Wrapup: WAI Operations Summit & Wire Expo 2014 by Wire Journal International, Inc.

WIRE JOURNAL JUNE 2014

INTERNATIONAL www.wirenet.org

 Event

wrap-up

 Dies:

from the show floor

s k n a h T ! g n i m o for c OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

INTERNATIONAL

CONTENTS

www.wirenet.org

Volume 47 | Number 6 | June 2014

 Event

wrap-up

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

 Dies:

F EATURES

from the show floo

Calendar . . . . . . . . . . . . . . . . . 8 Industry News. . . . . . . . . . . . 10

Thankisng! for com

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

WireLink Scholar report . . . . . . . 34

The 2014 U.S. WireLink Scholar recounts her memoOFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL rable experience in the U.K. and at wire Düsseldorf.

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

Wrapup: WAI Operations Summit & Wire Expo 2014 . . . . . . . . . . . . 38

Chapter Corner . . . . . . . . . . . 33

Exhibitors and attendees alike were roundly pleased with both the event and the setting.

Technical Papers . . . . . . 58-71 Products . . . . . . . . . . . . . . . . 72 Classified . . . . . . . . . . . . . . . 77 Career Opportunities . . . . . . 77 Advertisers’ Index . . . . . . . . 79

Next issue July 2014

• Equipment at

wire Düsseldorf

Dies at Wire Expo . . . . . . . . . . . . 46 Suppliers of dies, most of whom were at Wire Expo, discuss their field. Whether you consider dies to be a commidity or not, there’s plenty to talk about.

T ECHNICAL PAPERS Degradation of mechanical properties of drawn copper wire by occurrence of dynamic recrystallization Kazunari Yoshida, Naoyuki Katsuoka, Kota Doi and Yasutoshi Takemoto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Improved Wire quality with advanced TCHP dies Daniel Cunningham, Roger N. Wright and John Keane. . 64 IWCS Paper: Evaluation of Green Jacket Materials in Communication Cables Justin Quinn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Cover: The welcome mat was out in Indianapolis for WAI’s Operations Summit & Wire Expo 2014.

JUNE 2014 | 3

INSIDE THIS ISSUE CONTENTS

EVERYONE A STAR AT WAI RECEPTION . . 38 James Marr, WAI president from 1990-91, was among the many attendees at the Operations Summit & Wire Expo 2014 reception at Lucas Oil Stadium who took full advantage of the tour of the football field. The site also included a dragster, a taken-apart racing engine held in place by wires, a period diner and, of course, lots of food and drink. Needless to say, a good time was had by one and all.

4 | WIRE JOURNAL INTERNATIONAL

U.K.

ROAD SCHOLAR REPORT

. . . . 34

WireLink Scholar Renee Earley’s tour of the U.K. included a stop at Caparo Wire in Wrexham, where she met Technical Manager Jonathan Chappell. She got to see the company’s electroplating line in action as well as a metric board on the floor that allowed the production team to see the results of their work. Her visit, which combined plant tours (both industry direct and indirect) and the opportunity to attend wire Düsseldorf in Germany, also included an unexpected exclusive visit to a well-known U.K. site.

EDITORIAL WIRE JOURNAL ®

EDITORIAL

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

Operations Summit & Wire Expo Review As the WAI President, my perspective regarding the Association’s events is much different now than it was 25 years ago when I was an interested, but not vested, attendee. The difference is that I have seen the inner workings of WAI and have a better understanding of how things happen. That was especially true with the recently produced Operations Summit & Wire Expo. Like every successful wire and cable operation, producing a show is clearly a team effort. The volunteer commitment in the preparation stage is considerable, and onsite, their work is equally meaningful. You probably wouldn’t be surprised to know that the Conference Programming, Education, and Exhibition Planning committees are already working on the 2015 Interwire. I am grateful for the incredible support of the supplier community as they are an essential element of the event. The exhibits are the foundation from which we build the event, and the growing sponsorship support truly helps with the economic side of the event. We know that the suppliers are pulled in many directions, so we appreciate their support of this event. As a representative of an exhibiting company with five wire mills in our portfolio, we are keenly sensitive to the subject of quality attendance. For Leggett & Platt, I can say that we appreciated the good traffic on Tuesday, the total attendance of 1,600 and the valuable networking opportunity that the event provided. I heard only good things about the reception at Lucas Oil Stadium. I was also very pleased with the venue of not only the Indiana Convention Center and the assortment of nearby hotels, but the city of Indianapolis. It turned out to be a terrific choice by our Exhibition Planning Committee. We knew that the city would be buzzing with AISTech co-located with us, but it provided an accurate gauge in the event we decide to return down the road with either the Operations Summit or Interwire. I encourage you to read the full report on page 38 and to mark your calendars for the next Interwire, to be held April 28-30, 2015, in Atlanta, and the 3rd Operations Summit & Wire Expo to be held June 8-9, 2016 at Mohegan Sun in Connecticut. I’d like to thank all the individuals and their employers who supported the second staging of the WAI Operations Summit & Wire Expo. That kind of support is the base the Association needs to be able to continue to offer the industry a venue that we all benefit from.

William (Bill) A. Avise Leggett & Platt WAI President

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail editorial@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2014 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313-761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

CALENDAR

CALENDAR June 16-18, 2014: 15th Guangzhou International Metal & Metallurgy Exhibition Guangzhou, China. To be held at the China Import and Export Fair Pazhou Complex. Contact: MeiWen, tel. 86-1-800-2266711 or tel. 86-20-38621295, meiwen@julang.com.cn, www.julang.com.cn.

June 17-18, 2014: Polymers in Cables Philadelphia, Pennsylvania, USA. To be held at the Hotel Sofitel Philadelphia. Contact: Kelly Cressman, AMI Conferences, tel. 610-478-0800, www.amiplastics-na.com.

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Oct. 28-30, 2014: Wire & Cable India WJI Mumbai, India. To be held at the Bombay 1/2 PAGE Convention & Exhibition Centre. Contact: Messe Düsseldorf ISLAND North America, non-bleed tel. 312-781-5180, info@mdna.com, www.mdna.com.

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Nov. 26-28, 2014: MFSH 2014 Questions? Shanghai, China. To be held at the Please contact:International Exhibition China (Shanghai) Center, this event includes bar, wire, steel rope and more. Contact: Shanghai Aoya Vanessa Steinebach Exhibition Co., at 86-21-3351 8138, Graphic Designer ayexpo@vip.163.com.

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Best Medical International, Inc. April 28-30, 2015: Interwire 2015 & WAI’s 85th Annual 7643 Fullerton RoadConvention Atlanta, Georgia, WAI returns to the Springfield, VAUSA. 22153 Georgia World Congress Center to stage 703-451-2378, ext. technical 169 its biennial trade show, programs 800-336-4970 and 85th Annual Convention. Contact: WAI, USA. Tel. 001-203-453-2777; fax 703-451-4977 fax 001-203-453-8384; www.wirenet.org.

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Sept. 24-27, 2014: wire China 2014 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

vanessa@teambest.com 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, info@mdna.com, www.mdna.com.

5/13/14 1:58:06 PM

86th Annual Convention. WAI, USA. Tel. 001-203-4532777; fax 001-203-453-8384; www.wirenet.org. See p. 32.

Wire Association International Events For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. June 20, 2014: Midwest Chapter 12th Annual Golf Oct. 2, 2014. The Vannais Southeast Chapter’s 13th Tournament Annual Golf Tournament West Chicago, Illinois, USA. The Midwest Chapter Conover, North Carolina, USA. The Southeast Chapter will return to the St. Andrews Golf & Country Club. will return to the Rock Barn Golf and Spa. Contact: Art Contact: Steve Fetteroll, tel. 203-453-2777, ext. 115, Deming, tel. 252-955-9451, art.deming@nexans.com. sfetteroll@wirenet.org. AESA Cortaillod’s booth offered both equipment and sharing of technical information. April 28-30, 2015: Interwire 2015 & WAI’s 85th Sept. 8, 2014: New England Chapter 20th Annual Annual Convention visits and that he left the show with a positive sense for came to discuss for imminent Golf Tournament Atlanta, Georgia,requirements USA. See main listing. projects.” business forward.USA. The New England Chapter The next concurrent staging of wire and Tube will Ellington,going Connecticut, U.K.-based reported thatCountry it is nowClub. deeply place 8-9, from2016: AprilWAI 4-8, 2016, in Düsseldorf, will return to Meltech the Ellington Ridge Contact: June Operations Summit Germany. involved in talking to contacts made at the show, both ForWire further information on visiting or exhibiting WAI’s Anna Bzowski, tel. 203-453-2777, ext. 126, & Expo new and old. “The feeling leaving the halls was definitely at wire or Tube 2016, contact Düsseldorf abzowski@wirenet.org. Uncasville, Connecticut, USA. Messe See main listing. positive, and we ourselves had our best show to date with North America, tel. 312-781-5180, info@mdna.com, more visitors than ever before to the stand, many of whom www.mdna.com. 

JUNE2014 2014| |37 9 MAY

CALENDAR WIRE DÜSSELDORF

June 8-9, 2016: WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. This WAI event, which will be held at the Mohegan Sun Resort Center, will include its trade show, technical programs and WAI’s

INDUSTRY NEWS

INDUSTRY NEWS Johnstown Wire Technologies acquired by investment group

U.S. Commerce Department confirms duties on steel wire from China and Mexico

Johnstown Wire Technologies, Inc., the largest independent producer of high-quality, value-added carbon and alloy wire in North America, reports that it has been acquired by Aterian Investment Partners, a private equity group. Based in Johnstown, Pennsylvania, USA, and formed from the assets of Bethlehem Steel Corp. in 1992, the company is one of the largest producers of value-added carbon and alloy wire in North America. Its products are sold into a variety of end markets, including transportation, construction, utilities, and select consumer durables. The company focuses on segments where metallurgical quality is a differentiating factor. It operates from a single 638,000-sq-ft facility in Johnstown, and has 260 employees. The company was sold by former owner Ridgemont Equity Partners, which is based out of Charlotte, North Carolina. “This transaction is a significant step in the company’s history,” said Johnston Wire President Walt Robertson. He noted in a press release that Aterian has a demonstrated track record of expanding product development and capabilities, investing in operations, and growing businesses alongside management. “Aterian’s support will allow Johnstown to continue to drive results through execution of its strategic plan and its relentless focus on product excellence and customer service.” WJI was told that the company’s current leadership will continue and that there were no specific changes planned for Johnstown Wire at this time. Asked about Arterian’s expected role in the business, a spokesperson replied, “Aterian is fully supportive of the management team at JWT.” The Aterian Group does not have any other wire and cable businesses in its holdings. “For more than 100 years, Johnstown Wire has been a leader with unmatched depth and breadth of its product portfolio and excellence in quality and customer service,” said Aterian Partner Christopher H. Thomas. “We look forward to working with management and supporting the Company in its growth and strategic initiatives while delivering value to its customers.” The release said that Aterian “seeks to focus on the critical growth, operational and liquidity initiatives of a business in an effort to drive value creation for all stakeholders.”

The U.S. Commerce Department confirmed plans for duties on concrete steel rail tie wire from China and Mexico after finding the products were being sold below fair value. A Reuters report said that in its final ruling on the prestressed wire, which is primarily used in commuter and high speed rail lines, Commerce set dumping margins on Chinese imports of between 31.4% and 35.3%, slightly higher than its preliminary ruling. Commerce lowered the dumping margin on imports from Mexico to 9.99% and said there was no dumping of wire from Thailand. The report said that the complaint was lodged by Insteel Wire Products Company, a division of Insteel Industries, and Davis Wire Corporation. In 2013, imports of the wire from China were valued at $31.1 million and from Mexico at $21.3 million. The U.S. International Trade Commission is due to make its final ruling in the case on June 12.

World’s longest superconductor cable integrated into German power grid Nexans reports that a one-km stretch of superconductor cable recently integrated into a power grid in Essen, Germany, connecting two substations in the city center, represents the world’s longest such cable use, and offers hope that more such commercialization will follow. A press release said that the RWE project, called AmpaCity, is now in a field test that over the next two years will determine just how well and efficiently the technology works. It is designed to transports five times

A close-up view of the superconductor cable. KIT photo.

Does your company have news that belongs here? E-mail it to the WJI at editorial@wirenet.org. 10 | WIRE JOURNAL INTERNATIONAL

JUNE 2014 2014 || 17 11 APRIL

INDUSTRY INDUSTRYNEWS NEWS

more than conventional cables, almost without Prysmian Group its wins high-voltage “Theelectricity Columbus Region’s proximity to key automotive LS Cable credits subsidiaries for any losses, while taking up less space. customers provides a strategic location to continue to cable contract for Australian project contracts won in India and Chile Theour properties of thesaid superconducting a grow operations,” Bick Marshall,material, Vice President, Italy’sKorea’s Prysmian announced thatCable) it has reports won a special type of ceramics, and its cooling to minus 200 South LSGroup Cable & System (LS Sumitomo Electric Wiring Systems, Inc. North America. contract to supply 132 kV underground high-voltage degrees Celsius, turn the cable into an ideal electrical conthat it has won contracts in India and Chile that it said were “Consolidating all of our existing Marysville-based assocables (HVC) the North Shore cable upgrade in project ductor,under the release explained. At much Essen,greater the 10,000-volt achieved by thefor efforts of its overseas subsidiaries India, ciates one roof will create efficienby Ausgrid, a state-owned utility of New South Wales superconductor cable replaces a conventional 110,000Vietnam and China. cies, and be beneficial to our workforce, our customers (Australia) managing distribution and transmission assets. voltour transmission line, allows a reduction in transformer and community.” A press release said that the contract, worth approximatestations and moving them to the outskirts of cities, it said. Owned by Japan-based Sumitomo ly €30 million, follows a separate smaller related contract This, it noted, “would make valuable sites in city centers Electric Industries, Ltd. and Visit us at Wire Expo booth # 531 available again for other purposes.” Sumitomo Wiring Systems, the Widespread use of such has firm’s commitment of 15technology new the potential to save billions of dollars jobs will revolve around new testin global powerbeing industry costs. ing capabilities added to “High-temperature superconducting Sumitomo’s Columbus Region energy cables readysaid. for The commeroperations, the are release cialization. It took about 30 for company’s four existing Ohioyears facilihigh-temperature superconductors ties, all located in Marysville, focusto develop fromservice, an ideadevelopment worth a Nobel on customer Prize to an industrial application,” said and repacking capabilities. Mathias Noe, head of the KIT Institute of Technical Physics and a project Leoni reports winning 22 partner of AmpaCity. The RWE project was fundedfor million euro contract by grants of the German Federal refinery project in India Economics Ministry for the Germany’s Leoni announced that Environment and Energy (BMWi), itwhich has won a contract worth about contributed €5.9 million to the 22 million euro to supply what was €13.5 million invested in the project described as the world’s largest by RWE and its project partners,oil the and gas said. refinery India. include release The in partners A presswhich release said that thea superNexans, also designed contract, from India’s Reliance conducting short-circuit current limiter Industries, calls for Leonifor the apart from Ltd., the superconductor to supply the wiring the third trial operation, it said.for“Following expansion stage of its refinery more than 10 years of R&D in the plant in superconductor Gujarat, which requires field of technology, instrumentation and field bus with cableour we can demonstrate, together for measurement and control equippartner RWE, by way of AmpaCity ment. Leoni previously provided that superconduction makes economspecial cables the first two ic sense,” said for Christof Barklage, construction phases. Those cables, at chairman of the Board of Directors itNexans said, were made at Leoni’s facilGermany. ity“Today, in Stolberg, Germany. Leoni scientists and researchers will the frombeallmanufacturing over the worldhalf are of rightly ordered products at its plant in looking to Essen with great interest,” Pune, which was opened CEO in 2013. said Dr. Arndt Neuhaus, of RWE By the end of 2014, 80% of with the the Deutschland AG. “Together cables areour scheduled to be made city and project partners we are and delivered. translating a pioneering pilot projfromonReliance, longectThis intoorder practice a unique ascale. standing customer, underscores the Following the successful installation significance of India to Leoni’s of the superconductor cable, we are business, given thatthe thetwo-year country trial now happy to start promises appealing, medium and operation.” long-term growth prospects for several of the company’s target markets, the release said.

INDUSTRY NEWS

(Engadine) awarded in September 2013 that was worth approximately €5 million. These projects, it said, form part of Ausgrid’s network plans to replace cables and equipment that had been installed about 40 years ago. The areas are: the Willoughby-Lindfield-Castle Cove area on Sydney’s North Shore and the Engadine area, just south of Sydney. The contracts call for design, manufacture, supply, civil works, installation, and test of 132 kV XLPE underground cables for both projects. Multiple Prymsian locations will produce the cables, the release said. The Chinese operations will supply approximately 105 km in total of 132 kV cable, China and the Netherlands will supply joints and outdoor terminations and Prysmian Australia’s Liverpool and Dee Why plants will supply bonding and fiber-optic communications cables, respectively, it said. The Engadine project, it noted, is currently in the installation phase with completion scheduled for this month, after which works on the North Shore cable upgrade project will begin. “This new contract has a strategic importance for Prysmian,” said Frederick Persson CEO of Prysmian Group in Australia & New Zealand. “It underlines our long-standing leading position as a major supplier of an extensive range of products to power utilities, telecommunication carriers, electrical wholesalers and contractors, OEMs, the mining industry and petrochemical facilities.” The release said that Australia represents a major market for the Group, with a number of projects currently ongoing and already accomplished. These include “Basslink,” the Victoria-Tasmania submarine HVDC interconnector; the NBN project for the supply of fiber optic cables for the development of the new National Broadband Network; and the Pluto, Gorgon, Wheatstone, Australia Pacific and Queensland Curtis LNG projects.

Alcatel-Lucent/Nextgen to supply cable for Australian LNG projects Alcatel-Lucent and the Nextgen Group will provide oil and gas giants Shell and INPEX an optical fiber cable to the companies’ liquefied natural gas (LNG) projects off the Kimberley coast of Australia. The project, valued at $100 million, au.news.com reports, calls for Nextgen to build, own and operate the cable system supporting INPEX Ichthys LNG project and Shell’s Prelude LNG project in the Browse Basin. The system, it said, will stretch about 2000 km between Darwin and Port Hedland. Based on Alcatel-Lucent’s undersea technology, the cable will have a design capacity of more than 8 terabits per second and the potential to be upgraded to more than 32 terabits per second. The cable will enable INPEX and Shell to provide a full range of communications services for the life of both the Ichthys and Prelude projects. Work has begun and is scheduled for completion in 2016, it said. “This project further expands our presence in the oil and gas sector and is a prime example of how submarine

12 | WIRE JOURNAL INTERNATIONAL

The proposed undersea optical fiber cable off the coast of Australia. fiber optic has become a standard for oil and gas companies to connect their offshore assets,” said Philippe Dumont, president of Alcatel-Lucent Submarine Networks. “It also demonstrates how technology advances can accompany the evolution of economic and energy needs, and address the needs of our customers to better control risks regarding system quality and project management.” Shell’s Prelude project will be world’s first floating LNG project, the report said. “This will help to unlock new energy resources offshore and has the potential to revolutionize the way natural gas resources are developed.”

nkt cables gets final okay for Gemini Project funding Denmark’s nkt cables, part of NKT Holding, reports that the Gemini offshore wind farm project developed by Typhoon Offshore B.V. and owned by a consortium of investors has finalized financing and resulted in the company getting a binding order worth approximately €165 million. A press release said that the company will deliver more than 200 km of 220 kV high-voltage submarine cables and related accessories, all to be manufactured in Cologne, Germany. The cables are to be delivered ready for installation starting early 2015 to the EPC contractor for the Gemini project, Van Oord. It added that the company received an order for supply of the land cable portion of this project, which includes 5 km of 380 kV cables and around 30 km of 220 kV, to complete the windfarms’ connection to the Dutch onshore high voltage grid. Per the release, Project Gemini consists of the Buitengaats and ZeeEnergie wind farms to be situated in the Dutch zone of the North Sea, 55 kilometers northeast of the island of Schiermonnikoog, and will have a capacity of 600 MW. With 150 turbines, the wind farms will produce electricity for more than 1.5 million inhabitants. It added that Gemini represents nkt cables’ 10th offshore wind farm project since 2010 when the submarine cable factory in Cologne first started the production of submarine cables.

