Green - Thinking WAY outside the box by Wire Journal International, Inc.

WIRE JOURNAL DECEMBER 2012

I N T E R N AT I O N A L www.wirenet.org

green — Thinking WAY outside the box

wire China wrapup OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

D ĂƵƚŽŵĂƚĞĚ ƚĞƐƟŶŐ ƐŽůƵƟŽŶƐ ĐĂŶ ŚĞůƉ ǇŽƵ ƚĞƐƚ ŵŽƌĞ > E ĐĂďůĞ ŝŶ ůĞƐƐ ƟŵĞ ĨŽƌ ŚŝŐŚĞƌ ƋƵĂůŝƚǇ ƌĞƐƵůƚƐ͘

dĞƐƚ ϰͲWĂŝƌ ĂďůĞƐ ƵƉ ƚŽ Ϯ ',ǌ

dĞƐƚ ϰͲWĂŝƌ ĂďůĞƐ ƵƉ ƚŽ ϲϬϬ D,ǌ

dĞƐƚ ϰͲWĂŝƌ ƚŽ ϮϴͲWĂŝƌ ĂďůĞƐ ƵƉ ƚŽ ϭ ',ǌ

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Test Cat 7/7A ISTP cables with

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ƐǇƐƚĞŵ ϰϬ 'ŝŐĂďŝƚ ƚŚĞƌŶĞƚ ĂƉƉůŝĐĂƟŽŶƐ

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^ŝŵƉůĞ͕ ĞĂƐǇͲƚŽͲƵƐĞ ƐŽŌǁĂƌĞ

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ƌŽƐƐƚĂůŬ ŝŶ ŵŝŶƵƚĞƐ

Test seven 4-pair cables in

Shielded (STP/FTP) Twisted Pairs

ĨŽƌ ĂƵƚŽŵĂƚĞĚ ƚĞƐƟŶŐ

ϮϴͲƉĂŝƌ ƉůĂƞŽƌŵ ƚĞƐƚƐ ůŝĞŶ

ŽŶĞ ŽƉĞƌĂƟŽŶ

ƵƚŽŵĂƟĐ ŝŶƚĞƌŶĂů ĐĂůŝďƌĂƟŽŶ

^ŝŵƉůĞ͕ ĞĂƐǇͲƚŽͲƵƐĞ ƐŽŌǁĂƌĞ

ƌŽƵƟŶĞ ĐŽŵƉůĞƚĞĚ ŝŶ ƐĞĐŽŶĚƐ

ĨŽƌ ĂƵƚŽŵĂƚĞĚ ƚĞƐƟŶŐ

dŝŵĞͲƐĂǀŝŶŐ͕ ƐŝŶŐůĞͲĐŽŶŶĞĐƟŽŶ

ĨŽƌ ,& ĂŶĚ >& ƚĞƐƟŶŐ

ƵƚŽŵĂƟĐ ŝŶƚĞƌŶĂů ĐĂůŝďƌĂƟŽŶ

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WIRE JOURNAL

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

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

CONTENTS

Volume 45 | Number 12 | December 2012

F EATURE

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 20 People . . . . . . . . . . . . . . . . . 22 Fiber Watch . . . . . . . . . . . . . 26 Fastener Update . . . . . . . . . . 28 WAI News . . . . . . . . . . . . . . 30 Chapter Corner . . . . . . . . . . . 36 Technical Papers . . . . . . . 58-68 Products. . . . . . . . . . . . . . . . 70 Classified . . . . . . . . . . . . . . . 75

Wrapup: wire China 2012 . . . . . . .38 Organizers of wire China 2012 report that the event topped the prior show for both the number of exhibitors and attendance.

Green: Part 2 . . . . . . . . . . . . . . . .42 This feature focuses on a subset of one high-profile renewable energy source—windpower—that literally soars above the traditional field of tall wind turbines yet gets surprisingly little attention, and includes a look at a more fluid location for generating solar energy.

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

Next issue

M ORDIC A L ECTURE Crystallographic texture in drawn wires: measurement, modeling and effect on mechanical properties Prof. Paul Van Houtte . . . . . . . . . . . . . . . . . . . . . . . . . .58

January 2013 • India Outlook • New WAI Officers Cover: An Altaeros airborne wind turbine prototype, one of the multiple alternatives to traditional wind mills. Developers of such lesser-publicized methods insist that their technology should be a crucial cog in the overall approach to generating renewable energy. Maybe thinking outside the box requires looking to the skies. See p. 42.

DECEMBER 2012 | 3

INSIDE THIS ISSUE CONTENTS

JOB HAD GOOD ‘SLIPPERY SLOPE’ ISSUES . .11

Workers reach for a guidewire on a tower being flown in to Vail, Colorado, as part of construction of what is described as the world’s fastest single-cable, 10-person gondola. A key to the project was a single reel of wire rope supplied by ArcelorMittal. That reel, which carried 20,000 sq ft of hightensive strength steel wire rope, is said to be one of the heaviest stranded ropes ever produced for such an application in North America. Photo by Jack Affleck/Vail Resorts.

4 | WIRE JOURNAL INTERNATIONAL

WIRE

CHINA 2012 . . . . . . . . . . . . . . . .38

Nearly 1,400 exhibits awaited attendees at wire China 2012, which organizers said saw exhibitors present the latest information on machines, plants and products from the wire, cable and tube processing industries to 33,469 visitors at the Shanghai New International Expo Centre.

EDITORIAL WIRE JOURNAL

EDITORIAL

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

Power woes, expectations and a call for simplicity Publisher | Steven J. Fetteroll

Post the carnage that Hurricane Sandy delivered to the U.S. on Oct. 29, when more than 6.6 million homes and businesses lost electricity, it didn’t take long for a dormant topic to once again make a heady return: the need to bury power cable. If that story sounds very familiar, it should, as it was only about 14 months before that Hurricane Irene had come by, knocking out power to some 7.4 million homes and businesses. In both cases, there were millions of irate people in the dark for up to a week or more, many for the second time. As Hurricane Sandy’s winds began closing in, more than one wife asked her husband why he had not bought a generator after Hurricane Irene; in one case the resulting conversation showed that even editors can be at a loss for words. The real issue is that the vast majority of power outages, aside from the coastal areas that suffered flooding, were caused by trees taking down power lines. That problem is at least twofold. Burying power cable is extremely expensive, but even if the cost was not an issue it would still take decades to make that transition. In 2009, a report done for the state of New Hampshire concluded that such a project would cost the state $43 billion, take more than 40 years and carry an average cost of $68,313 per customer. Even if one halved that estimate, it would still be a considerable price tag, even more so if one could figure out how to factor in the angst and inherent madness of streets and entire neighborhoods being ripped up for weeks and weeks. There is a need for more reliable power supply, and the technology does exist to do it, but as noted above, it comes with a significant price tag. Eventually, the issue will once again fade away, just as it has before, over and over, because there is no great will to pay. I’d like to propose a solution that is so simple that nobody will support it: if falling trees are the problem, why not create a “no-treehigher-than-a-power-line” buffer zone for a minimum of xx feet from the power lines? State, federal and local government would do their properties, homeowners would do theirs, and maybe a tax credit could be offered to make it easier. Of course, many homeowners would never allow their beloved trees to be taken down, so well, we can’t do that. Most likely, what will happen is a continued policy of benign neglect and/or “bandaids” to the majority of existing systems of overhead power lines. Until the next big power outage, at which point a dormant topic will once again surface.

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 editorial@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2012 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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CALENDAR

CALENDAR April 3-5, 2013: Kyiv Technical Trade Show 2013 Kyiv, Ukraine. The eighth staging of this event will be held at the Kyiv Expo Plaza Exhibition Centre. It is a specialized show for companies engaged in the wire and tube industry, surface preparation and sheet metal industry. Contact: TDS-Expo Ltd., tel. 380-44-596-93-08, fax 380-44-596-92-20, www.weldexpo.com.ua, skype: krasko_olga. April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its trade show, technical programs and the Association’s 83rd Annual Convention. May 23-26, 2013: wire Russia 2013 Moscow, Russia. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Sept. 17-19, 2013: wire Southeast Asia Bangkok, Thailand. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Oct. 8-13, 2013: wire South America 2013 São Paulo, Brazil. Messe Düsseldorf and its partner Grupo Cipa will stage this new fair for the Brazilian market. The new event will be held in parallel with TUBOTECH at the Imigrantes Exposicoes Exhibition Centre in São Paulo. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Nov. 10-13, 2013: 62nd IWCS ConferenceTM Charlotte, North Carolina, USA. To be held at the Charlotte Convention Center. Contact: Pat Hudak, IWCS, tel. 732-389-0090, phudak@iwcs.org, www.iwcs.org.

April 7-11, 2014: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. June 16-18, 2014: 14th Guangzhou International Metal Plate, Bar, Wire, Metal Processing & Setting Equipment Exhibition Guangzhou, China. This event, to be held at the China Import and Export Fair Pazhou Complex, is organized by Guangzhou Julang Exhibition Design Co., Ltd. The event organizers can be contacted at tel. 86-2038621071, fax 86-20-38620781, expo@julang.com.cn, www.metalchina-gz.com. Sept. 24-27, 2014: wire China 2014 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

WAI

CONTACT INFO

Steven J. Fetteroll, executive director 203-453-2777 x 115, sfetteroll@wirenet.org Mark Marselli, editor-in-chief 203-453-2777 x 132, mmarselli@wirenet.org Marc Murray, education director 203-453-2777 x 121, mmurray@wirenet.org Janice Swindells, director of marketing services 203-453-2777 x 117, jswindells@wirenet.org Robert Xeller, director of sales 203-458-7578, bxeller@wirenet.org

WIRE A SSOCIATION INT’L EVENT For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. Jan. 24, 2013: New England Chapter Meeting Uncasville, Connecticut, USA. The chapter will hold its 19th annual meeting at the Mohegan Sun Resort Conference Center. Contact: Anna Bzowski, tel. 203453-2777, ext. 126, abzowski@wirenet.org. See p. 36.

8 | WIRE JOURNAL INTERNATIONAL

April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its trade show, technical programs and the Association’s 83rd Annual Convention.

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INDUSTRY NEWS

INDUSTRY NEWS General Cable Corp expansion mode continues with Prestolite acquisition U.S.-based General Cable Corporation continued its expansion mode with its recent announcement that it has acquired Prestolite Wire LLC, a privately owned manufacturer with two manufacturing facilities in the U.S. and Mexico. A press release said that Prestolite, which offers a broad range of wire and cable products and harnesses serving predominantly transportation OEMs, Tier One Suppliers and OEM distribution customers, reported 2011 revenues of $170 million. “Prestolite has built a strong brand and a broad base of long-standing customers through its reputation as a manufacturer of superior quality products and innovation, with a sharp focus on high temperature and abrasion- and corrosion-resistant applications,” said Roger Roundhouse, General Cable's Senior Vice President and General Manager, Transportation Wire & Assemblies. “This acquisi-

The Prestolite website notes that the company, established in 1985, has two divisions: Prestolite Wire and Cable, a manufacturer of copper wire and cable products that has its offices and manufacturing facility in Paragould, Arkansas; and Prestolite Wire Harness and Ignition Wire, whose offices and manufacturing facility are located in Nogales, Mexico, with distribution and customer service located in Nogales, Arizona. It further notes that the 460,000-sq-ft Paragould plant has ISO 9001 and TS 16949 certifications as well as multiple approvals for SAE and UL style products while the Nogales plant has TS16949 & ISO14001 certifications and has been honored repeatedly with customer quality and service awards. The purchase of Prestolite represents the latest in a series of expansion moves by General Cable this year. In September, the company reported the completion of its acquisition of the North American portion of Alcan Cable for $151 million; in June, it announced that it had agreed to acquire a majority interest (60%) in Procables S.A. (Procables) for $45 million, bolstering its presence in Latin America; and in April, it completed construction of a new manufacturing facility in Baddi, Himachal Pradesh, India.

Major subsea contract is split between Nexans and Prysmian

tion is highly complementary to our existing transportation related businesses as approximately 90% of Prestolite’s revenues are generated from products that are incremental to (our) existing product portfolio. We are excited about the growth opportunities that will be afforded to us as a result of this acquisition through new products as well as through greater access to the growing and evolving automotive segment of the wire and cable industry.” “Speaking for the associates at Prestolite Wire, I can say we are very happy to join the General Cable team,” said Prestolite President Greg Ulewicz, who will remain with General Cable and continue to run the Prestolite Wire business. “The combination of General Cable’s broader capabilities and geographic reach coupled with Prestolite’s product offering and access to markets in the transportation related industry makes synergistic sense and presents significant future opportunities for our combined business. The Prestolite Team is pleased that we have been acquired by a strategic buyer, but for that company to be General Cable— a company that really knows our business—gives me the confidence to tell all Prestolite associates that our future looks very bright.”

Terna Rete Italia S.p.A., part of Terna S.p.A., the operator of Italy’s electricity transmission system, has awarded two major contracts for an energy transmission project to link Italy and Montenegro (MON.ITA) to Prysmian and Nexans. A press release said that the link, which will connect the Italian peninsula with the Balkans, will help improve the integration of the European countries’ electricity systems. The HVDC interconnection between Italy and Montenegro, about 415 km in length, will include 393 km of subsea cable and 22 km of underground cable for the onshore connections. It will feature two 500 kV HVDC cables in a bipolar configuration (2 x 500 MW), with Nexans and Prysmian each providing one. Prysmian reported that its contract, worth about 400 million euros, calls for it to supply and lay about 415 km of extra-high, voltage direct current (500 kV) subsea cable system with a rated power of 1000 MW, as well as specialist civil works both in Italy and in Montenegro. Prysmian will also supply and install the marine electrodes to enable the system’s emergency operation. “It’s a source of great satisfaction to be involved in the realization of an infrastructure of such great strategic importance not only for our own country but for Europe itself,” said Prysmian Group CEO Valerio Battista. “The track record of projects carried out and on-going, further confirms our leading role in the development of interconnections for

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

10 | WIRE JOURNAL INTERNATIONAL

plates onto the bridge to help diffuse the weight, and the load was safely transported to the bottom station of the new ski lift. It took just five months to install the 26 towers, 111 gondola cabins and 20,000 foot steel rope with the help of helicopters, special cranes and hundreds of workers. On November 16th, the lift welcomed its first passengers.The new gondola, able to move 1,200 feet per minute, will be the fastest of its type in the world, creating a 40% increase in uphill capacity. The silver gondola cabins, designed by French manufacturer Sigma, will carry 10 passengers each and will feature heated, black cushioned seats and Wi-Fi access for guests. The new gondola will reduce ride time from 9 minutes to 7.5 minutes. “ArcelorMittal has sold cables in North America for 20 years with an outstanding reputation among our customers for quality,” said Marco Desmarais, sales manager at ArcelorMittal Long Carbon North America. “Our steel

The order was filled with a single reel, but what a reel it was: at 12 ft in diameter and 10 ft wide, and weighing in at about 90 tons, it held nearly 20,000 ft of steel wire rope that was used for a new ski lift in Vail, Colorado, that is said to represent the world’s fastest single cable, 10-person gondola. A press release noted the following about the project. To celebrate Vail’s 50th anniversary as a luxury ski resort, the developers chose ArcelorMittal to help build a new ski lift with a steel rope that is capable of withstanding extreme weather conditions at 8,500 ft. Per the specifications of Leitner-Poma of America, which was in charge of the project, the steel cable supporting the new ski lift began its journey near Lyon, France at ArcelorMittal Bourg-enBresse. Per the company, the technical name for the ArcelorMittal cable is 6*36WSR, compacted strand, low stretch, unique solid plastic core design. The minimum breaking load is 550,782 lb force. The exact dimensions are 19,782 ft long by 2.2 in. in diameter. The finished cable is one of the heaviest stranded ropes ever produced for such an application in North America. The rope had to be wrapped carefully around a reel constructed especially for the transatlantic journey. This reel was 12 feet in diameter by 10 feet wide and weighed around 172,000 lb. In June 2012, after undergoing six months of production, testing and fine tuning, the rope was wound around an enormous reel and transported by special convoy to Antwerp in Belgium. The cargo was loaded onto a Fednav vessel called the Federal Yukon bound for Hamilton, Canada. Upon arrival in North America, The mammoth reel carrying neqrly 20,000 ft of steel wire rope under transport to Vail, Colorado. Photo Vail Resorts. the reel was carefully transported via rail through Chicago and then on to Colorado where it was loaded on to another special convoy truck. cables are known for offering the lowest stretch in the Just 40 miles from Vail, the transport came to a standstill industry and best return on investments. We have also when a local bridge was declared too weak to withstand proved year after year that we can deliver huge ropes on the 137.5-metric ton weight of the 13-axle truck trailer and time, anywhere in North America.” ArcelorMittal reel. Quick thinking engineers installed steel

increasingly efficient and sustainable power transmission grids in Europe and worldwide. With MON.ITA we consolidate our technological and market leadership and our order portfolio increases to more than 2.5 billion euros.” The Nexans contract, the release said, was valued at about 300 million euros. “Nexans is proud to have been awarded by Terna this major contract for the link between Italy and Montenegro,” said Nexans Senior Corporate Executive Vice President Frédéric Michelland. “We believe that both parties are satisfied with the result of the negotiation and now our teams are eager to start working on the execution of the project. The successful delivery of high profile HVDC proj-

ects such as Skagerrak, NorNed, Cometa and Fenno-Skan II has played an important role in our ability of being selected for this challenging link.” The contract, the release said, “reinforces Nexans’ leading position in the global power interconnection sector and further develops its focus on high technology submarine cable solutions.” It notes that over the last 20 years, Nexans has supplied and installed more than 3,000 km of HVDC submarine cables. “The ‘MON.ITA’ project will also enhance Prysmian’s unique track record in the field of deep-water cable systems, which already includes SA.PE.I. (with a record max. depth of 1650 m), the link between Majorca DECEMBER 2012 | 11

INDUSTRY NEWS

ArcelorMittal wire rope sent to slopes in Vail, Colorado, for record ski lift

INDUSTRY NEWS

and the Iberian Peninsula (with a max. depth of 1400 m) and the Italy-Greece link (with a max. depth of 1000 m),” it said.

Malaysia wraps up initial probe into AD on imported steel wire rods The Malaysian government has completed preliminary investigations into anti-dumping of imported steel wire rods from Taiwan, China, Indonesia, South Korea and Turkey, finding that there was sufficient evidence to continue with further investigations on the importation of the rods from the five countries. Bernama reports the government has decided to impose a provisional anti-dumping duty guaranteed by a security equal to the amount of the dumping margin determined through the preliminary investigations. The duties, it said, which “range from nil to 33.62% will be imposed on imports from the countries and shall be effective not more than 120 days from the date of the government gazette.”

ABB: breaker technology advance will boost DC cable deployment ABB, the leading power and automation technology group, announced a breakthrough in the ability to interrupt direct current, solving a 100-year-old electrical engineering puzzle and paving the way for a more efficient and reliable electricity supply system. A press release said that, after years of research, ABB has developed the world’s first circuit breaker for high-voltage direct current (HVDC). It combines very fast mechanics with power electronics, and will be capable of “interrupting” power flows equivalent to the output of a large power station within five milliseconds, which is 30 times faster than the blink of a human eye, it said. The breakthrough removes the longtime barrier to the development of DC transmission grids, which will enable the efficient integration and exchange of renewable energy, the release said. DC grids will also improve grid reliability and enhance the capability of existing AC (alternating current) networks, and ABB is in discussions with power utilities to identify pilot projects for the new development, it said. The advance was made possible by ABB’s extensive research activities, which it noted represent more than a $1 billion a year investment. “The breadth of ABB's portfolio and unique combination of in-house manufacturing capability for power semiconductors, converters and high voltage cables (key components of HVDC systems) were distinct advantages in the new development,” it said. “ABB has written a new chapter in the history of electrical engineering,” said ABB CEO Joe Hogan. “This historical breakthrough will make it possible to build the grid of the future. Overlay DC grids will be able to interconnect countries and continents, balance loads and reinforce the existing AC transmission networks.” The HVDC technology is needed to facilitate the long distance transfer of power from hydropower plants, the integra12 | WIRE JOURNAL INTERNATIONAL

tion of offshore wind power, the development of visionary solar projects, and the interconnection of different power networks, the release said. The company, it noted, has been involved with more than 70 HVDC projects, accounting for about half the global installed base, representing an installed capacity of more than 60,000 megawatts (MW). “Deployment of HVDC has led to an increasing number of point-to-point connections in different parts of the world. The logical next step is to connect the lines and optimize the network. ABB is already working on the construction of multi-terminal systems and the latest DC breaker innovation is a major step in the evolution of HVDC grids. In parallel to the new hybrid breaker development, ABB has an established HVDC grid simulation center developing solutions for future DC overlay grid operations.”

HTS line to be installed by year’s end U.S.-based Superconductor Technologies, Inc. (STI), reports that it expects that it will have a new high temperature superconducting (HTS) line up and running by the end of 2012. A press release said that the elements needed for the 2G HTS wire production are in place at the company’s new plant in Austin, Texas. “Achieving this program milestone positions us to meet the growing demand for our Conductus(R) wire in 2013 and begin preparations for commercial production in 2014,” said STI Vice president of Marketing and Product Line Management Adam Shelton. The release said that an SDP and Ion Beam Assisted Deposition (IBAD) machine that was installed in April will work together to produce one-km lengths of complete wire template that will be used in the next generation Reactive Coevaporation Cyclic Deposition and Reaction (RCE-CDR) system that was installed in October. The RCE-CDR system, it said, deposits the HTS material onto the template using STI’s proprietary Solution Deposition Planarization (SDP) process. That capability is very important as SDP makes it possible to provide the very smooth surface conditions needed for superconducting wire while eliminating the need to polish the template, reducing both cost and chemical waste, it said. The process, it said, eliminates strong acids associated with electroplating alternatives. It noted that STI has produced SDP templates with one nanometer root mean square (RMS) surface roughness starting from unpolished metal tape, and that the SDP also acts as a diffusion barrier, blocking metal contaminates from the substrate passing into the superconducting layers.

Würz and Redex form alliance to supply cold-rolling wire technology Germany’s Würz and France’s Redex, two companies specializing in high-precision manufacturing technology and precision machinery, report that they “have settled their first foundation stone on their way towards a European company group with more than 500 collaborators.” The subsidiaries, Bühler Würz Kaltwalztechnik GmbH

INDUSTRY NEWS

and B+R SAS, collaborate in the field of cold forming of metals, to develop and improve high technology cold rolling equipment for the wire and strip industry, a press release said. It noted that their extended capacities and developments create a base for further growth. “This collaboration generates big synergy effects and both well known brands Bühler and Redex, with combined experience of more than a century are consolidated as they complement one another perfectly in the market,” it said. Bühler Würz GmbH is part of the WÜRZ group, which has a very wide scope that includes mechanical components and precision parts, high precise shaping tools and state-ofthe-art cold-rolling mills, all part of the company's extensive product portfolio that is based on technically demanding and multipurpose machining, an excellent quality standard and an outstanding flexibility, the release said. B+R SAS is part of the Redex Group, which has a passion for operational excellence, quality and innovation, and is a leader in mechanical high technology and mechatronics in various industries, the release said. “Redex aims to fulfill the highest performances for their customers, from the most sophisticated machine-tool drives, to tension leveling line and cold rolling mills for strip and wire.”

