Green by Wire Journal International, Inc.

NOVEMBER 2015

WIRE JOURNAL

速

INTERNATIONAL

www.wirenet.org

n e e r G OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

WIRE JOURNAL

NOVEMBER 2015

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

Editorial . . . . . . . . . . . . . . . . . 6 Calendar . . . . . . . . . . . . . . . . . 8 Industry News. . . . . . . . . . . . 10

FEATURES

Green

Asian Focus . . . . . . . . . . . . . 18 People. . . . . . . . . . . . . . . . . . 20 Fiber Watch . . . . . . . . . . . . . 22 Fastener Update . . . . . . . . . . 24

Wrapup: IWCS . . . . . . . . . . . . . 34

WAI News . . . . . . . . . . . . . . . 26

IWCS found Atlanta to be an apt one-year location to stage its annual event.

Chapter Corner . . . . . . . . . . . 32

Wrapup: wire Southeast Asia . . 40

Technical Paper . . . . . . . 54-67

Messe Düsseldorf reports that wire Southeast Asia and its sister tube event in Bangkok drew more than 7,000 international trade visitors from 56 countries.

Products . . . . . . . . . . . . . . . . 69 Classified . . . . . . . . . . . . . . . 77 Career Opportunities . . . . . . 77 Advertisers’ Index . . . . . . . . 79

Next issue

December 2015

• Wrapup: wire South America • Manufacturing Focus

Green . . . . . . . . . . . . . . . . . . . . 44 The feature returns to this perennial topic, with a look at two companies that have achieved admirable results, a look at a resource for “friendlier” plasticizers, a brief update on a story that ran in WJI ﬁve years ago, and more.

TECHNICAL PAPER Mordica Lecture: The development of conductive material technology for current and future needs of overhead power lines Tadeusz Knych . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Cover: Green can mean a lot of different things to people...and to companies.

NOVEMBER 2015 | 3

CONTENTS

Volume 48 | Number 11 | November 2015

INSIDE THIS ISSUE CONTENTS

Proton Products International/U.K.

At Interwire, Proton Products International showcased the company’s InteliSENS SL series speed and length gauges, which it noted are saving cable manufacturers IWCS: TECH EXCELS . 34 serious money everyFORMULA day around STILL the world. As cable manufacturers purchase raw materials by the ton and then sell by length, it’s extremely important to make sure that when you sell a reel of cable at 1000 ft, its is not 1003 ft or 1005 ft, essentially giving away 0.3% or 0.5% for free, which can be typical in many production facilities. The InteliSENS SL Series gauges are calibrated to 0.03%, and with no moving parts to wear and non-contact operation eliminating slippage, we are extremely proud to work with our customers and provide a gauge that truly helps save money and improve proﬁtability. The DGK Series of gauges have no moving parts and measure the diameter an amazing 10,000 times per second,The persetting axis. Available either dual-different, or triple-axis (Atlanta) as may havea been but gauge, Super Fast Processing Technology analyzes IWCSthe once again presented an exemplary technical upprogram. to 30,000Itsmeasurements per second display and 64th annual event includedto130 technical papers and presentations as well as industry outlook communicate diameter, ovality, lumps and neckdowns. presentations, Suppliers Exhibition, lots of of products networking The company aalso showed a full range opportunities, and a far-reaching focus that is including spark testers, capacitance gauges, disclosed lump and in adetectors, Q&A withpre IWCS CEO/Director Dave Kiddoo. neck heaters, speed & length gauges and

4 | WIRE JOURNAL INTERNATIONAL

the hugely popular combined Diameter and Flaw Detection Gage DGK SuperFast Series. ”We’d like to say a big ‘thank you’ to all who visited (us) at Interwire 2015.

WIRE SOUTHEAST ASIA = ACTIVITY . . 40

Per Messe Düsseldorf Asia, the 11th staging of wire Grant Latimer, Products. Southeast Asia at Proton the Bangkok International Trade & Exhibition Centre in Bangkok, Thailand, was a success, It was without doubt busiest exhibition and our full with it and its sister tubeour show ﬁelding 411 exhibitors team of agents and employees were on hand take care from 33 countries, including seven national grouptoexhibour Austria, customers.” Latimer, itsoffrom China,Grant Germany, Italy, managing Taiwan, thedirector, g.latimer@protonproducts.com. U.K. and the U.S.

JUNE 2015 | 73

EDITORIAL EDITORIAL

Price tags: at best a hint of things to come The teenage version of this trade editor once firmly believed that life was black and white. Right was right and wrong was wrong, and you were either in one camp or the other. Only life experience, a pesky unrelenting essence, has a way of dulling that sharp separation. And “green,” well, it may be the ultimate black-and-white misfit, as on any level it can be both so easy and so hard to judge. Take the feature in this issue, which includes one company building a solar park while another achieved the wire and cable industry’s first-ever zero landfill rate for one of its plants, accomplishments that are both laudable and win-win green. But there is another bigger green picture, this one on a higher level, that ultimately could affect U.S. manufacturing as a whole. President Obama, who set out his first term to create a legacy with ObamaCare, wants to leave his second term with another: making the U.S. a world leader in reducing carbon dioxide emissions. To that end, he has proposed even higher standards (32% cut in greenhouse gas emissions by 2030) than those earlier proposed by EPA. So, one might ask, is there a logistics point at which the costs for reducing emissions turns from helpful to the environment to crippling for industry? The American Iron and Steel Institute (AISI) thinks there is. It has joined 15 other associations in a court challenge. “This rule puts the affordability of electricity for steel producers at serious risk,” said AISI CEO Thomas Gibson, claiming that the EPA has overstepped its powers. Further, even my teenage self would have flinched at the idea of certain countries resolutely following this lead. It’s not that I would expect widespread cheating. Rather, I can see how there could be some compliance at one level and, shall we say, less compliance at another. A spotlight would be on the U.S., so it’s a given that its manufacturing would have to abide by the rules and pay higher costs. There would also be high expectations for parts of Europe and some other countries, but the likelihood that others would outwardly agree, only to smile inwardly within for this welcome new advantage, leaves a bad green taste. Recalling echoes of a past hollow pledge, “You’re going to be able to keep your family doctor and save thousands in medical insurance,” the current me was able to rediscover and confer with the long-lost black-and-white me: neither version is buying into what’s being planned for the next latest and greatest government menu.

Mark Marselli Editor-in-chief

6 | WIRE JOURNAL INTERNATIONAL

WIRE JOURNAL

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

CALENDAR

CALENDAR Dec. 3-5, 2015: Cable & Wire Fair 2015 New Delhi, India. To be held at the Pragati Maidan. Contact: Tulip 3P Media Pvt. Ltd., tel. 91-11- 45678 421/22/23, info@wirecable.in. April 4-8, 2016: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180 May 11-12, 2016: Electrical Wire Processing Technology Expo Milwaukee, Wisconsin, USA. To be held at the Wisconsin Center. Contact: Expo Productions, tel. 800-367-5520, www.electricalwireshow.com.

WIRE ASSOCIATION INTERNATIONAL EVENT June 7-9, 2016 WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. This WAI event, which will be held at the Mohegan Sun, will include its trade show, technical programs and 86th Annual Convention. www.wirenet.org

8 | WIRE JOURNAL INTERNATIONAL

June 12-14, 2016: 17th Guangzhou International Platemetal, Bar, Wire, Metal Processing & Setting Equipment Exhibition Guangzhou, China. To be held at the China Import and Export Fair Pazhou Complex, Guangzhou. Contact: Julang Exhibition Co., Ltd., tel. 86-203862 0771, expo@julang.com.cn. Sept. 26-29, 2016: wire China 2016 Shanghai, China. The 7th All China International Wire & Cable Industry Trade Fair will be held at the Shanghai New International Expo Center (SNIEC). Contact: Messe Düsseldorf North America, tel. 312781-5180, info@mdna.com, www.mdna.com. Oct. 2-5, 2016: 65th IWCS ConferenceTM Providence, Rhode Island, USA. To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, www.iwcs.org. Oct. 5-7, 2016: Spring World 2016 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center, this event is organized by CASMI (Chicago Association of Spring Manufacturers, Inc.) Contact: CASMI Ofﬁce, tel. 847-447-1087, info@casmi-springworld.org. Oct. 5-7, 2016: Wire & Cable India Mumbai, India. This event will be held at the Bombay Convention & Exhibition Center. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

INDUSTRY NEWS

INDUSTRY NEWS Bekaert officially reopens its bead wire plant in Georgia in a grand manner

Bekaert has ofﬁcially reopened its U.S. bead wire production plant in Rome, Georgia, with a grand opening that saw company executives, local and European ofﬁcials and guests on hand to celebrate the occasion. A press release said that the opening on Oct. 7 saw Bekaert CEO Matthew Taylor and members of the Bekaert Group Executive and the regional management team welcome attendees, which included Geert Bourgeois, Minister-President of the government of Flanders, who was co-leading a Flemish-Dutch economic mission to Georgia.

Bekaert CEO Mathew Taylor, l, and Geert Bourgeois, Minister-President of the government of Flanders. “Bekaert Rome is poised to return as the preferred bead wire supplier to U.S. tire makers,” Taylor told attendees. “The team clearly shows their commitment and determination in proving their capability and ambitions to serve US-based tire makers with optimal quality and service. Their ‘can-do attitude’ has been present in all phases of the reconstruction: from clean-up to repair and rebuilding, to the installation of the brand new equipment and the approval procedures during test runs.” The Bekaert bead wire plant in Rome had been temporarily shut down after a fire caused structural damage to the site on Nov. 19, 2014. Reconstruction work was finalized in June 2015, and the plant has been equipped with state-of-the-art, high-performance bead wire production lines. Extensive test runs and approval procedures have taken place and tire makers have qualified Rome’s production from the new bead wire lines. Over the past months, Bekaert teams have worked closely together with the customers to maximally meet their supply needs during the repair phase following the fire incident, Taylor said. Per a company press release, the brass-plated hydraulic hose wire activities were able to resume operations in

January 2015, while a contingency plan was put in place to bridge the supply shortage of bead wire during reconstruction works with imports from other Bekaert plants.

New York Wire files for bankruptcy, company is seeking buyer for business

New York Wire, the oldest U.S. wire weaver, is seeking Chapter 11 bankruptcy protection as it looks for a buyer. A story in the Evening Sun reported that the official request for bankruptcy, which seeks financing to continue operations, was filed by Wire Company Holdings, LLC, whose address in Hanover, Pennsylvania, is the same as the wire manufacturer. The filing said that as of Sept. 1, New York Wire employed 237 people at Hanover and at other locations in York County. The report said that the company has more than $12.2 million in outstanding secured debt and $3.4 million in other obligations. A list of the company’s 30 largest creditors of unsecured claims showed that the wire company owes at least $2.2 million in debts for raw materials, health insurance, freight, gas, electricity and other services. “A reasonably prompt sale of the Debtors’ businesses...is essential to not only preserve the underlying value of their operations by providing customers and employees with a clear path forward, but also to maximize the value of the Debtors’ assets for the benefit of the Debtors’ creditors,” the document said. In its filings, the company cited problems relating to its 2012 opening of a manufacturing facility in China that “experienced long and expensive start-up issues, including high turnover in the general manager position as well as production delays and other problems.”

MFL Group reports official acquisition of Construcciones Mecánicas Caballé Italy’s MFL Group (MARIO FRIGERIO/ FRIGECO) announced the ofﬁcial acquisition of Construcciones Mecánicas Caballé S.A., a well-known Spanish cable machinery manufacturer, and its other operations.

A press release said that the transaction, which was concluded on Sept. 23, “will signiﬁcantly strengthen MFL Group’s scope of supply for nonferrous wire drawing, stranding and extrusion equipment.” The acquisition

Got news? E-mail it to the WJI at editorial@wirenet.org.

10 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

includes Caballé, OM Lesmo and Eurodraw Energy brands with their corresponding intellectual property, it said. “These well-established brands, along with MFL Group’s financial muscle, our 120 years of industry experience, and the broadest engineering and manufacturing knowledge base in the sector, further reinforce our commitment to our nonferrous wire and cable customers,” the release said. “By exploiting the combined history of Caballé, OM Lesmo, Eurodraw Energy and FRIGECO we can guarantee continuous technical improvement and unmatched customer service. We are looking forward to strengthen our business relationship with our customers and suppliers around the world.”

Explosive delay for wind farm project

DONG Energy says it has safely detonated or removed 41 items of unexploded ordnance (UXO) from World War II off the Norfolk, U.K., coast, after the explosives were discovered on the export cable route for the developer’s 580 MW Race Bank offshore wind farm. Per multiple media reports, during a large-scale offshore inspection

There’s a reason new cable routes are first inspected. campaign on the Race Bank site, DONG found UXO items ranging from small rockets to larger 1,000 lb high-explosive bombs. The most notable item discovered was a German Luftmine B ground mine containing a net explosive quantity of 698 kg of hexanite. A total of 36 live, high-

Graham Engineering Corp. CEO David Schroeder at the crosswalks of the company’s new location in Pennsylvania.

American Kuhne to relocate from Rhode Island to join its parent company American Kuhne, a supplier of extrusion technology, will move from its current location in Ashaway, Rhode Island, to York, Pennsylvania, where it will join the expanded operations of its parent company. A press release said that Graham Engineering Corporation (GEC) plans to move its American Kuhne brand into its York location, which was expanded 35% in 2013. “Continued growth in our extrusion business prompted this decision, a logical next step,” said GEC CEO David Schroeder. “We are simply outgrowing the Ashaway facility, which houses our extruder assembly.” The company will maintain a satellite office near the present Ashaway location and many of the employees there will have the opportunity to relocate to York. The Graham Group acquired majority interest in

American Kuhne in 2012, followed by GEC’s acquisition of Welex in 2013. Together, GEC, American Kuhne and Welex create a convergence of leading technologies, people, and capabilities in extrusion, the release said. American Kuhne provides standard and custom single screw extruders, feed screws, extrusion systems, and specialized turnkey systems for sectors that include wire and cable; Welex supplies sheet extrusion solutions; and GEC supplies wheel and industrial extrusion blow molding solutions. “This move enables an even greater level of knowledge-sharing, cooperation, and cross-functional collaboration under one roof, benefiting our customers not only in time to market, but also with enhanced custom design, testing, training, and run-off capabilities” said Bob Deitrick, vice president of global sales.

NOVEMBER 2015 | 11

INDUSTRY NEWS

explosive-filled items were destroyed in their current locations at sea using highly skilled specialist contractors, while five items certified as “free from explosives” were recovered to shore, where they were safely scrapped in approved facilities. “As a routine part of the preparatory work before construction of an offshore wind farm, seabed surveys are carried out to ensure the seabed is clear of obstacles, including unexploded ordnance,” explains Eleftheria Melekou, site investigations project manager at DONG Energy. “This is standard procedure, although the number of items discovered was a surprise and the most we have seen on a DONG Energy project to date.

HELUKABEL GmbH breaks ground for expansion of plant in Germany

Cable-manufacturer HELUKABEL GmbH recently held a ground-breaking ceremony for an expansion at its manufacturing plant in Windsbach, Germany. A press release said that once the project, estimated to cost US$22.4 million, is completed in the fall of 2016, the new building will offer more than 96,875 sq ft of additional ofﬁce, laboratory and production space. The current facility is 126,000 sq ft, of which 115,000 sq ft is for production, R&D and testing facilities, the remainder ofﬁce space. The expansion will also allow the company

DESIGNERS & MANUFACTURERS ISO9001 OF PAYOFF & TENSION CONTROL REGISTERED EQUIPMENT FOR WIRE & CABLE

From l-r at the ground-breaking ceremony, were Andreas Leninger, Planungsbüro GCA; Thomas Mann, factory technical manager, HELUKABEL Windsbach; HELUKABEL founder Helmut Luksch; and two local representatives. to combine its global R&D capabilities with its test and inspection facilities in the new technology center. “We have been manufacturing here since 1988,” CEO Helmut Luksch said in the release. “Thanks to the largest ever investment in this facility to date, we are conﬁdent that we can meet future market demand.” The Windsbach manufacturing plant employs 170 people, and there are plans to hire an additional 30 people

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General Cable on track to close plant in Franklin

KEIR - BackBone™

Features:

General Cable Corporation, which has undergone significant changes in recent years, is closing its plant in Franklin, Massachusetts, USA, with production shifted to other plants. A spokesperson confirmed that the plant, which manufactures electronic/ data communications/fiber optic cables, will be closed in 2016. Employees were notified to that effect earlier this year. “After evaluating all aspects of the Franklin facility, it was determined that it is operationally more cost-effective to relocate the manufacturing of the products made there to other General Cable locations.” In 2010, the Franklin plant was named an IndustryWeek “Best Plant.” At that time, the 158,000 sq ft plant had 152 nonunion employees, and produced more than a half billion ft of cable a year. The plant was cited for improvements in both product quality and lost time due to injuries as well as for prompt delivery rates.

• Improved bow strength (no holes) • Wire is out of the air stream • Bow shaped like a wing for improved aerodynamics and low cw factor • Wear strip eliminated and replaced by wear bushings with windows for easy inspection and dust cleaning • Wear bushings can be changed while bow is mounted on the rotor

Advantages: • Up to 40% lower power (amps) consumption and reduced noise • Higher TPM - maintaining wire quality • Reduced elongation @ higher TPM • Reduced bow breakage • Increased life on wear surfaces reducing downtimes and maintenance • Easy assembly and change out of wear bushings • Wire breaks are contained within the bow - extending bow life

Champlain Cable Corp. closes its Leeds plant U.S.-based Champlain Cable Corp. has closed its cable plant in Leeds, Massachusetts, as part of a company reorganization that will see production transferred to its other operations. Per the company, it has begun ramping down its plant in Leeds and moving the equipment to its facility in El Paso, Texas. The closing saw the loss of 22 positions. The plant operations were relocated due to customer requirements to have their products closer to point of use and logistics.

Flyer Bow

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NOVEMBER 2015 | 13

INDUSTRY NEWS

once the new machines have been installed. The expanWTO: Chile has launched safeguard sion will house production lines that primarily manufacinvestigation into steel wire exports turing cables used in automation, such as control cables, A report at the World Trade Organization (WTO) especially continuous flex and robotic cables. It will also notes that Chile has indicated that it is investigating focus on producing cables supporting the internet of steel wire being exported to the country. things (IoT). “In accordance with Article 12.4 of the Agreement on HELUKABEL GmbH notes that its operations include Safeguards, Chile is prepared to hold consultations on 24 locations around the world, including its 45,000-sq-ft the provisional safeguard measure, once the measure subsidiary, HELUKABEL USA, which it notes stocks has been adopted, with those Members that have a over 4,000 cables, wires and accessory line items for substantial interest as exporters of the subject product,” a multitude of industrial and commercial applications Visit our stand #703 at Interwire 2015 across a wide range of vertical market segments.

INDUSTRY NEWS

a press release said. It did not present speciﬁc details about the product of which country/countries it was focusing on. A safeguard investigation, the release said, “seeks to determine whether increased imports of a product are causing, or is threatening to cause, serious injury to a domestic industry. During a safeguard investigation, importers, exporters and other interested parties may present evidence and views and respond to the presentations of other parties. A WTO member may take a safeguard action (i.e. restrict imports of a product temporarily) only if the increased imports of the product are found to be causing, or threatening to cause, serious injury.”