INDUSTRY NEWS

Ameritherm acquired by investment firm Graycliff Partners, an independent investment firm focused on middle market private equity investments, announced it closed on its investment in a majority stake in Ameritherm (known as Ambrell), a designer and manufacturer of precision induction heating products and systems. A press release said the Ambrell management team retained a significant amount of equity as part of the transaction. Based in Scottsville, New York, Ambrell designs, manufactures, and markets precision induction heating products for sectors that include the wire and cable industry. The company was founded over 25 years ago, and notes that it has sold more than 10,000 systems in more than 50 countries. In recent years it expanded its operations in Scottsville, adding a second manufacturing line for producing high-power induction heating systems.

Nexans to supply DEH system for record Caspian Sea project Earlier this year, Nexans announced that it will provide and install Direct Electrical Heating (DEH) cable systems that will help maintaining the reliable flow of products from the Shah Deniz natural gas field that is located in the Azerbaijan sector of the Caspian Sea.

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14 | WIRE JOURNAL INTERNATIONAL

A press release said that the project, valued at approximately 100 million euros, represents the largest DEH effort to date. It noted the following. Nexans will deliver a total of 130 km of the cable system to provide flow assurance for 10 subsea flow lines. The DEH systems, including riser cables, piggy back cables and accessories, will be designed, engineered and manufactured at Nexans’ specialized subsea cable and umbilicals facility in Halden, Norway. They will include a modern integrated protection system (IPS) to protect the sophisticated piggy back cables against damage after installation on the sea floor. The first system delivery is scheduled for July 2014, and second for June 2016. “This contract forms part of the 10-year frame agreement Nexans concluded with BP to supply umbilical cables, DEH systems, accessories and services for various deep-water oil and gas projects across the globe,” said Krister Granlie, vice president of the company’s Hybrid Underwater Cables Division, Nexans Norway. He said the DEH technology presents a reliable and environmentally friendly flow assurance, and that the company has already done several pre-studies in cooperation with BP regarding the application of DEH systems across the Shah Deniz field. Per the release, DEH technology safeguards the wellstream flow through the pipeline to the platform. Alternating current (AC) transmitted from the DEH cable runs through the steel in the pipe, which heats up due to its own electrical resistance. By controlling the current, the pipeline inner wall can at all times be maintained above the critical temperature for wax and hydrate formation.

Russian order for steelworks from the SMS Group includes wire rod capacity Germany’s SMS Group announced that it has won an order worth 180 million euros from Tulachermet-Steel to supply a complete steelworks complex that will include converter-based steel and rolling mill complex that includes capacity for steel wire rod. A press release said that the complex will be located in the immediate vicinity of the Tulachermet iron works, about 200 km south of Moscow. Tulachermet-Steel will assume the project management and the construction activities, with the contracts for the construction and installation work placed with Russian companies, it said. The rolling mills, which will make light sections, bar steel and wire rod, will be designed for an annual capacity of 1.5 million tons in the first phase, with the possibility of a later increase to two million tons, the release said. The major part of the production will be supplied to Moscow and to other regions in Central Russia. Here, there is a demand for high-quality steel products, above all from the construction industry and from mechanical engineering and automotive companies. The steelworks and rolling mill complex will go into operation in 2016. SMS Meer is supplying two almost

INDUSTRY NEWS

identical light-section mills, each of which will be supplied by a walking beam furnace with a capacity of 160 tons per hour, the release said. One of these light-section mills will be equipped with a wire rod line for the production of quality steel in the form of bar steel and wire rod, it said. Tulachermet-Steel is a Russian-based company established by several investors with the participation of shareholders of the KOKS Group. The KOKS Group is a leading producer of merchant pig iron and coke. The group possesses various assets for the production of high-quality coking coal and the extraction and processing of iron ore.

DSM announces successful defense of fiber optic coating patent portfolio DSM reports that it has successfully defended multiple patents in their fiber optic coating patent portfolio against a validity challenge at the U.S. Patent and Trademark Office (USPTO). A press release said that in November 2012, eight of DSM’s patents were challenged in 10 Inter Partes Review (IPR) proceedings. On May 1 and 9, the USPTO Patent Trial and Appeal Board upheld the patentability of a substantial majority of the claims in the challenged patents and in four of the patents every claim was upheld. “DSM remains confident in the strength of its patent portfolio and expected this very positive outcome,” said Rob Crowell, president, DSM Functional Materials. “Developing and protecting intellectual property is a key component of our strategy to support our significant investments. These decisions by the USPTO validate our ongoing commitment to innovation.” The release said that the patents where all claims were confirmed valid include: U.S. Patents 6,961,508 and 7,171,103 titled “Coated Optical Fibers,” 6,438,306 titled “Radiation Curable Resin Composition,” and 6,339,666 titled “Radiation-Curable Optical Glass Fiber Coating Compositions, Coated Optical Glass Fibers, and Optical Glass Fiber Assemblies.” These IPRs, it noted, were among the first cases in which a patent owner was successful in defending the patentability of their patents.

Suzlon deploys Nexans’ cable technology for wind turbines Nexans is providing complete end-to-end cable solutions for approximately 150 wind turbine generators to be produced by India’s Suzlon for projects in Brazil. A press release said that Nexans will help Suzlon “achieve effective and reliable connections” for the generators. The contract, valued at about €11 million, calls for Nexans to supply its WINDLINK® LV and MV tower cables, site kits and accessories together with MV inter-array cables and HV export cables that form the connection to local substations as well as comprehensive technical and logistical support. JUNE 2014 | 15

INDUSTRY NEWS

While the wind farm projects are located across Brazil, Nexans is delivering the cables to Suzlon production sites around the world including Vietnam, Indonesia, South Korea and Brazil, the release said. The Suzlon Group notes that it has some 10,000 employees and was ranked as the world’s fifth largest wind turbine supplier at the end of 2013. It supplies technology from sub-megawatt onshore turbines to the world’s largest commercially available offshore turbine at 6.15 MW.

panies are currently building a steel fiber manufacturing plant in the Orotina industrial site at a cost of more than US$20 million over two years, it said. Citing Espeschit, the Reuters report said that the move “will improve our competitiveness and help us add more value to our products. BBA output of steel wire and related products is targeted at about 750,000 metric tons in Brazil this year, although production might end the year closer to 700,000 metric tons.”

ArcelorMittal and Bekaert agree to swap stakes in Latin America wire ventures

nkt cables tasked with monitoring submarine cables for Baltic 2 project

ArcelorMittal SA and Bekaert Group have agreed to swap their stakes in their Brazil, Costa Rica and Ecuador ventures, part of a broader plan to extend a four decade partnership in fast-growing markets. A report in Reuters cited Augusto Espeschit, president of Belgo Bekaert Arames, as explaining that the plan calls “for ArcelorMittal to transfer its 55% stake in a rope-producing venture to Bekaert, allowing the latter to control all of Bekaert Cimaf Cabos Ltda in exchange for steady supply of wire.” Further, ArcelorMittal will have a minority shareholding in Bekaert-controlled wire producer, Ideal Alambrec, in Ecuador, taking advantage of rapid expansion in the country’s civil construction sector, he said. In Costa Rica, both companies agreed to split their share in a steel wire plant, with Bekaert taking a 73% stake and agreeing to leave the steelmaking business all under ArcelorMittal’s control, the report said. The com-

Denmark’s nkt cables reports that following its successful use of its VALCAP Load Management System for monitoring the Baltic 1 submarine power cable, the company has been asked by the German electricity transmission system operator 50Hertz to monitor the Baltic 2 project cables as well. Both Baltic 1 and Baltic 2 are important submarine cable connections in the Baltic sea that are used to securely transport wind energy from the Offshore Wind Parks Baltic 1 and Baltic 2 to the mainland grid of 50Hertz, the release said. The monitoring system, it noted, allows additional transmission capacity to be used for this purpose, and therefore provides technical as well as financial benefits. VALCAP, the release said, continuously monitors the conductor temperature and transmission capacity of power cables, taking into account the impact of changing environmental conditions in the surroundings of power cables, and provides an intelligent warning and alarm system that is integrated into the customer’s infrastructure.

Germany’s Carl BECHEM GmbH buys interest in U.S. joint venture Germany’s Carl BECHEM GmbH reports that it has purchased all of its joint venture’s interest in Etna-Bechem Lubricants, Ltd., which it has renamed BECHAM Lubrication Technology, LLC. A press release said that Etna Products, Inc. the joint venture partner, will continue to operate and to serve its lubricant customers as an independent privately held company “just as it has done for the last 70 plus years,” while BECHEM Lubrication Technology, LLC, will continue to focus on the growth and expansion of the current lubricant markets being served, while looking to further expand into other niche markets with the globally recognized Carl Bechem technologies and brands. The company notes that it has operations in China and India, and that this move allows it to have wholly owned entities in the world’s major engineering centers. The release said that John C. Steigerwald, who had served as president of the joint venture, “will continue to lead the continuing business expansion” of the new entity in North America.”

16 | WIRE JOURNAL INTERNATIONAL

PRODUCTS & MEDIA

INDUSTRY NEWS

facturing where a small scratch or nick can be an unacWeb Industries celebrates 45 years News briefs Air-cooled extruder provides quality ceptable defect. The result is the Surface Inspector, which U.S.-based Web Industries, Inc., is celebrating its 45th Alpha Wire has been recognized by the Genie flow of insulation for vulcanizing line comes in two models, the SI3100 and SI4100. year providing outsource flexible material converting and Group as Partner of the Year at its annual conference.

WAI OPERATIONS SUMMIT & WIRE EXPO 2014

At wire Düsseldorf, Maillefer presented The Surfaceservices Inspector operator withThe Genie Group, contract manufacturing for provides fields thatthe include which aligns itself with 44 premier an air-cooled extruder, 150, that provides 300 kg/h output up-to-the-second digital image feedback of the current wire and cable, for which it offers products such as cable suppliers, notes that itmodel is the MXI largest electronic marketing with a low melt temperature. jacket, bar or water soluble tape quality on any producfillers, tape, traverse mechanisms. group in the U.S., with collective buying power over $1 tion line. This continuous stream of real time informaThe company was founded in 1969 by Robert Fulton billion, a press release said. Alpha Wire was awarded the and failure images–allows the operator on $10,000 tion–especially raised from family friends, initially servwith three awards: Excellence in Marketing, Excellence to goods isolateslitting causesand of jacket imperfections and waterinsoling the rolled spooling market. Today, Service and Delivery, and the Partnership Award. The ublehas tapeseven folds. This result you toand identify the Web Industries facilities in sixallows U.S. states marketing award was related to Alpha Wire’s successful causes surface sq defects and prevents customer comGermany, with overof600,000 ft of advanced converting new product introductions, most notably for its launch of plaints or rejects. and manufacturing capacity, and its customers include EcoGen, it said. ... Outokumpu’s rod mill in Sheffield, the Surface Inspector, you can capture images of has won a gold achievement award in the RoSPA Fortune 100 Using corporations. U.K., printed cable, imagessaid to disk them Companyyour President and CEOsave Donthe Romine that and printOccupational Health and Safety Awards 2014 for the outhas to successfully include in your quality reporting both internally the company transitioned from slitting site’s occupational health and safety management sysandrolled to your customers. Surfaceconverting Inspector’s display commoditized paper goods toThe high-tech tems and practices. The rod mill award is quite unusual also makes it easy for engineering and MFL . . . a . .first-time . . . . . . . . .applicant . . . . . . 529 Mossberg Associates Inc of . . . . . . . . . 444 and manufacturing services for specialized markets.production “OurGroupsuperfor and demonstrates the amount visors toimprovement examine the through defect. innovation, focus on continual effort of Inc the . Outokumpu team over the past few years,” MGS Manufacturing . . . . . . . . . 103 Mossberg Industries Inc . . . . . . . . . . 421 Defect locations can also beemployee-owners recorded, this will allow reinvention, and reinvestment in Web’s said Rob Charlesworth, EHSQ manager, Outokumpu rod Co . . . . . . . . . . . . . . 132 Nextrom (USA) Inc . . . . . . . . . . . . . . 333 for further analysis of the defects later to on.Micro TheProducts Surface has been the key to our success and will continue guide mill. “We saw the RoSPA awards as an opportunity to Inspector defectsFounder on the wires before they reach Mid-South Wire . . . . . . . our . . . .systems . . . . . . 110 Oy . . . . . .in . . the . . . . . . . . . . . 333 Web Industries for thewill nextcatch 45 years.” Robert benchmark against Nextrom the top industries youractive customers failcompany, in the field. Corp . . . . . . is . . an . . .acronym . . . 127 of the Niehoff Endex Northfor America Fulton remains withinorthe serving asMorgan-Koch U.K. RoSPA Royal Society the Inc . . . 317 unit ensures Contact: Girdwood, Taymer International, Prevention Inc., chairman emeritus on Craig the Board of Directors. ofThe Accidents.  good medium-voltage cable durability due to the homogenous melt, resulting in high insulation tel. 905-479-2614, ext. 232, craig.girdwood@taymer.com, quality. The MXI 150, which is easy to operate and www.taymer.com. Visit us at Wire Expo Visit us at Wire has low maintenance needs, is booth # 531 part of the company’s medium voltage catenary continuous vulcanizing line, EPL 30/Enter. EPL 30/Enter is a compact quality solution for more sustainable production. It offers affordable investment that is easy to start and maintain in different production environments. The Maillefer medium-voltage catenary vulcanizing line is designed for continuous insulation of XLPE insulated cable cores. The conductor is insulated by proven XLPE extruders and triple crossheads. The combination of the advanced Autocure line control system, triple crosshead and X-ray dimensional measurement provides the possibility to minimize start-up scrap and material over-consumption during your cable production run. Contact: Jorma Leppänen, Maillefer, tel. 358-40-504 8308, jorma.leppanen@maillefer.net, www.maillefernet. n

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JUNE 2014 | 17

ASIAN FOCUS

ASIAN FOCUS Debt and lawsuits part of landscape for Chinese steel trading companies China’s steel market remains the world leader, but one indirect threat to its positioning is the shaky condition of its steel trading companies, as spelled out in recent stories in Macro-business (www.macrobusiness.com. au) and Global Times (www.globaltimes.cn). The articles explained that while the challenges faced by the country’s steel trading companies do not directly impact steel manufacturers, because of their ownership, investments and relationships it could be one more negative factor for a field that already faces overcapacity issues, pollution concerns and trade cases. An article in Macro-business focused on the debt and legal problems that the steel trading companies face. Last year they were the subject of some 2,500 lawsuits at the relevant court in Pudong, Shanghai; in the first quarter of 2014 there were 1,051 lawsuits. Last year the cases amounted to 19 billion yen, this year they are already 11.4 billion yen, in other words the average case in 2013 was about 7.6 million yen, but this year it is up to 10.8 million yen, an increase of 40%. The situation is expected to continue to worsen into next year. The Macro-business article, citing a court insider, said that this year’s cases have some new characteristics. One is concentrated debt, one example of which it said was Xiao Jiashou, a Shanghai steel trading king, which saw the seizing of assets worth 460 million yen. Second is that in general cases are getting larger and larger, with those over 10 million yen in debt becoming more frequent. Third, the service rate is down (service of process) because the defendants have fled. Last year the assets in these cases were better, and people were willing to mediate, said the Macro-business article, which noted the following. “This year asset quality has deteriorated and so defendants don’t care. In 2013, banks lent about 200 billion yen to the steel trading industry. About 70 billion yen of that sum is in default, and another big chunk of it is not due until next year, but is expected to default. Many banks lent to dealers who have relationships with the steel mills. If the dealer can’t sell the product, many mills agree to buy it back, thus the banks are going after the mills. This spreads the credit risk from the dealers right to the top of the steel industry. Already there are rumors of private steel mills going bankrupt.” The article said that the loans were not limited to steel trading. Some 10-20% of the proceeds were used to make high-interest loans or for speculation in real estate and land. Those conditions, it said, have led to some of the steel trading firms becoming empty shells, with one business steel trading and the other finance. Shanghai has more than 80 guarantor companies and nearly 40% of

18 | WIRE JOURNAL INTERNATIONAL

them were opened by Zhouning, Fujian steel trading companies (aforementioned Xiao Jiaoshou is from Zhouning). The Global Times story reported that Shanghai-listed Ningxia Xinri Hengli Steel Wire said in a filing that the company’s actual controller risks are being replaced because 80 million shares, or a 29.2% stake, was held by its largest shareholder, Shanghai Xinri Equity Investment Co., and had been frozen by Shanghai Pudong New Area People’s Court. Shanghai Xinri used to be controlled by Xiao. The freezing order was because Shanghai Xinri assumes joint liability on its credit guarantee activities, the filing said, also noting that Shanghai Xinri and its actual controller are persuading debtors to repay bank loans as soon as possible. Per a prior filing, the same court also froze Xiao’s 31.07% stake in Shanghai Xinri Equity Investment, worth 460 million yuan, due to a loan dispute with Minsheng Bank. The Global Times story cited industry “watchers” who said that the lawsuits filed against Xiao and Zhou were often triggered by webs of credit guarantees among Zhouning merchants. “Big steel traders guaranteed the loans of smaller steel trading firms, and sometimes traders used property as collateral to several banks at the same time,” one analyst was quoted as saying. “The close relationship helped Zhouning merchants have easier access to loans. But if one of them meets problems, it is very likely to have a domino effect.” The growing number of lawsuits Chinese banks have taken against steel traders have exposed flaws in China’s 4 trillion yuan economic stimulus plan in 2008 following the global finance crisis, analysts said. “Steel traders went on a borrowing binge between 2009 and 2011 fueled by the stimulus. Then a lot of them used the loans to invest in real estate and the stock market,” Liu Xinwei, a steel industry analyst with Shandong-based consultancy Sublime China Information, told the Global Times. The risk of steel trade loans began to emerge in 2012 when more than 20 Shanghai-based steel traders were sued by banks as they failed to repay loans. Also, in 2012, the China Banking Regulatory Commission warned about excessive loans to steel makers and traders. The crisis has gradually extended to big steel traders from smaller ones, Liu said. Per a Xinhua News Agency report citing insiders, about one-third of China’s more than 200,000 steel traders will collapse as the loan crisis emerges. Analysts said the current credit crisis among steel traders has little influence on steel mills. “But if a large number of steel traders are eliminated from the market as Xinhua estimated, steel mills’ sales will be dragged down,” Liu said. China CITIC Bank’s outstanding loans in the steel trading sector reached about 40 billion yuan by the end of June 2013, with the non-performing loan (NPL) rate surpassing 8%, per a report from the 21st Century Business Herald.

