveform (Fig. 7). As rise time decreases, the interturn stress increases, reducing the PDIV. It is noteworthy that PDIV does not seem to be affected significantly by frequency for both twisted pair and motor stator samples. These experimental results constituted the starting point for preparation of IEC standards on rotating machines fed by voltage converters discussed very recently within some working groups of IEC TC27-10. First of all, the standards divide the insulation systems for rotating machines in two main categories: one constituted by organic insulating materials which are not expected to experience PD activity in service (type I)7 and the other characterized by organic/inorganic materials which are expected to withstand PD activity in any part of the insulation system during service (type II)8. In particular, different standards for the two insulation systems were issued, taking into account different experimental techniques. Since Type I insulation systems are intended for use in the absence of partial discharge activity during their lifetime, it is essential to measure the PDIV9. The voltage waveshape to be used with each kind of specimen (twisted pairs, motorette, motor stator, etc.) is specified

lowing down this line (arrow B). Combining the frequency and voltage dependent life equations, i.e. Eq. (2) and (3) a general expression can be achieved: Eq. (4) where: Lf2,u2 is the life at frequency f2 and voltage U2 and Lf1,u1 is the life at frequency f1 and voltage U1. This equation allows to calculate lifetime at different frequency and voltage values, once the endurance coefficient is estimated, as explained in the previous section. It must be noted that this simplified approach in calculating life under impulse voltages by means of life tests at sinusoidal conditions, is approximated. Experimental evidences exist, in fact, to support the validity of this approach for impulse voltages up to 1 kHz, since the variation of the endurance coefficient, n, with frequency is negligible. At higher frequency, on the contrary, a decrease of n is observed (see Fig. 5) with respect to power frequency (e.g., for #B from 7.9 to 5.1 at 50 and 10000 Hz, respectively). Moreover, even if the dominant aging factor is the peak-topeak voltage at the fundamental frequency (Upk/pk in Fig. 1), another significant contribution to aging comes from the impulse frequency peak-topeak voltage transitions (Uâ&#x20AC;&#x2122;pk/pk in Fig. 1) for insulation systems fed from converters8. This is usually a second order effect particularly for 3-level converters compared with 2-level converters. Nevertheless, this contribution can be calculated simply using the following procedure, based on the general life expression reported in (2). Considering that the aging rate per pulse is proportional to 1/L, the contribution to aging for a fundamental pulse at 50 Hz, A50, and a peak-to-peak fundamental voltage of Upk/pk is given by:

Eq. (5) where k is a constant. For a 3-level converter, the contribution to aging, Af1, from impulses at frequency f1, is given by Eq. (4) which becomes (see Fig. 1): Eq. (6)

Eq. (3) where L2 is the life at frequency f2; L1 is the life at frequency f1. This is equivalent to translate the life line on the left, if f2>f1, reducing, thus, lifetime (see Fig. 8). If it is expected in service that the insulation system could be subjected to a frequency, e.g., 10 times higher than that used to obtain the life curve, according to the above observations, the appropriate life curve for this operating condition must be translated to the left (arrow A, Fig. 8) by one decade. The insulation stress should be reduced, thus, to restore the life to the original value, fol-

According to the cumulative aging rate theory and in the absence of synergism, the total aging rate is, thus, the sum of these two contributions. Table 1 shows the values of Af1 in percentage of A50 for f1= 1 kHz. As an example, a 20% overshoot factor would give Uâ&#x20AC;˛pk/pk = 1.4Ua and Upk/pk = 2.4Ua and the percentage contribution to aging from the converter impulses for n = 10 is about 9%. It is noteworthy that the contribution to aging from the pulse frequency impulse voltage is negligible at 1 kHz for values of n equal to 10 or more. It has been shown that magnet wires having organic insula-

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by the standard7, since it may affect PDIV measurements, as it is seen by Fig. 6. For qualification tests, there should be at least five samples on which PD tests may be performed in order to achieve a statistically valid outcome to the test, except in the case of complete stators where one sample is considered adequate. Then, specified test values multiplied by a safety factor (since the overshoot amplitude of Fig. 1 is not known apriori), are defined. The insulation system is deemed to be qualified if the PDIV stands over the specified test value at the end of the aging cycles. Type tests are usually performed on a complete stator winding or machine. A PDIV in excess of the specified value for the selected stress category should be demonstrated. The test is performed with the appropriate waveform for the selected stress category (interturn, turn-to-ground, etc.). This test is performed by agreement between the purchaser and manufacturer. It should be observed, however, that the worst case occurs when a complete stator is supplied with a square wave having the shortest possible rise time. In this case, in fact, PDIV is significantly smaller than under sinusoidal conditions, as previously observed (see Figs. 6-7) so that any insulation system defect could be evidenced better. For Type II insulation systems (like, e.g., material #B), the qualification of the ground and turn insulation systems is carried out through voltage endurance testing on specimens at different temperatures, as shown in the previous Section [8]. In particular, life curves may be obtained by performing aging tests at different voltages and frequencies. On the basis of the following assumptions, resulting from the experimental measurements reported in the previous Section, life of the insulation system under impulse conditions can be estimated even from sinusoidal voltage testing. The aging rate associated with impulse and power frequency voltages is about the same, provided the peak-to-peak values and the number of fundamental voltage cycles are the same (see Fig. 5); The lifetime exponent, n, is not frequency dependent below 1 kHz and no significant influence of the voltage frequency on the number of impulses to failure or the number of voltage cycles to failure is observed. Therefore, the following equation can be used to evaluate the expected life for a given peak voltage at a frequency f2, different from the test frequency f1:

TECHNICAL PAPERS

tion (type I) are affected dramatically by PD activity due to pulse-like waveforms. Since type I insulated motors cannot withstand PD activity, PD measurements are needed to ensure that during operation with most electronic voltage converters PD inception voltage is not exceeded. New organic/inorganic materials (Type II), on the contrary, are able to withstand much better PD activity than the conventional ones. Thus, a moderate PD activity can be accepted during motor operation. Nevertheless, a qualification of the insulation, through longterm voltage endurance tests is strongly suggested in order to maximize the reliability of the designed insulation system.

References 1. G. C. Stone, S. Campbell and S. Tetreault, “Inverter-Fed Drives: Which Motor Stators are at Risk?” IEEE Ind. Appl. Magazine, Vol. 6, N. 5, pp. 17-22, October 2000. 2. Weijun Yin, “Failure Mechanism of Winding Insulation in Inverter-Fed Motors,” IEEE El. Ins. Magazine, Vol. 13, N. 6, pp.18-23, November 1997. 3. M. Kaufhold, G. Borner, M. Eberhardt and J. Speck, “Failure Mechanism of Low Voltage Electric Machines Fed by Pulse-Controlled Inverters,” IEEE El. Ins. Magazine, Vol. 12, n. 5, pp. 9-15, September 1996. 4. D. Fabiani and G.C. Montanari, “The Effect of Voltage Distortion on Aging Acceleration of Insulation Systems Under Partial Discharge Activity,” IEEE El. Ins. Magazine, Vol. 17, N. 3, May 2001. 5. D. Fabiani, Accelerated degradation of ac-motor winding insulation due to voltage waveforms generated by adjustable speed drives, Gedit Edizioni, Bologna, Italy, 2003, ISBN: 8888120-31-9. 6. M. Melfi, A. M. J. Sung, S. Bell, and G. L. Skibinski, “Effect of Surge Voltage Risetime on the Insulation of Lowvoltage Machines Fed by PWM Converters,” IEEE Trans. on Ind. Appl. Vol. 34, n. 4, pp. 766-775, August 1998. 7. IEC 60034-18-41 TS, Qualification and type tests for Type I electrical insulation systems used in rotating electrical machines when fed from voltage converters, 2006. 8. IEC 60034-18-42 TS, Qualification and acceptance tests for partial discharge resistant electrical insulation systems (Type II) used in rotating electrical machines when fed from voltage converters, 2006. 9. IEC 61934 TS, Electrical measurements of partial discharges during short risetime repetitive voltage impulses. 10. IEC 62068-1, Electrical stresses produced by repetitive impulses – Part 1: General method of evaluation of electrical endurance. 11. ASTM Standard D1676, Standard Methods for Testing Film-Insulated Magnet Wire, Annual Book of ASTM Standards, Vol. 01.03, 1983. ■