Integer Top 100 cable companies: Prysmian still #1; China a bit flat For the second year in a row, Prysmian Group has achieved the number one position in the Integer Research Top 100 Global Wire & Cable Producer Database 2015 rankings, but the other news was that China’s surging cable industry appears to have leveled off. The U.K.-based industry research and consulting firm, said that strong sales of submarine power cables and fiber optic cables in 2014 helped the company retain the top spot ahead of global rival Nexans, even though the gap between these two key players has narrowed noticeably. Per a press release for Integer, the Top 100 producers generated insulated wire and cable revenues of US$110 billion in 2014, representing 51% of the global market. The world insulated wire and cable market reached a total of US$215 billion in 2014. After Prysmian and Nexans, U.S.-based General Cable, came in third, although it has been reducing its overseas operations, and is close to being overtaken by Japan’s Sumitomo Electric. U.S.-based Southwire has also continued to rise up the rankings, helped by high demand for cable in the U.S. and acquisitions in recent years. The ranking of the 100 largest global wire and cable producers includes companies headquartered in the Middle East and North Africa (Riyadh Cable Group, El Sewedy Electric, Al Fanar, Bahra Cables, Elloumi Group and Coficab), confirming a rise in revenues in this part of the globe. For the first time in seven years, the leading Chinese companies have not risen up the rankings against their global peers. Indeed, leading Chinese cable maker, Far East Smarter Energy (formerly Far East Cable) went down one place compared with the previous year to 14th place in this year’s ranking. Overall, there are 39 Chinese cable makers in the Top 100, and their combined sales grew by less than 1% to reach US$24.7 billion in 2014, 14 | WIRE JOURNAL INTERNATIONAL

reﬂecting the slowing growth rates in the Chinese economy. In contrast, there has been a continued recovery in the U.S. and Mexico, with new investment in cable factories and increased merger and acquisition activity in the automotive wire, ﬁber optic cable and tray cable markets. For more details, contact Integer Research at www.integer-research.com.

Fenn Open House showcased company’s legacy and new plant Fenn celebrated its new facility at a September 19th Open House in East Berlin, Connecticut, but it was also a time to reﬂect on the legacy of both the company and its parent company, Quality Products, Inc. (QPI)

QPI CEO David Sommers (holding scissors) and, left of him, Fenn President Paul Uccello, at the Open House. “Today marks the beginning of a new chapter in Fenn’s long and illustrious history,” QPI CEO David Sommers told the customers, staffers and guests that included state and local officials. He explained how the collective histories of Fenn and QPI—which now has five divisions in four states that employ over 160 people—present a classic story of U.S. ingenuity and persistence. In 1900, Wilson Fenn founded Fenn Technologies, a small machine shop in Hartford, Connecticut. It produced metal forming machinery as well as flight critical assemblies for airplanes in World War II. In 2001, Fenn was acquired by SPX Corporation. In 2003, Fenn acquired BHS-Torin, a Connecticut based supplier of rolling mills, wire flattening and shaping equipment and the well® known Torin brand of spring coilers. In 2014, the Fenn division was sold to QPI, Inc., and with its backing and support, Fenn upgraded to its new facility in East Berlin, Connecticut. “After 60 years located on Fenn Road, we are today opening a new facility here in Berlin, designed to take us into the future,” Sommers said. “We are the last American manufacturer of our kind left in the U.S., and in our talks with our American customers, they want to support us and are excited that they can still buy American.” Sommers said that Fenn’s machines have helped promote metallurgy research and education in labs and universities, helped support the American war efforts through the decades including WWI, WWII and the recent wars in the Middle East. That legacy will continue, he said.

INDUSTRY NEWS

“Despite economic recession and depressions, World Wars, and fierce global competition, our customers see the value in our products and continue to support us. We look forward to many more years of continued growth and success.” Sommers thanked Fenn staff for their dedication, commitment and loyalty. “It makes me very optimistic about our success for the next 115 years.”

Alcatel-Lucent unit chosen for SOOC undersea network project

Alcatel-Lucent Submarine Networks (ASN), the undersea cables subsidiary of Alcatel-Lucent has been awarded the development of the Sonangol Offshore Optical Cable (SOOC), a critical infrastructure project designed to reduce the cost-per-bit associated with the delivery of data traffic to Angola, including its offshore oil and gas production facilities. A press release said that the 1,900 km SOOC undersea network will connect to landing points at four locations along the Angolan coast, providing a high-speed connection between the Luanda area and Cabinda to fulfill national telecom needs. The development phase is under way and construction work is scheduled to start in the second half of 2016. “After connecting Angola to the global network through several undersea cables, ASN is pleased to further contribute to the development of the Angolan fiber optical infrastructure,” said ASN Oil & Gas General Manager Yohann Bénard. “This award is a prime illustration that submarine fiber-optic technology is becoming the standard telecom medium for offshore assets.”

Samoa government: activity has begun for submarine cable project

Samoa’s government has established a submarine cable company, Samoa Submarine Cable Company (SSCC), that it notes is the country’s first locally owned such entity. That statement may be a bit misleading as

16 | WIRE JOURNAL INTERNATIONAL

the actual news is that SSCC, at a cost of $49 million, is getting a cable that “will span 1,300 km and link Samoa’s largest islands of Upolu and Savai’i to the Southern Cross cable network in Suva, Fiji.” Multiple media reports noted that Tuisugaletaua Sofara Aveau, Samoa’s minister of communication and IT, said that the project will mean improved internet for Samoans, while the new cable will also allow existing carriers to reduce internet costs substantially. He says the project will take 18 months to build and come into service. Per the reports, the business is the result of the partnership between Samoan operators Bluesky and Digicel, the Computer Service, and financial investors the Samoa National Provident Fund, the Unit Trust of Samoa and Samoa Life Assurance. The project has been established with financial assistance from the World Bank, the Asian Development Bank, and Australia’s Department of Foreign Affairs and Trade. Per Wikipedia, Samoa has a population of 194,320. It is located south of the equator, about halfway between Hawaii and New Zealand in the Polynesian region of the Pacific Ocean, with a total land area of 1,097 sq mi.

Midal Cables reports plans to build aluminum conductor plant in India

Bahrain-based Midal Cables has reported that it plans to set up an aluminum conductor unit in Angul, which is part of India’s state of Odisha. Per a report in Business Standard, the project was recently cleared by the State Level Single Window Clearance Authority (SLSWCA). The facility, which will have annual production capacity of 60,000 metric tons, would be located at the aluminum park in Angul that is being jointly developed by National Aluminium Company (Nalco) and a state-owned agency for land acquisition and industrial infrastructure development, Odisha Industrial Infrastructure Development Corporation Ltd (Idco). “The project by Midal Cables will create employment opportunities for 350 people,” the report said.

A report from Research and Markets projects that the global market for low voltage (LV) cable and accessories will grow by an annual compound growth rate of 7% from 2015 through 2020. The report, “Low Voltage Cable Market by Overhead, by Underground, by End-User and by Region - Global Trends & Forecast to 2020,” estimates the 2014 global market was US$99.2 billion. A press release said that growth will be driven by spending on transmission and distribution networks, growing industrialization and urbanization, and the shift in focus towards renewable energy production. It noted that the transmission & distribution (T&D) network is expanding from a global increase in power generation to satisfy the growing demand for electricity. Power cables and accessories are vital components for T&D networks and will also grow in sync with the growth in T&D networks. Also, the low-voltage cables and accessories market is expected to grow faster in developing countries where the T&D industry is in the growth stage. For more study details, go to www.researchandmarkets.com.

produces the SIEBE Color Match (SCM) for in-line/offline color control. CCC provides access to European technical developments in electric cable technology. “The SIEBE range of extruders is a welcomed addition to the CCC range of cabling, stranding, re-spooling, wire drawing lines and wire cleaning systems.” CCC can be contacted in Larchmont, New York, at tel. 914-834-8865, info@cableconsultantscorp, and in Charlotte, North Carolina, at tel. 704-375-9313, fhardy@cableconsultantscorp.com, www.cableconsultantscorp.com.

CCC to rep SIEBE in U.S./Canada Cable Consultants Corp (CCC) reports that it has been appointed the U.S. and Canadian representative for Germany’s SIEBE Engineering GmbH, a supplier of extrusion technology. A press release said that for more than 30 years, SIEBE Engineering GmbH, Neustadt/ Wied, Germany, has made single screw extruders, horizontal CV-lines and extrusion lines for automotive cables, data-communication cables, special cables, medical and industrial plastic tubing. It also

NOVEMBER 2015 | 17

INDUSTRY NEWS

Industry report: market for LV cable & accessories looks good to 2020

ASIAN FOCUS

ASIAN FOCUS Underground power cables called a must for energy project in India The main power company serving the eastern part of Pune, India, has agreed to spend an estimated US$151 million for a system of underground power cable lines. Per an online report in India Express, Maharashtra State Electricity Distribution Limited (MSEDCL) ofﬁcials have agreed to invest in the infrastructure upgrade. The utility’s ambitious project will require 27 sub-stations and 1,015 km of underground cable as well as setting up of over 800 transformers, 2500 feeder pillars and other works. The need for the underground cables was reinforced by residents of Wanowrie, NIBM Road, Kondhwa, Yeolewadi, and others in the eastern part of Pune, who have suffered a continual series of power disruptions. The problem is particularly acute in areas that have a heavy tree cover as the resulting fallen branches on overhead cables was a major source of outages. Ganesh Edke, executive engineer, Rasta Peth urban circle, MSEDCL, told Pune Newsline that there were other issues as well, such as a feeder pillar near Raheja Garden society in Wanowrie that was submerged in rain water, forcing the power supply to be shut till the water

People are silhouetted by backdrop of overhead wires and cables on a street in India. Reuters photo. was drained. Ultimately, the solution to the problem rests on laying underground cables, he said. “We have completed the survey and are now waiting for PCB authorities to give us the go-ahead to start the road digging work to lay underground cables. This will solve the problem of power disruption in the area.”

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18 | WIRE JOURNAL INTERNATIONAL

DIA

CHINA

SOUTH AFRICA

be leaning over 11 degrees, local authorities drew up Wire serves both as a literal tie (and short time. plans. India isThey a are still waiting for funds from “the growth of any country is possible only if the number renovation contrast) to a historic pagoda China hugegovernment. country, a place of employed persons grows” is satisfi ed, Indiainwill be the with a multitude of the reli-wire continues to hold up the theIt’s next we mustbut serve intensively our notterritory a classicthat approach, a simple stretchwith of steel In the meantime, gions/cultures, and from equipment course, infrawire servesand as atechnology. short-term Of solution forthe anbasic historic strucpagoda. The story said that there are also plans to reloan industrial point of structures presently not sufficient and not adequate ture in an are unusual setting. cate the chicken farm. view it’s not possible to toPer permit the in harmonious this giant. Carmelo a story Huashanggrowth Daily, of a tourist generalize into a single Maria Continuus-Properzi. traveledBrocato, to Tongchuan, in Northwest China’s evaluation. What is cerShaanxi Province, to get a close-up look at a tain is that India is a land China is and will remain the most important BRICS renowned pagoda there. The structure, which that has thousands of opmember country, despite slowing growth. Brazil is lookdates back more than 1,000 years to the Song portunities, as does—to ing more like India, mired in corruption scandals, while Dynasty (960-1279), wasa listed in 2013 as the most a lesser extent and all the India at this point under new regime holds one of theAgain, national key cultural relicspromised protec- by the differences considered promise. whether the reforms tion units. —South Africa. Companew government in India lead to rapid growth remains Bellina touristRussia was stunned to findtothat theproblems and it nies in South African are toThe be seen. will continue have cultural wasyears leaning, held infrom placeWestern-imposed by focusing on quality and innovation and our Group is laywill takerelic several to recover a wire. A photo of thehas pagoda showsfrom that South it ing the groundwork for a big market development there. sanctions. Not much been heard Africa, is located a scruffy setting. To the left is Brazil, the world’s sixth largest economy—even though though it isinnow officially a member. it is very far from Italy and presents some customs clearthink that the BRICS are going continue aIraised highway, and just yards to away is a to be relevant. ance and trade policies issues—is a market increasingly While thefarm. pace of GDP growth may slow for a few years chicken important for our strategic framework. due political and socio-economic factorscites or sanctions, Pertothe Huashang Daily report, which One other thought: the BRICS acronym was originally etc., these remainRelics temporary roadblocks at best. As 40% the Tongchuan and Tourism Bureau, used to define countries characterized by a developing of world’s population in 2005. these countries, it is thethe pagoda first started toresides lean in At economic situation, a strong growth in GDP, a large popinevitable thatthe at wire somewas pointfixed in the future they will produce some point, between it and ulation, a vast territory and abundant natural resources. and consume the majority of the world’s output. Rahul a nearby telegraph pole as part of a repair In 2015, we can’t talk of them any more as “developing Sachdev, Wire & Plastic Machinery. project launched by local urban management countries” superpowers together with the G7 A historic pagoda, next but to aaschicken farm inthat, China, is held in place committee. The leaning continued, and two countries, dominate the worldwide market. Fabio BelliRussia faced economic and political distresses in 2014 wire. years ago, the tower discovered to in aby na, TKT Group. but now theafter situation may was be back to normal very

OCTOBER 2015 | 19 MAY 2015 | 37

FEATURE ASIAN FOCUS

PEOPLE

PEOPLE Champlain Cable Corporation (CCC) announced that William Reichert will take over as president at year’s end. He rejoined Champlain 12 years ago, and has led many operational improvements as well as plant startups in El Paso and an acquisition integration. His 30-year wire and cable background includes Reichert sales, business development, quality, engineering and operations roles with several organizations. He currently serves as president of the Wire Association International and is a member of the Wire and Cable Manufacturer’s Alliance (WCMA). He holds a B.S. degree in chemistry and an MBA from the University of Vermont. He will replace Richard A. Hall, who will retire from the day-to-day responsibilities of the president’s position that he has held since 2002. He will continue to serve as CEO. Based in Colchester, Vermont, USA, and celebrating its 60th anniversary this year, Champlain Cable Corporation manufactures a range of high-performance wire and cable. BECHEM Lubrication Technology, LLC, announced that David Skaggs has joined the

company’s Sales & Application Engineering team. He has years of industry experience, especially in nonferrous wire, where he has held various engineering roles. He most recently was a manufacturing manager at Superior Essex. He holds a degree in mechanical engineering from Purdue University. BECHEM Lubrication Technology, LLC, is the U.S. subsidiary of Germany’s Skaggs BECHEM, a global supplier of lubricants to industries that include wire and cable. Leistritz Extrusion has named William L. Novak as a product area manager. He will be responsible for business development efforts to expand the use of twin screw extrusion into new areas and applications, as well as assuming regional responsibilities. He most recently was a regional sales manager for Coperion. He holds a B.S. degree in engineering from Stevens Institute of Technology. Based in Somerville, New Jersey, USA, Leistritz Extrusion supplies a range of compounding and extrusion Novak technology.

New dog, new tricks

WIRE STRAIGHTENERS

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STRAIGHTENER ROLLS

20 | WIRE JOURNAL INTERNATIONAL

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WIRE PULLERS / WEDGE GRIPS

Douglas John Thornton, president of Nano-Diamond America and Sanxin Wire Die, died from cancer on July 2, 2015, at the age of 73. He was well known in the industry for his enthusiasm, work ethic and hectic travel schedule. Thornton’s career in the wire and cable industry was unusual in that it was a second career for him. A native of Australia, his first professional life included 20 years as an Australian Naval Officer. In the course of his naval training, he studied engineering at London University and was awarded the Queen’s medal for academic excellence in 1965. He subsequently served at sea as an electrical engineering officer on the HMAS Vampire, a destroyer, and was involved in the management of defense projects. Thornton then spent several years in sales with Hewlett Packard in U.S. in the 1970s. With that base, in the 1980s he started his own company, where he developed and installed a range of turnkey CAD/CAM systems for the sheet metal and punch press industries in Australia for more than 10 years. At age 62, he moved back to the U.S. to start up a brand new business in the wire industry. He led the team that brought the Nano-die to the wire industry, traveling extensively the last 10 years. He thoroughly enjoyed what he did and continued to work until near the end of his life, including from a hospital bed two weeks prior to his passing. He was utterly tenacious.

PEOPLE

OBITUARY

A 2011 photo of Doug Thornton with Shanghai Jiaoyou Diamond Coating Co, Ltd. CEO Songshou Guo.

“Whether it was at a trade show or over a phone call, Doug just would not give up until he had persuaded you that his company deserved really good play in a feature. That’s just the way he was,” recalled WJI editor Mark Marselli. Thornton leaves his wife, Lee, and sons Matthew, Owen, Zain and Christopher, and their desire to see his legacy continue. “While we are in deep grief, the Nano Diamond America team is inspired by Doug’s tenacity and is determined to further develop the business by taking it into a new horizon. This is the only way for us to truly honor Doug.” 

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MAGNETIC BRAKES & CLUTCHES

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TESTING & HANDLING AUGUST 2015 | 21

FIBER WATCH

FIBER WATCH ‘Gig City’ offers world’s 1st community wide network with 10 Gigabit service Chattanooga, Tennessee, which became known as “Gig City” for being the first in the United States to build a community-wide fiber optic network, EPB, capable of delivering 1 gigabit (1,000 Mbps) internet speeds, reports that it now offers the world’s first 10 gigabit (10 Gig) Internet service to be made available across a large community-wide territory. A press release said that, unlike point-to-point commercial installations, which have been possible for some time, EPB’s 10 Gig service is now available for access by every home and business in a 600-sq-mile area through AlcatelLucent’s TWDM-PON broadband technology. The new solution, it said, is the world’s most advanced ultra-broadband technology because it delivers the scalability to offer up to 10 gigabits per second internet speeds across a community-wide network. The 10 Gig residential service is available everywhere in EPB’s service area for $299 per month with free installation, no contracts and no cancellation fees. “Five years ago, Chattanooga and Hamilton County became the first in the U.S. to offer up to 1 Gig Internet speeds,” said Harold DePriest, president and CEO of

EPB. “Today, we become the first community in the world capable of delivering up to 10 Gigs to all 170,000 households and businesses in our service area.” EPB is also launching 5 Gig and 10 Gig internet products for small businesses as well as 3 Gig, 5 Gig and 10 Gig “Professional” products for larger enterprises. These Internet services are available at varying price points. According to DePriest, Chattanooga’s community-wide fiber optic network sets it apart as a living laboratory that can deliver next-generation internet speeds anywhere in a the coverage area, which included urban, suburban and rural businesses and residences. “Chattanooga’s 10 Gig fiber optic network is a worldclass platform for innovation,” DePriest said in the press release. “In recent years, the need for faster Internet speeds has increased rapidly. Chattanooga is the perfect place for companies to enhance their productivity today and test the applications everyone in the country will want tomorrow.” For companies that need to upload and download large files including ventures involved in 3D printing, film production, gaming, medical image diagnostics, software development, big data, etc., Chattanooga offers a unique opportunity to dramatically increase productivity and workflow whether employees are working from home or the office.

Huestis Industrial Cable Jacket Strippers Who do you call when you’ve just run a rush order, the jacket has defects, and there isn’t enough time to remake the entire job? Huestis Industrial, of course! Our cable jacket strippers will save you time and money salvaging the valuable core, allowing you to re-extrude the job fast to keep your customers happy and your remake costs down. In many cases, one job provides the payback for your investment.