Viakon opens cable recycling plant Viakon Conductores Monterrey, the largest producer of electrical cables in Mexico, has installed all new equipment for recycling cable products. A press release from Sweden’s Eldan Recycling A/S, the supplier of the complete cable granulation and separation plant, said that its technology will enable Viakon to “turn mixed cables and wire into pure copper and plastic at approximately 1000 kg per production hour.” The order, the release said, represents an upgrade as Viakon acquired its first Eldan cable recycling system in 1984. Nearly 30 years later, the equipment has now been replaced with more current equipment, it said, adding that Viakon staffers visited the Eldan plant in Faaborg to inspect the new technology. “We have chosen Eldan equipment again due to the reliability and low maintenance cost,” Viakon Maintenance Manager Hector Gámez Báez said in the release. Added

DECEMBER 2012 | 13

INDUSTRY NEWS

Viakon Conductores Monterrey has updated its recycling equipment. Photo Eldan Recycling. Viakon Technical Manager Francisco Monsiváis Contreras, “Copper is very expensive, which is why it is important for us as a cable producer to reuse any waste production material.” The release said that Viakon staff inspected the new equipment at the Eldan Recycling production facility in Faaborg. At its website, the company notes that its recycling technology has been used in more than 800 plants, with 7,000 single machines delivered all over the world. At its website, Eldan Recycling notes that it offers systems to processes to dry cables, jelly filled telecommunication cables and greasy underground cables. The standard setup includes a Rasper, a Granulator and a Separation Table. Standard plants have capacities from 300-4000 kg/production hour, but custom sites can process 6,000, 8,000 or 10,000 kg/production hour.

Alcatel-Lucent and Angola Cables partner on superfast data link ... Alcatel-Lucent reported that it and Angola Cables, a consortium of Angolan telecommunications operators, plan “to dramatically expand the availability of high-speed Internet access and data services throughout Angola and to the rest of world.” A press release said that Angola Cables is establishing a terrestrial fiber-optic link with the West African Cable System (WACS), the submarine communications network connecting the countries of West Africa with Europe. The new fiber-optic network in Angola—established using 100 gigabit-per-second (100G) optical coherent technology from Alcatel-Lucent—will support Internet services for customers of communications service providers in Angola as well as in neighboring countries, dramatically increasing Internet availability in this underserved region, it said. The 100G network, the release said, will enable the transport of vast volumes of data traffic throughout Angola, contributing to the revival of the economy in the region which has struggled to recover after decades of conflict. “Angola already has connectivity to the outside world, but with this new connection to the WACS through the establishment of this 100G link, consumers and businesses in Angola and throughout the region will benefit from a dramatic increase in the availability of communications services, and stronger connections with the global community,” said Angola Cables CEO Antonio Nunes. Alcatel-Lucent’s 100G next-generation coherent technology will be supported by a 1830 Photonic Service Switch

14 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

(PSS), the release said. Designed to address booming demand for bandwidth, driven by video streaming, web applications and cloud services, Alcatel-Lucent 100G technology offers exceptional performance, resilience and reliability in existing and ‘greenfield’ optical transmission networks.

... and Angola Cable has other plans Angola Cables announced the selection of APTelecom, a facilities-based telecom consulting and service company specializing in emerging markets, as international sales manager in the creation of a new submarine cable system joining Africa and South America, under the name SACS (South Atlantic Cable System (Angola–Brazil). TeleGeography reports that the cable will contain four fiber pairs, each capable of transmitting 100 wavelengths and initial speeds of 40 Gbps, with provision to upgrade to 100 Gbp’s. The SACS cable is scheduled to go live in 2014, and as part of the overall project management, APTelecom will provide specialists in the various commercial aspects of system design, procurement and the sales strategy behind leveraging the capabilities and reach of their network, it said. The SACS is designed to provide unique secure low latency routing avoiding current bottleneck locations routing via Africa and Asia to the United States and Europe, the release said. This new route, it noted will provide the global carrier community, content players, and ultra-low latency sensitive customers security through a diverse route via the Southern Hemisphere. At its website, Angola Cables is described as being formed in 2009 and owned by the following major Angolan telecoms companies: Angola Telecom with 51% of the capital, Unitel with 31%, MSTelcom with 9%, Movicel with 6%, and Startel with 3%. The consortium company is one of the major investors in the WACS submarine cable and is also operating a data centre at its POP in Luanda, it said.

ArcelorMittal Georgetown pares workforce at its mill in South Carolina ArcelorMittal Georgetown, a producer of wire rod that was forced to close in 2009 because of poor market conditons and reopened 17 months later under ArcelorMittal in 2011, recently pared 20 employees at its mill in Georgetown, South Carolina. Myrtle Beach Online reports that the company went from three shifts to two shifts, and now has slightly less than 200 employees. In 2008, it noted, the company had four crews and 282 employees.

DECEMBER 2012 | 15

INDUSTRY NEWS

Prysmian helping create body to develop Northern Seas wind power The Prysmian Group reports that it is participating in the creation of Norstec, an association whose members will collaborate and share information to ensure that the benefits offered by the vast clean energy potential in the Northern Seas are fully realized. A press release said that the association will include the main players such as Alstom, Areva, E.On, National Grid, Siemens, Vattenfall and Vestas. It will promote policies geared towards the growth of the offshore wind power industry in the Northern Seas by exploiting the available resources and transforming them into economic and development opportunities. The members of the association will collaborate and share information to ensure that the benefits offered by the vast clean energy potential in the Northern Seas are fully realized, it said.

Nexans and Prysmian see court ruling in their favor over cartel charges A European Union court ruled that the European Commission did not have enough evidence to force Nexans SA and Prysmian SpA to turn over information about all their electric cable businesses during a cartel raid, a decision

16 | WIRE JOURNAL INTERNATIONAL

that some observers said could affect how such oversight efforts are made in the future. Per multiple media reports, the EU General Court party annulled decisions by the EU from 2009 to raid the companies for their alleged activity in fixing prices for undersea and underground high-voltage power cables. “The commission has not demonstrated that it has reasonable grounds for ordering an inspection covering all electric cables and the material associated with those cables.” A Bloomberg article said that following its raids at Nexans and Prysmian, EU’s antitrust watchdog sent formal complaints last years to as many as nine companies, including ABB Ltd. “Prysmian and Nexans argued that the officials failed to adequately define the goal of the inspections, during which officials mined the contents of entire hard drives of several managers,” it said.

Sumitomo supplies superconducting wire for HTS DC project in Russia Sumitomo Electric Industries, Ltd., announced that it has begun shipment of Bismuth-based high temperature superconducting wire (HTS-CA DI-BSCCO) for a cable project in Russia. A press release said that the HTS DC project, located in St. Petersburg, Russia, is led by the Russian utility company

INDUSTRY NEWS

Federal Grid Company of Unified Energy System (FGC UES) and its R&D division center. The project calls for 2.5 km of the DC cable, and represents “the world’s first attempt to connect two electric power substations by HTS medium-voltage DC cable,” it said. The system, the release said, is scheduled to be commissioned in the end of 2014. “There after, the cable will operate as part of the power grid to demonstrate a replicated HTS DC link between the two substations.” The company has already shipped approximately 100 km of HT-CA DI-BSCCO wires, and plans to deliver them to the R&D center by the spring of 2013, the release said, noting that “the wires are well received by the market and have already been used for many HTS cable projects in the world including an HTS cable project in Yokohama, Japan.” It added that the company has established mass production technology for HT-CA DI-BSCCO.

Tata Steel seeks duties imposed on Chinese wire sold in Thailand The Bangkok Post reports that Tata Steel Plc wants Thailand’s government to set anti-dumping duties of 20% or more on steel wire from China that allegedly avoids import taxes by false representations. The story cited Tata Steel VP Thana Reungsilasing as saying that the Chinese steel wire is being priced in Thailand below its domestic costs, claiming that this happens “because Beijing subsidizes the products in the form of export tax rebates of about 9%.” It claims that the subsidized imports are being sold as much as 14% cheaper than its own products in the local market. Further, it says that the Chinese wire is being identified as being “a compound of boron and chromium, which qualifies them for import duty exemptions,” thus enabling it to not pay a 5% import tax.

McDermott wins contract for offshore cable procurement and installation McDermott International has been awarded a cable contract from Saudi Aramco for the Safaniya, Abu Safah, and Marjan offshore fields. A press release said that the order, part of an existing long-term agreement between McDermott and Saudi Aramco, will include procurement, transportation, installation, hookup, and testing of seven composite cables and corresponding anode sleds. McDermott’s engineering office in Al-Khobar will handle the design and installation, engineering, and procurement, while its Jabil Ali office will handle fabrication and cable installation, it said. Per the release, a 15 kilovolt (kV) composite cable covering 16.7 miles (26.9 kilometers) will be installed in six segments on the Safaniya and Abu Safa fields, while the Marjan field will utilize a 35kV composite cable, which will cover 17.6 miles (28.4 kilometers). Part of the contract relates to electrified production deck modules (PDMs) in the Safaniya and Marjan fields.

DECEMBER 2012 | 17

INDUSTRY NEWS

The best die selection

Cavotec reports 2 reel contracts The Cavotec Egineering Group reported that it has won orders in the U.S., where it has a rapidly growing presence, from two leading industrial groups: ThyssenKrupp and The Robbins Company. “These orders demonstrate Cavotec’s growing presence in the United States, and the trust Cavotec has with customers such as ThyssenKrupp and Robbins,” Cavotec USA Product Manager Diego Sanchez saind in a press release. For ThyssenKrupp, Cavotec will manufacture explosion proof (Zone 21) Atex cable and hose reels, medium-voltage cables, one Brevetti stainless steel circular power cable chain and related material, the release said. The equipment will be used to power indoor stacker and reclaimer machines. ThyssenKrupp’s end customer is Technint, a construction and engineering group it said, noting that the order is part of a new-build refinery project.

Southwire Company is named ‘Best Overall Supplier’ by tED Southwire Company has been named “Best Overall Supplier” by the Electrical Distributor (tED), a leading trade publication in the electrical industry that also recognized three of Southwire’s marketing campaigns as “Best of the Best.” tED said that the U.S.-based company has a “legacy of achievement” and that “simplicity and customer productivity underscore Southwire’s renowned market approach.” “We are extremely proud that tED has selected Southwire Company for this honor,” Southwire Company Director of Marketing Communications Rhonda Gauthreaux said. “Our goal is not only to supply products that transmit electricity effectively, but to also develop products that enhance jobsite efficiency and safety for electrical contractors. Having tED recognize the innovation and creativity of Southwire’s employees is confirmation of the great work our team does every day.”

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Last call for WCMA annual meeting to be held Dec. 13 at Bradley Airport It may not be too late to sign up for the Wire & Cable Manufacturers Alliance (WCMA)’s annual meeting and holiday luncheon on Thursday, Dec. 13, at the Sheraton Hotel at Bradley Airport in Windsor Locks, Connecticut. Call WCMA Executive Director Deb Mathiasen at tel. 860-873-2311 or by e-mail at mrcdm@snet.net to register. The event starts at 11:30 am with a networking and social hour. The Annual Member Meeting will take place during lunch, with an industry presentation. and announcement of the 2013 Distinguished Career Award recipients. Charitable contributions are again sought for the U.S. Marine Corps Toys for Tots, and attendees are encouraged to either bring an unwrapped toy or game (for ages 2-12) for the gift table or to give a check for any amount, made out to “Toys for Tots,” at the registration desk.

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ASIAN FOCUS

ASIAN FOCUS Report: Asia-Pacific market to be driver for industrial fasteners through 2018 A new report from Global Industry Analysts, Inc. (GIA) Industrial Fasteners: A Global Strategic Business Report, projects that, driven by the Asia-Pacific, the global market for industrial fasteners is forecast to reach US$81 billion by the year 2018. The Fastener section on p. 28 has full details on the report, but this report focuses on the Asian role, which is significant. A press release said that demand for durable goods and a strong rebound in the motor vehicle output are anticipated to fuel growth at a fast pace in the global industrial fasteners market, and that a major portion of such sales growth would come from emerging markets located in the Asia-Pacific region, especially China. It noted that continuous increase in motor vehicle production provided industrial fastener manufacturers with new sales opportunities in countries such as China, which emerged as the largest manufacturer of motor vehicles in 2009. The release said that fastener production in China is projected to surpass domestic demand the next few years. While U.S. manufacturers produced more fasteners in terms of value in 2009, Chinese suppliers will be able to surpass U.S. record production levels, thereby becoming the leading manufacturers of fasteners in the world, it said. However, manufacturers based in developed regions including Japan, Western Europe and the U.S. will continue to lead the production scenario for superior and highly engineered fasteners, it noted. “Nonetheless, Chinese manufacturers, in an attempt to remain competitive, are narrowing down the technological gap by acquiring technological and manufacturing expertise, and improving their accessibility to capital. Thus, by far, growth in demand for industrial fasteners in developed regions such as Japan, Western Europe and the U.S. has been considerably slower compared to advances in the developing nations.” The release said that heightened fixed investments and rise in number of manufacturing bases have boosted fastener demand from the emerging economies compared to the more developed markets. “Subsequently, rapid sales growth in Asia/Pacific, Latin America, Middle East/Africa and Eastern Europe is expected to outpace demand in China, Japan, Europe and the U.S. ... Increased number of manu-

facturing activities, investments and developments in the direction of becoming an economic superpower, China is anticipated to register largest gains compared to any national market in the world. Further, favorable economic climate and rising income levels leading to increase in demand for durable goods would drive growth in Russia, India, Thailand and Taiwan. Irrespective of the fact that emerging economies would grow at a fast pace, developed economies such as Western Europe, the US, Japan and Canada would continue to lead the market in terms of number of intensive users for fastening products, revealing the technological and industrially advanced nature of these countries.” The Asia-Pacific represents the largest and fastest growing regional market worldwide, growing at a compounded annual rate of 10.5% over the analysis period, the release said. Tremendous growth in the Asia-Pacific market can be attributed to China, which is the leading producer and exporter of industrial fasteners in the world, it said. Increased production of motor vehicles, industrial machinery, and electrical and electronic components and renovation of infrastructure provided ample opportunities for growth of the industrial fasteners market in China, it said. Government investments in commercial and military aircraft and impending aerospace projects such as solar research, aerospace shuttles and scientific recoverable satellites, have added to the growth in demand for aerospace fasteners while restrictions on Chinese fastener imports have popularized such fasteners from Taiwan in the global market, it said. For more details on the report, go to www.strategyr.com.

ASIAN NEWS BRIEFS China’s Tongling orders a copper rod casting and rolling plant from SMS Meer The Tongling Nonferrous Metals Group from Anhui Province, China, has placed an order with SMS Meer, Germany, for the supply of a complete CONTIROD® casting and rolling plant for the production of copper wire rod in Tongling, Anhui Province. “With this new wire rod mill, Tongling will further strengthen its position in the copper business,” a press release said. The wire rod line is designed to produce

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

20 | WIRE JOURNAL INTERNATIONAL

Showa Denko plans to close affiliate in 2013 Citing JCN Newswire, Bloomberg reports that Showa Denko K.K. (SDK) plans to dissolve its affiliate, Tokyo Aluminum Wire Co., Ltd. (TAW), on Sept. 30, 2013. The story said that TAW, founded in 1965, will close because demand for the aluminum wire electric cables and rough drawing wire it produces for new construction

or replacement work is projected to â&#x20AC;&#x153;remain at a low level for many years to come.â&#x20AC;? The companyâ&#x20AC;&#x2122;s shareholders were identified in the story as: Showa Denko K.K. (17%); Fujikura Ltd. (17%); Hitachi Cable, Ltd. (17%); SWCC Showa Cable Systems Co., Ltd. (17%); Furukawa Electric Co., Ltd. (17%); Tokyo Electric Power Company (13%); and Kandenko Co., Ltd. (2%). A resolution to dissolve the company will be adopted at the end of September 2013, it said, adding that it will be liquidated by the end of December 2013.

TATA Steel Thailand urges government to impose AD duties on Chinese steel wire TATA Steel Thailand has urged the Thai government to impose antidumping (AD) duties of at least 20% against steel wire from China due to unfair competition from Chinese competitors who received a Chinese government subsidy. Multiple media reports said that the vice president of TATA Steel Thailand claimed that the price gap between Chinese steel wire and their product is 14%, which is critical for the companyâ&#x20AC;&#x2122;s business since the steel wire accounts for 40% of the companyâ&#x20AC;&#x2122;s total production capacity. He added that if the government does not act to protect local producers, they would have to switch from steel wire to other products that can compete with imports.

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225,000 t of quality copper wire rod per year from cathodes, with the CONTIROD line capacity will be 35 t per hour, making this â&#x20AC;&#x153;one of the largest integrated copper casting and rolling plants in China,â&#x20AC;? it said. The line comprises an innovative gas control system on the shaft furnace for melting copper cathodes and a modular Hazelett twin-belt caster, the release said. The casting cross-section is 90 mm x 70 mm, followed by the rolling line with a 12-stand rolling mill. The enormous reduction in the cross-sectional area from the cast ingot to the wire rod creates a very fine-grained material microstructure, a fundamental precondition for the outstanding quality of the finished products, it said. â&#x20AC;&#x153;The modern and energy-efficient technology such as the gas control system and the variable-frequency drives make the plant one of the most cost-effective of its kind,â&#x20AC;? said SMS Meer Project Manager Thomas Schatz. The line is scheduled for commissioning in fall of 2013.

PEOPLE

PEOPLE Davis-Standard, LLC, reported a number of personnel announcements. As part of the consolidation of its global sales and marketing team that will see the combining of the company’s extrusion and converting equipment lines into one product portfolio, Bob Florence has been named vice president of global sales and marketing. He will oversee the direction of sales, product management, marketing and proposal/estimating groups worldwide. He has more than 21 years of experience at GE Plastics, Apple and, most recently, Solazyme. With this change, Jim Murphy has been Bob Florence appointed vice president of product line management, reporting to Florence. Murphy, who has been with Davis-Standard in various leadership roles for more than 23 years, will be responsible for providing guidance and direction to product line leaders, and developing customer-focused business strategies. Mark Panozzo, who served as president of converting systems, has decided to pursue other oppor-

tunities. The company also reported the following appointment of vice presidents. Sekaran Murugaiah has been named vice president of business development for Asia-Pacific. He will lead the sales, service and installation organizations within the AsiaPacific region. He has 30 years of broad leadership and functional experience, with a history of general management, commercial and operations leadership positions in various industries and countries in the AsiaSekaran Pacific Murugaiah area. He last served as general manager, AsiaPacific, for the Graphics and Reflective division of Avery Dennison. He holds a B.S. degree in engineering degree from Imperial College of Science and Technology, Todd Pearson London. Todd Pearson has become

OBITUARIES Victor J. Baxt, who played an important role in the development of Teknor Apex Company into a leading custom compounders of plastics, died Oct. 7 at age 95. The chairman of Teknor Apex at the time of his death, he was esteemed in his native Rhode Island as both a philanthropist and civic leader. In 1946, he joined the company that would become Teknor Victor J. Baxt Apex as a college friend of Norman M. Fain, the son of Alfred A. Fain, who founded the business in 1924. The company started producing vinyl compounds in 1949. In the decades to follow, Norman Fain, Baxt and Herbert Malin, who joined in 1956, were partners in leading the transformation of the company from a business focused on the tire and rubber market to a diversified plastics enterprise. Baxt worked at Teknor Apex for 66 years, until shortly before his death. After serving as president and vice chairman, he became chairman upon the death of Norman Fain in 2003. He was very active in the local community, serving on the board of trustees and many committees for Miriam Hospital in Providence, and was honored as the hospital’s Person of the Year in 2006. A longtime supporter of the University of Rhode Island (URI), he established an endowed scholarship for undergraduate students of chemistry and chemical engineering, founded the Victor

22 | WIRE JOURNAL INTERNATIONAL

Baxt Chair in Polymer Engineering; and supported construction of new facilities at the university, which awarded him an honorary doctorate in 2011. He was an active member of the Jewish community in Providence, serving on the boards of a number of organizations. A chemist, Baxt received his BS degree from URI and an MS degree from Duke University. He is survived by his wife Gussie, two sons, three grandchildren, and five great grandchildren. Randy Duenn, a long-time part of the wire rope industry, died Oct. 15 from cancer at age 56. He began his career in the wire rope business with UNA-Anchor Wire Rope, where he was warehouse manager. He then worked for Criterion Metals and then for Alps Wire Rope Corporation, where he was a key customer service staffer. He was known for his funRandy Duenn loving nature and positive attitude. He is survived by his wife, two daughters and grandchildren. He will also be missed by his second family at Alps Wire Rope, which noted the following in its announcement: If a man’s life is but a vapor, Randy was a giant cumulus cloud at sunset, large and full of color.

Beta LaserMike reported two personnel announcements. Hans Liu was named Southern China sales manager, based out of Guangzhou. He has years of experience in the automation and controls technology sector, where he has held positions that include industrial engineer, OEM sales manager, and most recently, business promoter. He holds a B.S. Hans Liu degree in mechanical design and manufacturing automation and an MBA degree in electronics and automation from South China Agricultural University. Randy Luffman has joined the company as vice president of global sales. He previously worked for RedZone Associates as a managing partner for the company’s business of designing, recruiting, training, and leading sales organizations for B2B clients. He previously worked for MarketSource, a B2B sales and marketing services firm; director of global sales and technical service for Agilent Technologies; and in sales and marketing positions with Hewlett-Packard. He holds a B.S. degree in chemistry from East Carolina University and an Executive MBA degree from Harvard Business School. Based in Dayton, Ohio, USA, Beta LaserMike is a global supplier of gauging and testing systems. Stephen Mickey has been named product development manager of Cerro Wire LLC’s electrical distribution segment, responsible for improving current products and

generating new ideas for products and services. He most recently served as a project engineer at Cerro Flow Products, and prior to that was an applications engineer and administrative manager at leading packaging and manufacturing companies. He holds a B.S. degree in mechanical engineering from the University of Nevada, Las Vegas and is a registered Stephen Mickey E.I.T. Based in Hartselle, Alabama, USA, and a part of Marmon Wire & Cable/ Berkshire Hathaway, Cerro Wire manufactures building wire and cable. Gibbs Wire & Steel Company recently named Dale Porter as warehouse manager of its California service

RETIREMENT David F. Stecker, a longtime industry member and a past president of the Wire Association International, is retiring as president of Microdia USA, effective Dec. 15. In 1961 to 1965, Stecker served in a U.S. Navy fighter squadron, where as a plane captain he qualified pilots for carrier landings in a F-4B Phantom II. He joined Telecast Corporation in 1965 as a tool maker until 1975, and then spent eight years at Guill Tool, where he was manager of its wire and cable division. He joined Clipper Machines as vice David F. Stecker president of sales and marketing in 1984 and became company president in 1987, helping the company grow its market share in North America while much of the rest of the industry experienced a shakeout. He headed the equipment manufacturer through 1991. He recalled that he most enjoyed “competing against the Europeans and doing what’s best for repeat business.” In 1993, he formed his own company, Key Accounts Incorporated, and in 1995 added the position of president of Microdia USA, representing the company’s extrusion technology in the U.S. A resident of North Kingston, Rhode Island, and a WAI Life Member, Stecker joined the Association in 1976, and became active in the organization in 1986, when he joined its board of directors. He served on the executive committee in 1986, was vice president in 1988 then president in 1989. Stecker plans to travel with his wife, Suzanne, to Europe, spend more time in Florida and get more sailing time in. “What I’ll miss most about the industry is the people,” he said.