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Andrea Cavallini is an associate professor at the University of Bologna, Italy. His research interests are diagnostics of insulation systems by partial discharge analysis, reliability of electrical systems, and artificial intelligence. He previously was a researcher at the Cavallini University of Ferrara, Italy. He holds Ph.D. and master’s degrees in electrical engineering from the University of Bologna. Davide Fabiani is assistant professor in the Department of Electrical Engineering at the University of Bologna. His research interests deal with harmonic effects on accelerating insulation degradation; characterization Fabiani of magnetic, superconducting, nanocomposite and electret materials; aging investigation and diagnostics on power system insulation; and motor windings subjected to fast repetitive pulses. He holds Ph.D. and M.Sc. degrees in electrical engineering from the University of Bologna. He is author or co-author of more than 70 papers. Gian Carlo Montanari Montanari is a full professor of electrical technology in the Department of Electrical Engineering of the University of Bologna. He teaches courses on technology and reliability. He is founder and president of TechImp SpA, Bologna. He holds a master’s degree in electrical engineering from the University of Bologna. He is author or co-author of some 450 scientific papers. This paper, which was presented at Wire Bologna 2007, Bologna, Italy, November 2007, won the WAI’s Silver Certificate Award in the Electrical Division.

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TECHNICAL PAPERS

TECHNICAL PAPER Effect of die semi-angle and multi-pass drawing on additional shear strain layer The additional shear strain layer on the outer layer of fine-drawn wire, generated by the friction between wire and dies, is hardened during drawing with a low semi-angle die, and can include subdivisions of crystal grains caused by shear deformation.

By Kazuki Hosoda, Motoo Asakawa, Satoshi Kajino and Y. Maeda

Fine wires in the order of 0.1 mm in diameter have received greater attention as more demanding electrical applications have been developed. It is well known that fine wires have a high tensile strength while maintaining ductility compared to bulk wires, an attribute known as the “size effect.” Clarifying the factors of these superior properties contributes to the understanding of size effect. During the drawing process, a hardened layer, referred to as the “additional shear strain layer,” is generated at the surface of the wires as shown in Fig. 11,2. This layer is constant in depth and is not related to the diameter. See Fig. 2. It was demonstrated that this layer is hardened by the subdivision of crystal grains by a large shear deformation. This layer is

considered to be one of the main factors for the increase in tensile strength of entire fine wires. This paper aims to clarify the following: • the effect of the die semi-angle on the additional shear strain layer; and • the behavior of the additional shear strain layer in multipass drawing.

Fig. 1. Hardness test result of 1.38 mm diameter wire.

Fig. 2. Depth of additional shear strain layer.

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Effect of die semi-angle on the additional shear strain layer It has been proposed that the die semi-angle has an influence on the additional shear strain layer, as the degree of friction is altered by the contact length between the die and wires. In

TECHNICAL PAPERS

Table 1. Drawing conditions.

order to determine the effect of the die semi-angle α on the additional shear strain layer, annealed low-carbon steel wires were drawn from 0.30 mm to 0.275 mm diameter at varying die semi-angles. Table 1 and Fig. 3 demonstrate the drawing conditions and the result of drawing stress in each of the die semi-angles. The drawing stress was convex-downward for die semi-angle α to a limit of 7°. Tensile tests for fine wires drawn at α = 2, 7 and 12° dies were carried out by removing the surface of the wires by electro-polishing as shown in Fig. 4. The tensile strength of the removed area is shown in Fig. 5. In all figures, it was obvious that the tensile strength of the surface layer was higher than that of the center layer. In order to measure the increase in tensile strength contributed by the additional shear strain layer, the difference in tensile strength σs-c between the surface layer and the center layer was calculated, the results of which are shown in Fig. 6. In fine wires drawn in a die where α = 2°, the difference was the greatest; in fine wires drawn at the other semi-angle dies, the difference tends towards constant. This result indicates that the tensile strength of the additional shear strain layer increases as the contact length increases. This result can be explained by the subdivision of crystal grains becoming finer in the surface of the wire as the die semi-angle decreased. In order to investigate this subdivision, the crystal orientation was observed with Scanning Electron Microscope-Electron Back-Scatter Diffraction (SEM-EBSD)

Fig. 4. Electro-polishing device.

Fig. 3. Drawing stress in each die semi-angle.

Fig. 5. Tensile strength of the removed area.

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TECHNICAL PAPERS Fig. 6. Tensile strength between surface and center layers of wires drawn at each die semi-angle.

Fig. 7. Material coordinate system and measurement areas.

in the longitudinal direction along the drawing direction. The spot diameter of the SEM-EBSD was set at 0.5 μm and the wire surface and center were observed as shown in Fig. 7. In this measurement, the grain boundary was determined: the misorientation angle between each spot was larger than the given angle θ ranging from 2 to 15°. Fig. 8 shows the relation between the ratio of the crystal grain quantity Nθ/N15 and the misorientation angle θ. In wires drawn at α = 2° die, the increase in the grain quantity in the surface layer was generated at θ = 8°. Similarly, in wires drawn at α = 7° die, the increase was at α = 5° and with α = 12° die, the increase was at θ = 2°. This confirmed that larger-misorientation angle boundaries were generated in the surface layer compared to the center layer, as the die semi-angle was reduced. Friction work is considered as one of the reasons for these results. In general, the drawing stress is divided into three works: ideal work, friction work and redundant work

Fig. 8. Ratio of grain quantity in each misorientation angle.

70 | WIRE JOURNAL INTERNATIONAL

Fig. 9. Ideal, redundant and friction works in drawing process.

TECHNICAL PAPERS Table 2. Pass-schedule.

Fig. 10. Tensile strength as surface layer was thinned by electro-polishing.

as shown in Fig. 9. Friction work is generated at the surface of wires, when wires flux against the friction between the die and wires. As the die semi-angle is decreased, the contact area increases and friction increases. Meanwhile, the redundant work is generated by the internal shearing in the materials due to the change of the material flow direction. As the die semiangle increases, the change in the material flow direction increase and redundant work also increases. This defines the optimum die semi-angle, αo, at 7° in this study. The friction work mainly influences the additional shear strain layer at α = 2°, while the redundant work will have an effect on the additional shear strain layer at α = 12°. Thus, friction work is more influential on the generation of the additional shear strain layer than the redundant work. This can be explained by the fact that friction work only occurs at the surface of the wire, whereas, the redundant work effects the entire wires. Also, considering the constant depth of the additional shear

strain layer, it can be concluded that redundant work has a slight effect on the generation of additional shear strain layer.

Fig. 11. Difference in tensile strength between surface and center layer.

Fig. 12. Depth of additional shear strain layer.