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FASTENER UPDATE

FASTENER UPDATE Alcoa reports contract with Airbus could be worth up to US$1 billion

A past article on the new plane in Composites World said that the A350’s composite panels incorporate an outer copper mesh to manage the direct effects of lightU.S.-based Alcoa has signed a contract to supply ning. They maintain the Faraday cage principle, channelhigh-tech, multi-material aerospace fastening systems to ing the electrical current around the fuselage harmlessly Airbus, a deal that it said was valued at approximately rather than letting it pass through to damage fasteners $1 billion. and operational structures. A press release said that Alcoa’s fasteners are made the contract is Alcoa’s largest from stainless steel, titanium fastener contract ever with and nickel-based superalloys, the aircraft manufacturer. It which improve fatigue life, notes that Alcoa’s fasteners enable lightning strike protecﬂy on every Airbus platform. tion, and improve wear and Per the release, Alcoa’s reusability on conventional fasteners will be used to and composite aircraft. They assemble some of Airbus’s will be made at 14 of its globlatest high-growth airplanes, al manufacturing facilities. including the A350 XWB, Alcoa notes that the comThe A350 XWB Airbus will use many Alcoa fasteners. Airbus’ newest commercial pany has been seeking to airplane (pictured) and the capture growth in the global A320neo as well as longer-running platforms such as the aerospace market in support of its broader transforA330. As part of the deal, Alcoa will supply advanced mation. That goal has seen it acquired global titanium fastening systems, such as those that enhance the assemleader RTI International Metals, aerospace components bly of aircraft panels and engine pylons on newer airmanufacturer TITAL and global jet engine parts leader planes with sophisticated design features. Firth Rixson.

24 | WIRE JOURNAL INTERNATIONAL

Borlink™ Technology: the energy to enable a sustainable future

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Our Borlink™ technology creates the innovation links that secure world-class, stepchanging solutions that benefit the whole wire and cable value chain from the wind farm to the end consumer. Borlink™ LS4258DCE, our latest step-change HVDC innovation enabling more efficient electricity transmission at higher voltage levels over longer distances, will support the further integration of renewable energies into the grid and the establishment of more interconnections among countries in major infrastructure projects around the world. Borealis and Borouge – Bringing energy all around.

WAI NEWS

WAI NOVEMBER 2015

MEMBERSHIP

SPOTLIGHT This section introduces a new WAI member each issue.

Clifton Vandenburgh Printer Support Engineer Gem Gravure Co., Inc Q: What does your company do? A: Gem Gravure was the first company to create printing wheels and ink for wire marking. We held the original patents. Gem was also first in expanding ink jet marking into wire and cable. We provide the whole coding package since we design and manufacture custom wire marking inks. Q: What is your role there? A: I actually serve two roles right now. Since I have a degree in engineering design & configuration management and a lot of experience with CAD programs, I support manufacturing. This includes creating specifications and drawings. On the other hand, I’m trained as a printer support engineer. I perform service on customer equipment when needed. Q: What do you like best about your position? A: I like the variety. Every day is different. Every day brings a new challenge. Q: How does your company remain competitive? A: The best thing we do to stay competitive is to stay in contact with our customers. The more we understand about what’s important to their business, the better we can support them. Internally, we constantly work on our manufacturing processes to keep our high level of quality. Q: Why did you recently join WAI? A: It’s a great way to find out what’s happening in the industry and how it affects our customers!

26 | WIRE JOURNAL INTERNATIONAL

The following individuals either recently joined WAI or became Platinum Members through their companies. Yan Bousquet Plant Manager J Hamelin Industries Ernie Caputo Sr. Account Executive Dow Elastomer Electrical & Telecom Albert J Emery Materials Engineer Lockheed Martin Corp Hamza Menemencioglu Plant Engineer Guney Celik Call 315.331.6222

Waheed Rehman Head of Operations Sterlite Copper, a unit of Vedanta Limited Mike Terenzetti Supply Chain Manager Champlain Cable Corp Clifton Vandenburg Printer Support Engineer Gem Gravure Co Inc Brandon Wright Owner Wrights Fabrication LLC

Donald Nelson Reeves Email sales@refractron.com Lanie Yu ChiefVisit Commercial Ofﬁcer www.refractron.com Hypertech Wire Atlantic Coast © 2015 Refractron Technologies Corp. and Cable, Inc. Engineered Metals REFRAC_11593_IzoryAdHlfHrz_WJI.indd 1

Official update call for WAI Reference Guide ®

Izory, so reliable you can

If your company proﬁle appears (or should appear!) in WAI’s annual WJI Reference Guide, now is the time to either update or send your details in. Listings are free, and data received by Nov. 30 will be Interwire included in the 2016 edition. A lot can happen in a year, Booth # 302 so companies with listings should review their entries. Does the listing accurately describe your products and services? If not, please go to www.wirenet.org, and log in with your e-mail address and password. Click on the “My Listings” link on the left-hand side of the page to access your listings, and press the “Edit Entry” button at the top right-hand side to start the process. If you forgot your password, there’s help at the page. It’s worth the two minutes this takes as the online data alone is accessed by more than 15,000 visitors annually. For certifi a newed listing, click the “Industry Search link at the left side of the home page and then the “Add Entry” tab at the subsequent page.

give your maintenance crew a rest.

12/19/14 10:33 AM

NOVEMBER 2015 | 27

WAI NEWS

MEET YOUR PEERS. ACHIEVE YOUR GOALS. JOIN WAI TODAY.

Food for thought:

It’s such a favorite, we’re taking reservations for 2016. Here’s a way to let your brand do the talking all year long. Reserve a display ad in the 2016 WJI Reference Guide and we’ll serve your marketing message to your customers. To prospectsturned-customers. And to the entire Wire Association network.



Let them all know what you bring to the table in this annual buyer’s guide. If you sell wire, cable, manufacturing supplies, or equipment, you’re in. Company profiles are complimentary. WAI’s sales team is ready to take your advertising order.

Call №. 001-203-453-2777, ext. 119 or 126 And here's a tip: Hurry. Ad sales end 11.12.15!

The Wire Association International, Inc. | www.wirenet.org

John Scott speaking before winding the clock.

John Scott, a long-time U.K. wire industry veteran, came to WAI on Oct. 13 to serve as the 2015 Clockwinder, but it was not quite the usual trip for the event that annually sees a U.K. industry representative travel here to wind the grandfather’s clock that the British wire industry gave to the Wire Association in gratitude for help during World War II. Scott and his wife, Claire, live in Florida, and are citizens of both the U.S. and the U.K. Scott has most certainly not lost his U.K. roots as he has traveled extensively across “the pond,” logging dozens of trips in one ﬁve-year period. He spoke to WAI staff and visitors that included WAI President Bill Reichert, who introduced him, and board member David Ferraro. He focused on the degree of change he has seen since he started out at Tinsley Wire Industries Ltd. (TWIL) in the early 1970s. At that time, the company, formed by Bekaert, British Ropes Ltd (Bridon) and the United Steel Companies, Ltd., was the fourth largest wire manufacturer in the U.K., producing galvanized steel wire for fencing, barbed wire and welded panels. (continued next page)

Booth positions are still available for Wire Expo 2016 With Wire Expo 2016 still eight months away, roughly two-thirds of the available booth space has been taken for the trade show, which will be held next June along with the WAI Operations Summit & Wire Expo at the Mohegan Sun Resort Center in Uncasville, Connecticut. WAI Sales Director Bob Xeller said that 130 of the single booths have been sold, with 77 (35%) remaining, and that ﬁve of the eight large booths (each equal to four

smaller units) have been taken. “This is a good time to ﬁnalize plans if you’ve been thinking of exhibiting at this new location,” he said. Even if you have eagle-caliber eyes, most company names here are too small to see, but you can access an interactive version of the ﬂoorplan that can be found at http://www.wireexpo16.com/expocad/2016wir/default. html. Or, contact sales@wirenet.org. NOVEMBER 2015 | 29

WAI NEWS

Clockwinding tradition continues with a U.S. twist

Join WAI at the Sun for the best wire networking setting under the sun.

& SAVE THE DATE: June 7-9, 2016 Mohegan Sun Casino Resort | Uncasville, CT, USA Look directly to the Sun and the Wire Association Operations Summit & Wire Expo 2016 for the brightest ideas in wire and cable manufacturing, supplies, and equipment. Two full days of exhibits, wire industry insight, and practical information. Nothing beats a front row seat at a Wire Association conference to eclipse the competition. Travel to this regional oasis is simple and convenient. And who knows? Yours may turn out to be a win-dough seat.

Find details about Exhibiting, Speaking & Sponsorship Opportunities in Wire Journal International.

The Wire Association International, Inc. | Telephone: (001) 203-453-2777 | www.wirenet.org

NOVEMBER 2015 | 31

WAI NEWS

Through acquisitions and organic growth, the Bekaert company was the largest U.K. wire producer at the time he left it in 1991 to move to Belgium, where he served as business development manager for Bekaert. He served in a number of marketing and business development positions, including stints in the U.S. from 1994 through 2006, at which time he returned to Belgium, where he stayed until his retirement from Bekaert in 2011. Since then, John and Claire Scott, along with WAI board member Dave Ferraro, 4th from l, TWIL, which once had as many as WAI President Bill Reichert, next to Claire, and WAI staff. 2,500 employees, has seen its opersince it was started in 1986 and opened its U.K. operaations pared down considerably. The tion in 2007. Today, Accent Wire’s overall operations repmain part has been sold for retail, and the remaining resent the largest worldwide consumer and user of wire elements have 120 employees. “It’s a sad thing to see for the waste and recycling industries. the way the U.K. has become a rump of what it used to Scott said that he was both surprised and proud to be,” he said. discover that the man who in 1973 hired him as a comScott became an independent consultant, and started mercial trainee, Derek Newbould, served as the 1983 working for Accent Wire, a multi-national company that Clockwinder. Scanning the list of the prior clockwinders, has shown considerable growth in steel wire. Having he saw that in addition to Newbould, it included three of experienced the rise and fall of TWIL, he said he felt his former bosses as well as three people who had worked lucky to work for the U.S.-based company, representing for him. “It is an honor for me to do this now,” he said, it in the U.K., continental Europe and in the U.S. The before he wound the clock. company, he explained, has showed remarkable growth

CHAPTER CORNER

CHAPTER CORNER Vannais golf outing produces near-perfect day … on multiple levels The adjectives were numerous as the players made their way through the 2015 Vannais Golf Outing. Beautiful, challenging, fun, and frustrating were some of the words heard on the course and at the post event dinner to describe this 14th golf outing produced by the

The winning team, l-r, of Mark Whisenant, Doug Herrick, Brandon Bennett and Richard Miller.

Putting contest winner James Moore (2nd from left) flanked by putting contest officials and chapter Board Members Tim McElhany (far left), Woody Holland (2nd from right) and John Dognazzi (far right).

Dave Rascati of Premier Wire Die was the lucky winner of the raffle’s grand prize, which was a full set of irons. 32 | WIRE JOURNAL INTERNATIONAL

WAI Southeast Chapter, held October 15 at the Rock Barn Golf & Spa in Conover, North Carolina. Many of the players have experienced the challenging play of the Robert Trent Jones course, one of two championship quality courses at Rock Barn, but this year the chapter Board decided to add a new layer of contests, while eliminating mulligans. “The intent was to make sure the event stays fun and the pace of play remains favorable,” said Chapter President Art Deming of Nexans Aerospace. “The reaction was positive, and most importantly, the amount donated to the scholarship program was as generous as ever.” For those that finished in the top three groups, there were no complaints as they bested the field of 102 players. “There are some very good golfers that participate every year, but no one takes it too seriously,” said Tim McElhany, who organized the chapter’s earliest outings alongside the late Steve Vannais. “The wire and cable industry works hard throughout the year and this is one of the few chances it has to re-energize.” Taking top honors was the a trio from Southwire, Mark Whisenant, Brandon Bennett and Richard Miller, and Doug Herrick of Chase Corp. Finishing second was a CommScope team of Paul McConnell, Brian Deese, Marcus Kirby and Brian Yount. The third place team included Dave Rascati of Premier Wire Die, Darryl Deitsch of Gateway Recovery, and Craig Shell and Steve Pinnix, both of T & T Marketing. While every player participates in the qualifying round of the putting contest, only 18 advanced to the second and final round. The shot on the final round was purposely set as very challenging, which proved to be the case for everyone except James Moore. The field struggled to get within two feet of the cup, but not Moore, who calmly drained the near impossible shot. Tournament Sponsors included: • Maillefer Extrusion Oy • Commission Brokers • NDC Technologies – Beta • 360 Control Technologies LaserMike • Teknikor Contracting • Rosendahl Nextrom USA • Okonite • Sonoco Plastics • Sonoco Reels • Technical Development • Wire & Plastic Machinery • Sikora • Zumbach • W. Gillies Technologies • Amco Polymers • Henderson Sales & Service • Southwire • J.J. Lowe Associates Hole sponsors included: American Kuhne, Axjo, Breen Color Concentrates, Carris Reels, Chase, Clinton Instruments, Davis-Standard, Gem Gravure, Keir Manufacturing, PolyOne Distribution, Process Controls, Progressive Machinery, Joe Snee Associates, Sonoco Plastics, Sonoco Reels, Southwire, T & T Marketing, Tulsa Power, Windak, Wire & Plastic Machinery.

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INDUSTRY EVENT

WRAPUP IWCS: Atlanta a sound ‘fill in’ for event IWCS did not set out to move its annual event to Atlanta, Georgia, but a wish list of logistics and available schedules at anchor locations in Providence, Rhode Island, and Charlotte, North Carolina, led the organization to the Hyatt Regency Atlanta. The hotel proved to be a remarkably good host. IWCS CEO/Director David B. Kiddoo comments on this and other aspects (including a possible event in China!) in the Q&A that starts on the opposite page, but for a location that was a bit of a surprise, it was quite attendee-friendly. Per IWCS, the technical program, the most important element of the event, had more than 130 technical papers and presentations. One especially interesting session covered power over communications cable, a topic that will be addressed in the December WJI feature, while other noteworthy sessions covered global codes and standards, data centers and micro-cables. CommScope Inc.’s Robert Wessels, the IWCS’s long-serving chairman of the board, welcomed attendees to the event, which had 850 registrants, with attendees from 27 countries. Nearly 30% of attendees were from outside the U.S. The registration number is on the low side, but it reflects one of the challenges of the location: the Suppliers Exhibition could only fit 99 booth spaces, compared to the 125 that can be filled at Providence and Charlotte. The Professional Development Courses, held the day before the full event begins, continues to serve as a forum for core and advanced industry education. The technical papers, presented over three days in 18 sessions, along with the Poster Paper display, ultimately are the anchor of the event. That said, the Executive Track session, chaired by Robert Canny, RSCC Wire & Cable LLC, remains the place to go to for a taste of the “state of the industry.”

CRU’s Richard Mack said fiber is doing well, but China’s rapid growth may slow.

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CRU International’s Richard Mack led off the session with the optical fiber outlook. In 2014, the global optical cable business was worth US$10 billion. The driver has been China, which driven by 4G and FTTH, accounted for more than half of all optical cable deployment in 2015. The installed fiber in cable base is expected to reach three billion km in 2016, and demand is going to require more fiber investment in preform capacity. However, the very success that China has seen may dampen future demand as it has major projects have been completed, raising question marks about future orders. Mack was followed by colleague Rob Daniels, presenting insulated copper wire and cable. He said that the 2014 global metallic market was worth US$173 billion in 2014, down 0.3% from 2013. CRU has cut its growth outlook for the 2015 overall global market for insulated metallic wire and cable from 3.0% to 2.5%. One reason for that has been the declining prices for copper as well as aluminum, but there also has been weakness in Russian, Brazilian and Japanese markets. Sectors that appear to remain strong include underground high-voltage cables and submarine power cables. Looking ahead, he projected growth of 3.5% in 2016, then 4% though 2019. He added that India has the potential to become the fastest growing market in this period, but noted that “history has shown that its track record in meeting its potential is not good.” The CRU reports, which are a mainstay at IWCS, are direct industry presentations. As in past years, a good number of attendees clicked away at each of the slides as they appeared on the screens. Economist Robert Fry, another perennial presenter at IWCS, shared his global thoughts. “People are too negative on Europe,” he said, noting that it has improved as

Economist Robert Fry believes that low oil prices should be enjoyed.

The copper outlook appears better, CRU’s Rob Daniels reported.

INDUSTRY EVENT Dr. Stephan Puissant, BCIAG, taught one of the Professional Development courses.

Activity at the Maillefer Extrusion booth. a whole, while Japan’s long-term growth continues to be about zero. He does not think highly of China’s release of its year-on-year growth numbers, which for August were up 6.1%. He said that he and some other economists created their own basis to determine growth, using 73 industry products. Their unofficial results were that growth in China likely was as low as zero the last three months. The good news for most of the world, however, continues to be that low oil prices should continue for some time. At the Plenary Lunch, keynote speaker Michael Bell, Sr. Vice President & General Manager, Optical Connectivity Solutions, Corning Optical Communication, spoke about how the “Internet of Things” will drive future demand. The Suppliers Exhibition offered attendees an opportunity to meet industry suppliers to discuss their needs.

Among the exhibitors who were pleased with the results was Maillefer Product Engineer Juha Kotala. “It is great to meet customers and partners annually and introduce our latest developments in the fiber optic cable making technology.” He and colleague R&D Director Dr. Mikko Lahti observed that the venue is practical. “It is really beneficial to exchange ideas and experiences, and the show provides a perfect opportunity for further networking during the evening events.” IWCS does not have any plans to return to Atlanta as it is seeking to return to its alternate year locations of Providence and Charlotte, although plans do call for a return to Orlando in 2017. The dates for the next event, in Providence, are Oct. 2-5, 2016. For more details, go to www.iwcs.org.

IWCS CEO/Director: a different view of a very familiar event Dave Kiddoo, a compounds industry veteran, has long been active at IWCS, but the 2015 staging was the first time he was there as the event’s CEO/Director. WJI asked for his thoughts on the event. WJI: As a perennial IWCS attendee, what was it like to experience the event as the CEO/Director? Kiddoo: There are many details that must be addressed to create the most attractive and memorable event for our attendees. I approached every event aspect as though I were the attendee and how I would want the experience to be. It was also extremely rewarding to have had the support of our IWCS staff, the Board of Directors and each member of the Symposium Committee to contribute ideas, resources and sponsorship for the many valuable events throughout the conference.