DECEMBER 2012 | 23

PEOPLE

vice president of global operational excellence. He previously was director of operations, Asia Pacific, for Belden, based in Suzhou, China. He has worked extensively in international assignments where he was responsible for LEAN transformation in Europe, the Middle East, and Asia. He was also lean manufacturing manager for Chrysler LLC and Danaher Corp. He holds a B.S. degree in business and an MBA degree from Michigan State University. Chetan Balsara has become a vice president and chief information officer. He will provide leadership and direction for the company’s Information Technology group worldwide. He previously worked at Buckeye Partners in Texas as director of application services. Prior to that position, he was the senior director of IT at J.B. Poindexter and Co., and the tech and global infrastructure manag- Chetan Balsara er for Wilbur-Ellis, in Seattle, Washington. He holds a B.S. degree in electronics engineering from Fr. Conceicao Rodrigues College of Engineering in Mumbai, India. Based in Pawcatuck, Connecticut, USA, Davis-Standard LLC is a global supplier of extrusion technology.

PEOPLE

center. He has more than 20 years of general management experience, including positions at Stater Bros. Markets and Lowe's Home Improvement Warehouses. Based in Southington, Connecticut, USA, Gibbs Wire & Steel supplies steel wire and strip. Shannon King has joined the metallurgical team of Beneke Wire Company. A 14-year veteran in the aluminum wire and rod industry, he has previously worked at Nichols Wire and Kaiser Florence. He holds a B.S. degree in metallurgy from the University of Alabama. Based in Louisville, Kentucky, USA, Beneke Wire Company supplies round drawn aluminum cold heading wire and rod as well as round and hex drawn bar.

Shannon King

C&M Corporation has named Robert Conway as senior vice president of sales and marketing. He has more than 20 years of experience in managing sales, marketing and engineering at the regional, national and international levels. Most recently, he was executive vice president of sales for The Lapp Group, where he held multiple senior sales positions since 2000. Prior to that, he served as a

regional sales manager for Alpha Gary Corporation. Based in Wauregan, Connecticut, USA, C&M Corporation is a vertically integrated manufacturer of bulk cable, coil cords, and cable assemblies. Lincoln Electric has promoted Bruce Chantry to director of marketing, North America. He has been with the company for 17 years, the last four as a portfolio manager for welding equipment. Before that, he was a product manager for advanced welding equipment and a regional manager for the company’s Sub-Saharan Africa region. He holds a B.S.degree in electrical engineering from The Colorado School of Mines and graduated from the Thunderbird School of Global Management’s International Consortia Program. Based in Cleveland, Ohio, USA, The Lincoln Electric Company is a global supplier of welding technology. Neil Yingling has joined DeWAL Industries as sales manager for the west coast of the U.S., including Arizona. He has considerable background in business and sales of manufacturing goods and supplies and is expected to further improve communication and response time for west coast clients. Based in Narragansett, Rhode Island, USA, DeWAL Industries’s products include tapes from PTFE, UHMW-PE, polyimide and PTFE coated glass fabric.

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FIBER WATCH

FIBER WATCH A tiny island paradise is now a giant land in terms of optical fiber U.K.-based Globe Telecom reports that it has successfully interconnected Boracay through fiber optics, effectively boosting the connections and strengthening the network coverage of the island. Boracay, a small island in the Philippines, is located approximately 315 km (196 mi) south of Manila and 2 km off the northwest tip of Panay Island in the Western Visayas region of the Philippines. Boracay Island and its beaches have received awards from numerous travel publications and agencies. Now, it is also land of idyllic communication. A press release said that the transformation was accomplished through the Boracay Submarine Cable System, a two-km fiber optic cable that is able to transmit 80 wavelengths of Dense Wavelength Division Multiplexing or DWDM systems with a capacity of 40 gigabytes per sec-

Boracay, a small Philippines island renowned for its beauty, will now also be known for its fiber optic access. ond (GBPS) per wavelength and is expandable to 100 GBPS. This technology can provide "near to limitless transmission capacity, which will result to crystal-clear voice call and superfast surfing,” said Globe Chief Technical Advisor Robert Tan. Along with Tan and other key company officials, Huawei, its partner for the ongoing network modernization, spearheaded the landing of the submarine cable from Caticlan in the town of Malay, Antique, to Boracay, the release said. “Definitely, we consider this a major milestone for Globe as we have powered up our cell sites with 3G and HSPA+ connectivity,” Tan said, adding that “this submarine cable system will provide Globe a future-proof infrastructure, along with those for the entire archipelago, ready for the next generation communication technology.” Globe President and CEO Ernest Cu said that the development further bolsters the progress of the company's network modernization, which has already breached the 60% milestone “in record time.” “We have finished our optical fiber systems highway to 26 | WIRE JOURNAL INTERNATIONAL

Boracay and this progress is a significant part of building our brand new network,” Cu said. “This augurs well for one of the major travel destinations not just of the Philippines but of the rest of the world, amplifying tourism economics and activities in the island jewel.” Per Wikipedia, the island of Boracay is approximately seven km long, dog-bone shaped with the narrowest spot being less than one km wide, and has a total land area of 10.32 sq km.

Report: Broadband is no longer a luxury for emerging countries “Fixed-Broadband Infrastructure in the Emerging Markets Report 2012-2017: The Shifting Dynamics of Connectivity,” a new 134-page report from Visiongain, an independent business information provide, states that demand for fiber optic technology for online services is so strong that it is becoming the “inarguable future” for broadband. “Formerly treated as a luxury in developed nations, fixed-broadband access to the world wide web is quickly becoming a global norm,” a press release said. “Ubiquitous high-speed connectivity is being engendered by network operators and national governments alike. Visiongain has determined that fixed-broadband infrastructure revenue in the emerging markets will reach $23.25 billion in 2012.” The ultimate goal for many emerging economies, the release said, is to have a vast majority (typically above 95%) of the national population under broadband coverage and with access to a broadband connection. Specific objectives, timetables, and parameters set forth by governments, both national and regional, will drive broadband infrastructure in the emerging markets over the forecast period and beyond, it said. “The changing nature of online media has forced telecoms operators into a corner. They must adapt or perish,” the release said. It noted that for network equipment vendors to be successful, they must be able to integrate “legacy architecture” into next-generation broadband networks, the firm added. Universal connectivity, gigabit Ethernet and fiber optic broadband networks are expectd to become commonplace in developed and emerging markets alike, it said. The report, the release said, identifies and examines key players in a market poised for substantial growth. It includes 116 tables, charts, and figures, a global fixedbroadband infrastructure market forecasts between 20122017 and for fixed-broadband infrastructure revenue in four emerging regional markets from 2012-2017, and more. For further details, go to www.visiongain.com.

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FASTENER UPDATE three in the Middle East and one in Africa. Bolts represent the largest product segment in the industrial fasteners market, the release said. Growing demand for A new comprehensive report from Global Industry specialized aircraft products and renovations, upgrades, addAnalysts, Inc. (GIA) Industrial Fasteners: A Global ons of existing houses, apartment complexes, and other Strategic Business Report, projects that the global market buildings are major factors propelling growth in this product for industrial fasteners is forecast to reach US$81 billion by category, it said. Non-threaded standard and high performthe year 2018. ance fasteners, it noted, are forecast to experience the highThe outlook for the Asian segment, a key focus of the est demand in the next few years, and high performance fasreport, is presented in the Asia Focus section on p. 28, but a teners are likely to derive demand from new car and autopress release from the company said that global outlook has motive applications. become better. â&#x20AC;&#x153;The global industrial fastener market staged Aerospace and automotive, the report said, would contina dramatic comeback post the dismal market conditions ue to generate the bulk of the industrial fastener demand, prevalent during the global economic crisis. Burgeoning while fasteners used in electronic products, along with plasdemand for durable goods and a strong rebound in the tic fasteners and high-performance and high-end specialty motor vehicle output are anticipated to fuel growth at a fast designs, are expected to have fastest growth rates, it said. pace in the global industrial fasteners market.â&#x20AC;? Screws constitute the second largest product category in A press release said that the global industrial fastener key factors fueling market market. growth include revival in The highly fragmented indusmotor vehicle production, trial fasteners market is characincreased demand from terized by aggressive competideveloping regions, and tion with several large and A Global Industry Analysts, Inc. report sees good times potential growth in consmall players competing to ahead for industrial fasteners. struction, electrical and maintain their respective market electronic, and aerospace positions. In various regions, sectors. Fasteners, it said, are also in high demand in the industry consolidation was a predominant trend manufacture of electrical oriented products, such as lightenas small players merged operations with larger prominent ing and wiring devices, home appliances, and construction players to leverage their resources. Key players profiled equipment. in the report include Acument Global Technologies Inc., The 628-page report costs $4950, but the individual eleAlcoa Fastening Systems, FabriSteel, Finnveden Bulten AB, ments that comprise the report can be bought separately. Illinois Tool Works Inc., Anixter International, LISI Group, The report includes definitions, an industry overview, select MacLean-Fogg Company, MNP Corp., Nitto Seiko Co., issues and trends, competitive analysis, product overview, Ltd., Nucor Corp., Sundram Fasteners Limited, The recent industry activity (news), corporate activity, product Marmon Group LLC, Atlas Bolt & Screw Company, innovations/introductions, product innovations/introductions and TRW Automotive, among others. in recent past - a perspective builder, focus on select global The report provides annual sales estimates and projections players, global market perspective, individual country and for the years 2010 through 2018 in value (US$) for georegional markets, and more. graphic markets including the US, Canada, Japan, Europe, Tables presented in the section can each be bought. For Asia-Pacific, Latin America and Rest of World. Key product instance, the U.K. section and the Rest of World, can each segments analyzed include Bolts, Nuts, Screws, be purchased for $950. The ROW section includes a Market Rivets/Washers and Others. Key end-use sectors analyzed Analysis (A & B) and six tables, each of which can be include Automotive, Aerospace, Construction, Mechanical individually purchased. A typical table, #155, Rest of Engineering and Others. The study also provides historic World 15-Year Perspective for Industrial Fasteners by data for an insight into market evolution over the period End-Use Segment-Percentage Breakdown of Value Sales 2004 through 2009. for Automotive, Aerospace, Construction, Mechanical At its website, GIA notes that it currently serves more Engineering, and Other Application Markets for Years 2004, than 9,500 companies from 36 countries worldwide. The 2011 & 2018 (includes corresponding Graph/Chart), cost company, founded in 1987, initially was a research boutique $200. News of corporate activity can also be bought by the specializing in the medical industry. Over the past 25 years, story, most for $100. it expanded its coverage and now publishes extensively A total of 244 companies are profiled, and when divisions upon more than 180 major industries. More details and subsidiaries are added, the number is 280. Of those, 146 on the report can be found at www.strategyr.com. companies are located in the U.S., six in Canada, four in Japan, 84 in Europe, 36 in Asia-Pacific (excluding Japan),

Report: global industrial fastener market looks strong through 2018

28 | WIRE JOURNAL INTERNATIONAL

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WAI NEWS

WAI

NEWS

Clockwinding tradition at WAI is not stymied by hurricane threat The crowd may have been smaller than usual but the spirit of the annual clockwinding ceremony was in full force on Sunday, Oct. 28, at WAI’s headquarters in Guilford, Connecticut, where the U.K. representative who had flown in on an altered travel schedule due to Hurricane Sandy continued a decades-old tradition that began in 1948. “Sandy wasn’t going to stop 64 years of clockwinding,” John Swain declared before he wound the stately grandfather clock in the lobby that had been presented by 32 U.K. companies in 1948 as a way of thanking U.S. wire industry support during World War II. Swain, a long-time member of the British wire industry who was accompanied by his wife, Wendy, was able to change his schedule to accommodate the clockwinding being held on Sunday instead of Monday, when Hurricane Sandy was due.

The U.S. and U.K. flags flew in brisk pre-hurricane winds for Clockwinder John Swain, r, with his wife Wendy and WAI President Nick Nickoletopoulos.

David M Braun VP Bus/Prod/Dev Cable Components Group

Jim L Cloer Mftg Eng TE Connectivity

Michael Frigo Exec VP Coleman Cable Inc

Chad R Braunecker Proc Eng Mgr Cerro Wire LLC

Raffaele Contini Sls Mgr Steel Div Cortinovis Machinery SpA

Paulo S Gabrielli VP Glbl Mftg Phelps Dodge Int’l Corp

Federico Bussola Sls & Mktg Mgr Cortinovis Machinery SpA

Timothy Copp REELEX Packaging Solutions Inc

James S George Global Bus Mgr Neptco Inc

The following individuals recently joined WAI.

Andrea Camparada Mng Dir Cortinovis Machinery SpA

Richard Copp Acct Mgr Cable Mtrls NEPTCO Inc

George Gong Sr Proc Eng General Cable Corp

Mohammed Albedour Sls Eng Filtertech Inc

Lee Campo VP/Gen Mgr Specialty Wire & Cord Sets Inc

David Coye Dir of Qual Chase Corp Global Operations Center

Matt Gongwer Fab Plt Mgr Coleman Cable Inc

Mark R Canrobert Bus Unit Mgr Copper Cable Matls NEPTCO

Brad Davies General Cable Corp

Jose Gonzalez Eng Mgr General Cable Corp

Joe Dixon President Joe-Tools Inc

Steve Hart Plt Mgr Cerro Wire LLC

Lawrence El-Hindi Qual Mgr Filtertech Inc

Bern D Harty Qual Eng Whitney Blake Co

Leslie Brian Evans Steelforce Holdings

Michael J Hendricks Gen Mgr Carris Reels Inc

William A Alonso President Rebel Arc Inc Mandy Baeumel Div HR Mgr Ind Southwire Co

Laurent Cartier Bus Dev Mgr Arkema Inc

Ron Barilone Oper Mgr Chase Corp Global Operations Center

Mike Chehade Nexans Canada Inc

Neal Booker Engrg Mgr General Cable Corp

Eugene A Ciarleglio CFO PA Industries

30 | WIRE JOURNAL INTERNATIONAL

Craig M Forbes Glbl Comm Mgr AFC Cable Systems Inc

Rick Hernandez Plt Mgr Coleman Cable Inc

Shannon McIntyre Fab Plt Mgr Coleman Cable Inc

Greg Powell Gen Mgr Sonoco Reels

Jeffrey Stanfield Fab Plt Mgr Coleman Cable Inc

Mike Hughes Prod Mgr Coleman Cable Inc

Bradley J Mealy Eng Mgr Paramount Die Co

Robert D Rebinsky Proc/Proj Eng Nexans Canada Inc

Brooke Stonesifer Sonoco Reels

Mike Humphrey Lean Enterprise Mgr Coleman Cable Inc

Deanna M Merrill Prodn Mgr Whitney Blake Co

Gene R Redfield QA Mgr Whitney Blake Co

Robert D Johnson Pres/CEO Northampton Machinery Co USA

Pete Mikucki Strgc Acct Mgr NEPTCO Inc

Kermit L Reins Rod Mill Gen Mgr Sterling Steel Co

Vittorio Mion Dir Sls & Mktg Vitari SpA a Eurolls Company

Guido Ricci Area Sls Mgr Eurolls SpA Div Macchine Filo

Amita Kar IOCF Alliance Books Suppliers Aaron Klejman Man Mgr Shawflex Wayne Kowalski VP Spec Coleman Cable Inc Joe Kuehler Dir Lean Enterprise Coleman Cable Inc

Matt Morrison Corp QC Mgr Coleman Cable Inc Larry Musick Eng Coleman Cable Inc Stephen A Navarette Bus Unit Dir Chase Wire & Cable Materials

Patricia Lally Purch Whitney Blake Co

Steven Nichols Sls Mgr Cortinovis Machinery America Inc

Michael B Langlais Eng Guill Tool & Engineering Co

Simone Nunez QC Mgr Coleman Cable Inc

Phil Leung Eng Coleman Cable Inc

Paul J Obuchowski Opers Mgr Whitney Blake Co

Martha Luna Eng Coleman Cable Inc

Margaret Oâ&#x20AC;&#x2122;Malley Info Mgr Institute of Spring Technology

Randy Lusk Gen Mgr Sonoco Reels

Walter E Parsell Mfg & Maint Mgr General Cable

Tim Lybeck, Jr Plt Mgr/Prin Eng Carris Reels Inc

Dan Patton Rubber Plt Mgr Coleman Cable Inc

Andrea Macorig Bus Mgr Eurolls SpA

Michael Pawlish CEO Lone Star Reel Corp

David L Marquardt Pres Concord Guides

Dale A Plautz, Jr Dir Corp Purch Coleman Cable Inc

Stacy M Martin Sr Proc Eng General Cable

Andrew M Pluister Dir Engrg Coleman Cable Inc

Randy Szilagyi Nexans Canada Inc David W Taylor Eng Coleman Cable Inc Sean Toland Dir of Oper Rubadue Wire Co Inc Eugene Urbina Eng Tech General Cable Corp

Brandon Rogers Ins Plt Mgr Coleman Cable Inc

Carsten Vanderputten Prod Mgr Esteves Group USA

Olalekan Saba Nexans Canada Inc

Niles Voekel Rubber Eng Coleman Cable Inc

Jeff Sargeant Dir of R & D Chase Corp Global Operations Center

Bernd Vortherms Sls Mgr RSD Technik GmbH

Rick Scheiderich Superior Energy

Jim R Waryas Whitney Blake Co

Joseph F Scott Purch Mgr Coleman Cable Inc

Greg Weiser Maint Mgr Coleman Cable Inc

Shanna M Sharum-Plis Inside Sls Carris Reels Inc

Thomas W Wells Dir Eng Str & Tech Spprt Leggett & Platt Inc

Phillip D Shows Prod/Acct Mgr Neptco Inc

John White Facil Eng General Cable Corp

Thomas S Simon Sls Mgr Solar Compounds Corp

Wendy Williams Acct Mgr Sonoco Plastics

Gerry Simons QC Coleman Cable Inc

James Williams Engr Mgr Joe-Tools Inc

Don Singley Maint Mgr Coleman Cable Inc

Chris Wilson Dir of Mktg Chase Wire & Cable Materials

Brian P Skocypec Eng Mgr General Cable Corp

Andy R Wiseman Plt Mgr Coleman Cable Inc

Don Smith Maint Mgr Coleman Cable Inc

William Wright Reg Acct Mgr International Wire Group Base Wire Div

Lee Sneed Plant Manager General Cable Corp

DECEMBER 2012 | 31

WAI NEWS

Todd A Huff Rubber Eng Coleman Cable Inc

WAI NEWS Clockwinder John Swain speaks prior to the clockwinding.

Clockwinder John Swain displays a drawing of the clock presented by WAI President Nick Nickoletopoulos.

“It is a great honor and privilege to have been chosen as a clockwinder,” said Swain, who started his career at Tinsley Wire in 1965. During his 35 years with Tinsley Wire he held progressively responsible positions and has continued to stay active in the industry and is currently consulting for Siddall and Hilton at Brighouse Yorkshire, another long-established U.K. wire company. He observed that the U.K. wire industry has changed greatly. Only a few of the 32 original U.K. companies that started the tradition are still active. “Sadly, there are now only two substantial wiredrawing companies and four or five significant wire product manufacturers in the U.K.” WAI President Nick Nickoletopoulos, who had driven down from Canada for the ceremony, spoke about the lesser-known Canadian role during World War II. “This clock and the ceremony that takes place every year is

truly a reminder of the power of collaboration. It was certainly the case between the wire industries in Great Britain and the U.S., when Britain and France declared war on Germany on Sept. 3, 1939. Seven days later the Parliament of Canada likewise declared war on Germany, the country’s first independent declaration of war. By war’s end, over one million citizens would serve in military uniform, which is amazing as Canada’s population at the time was about 12 million. John Swain made the long trip with his wife Wendy and we are grateful for their special contribution to a very important tradition.” Following the clockwinding, Nickoletopoulos presented Swain with the framed history of the clockwinding tradition and an image of the clock, previously sketched by staff member Bill Branch, as well as a soecial tie that is worn only by past clockwinders, usually at their reunion dinner that precedes the wire show in Germany every two years. Swain thanked Nickoletopoulos for making the long trek to the office in questionable conditions, and also WAI Executive Director Steve Fetteroll, who was not able to attend as he was at the wire India trade show, for helping the tradition continue. Following a celebratory dinner, Swain and his wife went on to Boston and then to Las Vega to celebrate his 70th birthday. After dinner at a local restaurant, Nickoletopoulos began the return drive to Canada, which proved to be a good decision as Hurricane Sandy dealt a quite nasty blow to New York, New Jersey and Connecticut, especially the shoreline areas. Power was knocked out to more than 80% of Guilford, including WAI headquarters, which was out for a week. But power was restored, work began again and despite considerable adjustments, a tradition between two continents had continued.

The day following the clockwinding ceremony, a tree blocks the entrance to WAI’s headquarters in Guilford, Connecticut. The office was closed for a week due to the resulting power outage.

32 | WIRE JOURNAL INTERNATIONAL

An Austrian pavilion has been established at Interwire 2013 that will see eight companies share a 1950-sq-ft booth at the Georgia World Congress Center in Atlanta, Georgia, The eight companies are: Dunst GmbH, Eder Engineering GmbH, Lenzing Plastics GmbH, Mali GmbH, Medek & Schorner GmbH, Rosendahl Maschinen GmbH, VODKM/AWCMA and voestalpine Austria Draht GmbH. With that contract, more than 95% of the available floor space has now been taken for the event, to be held April 23-25 in Atlanta, Georgia, USA, said WAI Sales Director Robert Xeller. He noted that smaller units are available, and it may be feasible to expand the show floor if there is enough demand to justify doing so. For more details on exhibiting at Interwire 2013, contact WAI’s Bob Xeller or Anna Bzowski at tel. 203-453-2777, sales@wirenet.org.