Behavior of additional shear strain layer in multi-pass drawing The additional shear strain layer on the single-pass drawn wire was discussed earlier in this paper. However, multi-pass drawn wires are generally used in many products. Therefore, it is necessary to investigate the behavior of the additional shear strain layer in multi-pass drawing processes. In this experiment, low-carbon steel wires were drawn continuously from 1.1 mm to 0.325 mm diameter and annealed at 1023°K for 30 minutes. Following this, these wires were drawn through six passes following the pass-schedule shown in Table 2. After each pass, tensile tests were carried out, by removing the surface layer of wires with electro-polishing. Fig. 10 shows the results of tensile tests. From the results it is

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TECHNICAL PAPERS

obvious that the tensile strength of the surface layer increased compared to that of the center layer in each pass. Additionally, the difference of tensile strength Δσs -c between the surface and center (as shown in Fig. 11) and also the depth of additional shear strain layer (as shown in Fig. 12) were calculated from the results shown in Fig. 10. The difference tends to increase until the true strain reaches 0.2 and following which, the difference tends towards constant value, approximately 120 MPa. The depth of the layer was constant at 60 μm, when the true strain was greater than 0.25. From these results, the additional shear strain layer occupies a larger area of the cross section, as the wire diameter became finer, which resulted in strengthening the entire wire. Additionally, the crystal orientation was measured by SEM-EBSD. The experimental method was the same as that previously described above. In this section, the ratio of grain quantity at misorientation angle θ = 5° was calculated after each pass. Fig. 13 shows the relation between the true strain and the ratio of grain quantity in case of the 5° boundary. It was determined that the ratio in the surface layer increases more rapidly than that of the center layer. From this result, the ratio of crystal quantity between the surface and center at θ = 5° Nqs/c was calculated as shown in Fig. 14. This Nqs/c is acquired by dividing the ratio of grain quantity in the surface by that in the center. When this ratio is greater than 1, the surface increase in crystal grain quantity is greater than that of the center layer. The result shows that Nqs/c increases until the true strain reaches 0.2. In contrast, Nqs/c tends towards a constant at 1.4 when the true strain exceeds 0.2. This tendency corresponds with the differences in tensile strength between the surface and center shown in Fig. 11. From these results, it can be concluded that the subdivision of crystal grains in the surface layer generates the difference in tensile strength between the surface and center layer until the true strain is 0.2. after which the difference tends to a

Fig. 14. Transition of ratio of crystal grain quantity between surface and center Nqs/c. 72 | WIRE JOURNAL INTERNATIONAL

Fig. 13. Transition of ratio of crystal grain quantity (six-pass drawn wire, Re = 5%).

constant value since the increase in the ratio of crystal grain quantity between the surface and center layer is steady when the true strain exceeds 0.2.

The behavior of the additional shear strain layer in high-carbon steel wire In order to investigate the behavior of the additional shear strain layer in high carbon steel wires, eutectoid steel wires were prepared and drawn continuously from 0.98 mm to 0.325 mm through twice patenting and finally patented at 1223°K for 1 min. The wires were then drawn from 0.325 mm to 0.300 mm. Single-pass drawn wires and patented wires were tensile tested by removing the surface of wires as before. Fig. 15 shows the tensile strength of the removed area. It was observed that the tensile strength of surface layer in drawn

Fig. 15. Tensile strength of removed area in one-pass drawn wire.

Summary and conclusions The effects of the die semi-angle and multi-pass drawing on the additional shear strain layer were investigated. The conclusions are as follows: • The increase in friction work at a low die semi-angle promotes the generation of a larger angle boundary in the surface layer of fine wires, strengthening the entire wire. • The difference in tensile strength between the surface and center of the wire tends to increase until the true strain is 0.2, after which the difference becomes constant at approximately 120 MPa. The depth of the additional shear strain layer tends to a constant 60 μm after the true strain exceeds 0.25. • The subdivision of the crystal grains in the surface layer generates a difference in tensile strength between the surface and center layer until the true strain is 0.2. The difference then becomes constant since the increase in the ratio of crystal grain quantity between the surface and center layer becomes constant when the true strain exceeds 0.2. The behavior of the additional shear strain layer in highcarbon steel fine wires was investigated. The following conclusion was obtained: • The additional shear strain layer is also generated in highcarbon steel wires.

References 1. N. Inakazu, Metal drawing and fiber texture, First edition, Kindai Hensyu Ltd. 2. S. Kajino and M. Asakawa, Metal Forming 2004, Proceeding, 2004, pp. 635-639. 3. S. Kajino and M. Asakawa, J.S.M.E, M&P 2004, 2004, pp. 435-436. 4. S. Kajino and M. Asakawa, Metal Forming 2006, Proceeding, 2006, pp. 704-708. 5. S. Torizuka, et al, Scripta Mat., 2006. 6. S. Torizuka, et al, Tetsu-to-Hagane, Vol. 88, 2000, pp. 854-864. 7. M. Umemoto, Y. Todaka and K. Tsuchiya, CAMP-ISIJ, Vol. 16, 2003, p. 1321. ■

Kazuki Hosoda is a graduate student in the school of science and engineering at Waseda University, Tokyo, Japan. Dr. Motoo Asakawa is a professor in the mechanical engineering department at the Waseda school of science and engineering. 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 Japan’s Okochi Memorial Prize, the Society for Technology of Plasticity Prize, the Institute of Metals Prize, and Iron & Steel Institute Prize. Satoshi Kajino works at the National Institute of Advanced Industrial Science and Technology (AIST), Japan. He earned a doctoral degree in engineering from Waseda University. He is a recipient of the WAI Silver Certificate Award for best paper in the ferrous division for 2005. Y. Maeda is a student in the school of science and engineering at Waseda. This paper was presented at WAI’s 77th Annual Convention, May 2007, Cleveland, Ohio, USA.

TECHNICAL PAPERS

wires was hardened more than the center layer. This was the same result attained for low-carbon steel wires. The depth of the additional shear strain layer was calculated from the tensile test results at about 35 μm, which is approximately the same as the depth in low carbon steel wires. From these results, it is found that the additional hear strain layer is generated in high-carbon steel wires as well as low carbon steel wires.

Hosoda

Asakawa

Kajino

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TECHNICAL PAPERS

TECHNICAL PAPER Zinc-aluminum coating: management of Galfan® lines The market has shown an increasing demand for zinc-aluminum coating lines that require precise design work and supervision to ensure that the corrosion-resistant coatings work properly for applications such as harsh off-shore environments. By René Branders and Andrew Stacey

In the mid 1960s, Bethlehem Steel developed a highly corrosion resistant coating, Galvalume, which they marketed as an alternative to zinc. The composition was 55% Al, 43.5 % Zn, 1.5% Si. If this were adopted to any significant extent, at the expense of galvanizing, it would result in a major loss of zinc sales, (galvanizing accounts for more than half of the world’s zinc consumption). The zinc-producers therefore, commissioned the International Lead Zinc Research Organisation (ILZRO) to develop a corrosion-resistant coating, which was equal to or better than “Galvalume,” but one that contained substantially more zinc. Previous work into zinc– aluminum alloys showed that the eutectic ratio (95% Zn, 5% Al) provided the best corrosion resistance. Early testing demonstrated that the alloy was supe-

Fig. 1. Eutectic Galfan® alloy and out-of-eutectic alloy. 74 | WIRE JOURNAL INTERNATIONAL

rior to zinc in terms of coat adherence and formability, but unfortunately, the surface had bare spots after coating. This feature prevented its commercial development. ILZRO purchased the patent rights and commissioned CRM (Liege) to study the problem. It found that adding small quantities of Mischmetal (a mixture of rare earths cerium and lanthanum) improved the wetting characteristics and eliminated bare spots. The eutectic alloy was not by itself patentable. ILZRO patented the combination of Zn 5%, Al + Mischmetal and the name Galfan® was registered as a trademark. Some 20 years of testing consistently confirms that Galfan has a corrosion life two to three times that of zinc. The application of a zinc-aluminum coating was frozen for years due to high production costs but higher oil prices have

The alloy Composition and wettability. Galfan baths contain not only 95% zinc and 5% aluminum but also rare earths, which counteract the tendency to oxidation, thus avoiding bare spots. A typical Galfan ingot should fulfil the ASTM B 750 norm. The composition is Al: 4.2 to 7.2%, target 5%; Mischmetal: 0.03% to 0.1%; Fe: Max 0.075%; Si: Max 0.015%; Pb: Max 0.005%; Cd: Max 0.005%; Sn: Max: 0.002%; Mg: Max 0.1%; and remainder: Zn. However, the composition of the Galfan bath will change over time due to the oxidation of aluminum, zinc drag-out of from the first galvanizing stage into the Galfan bath and a gradual increase in trace elements such as lead pick up from the wire surface.