WJI: The technical papers appeared quite good: was that due to aggressive pursuit of good papers? Kiddoo: Over the past few years, the Symposium Committee has developed a strong procedure to define topics of current interest and to actively solicit technical papers and supply chain contributions from both their own companies as well as their customers and suppliers. Through strong leadership and constant guidance, the number of strong abstracts received this year exceeded all previous expectations. (continued next page)

IWCS CEO/Director Dave Kiddoo welcomes attendees. IWCS photo. NOVEMBER 2015 | 35

INDUSTRY EVENT

WJI: Providence is seen as your even-year anchor location: was Atlanta a one-time setting? Kiddoo: Atlanta was selected to provide a hotel venue that could support both our Technical Symposium and the Suppliers’ Exhibition. Having both in one venue was a great success. It’s hard to ﬁnd a venue that is also “central” to our global cable and connectivity audience, which includes attendees from both Europe and Asia. We can also do this for 2017 in Orlando, but due to the costs and ease of participation in Providence and in Charlotte we have agreed to a rotation of Providence in the even years and Charlotte in 2019/2021. The advantages of Providence and Charlotte are the ease of logistics for one-day drive-in attendees and additional exhibitors. WJI: Aside from the location, how was IWCS most different from the last few shows? Kiddoo: IWCS 2015 had a very vibrant feel to it, relative to previous years. I think that this was directly related to the strong content of the symposium as well as a stronger international presence, with 11% of

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our attendees from Europe and 14% from Asia. IWCS 2015 had 65 visitors from China, along with 36 from Japan! WJI: Why do your key sponsor companies continue to support IWCS? How vital is their support? Kiddoo: IWCS is honored to have 21 dedicated sponsors at various levels of contribution. Each obtain a high level of recognition and prestige as being a signiﬁcant contributor to the leading technology forum for the cable and connectivity supply chain. As industry leaders they are committed to bringing the ongoing technology advances to their customers. Their support is vital for the content and attendance that they provide to IWCS events each and every year. WJI: Is IWCS continuing to evolve? Kiddoo: IWCS is certainly evolving to meet the high expectations that our attendees demand. Bringing technology and conversation on the important issues facing the cable and connectivity industry will always be the core of our events. Our growth will be based on content and panel conversations that involve down-

stream connectivity providers, regulators and network innovators to support such technologies as the Internet of Things, industrial networks or 3D printing/manufacturing. We have also launched our IWCS Webinar Series, which will feature selected presentations from the recent conference as well as important topics that companies wish to bring to our industry. We are also working with our partner companies and trade associations to deﬁne the opportunities to provide for a “supplemental” IWCS Conference in China. Several “topical” conferences have taken place in Asia over the past several years with varying degrees of success. Attendance is always good because the local companies are very eager to hear of technologies being innovated around the world in our industry. If there is a business model that beneﬁts our partners and IWCS to be the provider of a cable and connectivity technology conference in China, we will pursue this opportunity to enhance our IWCS brand and promote attendance at our annual conference.

INDUSTRY EVENT

Social Media questions The wire and cable industry is not generally recognized as a vanguard of social media, but IWCS took a brave first step forward in its use at Atlanta, and was willing to share the results. WJI: How did your use of social media at IWCS come about? Who led the efforts? IWCS: The IWCS planning committee has always been interested in communicating with the next generation, which is evident by the scholarships offered to encourage students to enter our industry. The committee decided this year to reach a broader, younger audience through social media.

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Event staffers spreading the good word from IWCS.

WJI: What were the expectations? Did the plan you started with evolve as it was deployed? IWCS: We decided to jump into the pool by ďŹ rst setting up the basic social media platforms of Twitter, Facebook, LinkedIn and Instagram and were very realistic about not becoming Olympic swimmers, since we started the effort just two weeks before the conference. The goal was

to introduce the audience to those IWCS social media venues and encourage them to participate. We initially thought that attendees would be the most active by posting photos at the show and comments/opinions. We quickly realized that this would take more time for them to be comfortable doing that at this symposium, so we decided to research the companies that were presenting or exhibiting

WJI: What, specifically, was accomplished during the event? Were you able to track how many “messages” were sent out? IWCS: A big benefit of social media is that you can track everything – how many tweets, re-tweets, posts, likes, followers, etc. For example, we could see that one company’s re-tweet of our information had a potential reach of over 10,000 of their followers. WJI: What aspect/approach worked best for social media? IWCS: Photos are the most appealing. WJI: Based on the work it took and the results, do you plan to do this again next year, and if so, is there any part(s) you plan to do differently? IWCS: Since we plan to engage the audience throughout the year by offering an IWCS webinar series, we will continue to engage them on a small but consistent scale through social media as well. Through that we hope to encourage attendees to participate on our platforms, both during the year and during the next conference. WJI: Is it fair to say that there is a touch of irony in that IWCS, which epitomizes the dissemination of advances in wire and cable technology, had to undergo a metamorphosis for social media? IWCS: Yes.

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INDUSTRY EVENT

WJI: How many people were involved in this effort? Was this a combination of people familiar with such usage, or was it a “learning experience” for some/many? IWCS: Our marketing team was guided by a social media consultant experienced with conference work, plus a photographer who knew the type of photos needed and could edit and turn them around quickly. Each were new to IWCS, so the knowledge of the IWCS staff regarding the conference and exhibition was important. The team worked like a well-oiled machine, but the social media aspect definitely was a learning experience for many of us in the IWCS organization.

INDUSTRY EVENT

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EVENT WRAPUP PREVIEW Dignitaries at the 2015 opening event of wire Southeast Asia at the Bangkok International Trade & Exhibition Centre in Bangkok, Thailand.

wire Southeast Asia: good activity Organizers of the 11th staging of wire Southeast Asia The wrapup from Messe Düsseldorf said that potential for the region is being heightened by the formation report that the three-day event, along with its concurrent of the single-economy ASEAN Economic Community tube sister show, saw “strong activities on the show floor” (AEC) that will take place at the end of this year. at the Bangkok International Trade & Exhibition Centre in Combined with the Bangkok, Thailand. start of Thailand’s Per Messe Infrastructure Düsseldorf Asia, a Development Plan total of 411 interthat calls for massive national companies transformation to from 33 countries– the country’s overall including seven national infrastructure national group from 2015 to 2022, exhibits from Austria, the effect should China, Germany, result in robust busiItaly, Taiwan, the ness opportunities U.K. and the U.S. for the wire and tube –showcased their industries in the comlatest technologies to ing years. “The stag7,144 international ing of the synergistic trade visitors from 56 trade fairs comes at countries at the two a timely juncture, events. “With almost Attendees at the SAMPSISTEMI booth at wire Southeast Asia. presenting itself as a 33% of these visitors valuable platform to promote better understanding and coming from outside Thailand–from countries such as business connections between Thailand, the region and Bangladesh, India, Malaysia, Singapore, Taiwan, Indonesia, the international community for mutual benefit,” said Myanmar and Pakistan as well as visiting delegations from Messe Düsseldorf Managing Director Gernot Ringling. China, Japan, Korea and Vietnam–wire and Tube Southeast The release cited good experiences from a range of ASIA 2015 confirmed their status as the regional platform event exhibitors. for the wire and tube industries.”

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EVENT WRAPUP

“Our main objective for participating is to showcase our latest machinery to customers from the region,” said Christian Schalich, area sales manager for Germany’s SIKORA AG. “We were able to accomplish this and at the same time explain the advanced technologies of our machines while the customers test them. Having talked with more visitors than two years ago, I am pleased that we have met our objective fully and will surely be back in 2017.” France’s Numalliance also reported good results, including the sale of a machine to a Thailand customer that was the highlight of their participation. “Not only does this trade exhibition Niehoff GmbH was among the 411 exhibitors at the combined trade events. reach out to the domestic Thai mar(IWCEA), the Austrian Wire and Cable Machinery ket, but it also drew large numbers of Manufacturers Association (VÖDKM-AWCMA) as well industry visitors from regional countries who otherwise as the International Wire and Cable Exhibitors Association wouldn’t be entering the European markets,” said Patrick - France (IWCEA-FRANCE), the German Wire and Cable Maurissen, sales director for Numalliance. Machine Manufacturers Association (VDKM) and the wire Southeast Asia 2015 was supported by internaWire and Cable Industry Suppliers Association (WCISA). tional industry partners including International Wire Association representatives were very positive about & Machinery Association (IWMA), the Italian Wire the opportunity offered for their members. “This edition Machinery Manufacturers Association (ACIMAF), the International Wire & Cable Exhibitors Association Micro-SMac-WJI Novmbr15-Ad 10/27/15 12:20 PM Pageis1better than the last and we have seen good numbers

EVENT PREVIEW A WAFIOS bending system is displayed on the show ﬂoor. and quality visitors. We’ve also received a steady stream of enquiries,” said ACIMAF President Ferruccio Bellina. Added Amanda Shehab, recently named chairman of IWMA, “The Southeast Asian market is a signiﬁcant and growing one, and thus the trade fair presents a great opportunity for the industry to explore the region’s potential.” Both the wire and tube events featured a series of conferences and seminars by industry experts, including the King Mongkut’s University of Technology Thonburi,

the Engineering Institute of Thailand, the Technology Promotion Agency, the International Copper Association and the TumCivil.com Training Center. Topics ranged from safety and energy saving initiatives to installation standards, conversion of overhead power lines and structural analysis and design. Ringling said that plans are already underway for an enhanced and further improved 2017 edition of the trade fairs in 2017. “As specialist trade exhibition organizers with an established history of almost two decades in Southeast Asia, driven by the world’s leading trade fairs –wire Düsseldorf and Tube Düsseldorf– we are committed to working hand in hand with our international industry partners and supporting industry associations to present yet another two world-class exhibitions in wire and Tube Southeast ASIA 2017, reﬂecting the upcoming economic and industry advancements.” The next staging of wire and Tube Southeast ASIA will be held in 2017 at a date to be announced later. For more information on visiting or exhibiting, contact Messe Düsseldorf North America, tel. 312-781-5180; info@mdna.com; www.mdna.com.

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FEATURE

Green: an industry conundrum Whatever “green” is, it has helped keep some wire and cable manufacturers quite busy, as well as led to some operations achieve admirable advances. This feature presents a look at what two manufacturers have accomplished and a group effort to identify safer chemicals, but it also includes a reminder that the industry has not quite turned to tree hugging, and a warning below that ambitious goals can carry a hefty price tag.

The manufacturing cost for ‘doing right’ matters It might not come across in mainstream media, but Scott wrote that considerable advances have been U.S. manufacturers have done quite well reducing polachieved: in particular, SO2 emissions fell from about lution over the past two decades. Per one study, factory 16 million short tons (mst) in 1990 to 3.4 mst in 2012, air emissions fell by two-thirds, even as the real value and NOx emissions from 6 mst in 1990 to 1.8 mst in of manufacturing output grew by 35%, the equivalent of 2012. EPA’s proposed rules that would further tighten a 90% gain. However, those gains are ancient history as restrictions on smog-causing (i.e., ground-level) ozone, exacting EPA regulations appear to be well on their way. lowering allowable levels from 75 ppb to 65 ppb, he In an article in IndustryWeek earlier this year, said. “Judging by EPA data, if the rules go into effect, Stephen Gold, CEO of the Manufacturers Alliance for three-quarters of the country would be unable to meet Productivity and Innovation (MAPI), discussed the realthe new standard. Pursuing these remaining emissions ities of issuing lofty goals. He said MAPI compared polwill demand many, many more resources. Which is why, lution abatement costs and according to another study by found that U.S. manufacturNAM and NERA Economic 2014 U.S. Energy ers pay roughly double than Consulting, it could be the Sector Sources their peers in Japan, three most expensive regulation times as much as Germany ever imposed. A classic and about six times as example of diminishing much as those in Canada returns,” he said. and Korea. The analysis In August, President Obama (air pollution, greenhouse called for even stronger regugases, waste disposal and lations. These would require wastewater treatment) pegs the nation’s existing power annual cost for U.S. manuplants to cut emissions 32% Source: U.S. Energy facturers at $25 billion. from 2005 levels by 2030, Information Admin. “The 1990 Clean Air an increase from the 30% Total not 100% Act Amendments clearly target proposed in the draft due to rounding. (encouraged) industry to regulation. He said the new develop new technologies rules would be “the biggest, Per MAPI, the cost for replacing coal, long an electhat have led to a far more most important step we’ve tricity mainstay, could hobble U.S. manufacturing. efficient and cleaner manever taken to combat climate ufacturing sector. So the change.” He said it would help question isn’t one of effectiveness, it’s one of efficiency, press China to follow suit when a climate deal is sought that is, as we become a cleaner society, how do we reduce this December in Paris. pollution without reducing U.S. manufacturers’ competSen. Mitch McConnell countered that the deal made itiveness?” Gold wrote. “It’s a very relevant question: as China do nothing until at least 2030 while stricter U.S. more resources are invested on a fixed resource, you... regulations would hurt America’s economy much soonreach a point at which additional investments yield proer. The result could actually hurt global warming efforts gressively smaller results. In pollution control this means by “outsourcing energy production to countries with it’s becoming progressively more expensive.” poor environmental records, like India and China.”

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It is a good time to be a global supplier of power cables, especially for renewable energy plants, and even more so for offshore winds projects. Per the Global Wind Energy Council (GWEC), total installed offshore capacity for wind power was 8,759 megawatts in 2014, about 2% of the world’s capacity. The GWEC notes that while the world now uses about seven terawatts of power from all sources, one study pegs global wind power (land/offshore) potential at 72 terawatts. Solar farms supporters might want to chime in, and hydro folks may want to point out that they still top wind, but the focus here is offshore. The ﬁrst offshore wind project was installed off the coast of Denmark in

1991, but at this time construction still continues on what will be the first U.S. offshore wind site, a 30-megawatt, five turbine project off Block Island, so there’s a lot of potential work to come. The National Renewable Energy Laboratory’s (NREL) has previously estimated that the potential capacity of gross wind power off the coasts of the U.S. at 4,223 GW. That figure, it states, is roughly four times the generating capacity of the current U.S. electric grid. Of note, the percentage of the grid connection cost for an off-shore project, which also includes transformers and sub stations, is between 9% and 14% for an onshore unit compared to 15% to 30% for an offshore unit.

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NOVEMBER 2015 | 45

FEATURE CHAPTER CORNER

Offshore wind farms can turn ‘green’ cable to gold

FEATURE

Leoni to literally become a ‘green’ powerhouse

Leoni Cable Inc., the North American branch of Leoni Group, a global supplier of cables and cable systems to the automotive sector and other industries, was named Yazaki’s 2015 Green Supplier of the Year in its “bulk and raw material commodity” category. Leoni reduced its annual water usage by four million gallons and eliminated more than 30,000 tons of potential landfill material per year. However, its efforts have gone much further, including an industry first: a $30 million solar park in Chihuahua that will generate most of the needed energy for its plant in Cuauhtémoc, Mexico, which in 2014 produced four million km of cables. Below, William Livengood, president, Leoni Cable Inc., shares his thoughts on green efforts with WJI. WJI: Your ongoing effort for the solar park to power your Cuauhtémoc plant represents a signiﬁcant investment: will this be Leoni’s most extreme “green” project? Livengood: It is fair to say that this is the largest “green” project that Leoni has ever undertaken. WJI: Why is Leoni doing this? Livengood: Sustainability is an integral part of our Group policy. In 2010, we were the ﬁrst cable manufacturer in the world to develop a holistic concept for “green technology.” This was done in line with our strategy to align our overall business with global trends, one of them being environmental awareness and the shortage of resources. Ever since, William Livengood speaks at the we have tried to Cuauhtémoc plant. enlarge our portfolio of green products, improve production processes and develop more products for green applications. WJI: How did you decide what the Cuauhtémoc project would require to be effective on an industrial scale? Livengood: For solar energy, we wanted more than a couple of solar panels on the roof. We use about three GigaWatt hours of electricity every month, driven largely by our wire drawing and bunching operations. We needed a “utility scale” implementation, and for our Solar Park in Chihiuahua we are working closely with our partner, Buenavista Renewables. WJI: When the solar park is completed in 2016, how much power is it expected to produce a year? Livengood: The solar park, which is located about 175 km away, will utilize over 52,000 polycrystalline photovol-

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taic solar panels to generate 40 GigaWatt hours of electricity per year, saving more than 16,700 metric tons of CO2 a year. Leoni will utilize 30 GWH, the remainder by LaSalle University at 30 different locations in Mexico. This project will be the first utility-scale Photovoltaic (PV) solar project interconnected in Mexico under the self-supply scheme. We aim to set a good example in the automotive supply chain by continuing to minimize our carbon footprint. This project is a great step forward and also supports Mexico’s goal for renewable energy targets. WJI: The solar park is a huge expenditure: how do you balance that with your other efforts? Livengood: For small and midsize projects, we have a number of our own ideas created internally and also shared from other Leoni cable plants worldwide. Further, we do invite consultants in for assistance to ensure that we are evaluating creative solutions that have been successful at other companies. Not every idea has to come from inside. WJI: Does a project have to have a defined payback? Livengood: Not all projects require significant investment. Energy savings can take many forms. It can be the reduction of input needed to manufacture, or savings can be created by improving production yields. We find that most environmental measures also have a financial payback, which makes it even easier to decide to invest. While the solar park will cost more than $30 million, most projects cost less than $10,000. Some activities, such as our educational programs for local schools, have no financial payback, but we feel that the long-term benefit for the community is invaluable. WJI: How do you assess given projects, big or small, to determine whether they should be used elsewhere? Livengood: Our automotive cable plants actively benchmark one another, sharing their most effective projects. Assessments for small and mid-size projects can normally be estimated prior to implementation, and then measured to confirm effectiveness of actions within a matter of months. While we don’t announce performance expectations, our target is for continuous improvement. As

FEATURE CHAPTER CORNER From l-r, the Cuauhtémoc “green” team of Carlos Reynoso, Fabian Cruz, Jorge Nuñez, Adarik Jurado, Raciel Arana, Everardo Ávila, Nora Hernandez, Humberto Bustillos, Alfonso Reynoso and Cesar Vargas. reported in our UN Global Compact Report, we are making progress in developing products that support green technology and increasing products made in certified plants. WJI: Does Leoni issue “green” measures for all its plants to follow, or does it ask staff at those plants to submit proposals? Livengood: Although Leoni does have a Corporate Environmental Policy, each facility is requested to evaluate their own activities and propose actions to minimize their environmental footprint. We have a monthly Environmental Team meeting that consists of members from our North American locations. We evaluate ideas from team members and ideas created from our Kaizen Activities as well as corporate initiatives. Environmental KPIs including utilization of natural resources (electricity/water/gas/cardboard waste/cleaning rag waste) are part of our monthly metrics. WJI: Are any of the changes especially difficult? Livengood: Some items do become technically challenging, like the time we tried to create a cable sauna based on our “waste steam.” Most importantly, we need to understand each operation to recognize the biggest areas in which we can make a difference. WJI: Do any of the measures (taken or considered) include steps outside the plants themselves? Livengood: Shipping is an important way to minimize our carbon footprint. Nothing is more expensive to ship than air (monetarily and environmentally). We have set internal goals for our own packing efficiency of trucks, even as we increase the diversity of our product and customer base. We have increased our packing efficiency from 70% in 2009 to 91.5% in 2012 to nearly 97% in 2015. We encourage participation with our suppliers and we are willing to share our ideas with them.