India’s SAIL looks to emerging markets for future growth The steel ministry has asked the Steel Authority of India Ltd (SAIL) to explore emerging markets in Africa, the Middle East and South-East Asia. A report in Live Mint said that the steel ministry acknowledged that the focus could result in a temporary hit to the profitability of the state-owned steel maker. It noted that SAIL has also teamed up with Kobe Steel Ltd., Japan’s third-biggest mill, for technology tie-ups to produce high-value products including special alloy steel, bars and stainless steel tubes that offer higher margins than raw steel products. “I have told them that in terms of production you cannot look at domestic markets alone,” steel secretary Mohan Kumar was quoted as saying. “Indian steel always has a cost advantage as we have raw material availability. I think we are next to Russia in terms of cost of production. The only thing that deters steel makers (from selling in overseas markets) is that international prices are not as remunerative.” SAIL achieved a 7% rise in sales by volume to 12.1 million tonnes (mt) in 2013-14, but exports just formed a small fraction of overall sales at 0.47 mt. Its export portfolio includes wire rods, rails, hot-rolled and cold-rolled coils, stainless steel and billets.

Davis-Standard opens support site in China to support Asian customers U.S.-based Davis-Standard Corporation announced that it has opened a spare parts and service center in Suzhou, China, that it said will specialize in high-usage maintenance items for customers throughout the region. A press release said that the ongoing expansion of service capabilities is aligned with Davis-Standard’s Global Advantage™ initiative to help customers increase productivity by keeping equipment in the best working condition. The center will maintain an inventory of maintenance items, offer local language support and shipment within 24 hours of order for stock inventory, with payment accepted in RMB. The toll free number for the parts and services hotline for customers within China is 800-820-7477. For customers outside China, call +86-21-6440-0468, ext. 108, or e-mail nicole.wang@davis-standard.com.

Former cable installer files suit A former worker is seeking $110,000 in compensation from the operator of Japan’s Fukushima nuclear plant for exposing him to high levels of radiation after the 2011 tsunami. Per an AP report, he was part of a team sent to lay electric cables in one of the reactors 13 days after the disaster. The worker said that plant operator Tokyo Electric Power Co. should have known about the high radiation levels and warned them. 

JUNE 2014 | 19

ASIAN FOCUS

ASIAN NEWS BRIEF

PEOPLE

PEOPLE Harish Panchal has joined Lloyd & Bouvier as the company’s national sales manager, responsible for the sales and marketing activities. He has more than 30 years of experience in the wire and cable industry in engineering and sales. His latest position was area sales manager in the U.S. for Italy’s OM Lesmo Harish Panchal Group. Prior to that, he was director of technical services at International Wire Group. He has extensive experience in turnkey project management and machinery sales as well as bare wire manufacturing and cabling processes. He holds a bachelor’s degree in metallurgical engineering. Based in Clinton, Massachusetts, USA, Lloyd & Bouvier provides used, new and rebuilt equipment to the wire and cable industry. General Cable Corporation named Robert (Bob) Kenny as president and CEO of General Cable Europe and Mediterranean, effective August 1. He holds a B.S. degree in electrical engineering from Ohio Northern University. He has more than 25 years of experience in the wire and cable industry, and has been named in more than 50 published patents in the U.S. and Europe. He joined General Cable in 2007 as vice president and general manager of its data communications business and assumed responsibility for the product portfolio throughout Europe. In 2013, he was promoted to senior vice president and general manager of the company’s global communications business. He will succeed Emmanuel Sabonnadiere, who will continue to be active with the company. Based in Highland Heights, Kentucky, USA, General Cable Corporation is a global leader in copper, aluminum and fiber optic wire and cable products. Industrial Steel & Wire (ISW) announced three personnel changes as part of a management restructuring. Dan Foster was promoted to vice president of sales & marketing. He joined ISW in 2011 as director of sales, with an extensive background in steel wire sales and marketing. In his new expanded role, he will be responsible for world-wide strategic sales development and execution, outside sales and customer service management, continual improvement of customer satisfaction, and new product and market development. John Dickman was promoted to vice president of purchasing & operations. A 25-year veteran of ISW, he rose through the ranks to become national purchasing manager and a member of the company’s executive committee in 2001. Scott Weldon was named the company’s new vice president and CFO. He has more 20 | WIRE JOURNAL INTERNATIONAL

John Dognazzi has been promoted to managing director of Sikora International. He joined the company in 2012 as a business development sales engineer. He previously was a business development engineer with DaPro Rubber, Inc., and prior to that held the same position at Enplas USA. He holds a B.S. John Dognazzi degree in mechanical engineering from Southern Polytechnic State University and an MBA degree in business from State University of West Georgia. He replaces Jeff Swinchatt, who left the industry for other challenges. Based in Peachtree, Georgia, USA, Sikora International is the U.S. subsidiary of Germany’s Sikora AG, a global supplier of testing and measuring equipment.

PEOPLE

than 20 years of experience in purchasing, operations and finance. Based in Chicago, Illinois, USA, Industrial Steel & Wire supplies wire and strip products, and notes that it is one of the world’s largest stocking distributors of spring wire.

obituaries Edward Daley, 80, who worked in both the metals and lubricants sectors during his career, died May 2. He earned a degree in finance at the University of Connecticut and served in the U.S. Army. He began his career at Anaconda American Brass of Waterbury, Connecticut, and later at Elf Atochem in Homer, New York. He was known for his knowledge and work ethic within the industry and enjoyed traveling the country on behalf of his employers. He was a 20-year-member of WAI and at one point worked part-time at the WAI’s office in Guilford, Connecticut. He is survived by his wife of 45 years; a son, Edward Daly, and his wife, Beth. He was predeceased by his brother Donald Daley. The Wire Cable Manufacturers Alliance (WCMA) reports the death of “Sonny” D.K. Sanghavi, a 1998 recipient of the group’s Charles D. Scott Distinguished Career Award, who died April 12 at age 75. A native of India and the eldest of seven children, he emigrated to the U.S. in 1959 and obtained a degree in chemical engineering from the University at Fort Wayne, Indiana. In 1989, he became general manager of the Montgomery Wire Company and worked for the company until 2006, at which time he became sales manager for Global Signal Inc., a company in India. He maintained an office at New England Wire Technologies in Lisbon, New Hampshire, for his operations. He is survived by his wife of 47 years, Renate “Ravi” Sanghavi.  JUNE 2014 | 21

FIBER WATCH FIBER WATCH

FIBER WATCH

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Report says global demand is good for optical fiber broadband growth The worldwide cable, DSL and fiber-optic fixed-line broadband subscriber base grew 6% in 2013 surpassing 665.4 million subscribers, notes a quarterly report from U.S.-based ABI Research, “Broadband Carriers and Revenue.” The fiber-optic broadband segment grew at a robust rate, 29% from 2012 to 126.6 million subscribers in 2013, the report said, predicting that by 2019, fiber-optic broadband subscriptions will grow to 265 million subscribers. It noted the following. The global cable broadband market grew nearly 7% to 161 million subscribers while the DSL broadband market contracted around 1% to 378 million subscribers in 2013. An increasing number of customers opting for high-speed fiber-optic broadband service contributed to a decline in DSL broadband subscriptions in Asia-Pacific and North America. “Global DSL broadband service revenue dropped nearly 2% in 2013, mainly due to a declining subscriber base and average revenue per user in the Asia-Pacific,” said Jake Saunders, VP and practice director of core forecasting. Worldwide fiber-optic broadband service revenue grew over 15% to $46 billion in 2013. Operators such as British Telecom from the UK and VimpelCom from Russia reported that growth in its fiber-optic broadband customers contributed to overall service revenue growth in 2013. “Since revenue from traditional services such as voice and messaging is declining, innovative services and content over high-speed broadband networks are proving essential for operators to maintain overall service revenue growth. ABI Research forecast that the worldwide fiber-optic broadband market will generate $100 billion in 2019.” Chinese operators dominate the fixed broadband subscriber rankings. China Telecom and China Unicom lead the global fixed broadband market shares with over 100 million and 64 million broadband subscribers respectively at the end of 2013. Currently the two companies own 53% and 34% market share respectively. The ABI Research quarterly report provides broadband subscription by operator, by country, and by technology. The database forms part of the company’s Broadband Subscribers Market Research. ABI Research provides analysis and quantitative forecasting of trends in global connectivity and other emerging technologies. ABI Research has a global team of experts who provide information for the company’s 70+ research and advisory services. For more information go to www.abiresearch.com or call tel. 516-624-2500. 

FASTENER UPDATE

FASTENER UPDATE Long-time U.S. fastener company could be closed as soon as July A Westbury, New York, company that made fasteners for the airplane that Charles Lindbergh flew solo across the Atlantic has filed for Chapter 11 bankruptcy protection and notified employees that it could close by July. John Hassall Inc. could lay off all 83 employees between July 28 and Aug. 10, the company said in a regulatory filing. The potential closure is due to “economic” factors, according to the notice, which is required by the state Worker Adjustment and Retraining Notification Act. The act requires employers with at least 50 full-time employees to give a 90-day notice before a major layoff or closing. Multiple media stories said that a published report by Richard Bennett, a financial consultant for Hassall, said the company has enough financing to continue operations, and that it hopes to emerge intact from bankruptcy. Hassall makes custom-designed metal parts and fasteners for the aerospace, automotive, defense and other industries in its 65,000-square-foot plant, according to its website. The 157-year-old company notes that its products have ranged from metal parts on the “Spirit of St.

Louis,” which Lindbergh flew in 1927 on the first nonstop flight across the Atlantic, to high-strength bolts in modern jet engines. The company has assets of $8.5 million and liabilities of nearly $5.5 million, president and chief executive Theodore B. Smith III wrote in a court affidavit that was filed the day before the company filed for bankruptcy protection. It has suffered “declining revenue as a result of the general downturn” in the industries it serves and the economy as a whole, and its sales during the first quarter were lower than expected, Smith wrote. Hassall explored a potential sale of its business lines and assets last year, but it was unable to come to terms with potential buyers, Smith wrote. It filed for bankruptcy so it could resume its search for a buyer, he wrote. The company was reported to have 55 union employees, whose contract expired in 2011. Contract negotiations ended in an impasse, and the company imposed new terms in 2012, Smith wrote. Hassall also is engaged in a court fight with its landlord, according to Smith’s affidavit. The company sued the landlord last year, charging that the roof leaked from 2008 through 2012, interrupting work at the plant; the landlord countersued, and the dispute remains unresolved, Smith wrote. 

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

Wyrepak Industries has long recognized the value of making a quality product — cost-effective manufacturing applications, backed by a solid guarantee and excellent customer service — Wyrepak has it all! For more details on any of our manufacturing product solutions, call us at 800-972-9222 or email sales@wyrepak.com WYREPAK INDUSTRIES — A Huestis Industrial Company • www.WYREPAK.com

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WAI NEWS

June 2014

WAI MEMBERSHIP

SPOTLIGHT This section introduces a new WAI member each issue.

Justin Landrum Refined Casting Manager ASARCO

Q: What does your company do? A: Asarco is a fully integrated miner, smelter and refiner of copper in the United States. Asarco’s domestic mines annually produce approximately 350-400 million pounds of copper. Our facility in Amarillo, Texas, is built around an electrolytic copper refinery utilizing conventional starter-sheet technology. Our final copper products are copper cathodes, continuous cast copper rod, and semi-continuous cast copper cake. Q: What is your role there? A: As refined casting manager, I am responsible for the production of rod and cake as well as the shipment of our final copper products to our customers. Q: What do you like best about your position? A: My position allows me to see and be involved in the coordination of efforts of various production and support departments throughout our corporation. All of these efforts come together to supply products to our customers, which generates the majority of the revenue to operate all of Asarco’s facilities. Q: How has the industry most changed? A: The biggest change has been the generational gap in our workforce. Our experienced employees are retiring, often leaving a 15-20 year gap in knowledge. We are also seeing people work longer so there are as many as four generations of employees competing for jobs and working together with varied degrees of different work habits and communication styles. A close second to that change has been the increase in request of information from our customers: RoHS compliance, certifications, actual test data, special packaging and labeling requirements. Q: How does your company remain competitive? A: We adjust to our customer needs and focus on retaining our experienced employees’ knowledge so we can pass it on to the next generation. Q: Why did you recently join WAI? A: I joined WAI to increase my knowledge and awareness of the wire industry.

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Steven S Jones General Manager Asarco LLC

The following individuals either recently joined WAI or became Platinum Members through their companies.

Al Abedi Vice President Manufacturing AB Carter Inc Pill S Alexander Development Engineer Southwire Co Tony Carreiro Sales Isotek Corporation Saturnino Castilho, Jr Owner Dacota Conductores Electricos Mark Ferreira Sales Director Isotek Corporation Alex Gurley Process Engineer Asarco LLC Elvir Handanovic Sales Kreher Steel David Hazelett President Hazelett Strip-Casting Corp Jason Hendrix CFO Coastal Wire Co Inc

Erick Kuntzelman Sales Manager Okaya (U.S.A.), Inc. Bob Lajoie Copper Group Service Manager Hazelett Strip-Casting Corp

Luc Van Genechten Copper Group Sales Manager Hazelett Strip-Casting Corp

WAI NEWS

Jon Huber Sales Engineer Condat Corp

Doug Wendel, Jr President/CEO Coastal Wire Co Inc Rob White Copper Group Manager Hazelett Strip-Casting Corp Kelly Ann Wrage Process Engineer General Cable Corp

Justin Landrum Process Engineer Asarco LLC Denis Moos CEO Sadevinox Tracy T Morris Operations Manager Asarco LLC Christopher M Porada Metrologist Johnstown Wire Technologies Inc

New WAI Platinum Membership Companies

Brad Sandlin Asarco LLC

Asarco LLC Hazelett Strip-Casting Corp

David Ashley Stephens Maintenance and Engineering Manager Southwire Co Wojtek Szczypiorski Manager Material Technology Hazelett Strip-Casting Corp Steve Tucker Manager Metrock Steel & Wire/ division of Leggett & Platt Wire Group

Industry leaders can contact WAI Executive Director Steve Fetteroll at sfetteroll@wirenet.org or 203-453-2777, ext. 115, to learn more about this special membership program. Such organizations actively support the Association by participating as exhibitors, advertisers, sponsors or content providers for WAI-organized events, publications and educational programs.

JUNE 2014 | 27

WAI NEWS

WAI’s 2016 traveling road show to be at Mohegan Sun Resort Conference Center The WAI’s Operations Summit & Wire Expo event will be held in the Nutmeg state for the first time when the WAI’s 86th Annual Convention is staged June 8-9, 2016, at the Mohegan Sun Resort Conference Center in Uncasville, Connecticut. There had been interest in staging the event at a different venue, and Las Vegas had been considered, but a lengthy process with much discussion finally concluded with the Association’s Exhibition Planning Committee and Board

of Directors agreeing on the Mohegan Sun, which is one of two mammoth casinos in Connecticut. It is also well known to members of WAI’s New England Chapter, which has held its annual meeting there many years. “There was much good discussion on this topic, and the folks at Mohegan Sun were very accommodating. Based on the very good experience we’ve had there for years through our New England Chapter, we believe that exhibitors and attendees alike will enjoy this venue,” said WAI Executive Director Steve Fetteroll. The Mohegan Sun may be best known for its three casinos (one smoke-free) and entertainment, but the site

An exterior view of the Mohegan Sun complex in Uncasville, Connecticut, which will be a first-time host to WAI’s Operations Summit & Wire Expo event in 2016.

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

Wyrepak Industries offers high quality machines and solutions for wire and cable companies as well as other industrial applications. From tension controls, pay-offs, pulleys, sheaves, bobbin winders and custom applications — Wyrepak does it all! For more details on any of our manufacturing product solutions, call us at 800-972-9222 or email sales@wyrepak.com WYREPAK INDUSTRIES — A Huestis Industrial Company • www.WYREPAK.com

68 Buttonwood Street, Bristol, Rhode Island 02809-0718 USA • tel: 800.972.9222 or 401.253.5500 fax: 401.253.7350 2C_BW_WYREPAKHuestis_OffersHighQualityMachines_WJI_halfHoriz_v4_05102013_PICset2_variousCombos_press.indd 1

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and sporting events. It has a 34-story, 1,200-room luxury hotel tower; a 20,000 sq-ft world-class spa; 130,000 sq-ft of retail shopping; 40 restaurants, bars and lounges; three entertainment venues, including a 10,000-seat arena; a 350-seat Cabaret Theatre and a 300-seat Wolf Den; a professionally-managed business center; a 10,000 sq-ft indoor pool; a 17,500 sq-ft outdoor sun terrace; a three-story crystal mountain; and more.

U.K. Clockwinder’s dinner continues a generations-old tie to U.S. wire industry The account of the Long Case clock that was gifted to the American wire industry and the Wire Association in 1948 is an ongoing story that is renewed and extended by a group committed to not only maintaining, but expanding the collaborative meaning associated with this beautiful clock that resides at the WAI offices in Guilford, CT, USA. The most recent chapter in the Clockwinding tradition was the 2014 Clockwinders’ Reunion Dinner that was held on April 11. This every other year event serves as a gathering place for Clockwinders and their spouses. This year’s dinner involved 14 past Clockwinders along with many spouses and guests of WAI President Bill Avise, Executive Director Steve Fetteroll and Wire Link Traveling Scholarship recipient Renee Early. The Clockwinders in attendance were: Peter and Sue Rigby, 1979 and 1998; Roger and Jackie Matzen, 1980; George Dickens, 1990; Dil and Rita Scrivens, 1993; Peter and Margaret Wilcock, 1995; Peter and Kate Siddall, 1999 and 2010 respectively; Nigel and Jeanine Lane, 2000; Ken and Jean Scott, 2001; Alan and Val Stephenson, 2002; Mark and Mandy Hayes, 2005; John Perry, 2009; John and Wendy Swain, 2012; and Jonathan and Georgie Rigby, 2013.