Lead, as later described, must absolutely be avoided by active control of lead pollution in the galvanizing bath. Mischmetal, an alloy containing rare earths, is very unstable due to its exothermic properties. It melts at 800°C while the Galfan bath is normally operated at 430°C. The bath is made up with Galfan ingots that already contain Mischmetal so there is no need for separate additions of pure Mischmetal. In the case of an original Galfan ingot, this alloy is already present. A customer who does has not have access to Galfan ingots can prepare an equivalent composition. To add the rare earths, one must use a “Master Alloy” that melts at 490°C. This alloy is made of: 48% La, 28% Ce, 9% Nd, 3% Pr and 12% Zn. Therefore the bath must theoretically be brought up to 490°C. Since the bath holding the zinc-aluminum may not be designed to operate at temperatures around 500°C, it is recommended that a separate crucible is used to melt the master alloy before adding to the molten Zn-Al bath. Stirring is necessary to assist with the homogenization. Alloy dosing. To maintain the correct bath composition, ILZRO recommend the use of inductive coupled Argon plasma analysis as described in the ASTM E-1277 specification. Any major variation in the ratio of zinc and aluminum content could have harmful consequences. Significant deviation from the preferred Zn/Al ratio will induce globules of zinc or aluminum that will be sources of accelerated corrosion. Figs. 1-3 illustrate this problem.

Fig. 2. Corrosion rate of zinc and Galfan in marine (chloride) and industrial (sulphur dioxide) environments. NOVEMBER 2008 | 75

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led to a demand for offshore platforms, which require fittings and ropes with especially strong anti-corrosives coatings. There has also been increased demand for gabions for use in salty or “high humidity” conditions, a boon for the wire market. While the brand name Galfan is still protected, the ILZRO patent has expired and “equivalent” alloys have been specifically developed by several wire producers. Experience has shown, however, that the corrosion characteristics and the coating adhesion of 95% zinc 5% aluminum are very sensitive to proper management of the “zinc-aluminum” baths. This paper provides an overview of current trends in the use and application of zinc-aluminium coating technology.

TECHNICAL PAPERS

Lead contamination. Lead contamination can occur through carry over by the wire from the lead patenting process. Intergranular corrosion is not a problem associated with normal galvanizing, but can occur in zinc-aluminum alloys. Antimony, bismuth, cadmium, tin and lead in a zinc-aluminum alloy coating can increase the susceptibility of the coating to intergranular corrosion. The mechanism is not fully understood, but these impurities are known to collect at grain or phase boundaries. They may act as cathodes, preferentially corroding the zinc. The corrosion products create pressures that cause micro-cracks. Lead creates the greatest problems in wire coating. ILZRO therefore limited the lead on Galfan coated wires to 300 ppm (0.03%) to minimize intergranular corrosion or poor wrap tests. Coating characteristics. The corrosion resistance of Galfan is optimum when the microstructure is 100% fine-layered lamella eutectic. To achieve this, the coating must be at the eutectic composition (Zn-5.2%Al) and rapidly solidified. The Al-Fe-Zn intermetallic is soft and ductile, containing 25% Al, unlike the Fe-Zn from galvanizing. It is very corrosion resistant and sacrificial to the underlying steel. It will not show red rust until the residual coating is less than 5 microns. The Fe-Zn alloys show red rust at 15 microns or even higher. The Galfan surface takes on a patina with time; the silver appearance becomes duller and gray colored. After a few months the Galfan has almost the same appearance as uncoated steel wire. Most galvanizers use the volumetric method to measure coat weight. It is easier and quicker than the gravimetric method. Because zinc and aluminum release different quantities of hydrogen the volumetric method is not generally suitable for Galfan. The coating weight of Galfan is therefore measured by the gravimetric method.

Galfan density is 6.6g/cc. For the same thickness Galfan coat weights are about 10% less than for zinc. Specifications do not normally acknowledge this difference, or indeed the significantly higher corrosion resistance of Galfan. Application. The application of a zinc-aluminum coating could be carried out theoretically in two ways: a direct coating and a double process dipping. In the wire industry, a direct Galfan coating is not usually used. In fact very few lines are dedicated only to Galfan. Therefore, the technology related to direct coating of Galfan will not be pursued here. The use of in-line, double-dip technology is the preferred practice for providing an economical solution for Galfan coating.

Equipment Coating process. There are two stages in the coating process. The first stage requires the formation of zinc-iron alloy and the process follows standard galvanizing practice. Zinc pick-up must be well controlled and consistent. Nitrogen wiping is often used to control coating thickness as well as bath surface oxidation.The galvanized wire is then given a second dip into the Galfan bath. Great care is required on: a) wire guidance to achieve stability of the wires, through the use of low wire back tension; and b) Uniform cooling of the coating. Synchronized take-ups and payoffs are preferred, as the â&#x20AC;&#x153;hardâ&#x20AC;? zinc-iron alloy will be converted into a smooth and relatively soft zinc-iron-aluminum coating, which can be destroyed if excessive tension is applied to the wire. Galfan bath. A low carbon iron is often used for zinc baths but is unsuitable for Galfan as the reactivity of zinc aluminum alloys is quite different to that of zinc. Grey cast iron or AISI 316 stainless steel or ceramic baths are normally recommended for Galfan. With Galfan, dross has a tendency to float on

Fig. 3. Effect of aluminum content on corrosion resistance of zinc aluminum alloys. 76 | WIRE JOURNAL INTERNATIONAL

Conclusions An effective zinc-aluminum coating process requires a lot of care both on the process itself as well as on the chemical controls and mechanical design. Experience has shown that the presence of rare earths is necessary to achieve the optimum coating quality of zinc-aluminum alloy coated wire. The benefits of Galfan in improving the corrosion resistance of wire, particularly in a marine environment, are indisputable. Therefore, to maximize these benefits it is important to apply all the measures presented in this paper. Insufficient process control can result in poor coat quality with consequent customer dissatisfaction and damage the reputation of Galfan. ■

René Branders is responsible for the direction of the commercial department at FIB Belgium SA, Belgium. He has held various positions at the company over the years, including roles in R&D, engineering and quality control. He holds a degree in civil engineering from Université Libre de Bruxelles, Belgium. Andrew Stacey is chairman of Stonepark Consultancy Ltd., a U.K.-based specialist in steel wire and wire rope technology. He previously worked for Bridon for 26 years, in positions that included Group Technical Director. He earned a Ph.D degree in metallurgy at Sheffield Hallam University in 1972. This paper was presented at Wire Bologna 2007, Bologna, Italy, November 2007.

TECHNICAL PAPERS

the surface. As a consequence, a top-fired ceramic bath must be avoided and an immersion burner heating system should be used, applying great care on the de-drossing operation around the tubes. Galfan wiping. Due the presence of aluminium, the surface of Galfan or zinc-aluminium alloy is very sensitive to oxidation. Nitrogen wiping should be used to prevent this. A nitrogen wipe also helps with operating at high speeds and can be coupled with a monitoring system for the control of coat weight.