WJI: Has Leoni taken all the “low hanging fruit”? In other words, have all the efforts likely to bring about the greatest green returns already been taken? Or, are there other measures, maybe much smaller in terms of results, that you can still do at a later point? Livengood: We are never done. There is always so much more to do. Of course, the solar park moves the needle quite dramatically towards a more environmentally friendly business. We have also earned our Green Industry Designation from the Mexican Government (PROFEPA) and we are targeting ISO 50001 registration as well. When we think of “Green,” we also think of the activities that we pursue on the product development side of the equation. We are developing a number of products, such as CuSn, CuAg and CuMg, that enable the “light-weighting” of existing automotive cables. These activities can reduce cable weights by 7-10%. We already have an existing portfolio of aluminum conductor products which also signiﬁcantly reduce cable weight in vehicles. WJI: Was convincing staffers to take the project goals part of the project? How many staffers were involved in this project in some way? Livengood: The leadership team is enthusiastic about these activities as it helps promote good stewardship of our natural resources and makes us feel better for “making a difference” to our customers and our community. Therefore it has been easy for everyone else to become energized as well. For the past four years, the Leoni Cuauhtémoc “green” team has consistently discovered ways to reduce the amount of water, gas and electricity needed per kg of production. What we have accomplished so far reﬂects our commitment both to the industry and our desire to do right as corporate citizens. We believe that these goals can be one and the same.

NOVEMBER 2015 | 47

FEATURE

Superior Essex: 1st cabler to score 100% for zero landfill ... In its July 2015 Sustainability Report (see next page), Superior Essex notes that from 2012-14, the company diverted more than 25 million pounds of waste from landfills through recycling, reuse and incineration. Those efforts were highlighted by the company’s achieving Zero Waste to Landfill certification from GreenCircle (see p. 50) for its copper data cable manufacturing facility in Hoisington, Kansas, the first-ever for a communications cable manufacturer. Below, Eric Perry, Vice President, Applications Engineering/Quality, discusses the company’s efforts that made this possible. WJI: When did your Hoisington plant set out to achieve zero landfill waste? Perry: The commitment to waste diversion began in the Hoisington facility around 10 years ago, and certainly you can easily sort and recycle obvious things like cardboard, scrap plastics, and wood. By various means, we were able to reach 91% in 2014.

Eric Perry, VP Applications Engineering/Quality, Superior Essex. WJI: How did you solve the remaining 9%? What was the hardest part? Perry: The waste diversion certification at our Hoisington facility is based not only on the factory not sending materials directly to the landfill, but also on our downstream waste management and recycling partners. The majority of the remaining 9% was identified through 3rd party audits of these companies, and working with them to develop actionable plans to eliminate waste to landfill. Overall, the Hoisington plant actually received great cooperation. For instance, we were able to identify materials being sent to landfills by these companies and locate an alternate outlet, such as a waste-to-energy facility. We use such facilities for less than 2% of our waste materials. 48 | WIRE JOURNAL INTERNATIONAL

Superior Essex became the wire and cable industry to earn Green Circle’s certification for zero waste to landfill. WJI: Is it feasible for you to duplicate your Hoisington success at your other plants, or are there some, because of their products and processes, that will never be able to achieve 100%? If so, do you then try to shoot for the most attainable percentage? Perry: It’s important to recognize that the Hoisington facility is currently only one of five facilities in the entire U.S. that has achieved the Zero Waste to Landfill certification. It truly is a remarkable achievement and is a testament to the dedication and passion of the Hoisington employees to have a positive impact on the environment. Given the success at Hoisington in developing world-class waste diversion processes, we believe than we can use many of the same processes to improve upon our waste diversion efforts at other Superior Essex facilities. WJI: Do you now have set goals for each plant, or if not, will you be developing them? Perry: We are in the process of developing better metrics and fully understanding waste streams to move ahead with additional improvements at other facilities. WJI: To what degree was this project based on a belief that the changes you made would either result in long-term profits or a break-even state? Perry: In the long run, we do believe there will be a payback from the market. Increasingly, our customers want to do business with companies that embrace sustainable manufacturing practices, understand their impact on the environment, and find tangible ways to improve on those impacts.

● Superior Essex is the first in the communications cabling industry to be able to contribute points toward LEED certified building projects as a result of developing Environmental Product Declarations (EPD) as a source of transparent, scientifically based information which discloses the full environmental impact of our high-performance copper and fiber optic data cable from cradle to grave. ● Superior Essex is the first in the communications cabling industry to have developed a Health Product Declarations (HPD) as a source of transparent, scientifically based information which discloses the potential chemicals of concern in products by comparing product ingredients to a wide variety of “hazard” lists published by government authorities and scientific associations. ● Superior Essex, which ships more than 100,000 wooden reels a year, has a recycling program that helps reduce annual use of new wooden reels by up to four million pounds. Its refurbishment process allows wooden reels to be reused an average of five times. ● Superior Essex has reduced annual energy consumption by more than 8 million kWh through the use of highly efficient lighting and upgraded equipment that promotes efficient energy use. ● Superior Essex has reduced the amount of material content required in multiple data cables by using higher grade compounds. By using less material, Superior Essex effectively reduces waste at end of a product’s life cycle as well as in landfills. “Our environmental initiative is more than just a company objective; it is an ethical responsibility to our communities and to future generations,” company President Tim Waldner stated in the report. “As one of our top goals of our operations and our product designs, we strive to be the environmental leader in our industry that provides a strong commitment to preserve and protect the Superior Essex natural environment.” President Tim Waldner.

FEATURE CHAPTER CORNER

Superior Essex was pleased to report achieving the industry’s first Zero Waste to Landfill certification, but the company’s 2015 Sustainability Report notes that this is part of a much larger focus. Below are some other highlights excerpted from the report.

FEATURE

... but sustainability is more than just setting a record

REMOVE PRINT FROM CABLE WIPE AWAY MISPRINTED TEXT FROM CABLE & TUBING

SINGLE & MULTI WIRE U-SONIC CLEANING SYSTEMS FOR WIRE . CABLE . STRIP

NOVEMBER 2015 | 49

FEATURE

This ‘circle of green’ leads back to the need for it ... Founded in 2009, U.S.-based GreenCircle Certified, LLC, www.greencirclecertified.com, provides specific, third-party certification of environmental claims by companies. Its customers include Superior Essex, which earlier this year saw its plant in Hoisington, Kansas, earn GreenCircle’s first-ever wire and cable industry certification for zero landfill waste (see p. 48). Below, company co-founder and chief certification officer Tad Radzinski discusses the company’s goals. WJI: What does GreenCircle do? Radzinski: We created GreenCircle to ensure specificity, honesty and simplicity in third-party certification. Our goal is to audit and validate our client’s sustainability claims with total truthfulness, so they can use these verified claims to promote their green practices and sell a susTad Radzinski tainable product. Because of our services, consumers can be better informed and make better choices. WJI: Relatively few wire and cable industry’s customers are direct consumers who may indeed care about “green.” Rather, their customers want the lowest price for products that meet applicable codes/standards. If not required to be “greener,” why should wire and cable manufacturers go beyond what they do now? Radzinski: The marketplace is changing. Cost is a necessary and important aspect of sustainability, but focusing on the cost does not capture the whole picture. Major corporations, the federal government, architects, engineers, and builders are developing sustainable purchasing requirements and integrating sustainable design and sustainable products into their decisions. These new requirements are strict, far-reaching, and increasing in number, so your company may no longer have a choice. If you are to evolve and stay competitive in this new market, it’s necessary to understand the sustainability impacts of products and materials. Even more, green building codes and standards (LEED and others) are requiring low-impact and sustainable products for credits. WJI: Do you see more “green” interest from industry? Radzinski: We are constantly approached by manufacturers who want to validate their sustainability claims. They already see the value of being green in the

50 | WIRE JOURNAL INTERNATIONAL

new marketplace, and they want their customers to see and understand the positive impact that their company has. Industry knows the sustainability and transparency matter to the consumer, so yes, we absolutely see interest across the board. WJI: How big a step is it for a manufacturer to seek certification to “zero landfill waste”? Radzinski: Zero waste is difficult, but it’s not impossible. Our clients have found waste reduction to be very manageable. In fact, most of them were doing it already without realizing! Waste minimization, reuse and recycling are most likely already integrated into a company’s strategy, because it inherently cuts costs and makes financial sense. However, by tracking your waste or getting certified, you can get a validated understanding of where your waste goes and how you can integrate waste reduction further into your strategy. We will also highlight areas of improvement which often leads to higher waste diversion numbers and increased cost savings. Our Waste Diversion from Landfill certification is one of our most popular, as it certifies a percentage of waste that a manufacturer is diverting from landfill. WJI: If a company commits to a green direction, can it do so with hopes to eventually find either long-term savings or a break-even point in its investment? Radzinski: Committing to sustainability yields an enormous return on investment, and I would argue that all of our friends in the industry agree. WJI: What would you say to a company leader who simply sees no value in going through an expensive procedure that could also be very disruptive to an existing process? Radzinski: Sustainability can easily be integrated into a company’s existing processes. We have produced “Sustainability Scorecards,” for example, that are designed to fit right into the New Product Design process. And again, many of these things you are probably already doing, such as recycling in the office, or purchasing recycled materials. By examining your product design process, business strategy, and supply chains, you will be able to determine exactly what changes are feasible for your company.

FEATURE CHAPTER CORNER

A landﬁll is a deﬁned focal point where “green” can be a plus, but in a 2010 WJI feature, Mike Patel of Teknor Apex. said that when it comes to compounds, the U.S. market is not overly excited. WJI returned for an update.

FEATURE

... but it’s far from a standard

WJI: Five years later, has the situation changed any? Patel: Unfortunately, nothing has changed. The industry is still not willing to pay any extra for “green” nor is there much interest in it even at same price. Until there is a regulatory impetus to move to “green,” the industry appears to be perfectly satisfied with the status quo. WJI: With that assessment, has Teknor Apex backed off from further investment in “greener” compounds? Patel: Not at all. First, promulgation of environmental regulations restricting the use of certain chemicals continues unabated, and as the market leader Teknor Apex must be prepared to meet the resulting customer needs as they arise. Second, we have learned that one way to address this is to focus on niche marMike Patel at IWCS 2015. kets where a small price differential may be acceptable initially. Over time, we expect that this strategy will generate levels of volume sufficient to lower our costs for these materials, and we can pass the reductions on to customers. Years ago we led the industry in offering non-lead stabilized PVC compounds. Since then, we have developed LSHF flame retardant compounds, grades with bromine-free flame retardants, materials plasticized with bioplasticizers, and other products designed to help customers meet specific “green” criteria. WJI: How do you feel about the lack of interest? Patel: I think it would make good business sense for manufacturers to be more proactive in regard to “green” technologies, if only by working more closely with their compound suppliers so that, as new regulatory requirements inevitably arise, they will be ahead of the curve. That said, most sectors of the wire and cable industry remain intensely competitive, creating great resistance to adopting new “green” technologies and paying a premium for them. NOVEMBER 2015 | 51

FEATURE

Program identifies safer chemicals for use as plasticizers It took years of work, but an independent body formed by a cross section of business, industry, academics and public institutions started out with approximately a hundred plasticizers for wire and cable, specifically for the electronics sector, and a goal: to identify safer chemicals. The list was pared down to nine by methods that included a screening process, then assessed, with the result shown in the tables on the opposite page. The project, which came about through a pilot program of the Green Chemistry & Commerce Council (GC3), is not meant to be an endorsement. Instead, it provides an assessment of the products, and not all of them are complete. First, a bit of background. The GC3 work group, which including industry suppliers BASF, Dow Chemical, Teknor Apex and Hallstar, as well as OEMs/retail, university partners, Government and NGOs, hired an independent Becker toxicology consultant firm. That company, ToxServices, used the Clean Production Action’s (CPA) GreenScreen™ Method. Project group members reviewed the Draft GreenScreen™ assessments and provided additional data and comments. The study was completed in June 2013, but many companies in the electronics supply chain may not be aware of the results, the availability of the data, and the collaborative model that can be repeated for new plasticizers in wire and cable and other chemiMorose cals. More on that can be found at http://greenchemistryandcommerce. org/projects/preservatives-project. Per the study results, the project yielded detailed chemical hazard assessments for wire and cable applications. ® ® Of the nine, four—DEHT, DOZ, Hexamoll DINCH and TEHTM—were “verified” (subjected to rigorous peer review) by a protocol developed by CPA. These assessments are deemed “final,” while the others are considered “drafts” due to incomplete information. GreenScreen™ assessments of Dow’s Ecolibrium™ and HallStar’s Dioplex™ and Paraplex™ plasticizers have not been verified and the reports are redacted. Unlike the other plasticizers assessed in this project—which consist of a single chemical—these three products are formulations of multiple chemical ingredients. The manufacturers did not disclose the identities of the ingredients to the GC3 project 52 | WIRE JOURNAL INTERNATIONAL

group. Instead, the manufacturers provided chemical ingredient information to ToxServices under a non-disclosure agreement (NDA) and ToxServices issued redacted assessment reports. How did these results ever come about? In a past update of the project, GC3 co-director Monica Becker said that the process was not perfect, but that it offered progress via cooperation that otherwise would not come from competitors. “Some brands are finding that this is an area ripe for collaboration rather than competition. Pooling knowledge, funds and data to evaluate safer alternatives can lower the cost to individual companies; create more robust results; help avoid regrettable substitutions; and ultimately increase the demand, availability and lower the cost of the most promising substitutes.” It’s not easy to determine which substitutes make most sense, Becker said. “The path to elimination can be riddled with challenges. Finding a truly safer substitute that can deliver as good or better performance can be time-consuming and expensive, made difficult by the lack of toxicity and performance data on purported alternatives and the need in many cases to compel suppliers to make the switch.” Becker said that collaboration makes even more sense when the target chemical is in a commodity material or component that is common to products sold by multiple brands. “Take power cords for example. Many brands want power cords that are free of polyvinyl chloride, brominated flame retardants, and certain phthalate plasticizers. They source these cords from the same group of suppliers. If these brands are aligned on safer chemical alternatives, they stand a greater chance of getting what they want, cheaper and faster, from their supply chain.” Greg Morose, Research Manager at the Toxics Use Reduction Institute (TURI), was the initial project manager for the project initiative from 2010 to late 2011, at which time that role was assumed by Becker. He said that the nine plasticizers were chosen based upon the results of a survey that was sent to companies participating in this collaborative initiative. The survey asked them to identify the plasticizers they were interested in for further study, the priority for the plasticizers identified, and the reasons for identifying them, including cost, performance and EHS considerations. Beyond the immediate value, Morose said that the project follows strict scientific guidelines. “We wrote up our ‘playbook’ for the project in a Royal Society of Chemistry article so that others could replicate the collaborative model that we developed.” Per Becker and Morose, the findings are meaningful. “We believe that the detailed assessments and the benchmark scores can be very informative for companies that are trying to distinguish between alternative plasticizers based on chemical hazard,” they said. The full report can be found at http://greenchemistryandcommerce.org/documents/ PilotProjectFullReportOct2-final_000rev.pdf.

Plasticizer Acronym

Chemical Name

CAS No.

GreenScreen Benchmark (see explanations below)

DEHT (Eastman 168)

Di(2ethylhexyl) terephthalate

6422-86-2

Hexamoll® DINCH® (BASF)

Diisononyl cyclohexanedi carboxylate

DOZ

Bis(2ethylhexyl) azelate Tris(2ethylhexyl) trimellitate

166412-78-8 (outside the U.S.), 474919-59-0 (inside the U.S.) 103-24-2 3319-31-1

TEHTM

Link to GreenScreen Assessments

Notes Data gaps for neurotoxicity and respiratory sensitization Moderate endocrine activity

Veriﬁed GreenScreen

Data gaps for cancer and endocrine activity

Veriﬁed GreenScreen

Data gaps for cancer and endocrine activity

Veriﬁed GreenScreen

3DG

Veriﬁed GreenScreen

*BASFtoxicologists toxicologistsdisagree disagreewith withthe theassessment assessment endocrine activity Hexamoll® DINCH®. Their assessment is ® ® *BASF of of endocrine activity forfor Hexamoll DINCH . Their assessment is that ® ® that Hexamoll® not endocrine the endpoint for endocrine activitybe should asand that Hexamoll DINCHDINCH® is not is endocrine active,active, that thethat endpoint for endocrine activity should scoredbeasscored “Low”, the”Low”, GreenScreen should be 3 or higher. BASF that their assessment is supported by the published opinand thatBenchmark the GreenScreen Benchmark should bestates 3 or higher. BASF states that their assessment is supported ions number of opinions government scientiﬁc authoritativeand bodies, including Europeanbodies, Food Safety Authority (EFSA). by of thea published of aand number of government scientiﬁc authoritative including the European Food Safety Authority (EFSA). BASF’s detailed comments can be found on the GC3 website.

Table Table2.2.Results ResultsofofDraft Draft(i.e., (i.e.,unveriﬁed) unveriﬁed)GreenScreen GreenScreenassessments assessments Plasticizer Plasticizer Acronym Acronym

DPHP DPHP DINP DINP

Dow Dow Ecolibrium™ Ecolibrium™

HallStar HallStar Dioplex™ Dioplex™ and and Paraplex™ Paraplex™

Chemical Chemical Name Name

CAS CAS No. No.

Di(2-Propyl Di(2-Propyl Heptyl) Heptyl) phthalate phthalate Diisononyl Diisononyl phthalate phthalate

53306-54-0 53306-54-0 68515-48-0 68515-48-0

Modified Modified vegetable vegetable oil oil derivatives derivatives (confidential (confidential formulation) formulation) Polymeric Polymeric adipate adipate (confidential (confidential formulation) formulation)

Conﬁdential Conﬁdential

GreenScreen GreenScreen Benchmark Benchmark (see (see explanations explanations below) below) U* U**

Notes Notes

Link Linkto to GreenScreen GreenScreen Assessments Assessments

Data Datagaps gapsfor forcancer cancer and endocrine and endocrineactivity activity

Draft Draft GreenScreen GreenScreen

1* 1**

High Highendocrine endocrine activity, activity, developmental developmental and and reproductive reproductivetoxicity toxicity

Draft Draft GreenScreen GreenScreen

44 Formulations Formulations BM for 33 form.** form.* BM 33 for BM 2 for 1 BM 2 for 1 form.* form.*

The TheBM BMfor forthe the formulation formulationisisfor forthe the monomer with monomer withthe the lowest lowest GS GSBM BMscore score

Draft, Draft,Redacted Redacted GreenScreen GreenScreen

55 chemical chemical ingredients ingredients BM BM 33 for for44 ingred.* ingred.** BM BM 22 for for 11 ingred.* ingred.* * Based on Draft (i.e., unveriﬁed) GreenScreen assessment.

The TheBM BM22chemical chemicalisisaa Draft, Draft,Redacted Redacted fatty fattyalcohol alcoholmonomer monomer GreenScreen GreenScreen with withmoderate moderate developmental developmentaltoxicity toxicity

Chemical Hazard Assessments of Alternative Plasticizers for Wire & Cable Applications

NOVEMBER 2015 | 53

FEATURE CHAPTER CORNER

Table 1. Results of Veriﬁed GreenScreen assessments

TECHNICAL PAPERS

MORDICA LECTURE The development of conductive material technology for current and future needs of overhead power lines By Tadeusz Knych

From the position of a contemporary observer, the development of the world civilization without electricity would be unimaginable. However, while the annual worldwide consumption of this most noble of all forms of energy exceeded 20 thousand TWh, the per capita consumption reaches only 3 MWh, with several-fold (and in some cases even dozen-odd-fold) difference between different regions (countries) of the world. An analysis of the relationship which is formed between annual electric-

ity consumption per capita and the Human Development Index (HDI) leads to the conclusion that electricity consumption can be considered as a measure of the civilization development. See Figs. 1-2. At the same time, it is thought-provoking to observe that a rapid growth of the world population coincided with the beginnings of the era of electricity. See Fig. 3. One of the main technical issues is the transmission of electricity to customers in real time. Traditionally, this

Fig. 1. The relationship between electricity consumption in MWh per capita and HDI (Human Development Index) in 2006.19

Fig. 3. The rate of population growth in the world.20

Fig. 2. The production and consumption of electricity and the number of people in the world in the years 1960 to 2010, according to the World Bank.20

Fig. 4. Examples of overhead power lines conductors.