JUNE 2014 | 29

WAI NEWS

also includes spacious settings that will easily accommodate WAI’s Operations Summit & Wire Expo event. It has more than 100,000 sq-ft of flexible meeting space, which includes a 38,000 sq-ft, pillar-free Uncas Ballroom. The site, created in 1996 by the Mohegan Tribe of Connecticut, offers some of New England’s finest dining, hotel accommodations, retail shopping, live entertainment

WIRE & CABLE MAKING MACHINERY

PLANT OPERATIONS SESSIONS

SPEAKING OPPORTUNITIES

NEW TRENDS & PRODUCTS

SUPPLIES & EQUIPMENT

GLOBAL NETWORKING

SPONSORSHIPS

INTERWIRE 2015 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS. GEORGIA WORLD CONGRESS CENTER | ATLANTA, GEORGIA, USA

SAVE THE DATE EXPOSITION:

APRIL 28-30, 2015

CONVENTION:

APRIL 27-30, 2015

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

PARTICIPATING EXHIBITORS Ace Metal Inc. ADVARIS GmbH AIM Inc. All Forming Machinery Inc. Amacoil Inc. American & Efird Inc. Anbao Wire & Mesh Co. Ltd. Assomac Machines Ltd. AW Machinery LLC Aztech Lubricants LLC B & H Tool Co. Inc. B & Z Galvanized Wire Ind. Balloffet Die Corp. Bechem Lubrication Technology LLC Bergandi Machinery Co. Beta LaserMike Blachford Corp. Breen Color Concentrates Inc. Brookfield Wire Co. Butt Welders USA Bytewise Measurement Systems Caballe SA Cable Consultants Corp. Canterbury Engineering Co. Inc. Carris Reels Inc. Cemanco LC CERSA-MCI Chase Wire & Cable Materials Chemetall Chengdu Centran Industrial Co. Ltd. China Ruijin Fairs International Cimteq Clinton Instrument Co. CM Furnaces Inc CMEC International Exhibition Ltd. CN Wire Corp. Commission Brokers Inc. Condat Conneaut Industries Inc. Davis-Standard LLC Die Quip Corp. Domeks Makine Ltd. Sti Dynamex Corp. Ebner Furnaces Inc. Electron Beam Technologies Inc. Enercon Industries Engineered Machinery Group Inc. Enkotec Co. Inc. Esteves Group USA Etna Products Inc. Eurobend SA Eurolls Group Srl George Evans Corp. Fabritex Inc. Fil-Tec Inc. Filtertech Inc. Fine International Corp. Fisk Alloy Wire Inc. FMS USA Inc.

Foerster Instruments Inc. Fort Wayne Wire Die Inc. Frigeco USA Inc./ MFL USA Service Corp. Frontier Composites & Castings Inc. Fuhr GmbH & Co. Kg Gavlick Machinery Corp. GCR Eurodraw SpA Gem Gravure Co Inc. W. Gillies Technologies LLC GMP Slovakia s.r.o Guill Tool & Engineering Co. Hangzhou JR Exhibition Co. Ltd. Heany Industries Inc. Heatbath Corp. Heritage Wire Die Inc. Howar Equipment Inc. ICE Wire Line Equipment Inc. IDEAL Welding Systems INHOL LLC InnoVites International Wire & Cable Machinery Association IWG High Performance Conductors Inc. Joe Snee Associates, Inc. Joe-Tools Jouhsen-Bundgens Inc. KEIR Manufacturing Inc. Keystone Steel & Wire Co. Kinrei of America Lamnea Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. Magnetic Technologies Ltd. Maillefer Extrusion Oy Mathiasen Machinery Inc. Messe Düsseldorf North America MGS Manufacturing Inc. Micro Products Co. Microdia USA Morgan-Koch Corp. Niagara Composites Int’l.Inc. Niehoff Endex North America Inc. Nimsco LLC / SB2C Numalliance North America Inc. Oklahoma Steel & Wire OMCG North America Inc. Ozyasar Tel Ve Galvanizleme P & R Specialty Inc. Paramount Die Co. Parkway-Kew Corp. Paul Troester Maschinenfabrik Pentre Group Ltd.-Hearl Heaton Phifer Wire Inc. Plas-Ties Co. PolyOne Polytec Inc. Pourtier & Setic of America

Precision Die Technologies Inc. PrintSafe Progressive Machinery Inc. Properzi International Inc. QED Wire Lines Inc. Queins Machines Raajratna Stainless Wire Inc. Radyne Corp. Rainbow Rubber & Plastics Refractron Technologies Corp. RichardsApex Inc. Rosendahl Nextrom Technologies Roteq Machinery Inc. RSD Group USA S&E Specialty Polymers SAMP USA Inc. Sarkuysan SA Schlatter Inc. Shanghai Pudong International Exhibition Co. Sikora International Corp. SIMPACKS Sjogren Industries Inc. Sonoco Reels Stolberger Inc DBA Wardwell Braiding T & T Marketing Inc. Tapeformers Ltd. Taubensee Steel & Wire Co. Taymer International Inc. Tecnofil SA Teknikor Teknor Apex Tensor Machinery Ltd. TMS-Specialties Manufacturing Co. Inc. Traxit North America LLC Tubular Products Co. Tulsa Power Inc. Vandor Corp. Vollmer America Inc. WAFIOS Machinery Corp. Weber & Scher Mfg. Co. Inc. Welding Wire Machineries Windak Inc. Wire & Cable Technology International Wire & Plastic Machinery Corp. Wire Association International, Inc. Wire Journal Interanational Wire Lab Co. Wire Machine Systems (WMS) Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Zumbach Electronics Corp.

Visit us at Wire Expo booth # 232

48 32 || WIRE WIRE JOURNAL JOURNAL INTERNATIONAL INTERNATIONAL

MAY 2014 | 17

INDUSTRY NEWS

FEATURE WAI NEWS

Wire. Lane reminded The Reunion as Chinese wire rod the seem focus onwas the “big- the honor recognizes outstandFirsttopresented in 1962, innovations include the portabledid air/hydraulic powered group that Swain and organized by Nigel has a way of finding its his ger Theyand may ing picture.” achievement contributions to the copper industry. HP100 and HP200 machines, which provide effortless wife Wendy landed in Lane (Clockwinder way to market via downbe concerned about “NEMA extends itsour heartiest congratulations to Stu for welds on wire and strip 1 mm to 5 mm and 2 mm to 6.50 the U.S. in lateEven October 2000), who has been stream products. relationship with China, this honor. We ... are proud that a representative on our mm. All PWM machines and dies are precision engi- if it 2012, justthen as the larginstrumental inare maindoes work, rod and then there some Board of Governors is receiving this prestigious award,” neered in-house to stringent quality standards bywire PWM’s est Atlantic hurricane, taining the annual producers in Turkey and free traders who think said NEMA President and CEO Evan R. Gaddis. own team of skilled engineers and technicians. Hurricane Sandy, Clockwinding tradition. Russia will come in.was I and doset that, well, it’s not fair, but PWM’s worldwide network of experienced agents to devastate the northLane think that there is a day cheapdecided imports to arereturn good for its U.K. team provide fast and efficient on-site support PWM celebrates eastern U.S. With quick to the sitebecause of the it 2012 ofservice. reckoning coming the U.S. helps 30th at wire 2014 with full back-up and after-sales It notes thattoit thinking and a sincere not to be reunion, The George British company PWM (Pressure Welding Machines) China. It may be tame inflation worries. continues to focus on R&D to offer the most advanced intimidated approach, Hotel of Stamford. Theanniversary of service to the Ltd. celebrated its 30th in its effortsintothe slow down In terms of political and comprehensive range of cold welders world. the Swains adjusted their landmark property withat wire 2014, toasting the compawire andthe cable industry capacity, but many compaparties, Republicans For more on the company go to www.pwmltd.co.uk. n performed theThe nearly 1,000 of Below, it describes its evolution. ny’sno continued success. niesplans, are state-owned. are better years than the Clockwinding, repomemories isasanthey PWM, based inideal Kent, regional provincesand want Democrats are England, designs, sitioned themselves to setting for a The group that high-performanufactures andbigger supplies to keep jobs, and it’s not free traders. An inside view of Johnstown Wire’s plant in Johnstown, out of immecherishes InmachinesPennsylvania. mance cold welding and dies to goingBoston, to be easy to the change problem ishistory. that there’s diate path the storm. addition, The George wireleadership and cable worldwide. and of rationalize no inmanufacturers the U.S. A group photo of participants at the 2104 Clockwinders’ dinner. their ways The Swains are set to and Stamford are perIts first machines were small, manually capacity. Washington continues to return to the U.S. fectly positioned as the operated cold welders for joining fine wire There are several pluses for the U.S., and they areand be in a state of gridlock. There’s a lot of sensible ideas accompany the 2014 clockwinder, Robert Bache, who is near halfway point between London. and strip. The M10,manufacturing, M25, andYork M30and models energy and technology. At this time, we are the low-cost that could support but zero happens. We currently scheduled to in handle dutiesthis on is October 15. the newest to their first forLane wire sizes 0.10 mm to mm, are energy producer, and somethe sectors a market need a welcomed national forum, one1.80 toClockwinders spark the all U.S. economy The Swains a second chance at therod sightseeing Reunion Dinner; John that Swain (2012) and still produced today. changer. Forwill nowget though, wire and wire remains inthat with 10 action items everyone can Jonathan agree on.Rigby Can two did not occurI’m dueboth to the hurricane. n (2013, Clockwinder), Fox Over3rd thegeneration years, that PWM gradually dire straits. hopeful and discouraged. Give U.S. (political) parties can’t agree onmanaging the time director, of day, do expanded andaway introduced producers a chance to compete and I think the world that? You its canrange file that under larg“wishful thinking.” er,Will powered colddumping welders, case including thethe domestic rod would be shocked at what we can do. the latest filed by P1500have rod any welder for joining large mills impact? Maybe, but rod I’d be surprised if it At wire 2014, PWM showcased its technology and toasted 30 good years. sections up to 30 mm diameter. Recent

Poland Chapter plans to hold technical conference next March in Zakopane WAI’s Poland Chapter will stage its biennial technical conference on March 5-7, 2015, when it returns to the Antaɫówka Hotel in Zakopane, Poland, the past host to previous conferences, to stage “Modern technologies and modelling of drawing and manufacturing processes of metal products.” “Our goal is to provide a very good program that will present both theoretical and practical research results that will be useful to companies that manufacture wire and wire products,” said chapter President Jan Pilarczyk. a prolific author who is a professor at Częstochowa University of Technology (CUT). The organizing committee for the event is headed by Prof. Sylwia Wiewiorowska and the Scientific Committee is headed by Prof. Zbigniew Muskalski, both of CUT. The conference scope will include steel wire and wire products, nonferrous wire and wire products, electrical wires and special products, and a poster session. Authors wishing to present at the conference must have their

abstracts received by Sept. 30, 2014, with the full papers due by Oct. 15, 2014. The list of accepted papers will be available on Nov. 5. For details about submitting an abstract send an e-mail to wiewior@wip.pcz.pl or go to the event website at www.konferencja.wip.pcz. The event also includes a tabletop display as well as a social program and networking opportunities. This is the chapter’s sixth such event, and the last one saw a total of 109 participants from more than 40 institutions and companies, Pilarczyk said. That event featured 51 presentations in four sessions (ferrous, nonferrous, electrical and special products) as well as a poster session. Scheduled speakers came from Sweden, Spain, Japan, South Korea, U.S. Russia and the Czech Republic. One 11 technical universities and research institutes (AGH University of Science and Technology, CUT, Institute for Ferrous Metallurgy, Institute of Nonferrous Metals, Silesian University of Technology, Lublin University of Technology, Orebro University, Spain Technical University of Madrid UPM, Tokai University, Moscow Institute of Steel and Alloys, and the Technical University Ostrava. 

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JUNE 2014 | 33

CHAPTER CORNER

WIRE LINK REPORT

2014 Wire Link Scholar Report By Renee Earley The day I was told I was 2014 recipient of the WireLink Traveling scholarship, I began to visualize all the things I would see and experience overseas. To say that my trip exceeded all that I envisioned is a very bold statement, but a true one nonetheless. This was my first time out of the U.S., and I wanted to make every second count towards learning, both about the wire industry and the cultures and life in Germany and the U.K. Needless to say, I learned more than I ever imagined, and consider thise trip an experience of a lifetime; it certainly will not be my last time overseas. My trip began with a flight from my hometown of Fort Wayne, Indiana to Düsseldorf, Germany. I arrived early Saturday morning, April 5th, and explored the Altstadt for the day, ending the night at Zum Schiffchen–a favorite in the Altstadt–where I had the amazing “Metzgers Leibgericht,” three types of sausage and sauerkraut, and of course, an altbier! Sunday morning, I met up with John Drummond, president of The Wire Foundation, for a drive on the A Wire Link scholar learns the joy of autobahn to Köln, hearty German cuisine. Germany to tour Renee Earley, process engineer of the MP/DFT Department at Fort Wayne Metals, was the 2014 WireLink Traveling Scholar. The award, offered in alternate years to a U.K. and American professional 34 | WIRE JOURNAL INTERNATIONAL

Renee Earley and Matthew Farnsworth at Boeing AMRC. Cologne Cathedral and do some sightseeing along the Rhine River. The evening ended with a wonderful reception in Düsseldorf at Brauhaus “Joh. Albrecht,” hosted by WCISA. Here, I met many of the wire industry professionals I would encounter further along my journey. Monday through Thursday was a blur as I explored the wire show at the Messe Düsseldorf. John Drummond was kind enough to introduce me to some important contacts. The networking opportunities here were endless, and I couldn’t believe the scale of the show itself – it was absolutely enormous! Two-story vendor booths, machinery actually running and producing material, massive product displays, multiple media screens, food and drinks throughout the entire day – it was clear to me why the Düsseldorf show is regarded so high. I gathered a lot of valuable information to take back with me to Fort Wayne Metals. Friday morning, Steve Fetteroll, Bill Avise and I flew to London and rented a car up to Stamford for the Clockwinders Dinner that evening. It is a wonderful event that dates back many years celebrating the relationship

in the wire and cable industry, provides a two-week, all-expenses-paid opportunity to visit and learn about the industry on the other side of the Atlantic. The scholarship was created by the Worshipful Company of Tin

Plate Workers alias Wire Workers in the U.K. and the Wire Association International in America. As the 2014 U.S. representative, she toured companies in the U.K. and attended the wire Düsseldorf trade show in Germany.

a control room. This was a huge difference from what I’m used to when working with ultra-fine wire. The coil packaging operation was very fun to watch, and I was awed by the coil storage system’s organization and efficiency with tracking. I really enjoyed talking with Chris; as the 2011 WireLink Scholar, he was able to discuss his experiences from touring the US and share thoughts on the things I might see the rest of the week. Will Binnie, the 2013 WireLink Scholar, also joined us for the Tata Steel rod mill tour, as I had another tour planned for the afternoon with him at Kiveton Park Steel. Will is the technical sales engineer at KPS, however prior to that role, he was a quality/development and NDT engineer. This provided Will with a multifaceted background working with the processes that create KPS’s wire for cold heading, cold forming, spring making, and much more, so I was able to learn a great deal about their operations. I was impressed with their AS 9100 certification due to the fact that some parts are used in the aircraft industry for aerospace applications. I saw some similarities in the wire process flow, an efficient straight and cut operation, and some impressive crack detection testing. Will and his colleagues at KPS answered all my questions and were a very hospitable group during my time at the plant.

A wire scholar’s travels takes her to No. 10 Downing Street On Good Friday I attended an opera in London, and was headed back to my hotel when I spied a commotion out of the corner of my eye. A poor cat attempted crossing the road and was nearly hit! It scurried to my side of the street, so I crouched down and it ran right up, frightened but glad to see a friendly cat lover. I dialed the number on its collar and waited for an answer from the name given, Carol. “Carol… I have your cat!” I exclaimed, and explained where I had found her, near Buckingham Palace. “That is further than Freya usually goes,” Carol told me. I was worried Freya wouldn’t be able to find her way home. I asked Carol for the address, determined to return Freya to her home. Hesitant at first, Carol began to direct me. “Do you know Big Ben? Do you know Whitehall Road?…. Well, if you just take Freya to the big black gates at Downing Street, the guards will take her in.” In my head, all I could think was, “Who ARE you!?” I was now very intrigued and

began my walk carrying Freya home to Downing Street, with the biggest grin on my face. At the gates, the guards chuckled and thanked me. I even got to go inside the gates to take a photo holding Freya on the steps of 10 Downing Street. I had found the Chancellor’s cat, who is the current inhabitant of number 10. It was absolutely surreal. When I thought it couldn’t get any more interesting, Carol messaged the next morning and offered me a tour of the inside of 10 Downing Street later that day. I could not turn that offer down! I returned later and walked with Mark Batten, head of security, through the flat that so many British Prime Ministers have called home over the years. I toured the board room and stood next to “the Boss’s chair,” saw the lovely backyard garden, walked up the famous yellow staircase with all the portraits of Prime Ministers past displayed, and met the Prime Minister’s Cat, Larry, who they call their chief mouser!

Rennee Earley at a well-known London address, courtesy of a well-known Royal cat.

It was a chance of a lifetime–all because of my love for cats and one simple act of kindness.

JUNE 2014 | 35

WIRE LINK REPORT

between the U.S. and the U.K during WWII, which resulted in a U.K.-gifted clock that is kept at the WAI headquarters in Connecticut and wound each year by a U.K. wire industry professional. The dinner was held at the George Hotel in Stamford, which was a very original town that gave me a look into old English history with stunning 17th and 18th century buildings. The George Hotel’s first class gourmet dinner did not disappoint, and I could not have been in better company for the event! Some of those at my table included Nigel Lane, who organized the wonderful event yet again, as well as Jonathan Rigby, who I would later see again at Fox Wire. Saturday and Sunday offered more unique experiences for me, certainly not to be forgotten. I toured the Burghley House, enjoyed a hop-on-hop-off bus tour of Stratford Upon-Avon and the surrounding landmarks, and was also able to tour Warwick Castle, which was breathtaking in its nearly one thousand year-old glory. Sunday afternoon I caught a train to Sheffield to meet Darryl Lomas and begin my week of plant tours. My first tour on Monday was Tata Steel’s Scunthorpe rod mill, where Chris Barker, area manufacturing manager of the rod mill, showed us the outstanding automated line that turns blooms to billets to thousands of feet of coil, nearly completely operated from

WIRE LINK REPORT

Renee Earley and R. Andrew Davies at Gripple.