WAI’s Mordica Memorial Award goes to the late Thomas W. Tyl Thomas W. Tyl, the late principal for Tire Wire Technology (TWT), LLC, who died July 11, 2011, at the far too early age of 55, was named the winner of the WAI's Mordica Memorial Award, which honors individuals for their technical contributions to the wire and cable industry. Known for his industry knowledge, font of colorful stories and ready wit, Tyl worked for The Goodyear Tire & Rubber Company in key technology positions from 1989 to 2003 before starting his consulting company, which provided expertise on saw wire, tire cord, bead wire, hose wire, music wire and conveyor belt reinforcement, and other steel wire products. He was the inventor of seven new technologies, with patents pending in the U.S. and other countries. He held an MS degree in metallurgical engineering from Carnegie Mellon University, an MBA degree in manufacturing management from the University of Pittsburgh, and a BS degree in materials science from North Carolina Thomas W. Tyl State University. He authored 18 well-regarded technical papers and articles in WJI, including a very thought-provoking Perspective piece, “The Role of Culture (Mindset) in Technology,” in the December 2008 issue. Wrote one person supporting his choice, “I always enjoyed working with (Tom) as he continually had concepts and ideas that challenged the “accepted” process methods that everyone else took for granted. (His) concepts and direction...always took manufacturing processes one step beyond where they had been.” Tyl’s resume captures the essence of who he was. His stated company goals were to advance and to develop

new technology for the manufacture of steel tire cord and bead wire, and “to submit at least one new patent application per year that addresses an issue common to several of our clients.” His stated business principles declared: “Anything can be accomplished if no one cares who gets the credit; It is easy to be unpleasant and it is an art to maintain good relationships; Be sincere, be truthful, communicate well & often; Focus on the customer and become part of their team; The head is technology but the heart is people; Solve actual problems using root cause analysis; and Make decisions from data then act with tenacity.”

Eric A. Macs is named the winner of WAI’s Donnellan Memorial Award Erik A. Macs, an outgoing and incredibly WAI active member who is vice president of sales for Fine International Corp., a supplier of extrusion, cabling, braiding and taping machinery, has been named the winner of the WAI’s Donnellan Memorial Award, which honors an individual’s contributions to the Association. Macs, who joined WAI in 1991, served two terms on the board of directors. He is chairman of the Paper Awards Committee as well as a member of the Member Relations Committee and Education Committee. In the past he served on the Electrical Management Committee, Website Advisory Board and WAI’s Technical Council. A director of the New England Chapter of WAI, he also served as that chapter’s president in 2000. He developed “Introduction to Insulated Wire Manufacturing,” a seminar that was presented by the New England chapter in 2001 and 2002. In 2004 he was awarded the WAI President’s Award, which honors an individual for extraordinary volunteer service to the Erik A. Macs organization. He has served in multiple roles at WAI technical events and has further spread “the good word” about WAI activities through a newsletter he does called, Fine International News Bulletin, a monthly company newsletter that is an eclectic mix of company news, commentary, Association news and more. Before joining Fine International in 2005, Macs directed sales and marketing activities for Thermoplastics Engineering Corporation, a manufacturer of extrusion and cabling machinery. He also held a number of positions including: production planner at the Entwistle Company, extrusion foreman with Dennison Manufacturing; technical specialist with Union Camp Corporation; materials research associate engineer with Judd Wire; and director of research and development for American Durafilm Company. He holds a degree in mechanical engineering from Central New England College. Wrote one person supporting his choice, “(Erik) has brought, and continues to bring, fresh and innovative DECEMBER 2012 | 33

WAI NEWS

Austrian pavilion taken for Interwire 2013, more than 95% space taken

WAI NEWS

ideas for the betterment of all the members of WAI. His willingness to contribute his time and energy, above and beyond what could be expected of anyone, has earned my respect and admiration. His contribution to the WAI Technical Forum, through his work on the Web Site Advisory Board, has been instrumental in creating interactive dialog between the WAI members.”

Parkway-Kew webinar addressed a range of potential wiredrawing woes Individuals from 34 companies took part in WAI’s Nov. 14 webinar by Parkway-Kew Corporation (PKC), “How to Improve Your Wiredrawing Process and Gain a Competitive Advantage,” where PKC President Gene Klein, Sr., discussed multiple ways that manufacturers can hone their operations. The webinar, which lasted about 75 minutes, addressed concepts for improving the speed of wiredrawing machinery as well as product quality. It offered solutions, particularly for operations whose wire on the drawing blocks is not three quarters of the way up the drawing surface. It also addressed the use of considerations such as taper, radius and water cooling. Klein discussed practical strategies, such as proper use of coatings for capstans, pulleys, and tuner and guide rolls, as well as recording common-sense feedback on capstan

The webinar offered basic concepts for manufacturing.

Klein fielded the following questions: Is there a way to calculate a theoretical taper? Does taper affect overlap issues? If so how? What are the parameters that determine taper ie., speed, diameter, reduction, etc? Is there a “formula” for calculating the needed taper? What size taper would you need from .045-.010? Klein solicited input from registrants prior to the program in order to adjust the content to their needs. “I think attendees appreciated the personal touch of the instructor’s efforts to customize the material for them,” said WAI Director of Education & Member Services Marc Murray. One person thought that the webinar was a bit too focused on the ferrous end, but the majority of post-webinar comments were quite positive. “Excellent topic,” wrote one attendee. “While it got off to a slow start it picked up nicely. Very knowledgeable speaker and some good questions during presentation.” Another participant described the Parkway-kew webinar as “an excellent communication platform. I certainly enjoyed the event.” WAI webinars are free to Association members and $55 for non-members. Members also have free access to the online archives of past webinars. For Parkway-Kew Corporation President Gene Klein, Sr., addressed a range of more details, go to www.wirenet.org/events/ webinars. practical ways to improve manufacturing performance in his webinar. performance. He also explained how to set priorities for diagnosing and correcting problems such as overlapping and wire separation, and possible problem sources, such as heat problems or incorrect number of wraps. Individuals from a total of 34 companies took part in the webinar, which included a good amount of interaction. 34 | WIRE JOURNAL INTERNATIONAL

The technicians Networking with and new people in the suppliers I’ve industry is the met at WAI’s most valuable shows have asset of WAI helped me membership.” improve our Dick Pechie process.”

WAI helped me branch out into a new career.” Kevin Sopczak

Meeting people I’ve met many through WAI influential is the key to leaders taking you through WAI somewhere including a exciting in your U.S. President.” life and career.” Mark Spencer Lori Parent

I do business internationally and value the friendships I’ve made over the years through WAI.” Mark Mathiasen

Roberto Duralde

I joined WAI to interact with customers in a friendly environment when they are not having issues.”

WAI’s global resources can help me reach Venice. Venus is another story.” Mike Walters

I renew my WAI membership to keep up-to-date with machinery and process developments.” Peter Stewart-Hay

Paul Kulongowski

DISCOVER WAI. Some things you know as well as your name. Other times it takes a little searching to find—or learn— what you need, especially if you are new to the wire and cable industry or plan to keep pace with its innovative advances. Wire Association International (WAI) is the place to start. As a WAI member it’s easy to stay informed. Likewise, you won’t have to dig too deeply to uncover the industry’s rich history and accepted certainties.

WAI members rank NETWORKING as the #1 reason to join.

When you consider that wire making can be traced on one timeline from the golden threads in ancient Egyptian jewelry—through telephony, countless creature comforts, and modern infrastructure— toward yet unimagined applications, you can appreciate your vital role in the wire manufacturing continuum. WAI members represent a living history of the industry. Whatever your direction, if you earn a living with wire, cable, supplies, or equipment you’ve earned a place in WAI’s global network.

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CHAPTER CORNER

CHAPTER CORNER Southeast Chapter golf tourney sees record field with 122 players Everything about the 11th annual Southeast Chapter Golf Tournament, The Vannais, was special: the field was the largest ever, with 122 golfers; the sponsorship was oversubscribed, a much-appreciated boost for the chapter’s to scholarship program, and the course was in excellent condition. The event, once again, was held at the Robert Trent Jones Course at Rock Barn in Conover, North Carolina, which a week earlier played host to the Greater Hickory Classic, a PGA Champions Tour event. The centrally located course is convenient for many participants that work within driving distance of the course, especially for those who worked for CommScope, which has multiple operations in the area.

the best part of all the people were fantastic,” Deming said. “From the generous sponsors, the far traveling participants, especially our brothers from the New England Chapter, to the event volunteers, many, many thanks and a job well done.” Proceeds from the tournament fund the Southeast Chapter’s scholarship program, which awarded two scholarships in 2012. Event sponsors included Commission Brokers, Beta LaserMike, American Kuhne, Guill Tool, TSM, Teknikor Contracting, Okonite, Wire & Plastic Machinery, Tulsa Power, J.J. Lowe Associates, Maillefer Extrusion, W. Gillies Technologies, Zumbach, Lloyd & Bouvier, Sonoco Reels, Technical Development, Sikora, Rosendahl Nextrom Technologies, and Standridge Color Compounding. Corporate Hole Sponsors were Amaral Automation Associates, Axjo America, Clinton Instrument, DavisStandard, Gateway Recovery, Haynes Wire, Henderson Sales and Service, J.J. Lowe Associates, Kyocera Industrial Ceramics, Joe Snee Associates, Sonoco Plastics, Sonoco Reels, Superior Essex, T&T Marketing, Teknikor Contracting, Windak.

Expert on young employees to speak at New England Chapter’s annual meeting

From l to r, event Chairman Tim McElhany (Tulsa Power), with the winning team—Brooke Stonesifer (Sonoco), Scott Harvey (Sumitomo Electric), and Tom Heberling and Brandon Bennett (both of Southwire)— and Chapter President Art Deming (Superior Essex). “The record number of sponsors and players this year indicates the growing strength of the chapter,” said Event Chairman Tim McElhany, of Tulsa Power. “We had a great day and a beautiful venue with the scholarship fund reaping the benefit.” The winning team, which shot a stunning 56 in the scramble format, was Brooke Stonesifer of Sonoco, Scott Harvey of Sumitomo Electric, and Tom Heberling and Brandon Bennett, both of Southwire. Second place went to Doug Herrick and Steve Navarette of Chase, and Richard Miller and Mark Whisenant of Southwire, who also shot a 56, but were edged out when score cards were compared with the first place team. Third place with a score of 57 went to David Campbell of Breen and Paul McConnell, Jeff Munday, and Brian Deese of CommScope. Southeast Chapter President Art Deming of Superior Essex recognized McElhany for his excellent work in coordinating and scheduling the event. “This year was our biggest turn out, the weather was fine, the course great and 36 | WIRE JOURNAL INTERNATIONAL

The New England Chapter will return on Jan. 24 to the Mohegan Sun Resort Conference in Uncasville, Connecticut, USA, to hold its 19th Annual Meeting, where the Association’s largest chapter will introduce its new officers, provide time for mingling and to review the past year and look forward to future events. The event with a reception at 5 pm, followed by a buffet dinner. The keynote speaker will be Bruce Tulgan, an internationally recognized leading expert on young people in the workplace who focuses on leadership and management. “We thought that Bruce would be a good speaker because of his specialty in young employees,” said Chapter President John Rivers. “Any advice he can provide those of us who happened to be born before ‘Generation X’ should be able to benefit from his insights.” Tulgan, a best-selling author, is an adviser to business leaders all over the world, and a sought-after keynote speaker and management trainer. Since 1995, he has worked with tens of thousands of leaders and managers in hundreds of organizations ranging from Aetna to Wal-Mart; from the Army to the YMCA. He has been called “the new Tom Peters” by many who have seen him speak. In recent years, Bruce was named by Management Today as one of the few contemporary figures to stand out as a “management guru” and he was named to the 2009 Thinkers 50 rising star list (the Thinkers 50 is the definitive global ranking of the world’s top 50 business thinkers). And on August 13, 2009, he received Toastmasters International’s most prestigious honor, the Golden Gavel, an honor annually presented to a

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CHAPTER CORNER

single person who represents excellence in the fields of communication and leadership. Past winners have included Marcus Buckingham, Stephen Covey, Zig Ziglar, Deepak Chopra, Tony Robbins, Ken Blanchard, Tom Peters, Art Linkletter, Dr. Joyce Brothers, and Walter Cronkite. The newest book by Tulgan is IT’S OKAY TO MANAGE YOUR BOSS (Jossey-Bass, September 14, 2010). Previous books have included the recent best-seller IT’S OKAY TO BE THE BOSS (HarperCollins, 2007) and MANAGING GENERATION X (W.W. Norton, 2000; first published in 1995). His other books include WINNING THE TALENT WARS (W.W. Norton, 2001), which Brian Hirt, IEWC business analyst, spoke on the economy at the New received widespread acclaim from Fortune 500 England Chapter’s annual meeting in 2011. CEOs and business journalists; the best-seller FAST FEEDBACK (HRD Press, 1998); NOT EVERYONE GETS A TROPHY: HOW TO MANTulgan practiced law at the Wall Street firm of Carter, AGE GENERATION Y (Jossey-Bass, 2009); and MANAGLedyard & graduated with high honors from Amherst ING THE GENERATION MIX (HRD Press, 2006). Many College, received his law degree from the New York of his works have been published in foreign editions. University School of Law, and is still a member of the Bar Tulgan has written regularly in human resources, staffing in Massachusetts and New York. and management journals as well as publications such as For more details, including the cost for the event, chapter the Harvard Business Review, BusinessWeek, HR Magazine, members can go to the chapter’s page at www.wirenet.org the New York Times, the Los Angeles Times, and USA Today. or contact WAI’s Anna Bzowski at tel. 203-453-2777, ext. Prior to founding RainmakerThinking, Inc., in 1993, 132, abzowski@wirenet.org.

FEATURE The opening ceremony at wire China was full of pageantry and color. Organizers reported good activity at the events. Photos courtesy of Messe D端sseldorf.

wrapup: wire China Organizers of wire China and its sister event, Tube China, announced that the fifth staging of the biennial event showed continued strength, with a rise in both in exhibitor and visitor numbers. A press release from organizers Messe D端sseldorf said that the combined events, held Sept. 25-28 at the Shanghai New International Expo Centre, saw 1,399

exhibitors present the latest information on machines, plants and products from the wire, cable and tube processing industries to 33,469 visitors. It said that wire China exhibitors presented systems for wire manufacturing and processing, tools and auxiliary materials for process engineering as well as materials and special wires, and were able to discuss current trends and possibilities in the areas of cable, measuring and control technology as well as inspection technology.

Attendees at the combined events could see and hear about technology offered by 1,399 exhibitors.

38 | WIRE JOURNAL INTERNATIONAL

FEATURE With more than 30,000 attendees for the wire and tube trade shows, the registration area was kept quite busy.

well as its development into Asia’s biggest wire, cable The Messe Düsseldorf endeavor was bolstered by the and tube trade fair.” efforts of its subsidiary, Messe Düsseldorf China, the Exhibitors who responded to a WJI request for comMetallurgical Council of China Council for the Promotion ments about the event were generally quite positive. of International Trade (MC-CCPIT) and the Shanghai Pourtier, part of the Gauder Group, reported many good Electric Cable Research Institute (SECRI). The results, it visits. “Pourtier is deeply involved in the active market of said, were well received by exhibitors and attendees alike. submarine and umbilical cables equipment and is due to The event had strong Chinese participation, but many European exhibitors also travelled to Shanghai alongside those traditionally attending from North America, South-East Asia, Japan, South Korea and Taiwan, the release said. “These (exhibitors) welcomed numerous trade visitors and enjoyed lively order activities for the duration of the trade fair.” Messe Düsseldorf CEO Werner M. Dornscheidt, CEO of Messe Düsseldorf, said that the two trade events had once again met expectations. “As the organizer of wire and Tube Düsseldorf, the leading international trade fair for wire, cable and tubes, we are very proud to register the rapid growth of wire and Tube China in Shanghai as Dow had a considerable presence at wire China.

DECEMBER 2012 | 39

FEATURE

supply one of the biggest armoring line ever for this application,” it said. The statement noted that the company has a contract with a well known European cable maker for an armoring line for submarine applications that will process a large number of wires (over a hundred) with large diameters (up to 10 mm) and high tensile strength on large diameter power cable (up to 350 mm). The line will use large bobbins for the steel wire (DIN 1000) to provide very large capacity and capability, it said. Pourtier also noted that, during the show, some 100 visitors attended the submarine cable seminar presented by Christian Pavailler, the company’s French sales manager. Attendees were also able to see the latest from the other Gauder Group companies. Gauder Group China exhibited for the first time a cost-effective version of the wellknown Setic double-twist buncher, a single-bow design, “TD 630 EC” type, which can be equipped with the exclusive Greenbow, manufactured in Changzhou premises. Also, Setic’s double-twist bunchers/stranders for PC and automotive industry as well as lower-cost machinery from Daloo, which highlighted its competitive advantage, inviting customers to visit its workshop in Changzhou. “Visitors were then able to see by themselves why Daloo is different from common Chinese machine makers,” it said. “The wire China show in Shanghai was a great success for Maillefer,” a company statement said. “More than 300 visiting cable manufacturers and institute officials called upon our specialists. In addition, more than 200 participants attended our technical seminar, ‘High-end Cable Manufacturing Solution from Maillefer’. The seminar was considered as the most instructive one given in the

The Gauder Group booth reported many good visits. past four years. The Maillefer team would like to thank all customers for a great show and welcomes them to the next show in 2014.” Among those at wire China was the WAI, which was represented by WAI Executive Director Steve Fetteroll The next staging of the wire & Tube China events will he beld Sept. 24-24, 2014, when the trade shows will return to the Shanghai New International Expo Centre. For further information, contact on wire & Tube China contact Messe Düsseldorf GmbH, Daniel Ryfisch (by telephone at 49 (0) 211/4560-7793 or by e-mail at ryfischd@messe-duesseldorf.de. In North America, Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

North American exhibitors were pleased to see the brisk traffic flow. 40 | WIRE JOURNAL INTERNATIONAL

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FEATURE

A 30 kW wind turbine from Makani Power, Inc., which believes that utility-scale deployment is feasible.

green — Thinking WAY outside the box

ne plus of renewable energy is that there is no long-term power shortage, but another is that whatever the mode (wind, solar, etc.), they all

require wire and cable. This feature takes a literal look to the skies at the potential for untraditonal approaches for wind power as well as a concept for a floating solar island. The long-term trade winds, one could say, are increasingly favorable for generation of power by wind. A recent U.S. Energy Dept. report says that the U.S. now has 47 GW of wind energy generation capacity, enough to power 11.8 million homes, or 3.3% of the nation’s electricity demands. A second report, from the Global Wind Energy Council, says installed wind power capacity could increase more than four-fold, from 240 GW to 1,100 GW by 2020, representing between 11.7 and 12.6% of global electricity, while a third report projects that wind power could supply 20% of U.S. electricity by 2030, 4% from offshore wind. Land- and water-based wind turbine farms each have their pluses and minuses, both logistical and technical. One key stumbling block for wind as well as solar power remains funding—most notably, subsidies—for such renewable efforts. While there is much potential, it would be far greater if there were advances in energy-storing technology.

42 | WIRE JOURNAL INTERNATIONAL

Offshore wind farms, which carry much higher costs than comparable onshore wind farms, are extensively deployed in the U.K. but are just getting started in the U.S. Still, the choice for wind power essentially has been one or the other. Until recently, that is, as developers who have pursued a third approach report that they have begun to see promising test results not on land or sea but above. The idea is that airborne wind generators can tap into higher, stronger winds. They believe that their technology—classified as “kites,” although quite different in design, from the “blimp” approach seen on the cover to the “glider” system shown above—could and should be a key element of the technology’s future. They maintain that their technology is both more cost-effective and flexible, offering new potential, although this deployment also comes with its own set of pluses and minuses, one of which may be getting a “sky rights” blessing from the Federal Aviation Administration.

especially if one understands how effectively the technolA recent study from Carnegie Institution for Science, ogy can work at different levels. Using models, he said led by Kate Marvel of Lawrence Livermore National that the Carnegie team was able to quantify the amount of Laboratory, finds that there is enough wind power to power that could be generated from both surface and potentially meet all of the world’s energy demands by a atmospheric winds. They also looked at multiple of 20—and even a hundred the geophysical limitations of these techfold—if one is able to tap into the niques to find which were the most effirichest vein of the source, which “... if all costs are cient. They found that turbines create drag, they notes happens to be far, far or resistance, which removes momentum above ground level. Some propoconsidered, airborne from the winds and tends to slow them. nents of wind kites claim that if all wind energy would However, as the number of wind turbines costs are considered, airborne wind be the world’s increase, the amount of energy that is energy would be the world’s cheapextracted increases, but at some point, the est energy source, with the possible cheapest energy winds would be slowed so much that exceptions of some hydro sources source ...” adding more turbines would not generate and limited projects where surfacemore electricity. Combining their assorted based wind turbines supply relativeresearch, the team was able to determine ly local needs. that more than 400 terrawatts (TW) of power could be A press release from the Carnegie Institution said that extracted from surface winds and more than 1,800 terwith the help of airborne wind turbines—those that conrawatts could be generated by winds extracted throughout vert steadier and faster high-altitude winds into energy— the atmosphere. the planet would be able to generate far more power than Caldeira said that the planet is estimated to use about 18 with ground- and ocean-based units alone. TW of power, and harnessing near-surface winds could Ken Caldeira of the Carnegie Institution’s Department increase the rate of wind power by more than 20 times of Global Ecology, who worked with Marvel on the projtoday’s global power demand while using wind ect, believes that high-altitude wind power could have a (continued on p. 56) massive effect on the world’s renewable energy needs,

Wind kite tech flows on different levels There are multiple approaches to deploying wind turbines in the skies, with three different types of kite deployment concepts presented here. The first, shown on the cover, is a kite turbine that essentially stays in one place at or under 1,000 ft, providing energy for a below customer site that otherwise would be inaccessible; the second is meant to circle in a defined area as it operates at higher altitudes (2,000 ft); and a third will someday target the potentially most lucrative (and challenging) returns, which would be in the jet streams (some 30,000 ft). The fixed placement approach is used by Altaeros Energies, a U.S.-based company created by MIT and Harvard alumni that has tested the Altaeros Airborne Wind Turbine (AWT), a 35-ft scale prototype that looks like a giant blimp with a hole in the middle. It notes the following. “Altaeros is developing its first product to reduce energy costs by up to 65% by harnessing the stronger winds found over 1,000 ft high and reducing installation time from weeks to days. In addition, it is designed to have virtually no environmental or noise impact and to require minimal maintenance. The Altaeros AWT will displace expensive fuel used to power diesel generators at remote industrial, military, and village sites. In the long term, Altaeros plans to scale up the technology to reduce costs in the offshore wind market.”

A “fixed” ltaeros Airborne Wind Turbine (AWT).