Branders

Stacey

Fig. 4. 50 ppm lead and 1500 ppm lead. NOVEMBER 2008 | 77

PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS New crosshead design can provide cost reductions, offers more safety U.S.-based JoeTools announced that it has achieved a remarkable innovation that will be a standard feature on the company’s broad line of extrusion crossheads. JoeTools “ThermoGard™” insulation system can be a major advantage to wire and cable extrusion processors, offering a substantial reduction in operating costs while increasing operator safety, a press release said. The technology enables the insulated exterior to keep heat contained within the head, so processing temperatures are easier to control and maintain, it said, adding that this “can dramatically reduce the heating and cooling cycles and equipment starts and stops caused by continuous heat loss.” As a result, it said, the ThermoGard crossheads can help extrusion processors increase productivity, lower energy costs and minimize equipment wear. The crossheads also represent an exceptional concept for increasing operator safety, the release said. With its high-temperature fiberglass insulated layer and vinyl teflon sheathing, the insulated surface maintains a much lower temperature, thus presenting less risk of physical harm to operators, it noted. Further, the heat contained within the crossheads enables the overall temperature of the processing environment to be much cooler and more comfortable, allowing for alert and responsive production, it said. “So you may say, the new ThermoGard Insulation System makes JoeTools… ‘Joe Cool,’ ” the release said. Contact: JoeTools, tel. 877-832-7864, www. joe-tools.com.

Twister can process multiple products Italy’s Cortinovis, part of the Eurolls Group and represented in the U.S. by Cortinovis Machinery America, reports that it offers a drum twister that is capable of processing multiple products with bobbin sizes from 1600 mm at speeds to 160 rpm to 4000 mm at speeds to 40 rpm. A press release said that the drum twister can handle: the laying up of insulated conductors, round or sector shaped prespiralled for low, medium and high voltage, for cables up to 150 mm; laying up of insulated cores for

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control and instrumentation cables; stranding of sectors for Milliken copper conductors up to 3000 mm2; steel wire armoring for cables up to 120 mm and wires up to 4.0 mm; and copper and aluminum screening for wires from 0.6 up to 2.5 mm for cables up to 120 mm. The system can work in-line with all types of taping, including paper, plastic, copper, aluminum, bronze and steel tapes, the release said. Bobbin loading and unloading is done with lifting platforms and motorized trolleys and pintles and payoff for wires and insulated cores can be done from packs, coils and bobbins, with straighteners and tensioners, for control of broken wire, it said, adding that it also has full safety devices for bobbins fitting on rotating forks as well as a full centralized control with synoptic, alarms, predictive maintenance and recipes. Contact: Tony DeRosa, Corinovis Machinery America, tel. 908-479-9818; cortinovis@cortinovisamerica.com.

PFTE line can eliminate the use of perfluorooctanoic acid salts Japan’s Asahi Glass Co. (AGC) has introduced and plans to soon commercialize its Fluon® PTFE E-Series, a new line of PTFE (polytetrafluoroethylene) products that do not contain salts of perfluorooctanoic acid (PFOA). A press release said that the company’s Fluon PTFE E-Series can be used for applications such as wire and cable insulation, parts for electronics, hose and tubing and more. Plans call for Asahi to commercialize Fluon PTFE E-Series in early 2009 and to completely convert its current PTFE products to Fluon PTFE E-Series by the end of 2010, it said. The release explained that PFOA has long been widely used as a polymerization surfactant for fluoropolymer products, including PTFE. However, because of environmental concerns, AGC is participating in the global stewardship program to eliminate use of PFOA, its precursors and higher homolog chemicals, along with seven other companies, it said. “As a result of such efforts, AGC has successfully developed a new high-performance surfactant as an alternative to PFOA. By using this new surfactant, AGC is able to manufacture the Fluon PTFE ESeries products.” The new surfactant has been certified in Japan under its Chemical Substances Control Law, and has been

Power/control cable line is expanded U.S.-based Coleman Cable, Inc., has expanded its line of industrial products in three areas, one of which is RoyalÂŽ Tray Cable THHN/PVC. Coleman Cableâ&#x20AC;&#x2122;s Royal brand of Type TC power and control cable is a 600 volt cable constructed with THHN/THWN (14 AWG and larger) or TFFN (16 AWG) conductors which are cabled together with fillers as required and covered with suitable binder tape as needed, a press release said. An outer jacket of PVC protects the cable assembly against mechanical damage, heat, flame, moisture, chemicals and corrosion and the tray cable THHN/PVC is approved for cable tray, raceway, direct burial and aerial

installations when supported by a messenger, the release said. It added that the cables comply with the appropriate sections of NEC Articles 318, 340, 501 and 725. The company noted that it is also expanded its product lines with Royal SOOW Control Cables and Royal/ TriangleÂŽ Bare Copper Wire. Contact: Coleman Cable, Inc., www.colemancable.com.

Air wipes offer an efficient way for cable makers to dry wire or cable Japanâ&#x20AC;&#x2122;s T. Fukase & Co., Ltd., represented in North America by Urbano Associates, offers three types of air wipes that are efficient at removing unwanted water or other low viscosity liquids from wires or cable. The company noted the following about its technology. The Type FAS air wipe features top and bottom air inlets with bottom drain and absence of misting at the entering or exiting wire. The series allows both right-to-left and left-to-right wire line directions and easy threading because of the split, hinged PVC body structure. It is available in throughput wire sizes from 0.15 mm to 9.0 mm for speeds up to 400 m/min, with other sizes and hole profiles available on specific request. The Type FA air wipe features a solid PVC body struc-

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PRODUCTS & MEDIA

approved for use in the U.S. under the U.S. Toxic Substances Control Act (TSCA), the release said, noting that AGC is also in the process of registering the new surfactant in the EU under the REACH program. Contact: Asahi Glass Co., www.agc.co.jp.

PRODUCTS & MEDIA

ture with top air inlet nozzle, bottom drain and non-marking ceramic guides. Both right-to-left and left-to-right wire line directions are possible. It is available in throughput wire sizes from 0.15 mm to 7.0 mm. The Type TBM air wipes are designed for compact and efficient air wiping up to 400 m/min. They feature top and bottom air inlets and blow back of water mist along the inlet wire line. They are available in throughput wire sizes from 0.5 mm to 45 mm. Contact: T. Fukase & Co., Ltd., www.fukase.co.jp, In North America, contact Urbano Associates, www.urbanoassociates.com, urbassoc@verizon.net.

Vaughn drive replacement provides superior performance U.S.-based OEM Design Services reports that it is offering a drive replacement for Vaughn multi-hole wiredrawing machinery that can provide performance exceeding that of the original drives. A press release said that OEM Design Services is offering a new Siemens 6RA70 for the Vaughns that enable the machinery to maximize the speed and horsepower range, with superb dancer stability throughout full draft range. Dancers stay where set, all the time, and do not require readjustment for any draft or line speed, it said. Other features it cited include: software wire break detection for machine shutdown; Shift report, lb/shift, 7-day history; short-holing with a button press; cascade jog; diagnostic screens; die draft calculator lb/hr display; Ethernet connection for maintenance service from a remote location, Internet or even wireless; full documentation; and a line power factor equivalent to AC drives for when motor speed is at or above base motor speed. For 20 years, the Bonko drive with the 390-504 field regulator set the standard for controlling extended range DC motors on multi-hole Vaughn machines, the release said. “These drives are aging and becoming costly to keep operating,” it noted, adding that replacing such drives with Siemens’ 6RA70 DC REGEN drives will provide performance exceeding that of the original Bonko drives. One drive or the whole machine can be upgraded, it said. Contact: Michael Kaczynski, OEM Design Services, LLC, tel. 203-314-9159; mk@oemdesignservices.com, www.oemdesignservices.com.