Renee Earley and Chris Barker at Tata Steel’s Scunthorpe Rod Mill. Tuesday morning, I visited Boeing Advanced Manufacturing Research Centre. While waiting in the lobby for Matthew Farnsworth, Aero Structures Platform Group Lead, I was amazed to see so many people happily bustling about through the office; I got the feeling that people loved their jobs there. Matt took me out onto the production floor, which consisted mainly of computer aided machining. I was immediately amazed at the cleanliness of the facility, and it was phenomenal to learn the precision of the machining operations and how intelligent their systems are to accommodate the detailed requirements for aerospace components such as aerofoils, casings, and aeroengine discs. I was also pleased to hear that Boeing AMRC is involved in the CATAPULT High Value Manufacturing Program, where companies team up with manufacturing research and development facilities to reduce the risk involved with developing new products and technologies, which helps bridge the gap between emerging innovation and industrial-scale manufacturing. I view this approach to development as a great way to create more confidence within companies and balance in the economy, ultimately building stronger lasting relationships in the U.K. manufacturing industry. 36 | WIRE JOURNAL INTERNATIONAL

The afternoon led me to Gripple, where I was greeted by Hugh Facey, MBE (Most Excellent Order of the British Empire) and chairman of the company. We discussed the roots of Gripple in the fencing industry, and how their employee contract now includes a requirement to buy at least £1,000 worth of Gripple shares in their first year within the company. R. Andrew Davies, business development director, led the tour and discussed the details of Gripple production. Their clean production facility was very efficient, and I was impressed with the team of engineers who now design some of the production machines that produce Gripple products. Andy then took us for a walk through the office areas. There certainly was no lack of creativity at Gripple – their innovation and originality was not only apparent in the many awards displayed in the office, but also in their innovation center, a centralized room stocked with resources and designed to harbor the creative forces of the team. My tour at Gripple offered me a chance to see innovation at its finest in a genuinely unique work environment that I really enjoyed. On the way to my Wednesday morning tour of Sheffield Forgemasters International, Darryl and I stopped in at his employer, Semta, where I would meet Bob Flear, an apprenticeship coordinator and my guide for the tour. Semta is an apprenticeship resource for businesses who want to recruit, develop and mentor talented individuals. Apprenticeship is definitely not common back home in Indiana, so it was interesting to learn about different options that are available in the U.K. Upon arrival at Forgemasters, I met Rick Franckeiss, group training officer, who discussed some key points about the company. I learned that they provide products for many global industries including nuclear, offshore oil

JUNE 2014 | 37

WIRE LINK REPORT

and introduced me to Kevin Mansell, managing director. and gas, power plants, defense, steel rolls, and mills and During the tour, I enjoyed watching the electroplating presses–most of which I would see in production that day. I line run, and had many questions regarding its operadonned the required PPE and Scott Millar, production engition. One familiar thing I did see was the metric board neering manager, came to collect me for the tour. The first located out on the floor for the production team to view. thing I noticed was the size of the parts they are producing. I have noticed increased involvement of the work force When I inquired about the precision of their machining, in projects and management decision-making over the I was impressed with the tolerances they can hold when last few years in the industry, which I view positively, producing such lengthy hollow parts. It also interested me as those who work to produce the products often have to learn that some dome-shaped parts were not machined, some of the most valuable input. I think it is important but extruded through the existing structure. Not only does to let the workers behind the product know how the this limit the amount of machining and wasted material, it company is performing. positively impacts the grain structure of the part, providing After Caparo, I hurried to the train station a better structure and higher stress applicato make it into London for the night, where tion possible. The most impressive sight was I would be spending my last weekend in the definitely the forging press, where I watched U.K. I had some great activities planned: a huge block of red hot steel rotate and press Phantom of the Opera at Her Majesty’s into the required size, radiating intense heat Theater, and a bus tour to see Canterbury over to our vantage point. Overall, it was an Cathedral, Leeds Castle, the White Cliffs of outstanding look at forging and machining Dover, the Naval College, and Observatory in operations for me on a size scale that will Greenwich, complete with a boat ride down not, without a doubt, ever be topped. the River Thames. Let’s not forget the amazMy afternoon was spent at Fox Wire ing shopping on Oxford, Regent, and Bond Limited, where I once again saw Jonathan Street. It was such an amazing time, and I did Rigby, the managing director. He was not want to fly home! Upon my return to the accompanied by CEO Oliver Baker, as States, I was given the opportunity to attend well as Dan Williams, Shaun Stancliffe, the WAI Operations Summit and Wire Expo Neil Dimelow, and Stuart White, who gave 2014. At the keynote address and luncheon, I the tour. I learned that Fox Wire produces was honored to be presented with a plaque by 12,000 tonnes per year in various wire and John Drummond and Bill Avise (see p. xx), strand product types including stainless, and give a short speech on my experience. aluminum, brass and copper. I saw several My nerves disappeared completely as I saw familiar sights, including a well-developed The WireLink Scholarso many familiar faces in the audience. It was die room, strand annealing furnaces, and a very productive wire show and I was able skilled testing lab. In the lab, I was curious ship Award Certificate. to take away some great information from about their torsion tester. No sooner than the vendors I met with. It was also great to see I had asked about it, the lab technician had everyone from the WAI again that I met in Düsseldorf. a piece of wire in it, with one end rotating it to failure. I I cannot express enough gratitude to all of those was also pleased to see they could perform Eddy Current involved in making my trip the unforgettable experitesting, which is something I have been working with a ence it was. None of this would have been possible lot lately. It was encouraging to see similarities between without The Wire Association International, The Wire my company and Fox Wire, even though we supply difFoundation, The Worshipful Company of Tinplate ferent industries. Workers Alias Wire Workers – and lastly, Fort Wayne Wednesday evening held the promise of an elegant Metals, which continually supports my endeavors for dinner in Sheffield with great company: Elizabeth learning and career growth. I gained an immense depth Bonfield, head of Business Innovation EAL (Excellence, of information overseas and saw things that opened my Achievement and Learning Limited), and Bev Page from eyes to an entirely different world, both culturally and in The Worshipful Company of Tinplate Workers Alias the aspects of industry and business. My plant tours and Wire Workers (Tinplaters). Bev presented me with a conthe Düsseldorf wire show offered me much insight into gratulatory letter and certificate recognizing my achievewhat the wire industry presents outside of what I’m used ment of the WireLink Scholarship. He and Elizabeth to, and I would like to thank everyone who took time were able to provide some really great information on out of their day to share so much with me. I also plan to the Tinplaters. I was thankful to spend time with someshare as much as possible with those at my company, and one who helps to make the scholarship possible each and keep in touch with the wonderful people I met along the every year. way, many of which I can now call friends. In the end, I Thursday brought an early morning goodbye to think what I enjoyed most was seeing the overall culture Sheffield, as Darryl and I headed for Wales–I was of the wire industry; it really is just one big family–one I scheduled to tour Caparo Wire in Wrexham, where upon hope to stay in.  arrival, Jonathan Chappell, technical manager, greeted

WRAP UP

WAI OPERATIONS SUMMIT WIRE EXPO 2014

WIRE EXPO 2014

~ a wire & cable industry solution center ~

Indy event a WAI road win The WAI’s traveling road show took the checkered flag for its May visit to Indianapolis, Indiana, where it staged its 2014 Operations Summit & Wire Expo event at the Indiana Convention Center. The event hosted 1,602 participants, including crossover attendance from the co-located AISTech 2014 trade show, which filled the adjacent B-D Halls at the center. Representatives from 36 states and 22 countries shared in networking activities, panel and roundtable discussions, and interaction on the exhibit floor. “The second Operations Summit and Wire Expo turned out to be a big success as many positive comments were received about having the show in Indianapolis, with the hotels in close proximity to the convention center, great Opening Reception at Lucas Oil Stadium, and many sessions on pertinent production solutions,” said WAI President Bill Avise, Leggett & Platt, Inc. “Even the weather was great,” Avise said. “Several exhibitors told me that they felt positive about the activity in their booth, along with many members saying that the production oriented sessions were very informative and well attended. Plans for WAI’s Operations Summit and Wire Expo 2016 will continue to focus on providing plant operators with valuable information and networking.” The event included conference sessions revolving around the “Operational Excellence” theme, including ferrous and nonferrous equipment forums; a continuous improvement case study; a mobile classroom to General Cable; a machinery roundtable on drives and controls; and a safety forum.

Camarena Associates’ Fred Camarena, r, and son, Fred Camarena, Jr., at the reception at Lucas Oil Stadium. 38 | WIRE JOURNAL INTERNATIONAL

Other popular activities were the production solutions demonstrations on wire breaks, dies, and lubricants; and presentation of WAI’s highest annual honors—the Mordica Memorial and Donnellan Memorial awards—to Professor Motoo Asakawa, Waseda University, Japan, and Dane Armendariz, Chemetall, respectively. On the exhibits side, 207 industry suppliers and wire and cable makers were represented on the show floor, which had a healthy buzz of interaction. The WAI held committee and board meetings on Monday, and there was strong attendance for the Fundamentals of Wire Manufacturing program. The focus shifted that night with the staging of the Member Rewards event, which included the WAI’s annual meeting, at the Skyline Club. The session included the awarding of the President’s Award to Lesa Sieger, the widow of the late Terry Sieger of Woodburn Diamond Die, who died March 19. Avise, Past WAI President Sandy May and John Rumpz, who had been Terry’s boss, spoke about how positive a force he had been for the industry and Association. Accompanied by her family, Lesa thanked everyone for their support in what was a solemn yet fitting tribute to a much-beloved man. The event also saw the awarding of the Mordica Award to Prof. Asakawa, a prolific author and frequent contributor at WAI technical programs. Noting that he has spent 48 years in the field, he declared that it was “a great honor for me to receive this award.” Recognized for his WAI volunteer work over the years was Dane Armendariz. The Donnellan Award winner

Mordica Award winner Prof. Motoo Asakawa with WAI First Vice President William Reichert.

WIRE EXPO 2014 Keynote Speaker Dr. Phillip Cornwell spoke about the need to prepare students for the skills that will be needed in the future.

WAI President Bill Avise welcomes attendees.

observed that he had retired two years ago. “That lasted for exactly 87 days. When peopled asked why I went back to work I would say I had too much free time or high health insurance cost but the truth is I like the people, companies and working in this industry. A wise man once told me, ‘You have to put back more than you take out of life so that those coming after you have something to start with,’ and reflecting on what I put back into the WAI I realized I took far more that I could ever put back. Thank you for this award, it means a lot to me.” The event got into high gear on Tuesday with the full technical program and the opening of the exhibits.

“We were pleasantly surprised at the caliber of leads we received at the show,” said Mark MacKimm, Rainbow Rubber & Plastics, Inc. “The attendance was great and we were fortunate to meet many of our customers and new prospects.” Cheryl Hickman, Heatbath Corporation, said that traffic on the floor was brisk on Tuesday. “We met with many of our current customers and cultivated some promising prospects. Wednesday was a bit slower, but we were able to take a moment to enjoy the nice weather with a short walk and an outside table with a valued customer at a local eatery. I would not mind returning (to Indy) for another Wire Expo.”

Howar Equipment, Inc.’s Willie Hauer, c, was ready to field questions from any direction..

General Cable’s Heather Stolper on the bus taking attendees to a tour of the company’s compound facility. JUNE 2014 | 39

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WRAPP UP

WAI President Bill Avise stands by as Wire Foundation President John Drummond presents a plaque to WireLink Scholar Renee Earley, Fort Wayne Metals.

Joe Domblesky, Marquette University, presents Mechanics of Wiredrawing.

Donnellan Award winner Dane Armendariz with presenter Andy Talbot, Mid-South Wire.

Participants in the controls/drives roundtable included, l-r, Dave Hawker, Nexans; Michael Kaczynski, OEM Design Services; Bill Riley, Parker Hannifin Corp., SSD Drives Div.; Tim Tanner, Teknikor; and moderator Tom Renner, South Shore Controls.

Joined by presenter Tony DeRosa, c, were winners, l-r, of the best nonferrous technical paper: Grzegorz Kiesiewicz, Andrzej Mamala, Beata Smyrak and Tadeusz Knych. Not present were coauthors Eliza Sieja-Smaga, Artur Kawecki, Kinga Korzeń and Paweł Kwaśniewski. 40 | WIRE JOURNAL INTERNATIONAL

Winning the best electrical paper award was Julius Poltz, OptEM Engineering, Inc., with presenter Dave Hawker.

WIRE EXPO 2014

WRAPP UP Jamey Ford, Leggett & Platt, who attended the technical programs, said that he liked the Safety Forum on Wednesday morning, which was presented by two men from outside the industry. “I thought that this was well done...very informative. Although not related to wiredrawing operations, there were still some very good ideas that I could take away from the presentation. We are always looking for something new and different with regard to safety.” Tuesday’s roundtable discussion on drives and controls, moderated by Tom Renner, covered a lot of ground by panelists David Hawker, Nexans Energy Cables Div. NA; Michael Kaczynski, OEM Design Services; Bill Riley, Parker Hannifin Corp., SSD Drives Div.; and Tim Tanner, President, Teknikor. At the luncheon on Tuesday, Avise welcomed attendees and thanked event sponsors as well as his predecessor,

From l-r at the Lloyd & Bouvier booth are Ron Reed, Harish Pascal and Brian Bouvier.

Etna’s Bill Coode, l, and Troy Carr, explained lubricants during their Production Solutions session on the show floor.

Happiness abounded at the Taubensee Steel & Wire booth, especially Tuesday from 3 to 5 pm. 42 | WIRE JOURNAL INTERNATIONAL

Southwire’s Richard Miller, the 2013 WAI president, for his exhaustive efforts. Avise also shared his thoughts on the event, which at its last staging in 2012 introduced a technical program that was more focused on shop floor issues. He said that the Board of Directors wanted the Wire Expo name to more accurately reflect the purpose of the event. “To me, it is the gathering place of the North American operations professional.” Dave Gemelli, president of Gem Gravure Co., sponsored keynote speaker Dr. Phillip Cornwell, an award-winning professor at Rose-Hulman Institute of Technology, a top U.S. engineering university, who spoke about the need to prepare students for the skills that will be needed in the future. Cornwell observed that the U.S. ranks 27th among developed nations in the proportion of college students receiving undergraduate degrees in science or engineering. Less than

Bob Flower, Witels Albert, l, talked about his company’s straightener, roll, guide, feed and pre-former products.

Thank you for a job well done. The conference program at WAI’s 2014 Operations Summit was the result of the combined efforts of dozens of experts, volunteers, and special guests. This year’s successful program would not have been possible without their dedication to the Wire Association International’s educational mission. Authors / Speakers Jason Adams Motoo Asakawa Troy Carr Bill Coode Dana Darley Keith Donahue Steve Foust David Hawker Doug Hoffer Michael Kaczynski Gene Klein, Sr. Will Kraft Rodrigo Madariaga Thomas H. Maxwell Steve Montague Horace Pops

Bill Riley Richard Sarver Heather Stolper Tim Tanner Patrick Weister Buck Wright Moderators Dane Armendariz Tracy Gooding Bill Jarae Steve Jones Allen Lindholm Tom Moran Bill Reichert Tom Renner

Course Instructors Anand Bhagwat Joseph P. Domblesky C. Richard Gordon David P. Gzesh Erik A. Macs Thomas H. Maxwell Jack McAfee Horace Pops Rudolf Vey Keynote Speaker Phillip Cornwell

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Your time at Indy drives the industry ahead.

Safety Forum Feedback: Jamey Ford,

Leggett & Platt said, “I thought that this was well done...very informative. We are always looking for something new and different with regard to safety.”

WIRE EXPO 2014

WRAPP UP

From l-r at the WAI Member Rewards event, ParkwayKew’s Robert Galprin, Wire Lab’s Rob Fulop, Vollmer America’s Dick Pechie and consultant Lou Arcuri.

Past President Richard Miller, c, with Member Relations Committee co-chairmen Tim Wampler and Tom Heberling.

At Indianapolis, Enkotec Co., Inc., President Jan Sorige, l, whose one-year term on the Exhibition Planning Committee “extended” to six years, presided over his last meeting as the body’s chairman.

General Cable’s Mark Thackeray, second from r, won the 5K Industry run that was once again sponsored by Leoni. 44 | WIRE JOURNAL INTERNATIONAL

Heritage Wire Die’s Otto Fuhrman, B&H Tool’s Peter Neville and Gem Gravure’s Paul Gemelli at the WAI Member Rewards event,

Bhaskar Yalamanchilli and his son, Rajeev, at the WAI’s reception.

appeared to be resounding approval of the event as well as the location, with many saying that they would welcome a return trip. “I found Indianapolis to be an excellent choice to host this event,” said John Meir, Keystone Steel. “It’s centrally located and easy to travel to. There is a bounty of restaurants, bars and shops and plenty of entertainment. I would very much be in favor of seeing future events held here.” Robert Colton, Nucor, agreed. “It was a very good choice...for this event.” Avise thanked the following sponsors for supporting the event. Platinum level: Wire & Plastic Machinery Corp.; Gold level: Leggett & Platt Inc. and Southwire Co.; Silver level: Carris Reels, Frigeco USA, Inc., Fort Wayne Wire Die, Inc., Gem Gravure Co. Inc., Lloyd & Bouvier, The MGS Group, Nexans, Niehoff Endex, SAMPSISTEMI, Sikora International Corp., Steel Technologies LLC, and Windak Group; Bronze level: BASF, Caballé, Chemson, ExxonMobil Chemical, Radyne, RichardsApex, and Sonoco; as well as support from Baum’s Castorine, Commission Brokers, and Leoni. The next staging of the Operations Summit & Wire Expo will be at the Mohegan Sun Resort Conference Center on June 6-8, 2016. Additional event photographs are available on Pinterest at (http://www.pinterest.com/wireassociation/wire-expo-2014/). n

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5% of undergraduate degrees in the U.S. are for engineering, compared to more than 30% for China and 17% for Asia as a whole. Further, engineers seem to be held in higher regard in other countries, as eight out of nine top government officials in China have a science or engineering background, he said. “The world is changing. We need more technical professionals,” said Cornwell, who supports more focus on learning practical skills at college, with an emphasis on real-world internships, and more interaction by manufacturers. He believes that companies that offer such opportunities may benefit by making such a setting far more understandable and appealing to students who otherwise may opt for other fields. Wire Foundation President John Drummond introduced the 2014 WireLink Scholar, Renee Earley of Fort Wayne Metals, who spoke eloquently about her experiences. See p. 34. Wednesday had a quick start, with the staging of the 5K Industry Run, again sponsored by Leoni Wire. General Cable’s Mark Thackeray was the easy winner of the sparse early-morning field. The Mordica Lecture led off the rest of the official schedule, which included more activity with the exhibits and technical presentations, highlighted by the afternoon departure of the General Cable “Mobile Classroom,” where participants got to see the company’s compounds facility. In an industry where attendees and exhibitors are known for being quite candid--be it good and bad--there

FEATURE

Dies: an evolving industry constant Dies are the heart of the wiredrawing process. Below, suppliers, most of whom exhibited at Wire Expo 2014, share their thoughts on results, challenges and alternative materials. WJI: How has your role as an industry supplier most changed in recent years? Without a doubt, the die suppliers’ role has become increasingly more complex and interwoven within our customers’ workplace over the past decade due to the intense competitive nature of the global market. Gone are the days of having multiple die shop attendants within the wire mill. In most cases now, only one or two employees cover all the tooling needs as well as being responsible for maintaining lube, printers and other areas of concern. This, in turn, has placed more of the die room responsibilities, such as die inspection and inventory management, back with the die supplier. Many times, we become the troubleshooters by being able to analyze the results of the die wear characteristics. Bill Schwehn, sales manager, Woodburn Diamond Die. With each passing year, it seems clients expect more from their supplier than just being a provider of product. They are looking more and more to us as a provider of solutions to their problems, from increasing productivity with reduced wire breaks on their drawing machine, to improving the management of their die inventory or helping them design a new series of dies to produce a shaped profile wire. The world is not getting any simpler. For example, there are more wire die material choices available now than ever before. We try to help our customers navigate through this confusing array of choices and select the die material best suited for their unique set of conditions and requirements. Brad Scherer, vice president, Fort Wayne Wire Die (FWWD).

Our role in the industry has changed from that of a commodity die manufacturer to a company that partners with customers to help them improve their process. The result is a solution engineered to increase throughput, product quality, and profitability. Different applications require different die sets and die profiles, and even within the same application we find that the traditional “one-profile fits all” wire die is not up to the challenge of today’s competitive market. To customize new wire die solutions we have developed software that our engineers use to design dies and die strings for any given type of wire material and drawing process. The software takes specific wire material properties, machine mechanical requirements, and process speeds into account. It uses proprietary material science and algorithms to calculate precise die size sequences and profiles. The calculations result in optimized homogeneous material flow through the dies, minimizing wire breaks, maximizing die life, and allowing for increased process speeds. This custom engineered approach is the result of Esteves Group’s long-term vision and desire to help customers with their goals, expectations, and challenges. Gary Kantz, sales director, and Carsten van der Putten, product manager, Esteves Group. NDA’s role has not changed, but the way NDA operates continues to evolve to manage steady expansion of the market for Nano-Dies every year since incorporation in 2011. Nano-Dies are now in service in practically every industrial region of the world. The credit for the success of Nano-Dies goes to the product itself: great features and great performance at astonishingly low prices. Doug Thornton, president, Nano-Diamond America (NDA). In recent years we observed a boost of customer expectations on quality and we went along with their needs increasing dies quality and customized products. Koner SpA.