DECEMBER 2012 | 43

FEATURE

High-flying wind power can meet world energy demands

FEATURE

tem is integrated well for minimal maintenance in a variety “For decades, wind turbines have required cranes and of weather conditions at our customer sites. huge towers to lift a few hundred feet off the ground where In regards to acceptance of the technology, Rein said that winds can be slow and gusty,” said Altaeros CEO Ben customer perceptions are important. "This is why we are Glass, the inventor of the AWT. The AWT uses a heliumadapting the tethered helium aerostat technology that has filled, inflatable shell to ascend to higher altitudes where been used for over 30 years to lift heavy telecom, weather winds are more consistent and more than five times stronger monitoring, and surveillance equipment into the air for long than those reached by traditional tower-mounted turbines. periods of time. We have strong customer interest and are Strong tethers hold the AWT steady and send electricity currently in discussions with groups ranging from off-grid down to the ground. “We are excited to demonstrate that communities, developing world power sector, and remote modern inflatable materials can lift wind turbines into industrial companies.” more powerful winds almost everywhere—with a platform Taking the second approach is U.S.-based Makani Power, that is cost competitive and easy to setup from a shipping Inc., which has built a model capable of generating 30 kW container.” of electricity, enough for about 20 average U.S. homes. Adam Rein, the company co-founder, notes that the comMakani, which is partially backed by Google Inc., is also pany uses an “off-the-shelf” 2.5-kw, 3.7-meter, three-blade working on a portable “kite-in-a-box” for the Army to wind turbine merged with helium inflatables that have lifted radar systems for decades. The unit is rated to go to about 1,000 ft in the boundary layer. The tallest terrestrial wind turbine is 350 ft high. Deploying the AWT would be a boon for off-grid and hard-to-reach spots such as military bases, remote villages, oil and gas sites and even offshore applications where he said the actual total costs for diesel power can be $0.50 to $0.75 a kilowatt-hour, triple that for the AWT. He said that the FAA has put out draft regulaMakani staffers prepare their AWT for a test. tions for high-altitude tethered wind turbines and that the AWT design is also quieter than traditional wind turbines, with deploy during disaster-relief operations. Land-mounted less bird and radar impacts. wind turbines are a small, but rapidly growing, segment of Rein notes that the AWT is “relatively fixed” in the air, global power generation, it notes. The company has been although periodically it will adjust altitude and move within working with CTC Global for the cables its systems use. a narrow radius as it is blown back from the wind slightly." See sidebar on p. 46. The biggest technical challenges, he said, are to develop a At its website, the company notes the following. The key lighter wind turbine so that the inflatable shell can lift a to making these machines work is the ability of the rotors to wind turbine of bigger capacity, and to ensure that the sys-

Cable/copper use for windmills (multiply by 200,000+) Per the Global Wind Energy Council, at the end of 2011, there were more than 200,000 wind turbines in operation, with a collective capacity of 238,351 MW, which translates to a lot of wire and cable. As part of a market evaluation request by the Copper Development Association CDA in 2006, Oak Ridge National Laboratories (ORNL) did an analysis on the Buffalo Mountain Wind Farm run by the Tennessee Valley Authority (TVA) and developed the following information. At that time, the wind farm had two types of turbines: Vestas models V47 and V80. For the Vesta V47, a 660-kW turbine, the windings in the system used about 800 lb of copper. There are three of these turbines, and three 2/0 cables, each 270 ft long, that connect the generator at the

44 | WIRE JOURNAL INTERNATIONAL

top of the tower to the controller below. Approximately 100 lb of copper busing was located at the base.The control cabinet also used about 300 lb of various small gauge wires. Each tower has a grounding system that consists of a 1/0 copper cable that runs the length of the tower. Several circular rings of this cable surround the tower. The base of the tower is about 39 ft. Three 20 ft-long copper grounding rods, about 1/2” in diameter are associated with each tower. There are 15 V80 turbines rated at 1.8 MW each. The cable connection is 4/0. The transfer cabinet contains about 15 lb of copper. From the transfer cabinet, either 2/0 or 3/0 cable conveys the energy underground to a switch yard or collection point. From there, aluminum overhead transmission cable distributes the energy away from the farm.

needed for a traditional wind turbine and deliver more consistent power as it can access winds both at higher altitudes and above deep waters offshore, resources that are currently untapped. “Our goal is the Makani Power Chief Engineer Damon utility-scale Vander Lind. deployment of airborne turbines in offshore wind farms,” said Vander Lind. “We think the technology is scalable on the roughly four requirements the tethers must meet, and thus can be applied to very large systems, on the scale of 5 MW,” he said, adding the following. “The cable for our 600 kW device (our first commercial unit) weighs about 350 kg and is 450 meters long. We only have one tether and one kite in each system, though many of these are installed in a wind farm, similar to the commercial deployment of wind turbines. These all put power on (continued on p. 48)

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switch from power generators to propellers that can keep the kites aloft when the wind dies down. Onboard computers will make many thousands of adjustments to ensure the kite remains aloft for months at a time. The Makani machines are also capable of flying by themselves. If the tether were to break, the kites are programmed to fly down and belly flop in a predetermined spot. Makani’s machines aren’t kites like the balsa-wood-and-cloth toys that kids make dance in the wind. They are basically small aircraft capable of cutting through the wind in large circles, mimicking on a larger scale the path of traditional wind-turbine blades—recreating their power-generation abilities without the expensive tower and large blades. The turbines are mounted on kites made of carbon fiber, like the material used for surfboards, which has become cheaper in recent years. So have the cost of sensors needed to determine the orientation and location of the kites and the computing power needed to determine their paths. Further, unmannedflight technology has been improving by leaps and bounds, thanks to military-funded research on drone aircrafts, with some of the Pentagon’s advances in materials and navigational software becoming commercially available. “We’re offsetting a large amount of steel and concrete with computational sophistication,” said Makani Power Chief Engineer Damon Vander Lind. He pointed out that Makani’s wind turbines will use one-tenth of the materials

FEATURE

CTC Global: kite tether cable is well-grounded technology Based in the U.S., CTC Global provides cost-effective conductor solutions that it notes can double the capacity of congested transmission lines. It has been working with Makani Power, Inc., a U.S. supplier of kite wind technology. Below, Douglas Pilling, director of product engineering, discusses the technology the WJI.

WJI: Could the same cable be used for a larger version? Is there a point at which a higher voltage cable would be need to be used? Pilling: Each size kite/aircraft will demand a differently sized ACCC tether, due to load and power parameters, this will be considered a high voltage cable.

WJI: What specific type and size cable did you provide Makani? Pilling: CTC Global did not supply the kite prototype cable, which was created by Makani as a developmental test tether. We have provided samples and are providing cable that will be cycle fatigued for a Makani’s test fixture at their facility in the Bay area. We are partnering in development of the tether for the first commercial version of the Makani Power System, the 600 kW, 28-meter wing span kite. WJI: Is this an “off the shelf” cable, or are there requirements for this end use that required special CTG Global is helping Makani develop a tether for commercial deployment. characteristics? Pilling: The tether will not be an offWJI: There has been some discussion that regulatory the-shelf cable in both fiber type and conductor configuraproblems could present a bigger hurdle than the tion. The matrix or resin system will be the same as conventechnology: can you explain what in particular the tional ACCC, along with the core fiber architecture. The problem would be and why? aluminum conductor composite core (ACCC) supplied for Pilling: CTC Global cannot address this question, kite tethers will be a ULS (ultra low sag) version of the but we recognize that all “new technology” has a period CTC Global current offering. This type of conductor is of adoption and has to make a strong case for its being offered for extreme applications (long river crossings, widespread use. mountainous terrain, etc.). It shares the same fiber architecture but has higher strength fiber (16% overall higher WJI: Is the biggest challenge for this concept the technolstrength). The ACCC tether will be close to the same flexiogy or overcoming a perception that a “kite” is not somebility as the standard ACCC, but the outer conductor will be thing people used to massive wind farms will take seriously of a different configuration to allow +- dc current to flow in as an alternative wind energy source? a single cable. Pilling: CTC Global knows the wind turbine business and recognizes that power generation is all about numbers; WJI: Is there always a constant “pull” on the tethered Makani is generating the numbers with its prototype that cable, or can conditions result in erratic tugs, and if so, will sell the concept and the infrastructure to support it. could that lead to problems? Pilling: Constant pull with a minor variation in load as the WJI: What do you see as the primary attraction of this kite/aircraft travels through its arc is the normal operational technology? condition; erratic tugs will easily be tolerated by the tether Pilling: The beauty of this concept is the return on investbut they are not anticipated in normal operations. ment in kW per hour, this system is exposed to a very large area of moving air as opposed to conventional wind turWJI: What percentage of the 450-meter, 350 kg cable is bines. The Makani Power System also places its exposed actually “airborne”? Is there an uncoiled length that is wind generation system up in the path of wind that is of there “in reserve”? much higher velocity because it is at an altitude that is Pilling: One hundred percent of the 450-meter cable will above the structures and terrain that typically slow the wind. be “airborne” during power generation, the kite/aircraft will be in hover mode during reel out and retraction operation.

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FEATURE

is capable of producing power for as little as two cents per the grid through a very traditional interconnect. We can kW hour, transmitting the electricity generated by the spinlaunch and land in winds with severe turbulence up to and ning rotors to the ground through aluminum cables tethered above our cut-out speed of 25 m/s. The wings launch and to the frame. Sky WindPower hopes to build flying farms land near the ground, where winds are lower. At crosswind one day clustered in a 200-sq-mile restricted airspace zone. flight altitude (roughly 300 meters), the systems are stable Turbines constructed of aircraft materials would feature four in winds far in excess of the cut-out speed. The cable is 130-ft-diameter rotors and weigh in at 45,000 lb. The FEGs wound in a single wrap around a drum for storage. The would function like helicopters on liftoff, powered by the cable never comes near the ground during launch/land, so ground station until they can begin harvesting wind power. units use a ground area similar to the that of a wind turbine. Once in the jet stream, the FEG’s vertical stabilizers would The M600 weighs about one ton. Launch and land is actualtilt the rotors at different angles to balance the platform and ly highly stable due to the clever aerodynamic and electrooptimize wind speeds. mechanical design. Crosswind, power generating flight At its website, SWC reports that only 15% of the world’s tends to be more stable than hover. This is also the flight landmass—including coastlines, high ridges and flat mode in which the system spends the majority of its time.” plains—are adequate for traditional wind turbines. It also Vander Lind said that the beauty of the concept is the notes the following. Reaching winds at 500 ft to 2,000 ft return on investment in kW per hour, as this system is above ground level allow WATTS to address the other 85% exposed to a very large area of moving air as opposed to of the world’s land mass where traditional wind turbines are conventional wind turbines. The Makani Power System also not effective. WATTS is also mobile and can be rapidly places its exposed wind generation system up in the path of deployed and redeployed without the need for towers, founwind that is of much higher velocity because it is at an altidations or heavy cranes. WATTS is capable of operating in tude that is above the structures and terrain that typically a wider range of wind speeds, from nine mph to greater slow the wind, he said. “I think we get a bit of disbelief than 65 mph. High altitude winds are one of the most conwhen first mentioning the concept, but (our) 30 kW protocentrated sources of clean renewable energy, packing type speaks for itself. We think we have solved the major, enough power to meet global human energy needs many fundamental design problems at this point at our prototype times over. Jet-stream winds typically have 10 to 30 times 30 kW scale, and are progressing on the 600 kW units. Our the energy of ground-level wind. Even at altitudes of 300 board of advisors includes top tier companies in aerospace, to 2000 feet, SWP`s FEGs have a predicted capacity factor wind, and project development who are primarily in agreetwo to three times that of ground-based wind turbines. ment about the challenges. Some think regulatory problems The FEGs can will present a bigger hurdle.” carry a payload The third approach, tapping such as surveilinto the jet stream, is part of lance, communithe range of U.S.-based Sky cation, or moniWindPower Corporation (SWC), toring equipment which has created a system that and can still send looks like a mixture of a helicopsignificant residter and a kite. At its website, ual electrical SWC notes that it has developed energy to a Wind Airborne Tethered the ground SWC Turbine System (WATTS) using Sky WindPower’s prototype FEG. The technology was featured on reports. They can Flying Electric Generators the cover of the March 2011 issue of Popular Mechanics. be programmed to (FEGs) to convert high altitude take off and land wind energy into electricity. automatically in accordance with wind and weather condiWhile this approach could be used for generating larger tions and be directed to retain a constant hover coordinate amounts of electricity, its current focus is to produce FEGs or to change position, angle of attack, and altitude. All conthat can transmit power to ground stations at mobile or utilitrols can be programmed or operated manually. A WATTS ty scales of power and also carry instrument payloads for system can be transported in a standard 20-ft container. This civilian, scientific, and military purposes. The FEG`s rotors simple concept can be scaled up to generate Gigawatt-hours both lift the vehicle to altitude and convert the kinetic enerof electricity per year. Sky WindPower has built and flown gy in the wind flow to electricity. These craft can operate at several prototypes, one of which has successfully generated altitudes up to 2,000 ft or at higher altitudes in special use and transmitted power in repeated flight tests. The machines or restricted airspace. The excess wind energy not needed have flown autonomously, taking off, flying to altitude, to maintain position generates electricity that is transmitted executing pre-programmed maneuvers, making in-flight to the ground-station via an anchoring tether, which also adjustments for wind changes and gusts, and landing withserves as a conduit for data and instructions. out human intervention. WATTS is near ready for customer Focusing higher up, Sky WindPower believes that at an testing. altitude of between 15,000 and 30,000 ft, its 1,100-lb FEG

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FEATURE

An ‘island’ unto itself: solar The phrase “solar power” likely evokes images of either vast rows of solar panels in a field or desert or much smaller arrays on tops of buildings, but for one Norwegian company with a different mindset, their image is of an island. A floating island tethered offshore that could open up a new approach to deploying the technology. To that end, DNV KEMA Energy & Sustainability has developed SUNdy, a large-scale offshore solar field concept that was launched earlier this year during Singapore International Energy Week, as explained below by the company at its website. The core feature of the concept is a hexagonal array that floats on the sea surface. A collection of these arrays, totaling 4,200 solar panels, forms a solar island the size of a large football stadium, capable of generating 2 MW of power. Multiple islands connected together make up a solar field of 50 MW or more, producing enough electricity for 30,000 people. Islands would ideally be located in benign waters with depths ranging from 20 to 100 meters and about five miles from shore, away from shipping lanes. “We firmly believe the SUNdy floating solar field concept offers sound and sustainable development prospects, particularly in Asia and the congested coastal megacities where there’s limited opportunity for rooftop solar power and

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urban areas which command premium prices for largescale mounted solar production,” DNV KEMA COO Bjørn Tore Markussen said in the company’s announcement. “The island has been optimized for solar capability and cabling efficiency,” said Kevin Smith, global segment director for DNV KEMA’s Renewable Energy Services,who noted the following. The solar arrays are divided into electrical zones feeding electricity produced into two main switches collecting the power for voltage step up at a central transformer (2MVA 480/34.5 kV). From the offshore solar farm’s central island, 30 kV electrical transmission lines connect, tying other islands in series to form a closed loop and continue to the electrical sub-station onshore for grid connection. SUNdy’s system-wide modular design includes electrical connectors, arrays, cables and walkways, while the mid and perimeter markers are also common components and house water cannon for automatically cleaning the arrays. Perimeter buoys double as warning markers with navigational beacons. The entire island is therefore built up from a small number of repeated components. SUNdy’s photovoltaic solar modules have no moving parts, creating a reliable predictable and scalable system with low maintenance. The SUNdy concept is made possible using thin-film 560 W solar panels that are flexible and lighter than the tra-

FEATURE

ditional rigid glassbased modules, allowing them to undulate with the oceanâ&#x20AC;&#x2122;s surface, said Sanjay Kuttan, managing director of the companyâ&#x20AC;&#x2122;s Clean Technology Centre in Singapore. â&#x20AC;&#x153;The key to creating an oceanbased structure of this size is the use of a tension-only design. Rather like a spiderâ&#x20AC;&#x2122;s web, this dynamic, compliant structure yields to the waves, yet is capable of withstanding considerable external loads acting upon it.â&#x20AC;? He said that separating the solar arrays into prefabricated

A concept drawing of DNV KEMAâ&#x20AC;&#x2122;s proposed solar island.

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Short takes on 4 renewable sources: pluses and minuses Per one report, about 9% of all energy consumed in the United States in 2011 was from renewable sources, led by hydropower, with 35%. Wind power represented 13% while solar was listed in the 4% “other” category, although it has a fast growth rate. As demand for power is increasing and alternative energy is estimated to provide a third of the world’s energy by 2050, the future looks good for a wide range of power cables. Below are brief excerpts from multiple report. Not included: biomass, geothermal power and wave power. Solar Power. From an environmental perspective, this option is quite good. With solar, there’s no acid rain, no urban smog, no pollution of any kind. The costs are declining and small installations are practical. The downside is that costs are still high, generation is intermittent and not all locations are good. Of note: Siemens, once a world leader in supplying this technology, recently said that it will now focus all of its renewable energy activities on wind and hydropower, which it expects to be the biggest contributors to growth among renewables.

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Wind Power: Two different reports (Nature Climate Change and the Proceedings of the National Academy of Sciences) say that existing wind turbine technology could produce hundreds of trillions of watts of power. Generation can be intermittent, yet the real downside is not the potential but the logistics and costs in attaining it. Hydro Power: Hydroelectricity is long proven and deployed technology. Once built, dams produce electricity at a constant controllable rate. The downside is that dams are extremely expensive to build, they must be used for decades to become profitable and there are few places that offer the conditions needed for a new site. Tidal Power: Unlike solar and wind, tidal power is predictable as tides rise with great uniformity. Once a tidal plant starts running, costs are extremely low. Some downsides include its extremely high start-up costs, relatively few places where it is feasible to use, effect on marine life and potential for damage by severe weather.

MANUFACTURING RANGE NEW ARRIVALS - PRE-OWNED â&#x20AC;˘ Troester - Portal traversing take-up for reels 25 tons, flange Ă¸ max. 4500 mm (177 ) Tubular stranders â&#x20AC;˘ Rosendahl - Portal traversing take-up for reels 25 tons, flange Ă¸ max. 4000 mm (157 ) Rigid stranders â&#x20AC;˘ Lesmo - Automatic single spooler for bobbins 630 mm (24,8 ), incl. accumulator Planetary stranders Power cable drumtwisters Armouring lines Bow twister machines For contacts in USA: Skip stranders QMS INC. Pay-offs and take-ups, all designs Miami, Florida Belt-type caterpillar capstans Single- and double disc capstans Tel.: +1 (305) 665-2523 Rotating caterpillar capstans Fax: +1 (305) 740-9460 Taping heads for plastic- and steel tapes info@qmsmachinery.com Transposed wire machines &* ')! #** +) . '&* " , . $ . - . #& ' (, #&* '%

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sections allows for large scale manufacturing and streamlined assembly offshore. The cable grid provides for maintenance access in the form of floating gangways. The shape of the island is maintained by the tensile forces from the lengthy spread mooring. The company notes that the unveiling of the SUNdy concept comes at a time when solar photovoltaics (PV) is experiencing extraordinary market growth. Almost 30 GW of operating capacity has been added, increasing total global capacity by 74% to more than 69 GW according to the Renewable Energy Policy Network 2012 report. While the EU again dominated the global market, markets are expanding in other regions, and China has rapidly emerged as the dominant player in Asia. Emerging markets, such as Southeast Asia, are also aiming to A drawing showing how the individual solar panels are mounted grow their renewable energy production with an on a pliable flotation mat that undulates with the sea. increased presence in solar. electricity, and scarcity of fossil fuels. For DNV, technologiSome of the conceptâ&#x20AC;&#x2122;s other benefits, the company notes cal innovation is a key element in our strategy to help at its website, include the abundant available space for address these concerns and SUNdy, as an example of our locating such â&#x20AC;&#x153;islands,â&#x20AC;? the absence of moving parts, use research work, can help illustrate future applications for of buoyancy for a simple structure and low visibility profile. solar as a truly sustainable resource,â&#x20AC;? Markussen said. â&#x20AC;&#x153;The renewable energy market is rapidly changing due (continued on p. 56.) in main part to climate change, soaring global demand for

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FEATURE

High-flying wind ... (ctd. from p. 43) turbines on kites “could potentially capture 100 times the current global power demand!” There is a caveat to that potential as he told WJI that attaining that extraction level would have “dramatic climate effects, but at the scale of civilization’s energy use, climate consequences of wind power appear to be negligible.” And, from a practical standpoint, that potential is subjective. Jerry Taylor, an energy and environmental analyst at the conservative Cato Institute, has been cited as saying that the lack of economic reality in the studies made them “utterly irrelevant.” Those words may be strong, but Caldeira agreed that embracing the full potential of wind power would require a major effort. “To power civilization with wind turbines, I think you’re talking about a couple wind turbines every square mile. Its not a small undertaking.” A study by CI and California State University found that New York would be a Ken Caldeira, Dept. of Global prime location for Ecology, Carnegie Institution. exploiting high-altitude winds. The researchers found that the regions best suited for harvesting this energy match with population centers in the eastern U.S. and East Asia, but fluctuating wind strength still presents a challenge for exploiting this energy source on a large scale. Using 28 years of data from the National Center for Environmental Prediction and the Department of Energy, Caldeira and Cristina Archer of California State University, Chico, compiled the first-ever global survey of wind energy available at high altitudes in the atmosphere. The researchers assessed potential for wind power in terms of “wind power density,” which takes into account both wind speed and air density at different altitudes. “There is a huge amount of energy available in high altitude winds,” said Caldeira. “These winds blow much more strongly and steadily than near-surface winds, but you need to (be miles) up to get a big advantage. Ideally, you would like to be up near the jet streams, around 30,000 ft. Looking at the big picture, it is more likely that economic, technological or political factors will determine the growth of wind power around the world, rather than geophysical limitations.” he said. The question, of course, is how one can harvest air power at 30,000 ft. Surprisingly, there are options that are not necessarily the stuff of science fiction, although the concepts may seem...distant.

wind farms. Finally, they do not cause pollution and could lessen pollution by replacing other energy sources.” At the same time, observes ISF, the technology is only useful if it is used, and there are some roadblocks not related to desirability by power generators for flying turbines. “Despite all of the positives and all of the awesome prototypes being designed and tested, there are a few issues that would need to be addressed before these flying wind farms could be a mainstream reality. Probably the biggest challenge would be working out airspace with the Federal Aviation Administration so that aircraft and wind farms do not collide in mid air. In addition, decisions need to be made about where to put the tethers that anchor the wind farms to the ground. Another current problem is the lack of government involvement and capital to really develop a viable option. Observed Mark Moore, a NASA aerospace engineer working as part of the first federally funded project to research flying wind farms and how the federal government can be involved, “It is crazy there isn’t federal investment in this area, because the questions are just too great for small companies to answer.”