Programmable wire straightener meant for difficult applications U.S.-based TAK Enterprises, Inc., is offering a programmable rotary wire straightener, Model #0–PRWS, that it describes as a very advanced integrated system. 80 | WIRE JOURNAL INTERNATIONAL

The TAK system, which has a built-in spool payoff with a programmable back-tension value, has the ability to individually set each of the independent component values that interact to produce straight wire based on the conditions encountered for the application, said a press release that provided the following details. The wire passes through an anti-twist device and a wire cleaner/lubricator that improve system performance by ensuring a more consistent wire condition during the straightening process. The “prepped” wire then approaches the rotating arbor area in a much more consistent state and is worked in a circular motion by a pair of high-speed spinning arbors. Wire tension is maintained throughout the process by the speed feeder that pulls the wire at a pre-programmed speed though the system. Straightness is achieved by the wire block dies, within the spinning arbors, rotating around the full circumference of the wire as it slowly passes and working the wire into a straightened state. The operator sets the block dies for the wire size, threads the wire through the system components, enters program values of speed, feed, and tension, and starts the system. Arbor speeds can be set up to 12,000 rpm while the feed speed has a maximum setting of 100 fpm, the release said, with tension value able to be set up to a maximum of 35 inch lb in 1% increments. Contact: Norman A. Pierce, TAK Enterprises, Inc., tel. 860-583-0517, www.takenterprises.com.

Cable line among first to get new registration from industry body U.S.-based Belden reports that its family of IndustrialTuff® DataBus® Cables for FOUNDATION™ fieldbus applications is among the industry’s first to achieve registration to the FOUNDATION fieldbus H1 Cable Test Specification. A press release explained that The Fieldbus Foundation, a global nonprofit corporation consisting of leading process end users and automation companies, released its H1 Cable Test Specification last November “to provide users with increased assurance that their industrial cabling infrastructure will provide robust and reliable physical

TPE concentrates are RoHS-compliant U.S.-based Teknor Color Company has introduced a new series of concentrates for engineering-grade copolyester thermoplastic elastomers (TPEs) that includes a wide range of color choices, all fully compliant with the European Union’s RoHS Directive. The company recommends the new colors for use with high-performance TPEs like DuPont™ Hytrel® thermo-

plastic polyester elastomers, a press release said, noting that they can be used for applications such as wire and cable insulation, jackets and fiber optic buffers, as well as injection and blow molded parts, film, sheet, and profiles. “The new colorants for copolyester TPEs contain no heavy-metal pigments yet provide the same intensity and coloring efficiency as conventional colors for engineering-grade TPEs,” said Teknor Color Company Market Manager Eric Kalis. He said that the concentrates were formulated specifically for copolyester TPEs, which are often used in challenging applications because of their exceptional toughness, rubberlike resilience, chemical resistance and good performance at temperature extremes. “We began work on developing the concentrates in response to growing use of copolyester TPEs as a buffer in optical fiber cables,” he said.

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layer performance.” “(This) cable registration process … gives our customers additional assurance that our Type A cables will deliver the quality and performance we promise,” said Belden Industrial Line Product Manager Frank Koditek. The Belden product is a Type A 18 AWG stranded cable featuring a polyolefin insulation, with a PVC jacket and 100 percent Beldfoil® shield with TC drain wire. For a cable to qualify, its manufacturers must conduct testing and submit successful test results based on the IEC 61158-2:2003 standard for Type A cable, which includes (but is not limited to): impedance, capacitance unbalance, connector pin-outs, and attenuation. Contact: Belden, tel. 800.belden, www.belden.com.

PRODUCTS & MEDIA

The concentrates are available in black, blue, light blue, brown, gray, green, orange, purple, red, rose, white, and yellow. Contact: Teknor Color Company, tel. 401-725-8000, info@teknorcolor.com.

Cat. 6 cable for outdoor applications meets TIA/EIA industry requirements U.S.-based Berk-Tek, a Nexans Company, has introduced its newest Cat. 6 cable, designed for outdoor installations, that rounds out its offering of UTP cables for all indoor and outdoor environments. The cable, LANmark-6 OSP, includes a water-blocking gel compound within the core that encases the four UTP copper pairs and a rugged, but flexible, black polyolefin, UV-resistant jacket for a total OD of .250 in., a press release said. It noted that the cable meets the TIA/EIA568.B.2-1 industry standard requirements for a Cat. 6 cable, but is specifically designed to support facilities, such as portable classrooms, detached garages, guard shacks and other wet locations. The cable, it said, is also ideal for exterior security cameras, located outside buildings or even on parking lot lights. “This UTP cable can provide data, video and power on all four pairs through PoE capabilities, including adhering to the proposed IEEE 802.3at PoE Plus addendum. In addition, this cable complies with the stringent NEC codes, which require outdoor-rated cables to be used when conduit is located below the floor in slab-on-grade construction,” the release said. “Conventional Cat. 6 LAN cables, designed for indoor high-speed data, voice and video applications, do not meet specific codes for outdoor or wet locations due to the threat of moisture and extreme temperature fluctuations, which affect critical electrical characteristics,” said Berk-Tek Copper Products Manager James A. Frey. “The new LANmark-6 OSP cable provides full Category 6 performance to these difficult locations.” Contact: Berk-Tek, www.berktek.com.

MEDIA Book covers the efficient, effective use of Lean Manufacturing methods Lean Connections: Making Information Flow Efficiently and Effectively, a new 168- page book from Productivity Press, provides a framework to judge how well input is working in the process. A press release notes that the book: explains the role of information flow in lean production; demonstrates successful information flow from both directions; details information flow across all participants on the production floor; and illustrates human factors as well as the applications of technology. It shows how to achieve effective information flow

82 | WIRE JOURNAL INTERNATIONAL

through the extended value stream to the end customer. “While most managers understand how to make materials and manpower flow, the flow of information tends to be much more underdeveloped,” the release said. “Even companies that excel at recognizing waste and are otherwise adept at implementing the principles of lean production are often challenged to provide satisfactory information flow.” This book, it said, provides the building blocks of a comprehensive information-flow system, showing the calculations and methods that will allow a company to get the necessary information to those individuals who need it, when they need it. Employing a workbook format, the book follows RNA Manufacturing, a fictional company, through its implementation of a comprehensive lean production system, outlining its methods and thought processes, then pointing out how to discern changes to make information flow through a facility. Contact: Productivity Press, www.productivitypress.com.