54 | WIRE JOURNAL INTERNATIONAL

decided to focus on overhead power cable, with some of the core content stemming from doctor’s theses and doctoral dissertations written by students during the last decade, whose scientiﬁc supervisor, incidentally, I had the great pleasure of being. These works and complete on-topic literature are available, at AGH, at www.bg.agh.edu.pl. I would like to thank the WAI for positive assessment of my research and work as a contribution to the global development of nonferrous metal engineering and processing, in particular the drawing process. I also thank all those who contributed to my achievements in any way.

Conductor design and general characteristics of the materials used1,7,9 Overhead conductors are multi-wire, Class 2 products, with a regular multilayer structure, and the number of layers largely depends on the electrically active cross-section of a conductor. In general, one can speak of homogeneous structures (made of the same material) and bi-material ones, in which heavy-duty and rheologically resistant load-bearing cores are made of patented

Fig. 7. Microstructure of EN AW 6101 alloy as cast from Properzi casting wheel – SEM image.

Fig. 5. Pseudo-binary Al-Mg2Si equilibrium system.

Fig. 8. EN AW 6101alloy rod microstructure, produced on continuous casting and rolling line, using Continuus-Properzi method – SEM image.

Fig. 6. Precipitation sequence diagram in 6xxx series aluminium alloys.

Fig. 9. Al-Mg-Si alloy wire rod microstructure with visible heterogeneous precipitations, observed by TEM. NOVEMBER 2015 | 55

TECHNICAL PAPERS

is done by overhead power lines, which are divided into categories according to the rated voltage. Various operational exposures (climate, topography and environmental factors, as well as current ﬂow) lead to the degradation of properties and quality of conductors. They are often the cause of energy crises caused by blackouts. These factors should be taken into account in the design, construction and operation of overhead lines. The basic element in spans of overhead lines is the conductor, arranged as a stranded structure, which is required to meet an entire array of properties, including: high electrical conductivity of the material it was made of and low resistance, high ratio of tensile strength to mass density, high fatigue, rheological, tribological, thermal and corrosion resistance, along with corresponding operational properties and the ability to recycle easily. These properties depend not only on the type of material used and the wire manufacturing technology, but also on the assumed geometry of the conductor and the manner of its production. As this article was prepared for the 2015 Mordica award presented to me by the Wire Association International, I

TECHNICAL PAPERS Fig. 10. Evolution of EN AW 6101 alloy hardness in continuous casting and rolling Continuus-Properzi line.

Fig. 12. Evolution of EN AW 1370 aluminium hardness in continuous casting and rolling Continuus-Properzi line.

steel wires with zinc or aluminum anti-corrosion coating. Modern HTLS designs use cores of low thermal expandability, made of Invar or carbon fibres in a polymeric resin matrix, or Al2O3 ceramic fibres in a soft aluminum matrix. Wires can be circular or profiled. Fig. 4 shows typical examples of conductors and their historical development. Historically speaking, the first generation of overhead conductors was made of copper. It is worth mentioning that the first in the world, alternating current, overhead line powered a technology exhibition in Munich (1882). Strategic reasons, but mainly the development of an industrial aluminum production technology (Bayer1887/ Hall-Héroult-1886) enabled practical use of homogeneous aluminum conductors (second-generation conductors). However, insufficient strength properties of the metal quickly led to the development of bimetallic conductors, using high-strength, load-bearing steel cores (third generation), which dominate the market today. At the same time, assembly difficulties, the presence of a non-conductive core, and the sentiment among

designers towards homogeneous conductors, soon led to the development of a subsequent, fourth generation of homogeneous conductors made of precipitation-hardened AlMgSi alloys (so-called alloy conductors). These alloys created a previously unknown possibility to comprehensively shape an entire set of wire properties, by means of an appropriate selection of the chemical composition and the initial state of wire rod, as well as the sequence and parameters of heat treatment and plastic forming of the material. Used wires, made both of aluminum and alloys, are in a hardened state, in order to provide the conductor, along with the steel core, with sufficient mechanical strength. Due to the relatively low thermal resistance of these materials’ structures, the conductor operating temperature is +80°C. The need to increase the current carrying capacity inspired a search for materials with a higher heat resistance, without a simultaneous, significant decrease in their electrical conductivity. The group of heat-resistant and economically viable alloys includes aluminum-zirconium alloys gave rise to the fifth generation of overhead conductors known as HTLS

Fig. 11. Evolution of EN AW 6101 alloy resistivity in continuous casting and rolling Continuus-Properzi line.

Fig. 13. Evolution of EN AW 1370 aluminium resistivity in continuous casting and rolling Continuus-Properzi line.

56 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Fig. 14. Diagrams showing different AlMgSi alloy wire production technologies.

Fig. 16. Creep characteristics of AlMgSi alloy wires for different values of stress and temperature.

(High Strength Low Sag). These alloys, depending on the content of zirconium and wire manufacturing technologies, allow long-term conductor use at up to 230°C. Due to the high value of α∆T product, however, HTLS require low thermal expandability load-bearing cores. One of the distinguishing feature in HTLS conductors is the knee point in the sag-temperature characteristics. This corresponds to the temperature above which the conductor works mechanically only on the core, while AlZr wire screen plays only the electrically active part. Due to the high-current carrying capacity, these conductors, at the same time, generate high transmission losses, even though they meet the invaluable role of so-called “anti-blackout” conductors. Regardless of the above, the predominant need in recent years has been the minimization of losses in electric power transmission (low-loss conductors). Energy losses in transmission lines, generated by Joule-Lenz heat and the electromagnetic ﬁeld, reach up to 10%, which represents an annual estimated global costs in the hundreds of billions of dollars. Lowloss conductors are manufactured of proﬁled wires in

order to increase their electrically active cross section, compared with conductors of the same diameter, made of round wires. The latest, realistic concept of low-loss conductor materials is the elimination of non-conductive magnetic steel cores, and replacing them with cores made of high strength and highly conductive CuAg alloy wires. The idea of forming properties in this group of alloys is based on the use of a variable from the temperature of limited mutual solubility of copper and silver in the solid state. This allows, by means of a suitable combination of the chemical composition, supersaturation type heat treatment – aging and drawing – to obtain copper wires with silver nanoﬁbres in a copper matrix, with patented steel strength and electrical conductivity at the level of copper. The achievable limitation of transmission losses can be as high as 40%. Launching the production of graphene, in turn, created a chance to obtain new conductive materials at an electrical conductivity above 100% IACS. This area of research is increasingly used by various international laboratories, while pursuing various forms of copper/ aluminum synthesis with graphene and other allotropic

Fig. 15. Relationship between strength and electrical properties in AIMgSi alloy wires, according to DIN EN 50183: 2002.

Fig. 17. Creep characteristics of alloy wire under conditions of: 136MPa/1 h primary creep, 68 MPa secondary creep.

NOVEMBER 2015 | 57

TECHNICAL PAPERS

Properties Density Ultimate tensile strength (annealed temper) Elongation Elasticity modulus Melting temperature

Unit

Al/Cu

[kg/dm3]

8900

2700

0.30

[MPa]

220

0.36

[%]

1.00

[GPa]

120

0.58

[0C]

1083

660

0.61

varieties of carbon with super-standard electrical conductivity. Table 1 lists the most important properties of materials used in the construction of overhead power lines.

Wire rod and wire manufacturing technology16

Wires made of AlMgSi alloys are obtained from wire rod manufactured in a continuous casting and Temperature coefficient of resistivity, [1/ 0C] 0.0039 0.0041 1.05 rolling Continuus Properzi line. Wire rod is then subjected to heat % 0 Electrical conductivity (20 C) 100 63 0,63 treatment and drawing. In a correctly [IACS] executed process, the alloy is superElectrical resistivity (20 0C) [n m] 17.24 27.3 1.58 saturated on a casting wheel, and in subsequent mill stands, dynamTable 1. Conductive wires of AIMgSi alloys. ic aging takes place. The effects obtained depend on the thermodynamic conditions of casting and rolling processes and the value and speed of deformation, which results from pseudo-binary Al-Mg2Si system (see Fig. 5) and possible phase transformations, beginning from a supersaturated, solid solution to an equilibrium phase (see Fig. 6). Fig. 7 shows an SEM image of the microstructure of a casting made of EN AW 6101 alloy, coming from Properzi casting wheel, and Fig. 7-9 microstructure images of wire rod obtained from this cast. Both the cast and wire rod show visible separations of AlFeSi (bright) and also original AIMgSi separations, located next to them (dark). Moreover, heterogeneous separations are observed on various structure defects (see Fig. 9). Figs. 10-11 show changes in mechanical and electrical properties of the alloy, taking place along the rolling line, and for comparison, similar relationships in Figs. 11-12 for Fig. 18. Wire creep characteristics with cyclical stress EN AW 1370 grade aluminum. It is worth noting that changes from 85 MPa to 68 MPa, time step – 24 hours, despite hot deformation, aluminum does not undergo 20°C process temperature. a recrystallization process, which is evidenced by an increase in mechanical properties, and decrease of the material conductivity along the rolling line. This is a typical characteristic of materials with high stacking fault energy, in which a rapid recovery of the structure takes place whereby the dislocations energy is insufﬁcient for recrystallization. Wire rod from Properzi Continuus line can be subject to heat treatment into various tempers, of which wires are produced, with required tensile strength and electrical conductivity (see Fig. 14). The next step is drawing, which should take place on non-slip drawing machines with PCD drawing dies with a cone opening angle of 16o, with plant lubricants of kinematic viscosity of at least 350 - 400 cst). According to DIN EN 50183: 2002 standard, seven types of alloy wires can be distinguished (Al2–Al7) with Fig. 19. Alloy wire creep characteristics under conditions dimensions and properties as shown in Fig. 15. Evolution with negative temperature gradient; 136MPa/1h/20°C changing the wire assortment resulted from greater and primary creep , 136MPa/-5°C secondary creep. Thermal expansion coefﬁcient

58 | WIRE JOURNAL INTERNATIONAL

[10-6 / 0C]

16.6

23.8

1.43

TECHNICAL PAPERS Fig. 20. Types of rheological behaviour of 2.90 mm alloy wire, depending on stress drop volume and ofﬂoad speed.

Fig. 22. Change in % in resistivity of wires as function of exposure time. Wire diameter: 2.9 mm.

greater opportunities with respect to the forming of AlMgSi alloy properties. This was due to technical progress in the ﬁeld of industrial furnaces for low-temperature aging of wire rod and wires after drawing. The prototype of DIN EN 50183:2002 standard was IEC 104 (1987), in which A and B wire types were distinguished. The current standard distinguishes HC (high conductivity) and EHC (extra high conductivity) wires, and even EEHC, which, in terms of electrical conductivity, only slightly deviate from aluminum wires, maintaining materially higher mechanical properties. According to ASTM B 398, only two types of AlMgSi alloy wires are distinguished (see Table 2).

creep or stress relaxation. In AIMgSi alloy wires used in overhead power lines, low-temperature creep occurs, for which a dislocation mechanism is responsible (logarithmic creep). In accordance with requirements for overhead conductors, 10-year creep must not exceed 0.5 ‰. Fig. 16 shows selected characteristics of low-temperature creep in wires with a diameter of 2.9 mm under various stresses, and at different temperatures, obtained from EN AW 6101 grade wire rod (technology: 9.5 mm wire rod/ homogenization 530oC-10h /supersaturation in water/ natural aging/drawing /artiﬁcial aging of wires). On their basis, Norton-Bayley creep function was deﬁned as:

Rheological properties2,11,17

1.85; φ = 0.021; β = 0.209 are material constants,

Rheological processes are permanent material elongations occurring under loads not meeting the stress criterion of plasticity, and can be expressed in the form of

depending on chemical alloy composition and wire structural state (technology, wire rod mechanical state, size of

Fig. 21. Change in % of tensile strength of wires, as function of asinh (time). Wire diameter: 2.9 mm (arcsinh 200000 = 12.9).

Fig. 23. Images of von Karman vortices. NOVEMBER 2015 | 59

TECHNICAL PAPERS

deformation, parameters of wire artiﬁcial aging), while index

α0=7.17E-066

Fig. 25. S-N diagram; 1- CIGRE SBL – safe boundary line; 2 – conductors; 3 – aluminium wires; 4 – alloy wires. [CIGRE WG 22-01,1989, Report on Aeolian Vibration, Electra 124 (1989)].

Fig. 26. Examples of fatigue fractures (lower wires) against a clearly shaped neck, formed in the course of ordinary tension (upper wire); on wires with fatigue fractures), visible fretting signs.

refers to wire creep under 1 MPa tension, at a temp. of 0°C in 1 h. Creep defined by the above equation is called metallurgical creep. Conductor creep depends additionally on its geometrical structure (number of layers, wire diameters), and is greater than wire creep by 30 - 60% . This equation allows to specify the value of wire and conductor creep occurring in different operating conditions (time, stress, temperature). Creep, despite taking place, by definition, under constant load conditions, also occurs at variable tension. Such conditions occur in overhead lines and are caused by permanently changing temperatures and stresses. Figs. 17-19 illustrate exemplary wire creep characteristics under varying stresses and temperatures, and Fig. 20 shows possible states of rheological activity in this group of alloys, depending on the velocity and stress reduction value. Analyses of presented characteristics show that after stress or temperature drops, material rheological activity tends to decline. In general, depending on the speed and volume of the decline, three rheological states may occur: decreased rheological activity, temporary termination (dead time) and recurrence. In practice, this means that the actual creep time in homogeneous conductors made of AlMgSi alloys, stretched between spans of overhead power lines is significantly shorter than their lifetime, and depends on the span length, climatic conditions, stress and temperature variations, but mainly on the structural condition of wires, and Wire diameter [mm] 1.5÷3.25 3.25÷4.75

Tensile strength, [MPa]

Resistivity

[%] 3.0 3.0

[nΩm] 32.841 32.841

Table 2. AIMgSi wire types to be used in overhead conductors, according to ASTM B 398.

ASTM B 941-05

AT1

AT2

AT3

AT4

Al-Zr

159-169

225-248

159-169

159-165

Modulus of elasticity, [GPa]

[kg/m3]

2,703

Coefﬁcient of thermal expansion,

10-6

[1/oC]

Resistivity, [nΩm] Resistance change ratio,

Elongation

IEC 62004

Parameter \ Material

Speciﬁc mass,

Tensile strength [MPa] 330 315

10-6

[1/oC]

Permissible operating temperature,

[oC]

23 28.735

31.347

28.735

29.726

28.735

0.004

0.0036

0.004

0.0038

0.0036

150

210

230

210

Table 3. Properties of AlZr alloy wires used in HTLS conductor structure.

60 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS

their rheological history. Estimating rheological processes under variable stress and temperature conditions can be made using Robotnov hypothesis. From its analysis, it can be concluded that for real operating conditions, the actual conductor creep time can be 10-15 years, which is approx. 30% of the expected conductor lifetime.

Thermal resistance4 In general, the term heat resistance should be understood as dependence defining the speed of changes material properties as a function of temperature and exposure time. With respect to strength properties, which are finally formed by heat and mechanical treatment, this reasoning is associated with thermally activated processes of aging, recovery and recrystallization of hardened material, which, in a thermodynamically meta-stable state, seeks to reduce its energy level under the influence of temperature and the duration of its impact. Anticipating the pace of changes in wire strength properties, and the determination, on this basis, of a temperature acting on a long-term basis (e.g. 30-50 years) is a fundamental problem when designing overhead lines. On this basis, the present (dynamic) current carrying capacity it is determined for conductors. The traditionally adopted measure of heat resistance, especially for technically pure metals is their recrystallization temperature, usually interpreted as the temperature of a total degradation of consequences of deformation strengthening in a material exposed to one-hour holding. In wires exposed to low temperatures we are talking of long-term heat resistance. Precipitation-hardened alloy wires used in overhead lines are subject to long-term thermal exposure. For this reason, during the operation, further aging occurs. The effects will depend on the temperature and time of exposure. In general, increases in strength properties can be observed, especially at low temperatures, but after several-decade long exposures, there is the risk of strength degradation that may result in a power line failure. The wire temperature is determined based on the conductor heat balance, where, on the heat source side, there is Joule-Lenz heat and sunrays, and on the loss side, there is convection and radiation. Individual components of the balance are significantly dependent on climatic conditions and the conductor construction. Figs. 21-22 show variation characteristics of tensile strength and resistivity in alloy wires (6101), obtained from experimental data, as a function of temperature and time of exposure. It should be noted that for temperatures below 100°C, there is a favourable increase in the strength properties of wires. These translate into a decrease in the conductor effort, and result in a reduction in the rheological activity of the material and the risk of fatigue destruction of conductors. There is also an advantageous decrease in resistivity.

Fig. 27. Conductor showing a wire fatigue crack and the effects of fretting corrosion. Fatigue fracture morphologies with visible foci of fatigue cracks and fretting marks on the surface. (A type of destruction – longitudinal marks; type B – elliptical marks at an angle of 30° to the wire axis).

Fig. 28. Microstructure of fatigue fracture with typical “terraces.”

Fatigue Resistance18 A laminar wind stream, ﬂowing around the cable, causes von Karman vortices (see. Fig. 23), which, detaching from the conductor, excite its vertical vibrations at frequencies below 100 Hz and an amplitude not exceeding the conduc-

Fig. 29. Fragment of AlZr balance system for Al part.

NOVEMBER 2015 | 61

TECHNICAL PAPERS Fig. 30. Strength iso-lines W = 5; 10 and 15% of wires made of wire rod EN AW 1370 grade, in Arrhenius system.

tor diameter. The frequency of vortices depends on the wind speed, conductor diameter and Strouhal number. The the amplitude of vibrations through the conductor rigidity turns into a variable stress amplitude, which, in superposition with static stresses, accelerate fatigue wear of wires and, consequently, of conductors. Fatigue strength of wires depends on their hardening state (tensile strength). This, in turn, can be formed by selecting a suitable production technology, with respect to alloy wires (the content of silicon, magnesium, iron, mechanical state of the wire rod, sequence and parameters of drawing and artificial aging). The wire drawing technology is of considerable importance for fatigue strength, in particular the value of unit elongation, the geometry of drawing dies (especially the geometry of calibration bars) and the drawing machine type (slip, non-slip), which translates into inner stress state, and in consequence, into fatigue strength of the wire. The process of fatigue failure of conductors is intensified by the phenomenon of wire fretting between the layers, which significantly shortens the conductor lifetime. Fig. 24 shows curves: stress - number of vibration cycles to destruction (Woehler curves) for aluminum, and aluminum alloy wires, and for conductors, whereas Figs. 25-28, show sample images of fatigue fractures compared with ductile fractures (see Fig. 26).