Brad Scherer, Fort Wayne Wire Die. 46 | WIRE JOURNAL INTERNATIONAL

In the today’s economic climate, customers are daily being forced to take key short-term decisions to make sure they are doing things in the most efficient and economical way possible. Our role is to show and prove that cheaper tooling doesn’t lower overall manufacturing costs, if production and tool quality are sacrificed in the process. Diamond dies, PCD dies, extrusion tips and dies should not be considered as consumables or commodities but as real high quality tools that allow customers to reach great

A range of die products from Balloffet.

Our role has changed the most related to delivery. It seems yesterday isn't soon enough in today’s world! We understand the situation today’s manufacturing sector seems to be in. Everyone is trying to fill every order they can! As many of our customers are accepting small quantity, higher margin orders for “non-standard” products, and these situations really push Just-in-time delivery theory to the limit. We have added some quite extensive

Die thoughts from industry academian Roger Wright I have been asked by WJI to re�lect on what has changed and what has not changed over the years regarding drawing die usage, but as you will see, my below remarks are more advisory than historical. First of all, most metalworking unit operations are rather classical in nature, and rudiments of rolling mill rolls, extrusion dies and forging dies do not seem to have changed much over the years. The situation is similar in wiredrawing, as far as gross drawing die geometry is concerned. However, the range of drawing die materials available has increased considerably in the past 40 years, and the reliability and consistency of die performance has become much more important with the advent of multi-wire machines and �ine (high value added) drawing practices. Even so, wire die evaluation and the general acceptance of new die materials and designs move slowly. I have a saying that “now is about 10 years in the wire industry.” Some of this slow pace re�lects the long-term returns on investment implicit in certain capital equipment, but this is much more of a factor in rolling, forging and extrusion systems. In the particular case of wiredrawing dies, sluggish process engineering development seems to re�lect drawing industry

shortfalls in die speci�ication, die replacement (or recut) criteria, die performance data taking, and the all-important cost analysis. These matters can hardly be left to the die manufacturers. Good die makers may know a lot about wire drawing, but they do not have immediate contact with the drawing operations, and they don’t stay in business by drawing wire. A wire drawer must start by having an actual die design or design system. While this may seem like an elementary requirement, many drawers do not have die designs, or can’t �ind them, or haven’t updated them for a long time, etc. Even drawers with detailed die designs may not check as-received dies or may use dies with “blends” or states of wear that grossly alter the initial or of�icial design. I very recently heard a presentation by a leader in the die manufacturing industry who pointed out that any adhered-to die design provides a useful place to start die evaluation, whether it is optimum or not, and that failure of customers to have such a place to start is

a major stumbling block in the industry. Roger Wright So what should a progressive wire drawer do to have a decent place to start? Let me suggest addressing the following. Exit diameter. This should be rather straightforward. However, some drawers like to draw to a degree of “oversize” and even start with an undersize die in an attempt to get every last bit of life out of the die. The wear involved presents many problems and I am not a fan of drawing to the extent of wear throughout the bearing. There is nothing fundamentally wrong with starting with the correct diameter, and replacing (recutting, etc.) the die at some fraction of the drawn wire length that usually leads to oversize wire. Drawing cone angle. The drawing cone angle can be critical for most drawing operations, and it should be checked regularly as die shipments come in. Unfortunately, it is continued

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performances and surprising production cost reductions. Our customers are looking for new ideas and products that can make their operations more efficient. On top of a wide range of high quality products, our role is to offer to our customers a complete package of resources and services to help them maximizing operational efficiency by a better control of key wiredrawing parameters. Nicolas Barthod, president, Balloffet Group.

FEATURE

manufacturing capabilities in-house in order to react faster to the short lead times our customers require. Jon Fuhrman, owner, Heritage Wire Die. Most companies want a partner today that can show them how to lower their cost and keep them abreast of the changing die world, with improvement in technologies and products and how they may apply to their company. In addition to that they need 24 hour-quick response time to meet there customers’ needs. John Freiburger, owner, Precision Die Technologies.

quality, delivery and cost; we resolve quality-related issues of all aspects of the business in the earliest turnaround time; we work with design and production teams and outsource to manufacturers to ensure product quality is maintained during all the phases; we maintain frequent communication with our all customers and keep updated knowledge of all purchase orders, revised schedules and order changes; and we focus on perfect order delivery schedule that calls for sound supply chain processes right from procurement to delivery of the finished product. Ajex & Turner.

In recent years my wire manufacturers have lost their most knowledgeable wire die resources to retirement. This has given us opportunities to ask the new personnel questions to better understand their wire die needs. Vince Griffin, Premier Wire Die.

WJI: Beyond the price, what do customers most often ask you about dies? What should they ask you?

The market has become more customized, so our role as a supplier has changed. For instance, we manage resources and maintain fixed schedule requirements to meet required production and distribution demands; we ensure product

Beyond price, lead time is certainly a popular question. However, with six strategically located manufacturing plants in North and South America, Europe, and Asia, we are able to provide dies when needed, even

Very strict specifications, high quality and much quicker service. Koner SpA.

Die thoughts from an industry academian, continued not uncommon for included angles to vary 2° in a die string. This should not be happening if die angle is important to your process. Intended drawing reduction. The drawing cone length should be such that the incoming wire contacts the drawing cone about halfway along its length. Thus, the intended reduction dictates the length of the drawing cone. Delta. The mechanical effects of the drawing cone angle and drawing reduction may be efficiently described with the deformation zone shape parameter, delta. While delta analysis is not absolutely necessary, and beyond the scope of this article, it is a highly useful tool for die and pass schedule design. Bearing length. Bearing length specifications are problematical, particularly where the start of the bearing is obscured by “generous” blends. The basic reason for the bearing has been to allow die wear to occur without the drawn wire becoming oversize, or to allow recutting with retention of the exit diameter. A bearing is also consistent with nib bulk and strength

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at the die exit, although much the same can be said for back relief geometry. It is useful to ask yourself what you are actually using the bearing length for, and to avoid tedious specifications of such, unless they are clearly necessary. Die economics. Die wear is proportional to the length of wire drawn through the die. While it is tempting to substitute weight for length in die-life record keeping, it is easy to go astray using weightbased die life comparisons, and elementary use of spread sheet analysis will make length-based record keeping straightforward. My own, rather conservative criterion is that one should consider retiring dies at a certain fraction of the as-drawn wire length that produces oversize wire. An alternative approach, if the inside of the die may be seen, is to retire the die at a certain definite indication of a wear ring. And so on. The important point is that the die not be used to the extent that the wire is damaged or drawn out of specification. Analyses that I have seen and made often

indicate that the cost of dies, in terms of value added to the wire in drawing, is much smaller than might be imagined, especially if dies are not used to the point where the drawn wire is damaged and out of specification, or to the point where machine down time becomes an issue. Simple die cost models are available from at least some major die makers, although careful record keeping is always necessary. Have a longitudinal section drawing that shows your die design. If you cannot readily make such a drawing, then you don’t understand enough about the dies you are buying. Oh, and one other thing: Make sure your dies are seated properly (no dirt!) and are not in backwards (it happens!).

Roger Wright, a professor at Rensselaer Polytechnic Institute, has authored or co-authored 140 scientific papers. The author of Wire Technology: Process Engineering and Metallurgy, he also does a column for Wire & Cable Technology International.

Carsten van der Putten and Gary Kantz, Esteves Group. when this involves less than one week lead-times. In order for us to provide customers with a die solution that meets their challenges we look forward to answering the following questions: Is my current die size sequence optimal? What is the best die profile for my material and draft? What die material should I use to improve wire surface quality and die life? Gary Kantz/Carsten van der Putten, Esteves Group. While price pressure still exists and will continue to exist, a growing number of wire and cable manufacturers are becoming more concerned with getting better production efficiency from the best possible tool ROI (Return on Investment). This means we are focused on premium die quality, using superior raw materials, ensuring accurate geometries and excellent mirror polishing for high performances drawing process. Beyond that, Balloffet offers a global technical support and a wide range of equipment to inspect, measures, clean and maintain diamond and PCD diamond dies on the long term. The best example is our latest VISIODIAM n°2 measuring device that allow customers to use and optimize the true value of each diamond die or enameling dies. Nicolas Barthod, Balloffet Group.

We agree that price does matters but that remains the last concern when it comes to offering quality products. Moreover, customers should inquire about the quality of the blank to be used; life of the die; profile; and accuracy. To maintain our customers' desired die geometry, we use ‘Die Wizards’ software. We have developed PCD shape dies and compacting for copper, aluminum and multiwire dies. Dies and extrusion tools for Rosendahl, Maillefer, Nexans, Unitek and Supermac extrusion machines are also made per their specifications. Ajex & Turner.

Paramount’s customers most often ask what kind of die life they should get from its dies. They should ask how can your dies can help improve our operational efficiency and reduce overall manufacturing cost. Wire dies play a critical role in the wiredrawing process and if applied correctly can have a direct impact on profitability, which is many times greater than their cost. Richard Sarver, president, Paramount Die. Most wire mills are looking for improved wire die deliveries. They should be asking if their wire die profile and diamond micron size match their application. Vince Griffin, Premier Wire Die. NDA welcomes questions about Nano-Dies, and there are plenty of them, such as the following: why are the

Dies from Ajex & Turner. JUNE 2014 | 49

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dies so inexpensive? (Completely new diamond die technology); what is the bore diameter range? (1.2 mm to 60.0 mm, larger on request); how long does a Nano-Die last in a cable compacting process? (500-1,000 km of cable compacted at +0); how can Nano-Dies can save copper and aluminum in compacting processes? (Nano-Dies have extremely low friction. This brings many benefits, one of them being less damage to conductors, which means better electrical conductivity, hence the same cable electrical properties are achieved using less conductor material); can we draw stainless steel using Nano-Dies? (Yes. 100-500 metric tons drawn with a perfect finish at +0, depending on all the usual things…lubricant, UTS, drawing speed, reduction percentage etc.); what about surface finish? (superb, all applications); During that time, expect perfect surface finish); how long does a Nano-Die last in a wiredrawing process? (This is process dependent, but generally 10-15 times the life of a tungsten-carbide die); can we use existing lubricants? (Yes, certainly, but for an aluminum rod breakdown process, Nano-Dies give you an additional option: you can use water-based lubricants to save cost and reduce pollution); how can Nano-Dies last so long at +0? (Two reasons: 1. The millions of nanocrystalline diamond particles forming the Nano-Die surface are unidirectional, locked together in a pattern, like soldiers standing in close formation. Hence, the workpiece sees diamond always in the hardest orientation. 2). There is no relatively soft filler material in the NanoDie surface as it is all diamond). Doug Thornton, NanoDiamond America.

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requirements of their industry and specific end user. One question I actually wish I had more often concerns our products’ total cost of die ownership. A good example of this is the debate about whether it is more economical to use a lower cost PCD die blank that is near its maximum usable hole size, or a larger more costly die blank with greater recuttability potential. From the standpoint of initial purchase price, the smaller blank appears more economical, but quite possibly from a total cost of ownership angle the larger die blank that with recutting provides multiple uses, may actually provide a better value over the long run. Brad Scherer, Fort Wayne Wire Die.

Bill Schwehn, Woodburn Diamond Die. Although price and delivery are expected questions, they are also looking for advice on the proper type of die material that they should be using for the project being discussed. We try to offer input on the correct material type or blank size for the application that will be most cost efficient based on long-term use or expectations of the dies. Pertinent info should include knowing the material being drawn and incoming wire size, confirm the die profile and diameter tolerance requirements as well as the case specifications. Knowing your customer and their practices enables us to be very proactive in offering the proper guidance and is very much appreciated. Bill Schwehn, Woodburn Diamond Die. One of the most common, yet difficult questions we are often asked is “how long will a die last in the drawing machine?” This is a hard question to answer because of the large number of variables in the drawing process that can affect die life, not the least of which is the wire quality

WJI: Is there any reason to believe that the basic carbide die will not continue to be a staple for generations to come? If carbide will remain for some ferrous wire applications the most common product, special coating material and solid PCD diamond dies will continuously penetrate the global wire industry. For most drawing applications for round or shaped wire, solid PCD dies provide the best return on investment due to higher accuracy, tighter tolerances, a better and smoother wire surface state and much longer die life. With high-quality dies, diamond is definitely a good investment to reduce production costs and to get optimum drawing efficiency. Nicolas Barthod, Balloffet Group. It's actually not so easy to provide a definition for a “basic carbide die.” The simplest definition would apply the word basic to binary carbide grades which contain only two elements, tungsten and cobalt. The problem is that carbide quality can vary greatly around the world and the performance potential of binary carbide grades has increased substantially over the years. Today’s high-quality binary grades employing the latest Hot Isostatic Press

A technical look (see p. 64) at TCHP, a new die material At Allomet Corporation, we believe that die technology development is �irmly rooted in a history that covers many generations. During past decades, many die users have established their own “comfort zones” about how to reliably draw high-quality wire in a cost-effective way. It’s really not surprising that when something game-changing comes along, it takes a long time to get noticed and widely accepted. Frankly, it took years for PCDs to gain broad acceptance and now Allomet is on a similar (but hopefully faster) mission in the die market: industry-wide use of TCHP. Understandably, adoption of this new material technology is not an overnight event, but we’re gathering excellent momentum and are excited to explain why TCHP has the potential to produce the bene�its on the same scale as PCD. One simple request. Please read the award-winning technical paper, Improved Wire Quality with Advanced TCHP Dies, that starts on p. 64, and consider what the payoff could be if TCHP is given the opportunity to deliver high performance on your shop �loor.

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Allomet Corporation's Dan Cunningham

We cannot compare carbide with PCD. We cannot use PCD in all cases because it has dimensional limitations. PCD is tougher than carbide and has much better wear ratio. However, carbide remains in demand because of the price factor. Ajex & Turner. Carbide dies are currently still an excellent option for manufacturing certain ferrous and nonferrous rods and wires. They are also ideal for relatively short production and trial runs. For these processes, carbide dies are a cost effective choice of die material. There have been many advances in coating technologies that actually improve the use of carbide dies. These coatings reduce wire friction and improve galling resistance. As an example, Esteves Group recently added high quality diamond coated carbide dies (DC dies) to its product line, helping customers save material, improve surface quality, and lower electricity costs for bunching, stranding and compacting processes. Gary Kantz/Carsten van der Putten, Esteves. I believe the market for basic tungsten carbide dies will remain strong for quite a long time, especially in ferrous applications where “wet” lubricant is not always possible or utilized. The lower cost and good performance of TC dies as well as the available longer internal geometry of TC dies would be difficult and costly to substitute. Jon Fuhrman, Heritage Wire Die. The basic carbide die, improved and customized according customer needs, will remain the best solution for optimizing the price/quality ratio. Koner SpA.

I believe the carbide die will always have a place in the industry simply due to the reality that much of the ferrous market is fully dependent on the carbide die, which is often times the only product that will function with carbon steels and miscellaneous alloys. Even in the nonferrous market, there are still many applications where a carbide die offers the better value. Bill Schwehn, Woodburn Diamond Die. There will be a market for simple basic TC dies as long as there are people looking for the cheapest way to buy dies, regardless of performance. Some TC dies are very effective in ferrous wire applications, but many of those now may use Nano-Dies as an alternative, especially in low-carbon steel applications where they have established greatly improved price/performance and far better surface properties compared with TC dies. Where large bore diameters are required, TC dies have often previously been the only practical choice above, say 20 mm, either because PCD dies are simply too expensive to consider or they cannot be manufactured. But large TC dies may now be replaced with Nano-Dies in many applications up to 60.0 mm, larger on request. The large TC die now has some powerful competition, especially for compacting large power cables, where the rapid wear and high friction of TC dies is now seen as a serious disadvantage. In cable manufacture, a number of manufacturers have not yet upgraded from TC dies, even in the smaller bore diameters below 20.0 mm. But the upgrade to Nano-Dies is two to five times less costly than upgrading to PCD dies in the 3.0 mm to 20.0 mm range, and Nano-Dies enable very large copper and aluminum savings compared with using TC dies. The savings often dwarf the cost of the Nano-Dies. A medium-large producer of copper cables in Turkey upgraded from TC to Nano-Dies, specifically to save some copper. Nano-Dies have enabled them to save more than 2% of their total copper consumption. Aluminum savings tend to be even larger than copper savings. Doug Thornton, Nano-Diamond America. Even though we are not a carbide manufacturer we believe the basic carbide die will be around for a while. Many wire mills have rework equipment and trained personnel to use these dies. Vince Griffin, Premier Wire Die. WJI: PCDs are a staple for nonferrous applications: has there been meaningful advances in other materials? Are customers willing to try something different? Polycrystalline dies are indeed the premier choice for manufacturing nonferrous wires. There is a full line of PCD blanks/nibs available that lets us select the proper nib material to match a customer’s process and wire surface requirements and optimize die life. Also, Esteves Group has made significant advances in PCD processing that: minimizes wire friction, galling, fines and breaks; solves cast and helix challenges; and lowers power usage. JUNE 2014 | 51

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(HIP) cintering processes are stronger and much more capable than the carbide grades of the past. Standard binary grades, when combined with optimal lubrication, have enabled wiredrawers to reach extremely high-drawing speeds and have provided a much more durable and cost-effective soluRichard Sarver, Paramount Die. tion than other, more exotic material options. When combined with the fact that today’s binary grades are being used ever-more effectively in high-pressure lubrication systems, which reduce the stresses on the material itself, it is difficult to imagine “basic carbide” not continuing to be a staple for generations to come. Richard Sarver, Paramount Die.