DECEMBER 2012 | 57

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The Ian Somerhalder Foundation, which supports efforts that “positively impact the planet and its creatures,” explains at its website how this could work. “Imagine a giant balloon type structure flying 30,000 ft up in the sky. Imagine the balloon structure outfitted with turbines connected to long tubes that anchor it to the ground. Now picture the turbines are sending energy through those tubes back down to the ground to power your cities and homes. Known as flying wind farms, these giant balloon structures may be the wave of the future when it comes to harnessing wind energy.” ISF notes that there are reasons to take this non-traditional approach seriously. “Flying wind farms have many advantages. First, they have the potential to generate multiple times more energy than their grounded counterparts. Wind is more consistent, more powerful, and much faster at higher altitudes. NASA has estimated that at 30,000 feet, where turbines can tap in to the jet stream, as much as 20,000 to 40,000 watts per meter of energy could be generated as compared to a mere 500 watts per meter at ground level. Second, the flying wind farms could be reeled in to prevent damage during storms or for maintenance. Third, the flying wind farms require much less ground space than regular

TECHNICAL PAPERS

MORDICA LECTURE Crystallographic texture in drawn wires: measurement, modeling and effect on mechanical properties This overview covers a range of wiredrawing issues, from crystallographic textures to crystal plasticity models of plastic deformation of polycrystalline materials in an attempt to understand the ‘curling effect’ as well as two types of wiredrawing failures. By Prof. Paul Van Houtte

One of the important materials properties of the steel sheet delivered to automotive companies is the in-plane plastic anisotropy. Anisotropy means that the mechanical properties of the material depends on the angle of the direction in which it is measured with the surface of the plate. Auto makers specify a high degree of anisotropy for certain car body parts. In collaboration with the academic community, steel suppliers are doing very substantial research to understand the relation between texture and mechanical behavior as well as the technology needed to control the texture in the steel. It is therefore my conviction, that the ‘texture-anisotropy’ issue deserves serious attention by the wire drawing industry.

Crystallographic texture in steel wires Metallic products such as wire drawn from metallic rods, low-carbon steel, pure copper, tungsten, niobium (sometimes called columbium) and so on, consist of fine “grains,” each of which is actually a tiny metallic crystal. The chemistry of all these grains is the same for pure metals. However, in metals with alloying elements, two or more phases, each with their own chemistry, may be observed in the microstructure. For reasons of simplicity, what follows applies to a single phase, except when otherwise stated. As each grain is a tiny crystal, it has its own crystal orientation. Fig. 1 shows a small plate consisting of several grains; it could be a metallographic sample cut from a wire in such way that the top and the bottom sides of the plate belong to two parallel cross-sections of the wire. The figure shows three grains as well as the unit cells of their crystal lattices. The grains have different crystallographic orientations. A polycrystalline material may have “preferred orientations,” which means that certain crystal orientations occur more frequently than others. This is a typical property of a polycrystalline material; this property is called “crystallographic texture,” or just “texture.” The

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presence of preferred orientations is, in fact, the natural state of the material, whether cast, hot-worked, coldworked or annealed. What is really difficult, if not impossible, is to prepare a metallic sample without preferred orientations. Fig. 2 shows a texture that is infinitely “sharp,” i.e., all the grains have exactly the same crystal orientation. The example is unrealistic for wires, but there are materials which almost have such infinitely sharp texture, such as copper sheets subjected to cold rolling followed by annealing. Conversely, a polycrystalline material in which all imaginable crystal orientations occur with the same frequency is said to have the weakest possible texture, with a probability distribution of crystal orientations, also called orientation distribution function or ODF1, which is equal to 1 for all orientations. Textures can be measured by X-ray or neutron diffraction 2 , or by automated electron backscatter diffraction using a scanning electron microscope 3 . The result of a texture measurement can be representFig. 1. Metallographic sample cut ed either as a 2 from a wire. The grains have a “pole figure” cubic crystal structure. Unit cells or as an are shown for grains A, B and C. ODF1. Books For grain A, the crystallographic on this topic direction <110> is parallel with by Kocks, the longitudinal axis of the wire. Tomé and For grains B and C these are Wenk2 are a <100> and <111>, respectively. good starting

Fig. 2. Same as Fig. 1, but: the three grains now have the same crystal orientation, the crystallographic direction <100> being parallel with the longitudinal axis of the wire.

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Fig. 3a. Cross section of a hypothetical wire. Cubic unit cells of 24 grains are shown. All of them have one of their main crystallographic directions normal to the section plane (parallel to the wire axis). Fig. 3b. Same as Fig. 3, except a cyclic texture component is seen in the outer layer of the wire. The unit cells which belong to it are not randomly oriented in the section plane, as one of their main crystallographic directions is aligned with the radial direction.

point, whereas the book by Engler and Randle3 focuses more on the relationship between microstructure and texture. Earlier, I said that the sharp texture depicted by Fig. 2 is not realistic for a wire. All the grains in this figure have unit cells with the exact same orientation: for all of them, one of the 3 <100> crystal directions is parallel with the longitudinal axis of the wire, a second one with radial direction 1 and a third one with radial direction 2. However, this is not logical as a wire is axisymmetric: any of the infinite number of directions perpendicular to the wire’s longitudinal direction could be chosen to be radial direction 1 or 2, and there is no reason to make a particular choice. The grain orientations seen in Fig. 3a of a hypothetical wire cross-section seem conceptually more acceptable. Although it is conceivable that one of the main crystallographic directions of all the grains is aligned with the wire axis, the unit cells feel no preference for a particular transverse direction, and seem to have undergone random rotations around the wire axis with respect to each other. Such texture would be called a <hkl>-fiber texture, hkl being the Miller indices of the crystallographic direction which is parallel with the wire axis in all grains. The texture shown by Fig. 4b consists of a <110>-fiber texture. Unfortunately, it would be too simple if all wire textures would only consist of fiber textures. It is often observed that in the central region of the wire (as seen in a cross-section), the texture is indeed a mixture of nearly perfect fiber texture components, but not in the outer layer (Fig. 3b). The reason is that due to friction and shear in the contact zone between the wire and the drawing die, the deformation processes which take place in that layer are not perfectly symmetric around the wire axis, but have a second important axis, namely the normal to the surface. Depending on the amount of shear that took place in the contact region between the die and the wire during drawing, the texture that develops in the surface region may be a cyclic texture as seen in Fig. 3b. Fig. 5a (measured by neutron diffraction) shows the volume average of the deformation texture of the ferrite phase in a drawn pearlitic wire. It is a perfect <110>-fiber-texture. Fig. 5a

Fig. 4a. Sample prepared from segments of a wire and used for texture measurement at the surface. Special software was used for correction of the curvature. Fig. 4b. (110) pole figure showing the resulting ferrite texture at the surface of a 0.9 mm steel wire with 0.8 wt% C.

shows a mixture of such fiber texture component (however, slightly off-axis) with a cyclic texture component which is due to the shear at the surface. Fig. 5b shows the texture obtained by computer simulation of 26 consecutive wire drawing passes, each with a true strain of 0.1525. The halfdie angle α was 8°. Fig. 4b represents a surface texture measured by X-ray diffraction. Most texture components which can be seen here are of the fiber-type. In this measurement, the cyclic texture components were almost completely smeared out as the X-ray spot is larger than the wire diameter (Fig. 4a).

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Fig. 5. {110} pole figures of wire drawing textures. The vertical direction represents the wiredrawing direction. (a) nearly perfect fiber texture of the ferrite phase in the central region of a drawn pearlitic wire. The true strain was 1.96. Neutron diffraction measurement (after Eq. 4). (b) example a cyclic texture obtained at the surface of drawn steel wire. 26 drawing passes have been simulated. The true strain in elongation was 15.25 % in each pass, with an half-die angle of 8° (after Eq. 5).

Crystal plasticity General. The mechanical properties of drawn wire are mainly a function of the applied deformation, because the latter causes work hardening. Looking deeper into the matter, it seems that: (i) the deformation causes the texture and microstructure to change; however, during this process, texture and microstructure strongly influence each other, for example through the curling process, to later be explained. (ii) a lot of fundamental insight (including the knowledge of microstructure and texture and their evolution with deformation) is required to give a physics-based explanation of the strength of a wire. Many authors have treated this subject, including a notable 1977 article by George Langford6 on the deformation of pearlite, and a paper by Javier Gil Sevillano7, the 2010 Mordica Memorial Award winner, that together cite 126 references to other interesting papers that unfortunately are beyond the scope here. In all this, it is useful to understand the deformation mechanism of metallic crystals. Plastic deformation of such a crystal requires re-arrangement of the atoms. After a large plastic deformation, many, if not all atoms have been assigned a different place in the crystal lattice. Also, they no longer have the same neighbors. Early research suggested that under an applied shear stress, one half of a crystal could slide over the other half along certain crystallographic planes called “slip planes.” About 60 years ago, it was discovered that this process is in fact enabled by a nanoscopic mechanism called “dislocation glide.” Dislocations are lattice defects which extend along a line or a curve, and which can be moved under the action of an applied shear stress. Gottstein8 offers more information. In fcc metals (such as copper), slip by dislocation glide takes place along the {111} crystallographic planes and in the

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<110> crystallographic directions; this combination is called the “family of the {111}<110> slip systems.” However, two families of slip systems exist in bcc metals such as tungsten, niobium (columbium) or the ferrite phase in steel, namely {110}<111> and {110}<112>a. Note that each slip system has a sort of friction stress, which is called the “critical resolved shear stress (CRSS),” symbol τc.

Taylor factor Consider a single grain in the materials, with a known lattice orientation. The Generalized Schmid Law (see Kocks2 or Gottstein8) can be used to identify the slip systems which would be activated by an applied stress or an applied plastic strain rate (see Bishop-Hill method9-10 or Kocks2). Once they are known, it is possible to calculate . the slip rates γs on the active slip systems and obtain the stress σij which corresponds to a given plastic strain rate dij More details are available11. Note that this . stress scales with the critical resolved shear stress τc. W, the rate of dissipated plastic work per unit volume of the grain, can now be calculated.

Eq. (1) . It is clear that W scales with the critical resolved shear stress τc, but also with the magnitude of the strain rate dij The latter is characterized by the von Mises equivalent strain rate:

a Each of the families mentioned consists of 12 different individual slip systems.

The so-called Taylor factor of a single grain is now defined as follows:

Eq. (3) . in which W is taken from Eq. (1). It is seen that this Taylor factor does not scale with the magnitude of the prescribed strain rate dvm, nor with the value of the critical resolved shear stress τ c. It solely expresses the effect of the crystal orientation upon the work needed to deform the crystal: the higher the value of the Taylor factor, the harder it is to deform the crystal. In simple crystal deformation models, the task of taking work hardening due to dislocation accumulation into account is assigned to a sub-model that computes the critical resolved shear stress, τ c, whereas the Taylor factor expresses the effect of the plastic anisotropy of the crystal. For crystals with a given set of slip system families, the Taylor factor depends on: the crystal orientation and the “type” of the prescribed deformation, mathematically described by the ratio:

Models for polycrystals plastic deformation The models described below are assumed to be applied to a “representative volume element” (RVE) of the macroscopic length scale. Such RVE is supposed to contain a few hundreds or a few thousands of grains, yet remains just a ‘point’ at the engineering length scale, i.e. the length scale at which an entire wire or car body part might be modeled by means of an finite element model for metal forming. The crystal orientations of the grains inside the RVE must be representative for the texture of the material at the point considered. Static model. This very simple yet seldom used model assumes that the stress is the same in all crystals of the aggregate, regardless of their lattice orientation. The Generalized Schmid law2,8 would inevitably predict that, as one lets the stress level raise, there will be no plastic deformation at first, until plastic deformation begins in the weakest grain due to its crystal orientation. From then on, the uniform stress model can no longer be used. Sachs model. Contrary to what many researchers believe, the Sachs model12 does not assume a uniform stress field in the polycrystal. Careful reading of the paper reveals that Sachs considers a tensile test on a polycrystalline material. He uses the Schmid law to find the first activated slip system in every grain, as if they were stand-alone crystals. He realizes that every grain needs a different stress, depending on its crystal orientation. He explains that he assumes the existence of mutual interactions between the grains, leading to local fluctuations of the stress as to obtain the right

Eq. (4) The strain rate tensor dij is the symmetric part of it. It was explained earlier that it can be used to obtain the slip rates on the active slip systems and the stress σij in the grain. The lattice spin can also be obtained11. The macroscopic stress is taken to be the volume average of the local stresses. By doing a simulation on a large number of grains with different crystal orientations, together representative for the overall texture of the materials, one can predict the change of the grain orientations this texture has upon a small increment of deformation. By repeatedly doing this for a series of such increments, a deformation texture can be predicted. The stresses predicted by this model are not in equilibrium at the grain boundaries. Yet the agreement between measured and predicted deformation textures is most of the time much better for the Taylor than for the Sachs model, although this agreement was found to be only qualitative: the preferred orientations are reasonably well predicted, but their intensities are not correct11. It seems that neglecting the stress equilibrium is less detrimental than neglecting strain compatibility, as has been discussed by Kocks14. Models that take grain interaction into account. The Sachs and the Taylor models can, each according to their own assumptions, obtain the stress, strain rate and lattice rotation in individual crystals by means of purely “local” calculations, i.e. without having to use information about what happens in the neighboring crystals or in the material as a whole. As a result, even the Taylor model (the better of the two) is not capable of doing quantitative predictions of texture development, i.e. predicting the intensity of preferred orientations. In summary, these models cannot achieve both stress equilibrium and strain compatibility at grain boundaries. They moreover deliver solutions for

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Eq. (2)

stress to activate a slip system in every one of the crystallites. By introducing this notion of stress interactions between grains, Sachs was far ahead on his time. Today this notion is consciously accepted by almost all advanced polycrystal deformation models. Sachs, however, neglected the impact of the heterogeneity of the plastic strains predicted by his model, as the lateral strains of neighboring grains would be unrealistically incompatible. Mainly because of this, the deformation texture predictions by the Sachs model are unsatisfactory in many cases. Taylor model. This early model proposed by Taylor13 assumes that the plastic strain of all the grains of a polycrystal is the same. Suppose that the polycrystalline material is represented in the model by a multicrystal. The lattice orientations of its crystals are chosen in such way that the total set is representative for the texture of the materials. In modern implementations of the Taylor theory, this starting point is slightly modified by requiring that the velocity gradient tensor lij describing the plastic deformation of every given grain must be equal to the macroscopic plastic velocity gradient tensor Lij

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which the stress and strain distributions inside the grains are assumed to be homogenous, which does not correspond to reality. In the last 15 years, other models have emerged which try to do better. The highest accuracy can probably be achieved by the crystal plasticity finite element method (CPFEM), however at considerable computation cost15. The very new Crystal-Plasticity Fast Fourier (CP-FFT) model can possibly replace the CPFEM models for many applications at a considerably smaller computational effort16. Finally there are models that try to do better than the Taylor model by implementing certain types of interaction between individual grains and the average behavior of the RVE (so-called self consistent models, see Lebensohn17 for a comparison of these methods with the CP-FFT method), or between grains and their direct neighbors (GIA model, Engler) or ALAMEL model11). The latter models do not look at individual grains such as the Taylor model but rather at clusters of grains (eight for GIA and two for ALAMEL). They do not assume that the strain rates of the grains inside the clusters are the same. However, they require that the average strain rate of the cluster is equal to the average strain rate of the RVE of the polycrystal, while at the same time assuring stress equilibrium at the internal grain boundaries inside the cluster.

Eq. (8) _ M is the volume average of the Taylor factors M within the RVE. After an elapsed time Δt = t-t0, the total von Mises strain would be Eq. (9) and the total slip would be

Eq. (10) The evolution of Γ with the macroscopic stain εvM is in principle different in each grain; as a result, τc, which is a function of Γ, will also be different in each grain. Models as those described above can take that into account. However, for the present discussion, we will simplify _ matters by working with _ τc (Γ), the critical resolved shear stress calculated for Γ, the average of the total slip Γ over all grains of the within the RVE representing then polycrystal. . The average of W is then given by:

Modeling polycrystalline wire flow stress Average Taylor factor of a polycrystal.As explained earlier, every crystal in a polycrystal has its own Taylor factor M (Eq. (3)). These can be readily obtained after the completion of a simulation of the plastic deformation of a polycrystal. Per the Taylor theory, the von Mises equivalent strain rate dvm is the same for every crystal. Hence: Eq. (5) in which Dij is the macroscopic strain rate tensor of the RVE of the polycrystalline material. The average plastic work per unit time and volume . of this RVE is found by taking the volume average of W over all . the crystals of the RVE. Note that according to Eq. (3), W is equal to (Mτcdvm). Now, at least when a Taylor model is used, dvm = Dvm for all grains, but M is not. The critical resolved shear stress τc is usually believed to be a function of the total slip Γ that took place in the grain. The rate of Γ . is the sum of the absolute values of the slip rates γ s (see [2,8] for the exact definition of ‘slip rate’):

Eq. (6) It can be shown that2: Eq. (7) It depends on the crystal orientations. Averaging this equation over the RVE would lead to:

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Eq. (11) In a simple flow stress model like this, the average Taylor _ factor, M,, characterizes the contribution of the crystallographic texture to the plastic anisotropy of the material. Note that the following well-known equation , _ in which σvm is the macroscopic von Mises equivalent stress, cannot be used here since it is only valid for an isotropic material with a von Mises flow criterion, whereas our material here has texture-induced anisotropy. However, still valid is: Eq. (12a) _ in which σij is the macroscopic stress (average stress of the RVE of the polycrystal). For a tensile test in the direction x3, this reduces to: Eq. (12b) since for that case, the shear stresses and the transverse stresses are zero; in addition, D33 = Dvm . Using Eq. (11), the following result is then obtained for a tensile test: Eq. (13) _ In practice, the function τc (Γ) is obtained by fitting the model results to experimental measurements, for example in a torsion test. Once this has been done, the model can be

swept by a dislocation moving on a slip plane in the ferrite phase may vary widely depending on the angle that the slip plane makes with the cementite lamellae (assuming that the dislocations cannot penetrate these). It has been pro-

Fig. 6. TEM image of a cross section of a drawn pearlitic wire. True strain: 2.2. Figure width is 4 μm. First published by Dr. G. Langford6 in Metallurgical Transactions A. Reprinted courtesy of Springer Science+Business Media B.V.

posed by Sevillano21 that the critical resolved shear stress on such slip plane depends on this swept area, leading to the following formula21: Eq. (14) τ0 is a friction stress taken to be equal to 60 MPa. A = 1.21 is a constant for a line dislocation. G = 6.4 x 104 MPa is the shear modulus of ferrite and b = 0.248 nm is its Burgers vector, vf was the volume fraction of ferrite, and, finally, S = d/sinϕ, where d is the width of the ferrite lamella and ϕ is the angle between the vectors normal to the cementite lamellae and the slip plane. It can then be expected that, as the angles ϕ will depend on the inclination of the slip planes with respect to the cementite lamellae, τc will be different for every slip system. This anisotropic effect will . certainly have an influence of the values of the slip rates γs (which can be found as explained in section 3.2). It is also expected to have an effect on the deformation texture. The pearlite model21-22 is a variant of the Taylor model (see prior sections) which uses Eq. (14) to predict the texture in the ferrite phase of pearlite. In order to know the angle ϕ, it must also keep track of the orientation of the pearlite lamellae. At the start of a simulation, a random choice is made of the orientations or the cementite lamellae present in every ferrite grainb, hereby assuming that there are no preferred cementite lamella orientations in the initial material. The initial crystal orientation of the ferrite phase in such ‘grain’ is also taken ‘at random’ from the orientation distribution describing the initial texture of the ferrite phase. As the simulation goes on and the strain increases, crystal orientations are updated as explained in sections 3.2 and 4.3. But the orientations of the cementite lamellae are updated as well, using an affine transformation as illustrated by Fig. 7; see also Eq. 1822. Note that Eq. (14) takes the interlamellar spacing d into account as S depends on it. In the pearlite model, d is calculated for each grain separately as a function of the total

Fig. 7. Affine transformation: lines drawn on the surface of a piece of material which is elongated will then rotate and tend to become parallel with the axis of elongation. b

The term “grain” is used here to indicate a region in a pearlite colony in which the cemintite lamellae are almost parallel to each other.

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applied to cases with the same basic material but a different deformation process. A more advanced treatise of work hardening has been given19. Implementation of work hardening in Taylor models for single phase material. The flow stress _ found in a tensile test would by definition be equal to σ33. Eq. (13) separates the effect of crystallographic texture from the intrinsic work hardening, believed to be mainly the effect of dislocation interaction, and incorporated in τc. The specialized literature on work hardening (see Sevillano19) does indeed discuss the issue entirely in terms of Γ (Eq. 10) and τc. By doing so, texture effects are in fact taken into account. It is not possible to reproduce this discussion here in detail. For single-phase materials, it could be recommended to use a Voce equation for Stage III (which in polycrystalline materials is the first stage of plastic flow), followed by another Voce law (with different parameters) for the subsequent Stage IV. See Fig. 2-1 and Eqs. 2-7. Sevillano19. Note that the parameters should be obtained by fitting model predictions of the flow stress to experimental data. Modelling the anisotropy of the critical resolved shear stresses in the ferrite phase of pearlite. The author has long been interested in the behavior of pearlite, not in the least because of his intense collaboration with J. Gil Sevillano. The pearlite model, a special version of the Taylor model intended to be used for pearlite, will be discussed below. Fig. 6 shows a micrograph of the transverse section in the central region of a pearlitic wire which has been cold drawn up to a total elongation of 800 % (true strain 2.2). A rough inspection of the figure tells us that the average thickness of a ferrite lamella contained between two cementite lamellae is of the order of 5 nm, but its length may be several μm. So the aspect ratio of such ferrite lamella may be 50 or more. It is then clear that the area

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deformation, using the affine transformation (Fig. 7) applied to a pair of cementite lamella of the initial material in the considered grain. The pearlite model has been developed to capture anisotropic effects taking place in the ferrite phase of a pearlitic material. Mainly due to lack of knowledge of the defomation mechanisms of the cementite phase, it does not calculate the contribution of the cementite phase to the flow stress of the material. Hence the pearlite model in its current state should not be used to predict the strength of a wire. The literature19-22 has more discussion on this.