AlZr alloy wires6,15 A significant increase in the current-carrying capacity of transmission lines will necessitate a search for new conductor materials, which will be particularly resistant to high temperatures. This allows the maintenance of high level strength properties of wires throughout the entire conductor lifetime. It is accepted that the degradation of properties in the assumed conFig. 31. Strength iso-lines W = 5; 10 and 15% of wires made ductor lifetime is not more than 10%. It is known that of AlZr0,22 alloy wire rod, in Arrhenius system. the addition of zirconium to aluminum, as well as scandium, samarium and other rare earth elements increases the resistance to elevated temperatures. AlZr alloy wires, thanks to the presence of high-melting Al3Zr precipitates are characterized by a high thermal resistance, which was the main reason for their use in the design of high-temperature conductors. Fig. 29 shows a fragment of an AlZr equilibrium system, which demonstrates that in the aluminum part, it is charFig. 32. CuAg equilibrium system. On the right, a view of casting and wire microstructures after strong cold deformation.

62 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Fig. 33. Strength and electrical properties of CuAg 5 and CuAg15 alloy wires.

Fig. 34. Tensile strength – electrical conductivity relation for various copper alloys.

acterized by the presence of peritectic transformation, in result of which, during crystallization of alloys from the range of 0.11 to 0.28wt% Zr, due to the reaction of liquid metal containing 0.11 wt% Zr with Al3Zr phase crystals, a solid phase α is formed. This creates a possibility of supersaturation-type heat treatment - aging in order to

separate dispersion Al3Zr precipitates, segregating to grain boundaries and blocking their thermal migration. From the technological point of view, these are very difﬁcult alloys for casting, due to the presence of a heterogeneous liquid (L + Al3Zr).

W = 5% Time

W = 10%

Temperature

Time

W = 15%

Temperature

Time

Temperature

[h]

[years]

[oC]

[h]

[years]

[oC]

[h]

[years]

[oC]

438000

350400

262800

175200

87600

102

Table 4. Results of thermal resistance in aluminium wires, EN AW 1370 grade.

Drop UTS W = 5% Time Temperature

Drop UTS W = 10% Time Temperature

Drop UTSW = 15% Time Temperature

[h]

[years]

[oC]

[h]

[years]

[oC]

[h]

[years]

[oC]

438000

135

438000

160

438000

183

350400

136

350400

162

350400

185

262800

138

262800

164

262800

187

175200

140

175200

167

175200

190

87600

145

87600

172

87600

196

Table 5. Long-term heat resistance of wires made of AlZr0,22 alloy; H23 wire rod.

NOVEMBER 2015 | 63

TECHNICAL PAPERS Fig. 35. Example of CuAg alloy wires used in heavy-duty and highly-conductive cores for new generation low-loss hybrid conductors. In Europe at the beginning of this century, as the aftermath of pioneering works carried out by Japanese scientists, IEC 62004 standard for AlZr alloy wires was developed; the said alloys being classiﬁed in 8xxx aluminum alloy series (see Table 3). There are four types of wires working at temperatures of 150-230°C. ASTM B 941-05 standard distinguishes one type of wire with a working temperature of 210°C. Figs. 30-31 show respectively exemplary Arrhenius graphs for aluminum wires, EN AW 1370 grade, and AlZr alloy and

wires with zirconium content of 0.22% wt., made of wire rod obtained from a Continuus Properzi line, which underwent thermal pre-treatment. The drawings show diagrams for three values of tensile strength decrease, namely 5, 10 and 15%. Their analysis and the ﬁgures quoted in Tables 4 and 5 show that degradation of strength properties of 10% Al wires, exposed to a temperature of 86oC occurs only after 30 years, while AlZr0,22 alloy wires reach the same value of tensile strength drop after 30 year, continuous exposure to a temperature of 172oC.

Conductive wires of CuAg alloys3,13,12 The previously described types of conductor materials are based on aluminum matrix, which makes their strength, and especially electrical properties are transformed into aluminum wire features. Thinking about a new generation of overhead conductors possessing properties both of HTLS and low-loss conductors requires a transition to copper matrix. This is made possible thanks to CuAg alloys. The CuAg equilibrium system is charFig. 36. The concept of metallurgical copper-graphene synthesis.

64 | WIRE JOURNAL INTERNATIONAL

NOVEMBER 2015 | 65

TECHNICAL PAPERS

acterized by a limited, mutual solubility of copper and silver in their solid state. A practical aspect thereof is the possibility to create a technology to form alloy properties by means of repeated material aging at various temperatures, combined with an intense cold deformation. Such a technology allows the creation of α phase nanofibre structure (solid solution of silver in copper) in β-phase (solid solution of copper in silver), then β phase in α-phase, next α phase in β-phase etc., depending on the number of artificial aging cycles. Intensive cold forming processing, e.g. drawing, converts the separations of α and β phases into fibres with transverse nanometer dimensions, which results in very high mechanical strength of this composite, while maintaining electrical conductivity at the copper level. Fig. 32 shows the CuAg equilibrium system and an example of a microstructure of Fig. 37. Methods of property forming, and the tensile strength casting and wire after a large cold deformation, alloy conductivity relation. and in Fig. 33 are shown strength and electrical tubes with copper and other metals in order to change properties of wires as a function of actual defortheir physical properties and to improve the usability. mation, obtained from CuAg5alloy. CuAg alloys allow There are three main synthesis methods: graphene/ filling in the gap in conductive materials, with respect to carbon nanotube electro-deposition on the surface of a tensile strength – electrical conductivity relation (see. Fig. metal, metallurgy of powdered metals and graphene/car34 in the upper right corner). Fig. 35 shows an example of bon nanotubes, along with their further processing, and CuAg alloy wires used to manufacture cores for overhead unconventional, metallurgical synthesis of graphene/carconductors, as substitutes for steel cores. This combination bon nanotubes with liquid metals. In the first two of these allows the reduction of transmission losses even by 40%, methods there is a serious problem with the wettability of depending on the current carrying capacity of the line. carbon by copper. Due to the high geometrical similarity of Cu atom arrangement in a plane (111) with carbon Composite Cu-C, Al-C conductive wires. Will atoms in the graphene plane (see Fig. 36), high hopes are 14 there be a graphene era in overhead lines? associated with metallurgical synthesis, which makes it The development of an efficient production technology theoretically possible to obtain such structures as those for graphene and the discovery of its properties opened schematically shown in Fig. 36. With a proper orientation up new possibilities for conscious creation of materials of such structures with respect to the current flow direcwith non-standard, especially electrical properties. The tion one can, using the anisotropy of graphene electrical appearance of graphene was a sort of Renaissance with Feature Copper CNT Graphen respect to the research on use of carbon nanotubes to 1084 4520 4620 create materials with high- Melting temperature, [°C] er electrical conductivi- Density, [kg/m3] 8,960 1,300-1,400 1,100-1,500 ty. Table 6 shows selected physical properties of Specific electrical conductivity, [MS/m] 58 1.5-5 x Cu 1.5 – 2 Cu copper, graphene and nano59.6 tubes. What is noteworthy is 401 3500 4800-5300 the very high electrical con- Thermal conductivity, [W/mK] ductivity, low weight and 220-240 11000-63000 130000 high mechanical strength of UTS, [MPa] carbon materials in compar- Temperature coefficient of resistivity, [1/K] 3.9 10-3 ison with copper and aluminum. There are many cen- Longitudinal elasticity module, [GPa] 110 1000 1000 tres in the world, which, in 135 70 70 recent years have been very Atomic radius, [pm] active in conceptual work Lattice parameter, [pm] 361 142 142 and studies on the synthesis of graphene/carbon nano- Table 6. Selected properties of CNT’s copper and graphene.

TECHNICAL PAPERS

conductivity, obtain a Cu-C composite with a very high electrical conductivity. From the technological point of view, this requires a very fast alloy crystallization during a continuous casting process, during which graphene, as a solid, can ﬁt into the elementary cell structure of copper.

Summation Almost every day, contemporary material engineering faces an increasing number of practical challenges that establish new development trends. In the ﬁeld of conductive materials, two trends are generally observed. One is the search for methods helping obtain the highest possible chemical purity. This is a question of the highest possible electrical conductivity, whose measure can be, among others, losses in audio-video signals10. The second one is the search for methods of obtaining materials with new physico-chemical properties on the one hand5 and, on the other, with a very high level of an entire set of simultaneously present usability characteristics (mechanical, fatigue, rheological, thermal strength etc.)8. For this purpose, a database with a commonly known name of the “Periodic Table” is used, as well as known theories and technologies concerning synthesis and processing of obtained materials, along with the most advanced equipment and research labs. With respect to technically pure metals, the formation of strength properties is carried out by strain hardening. What is then subject to degradation is the electrical conductivity of the material to an extent dependent on the deformation volume and the type of material being deformed. With respect to alloys and mechanically consolidated composites, property changes can be caused in a variety of ways, using methods presented schematically in Fig. 37. The efﬁciency of each of them depends on the chemical composition of alloy, and on the type and parameters of the heat treatment applied. The best effects of mechanical strengthening in precipitation hardened alloys are obtained using sequential precipitation and deformation strengthening, and by an appropriate selection of heat treatment parameters, one can also obtain a desired electrical conductivity of the alloy. This is the way in which high strength and high-conductivity CuAg alloy wires are obtained. On the other hand, the use of graphene and nanotubes allows (at least theoretically) to exceed the boundary value (as of today) of copper electrical conductivity, through the development of synthesis technology of new generation materials using copper and the noblest carbon allotropic varieties. And this is the greatest contemporary expectation of the power engineering, and at the same time, the greatest challenge for metallurgy and material engineering of conductive materials.

Literature 1. Andrzej Mamala: AlMgSi alloy self -supported power overhead line conductors stress changes analysis as an effect of material rheological nature, PhD Thesis AGH

66 | WIRE JOURNAL INTERNATIONAL

- University of Science and Technology, 2001 (Tadeusz Knych-supervisor) 2. Beata Smyrak: Analysis of stress-temperature characteristics of AAAC overhead conductors, PhD Thesis AGH - University of Science and Technology, 2006 (T.Knych-supervisor) 3. Artur Kawecki: Research on material properties of trolley wires designed for high-speed rail vehicles, PhD Thesis AGH - University of Science and Technology, 2006 (T.Knych-supervisor) 4. Anna Tarasek: Analysis of mechanical and current-carrying capacity in overhead power lines made of AlMgSi alloys, doctor’s thesis, PhD Thesis AGH University of Science and Technology, 2007 (supervisor T. Knych) 5. Paweł Kwaśniewski: Research of stress relaxation characteristics in metallic materials of different rheological properties, PhD Thesis AGH - University of Science and Technology, 2008, (T.Knych – Supervisor) 6. Piotr Uliasz: The choice of the material and the development construction of high temperature electrical conductor based on AlZr alloys, PhD Thesis AGH University of Science and Technology, 2008, (T.Knych – Supervisor) 7. Tadeusz Knych: Elecroenergetic overhed conductors – Theory – Research - Application, ISBN 978-83-7464250-7, AGH Publishing House, Cracow, April 2010, 8. Michał Jabłoński: Examination of the iron inﬂuence on properties and formability of Al wire rod, won by Properzi method, PhD Thesis AGH - University of Science and Technology, 2011, (T.Knych – Supervisor) 9. Andrzej Mamala: Multi-Wire Homogeneous Power Overhead Line Conductors Model, WN AKAPIT, ISBN 978-83-60958-94-0 10. Monika Walkowicz: The inﬂuence of parameters of the casting process on shaping of material properties of oxygen-free copper for highly advanced applications in electronics and electrical engineering, PhD Thesis AGH - University of Science and Technology, 2011, (T.Knych – Supervisor) 11. Beata Smyrak: Phemenology of Al-Mg-Si Alloys Rheological Properties, Impuls Publishing House, 2013, ISBN: 978-83-7850-449-8 12. Grzegorz Kiesiewicz: Theoretical and experimental studies on contact wire drawing process with the use of polycrystalline diamond dies, PhD Thesis AGH University of Science and Technology, 2013, (T.Knych – Supervisor) 13. Artur Kawecki: High strength, high electrical conductivity Cu-Ag alloys ISBN 978-83-937325-2-4, 2013 14. Tadeusz Knych and all: Characterization of Nanocarbon Copper Composites Manufactured in Metallurgical Synthesis Process, Metallurgical and Materials Transactions B, 1196 Volume - 45 B August 2014 15. Marzena Piwowarska-Uliasz: Study of the effect Al-Zr alloys technology on the properties of wires for

stress and temperature, PhD Thesis AGH - University of Science and Technology, 2015, (T.Knych – Supervisor) 18. Andrzej Nowak: Research on the influence of aeolian vibrations on operational properties of overhead power conductors made of alloys PhD Thesis AGH - University of Science and Technology, 2013, (T.Knych – Supervisor) 19. United Nations Development Program, Human Development Report, 2012 20. Data base of World Bank.

Tadeusz Knych makes his Mordica Lecture presentation.

Tadeusz Knych displays his Mordica Memorial Award. With him is WAI President Bill Reichert, l, and WAI 1st Vice President Andy Talbot.

Tadeusz Knych is a full professor at AGH University of Science and Technology (AGH-UST), Krakow, Poland. He is a specialist in the field of metallurgy, especially synthesis of alloys, hot and cold plastic working, and testing of new materials with respect to modern overhead lines and the railway power engineering sector. He holds Ph.D. and M.Sc. degrees related to theoretical and experimental work on the drawing process. He holds many patents in the area of materials and technologies for overhead electricity and rail. He has authored or co-authored more than 300 papers, and has supervised more than 100 master’s and doctoral theses. He is winner of prestigious national and international awards (including the Prime Minister’s Awards for outstanding achievement in science and technology 2002, 2004, 2009). Prof. Knych is well known as an educator, but he is also well known as researcher and contributor to industry. He has worked with private companies, where his work has resulted in improvements. One such effort was his work for Tele-Fonika Kable, where he helped the company’s drawing process of Al-Fe micro-wires and for commercialization of enamelled Al wires. The scope of such work can be seen in contributions being part of 42 patents. He has been involved in 22 research projects as project manager, main contractor and/or promoter. Two of these projects have been/ are sponsored by the European Union. He also has been active in a long list of smaller projects and consulting work. This Mordica Lecture was presented at Interwire 2015, April, 2015, Atlanta, Georgia, USA.

NOVEMBER 2015 | 67

TECHNICAL PAPERS

electrical purposes, PhD Thesis AGH - University of Science and Technology, 2014, (T.Knych – Supervisor) 16. Piotr Osuch: Research on the process of shaping the properties of Al-Mg-Si wire rod in the ContinuusProperzi© line, PhD Thesis AGH - University of Science and Technology, 2014, (T.Knych – Supervisor) 17. Kinga Korzeń: Low - temperature creep tests of AlMgSi conductor alloys under changing conditions of

TECHNICAL PAPERS

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Pressure Welding Machines Ltd Tel: +44 (0) 1233 820847 Email: pwm@btinternet.com North America inquiries: Tel: 774-991-0504 Email: joe@jsnee.com

New PWM welders and dies available only from PWM or authorised distributors.

70 | WIRE JOURNAL INTERNATIONAL

ucts session, demonstrating the capabilities and advantages of CableBuilder3D, which bolsters the reputation of its ﬂagship product, CableBuilder, as the best cable design system. CableBuilder3D fully integrates into CableBuilder and has extensive 3D modelling graphics abilities, engineering drawing generation and full CAD capabilities. The system can take designs generated in CableBuilder and automatically transform them into 3D near-photorealistic drawings negating the need to hire in a photographer, draftsman or subcontract out to an external graphics agency. The high quality models that it produces are quick to generate and also can be easily adapted to ensure they are kept up to date. The beneﬁts span across multiple departments within a company. Design departments use the software to visualise and convey complex designs, while the high-quality graphics are valuable for marketing on websites and literature including datasheets and catalogues. The images can also be

integrated into a quotation report in order to provide visualisationmaintenance: of the product and addin thatChina, professional edge. Wire those Contact: Cimteq Ltd., www.cimteq.com.

afraid of heights need not apply The focus inInstrument WJI understandably is on wire and wire Clinton Company

production, butProduct sometimes what happens “downstream,” At the New Presentation at IWCS, Clinton meaning “later,” is noteworthy. In this instance, can Instrument Company discussd the advantages of theit comalso be downright scary. As the below account that pany’s new Model HF-15B high frequency sine-wave was spark published in China Daily shows, some types tester, which both replaces and improves uponof thewire highmaintenance not for the weak of heart. ly-successfulare HF-15A model. Clinton booth staff (pictured) included Woody Holland, He does not have muchLangley, interest who in superheroes, but David Carroll and Kristy note the following. Miao Yingjiao has turned himself one ofrobust, China’s Clinton has built its reputation oninto providing “Spider-Men,” growing armyequipment that spends cost-effective, the high-performance thatalmost is easy every night high tirelessly above thetoground mainto use. Thesuspended company works monitortoproduct tain railway lines. on this proud tradition while quality. Theoverhead HF-15B builds After midnight, local high-speed trainsThis come utilizing the mostwhen modern technology available. techallowed some new features. Utilizing tonology a halt,has Miao climbs ontoexciting thin wires six meters DSP-based the China’s HF-15B Guangxi differentiates between above Laibinfault Citytyping, of south Zhuang four types ofRegion. insulation defects: apinholes, multiplehepinAutonomous Carrying pair of pliers, holes, whether direct metal contact, grossand barethe wire. Each checks screws are and in place lines areof these fault types is counted and the total of all fault-types is properly connected. displayed. “My job is to guarantee that high-speed trains operate The HF-15B Series features a large alphanumeric properly in the daytime,” the 24-year-old says. “I display have can becareful mounted directly to the equipment or cancould be tothat be very because a single trivial mistake located remotely up to 200 feet away. The display allows cause a major accident.”

18 | WIRE JOURNAL INTERNATIONAL

access to information beyond test voltage, and total fault count, operators can now toggle switches to view totals of each of the faulttypes as well as the reintroduced percent load function. Four programmable relays allow customized outputs, including high-voltage-on indication, any-fault alarm, barewire alarm, and many more. PLC Integration is easy when connecting with Modbus RTU via RS-485 full duplex. Optional Ethernet/IP, Profinet, Profibus, Modbus TCP and analog communications alsoinoffered. Workers fasten electric are wires a rural area in China. The redesigned BD-12S Split Photo by Song Weixing/China electrode Daily. design opens to facilitate loading and closes around the product, ensuring maximum cableofcoverage. The HF-15B supports Miao is one many Spider-Men who meet automatic the test voltage demand and sensitivity calibration IEC and NEMA increasing for overhead linetomaintenance as the standards usingofClinton’s STCAL system. development high-speed railways continues on the Contact: Instrument Company, tel. the 860-669fast track. Clinton This group of workers came into spotlight 7548 www.clintoninstrument.com recently, when the Chinese ﬁnancial newspaper, the Economic Daily, featured Miao.