Company’s fiber guide outlines its full line of Audio/Visual products U.S.-based Liberty Wire & Cable has introduced a guide for the company’s fiber optic products and solutions for A/V pros. The guide provides vital information about bulk fiber and bulk fiber connectors, virtually unbreakable durable fiber, field termination kits, molded and custom fiber assemblies, and electronics using fiber connections — making it a convenient literature reference for busy professionals, a press release said. Specific products in the guide include Liberty’s bulk break-out fiber cables, bulk distribution cables, plenumrated cables, connectorspacks, tool kits and more. Services covered include Liberty’s manufacturing capabilities for custom cable assemblies in any length, with simplex or duplex jumpers, and many additional options. Liberty Wire & Cable, a division of Communications Supply Corp. (CSC), offers a full product line of wire and cable, primarily for audio/video and security applications. Contact: Liberty Wire & Cable, www.libertycable.com. ■

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking employment positions are entitled to FREE “Position Wanted” classified ads. Limit: one ad per issue, maximum three ads per year. This WAI membership benefit is not transferable to nonmembers or to companies. CLASSIFIED AD RATES: • $1.30 per word for Wire Journal International and on-line classifieds at wirenet.org (20 word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category. BLIND BOX INFO: Blind box numbers assure the confidentiality of the advertiser in both the WJI and the on-line publication. Responses are mailed out within two business

CAREER OPPORTUNITIES PRODUCTION SUPERVISOR/ MANAGER. Leading manufacturer of welded wire mesh products has an immediate opening for a hands-on Production Supervisor/Manager with experience in steel wire manufacturing. • Responsible for all phases of production to ensure that the manufacturing facility operates in the most cost efficient and safe way. • Responsible for day to day manpower, equipment and processing needs. Minimum of 4 years supervision experience in a process manufacturing environment. Please contact Box 11-1. ELECTRONICS TECHNICIAN. A privately held manufacturer of steel wire mesh products and a respected leader in the industry is seeking a highly motivated Electronics Technician, preferably with steel wire experience. • Associates degree in a technical field or equivalent • Knowledge of industrial drives, motors, and applications. • Experience with PLC computer controlled manufacturing equipment desired. • Experience troubleshooting and programming complex, computer controlled mechanical systems.

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

• Understand PLC programming, read electronic schematics, industrial electrical drawings and ladder logic.

diagnosis of machine programming and electronic systems. Please contact Box 11-2.

Responsibilities: Troubleshooting and

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

FOR SALE 1 1 1 3

12111 1 1 1 1 1 2

11-

NEB 64-Carrier CB-1 Cabler Braider WATSON 36” Rotating Cabler Line NORTHAMPTON ST1000 Cabler, 1999 NORTHAMPTON 630mm Cablers/ Bunchers CEECO 6-Bobbin 60” Closer MGS Model LC50.4 Caterpuller Capstans NIEHOFF M15 Wire Drawer, Annealer, SG45 Spooler D/S 4.5” 24:1 L/D Extruder, 200HP Motor, 1999 D/S 100mm 24:1 L/D Extrusion Line, 1998 D/S 3” 24:1 L/D Extruder D/S 2.5” 24:1 L/D Nylon Extruder D/S 2” 30:1 L/D Hi-Temp Extrusion Line D/S 1.25” 30:1 L/D Hi-Temp Extruder D/S 2” 24:1 L/D Extruder TULSA 24” Motorized Shaftless Payoffs, Model HSPO-1, 12/02 D/S 36” H.S. Dual Reel Take-up, twin Motors CLIPPER PS36 Parallel Axis Dual Reel Take-up, 1999

1 - ENTWISTLE 36” Dual Reel Take-up, Model THE 24/36 4 - D/S 30” Dual Reel Take-ups 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 7 - CLIPPER Model SP16 Dual Spoolers 1 - BARTELL 72” Shaftless Take-ups 3 - TULSA/KENRAKE Model WTR-656 Respoolers 2 - TEC Model 24STC Hi-Speed Twisters, rated 1300rpm 1 - ADVANTAGE Chiller, Model MK-25AM41HBX, 9/98 1 - NEW ENGLAND BUTT 60” Dual Wheel Capstan Assembly 1 - SCHLEUNIGER OS9400 OmniStripper, 1999 1 - SCHLEUNIGER CPS1500 Coiler 1 - SCHLEUNIGER WS500 Wire Stacker 1 - RAYMOND 3000lb Stacker Forklift 41 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels

Contact: Martin Kenner

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

NOVEMBER 2008 | 83

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”)

EXTRUDER OPERATING TECHNICIAN: Individual will be tasked with the set up and operation of extrusion lines used in the insulation and jacketing of wire and cable. Additionally, this individual will have the benefit of being employed by a long established family owned company based in sunny southwest Florida. All interested candidates should submit resumes and cover letters inclusive of salary requirements by e-mail to rferris@pelicanwire.com. MANAGER OF CUSTOMER AND VENDOR RELATIONS. This position in the wire and cable industry will lead the marketing, sales, quoting, and purchasing efforts while developing and maintaining good relationships with all customers and vendors. Monitor all sales, quoting and purchas-

ing processes and enforce their related policies and procedures. This position reports directly to the CFO. Minimum qualifications are a two year degree in business, finance, sales, marketing, or related field and five years experience in sales or marketing in a manufacturing environment as well as experience in sales and marketing analysis. Must demonstrate the desire to learn about new products and materials. Interested candidates should submit resumes and cover letters inclusive of salary requirements to rferris@pelicanwire.com. REGIONAL SALES. Sumiden Wire Products Corp (est 1979) is a leading manufacturer of seven wire prestressing steel strand with a well established customer base. We are seeking to hire a regional sales person to cover the Western U.S. market. The person will

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.

be responsible for maintaining existing accounts and developing new sales opportunities. 50% travel will be required. Please send an e-mail to jfeitler@sumidenwire.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.

WIRE JOURNAL

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

DECEMBER 2008: INDUSTRY TRENDS Market fluctuations. Cost of raw materials. Running Lean Flow and Six Sigma. What’s ahead for wire and cable manufacturers? Will changes arrive with a gust or will they simply infuse the industry with a new direction? Forecasted opinions will be part of the December issue of WJI. Place a display ad and let your product or service message sink in while your customers get wind of developing trends. Contact WJI’s Bob Xeller or Anna Bzowski today at Tel.: 001-203-453-2777 | E-mail: bxeller@wirenet.org or abzowski@wirenet.org

84 | WIRE JOURNAL INTERNATIONAL

Wire Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-6223000 or 800-394-WIRE. ACQUISITION SOUGHT Interested to acquire a medium size company operating in USA/Europe in the non-ferrous conductor industry, essentially into copper/copper alloys/ nickels/nickel alloys/bimetallics/ compensating alloys/precious metals & the like. Will be interested in outright purchase or equity partnership with operating exposure. Currently we have two operating plants manufacturing copper & copper alloy products. Please contact Box 11-3.

DIES

MACHINERY

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.

BEST WARRANTY-LOWEST PRICES on high quality Rolling Ring Traverses. YR Products, phone/fax: 708-672-5007 or e-mail kamoline@ comcast.net.

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

RECONDITIONED KINREI DOUBLE TWIST BUNCHERS FOR SALE. (5)-HK560 High Double Twists Bunchers and (1) NB-450 reconditioned, with partial warranty, currently available for use as either Buncher/Strander or Cabler/Twinner. All can be sold in an “as is” or in a reconditioned state. Machines may be currently viewed at Kinrei of America in New Jersey. These machines are in excellent condition and were built in 1999/2000 with approximately 13,000 hours of production time manufacturing Litz Wire. Pictures as well as complete details available by contacting Mitch Jacobsen at 973-494-6143 or email mjacobsen@kinreiusa.com.

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

WWW.URBANOASSOCIATES. COM. For New & Used Wire & Cable Equipment. Tel. 727-863-4700; fax 727-863-4711; or by e-mail at urbassoc@ verizon.net. NAIL PLANT FOR SALE. Wafios N3 (1) N4 (1) N5 (3) N6 (1) YT3 (2) YT4 (1). Collated Nails: Zeus high Frequency coil welder (1); Willy Heiff Plastic strip (3); Nail Threaders (3); 50 lbs packaging line with case erector; Wafios Tool Grinder (1); Nail Tumbling (1); Racking system 500 skids (1). Call: J-M or M-A Perron # 450-447-5000 ext: 24 or 23. WIRE FOR SALE INDUSTRIAL WIRE available in Charlotte, NC. Local producer can provide bright basic and hot dip galvanized wire in sizes from 11ga to ¼”. Call 704525-5554 or send an email to iwalsh@wirebond.com for more information. ■

Serving the non-ferrous and ferrous industries since 1983

NOVEMBER 2008 | 85

CLASSIFIEDS

E-mail Peter Carino or Jack Cutler pcarino@wireresources.com or jcutler@wireresources.com www.wireresources.com.