Results for wire drawing: some highlights The curling effect during wire drawing of b.c.c. metals. Fig. 6 shows a TEM image taken from a cross section of a drawn pearlitic wire. The total true strain was 2.2. Let us term ‘grain’ a region in which the cementite lamellae are more or less parallel (but with curvature, as can be seen in the image) and in which the ferrite phase has the same orientation; however, also with an orientation gradient, as could be observed by local diffraction. It is indeed seen that the grains are curved around each other, as if after extensive wire drawing they had developed the shape of elongated ribbons instead of that of cigars. As ribbons are not cigars, they have to curl around each other to, taken together, achieve axisymmetric deformation. This peculiar deformation pattern is called curling. It has not only been observed in heavily drawn pearlitic wire, but also in iron, tungsten and niobium (columbium)23. Already in 1964, Hosford24 explained the curling phenomenon. He had observed that a <011> fiber texture develops in wires made of bcc material during wiredrawing, as shown in Fig. 5a. So he discussed the plastic anisotropy of bcc crystal on which a tensile test is done in the direction [011]. In his calculation, he decided to consider only the {112}<111> slip systems, which is probably acceptable in this case. However, it is clear that a simple model cannot give an exact prediction of a complex phenomenon like curling. Today, one would use a crystal plasticity finite element model for such task, and that is exactly what has been done by Sevillano25 and Ocenásek26. The curling microstructure has been nicely predicted by these authors, as can be seen for example in Fig. 2 in Ref. 25. Another interesting finding by Sevillano25 was that the average transverse microstress acting on (100) planes is tensile and about one third of the nominal tensile stress of the material; however, the spread on this transverse stress was also looked at. In a non negligible fraction of the grains the transverse stress on (100) planes appeared to be actually larger than the nominal tensile stress. This led the authors to the conclusion that there is good reason for concern about the risk on the development of longitudinal internal cracks during wire drawing of bcc materials. Such cracks have indeed often been observed in drawn tungsten wires. Modeling of the textures in the center of drawn bcc wires. The half angles used in the industry for wire drawing are usually small enough that the region affected by the hetero-

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geneous flow pattern (the outer region as shown in Fig. 3b) does not extend itself all the way to the center of the wire. So there normally is a fair region in the center of the wire (Fig. 3b) in which the macroscopic strain rate has always been reasonably close to axisymmetric elongation during the wire drawing process. As mentioned above, the deformation texture which develops there would be a “<011> fiber texture.” The term “macroscopic” here means: average taken over a representative volume element (RVE) of the macroscopic length scale, consisting of a few hundred or a few thousands of grains. As discussed in the previous section, it is likely that, at a smaller length scale, the strain rates of individual grains would feature deviations from perfect axisymmetric deformation, leading to the curling effect. Chin27 and Rosenberg and Piehler28 were the first to explain this <011> fiber texture by means of the Taylor theory explained earlier. Fig. 8a shows a {110} pole figure derived from a very recent simulation. A discrete set consisting of 2000 grains was used as initial texture. 80 strain increments of 2.48 % axisysmmetric elongation strain have been simulated, amounting to a total true strain of 1.96. This corresponds to the total true strain of the wire of which a neutron diffraction {110} pole figure of the ferrite phase is shown by Fig. 5a. A special smoothing technique which makes use of Gaussian distributions was used to convert the discrete texture into a continuous intensity distribution. A detailed study (details not given here) of the evolution of the grain orientations in this simulation shows that they rotate towards a final orientation which is several degrees away from the ideal <110> orientation. This cannot be seen in Fig. 8a because of the smoothing and because of the multiplicity due the fiber-nature of this texture. Note furthermore that the fiber-texture nature has not been artificially forced upon this texture. It is solely due to the axisymmetry of the imposed velocity gradient tensor. Fig. 8b shows the result obtained by the ALAMEL model, also for a true strain of 1.96. This is an advanced Taylor-like model of the grain interaction type (see section 4.5). It operates on a cluster of two grains, hereby respecting the stress equilibrium at the internal cluster of the grain. It is known to produce excellent deformation texture predictions for rolling of fcc and bcc metals, even from a quantitative point of view. It is supposed to be applicable to all types of deformation models. So it has been tested here for the first time on the case of axisymmetric deformation of a bcc metal without any special adaption to curling. The same initial texture was used as in the case of the Taylor simulation (Fig. 8a). Fig. 8b is a preliminary result - a thorough examination of the trajectories of the grain orientations has not yet been made. However, of the two texture predictions, this is the one which has the best quantitative agreement with the experimental pole figure given by Fig. 5a - the agreement is actually amazingly good. The calculation time required for this simulation was only 20 % of the one needed for the Taylor simulation. Modeling of the textures at the surface of drawn bcc wires. The flow pattern in the wire drawing passes have to

Eq. (15)

In the Taylor simulation, n deformation increments will be devoted to the passage through AA’. The time increment should be chosen such that y’/(nΔt) does not exceed a few percent. The shears y’ are given by:

Eq. (16)

α is the half-die angle (Fig. 9). The angles β1 and β2 (Fig. 9) have been chosen as follows:

Eq. (17) It is furthermore assumed that between AA’ and BB’, an axisymmetric strain in the direction x’1 should be modeled by a series of increments, namely the same strain that corresponds to the diameter reduction of the die, i.e.. 2ln(rA/rB). Fig. 5b shows a cyclic texture which has been simulated in this way. The true strain in elongation was 15.25 % in each of 26 drawing passes, with an half-die angle of 8°5. It is clear that the modeling approach described here is rather approximate, although there is qualitative agreement with available experimental data obtained by means of Xray diffraction and data correction procedures (Montesin and Heizmann29). However, such experimental textures are also very difficult to obtain, and may also be rather qualitative than quantitative. Today, it would be possible to use a so-called hierarchical multi-scale (HMS) model to predict cyclic textures in a much more precise way30. Each wire drawing pass would be modeled by means of a continuum-type elasto-plastic finite element (FE) model which uses an anisotropic constitutive law for the plastic deformation of the material. The parameters of this law would be different for every integration point, as they are identified by means of virtual mechanical tests carried out by the ALAMEL model.

Fig. 8. {110} pole figures showing bcc wire drawing textures predicted by Taylor-type models. True strain = 1.96. Initial texture: without preferred orientations. Wire axis = vertical. (a) FC Taylor model. Maximum intensity ≈ 10 at the wire drawing direction. (b) ALAMEL-model. Maximum intensity ≈ 7.

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be taken into account in order to understand the development of the cyclic textures in the outer region of the cross section of the wire (Fig. 3b). Fig. 9 gives a schematic view of such flow pattern. The plastic zone is between the lines AA’ and BB’. These are “velocity discontinuity lines.” A particle coming from the left along a flow line would upon entering the plastic zone first be abruptly sheared off along AA’, taking at the same time a turn to the right, then travel to BB’ while undergoing axisymmetric deformation, and finally upon leaving the plastic zone at BB’ be abruptly sheared off, taking at the same time a turn to the left. Note that this very much simplified model neglects elastic effects. The advantage of the model is that it can easily be introduced in a Taylor model (or into another model for the plastic deformation of polycrystalline material), if at least the description of the deformation increments is done in a reference frame defined as follows: x’1 is parallel to the flow line at the beginning of the considered strain increment, x’2 is circumferential (normal to the plane in which Fig. 9 is drawn), and x’3 is normal to x’1 and x’2. The velocity gradient tensors describing the passage through the lines AA’ or BB’ are now given by5:

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This model is applied to the crystallographic texture associated to the integration point. Each of these textures is described by a discrete set of 5000 crystal orientations. The evolution of these textures with strain (in principle different in every integration point) is also modeled by the ALAMEL model, which receives the velocity gradient tensor describing the strain increment at the integration point considered from the finite element shell. This model has been successfully validated for cup drawing operations on steel sheet and aluminum sheet30. These calculations did not require years (as they would without optimization) but merely a day, thanks to three levels of optimization30. This model could also be used to predict the cyclic textures at the surface of drawn wires, and would probably be the best method to obtain quantitatively reliable textures. One of the reasons why the cyclic texture at the surfaces of drawn wires are of interest in the wire drawing industry is their effect on delamination during bunching of thin filaments of heavily drawn pearlitic wire. A study31 has been conducted on this problem by researchers from the company Bekaert (Belgium), the Department MTM of the KULeuven (Belgium) and the Centro de Estudios e Investigaciones Technicas de Guipuzcoa (CEIT) of San Sebastian (Spain). One of the results was that during torsion testing of such wire, shear bands extending along a radial/longitudinal plane may be initiated in a wire. See Fig. 10. They can accumulate an important shear localization, sometimes leading to fracture. This ductile fracture process, which has also been observed in other bcc metals, seems to be promoted by the presence of cyclic texture component at the surface of the wire. A possible mechanism to explain this type of shear banding has also been proposed32.

Conclusions As most metallic components, drawn wires feature a “texture,” i.e. all orientations do not have the same probability to occur; they are characterized by strong preferred orientations. In cold drawn wires of bcc metals (including the ferrite phase of pearlitic wires), most grains have an orientation with a <110> crystal direction close to the wire drawing axis. The deformation history of a particular grain has however a strong effect on this. In the core of the wires, deformation has been almost perfectly axisymmetric, leading to so-called fiber textures. However, close to the surface, the interaction with the wire drawing dies causes deviations from a pure axisymmetric deformation history, leading to textures which do not have the perfect rotational symmetry of fiber textures, but rather a so-called ‘cyclic’ texture symmetry. Crystal plasticity theory has made it possible to develop models for the plastic deformation of polycrystalline materials which can predict both microstresses and deformation textures during wire drawing. The classical FC Taylor theory assumes that all grains have the same plastic deformation. This assumption is certainly not true, as it conflicts with the condition for stress equilibrium at grain boundaries. Modern models such as ALAMEL (fast, more simplifying assumptions) or CPFEM (slow, less simplifying assumptions) try to find better solutions and do that with reasonable success. The curling effect observed in the microstructures of cold drawn wires of bcc metals (cross sections, central region)

Fig. 9. Schematic view of the flow pattern of the metal when being drawn through a die. Simplified model, with an abrupt turn to the right at the line AA’, and again to the left at the line BB’. When a material particle flows through such a velocity discontinuity line, it is instantly sheared off in a direction parallel with the line. 66 | WIRE JOURNAL INTERNATIONAL

Fig. 10. SEM image of the surface of a pearlitic wire, first heavily drawn, then submitted to a torsion test. Two generations of longitudinal shear bands, formed during the torsion test, are seen. The first generation became helix-shaped as torsion went on. These bands then were intersected by bands of the second generation.

Acknowledgements The author wishes to thank the company Bekaert for its financial support of part of this work. In addition, he is grateful for the many fruitful discussions with E. Aernoudt, U. D’Haene, J. Gil Sevillano, I. Lefever, A. Martin Meisozo, K. Van Acker, W. Van Raemdonck and P. Watté.

References 1. H.J. Bunge, Texture analysis in material science, Butterworths, London, 1982. 2. U.F. Kocks, C.N. Tomé and H.R. Wenk, Texture and Anisotropy: Preferred Orientations and their Effect on Materials Properties, Cambridge University Press, 1998, ISBN 0 521 46516 8. 3. O. Engler and V. Randle, Introduction to Texture Analysis: Macrotexture, Microtexture and Orientation Mapping, Second Edition, London: CRC Press, 2009, ISBN-10: 1420063650. 4. K. Van Acker, Internal stress States in cold worked Metals and in Metal Matrix composites, Ph. D. Thesis, Department MTM, Faculty of Engineering Sciences, KULeuven, 1996, ISBN 90-5682-042-7. 5. P. Van Houtte, P. Watte, E. Aernoudt, J.G. Sevillano, I. Lefever and W. Van Raemdonck, “Taylor simulation of cyclic textures at the surface of drawn wires using a simple flow field model,” Materials Science Forum, 157-162, 1994, 1881-1886. 6. G. Langford, Deformation of Pearlite. Metallurgical transactions A, 8A, 1977, pp. 861-875. 7. J.G. Sevillano, “A twist on heavily drawn wire,” Wire Journal International, February 2011, pp. 58-70. 8. G. Gottstein, Physical Foundations of Materials Science, Springer-Verlag, Berlin, Heidelberg, New York,

2004, ISBN 3-540-40139-3. 9. J.F.W. Bishop and R. Hill, “A theory of the plastic distortion of a polycrystalline aggregate under combined stresses,” Phil. Mag., 1951, 414. 10. J.F.W. Bishop and R. Hill, “A theoretical derivation of the plastic properties of a polycrystalline face-centred metal,” Phil. Mag. 42, 1951, 1298. 11. P. Van Houtte, S. Li, M. Seefeldt and L. Delannay, “Deformation texture prediction: from the Taylor model to the advanced Lamel model,” Int. J. Plasticity, 21, 2005, pp. 589-624. 12. G. Sachs, Zur Ableitung einer Fließbedingung. Z. Ver. Dtsch. Ing, 72, 1928, pp. 734-736. 13. G.I. Taylor, “Plastic strain in metals,” J. Inst. Metals, 62, 1938, pp. 307-324. 14. U.F. Kocks, “The relation between polycrystal deformation and single crystal deformation,” Metall. Trans, 1, 1970, pp. 1121-1143. 15. F. Roters, P. Eisenlohr, L. Hantcherli, D.D. Tjahjanto, T.R. Bieler and D. Raabe, “Overview of constitutive laws, kinematics, homogenization and multiscale methods in crystal plasticity finite-element modeling:Theory, experiments, applications,” Acta Mater., 58, 2010, pp. 11521211. 16. R.A. Lebensohn, A. Rollet and P. Suquet. JOM, March 2011, pp. 13-18. 17. R.A. Lebensohn, Y. Liu and P. Ponte Castañeda, “On the accuracy of the self-consistent approximation for polycrystals: comparison with full-field numerical simulations,” Acta Mater., 52, 2004, 5347-5361. 18. O. Engler, M. Crumbach and S. Li. Acta Mater, 53, 2005, pp. 2241-2257. 19. J. Gil Sevillano, Plastic Deformation and Fracture of Materials, ed. H. Mughrabi, Vol. 6 of Materials Science and Technology: A Comprehensive Treatment, eds. R.W. Cahn, P. Haasen and E.J. Kramer, Weinheim, Germany, New York, USA: VCH, 1993, pp. 19-88, ISBN 3-52726819-7 or 0-89573-694-2. 20. J. Gil Sevillano. J. Physique III, 1, 1991, p. 967. 21. P. Watte, P. Van Houtte, E. Aernoudt, J.G. Sevillano and W. Van Raemdonck, “The work hardening of pearlite during wire drawing,” Mater Sci Forum, 157-162, 1994, 1689. 22. X. Hu, P. Van Houtte, M. Liebeherr, A. Walentek, M. Seefeldt and H. Vandekinderen, “Modeling work hardening of pearlitic steels by phenomenological and Taylor type micromechanical models,” Acta Materialia, 54, 2006, pp. 1029-1040. 23. J.F. Peck and D.A. Tomas, “A study of fibrous tungsten and iron,” Trans. Met. Soc. AIME, 221, 1961, 1240. 24. W. Hosford, “Microstructural changes during deformation of [011] Fiber-Textured Metals,” Trans. Met. Soc. AIME, 230, 1964, pp. 12-15. 25. J.G. Sevillano, D. González and J.M. MartinezEsnaola, “Heterogeneous deformation and internal stresses developed in BCC wires by axisymmetric elongation,” Materials Science Forum, 550, 2007, pp. 75-84.

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is a striking deviation from the Taylor hypothesis of homogenous strain. However, it has turned out to be possible to predict the curling effect by means of a CPFE model. So far, only the FC Taylor model has been used to predict cyclic textures at the surface of drawn wires. For this, the flow pattern close to the surface has been modeled in a simple way. The results are qualitatively in good agreement with observed cyclic textures. Some of the findings reported in the paper may be important from an industrial point of view. Several studies of lateral micro-stresses developing in the central region of bcc material during drawing have demonstrated that some of these micro-stresses might become tensile and, in fact, just as high or higher than the stress in wire drawing direction. This might explain the observation of the occasional occurrence of longitudinal brittle cracks in the central region of certain materials (for example tungsten) during wire drawing. On the other hand, texture effects may be sometimes be related as well with ductile fracture, as it is believed that the occurrence of cyclic texture components may promote the so-called delamination effect during torsion-type deformation of highly drawn steel wire31-32.

TECHNICAL PAPERS

26. J. Ocenásek, M. Rodriguez Ripoll, S.M. Weygand and H. Riedel, Computational Materials Science, 39, 2007, pp. 23-28. 27. G.Y. Chin, W.L. Mammel and M.T. Dolan, “Taylor’s Theory of Texture for Axisymmetric Flow in BodyCentered Cubic Metals,” Trans. TMS-AIME, 239, 1967, 1854. 28. J.M. Rosenberg and H.R. Piehler, Calculation of the Taylor factor and lattice rotations for bcc metals deforming by pencil glide. Metallurgical and Materials Transactions B, 1971, pp. 257-259. 29. T. Montesin and J.J. Heizmann, “Evolution of crystallographic texture in thin wires,” J. Appl. Cryst., 25, 1992, pp. 665-673. 30. P. Van Houtte, J. Gawad, P. Eyckens, B. Van Bael, G. Samaey and D. Roose, “A full-field strategy to take texture

Paul Van Houtte, a full professor since 1995 at Katholieke Universiteit in Leuven, Belgium, was the winner of WAI’s Mordica Memorial Award for 2012. He joined Katholieke Universiteit in 1972 as a junior scientist. His published work has been so extensive over the years that it may be unparalleled in the wire and cable industry. He has been cited as a contributor to more than 400 publications, including as either the author or co-author of more than 190 papers in reviewed journals, and more than 180 in international conference proceedings as well as nine books. He developed ODF software that is now used by many companies and universities for analysis of drawing processes and deep drawing of metals and alloys. In cooperation with colleagues from Bekaert, K.U. Leuven and CEIT in Spain, Van Houtte elaborated the process parameters for avoiding a delamination of high-carbon steel wire. He contributed to the method of residual stresses measurement in textured materials with application of X-ray and neutron diffraction. This method has been recently extended to thin coatings and thin wires. He has won numerous awards, including an Honorary Doctoral Degree awarded from the University of Metz, France in 1998 and the “De Leeuw-Damry-Bourlat Prize” awarded by the Flemish National Science

68 | WIRE JOURNAL INTERNATIONAL

induced anisotropy into account during FE simulations of metal forming processes,” JOM: the Journal of the Minerals, Metals and Materials Society, Nov. 2011, pp. 37-43. 31. I. Lefever, U. D’Haene, W. Van Raemdonck, E. Aernoudt, P. Van Houtte and J. Gil Sevillano, “Modeling of the delamination of high strength steel wire,” Wire Journal International, November 1998, pp. 90-95. 32. P. Van Houtte, P. Watté, E. Aernoudt, J. Gil Sevillano, A. Martin Meisozo, W. Van Raemdonck and I. Lefever, “Model for longitudinal shear bands during torsion tests on cold drawn steel wires,” Modelling of Plastic Deformation and Its Engineering Applications (Proc. 13th Risø International Symposium on Material Science), S.I. Andersen et al., Eds., Risø National Laboratory, Roskilde, Denmark, 1992, pp. 485-490.

Prof. Paul Van Houtte, r, accepts the Mordica Memorial Award from WAI President Nick Nickoletopolous at Wire Expo 2012. Foundation in 2000. He also is a Fellow of the Institute of Physics in London and vice-governor of the Class of Natural Sciences of the Royal Academy of Sciences and Arts of Belgium (KVAB). His Mordica Award Lecture was presented during Wire Expo 2012, May 2012, Dallas, Texas, USA.

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PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS Touch and Form series offers multiple advantages for processing wire France’s NUMALLIANCE reports that the company’s new Touch and Form Series of wire bending equipment presents many advantages that enables them to produce better while using less energy. A press release said that using a modular system for the series allows the models to reduce the footprint of the equipment. “NUMALLIANCE’s core principle is based on the idea that it is better to rotate around the wire, and not spend a high amount of energy twisting the wire and all the straightening and feeding systems that go with it.” The result is greater consistency and repeatability for the produced part and reduced scrap and waste as well as setup time, it said. NUMALLIANCE, the release said, has focused on designing equipment to be geared for the right size material so it can provide an adequate amount of power where it needs to be. That results in optimum energy use, with some demanding equipment requiring one third the power of some competitors, it said. The company has engineered its own gearboxes for decades, improving speed with lighter-weight arms and accuracy with direct coupling, it noted, adding that the systems employ less hydraulics, which are intrinsically inefficient. The above elements, it said, result in the series being environmentally friendly. Contact: NUMALLIANCE, www.numalliance.com, and in the U.S., info@numamerica.com.

Stainless steel wire lubricant offers superior wear resistance At wire India 2012, U.K.-based Metalube, Ltd., launched a new stainless steel wire lubricant, Inoxol™ 5108, which it describes as an “innovative semi-synthetic stainless steel wire lubricant that reduces wear by more than 20% compared to its nearest competitor.” A press release said that the new lubricant is specifically designed for the wet drawing of stainless steel wire. “Inoxol 5108 contains the very latest synthetic additives, improving film strength and providing outstanding extreme-pressure and anti-wear properties,” it said. “Our test results for this product are exceptional,” said Metalube Technical Director Chris Nettleship. “We are

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witnessing excellent drawing performance that will considerably extend the life of dies, and as the cost of dies is noticeably higher than that of a lubricant, the results speak for themselves. Inoxol 5108 will radically reduce customer overheads.” Inoxol 5108, the release said, contains special additives to minimize thermal and oxidative degradation of the oil, extending the service life of the oil, reducing both the quantity of oil consumed as well as the cost of waste oil disposal. The improved lubricity benefits provided by these additives also produce an exceptionally bright surface finish, it noted, adding that laboratory wear tests have shown that INOXOL 5108 reduces wear by more than 20% compared to its nearest rival. Contact: Metalube Ltd., post@metalube.co.uk, www.metalube.co.uk.

Cables described as ideal for lab and environmental testing conditions U.S.-based API Technologies Corp. reports that the company’s new high-performance 40 GHz test cables, which feature low insertion loss, are available with armorized and weatherized protective coverings, making them ideal for rugged lab, production, and environmental testing conditions. “Operating with a frequency range from DC to 40 GHz, these precision cables provide low insertion loss with exceptional phase and amplitude stability,” said Larry Howanitz, vice president of the EIS & Sensors divisions of API Technologies, in a press release. “They are crush resistant and feature flexible stainless steel armor, a corrosion resistant shield, braided PET jacket and over-molded strain relief.” The release said that the cables are available in standard and custom lengths and as an individual assembly, pair, or phase matched set. A variety of connector options, including passivated stainless steel connectors, are also available, it said, noting that the company’s Electromagnetic Integrated Solutions (EIS) line of products includes filters and interconnects, advanced ceramics, specialty connectors and harnessing, power filters and film modules. Contact: API Technologies Corp., tel. 321-426-9058, sales@apitech.com, www.apitech.com.

U.S.-based Comtran Cable LLC has developed the Hub-LINK family of telecommunication and data transmission cables for use in applications such as fixed guideway and passenger railway tunnels and stations. A press release said that the UL Listed CM-LS products are manufactured from low-smoke, halogen-free materials, are highly flame retardant, have low toxicity and meet the requirements of NFPA-130 for use in stations and

optical fiber networks, it noted, adding that it provides fast, simple plug and play FTTA installation giving the flexibility for modern mobile network demand. Telecom Solutions Vice President Gert Hoefman said that xsMobile offers a full fiber optic solution for FTTA, from a flexible, easily upgradeable backhaul network through to “last mile” fiber to the Remote Radio Head (RRH) in the antenna tower. He noted that xsMobile “provides solutions for three antenna tower configurations: standalone, rooftop and distributed antenna systems (DAS) to deploy FEMTO cells.” Contact: Prysmian Group, www.prysmiangroup.com.