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PRODUCTS & MEDIA

ASIAN FOCUS

INTERWIRE PRODUCTSPREVIEW & MEDIA

GENCA ........................................940 Filtertech, Inc..............................1049 Enkotec Company Inc ..................108 This black dye based ink is Gem Gravure Co., Inc. General Copper...........................2160 Fine International Corporation .....332for marking Enshang Machinery now approved Gem Gravure Co.,.......................666 Inc., introduced a new line of wire Enterprise Co Ltd Finoptics Inc ...............................1801 by Boeing. BKG4361WisGillies Technologies, LLC ......958 jacket materials and processes IWCS that was showER-Bakir Elektrolitik Bakir ASat ...924 listed on process specGimax Srl......................................140 Fisk Alloy Inc .............................2140 cased at the new product session. ification BAC 5307. ERA Wire Inc ...............................354 GMP Slovakia Sro........................758 FLYMCAprod& FLYRO.................1907 Keeping ahead of the changes requires continuous Acceptance was based Ernst Koch GmbHMost & Co............1358 uct development. wire and cable manufacturers Golden Technologies Wire & FMS USA,have Inc ..............................618 on adhesion and solvent dark jacketed As a result, white inks are critical Cable Equipment Co, Ltd .... 912/06 Esteves Groupproducts. ...............................806 Foerster Instruments Inc ..............1814 resistance on specific wire for marking. Gem has 10 different white ink jet products. Granite Falls Etna Products, Inc ......................1706 surfaces. BKG4361 can be used in Furnace any style.................1562 of alphaJET Forever Cable New for 2015, WTG7160 has improved adhesion on Materials Group..512/03 ink jet printer. Guangzhou Hanstar Fluoro-Plastic Euroalpha Srl ................................558 Fort WTG7160 Wayne Wire Die, Inc..........1532 polyethylene (LDPE, MDPE, HDPE, XLPE). Recently introduced inks, BLG1866 pigmented Insulated Wires aqua Co, Ltd ....... 412/07 Eurobend GmbH ........................1058 resists transfer with improved rub resistance, even when Fortune Machinery .....................1053 ink, BKG7761 patented black ink for fluoropolymers and Guill Tool & Engineering ............211 printed Spa at room temperature. It sticks to EPDM rubber Eurolls ....................................858 GNG7761 patented green ink for fluoropolymers continue Fridea Srl ....................................1739 surfaces as well. to grow in popularity.Guney Celik ..................................652 EuroWire ......................................132 Frigeco USA WTG6460 white ink is designed with tire marking in Inc ........................1739 Hafner &Inc., Krulmann GmbH .........370 Contact: Gem Gravure Co. www.gemgravure.com. George Evans Corpbase ......................711 mind. The alcohol and methyl ethyl ketone Frigerio(MEK) USA Inc ........................1739 vom Hagen & Funke ....................140 EVG Inccan ........................................150 free ink be used to mark tires in the balancing proFrontier Composites & Castings..215 Huber Engineered Materials Hall Industries ...........................1032 cess. WTG6460 can be removed with alcohol when balEvolution Products, Inc ................133 FSP-One......................................2128 Huber Engineered Handuk Materials, based Atlanta, ancing is complete. The tire is undamaged by coding or UltrasonicinCo, Ltd ........2011 Fabritex, Inc..................................616 Fuhr GmbH...................................752 Georgia, produces an array of halogen-free fire retardant cleaning processes. Hangzhou Harbor Technology Fastener Engineers .....................2056 additives and ground calcium carbonate grades for wire WTG4560 is a popular Gem ink with a new application Gateway Recovery .....................2158 ............................... cable applicationsCo, thatLtd it discussed at IWCS.1512-11 used with an alphaJET pico printer to create the smallest Groupand Fenn LLC....................................1955 Gauder/Gauder ..................424 ® Hangzhou JR Exhibition .............. Huber recently introduced Kemgard 700Z,Co a zinc opaque codesSA on.........................1358 the market. The ink is heavy pigmented. FIB Belgium Gavlick Machinery Corp ............1053 217/306/318/1917/1919 molybdate/zinc borate complex. Kemgard 700Z is a The nozzle size is 42 microns. The result is a tiny white Fil-Tec Inc ..................................1502 smoke suppressant designed to be used in Gravure Co Inc ....................706 Hariton Machinery Co,both Inc flexible ..........147 code for special applications with low line Gem speeds. PVC and as a halogen-free compound in wire and cable BKG4361 is another Gem ink with a new application.

Visit our stand #711 at Interwire 2015

72 | WIRE JOURNAL INTERNATIONAL INTERNATIONAL

properties are often improved for those applications requiring it. Plasticizer levels can often be optimized for even greater ® cost savings. Huber offers a variety of Hubercarb calcium carbonates in 2 and 3-micron grades and high purity ® Optiﬁl calcium carbonate 1-micron grades for wire jacketing and insulation applications. Contact: Huber Engineered Materials, hubermaterials@huber.com

Inhol BV

The concept is a simple new approach: fire protection from the inside of the cable. At the annual IWCS conference, Ron Goethals of Inhol BV presented recently designed highly flame-retarded non-halogen bedding compounds. The continuing challenge to design budget friendly low smoke halogenated and non-halogenated cable constructions to meet stringent specifications will keep

NOVEMBER 2015 | 73

PRODUCTS & MEDIA

applications. The product has a median particle size of 2.5 microns. Huber also offers alumina trihydrate and magnesium hydroxide flame retardant products in a range of particle sizes and surface treatments for wire and cable. Two products of interest are Vertex® 100 magnesium hydroxide and Zerogen® 100 SP magnesium hydroxide. Vertex 100, with a median particle size of 1.5 microns and a surface area of 14 m2/g, is a product well-suited for halogen-free cable jackets. Vertex 100 is also available in surface-treated versions, which offers the compounder flexibility with physical properties. Zerogen 100 SP is an ultrafine particle size, low surface area, high purity grade designed to provide superior dry and wet electrical properties in halogen-free wire and cable compounds. Median particle size and surface area for Zerogen 100 SP is 0.8 microns and 5 m2/g respectively. A noticeable trend in the wire and cable industry is the increasing use of treated ground calcium carbonates in wire insulation compounds which historically have used non-surface treated calcium carbonates. The addition of treated ground calcium carbonate results in a dramatic increase in linear output and smoother surface finishes, due to the increased lubricity spread over the high surface area of the particles. In addition, cold weather physical

PRODUCTS & MEDIA the cable designers alert. The impact of applying bedding compounds to meet specifications like UL 1685 and UL 1277/CSA FT-4 will significantly change the cable world in a few years. Recent tests with bedding compounds have demonstrated remarkable results like reduced flame spread, low heat release and reduced total smoke release. The proof is there, the results are available to everybody on: www.inhol.com/downloads/ videos-presentations Bedding compounds with an LOI of 45% - 55% will not only fill gaps, embed braids and other armours. It will also provide easy peeling, replace tape and reduce toxic gases and reduce the price of up-to-date halogen and non-halogen cable constructions. In combination with LSZH jackets and flame-retarded or non flame-retarded XLPE insulation materials, a bedding compound can act as a filler with superior FR properties. A more economic jacket material can be used as the bedding compound will provide extra protection. Highly flame-retarded bedding compounds will act as the Fire Fighter from the inside! Specialists are available to support you in processing these type of bedding compounds. Processing can be made in a two-step (off-line) or tandem (in-line) extrusion system. Contact: Inhol BV, www.inhol.com.

NDC Technologies

At the new product session at IWCS, NDC Technologies, a leading global provider of precision measurement and control solutions, presented “Why Accurate Lay Length Measurement is Critical in Category Cable Quality and Performance.” 74 | WIRE JOURNAL INTERNATIONAL

The presentation by Stuart Manser, regional sales and channel manager for NDC’s Cable, Metals and Tubing business, was well received by the cable-making community. It gave an inside look at the innovative LayScan lay length measurement system technology, its applications and opportunities to improve product quality and reduce manufacturing costs. The latest version of LayScan accurately and consistently measures the lay length of twisted pairs in data communication cables, such as Cat 5e/6/6a/7a products. It solves scrap, costly rework and productivity loss problems due to manual, time-consuming lay length measurement methods and crosstalk performance issues from lay variations. LayScan can be used to measure the four pairs at the cabler or to measure an individual pair at a twinner to conﬁrm the accuracy of twisted-pair cable construction during production. A data acquisition and control system effectively collects and processes each lay length and enables cable makers to use off-line analysis tools such as trend charts, statistical analysis or FFT analysis

T & T Marketing, Inc. At IWCS, T & T Marketing focused on informing attendees of the range of products the company can offer, including some that it supplies itself. T & T Marketing offers practical, reliable solutions. We have had success with several of our compounds. One of those is PR 2003, a linear low-density polyoleﬁn concentrate that is offered in both black and gray. When blended at 5% with HDPE base resin and various moisture cure resins, PR 2003 offers an excellent balance of

Sales representation and distributioin to the Wire & Cable Industry

ultraviolet protection and track resistance. Blended with HDPE base resin, PR 2003 can be used as an insulating material for 5 to 15 kV Spacer Cable – Tree Wire. It may be used for primary and secondary wire insulation for overhead distribution. The blend of PR 2003 and HDPE is effective in preventing direct shorts and ﬂashovers. Contact: Jessica Hoogendoorn, T & T Marketing, Inc., tel. 610-438-1452, jhoogendoorn@ttmarketinginc. com, www.ttmarketinginc.com.

Teknor Apex At IWCS, Teknor Apex made a New Product ® Presentation on the company’s Fireguard jacket soltuions for emerging fiber optic and copper plenum cables. The diverse new flame retardant (FR) and smoke suppressant technologies have enhanced the performance of wire and cable compounds that are already a leader in PVC-based low-flame/low-smoke products for plenum applications. Four new grades in the Fireguard line of plenum cable compounds exhibit oxygen indices from 49 to 51.5%. Shore C hardness levels range from 80 to 90. The new grades, shown in the below chart, include: ● Fireguard 910A-72-NL for jacketing “hybrid” insulation in Cat. 5e and Cat. 6 unshielded plenum cables. ● Fireguard 910A-76-NL for jacketing “hybrid” insulation in Cat. 5e and Cat. 6 shielded plenum cables. ● Fireguard 910A-79-NL for jacketing of RG6 coaxial cable. ● Fireguard 910A-80 UVF-NL for jacketing of indoor/ outdoor fiber optic distribution cables. “In NFPA 262 flame tests, these new compounds generate lower levels of smoke and flame spread than any generically similar compound in the marketplace,” said Mike Patel, director of marketing and business development for the Vinyl Division of Teknor Apex. “They require no special equipment to process and can be extruded at the same high rates as standard Fireguard compounds.” Contact: Mike Patel, Teknor Apex, tel. 401-6423330 or 401-725-8000, mpatel@teknorapex.com, www.teknorapex.com.

NOVEMBER 2015 | 75

PRODUCTS & MEDIA

to readily observe, measure and report systematic lay variations. LayScan measures lay lengths up to 25.4 mm at throughput speeds up to 152.4 m/min with a measurement accuracy to within 1 mil on the same twisted pair. Contact: NDC Technologies, tel. 937-233-9935, www.ndc.com/betalasermike.

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

BLIND BOX INFO: Responses to Blind Box ads should be addressed to: Wire Journal International, Box number (as it appears in print or on-line), 71 Bradley Road, Suite 9, Madison, CT 06443-2662 USA.

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

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POSITION WANTED WIRE & CABLE REPRESENTATIVE AVAILABLE FOR THE AMERICAS. Do you need an experienced salesman in Mexico, Central and south America? Please contact Antonio Ayala at 1953ayala@gmail. com.

PERSONNEL SERVICES “LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting ﬁrm in the Wire & Cable Industry. Since 1967 we have partnered with industry Manufacturers to secure the services of executives, managers, and thousands of key individual contributors. Contact: Peter Carino, pcarino@ wireresources.com or online at www.linkedin.com/in/petercarino1/ Wire Resources Inc., PO Box 593, Riverside, CT 06878, tel. 203-6223000. www.wireresources.com.

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

MEDIA 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

DEADLINES: Copy is due a full month in advance. Contact: classiﬁed@wirenet.org for more details.

industry people as well as mechanical engineering students. It 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. The late author, Per Enghag, had more than 30 years of experience in metals, serving as director of The Swedish School of Mining and Metallurgy in the 1960s, working for steel wire

FOR SALE 7 - HERZOG 48-C, 72-C, 96-C Braiders 1 - NEB 72-C #2 Braider, Long Legs, Motor 2 - NEB 48-C Harness Braiders, Motors 1 - COBRA 450 36-Carrier Braider 1 - HACOBA Model DF24 24-Carrier Braider 12 - WARDWELL 24-Carrier Braiders 8 - WARDWELL 12-Carrier Braiders 1 - REEL-O-MATIC 24” Caterpuller Capstan 1 - FARRIS 30” Caterpuller Capstan 1 - ROYLE 48” Belt Wrap Capstan 1 - VITECK 36” Belt Wrap Capstan, CBW-36-D 2 - NEB 12-Wire 8” Vertical Planetary Cablers 1 - ALLARD 30” S.T. Closer 2 - NEXTROM 7-Wire MultiWire Drawers 1 - NEXTROM 12-Wire MultiWire Drawer 1 - ENTWISTLE 100mm 24:1 Extruder 1 - DAVIS STANDARD 4.5” 24:1 Extruder 1 - DAVIS STANDARD 3.5” Rubber Extruder 2 - DAVIS STANDARD 2”, 2.5” Hi-Temp Extruders 1 - ENTWISTLE 2” 24:1 Extruder 1 - DAVIS STANDARD 1.5” 24:1 Extruder 2 - TULSA 96” Payoffs, Model CTPO-30, 2005 Commission

1 - POURTIER 72” Rotating Payoff 1 - SKALTEK 1600mm Payoff, Model A16-4K 2 - TEC 2-Position 16” Powered Payoffs 1 - DYNAMEX Tape Payoff, Model TPB30-2-D 2 - TULSA 96” Gantry Traversing Take-ups, GTU-30 1 - SPHEREX 18” Dual Reel Take-up, refurbed 1 - CLIPPER Model SP16 Dual Spooler 1 - AL-BE Model MS12 Respooler, 18” Reels 7 - KINREI 560mm D.T. Twisters 1 - METEOR Model ME301 3-Head Winder 1 - TEC Model DTC630 D.T. Twister 1 - ENTWISTLE 4WDT24 4-W 24” D.T. Twister 2 - NEWMCO 16” D.T. Quadders 1 - FORMULABS 6050A Spiral Striper, 10’ Oven 1 - HALL Tape Accumulator 2 - IMCS Bulk Bag Unloaders, 4,000lb capacity 1 - EUBANKS Model 4000-04 C/S Machine 1 - SCHLEUNIGER Model HS4500 Hot Stamper 1 - SCHLEUNIGER Model CC36 CrimpCenter 1 - ARTOS CS7 Cut/Strip Machine for battery cables 1 - ARTOS MTX10 Multi-Task Wire Processor 1 - AUTOJECTOR HC70S Injection Molder

Commission Brokers Inc., Cranston, RI 02920 • 401-943-3777 www.CommissionBrokers.com • marty137@aol.com

B r o k e r s

NOVEMBER 2015 | 77

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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 ____

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producer Garphyttan in the 1970s, then founding Materialteknik HB in Örebro, Sweden, in 1980. The price is $110, $95 for WAI members, plus shipping. To purchase, go to wirenet. org and click on The WAI Store. INTRODUCTION TO WIREDRAWING FOR OPERATORS DVD. This instructional package is intended to educate beginning wiredrawers and refresh experienced wiredrawers in basic wiredrawing techniques. It is also a helpful educational tool for sales and customer service personnel and others in need of wiredrawing knowledge. It covers basic wiredrawing theory and leads into speciﬁc sections for the ferrous and nonferrous/electrical industries. It is based on several different sources, both old and new, with contributions made by several members of WAI. It covers the following subjects: basic wiredrawing theory, dies, die lineup and reduc-

tion theory, rod grades and defects, descaling, soap practice, helix and cast, packaging, die and block cooling, quality measurement, safety, how to read a micrometer, how to point rod and wire, how to string up and strip out, and how to weld rod and wire. Also available in Spanish. The price is $190, 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

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.

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. THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this 2011 135-page booth by industry expert Douglas Relyea, founder of Quality Principle Associates, a consulting ﬁrm specializing in the education and application of data analysis techniques to industrial problem solving. The list price is $45, $40 for WAI members, plus shipping. To buy, go to wirenet.org and click on The WAI Store. 

T H E W I R E A S S O C I AT I O N I N T E R N AT I O N A L , I N C . P R E S E N T S

& EDUCATIONAL PROGRAMS

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CONVENTION: JUNE 7-9 EXHIBITS: JUNE 8-9 It’s fast. It’s free. 16.COM WWW .WIREEXPO 78 | WIRE JOURNAL INTERNATIONAL

20 16

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

AlphaGary Corp ...........................................Cover 1

KEIR Manufacturing Inc.................................13, 72

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

Lamnea Bruk AB ..................................................31

Anbao Wire & Mesh Co Ltd .................................38

Metal Flex Co Ltd..................................................17

Borealis AG ...........................................................25

Micro Products .....................................................41

Cable Components Group...................................37

Mossberg Industries Inc ......................................27

Cable Consultants Corp ......................................49

NDC Technologies (Beta LaserMike Products) ...1

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

Niehoff GmbH & Co KG .......................................33

Commission Brokers Inc .....................................77

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

Eurotek Srl ............................................................73

Pressure Welding Machines Ltd .........................70

George Evans Corp..............................................72

Proton Products International Ltd ................19, 71

Fenn LLC ...............................................................23

Queins Machines GmbH ......................................39

GMP Slovakia........................................................38

Rainbow Rubber & Plastics Inc ............................2

Honeywell..............................................................15

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

Howar Equipment.............................................8, 70

Sjogren Industries Inc ....................................20-21

Howar Equipment/Unitek.....................................16

Steel Cable Reels .................................................18

Huestis Industrial .................................................22

August Strecker GmbH & Co KG........................45

Ideal-Werk .............................................................51

Talladega Castings and Machine Co Inc............24

Inosym Ltd ......................................................36, 69

Teknor Apex Co ....................................................43

NOVEMBER 2015 | 79

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX PEOPLE

ADVERTISERS’ INDEX ADVERTISER ............................ PAGE Unitek/Howar Equipment.....................................16 Windak Group .........................................................5 Wire & Plastic Machinery Corp .............................9 Wyrepak Industries ........................................12, 42

Jan. 2016 WJI Lubricants and ﬁltration WAI Report to Members New WAI ofﬁcers

WIRE ASSOCIATION INTERNATIONAL ADS WAI Reference Guide . . . . . . . . . . . . . . . . . 18, 28 WAI Operations Summit & Wire Expo 2016 . .30, 78 WAI Webinars . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Industry Search . . . . . . . . . . . . . . . . . . . . . . . . . 79

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SALES OFFICES NORTH AMERICA

Robert J. Xeller/Anna Bzowski Wire Journal International Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

ASIA/WAI

India Office Wire & Cable Services Pvt. Ltd. Rahatani, Pune - 411017, India Huned Contractor mobile - +91 988 1084 202 hcontractor@wirenet.org China Office Zhuang (Frank) zhilu Shanghai, China 200331 mobile - 0086-18018681117 zzs12151116@163.com

EUROPE

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. Tel/fax: 44-1223-360472 franksco @btopenworld.com Germany, Austria, & Switzerland Dagmar Melcher Media Service Int. Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

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Advertising Deadline: Dec. 1

Visit our stand #1350 at Interwire 2015