FEATURE

Other alternative materials exist, however, their meaningfulness needs to be proven. Diamond coated carbide is one such material, supplied by Esteves Group, that has been proven to be well-suited for certain bunching, stranding, and compacting processes. Our customers are very willing to try different products and processes in an effort to constantly improve. Gary Kantz/Carsten van der Putten, Esteves. Nano-Dies should be considered as an alternative to PCD dies in many processes above 2.0 mm where UTS ≤ 1,500 MPa (say 220,000 psi). Nano-Dies have demonstrated very significant advantages over PCD dies in: cable compacting processes; stainless steel rod and wiredrawing; aluminum and aluminum alloy rod breakdown processes; welding wire manufacture; and various applications in the tubes/welding field. Hence, Nano-Dies represent a highly meaningful advance over PCD dies in a number of processes in which PCD dies previously might have been regarded as a staple. In NDA’s experience, customers are very willing to try something different, when that something looks as though it may bring an improvement. The onus lies Doug Thornton, Nano-Diamond squarely on America. the shoulders of suppliers to communicate the benefits of their products in a truthful and credible manner. Doug Thornton, Nano-Diamond America. Recently there have been advances in alternative die materials so that today there are more choices than ever before. Two examples are the new engineered micro-structure composite materials that combine a high level of hardness, toughness and wear resistance in a single material, and the advances made in “treating” single crystal diamond in ways that alter their composition and potentially improve wear resistance, particularly when drawing abrasive metals such as nickel, and paladium. Our customers are generally receptive to testing a new die material IF there is the potential of it solving a problem in a cost effective way. Brad Scherer, Fort Wayne Wire Die. The alternatives such as coated carbide have seen some good results where the use of PCD is too costly, but, the coated dies have limits also, especially diameter tolerance limitations and once the coating is worn out, you are basi52 | WIRE JOURNAL INTERNATIONAL

Jon and Otto Fuhrman, Heritage Wire Die. cally left with a very expensive TC die that would require special recutting and recoating which doesn't seem practical. Jon Fuhrman, Heritage Wire Die. In today’s competitive landscape, we find customers more and more willing to try alternative materials. The problem is that with the very capable grades of carbide and PCD already available on the market, it is difficult to find alternative materials which provide the right mixture of cost, durability and performance to challenge these staples. While keeping informed and actively testing the latest material technologies remains an important initiative for Paramount’s product development engineers, more substantial advancements have been made over the past several years in the areas of die geometry, cooling and lubricant application. Richard Sarver, Paramount Die. The vast majority of our R&D efforts has been related to testing and development of single-crystal synthetic stones used for intermediate and smaller size ranges. Natural diamond has long been the cornerstone of the fine wire drawing process but due to global demand and advances for more uses within the gem and jewelry industry, die suppliers are finding the availability of good stones at reasonable prices exceedingly difficult to acquire. Hence, having enjoyed a historically solid relationship with our PCD source, they partnered with us to develop and test the earliest of the single-crystal synthetic stones that led to considerable cost savings to our customers that were involved with the field testing. Overall, our customers look to us for guidance on which products hold promise and which ones still need some research before compromising their resources and production time. Bill Schwehn, Woodburn Diamond Die. It is wrong to say that PCD is staple for nonferrous. Stainless steel is ferrous and its drawing is mainly done through PCD, which is also used for carbon steel wires. In India and abroad many companies are using PCD and natural diamond for high quality. Ajex & Turner.

WJI: How important is it for you to have an electronic presence (website)? Does its use have a measurable impact for your business? The internet has become such a common tool, that having a website is critical today. That's why we recently launched heritagewiredie.com. The website isn't 100% complete yet, but hopefully will be soon. Jon Fuhrman, Heritage Wire Die. Having a website has been a good asset for us as well as consumers of our products and those looking for some good general information on what dies actually are and how they relate to the wiredrawing practice. We have been fortunate to entertain conversations and subsequent work with those who visited our website as the first step. However, following that initial “electronic” contact, we strive to extend that contact into more meaningful dialog via plant visits and personal follow-up to learn the more intricate details of what the contact really needs. Bill Schwehn, Woodburn Diamond Die. History has shown us that this is a means of communication, but it is only a part of the marketing and the service we provide to customers. An electronic presence is important to detail the portfolio, but the technical and industrial global support we provide to customers

visiting them in their plant is more valuable to them. Being on site with our customers helps to increase the understanding of the products, to suggest some process improvements, and to listen to their expectations for today and tomorrow. Today, there is more and more of a partnership mentality and we are visiting customers on site to fill that role. Nicolas Barthod, Balloffet Group. It’s very important to share our company information quickly with worldwide customers. It impacts doubtless on our business, and can even change our direct relationship with the customer. Koner SpA. Having a presence on the internet is very important as our website allows customers to easily find us and then communicate their needs. Additionally, today’s interconnected world makes social engines such as LinkedIn, Twitter, Facebook, and Google+ valuable tools in that communication process. Our online presence creates a positive impact on our business. We receive calls and emails that are generated through these tools that ultimately lead to new business. Also, our website offers a free copy of our Drawing Die Wizard™ software that accurately replicates the important characteristics of a wiredrawing die in 2D or 3D. By simply entering data, the software will pre-select a drawing die blank and design a die profile in real-time. Gary Kantz/Carsten van der Putten, Esteves. Having an electronic presence is something that is needed in any business. It makes it easy for customers to find you easily from wherever they are. Not sure it has a large impact on the growth of our business since the wire industry is a mature industry. Vince Griffin, Premier Wire Die.

JUNE 2014 | 53

FEATURE

Most likely the biggest technological advance has come from the development of exchangeable wiredrawing inserts. Apart from lowering material and shipping costs, wiredrawing inserts enabled the development of highly efficient pressure die systems capable of withstanding extreme wire drawing lubricant pressures. Combined with modern drawing machinery and optimal drawing lubricant chemistries, Paramount’s pressure die systems have enabled wiredrawers to reach drawing speeds topping 10,000 feet per minute (50 meters per second). Richard Sarver, Paramount Die.

FEATURE

probably been the advent of the precision laser equipment for fine diameter dies. This technology and the subsequent changes in how we handle the ultra-fine and fine diameter dies following the lasering process have allowed us to consistently produce dies that meet the ever more stringent specifications being placed upon the die suppliers, while also removing some of the human aspect of electric drilling and shaping of dies that led the process to more of a craft/art as it has been described over the years. Bill Schwehn, Woodburn Diamond Die.

John Freiburger, Precision Die Technologies. The website today is our business card. We have just developed a smart phone app that is available to all wiredrawing operations in the world in English, Spanish and Portuguese. They can use the web site or down load the app for free. This app will allow them to make quick and accurate decisions when it comes to wire sizes changes. John Freiburger, Precision Die Technologies. In an age where people go online to read the news, watch movies and book travel, who is so bold as to say that a website is unhelpful? NDA is a child of the internet age. We cannot imagine doing business without a website. NDA receives a lot of enquiries via the contact page of our website. This fact alone makes the website an imperative. The great power of a website (we think) is that it enables a lot of useful information to be posted online in a way that can be found by customers and potential customers, with a little help from Google, at a time and in a way that suits the customer. It is true that some websites are absolutely gorgeous works of art, but we don't think this is the most important thing about a website. Doug Thornton, Nano-Diamond America. The internet is the most cost-effective way to trade domestically and internationally. This enhances the customer base, suppliers and distributors. We can generate more and more clients for our business without doing additional marketing. Today, an increasing number of customers are making purchases through the Internet. Ajex & Turner. WJI: Whether deserved or not, dies and lubes are largely viewed as a commodity: can you cite an example or two of how your R&D focus has resulted in meaningful technological advances? In my opinion, the most credible technology change in our industry, and at Woodburn, in the past decade has

54 | WIRE JOURNAL INTERNATIONAL

As mentioned earlier, custom engineered dies and die sets are not a commodity. Using high quality die materials is not the only part required to optimize a wire drawing process. To obtain maximum results, properly engineered die size sequences and die profiles are required. We have made several technological advances during the last few years. One of these is the improved ability to calculate die size sequences and optimal die profiles. We are now able to scientifically take various aspects of the wire material and drawing process into account. In order to supply these non-commodity products, R&D has been working together with our manufacturing plants to continuously improve our manufacturing processes to laser drill specific profiles and achieve the required die surface polish that is needed to obtain these maximum results. Gary Kantz/Carsten van der Putten, Esteves. One could say that drawing and extrusion tools are only one element of the overall wiredrawing process, but we know how important and critical the dies are in the drawing process. A lot of detailed parameters can have significant differences on the tool, and consequently, on drawing performances. The role of our R&D focus is to give to our customers the means to make a difference in their production so they can benefit from the results. Our latest R&D technological advances are focused on: diamond die performances (special diamond and PCD mounting to increase the die life, new raw materials for specific alloys, diamond enameling dies, special shaped dies); diamond die reconditioning equipment (new automatic wire sizing machine RF SA, ultra sonic latest full automatic machine BD 140VGA, die diameter quick measuring device VISIODIAM 2, die and wire optical analysis system with microscope + camera connected to a personal computer MICROCAM â&#x20AC;Ś). If Balloffet is still a worldwide leader after 144 years, our R&D daily work and developments are a big part of the success. Nicolas Barthod, Balloffet Group. We have set up many quality control systems with machines from Conoptica and others from Japan to check the die geometry in a range of 10 micron to 150 mm. We can also provide die geometry drawings of any size to our customers along with the dies to ensure perfect geometry of the drawing die with different metals of different reduction and we also suggest suitable lubricants for low consumption to save electricity and manpower. Ajex & Turner.

FEATURE

FEATURE A diferent view of a die, this one from Koner SpA. Koner R&D always strives for continuous technological improvements as, in recent years, patented worldwide Koner pressure dies or very innovative Koner long nibs for high-carbon wire drawing. Koner SpA. The inventor, developer and manufacturer of NanoDies is Shanghai Jiaoyou Diamond Coating Co. Ltd. To answer this question, NDA speaks on behalf of the inventor, developer and manufacturer. The product now called Nano-Dies is a result of intensive and high level R&D. Two or three layers of nanocrystalline diamond composites were strongly adhered to the working surface of a tungsten-carbide nib in a Chemical Vapor Deposition (CVD) process. The end result was a die with lower friction than a PCD die and a harder surface than a PCD die. It became clear at that time that the new dies could be manufactured at three to 10 times lower cost than PCD dies of the same size (today's comparisons around 2 to 8 times lower cost in the 3.0 mm to 30 mm range). The initial research led to a product range initially known as Nanocrystalline Diamond Composite (NCDC) dies, A Nano-Die offered by now widely known as Nano-Diamond America. Nano-Dies. Shanghai Jiaoyou is all about creating and then taking full advantage of the latest meaningful technological advances. NCDC dies were patented and were already winning various industry awards inside China by 2006-07. The first formal presentation of Nano-Dies in the U.S. was made in Atlanta in 2011 and it immediately won another award. In 2014, NanoDies have undergone further intensive development and refinement. Although a small number of imitations are now starting to appear, none of them possess the essential and, so far, unique qualities of Nano-Dies that astonish users with their extremely long life at +0, combined with excellent surface finish. If by â&#x20AC;&#x153;commodityâ&#x20AC;?

JUNE 2014 | 55

FEATURE

we mean a product differentiated from its competitors only by small price differences and no differences in features or performance, we respectfully submit that Nano-Dies are the precise opposite of a commodity. Doug Thornton, NanoDiamond America. We have developed two different die types that have allow each company to lead there industry in that particular product. John Freiburger, Precision Die Technologies. We have set up many quality control systems with machines from Conoptica and others from Japan to check the die geometry in a range of 10 micron to 150 mm. We can also provide die geometry drawings of any size to our customers along with the dies to ensure perfect geometry of the drawing die with different metals of different reduction and we also suggest suitable lubricants for low consumption to save electricity and manpower. Ajex & Turner. WJI: If there is an aspect of your business that differentiates your company in some way, do comment here: As owner of Heritage Wire Die, I have been blessed to have learned so many aspects of the wire industry from one of the true icons of the industry: my dad, Otto. He has shared with me the expertise he gained over the years, going back to his earliest days with Decatur Wire Die in 1979. We serve every customer with honesty, value, and integrity, just as I was taught. Jon Fuhrman, Heritage Wire Die.

Vince Griffin, Premier Wire Die. Our ability to understand our customer needs let us provide the quick turn around on diamond wire drawing dies. Our staff has a unique blend of wire drawing and die making experience to help our customers get the correct die profile and die material they need. Vince Griffin, Premier Wire Die. Several wire die related training sessions are available from Esteves Group that can be organized either on-site or within our own factories. At our factories customers are invited to view our manufacturing process and see how their dies are made. To help customers we plan and reserve capacity, have stocking programs, and partner

COMPANIES IN THIS FEATURE: Ajex & Turner. Based in India, Ajex & Turner manufactures wiredrawing dies (PCD, ND and carbide), extrusion tools, die polishing machines and accessories for wire and cable industries. It has been a pioneer in the development of nanocrystal dies which are a completely new set of diamond dies that are far less expensive than the solid diamond nibs. www. ajexturner.com.

Balloffet Based in France and with production sites in England, U.S., and Germany, Balloffet, a 144-year-old company, manufactures a wide range of product and services for the wire, tube and cable industry: single crystal diamond dies and a range of PCD dies as well as extrusion tips, tooling, service, training and more. www.balloffet.com.

56 | WIRE JOURNAL INTERNATIONAL

Esteves Group. A global business, the Esteves Group supplies a complete line of high-performance products, ranging from wire drawing dies to cabling tools and specialty products. We service all sectors within the ferrous, nonferrous, and specialty alloy industries with new and recut diamond and carbide dies as our core business. www.esteves.com.

Fort Wayne Wire Die. Fort Wayne Wire Die recently completed its 75th year as a leading supplier of drawing dies to the nonferrous and ferrous wiredrawing industries. We serve global markets with top quality products that include single crystal diamond and PCD wiredrawing dies, shaped profile dies, tungsten carbide dies, and recutting, design and consulting services. www.fwwd.com.

Heritage Wire Die. Based in the U.S., Heritage Wire Die produces natural diamond, single crystal synthetic diamond, PCD and tungsten carbide wire drawing dies as well as dies for bunching, stranding, tinning and other applications, both ferrous and nonferrous. www. heritagewiredie.com. Koner SpA. Part of Italy's TKT Group, Koner SpA supplies wiredrawing dies

The NDA style is to publish truthfully and to the best of our ability, allowing customers to decide when the time is right to make detailed enquiries. In this age of information overload, we believe this is the most courteous and effective way ahead for us. Doug Thornton, NanoDiamond America. We are truly customer driven company and we are a very family friendly company, realizing that our employees and our customers are key to our success. We are told that we are really easy to do business with. I am from a sales background and we focus on quality, speed of delivery, we develop processes, such as the inventories system that is now the norm in the industries, tell us what you want and how many you want and we do the rest cheaper than you can. We offer inventories management where you can receive over 2,000 recuts and new dies per week, simply tell us your usage on Monday and we ship a complete restocking of your inventory by Friday. We design specialty products for coating and drawing applications; the smarter your people are the more productive your

for the ferrous sector. It produces TC nibs for wiredrawing, TC and diamond drawing dies, the innovative and patented worldwide pressure dies K.340 and K.365, hard metal tools and accessories for dies working and grinding. It also offers customers die grinding and reconditioning services. www.tktgroup.it. Nano-Diamond America (NDA). NDA supplies Nano-

Dies速 for three major industry segments: the cable industry (compacting and stranding dies), wire industry (ferrous and nonferrous drawing dies); and the tube industry. www.nano-die.com.

Paramount Die Paramount Die is the world's leading supplier of wiredrawing inserts that are offered in range of material and diameter options to cover nearly every wiredraw-

company will be, so let us teach them what to look for in dies and die management. We do not see ourselves as a supplier, but as your partner. We will be glad to help any way that we can, if you need a second supplier that you can really count on, that's us. John Freiburger, Precision Die Technologies. In regards to what makes Woodburn Diamond Die special, I believe we view our relationships being built with the customer as one of being a true partner in terms of

helping them both survive and prosper in a very demanding age of global competition. They, in return, understand that this must be a mutually beneficial relationship in order to stand the test of time. Bill Schwehn, Woodburn Diamond Die. The factors which make us different from other players in the market are as follows: we allow the client to be in command of their costs and offer them a quicker turnaround time. Our clients come to us for our expertise. They could pay cheap prices for lesser work, but they know that with Ajex they will get an exceptional product range that beats the competition. We believe that market trends have changed and therefore do not take anything for granted. We keep evolving according to market demands. Ajex &Turner. n

ing application. www.paradie.com.

Precision Die Technologies. PDT, an international supplier of diamond wiredrawing dies celebrating its 25th anniversary, offers new, used, and recuts of all natural, Mono and PCD drawing dies. We serve all sectors but specialize in alloys and hard metals drawing, and are very good at shaped dies. We design specialty products for coating

and drawing applications, and offer inventory management service. www.pdtinc.com.

Premier Wire Die. PWD offers a full range of diamond wire drawing dies and diamond wire drawing die recutting services. We operate in all industries that use diamond wiredrawing dies. www.premierwiredie. com.

Woodburn Diamond Die. WDD supplies both single crystal and PCD diamond as well as carbide materials, with an emphasis dies for wiredrawing, bunching and stranding, and in enameling and coating processes. It has expertise in physically elongated multiwire sets for premium drawing efficiency, inventory management and recutting services, and individualized support for the tooling program. www.woodburndd.com.

JUNE 2014 | 57

FEATURE

with customers to be able to meet any urgent die requirements. With over 20 years of ferrous and nonferrous wire mill experience on our staff, along with our latest innovations for calculating die strings and profiles, we are helping our customers constantly improve their processes and productivity to keep them competitive in the global market place. We have a great crew of people that are happy, happy, happy to help. Gary Kantz/Carsten van der Putten, Esteves.

TECHNICAL PAPERS

TECHNICAL PAPERS Degradation of mechanical properties of drawn copper wire by occurrence of dynamic recrystallization by Kazunari Yoshida, Naoyuki Katsuoka, Kota Doi and Yasutoshi Takemoto

A decrease in the strength of copper wires can be naturally caused during wire-drawing, transportation or storage. The decrease in strength during cold wire-drawing is due to dynamic recrystallization1-5. However, the cause and timing of dynamic recrystallization are still not clear. Also, the reasons for the decrease in strength during the transportation or storage of drawn wires are not clear. The purpose of this study is to examine the cause of the occurrence of dynamic recrystallization during cold wire drawing and the reasons for the decrease in strength of drawn wires. The correlation between crystal texture and wire strength during wire-drawing and the effect of heating during transportation or storage on mechanical properties were examined. EBSD (electron back scatter diffraction) and XRD (X-ray diffraction) were used for crystal orientation analysis, and a nano-indenter and slit method were used for the measurement of Young’s modulus and residual stress respectively. High-purity copper wires, which have recently been used as bonding wires in electronic components, were drawn in addition to normal ETP (electric tough pitch) copper wires, and the ease of the occurrence of dynamic recrystallization was examined.

Tested materials and experimental method ETP copper wires (JIS C1100) of 8 mm and high-purity copper wires (6N level) were used in the experiment. Table 1 shows the chemical composition of the tested

Table 1. Chemical composition of tested copper wire. 58 | WIRE JOURNAL INTERNATIONAL

materials. A continuous wire-drawing machine, operating at 1002-1998 m/min was used with a water-soluble lubricant, Lubright®. A super-alloy die was used for drawing wire with a diameter of more than 1 mm, and a diamond die with an 8� half angle was used for drawing wire with a diameter of 1 mm or less. The reduction per pass was about 20%. The definitions of reduction per pass (R/P) and total reduction (Rt) are shown in Fig. 1. Here, dn is the diameter of the drawn wire after n passes.

Fig. 1. Definitions of reduction/pass R/P and total reduction Rt in wire drawing. SEM (scanning electron microscope) was used for metallographic observation, and EBSD and XRD were used for crystal orientation analysis. A micro-indentation hardness tester (nano-indenter) was used for the measurement of the Young’s modulus of drawn wires.

Test parameters A 8 mm wire rod was repeatedly drawn using a die (α=6�) with an R/P=20% and average drawing speed of 1500 m/min. The correlation between Rt (total reduction) and the tensile strength of drawn wires was examined. The results are shown in Fig. 2. The tensile strength of a drawn wire increases until Rt reaches 99.5%, but it decreases with further increasing of the total reduction. This is attributable to the occurrence of dynamic recrystallization, as shown in Fig. 3. The tensile strength of a wire drawn at a high speed is greater than that of a wire drawn at a low speed. However, as mentioned above, the tensile strength of a wire drawn to an excessive Rt decreases, even if the wire is drawn at a low speed.

TECHNICAL PAPERS Fig. 2. Change in tensile strength of drawn wires for various total reductions.

Fig. 4. {111} and {100} pole figures of continuously drawn wires with various Rt obtained by EBSD.