Flux-cored wire meets requirements for very demanding applications trainways as well as for cable trays, per IEEE 1202/FT4LS. The products also meet the performance standards for IEEE 383, UL 1685 and UL 444, it said. In a fire, materials used in these 90°C rated Hub-LINK cable products aid in the safe egress of occupants via: their low-smoke formulation, so in a fire people can see their way out; their low toxicity, so people are not overcome by toxic fumes; their halogen-free composition, which in a fire reduces the likelihood of people being overcome by toxic fumes; their halogen-free design, so in a fire there are no acid gas emissions that can damage equipment/buildings; and their flame retardancy, which helps prevent a fire or limits the damage if one starts, it said. Comtran’s transit cables are available as Cat. 5e (100Mhz), Cat. 6 (250 Mhz), four-pair data transmission cables, and various telecom cable constructions, the release said. The cable insulation, it noted, is a proprietary low smoke zero halogen (LSZH) polyolefin that is color-coded/band-marked to industry standards with an LSZH jacket. (Hub-LINK is a pending trademark) Contact: Comtran Cable LLC, tel. 508-399-7004, www.comtrancorp.com.

Fiber solution offered for FTTA Italy’s Prysmian Group has introduced a Fiber-to-theAntenna (FTTA) solution, xsMobile, that it said addresses the fast-growing mobile sector market. A press release said that xsMobile was introduced at the CommunicAsia 2012 exhibition in Singapore in June as the launching pad for the company’s latest addition to its telecoms cable system portfolio. The xsMobile, it said, “represents the solution needed for a full optical fiber antenna network to deliver 4G-LTE and LTE-Advanced services.” The xsMobile features bend insensitive BendBrightXS optical fiber (ITU-T standard G.652.A2/B2) complemented by a suite of optical cable products (pre-terminated or field-spliced) and a full connectivity portfolio, the release said. The new product range utilizes the deployment experience of FTTH and is fully compatible with existing

U.S.-based Lincoln Electric recently introduced UltraCore® SR-12, a new product it said that is capable of meeting stringent requirements in as-welded and stress-relieved conditions. A press release said that UltraCore, which has a 75% to 80% argon/balance CO2 gas-shielded, flux-cored (FCAW-G) wire, is an excellent choice for pressure vessel fabrication and many other applications requiring post-weld heat treatment (PWHT) of mild steel. The wire, it said, has robust mechanical properties, and exceeds AWS E71T-12M-JH8 strength and low-temperature impact toughness requirements in as-welded and stress-relieved conditions with impacts of 110 - 200 J (80-150 ft•lbf) @ -40°C (-40°F). It added that the product is also operator friendly as the welding wire offers premium arc performance and bead shape, making it easy to use for welders of all skill levels. The wire conforms to AWS A5.20/A5.20M: E71T-1MJH8, E71T-9M-JH8, and E71T-12M-JH8 classifications, the release said. It is available in 15 lb and 33 lb packages in the standard .045 in (1.1 mm) diameter. Contact: Lincoln Electric, www.lincolnelectric.com.

Heating cable line is self-regulating, easy to end and won’t overheat U.S.-based Heat Trace Products LLC has introduced a line of self-regulating heating cables that can be cut to length and terminated in the field, and will not overheat or burn out when overlapped. A press release said that the Heat Trace 2700 series of self-regulating heating cables, which provide freeze protection and process temperature maintenance for fluid transport and storage systems, features multi-layer construction and supply a specified amount of heat at any point along their length in direct response to local temperDECEMBER 2012 | 71

PRODUCTS & MEDIA

Cable line designed for telecom and data transmission applications

PRODUCTS & MEDIA

ature variations. The cables, it said, are capable of maintaining temperatures up to 150°F, with intermittent exposure to 185°F, adding that they are offered in output wattages of 3-, 5-, 8-, and 10-w/ft at 50°F. The cables, the release said, accept 110-227 VAC supply, and are FM, CSA, UL and CE approved. The cables are offered in ordinary and hazardous configurations and priced to length. Contact: Deborah DiIorio, Heat Trace Products, LLC, ddilorio@heattraceproducts.com, www.rscc-heattrace.com.

itive EASY operating software, the release said. “The combination makes programming simple enough so that even novice operators quickly feel comfortable. New quick-change mechanisms, wire feed assist and integrated lighting make set-up times fast and simple.” It noted that the CrimpCenter 36 S is compatible with Schleuniger’s innovative ToolingShuttle system for incredibly fast change-overs of the applicator and terminals. The CrimpCenter 36 S uses a standard TCP/IP protocol for easy machine networking while the optional EASY ProductionServer software helps optimize order processing and allows one to monitor and gather valuable production data from practically anywhere in the world, the release said. Service, it added, is made simple with online documentation, standard components, and an enhanced version of Schleuniger’s EASY ErrorExpert. Contact: Schleuniger North America, tel. 603- 6688117, sales@schleuniger.com, www.schleuniger.com.

Updated crimper offer multiple advantages for manufacturers

Platinum mesh anodes can be used for clad applications

Schleuniger North America reports that the CrimpCenter 36 S, which replaces the CrimpCenter 36, offers improvements and a stylish new look. A press release said that the new crimper has been upgraded to enhance precision and performance even more than before. The CrimpCenter 36 S still accommodates up to six processing stations to give incredible application flexibility, and features efficient motor programming and internal Ethernet communication coupled with a maximum feed rate of 8 m/sec that results in some of the highest production rates on the market, it said. The machine has a touch screen monitor and uses intu-

U.S.-based Anomet Products, Inc., has introduced a line of platinum mesh anodes for OEMs and endusers of electrochemical and metal finishing equipment that are clad rather than plated for optimum performance. A press release said that the clad mesh anodes incorporate a complete metallurgical bond between the platinum and niobium substrate, which is then woven to eliminate unplatinized edges. They are produced, it said, by

Sheaves - Pulleys Cable Guides ProcessSheaves.com 866-344-6774 72 | WIRE JOURNAL INTERNATIONAL

Workbench serves as a workcenter U.S.-based IAC Industries reports that its 950 Workbench, part of the company’s Pro Series Adjustable Height product line, is designed from the ground up with to goal of having the best ergonomics in a standalone workbench/workstation. A press release said that the workbench has a cantilever supporting leg design that provides two primary ergonomic advantages: by eliminating the front legs, it provides superior leg and knee clearance; and it is simple to adjust the worksurface height (30 to 42 in.) by a hand crank. to the side of the station, just under the worksurface. Sizes range from 48” long x 30” deep, to 72” long x 36” deep. This adjustable height workstation can move a total weight load

of 500 lbs. evenly distributed, which includes accessory items added to the bench. The static weight capacity is 600 lbs. Accessories include suspended drawers and cabinets, instrument shelves, MTS above-worksurface storage and utility system, and power channel options. Contact: IAC Industries, www.iacindustries.com

MEDIA Company offering unique market outlook and service for power cables U.K.-based CRU announced that it is offering a unique service to companies interested in the market outlook for power cables that combines a traditional report with access to company analysts. A press release said that the company’s report, “2012

DECEMBER 2012 | 73

PRODUCTS & MEDIA

weaving 0.020 in. platinum clad niobium wire in a 10 x 10 mesh pattern which is 10 wires per inch in both directions. The result, it noted, is mesh anodes that offer a more uniform current distribution, with lower operating current densities, and provide a longer life than plated mesh anodes. The anodes are available in virtually any size, up to 24 in. wide, in rolls, or cut to size, and framed. The standard platinum thickness is 100 microinches. Contact: Daniel F. Lambert, Anomet Products, Inc., tel. 508-842-3069, dlambert@anometproducts.com, www.anometproducts.com.

PRODUCTS & MEDIA

HV and EHV Cables Market Outlook,” provides individual and focused sections for high-voltage (HV), extrahigh voltage (EHV) and submarine power cables. The report provides extensive details that include: a market overview, production (by country/region), manufacturers and capacity, trade, consumption (by country/region), market drivers and issues and market forecasts. “Our service, the only one of its type available today, draws upon CRU’s established expertise in the global wire and cable markets to provide an in-depth examination of the global markets for HV, EHV and submarine power cables through the years ahead,” the release said. “Our independent and detailed analysis will enable you to examine how these opaque markets will evolve, what opportunities will emerge, and thereby optimally conduct your business and strategic planning.” The cost for full service, UK£12,600, enables customers to get the report (full online access for four individuals plus two hard copies of the report), as well as all statistical appendices and data online in Excel, the release said. Further, the full-service customers also can arrange a personal conference call with the editor of the study to discuss the findings of the study and market in more detail, and access CRU analysts in the future for further discussion when required, it said. Contact: CRU Wire and Cable, wireandcable@crugroup.com, www.crugroup.com.

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Company’s website features an expanded custom cable section U.S.-based Allied Wire & Cable has expanded the custom cable section of its website, which now. features custom cable articles, engineering resources, video, FAQs, design tools, case studies, and more. A press release said the company focuses on custom cable, which has now been developed it into a major component of the website. The Custom Cable Center, a onestop-shop for custom cable needs, includes an information center, design center and gallery, “each of which provides unique value to customers interested in custom cable manufacturing and design, whether they are brand new to ordering custom, or a seasoned veteran.” The information center allows customers to view custom cable articles, engineering resources with detailed information on cable components, materials, and construction concepts, FAQs, and see a video that serves as a great starting point for anyone new to custom cable; the gallery allows customers to browse case studies by industry, type of cable or as a slideshow; and the design center has a step-by-step form that walks the customer through their requirements, to create a solid foundation for their design and quote discussions with one of Allied’s custom cable experts, the release said. “It’s all part of our dedication to customer service. We want to give (customers) tools and information they can really use,” said Allied co-owner Tim Flynn. Contact: Allied Wire & Cable, www.awcwire.com.

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DIES APOLLO DIA-CARB COMPANY Sells Natural/PCD diamond dies. Fair prices/excellent lead times. Contact Paulette, Owner/Sales Tel. # 1 (508) 226-1508 or 1 (508) 226-0946 E-mail: apollodie@comcast.net

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industry, these books examine materials, equipment, and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire, and other applications. The set is divided into three separate handbooks. Part 1 is Wire and Cable Production Materials; Part 2 is Wire and Cable Production Processes, and Part 3 is Types of Cables. While the updated handbook includes the latest information available, the new format allows for more frequent future updates. Parts 1 and 2

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

FOR SALE 1 - CEECO 37-Wire 30” Rigid Strander Line 2 - WARDWELL 24-C Braiders 2 - NEB 48-C #2 Harness Braiders, Long Legs, Motor 1 - NEB 12-C #2 Braider, Long Legs, Motor 2 - NEB 24-Carrier, 36-Carrier Cable Braiders, 6” Horn Gears 3 - TMW 24-Carrier Cable Braiders, 6” Horn Gears 1 - EDMANDS 18-Wire, 6+12, 16” Planetary Cabler Line 2 - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 1 - SYNCRO F13 Rod Breakdown, refurbished 1 - DAVIS STANDARD 4.5” 24:1 L/D Extruder 1 - DAVIS STANDARD 2.5” 24:1 L/D Hi-Temp Extruder 1 - DAVIS STANDARD 1.5” 24:1 L/D Extruder 1 - HALL 40” Motorized Payoff w/Dancer 1 - CLIPPER DF6 Dual Cone Flyer Payoff (24” Reels) w/Reel Jacks 1 - BARTELL 12-Bay B64 Tubular Strander 1 - ROSENDAHL 630mm Parallel Axis Dual Reel Take-up, never used 1 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-up, 1997

1 - SPHEREX 18” Dual Reel Take-up, refurbished 1 - CLIPPER Model SP16 Dual Spooler 2 - AL-BE Model MS12 Respoolers, 12” Reels 1 - REEL-O-MATIC Model RD-5 Rim Drive Takeup w/Coiling Head 1 - WEMCO 84” Take-up, Model 8284B, w/Mobility Package 1 - TEC Model DTC630 D.T. Twister 2 - ENTWISTLE 4-Wire 24” D.T. Twisters, Model 4WDT24 1 - KENRAKE Model TWD101 Twister 1 - FINE Preheater, Model IP4000-180-1, 2007 1 - EUBANKS Model 4000-04 Cut and Strip Machine 3 - CARPENTER Strippers, Model 70-B 1 - SCHLEUNIGER EC3200 EcoCut 1 - MICRODIA Crosshead, Model M9000/10XFL 1 - FORMULABS ‘Codemaster 5’ Spiral Striper, w/5’ Oven 1 - KENRAKE Wire Insulation Tester, Model WTR-656 1 - REEL-O-MATIC Model SP-HJ/K5 Take-up 1 - REEL-O-MATIC Model ILB12X Dual Respooler 1 - DYNAMEX Tape Payoff, Model TPB30-2-D

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

DECEMBER 2012 | 75

CLASSIFIEDS

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

BLIND BOX? YES____ NO ____

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

are now available. The price is $99, $59 for WAI members, plus shipping. To purchase, go to wirenet.org and click on the WAI Bookstore. STEEL WIRE TECHNOLOGY, 4TH EDITION. This 348-page indexed book by Per Enghag, published in 2009, represents a bridge between

theory and practice, providing useful information as well as new material for both veteran wire industry people as well as mechanical engineering students. The newest edition includes two new chapters: Roller Dies, and Modeling and Simulation. Other topics include: wire rod preparation and scale removal; drafting; tribology, lubricant carriers and lubricants; wiredrawing machines and other wiredrawing machinery; drawing dies and die preparation; wire cleaning; material behavior in a die; heat treatment; drawing force and power; surface coating; work hardening; and wire testing. Some chapters have been updated to present new production and testing methods. The Steel chapter, now Steel and Steel Standards, includes a review of global steel standards. The price is $110, $95 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store. THE SMALL SHOP. This book, 327 pages, was written by Gary Conner, the author of Lean Manufacturing for the Small Shop, describes six sigma and how it is used in smaller companies. Published by the Society of Manufacturing Engineers, it shows the relationship between continuous improvement, lean, and quality, and focuses on implementation for operators, managers, and owners. It explains how continuous improvement tools support each other and how they can accomplish what just one or two tools by themselves cannot. The book includes a supplementary CD-ROM.

76 | WIRE JOURNAL INTERNATIONAL

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

Price, $95, $75 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store. PROCEEDINGS OF WAI'S 81ST ANNUAL CONVENTION, INTERWIRE 2011. These proceedings of WAI's 81st Annual Conv., Interwire 2011 Georgia World Congress Center, Atlanta, Georgia, USA.. Available only on CD-ROM, this is the Conference Proceedings of technical papers presented during the event. The price is $90, $75 for WAI members. To purchase, go to wirenet.org and click on The WAI Store. PROCEEDINGS OF WAI'S INTERNATIONAL TECH. CONFERENCE, MONTERREY, MEXICO, 2010. Available only on CD-ROM, this is the Conference Proceedings of technical papers presented during WAI's International Technical Conference, Monterrey, Mexico, October 2010. The price is $90, $75 for WAI members. To purchase, go to wirenet.org and click on The WAI Store. WASHINGTON ROEBLING'S FATHER: A MEMOIR OF JOHN A. ROEBLING. This 271-page, softcover, indexed book edited by WAI Historian Donald Sayenga and published in 2009 focuses on the legacy of the legendary engineers. Even among legendary engineers, the Roebling family stands out. The brilliant and irascible patriarch John A. Roebling achieved renown as a canal engineer, bridge designer, and innovator of wire rope—

STEEL WIRE TECHNOLOGY, 4TH EDITION. This 348-page indexed book by Per Enghag, published in 2009, represents a bridge between theory and practice, providing useful information as well as new material for both veteran wire industry people as well as mechanical engineering students. The newest edition includes two new chapters: Roller Dies, and Modeling and Simulation. Other topics include: wire rod preparation and scale removal; drafting; tribology, lubricant carriers and lubricants; wiredrawing machines and other wiredrawing machinery; drawing dies and die preparation; wire cleaning; material behavior in a die; heat treatment; drawing force and power; surface coating; work hardening; and wire testing. Some chapters have been updated to present new production and testing methods. The Steel chapter, now Steel and Steel Standards, includes a review of global steel standards. The Heat Treatment chapter now includes oxygen potential data (Ellingham diagrams) as well as thermodynamic principles. Diffusion

processes have been introduced and utilized for decarburization calculations. The book is useful as a practical resource for technicians, supplementary reading for students in mechanical engineering, or as course literature within a company. Author Per Enghag has more than 30 years of experience in metals. After starting his career as director of The Swedish School of Mining and Metallurgy in the 1960s, he moved to steel wire products producer Garphyttan in the 1970s. He has operated his own company, Materialteknik HB, in Örebro, Sweden, since 1980. The price is $110, $95 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store. THE ROEBLING LEGACY. This 288-page indexed book by Clifford W. Zink presents a different perspective of the Roebling legacy. “But it’s all wire,” proclaimed a 1950s Roebling Company brochure about its product line, which included wire rope, copper magnet and electrical wire, screens and hardware cloth, aircord and aircraft strand, flat and braided wire, PC wire and strand, galvanized bridge wire, among others. To maximize quality, the Roeblings started drawing their own wire in the 1850s, rolling bars into rods in the 1870s, and making their own steel in the 1900s. Wire is the binding thread through 125 years of Roebling and American industrial history chronicled in The Roebling Legacy. The price is $75, $50 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.

ing. The book delineates the process capability study, a powerful tool that, when understood and implemented, provides benefits to every department within a manufacturing organization. With easy to read, step-by-step flow diagrams on how to perform process capability studies and measurement process analyses, the book’s coverage includes: the benefits of statistical process control over statistical product control; realworld industrial examples and case studies illustrating how to use the techniques; ways for management to determine if the investment in process capability studies is providing an appropriate return; methods to correct lack of stability and capability once either condition has been identified, such as the ANOVA technique and the simple three-factor designed experiment; and a flow chart that enables machine operators to execute a process capability study without interfering with productivity. A great deal of information is available on the technical concepts of the process capability study, much of it emphasizing the mathematics. This book shows you how to use the process capability study to increase return on investment from your statistical process control/Six Sigma effort and make your company more competitive. The list price is $45, $40 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.

SIX SIGMA AND OTHER IMPROVEMENT TOOLS FOR THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this new (published in 2011) 135-page, indexed softcover book was written by industry expert Douglas B. Relyea, founder and senior partner of Quality Principle Associates, a New England-based consulting firm that specializes in the education and application of data analysis techniques to industrial problem solv-

DECEMBER 2012 | 77

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a technology that makes possible modern suspension bridges, high-rise elevators, construction cranes, and cable cars. All four of John’s sons inherited the family business, but only the eldest—the reserved, thoughtful Washington—staked an independent claim to fame, most notably for his work on the iconic Brooklyn Bridge. Between 1893 and 1907, Washington Roebling wrote about his father’s life, character, career, and achievements with candor and intimate family details. Part biography, part memoir, Washington Roebling’s Father makes available for the first time the text of this remarkable manuscript. Donald Sayenga, an internationally recognized authority on the history of wire rope, has painstakingly transcribed the original manuscript and tracked down annotations for hundreds of people, places, events, and technologies. The price is $55, $45 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.

ADVERTISERS’ INDEX

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

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

Amacoil Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

The Dow Chemical Co . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .73

Esteves Group USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Bergandi Machinery Co . . . . . . . . . . . . . . . . . . . . . . . . . . .57

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

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

GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Cable Components Group . . . . . . . . . . . . . . . . . . .13, 15, 17

Howar Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45, 78

Chemetall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

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

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Not All Cabl Cablee Jacket Strippers Stripppers Are Created Created Equal! There’s the Huestis There’s Huesstis Industrial Cablee Jacket Stripper, Stripper, and then you hav have ve all the rest... rest We have have more more satisﬁed satisﬁed customers We customers than than anyone else else because because ours anyone ours works works tthe he bbest! est! Safe and and quick quick — it it protects Safe protects the the valuable valuable never allowing allowing it it to to core from from damage, damage, never core touch the the blade, blade, shielded shielded by by our our patented patented touch process. Huestis Huestis Industrial Industrial machines machines — process. our performance iss legendary! legendary!

For more details or o to place an order, order, call uuss aatt 8800-972-9222, call 00-972-9222, or email us at sales@huestis.com sales@huestis.com

Model CJS 1000

Model BJS 1000 1000* Strippers can be customized to meet your speciﬁc requirements. * Model BJS 1000 is bench mounted. m s All other models are free standing.

ISO9001 ISO9001 REGISTERED

www.huestisindustrial.com www .huestisindustrial.com Air Wipes, Pay-offs, Ta Take-ups, ake-ups, Buncher Buncher h Pay-offs, Accumulators, Spoolers, Pressure Welders, Jacket Machinery Cold Pr essure W elders, Cable Jac cket Strippers, Custom Mac hinery

78 | WIRE JOURNAL INTERNATIONAL

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

MEPAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Queins Machines GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

REELEX Packaging Solutions Inc . . . . . . . . . . . . . . . . . . . .5

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Parkway-Kew Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

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

PolyOne Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Power Sonics LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

August Strecker GmbH & Co KG . . . . . . . . . . . . . . . . . . .37

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .73

Talladega Machinery & Supply Co . . . . . . . . . . . . . . . . . .16

Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . . . . .19

Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Equipment Sales | Equipment Purchasing | Reconditioning Services www.wireandplastic.com | Info@wireandplastic.com

DECEMBER 2012 | 79

ADVERTISERSâ&#x20AC;&#x2122; INDEX

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

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE WAFIOS Machinery Corp . . . . . . . . . . . . . . . . . . . . .Cover 2 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .79 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .14 Wyrepak Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . .21, 51

Feb. 2013 WJI • Packaging (reels, carriers & packaging equipment) Advertising Deadline: Jan. 1, 2012

Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . . . . . . .9

WIRE ASSOCIATION INTERNATIONAL ADS IWAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Interwire 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54-56

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

80 | WIRE JOURNAL INTERNATIONAL

SALES OFFICES ASIA/WAI INDIA OFFICE Germany, Austria, & Switzerland Dagmar Melcher Media Service International Spitzwegstraße 4 82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

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

Wind up with an Amacoil/Uhing assembly for perfect pitch every time Pitch is adjustable (10:1) without requiring gear changes or adjusting motor speed. A single Amacoil/Uhing assembly may be used for winding many different diameter materials. Automatic reversal of the traverse is mechanically controlled – without clutches, cams or gears. No electronics or programming needed. FEATURES • Zero backlash. • Automatically synchronizes pitch with take-up reel rotational speed. • Traverse drives with up to 800 lbs. axial thrust. • Smooth, unthreaded shaft won't clog or jam – no bellows assembly needed. • One inexpensive, unidirectional motor drives both the traverse and take-up reel. • Free movement lever – no need to "jog" system on and off to position linear drive. • Options and accessories for every winding situation. • Light, medium and heavy-duty systems.

For Brochure or CD-ROM Call toll free 800-252-2645

email: amacoil@amacoil.com

www.amacoil.com AMACOIL, INC. PO Box 2228 • Aston, PA 19014 • Phone: 610-485-8300 • Fax: 610-485-2357