ADVERTISERS’ INDEX

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

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

AIM Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Alloy Wire International . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Amaral Automation Associates . . . . . . . . . . . . . . . . . . . . .39

International Fastener Machinery & Suppliers Association . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .81 Bergandi Machinery Co . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .29 Cable Components Group . . . . . . . . . . . . . . . . . . . .Cover 2 Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .83 Die Quip Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Durant Tool Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Enkotec Co Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Esteves Group USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Eurolls Group/Cortinovis Machinery/Teurema . . . . . . .2, 23 George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Mario Frigerio SpA . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4 T Fukase & Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

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

NORTH AMERICA

EUROPE

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

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

86 | WIRE JOURNAL INTERNATIONAL

Joe-Tools Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Kinrei of America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Kiswire Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Lesmo Machinery America Inc/Cometo . . . . . . . . . . . . . .20 Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . .85 Metavan/HOWAR Equipment . . . . . . . . . . . . . . . . . . . . . . .40 Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Millennium Steel & Wire . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Milliman Extrusion Tool & Design Inc . . . . . . . . . . . . . . . .40 Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Numamerica/Numalliance . . . . . . . . . . . . . . . . . . . . . . . . .16 Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .14 Power Sonics LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

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

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

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

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . . .9

Wardwell Braiding Machine Co . . . . . . . . . . . . . . . . . . . . .54

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .87

Sanxin Wire Die, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Witels Albert USA Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Schlatter Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .79

Sikora International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Wyrepak Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . .9, 79

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 3

Sweed Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 TAK Enterprises Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . .41 Tubular Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 US Synthetic Wire Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Vandor Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Wafios Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .32

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Wire Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

wire and plastic

RECENT PURCHASES — INVENTORY HIGHLIGHTS CBR998 - (8) Setic 630mm PA630i D.T. Twinners, Yr. 1998. CBR1000 - 84” CABALLE/KALMAR/POURTIER Drum Twisting Line, 1990’s. EXPL325 - 6” Jktg. Line w/2) 60” Belt Cats, 96” Portal P/O, T/U, 30” multipass capstan. EXP902 - 120mm ROSENDAHL 24:1 air cooled extruder, 1999. EXR172/171 - 6” D.STD. & 4 1/2” 20:1 Rubber Extruders, roller feed water cooled. SKALTEK TAKE UPS U20T, U26, PAYOFFS: A16S, A204K, TKU1091 72“ HALL S/L Take up, TKU1079 72” HALL Portal Take up, CABALLE 72” portal, TKU1089 - 2.6m NOKIA BTU-6 Portal Trav. Take up, Yr. 1998. CAT433/CAT435 - 1.8m/1.2mm Belt Caterpullers, BCA-12, BCA-18. EXPL319 - (2) DEANGELI/SAMP 45mm Hi Temp Lines with Zumbach Prehe ater, SS multipass Capstan, 560mm Dual Parallel Axis Take ups. EXPL304 - ROSENDAHL Skin-Foam-Skin Insulation Line, 2000. Henrich Annealer, Preheater, 60/45/30mm Extruders w/gas injection, Multi capstan, Rosendahl DIN500 Dual Take up. CBR986 - (2) ENTWISTLE SC30 Single Twist Cablers CBR995/CBR989 - 630mm MGS & TEC D.T. Twinners, NMC 800mm D.T. CBR833 - 96”/2.50m CEECO Drum Twister, 1998, Oscillator W/dual Binder. CBR981 - 760mm SAMP D.T. Buncher, BM-760D. (1995) CBR923 - 1250mm POURTIER Drum Twister, 12-630mm Neutralizing Payoffs, Rotating Caterpuller, 1.25m Rotating Payoff.

CBR948 - 48” TEC Drum Twister w/(2) Conc. Tapers. NOKIA DUAL TAKEUPS - (2) EKP-5 2001, EKP-50 1998, EKP-100 1995. TKU1043 -36” CLIPPER Dual Reel Take up, PS-36 Recently rebuilt. TKU1077 36” CLIPPER DR-36 Take up with caliper disc brakes, motorized traverse, AB PanelView RWD445 - CLIPPER SP-16.Dual shaft Rewinder, RWD359 - 2.6 m SKALTEK Rewind Line. A264K Payoff, S60/L100 line controls. Measuring mach. Guide roller assy. U26T Take up. RWD466 - 96” BARTELL Shaftless Rewind Line WRD678 - SAMP 14 Wire Drawing line, Model MLS/5.T.14 w/MT8 Drawer R12.14.14.550 Annealer, (2) TE 65/M Spoolers, 1993, 14 AWG-34/38 AWG finish. WRD722 - NEXTROM Multi Wire Drawing Line, 7 Wire w/Annealer, 630mm Spooler, Yr. 1999 WRD818 - VAUGHN - Tandem Rod Breakdown Machine, 10 dies, 18” Capstan, 400 HP DC Drive, 30” spooler. WRD835 - ENDEX 18” Drop Coiler with Turntable. WRD837 - (4) NIEHOFF M30 Intermediate Wire Drawer w/VG_30 annealer, 75 kw DC motor, controls.

LATE MODEL HIGH QUALITY (BRAND NAME US & EUROPEAN) WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY EX-STOCK FROM (6) USA WAREHOUSES

NOVEMBER 2008 | 87

ADVERTISERS’ INDEX

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

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

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

Savings & Quality With the Right Measuring Solution Diameter

Wall Thickness

With ODAC Laser Gauges

With UMAC /WALLMASTER Ultrasonic Scanners

s Highest accuracy,

repeatability up to .0000001 in. / 0.05 μm

s Ultra high scan rate, up to 2000/s

s Worldwide, more than 60,000 gauges sold

s Up to 8 measuring points s Up to 15,000 measurements/s

Eccentricity With ODEX® Optical/ Magnetic Gauges

s Extremely fast

- 1200 readings/s - Fast data output for FFT

s Extremely compact and

s Novel concentric

transducer adjustment allows product diameter set in a few seconds

fully static, no moving mechanisms

s Automatic inductor

Material Savings and Process Optimization s Fast Return On Investment s Most efficient solution for specific application s Superior mechanical design, efficient protection = stability s Worldwide Zumbach Customer Service and Sales Offices

www.zumbach.com Zumbach Electronic AG – SWITZERLAND (H.Q.) Zumbach Electrónica Argentina S.R.L. – ARGENTINA Zumbach Electronic S.A. – BELGIUM Zumbach do Brasil Ltda – BRAZIL Zumbach Electronic Co., Ltd. – CHINA P.R. Zumbach Bureau France – FRANCE Zumbach Electronic GmbH – GERMANY

Zumbach Electronic India Pvt. Ltd. – INDIA Zumbach Electronic Srl – ITALY Zumbach Electrónica S.L. – SPAIN Zumbach Electronics Far East – TAIWAN Zumbach Electronics Ltd. – UK Zumbach Electronics Corp. – USA

We Measure Quality

control allows for installation in tight areas

OUR KNOW-HOW IS YOUR NEW WAY Cabmach: innovative technology born from 110 years of experience providing the rope and cable industries

Strong trees have deep roots. Thatâ&#x20AC;&#x2122;s why you can trust Cabmach. It was born from the experience and success of Mario Frigerio, the world wide leader in the ferrous wire industry that for 110 years has been engineering and producing state-of-the-art machinery with the right formula: care, reliability, high quality. A combination already achieved by Frigeco, the non ferrous wire division of Mario Frigerio. www.mariofrigerio.it

HARDWARE . EASY WIRE