Fig. 3. Change in tensile strength of drawn wires for various total reductions.

Transition of crystal orientation Regarding three types of drawn wire, the Rt values of which are 99.47%, 99.84%, and 99.99%, pole figures of {111} formed by drawing and {100} formed by recrystallization were made. They were analyzed to obtain a better understanding of the transition of crystal orientation caused by the occurrence of dynamic recrystallization in ETP copper wire continuous drawing. Fig. 4 shows the pole figures obtained by EBSD measurement for a wire of Rt=99.47% before the occurrence of dynamic recrystallization, a wire of Rt=99.84% in which the occurrence of dynamic recrystallization is just beginning, and a wire of Rt=99.99% in which dynamic recrystallization is ongoing.

First focusing on {111}, the wire of Rt=99.47% in Fig. 4(a), in which dynamic recrystallization has not yet occurred, shows a peak in the ND (normal direction), which is the drawing direction of the wire, and the orientation intensity is slightly lower than 14, meaning that the wire-drawing direction is highly oriented. However, the occurrence of dynamic recrystallization causes slight fluctuation on the hitherto stable ring, as shown in Fig. 4(b), and the orientation intensity toward the ND is decreased to slightly lower than 6. Further drawing promotes dynamic recrystallization and collapses the rings markedly, as shown in Fig. 4(c), and peaks are also formed in an area other than the ND as shown by dotted lines. Wire-drawing causes the partial occurrence of recrystallization but, on the other hand, {111} crystal grains are also formed due to slip, resulting in the fluctuation of the orientation intensity toward the ND. Looking at the {100} pole figure, it can be observed in Fig. 4(d) that there is a peak in the ND and stable rings are formed around the ND and its outer circumferential area when there is no occurrence of dynamic recrystallization. Compared with the {111}, the orientation intensity of drawn wire is slightly low, but the {100} texture, which is oriented in the direction of drawing, is formed. Owing to the occurrence of dynamic recrystallization, as shown in Fig. 4(e), rings start to fluctuate, and eventually marked fluctuation of rings occur, as shown in JUNE 2014 | 59

TECHNICAL PAPERS

Fig. 6. Relationship between Rt and Young’s modulus.

Fig. 5. {111} and {100} pole figures of continuously drawn wires with various Rt obtained by EBSD. Fig. 4(f), and then new peaks are formed in the dotted areas shown in Fig. 4(f). The {111} pole figure is formed in various locations and directions owing to the promotion of dynamic recrystallization. This result is very similar to the process6 in which crystal texture is formed by annealing. The {100} diffraction intensity of wires with different Rt was measured by using XRD. Fig. 5 shows the results and crystal orientation maps, which are analyzed by using EBSD. For microscale fine wires, multiple wires were lined up and measured by using XRD. The {100} diffraction intensity increases along with the increase in Rt until Rt reaches 99.5%, but it decreases rapidly once Rt exceeds 99.8%. It is clear that the result of diffraction intensity measurement by using XRD agrees well with the result of the crystal orientation map analyzed by using EBSD.

The Young’s modulus of drawn wires with on Rt of 99.9% or lower did not fluctuate, and showed values of 110-120GPa. Also, it became clear that there is little change in Young’s modulus from the center part to the surface part of a drawn wire. However, once Rt exceeds 99.99%, the Young’s modulus of a drawn wire decreases sharply to 90GPa. Also, it became clear that the Young’s modulus in the center part of a drawn wire is higher than that near the surface part. It is presumed that the Young’s modulus near the surface decreased much more than that in the center part because of the occurrence of dynamic recrystallization and the existence of many <100> direction in the surface part.

Axial residual stress of drawn wires Residual stress has an effect on wire fatigue strength, wire straightness, and productivity for post processing such as coiling8. Wires of Rt=88.2%, 95.4%, 97.0%, and 98.4%, in which dynamic recrystallization did not occur, and wires of Rt=99.999%, in which dynamic recrystallization occurred, were prepared and their

Young’s modulus of drawn wires The Young’s modulus of wires with different Rt was examined by using a nano-indenter. Wright has reported that the Young’s modulus of copper wire varies with the crystal orientation and there is a three-fold difference between <111> and <100>7. In this experiment, Young’s modulus was measured at nine points in three directions and each direction had three measurement points extending from the center part to the surface part. Fig. 6 shows the correlation between Rt and Young’s modulus, which was calculated by using the obtained data. 60 | WIRE JOURNAL INTERNATIONAL

Fig. 7. Residual stress of drawn wires measured by slit method and RMS-FIB method.

470

Change in tensile strength of low-temperature-heated drawn wires Wires of Rt=91%, 96.5%, and 99%, drawn at a low speed, were prepared and subjected to low-temperature heating at 100�C for 1 hour. Their tensile strength and breaking strain were examined, as well as the effect of low-temperature heating on the mechanical properties of the drawn wire. (See Fig. 9.)

0.08

440

0.06

410

0.04

380

0.02 Tensile strength 0

axial residual stresses were measured by the slit method. Drawn wires with a diameter of 1mm or more were slit by using a wire-cut electrical discharge machine. However, the diameter of wires of Rt=99.9995% is 30μm, so it was impossible to use the wire-cut electrical discharge machine, therefore, a portion of a half section of the wires was removed by using a FIB (focused ion beam)9. Axial residual stress was calculated from the wire end curvature after slitting10-11. Fig. 7 shows images of wires after wire cutting and values of axial residual stress. The correlation between Rt and axial residual stress is shown in Fig. 8. As shown in Fig. 8, axial residual stress has an effect on the occurrence of a large tensile stress on the wire surface and also the compression stress in the wire center part. Under such a stress condition, the larger the residual stress becomes, the larger the curvature of the slit wire end grows. In wire-drawing, axial residual stress increases along with the increase in Rt. A wire showed a maximum value of 300MPa when Rt was approximately 97%. This was caused by the difference in strain between the surface and the center part of a wire, which increases along with the increase in the number of instances of drawing. However, residual stress decreases rapidly thereafter, and the residual stress of a wire of Rt=99.999% became about 0. It is presumed that this event was caused by the following: dynamic recrystallization occurred in almost the entire area of the wire, the <111> crystal orientation decreased, and other crystal orientations increased.

0.1

Rt=99%

Rt=91%

350

Fig. 8. Measurement of axial residual stress of drawn wires by slit method.

Rt=96.5%

Breaking strain

Tensile strength / MPa

500

2 3 ln(A0/A)

Fig. 9 Change in mechanical properties

Fig. 9. Change mechanical properties for100℃. various forinvarious Rt upon heating to Rt upon heating to 100�C. For wires of Rt=91% or less, there is little change in tensile strength and breaking strain as a result of low-temperature heating. For wires of high Rt such as 96.5% and 99%, it is found that the tensile strength decreases by about 40MPa and the breaking strain increases by 0.02 even at the low heating temperature of 100�C. It is presumed from the above findings that wires of high Rt are more likely to undergo recrystallization and some crystals are recrystallized after low-temperature heating. As a result of the examination of the effect of low-temperature heating on Young’s modulus, it was found that the Young’s modulus of wires that show no dynamic recrystallization during drawing is likely to decrease along with the increase in Rt. This agrees with the report of Obara12, that the recrystallization temperature of copper decreases along with the increase in Rt. This indicates that the stacking-fault energy in a face-centered cubic crystal is indirectly related to the above results13.

Dynamic recrystallization in high-purity copper wire drawing High-purity copper wires are used in electric/electronic components14. They are processed into ultrafine wires by drawing before use, as is the case of ETP copper wires. It has been reported that the recrystallization temperature varies with the amount of impurities contained15. This suggests that the timing of when dynamic recrystallization occurs differs between ETP copper drawn wires and high-purity copper drawn wires. The amounts of impurities contained in wires used in this study were 0.015-0.04% in ETP copper and 0.00005% in high-purity copper, thus, there was a large difference in their purity. A further experiment was conducted to examine the ease of occurrence of dynamic recrystallization in high-purity copper wire drawing. A high-purity copper wire was drawn into a fine wire of Rt=99.99% by single drawing. Fig. 10 shows a SEM image of the cross-sectional metal structure of a JUNE 2014 | 61

TECHNICAL PAPERS

Heated wire (100℃)

Drawn wire

TECHNICAL PAPERS

the annealing process, selection of a suitable degree of drawing (Rt), and temperature control during the storage of drawn wires.

Conclusions 20μm

φ0.08

20μm

φ0.08

Fig. 10 Metal structure of high-purity copper Fig. 10 Metalafter structure of high-purity copper (Rt=99.99%). Fig. 10. Metalwire structuredrawing of high-purity copper wire wire after drawing (Rt=99.99%). after drawing (Rt=99.99%).

2.28 2.28 5.199 5.199

RD ND

(a) {111}

3.443

(b) {100}

11.854

(b) {100}

11.854

TD 11 {111} and {100} pole figures of Fig. high-purity copperpole wire (Rt=99.99%) Fig. 11 {111} and {100} figures of Fig. 11. {111} high-purity and pole figures high-purity after{100} low-speed drawing. copper wireof(Rt=99.99%) copper wire (Rt=99.99%) after low-speed drawing.

after low-speed drawing.

drawn wire of Rt=99.99%. Grain coarsening and the occurrence of dynamic recrystallization of a high-purity copper wire of Rt=99.99% can be confirmed. Crystal orientation analysis by using EBSD was conducted to clarify crystallographically that dynamic recrystallization occurs in high-purity copper wire. Fig 11 shows {111} and {100} pole figures of a high-purity copper wire of Rt=99.99%. As can be seen in Fig. 11(a), there is no intensified orientation in a particular direction. Orientation intensity to in the ND should be intensified by drawing, but it resulted in a slightly larger than 3, which is considerably below that of ETP copper wire drawing. Examining the dotted areas, it is possible to confirm that the orientation also disperses toward the TD (transverse direction) and RD (right angle direction). As can be seen in the {100} pole figure in Fig. 11(b), peaks in not only the ND but also the TD and RD, which are in the dotted areas, are newly formed, similarly to those for an ETP copper wire formed during continuous drawing. Moreover, the peak intensity of the two orientations perpendicular to the ND is reversed. Dynamic recrystallization occurred in high-purity copper wire drawing even under conditions where there was no occurrence of dynamic recrystallization when an ETP copper wire was drawn at a low speed. It was found that the higher the purity of a copper wire, the more likely dynamic recrystallization occurs. To prevent the decrease in strength of drawn wires, it is necessary to ensure the following: optimum timing for 62 | WIRE JOURNAL INTERNATIONAL

Experiments were conducted to determine the cause of the occurrence of dynamic recrystallization during copper wire drawing and the decrease in strength during transportation or storage after drawing. The ease of occurrence of dynamic recrystallization in drawing was compared between 6N high-purity copper wire and ETP copper wire. The results are as follows: • Along with the increase in Rt of a drawn ETP copper wire, the tensile strength of the wire increases. However, in the case of a wire for which Rt is 99.8% or more, dynamic recrystallization occurs when the wire is drawn, resulting in an abrupt decrease in tensile strength. • The crystal orientation of a wire changes when dynamic recrystallization of the ETP copper wire progresses owing to the excessive Rt, resulting in an orientation similar to the pole figures of {111} and {100} of annealed wire. • The Young’s modulus of a drawn ETP copper wire decreases when an excessive Rt is applied to the wire. In particular, the Young’s modulus around the wire surface becomes lower than that at the center part of the wire. The Rt at which the decrease in Young’s modulus starts agrees with the Rt at which dynamic recrystallization occurs. • The more excessive the Rt of a drawn wire, the easier the occurrence of dynamic recrystallization, even when the wire is processed by heat treatment at a low temperature of 100˚C. • 6N high-purity copper wires are more likely to undergo dynamic recrystallization than ETP copper wires. It follows that the control of the copper wire drawing process including Rt is important to prevent the decrease in strength and the occurrence of dynamic recrystallization of a drawn wire. Also, to prevent the decrease in strength during storage or transportation, the ambient temperature must not exceed the recrystallization temperature of a drawn wire, which is lowered by drawing. 

References 1. K. Yoshida, Y. Takemoto and N. Katsuoka, Wire J. International, January 2011, pp. 57-61. 2. K. Yoshida, Y. Takemoto and N. Katsuoka, 50th domestic conference of copper and brass association, 2010, 45-46. 3. H.J. Frost, M.F. Ashby, Deformation mechanism maps, Pergamon press, 1982, pp. 14-15. 4. H.J. Macqueen, J.of Metals, Feb. 1980, pp. 17.

Kazunari Yoshida

Kota Doi

Publishing Co., Ltd, 1974, pp. 115. 13. A.T. English and G.Y. Chin, Acta Metal, 13 1965, pp. 1013. 14. Mitsubishi Cable Industries, http://www.mitsubishi-cable.co.jp/ja/index.html. 15. K. Osamura, Study of metal structure, Asakura Publishing Co., Ltd, 1997, pp. 146.

Acknowledgement The authors would like to thank the researchers of Mitsubishi Materials Corporation for providing high-purity copper wires for this study. This study was partially supported by the Japan Society for Promotion of Science under grant.

Kazunari Yoshida is a professor of precision mechanics at the school of engineering at Tokai University, Japan. He researches wiredrawing, extrusion, and forging processes and has served as a member of the steering committee for Japanese Wire Drawing. He holds a Ph.D. degree in engineering. He authored a prize-winning paper for the Japan Society for Technology of Plasticity in 1984 and won medal awards from the Wire Association International, for the best paper in the nonferrous division in 1999, 2001, 2003, and 2004, and in the general division in 2008 and 2009. Naoyuki Katsuoka is a graduate student at Tokai. This paper was presented at WAI’s 83rd Annual Convention, Atlanta, Georgia, USA, May 2013.

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5. N. Inakazu, Y. Kaneko, Y. Take-moto, E. Suzuki and M. Fukagaya, Journal of the JSTP, 34-388, 1993, pp. 508-513. 6. N. Inakazu, Metal Drawing and Fiber Textures, Kindai Hensyu, 1985, pp. 337-338. 7. R.N. Wright, “Texture development in copper wire,” Wire Journal International, April, 1997, pp. 70-73. 8. N. Kuntani and M. Asakawa, Journal of the JSTP, 38-433, 1997, pp. 147-152. 9. T. Yamashita and K. Yoshida, Journal of the JSTP, 47-548, 2006, pp. 855-859. 10. H. Sutou, Residual stress and distortion, Uchida Rokakuho Publishing, 1994, pp. 48-49. 11. K. Yoshida and R. Koyama, “Reduction of residual stress of drawn wires,” Wire Journal International, July, 2012, pp. 56-60. 12. S. Kohara, Introduction of metallurgy, Asakura

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TECHNICAL PAPERS Improved wire quality with advanced TCHP dies by Daniel J. Cunningham, Roger N. Wright and John Keane

Tough Coated Hard Powders (TCHPs) are a new family of patented, high-performance metallurgical powders that incorporate unprecedented combinations of property extremes. They represent a class of engineered microstructure P/M-based hardmetals having combinations of critical properties that improve performance and productivity. These engineered property combinations include toughness, abrasive and chemical wear resistance, low coefficient of friction and light weight, at levels not previously seen. TCHP powders can be fabricated into a multitude of industrial metal-cutting and wear parts while leveraging their key attributes to improve manufacturing productivity. These powders are created by incorporating hard particles in a tough matrix using proprietary manufacturing technologies. Engineered nanostructures are created by encapsulating extremely hard

“core” particles with a tough outer layer(s), for example tungsten carbide and cobalt, which in the consolidation process become a contiguous matrix. TCHP powders and consolidated die blanks are manufactured and sold by Allomet Corporation as EternAloy®. The processing, structure and properties of TCHP have been described in previous publications1,2. Representative “core” particles include those traditionally used for extreme wear resistance, e.g., diamond, cBN, Ti(C,N), TiN, Al2O3 among others. One typical TCHP material utilizing alumina (Al2O3) as the core particle has shown to be highly resistant to abrasive wear and is especially suited to wiredrawing dies and similar applications. Fig. 1 shows an example of microstructures of such an alumina TCHP grade. Another recently developed EternAloy® material utilizes

Fig. 1. Alumina TCHP microstructure. (SEM photos, collected in backscattered electron mode (BSE) at 200x and 500x, of the alumina TCHP consolidated microstructure. The dark circular areas in the microstructure are the hard, alumina core particles and the bright regions illustrate the WC and Co matrix.)

Fig. 2. Titanium Carbonitride TCHP microstructure. (SEM photos, collected in backscattered electron mode (BSE) at 200X and 500X, of the Ti(C,N) TCHP consolidated structure. The dark areas in the microstructure are the hard, Ti(C,N) core particles and the bright regions illustrate the WC and Co matrix.) 64 | WIRE JOURNAL INTERNATIONAL

Manufacture of steel tire cord Considerable literature exists regarding the manufacture of high-carbon steel wire or filament, its cabling into strand and the ultimate assembly of these strands into tire cord. A detailed review may be found in the Steel Wire Handbook.3 Suffice it to say that electric arc furnace and basic-oxygen furnace practices are used to directly cast billets or continuous blooms which are hot rolled to rod diameters in the 5 to 11 mm range at speeds of 60 m/s or higher. The rod stock is processed so as to develop a patented microstructure that consists of fine pearlite containing alternating layers of ferrite and iron carbide. In its cold drawn form, the “patent wire” has the highest tensile strength range of any structural metal. This pearlitic microstructure can be largely developed by in-line controlled cooling of the hot-rolled rod, such as with the Stelmor process. More rigorous transformations to fine pearlite can be achieved through isothermal exposures using fluidized beds, molten salt, lead baths and other media. The patented rod may be directly drawn to a diameter of approximately 2 mm, at which point it is electrolytically plated with brass. The brass thickness is a few tenths of a micron. This coating enhances lubrication in the final wet drawing and facilitates the wire’s adhesion to rubber. The brass plating may also be undertaken after patenting the initially drawn wire. In any case, the final drawing process generally involves wet drawing through 20 to 25 dies to a final diameter in the 0.25 to 0.4 mm range. Subsequent to drawing, the filament wire is processed to various cord configurations, starting with the stranding operation. The efficacy and options of filament wire use in tire reinforcement increases with increases in wire strength and decreases in wire diameter. Strength increases can be achieved with extended drawing and increased carbon content, and current development and state-of-the-art practices involve carbon levels as high as 0.90%, diameters as low as 0.1 mm, and tensile strengths as high as 5000 MPa. It is a major issue that the drawing and forming of such fine, ultra-high strength wire is complicated by increasing break frequency, as strength increases. Breakage during drawing and stranding results in lost product and increased down time. For example, it is estimated that the typical strand-

ing break results in 20 minutes of down time. Optimized process design is, of course, fundamental to these continuing achievements, and die selection and management have been important. For example, a combination of PCD and WC dies may be employed when drawing 1080 grade steel. That is to say, many producers have transitioned to a split die line involving both polycrystalline diamond (PCD) and cobalt-bonded tungsten carbide (WC) dies. A typical split die line includes PCD dies at several of the entrance and exit locations and conventional WC dies in the central locations. The PCD entry dies “clean” the freshly brass plated wire and produce a uniform wire for the central die section. The PCD exit dies produce an improved surface finish and minimize the diameter variations at fine wire diameters. This also allows the WC central die positions to have a somewhat steady wear scenario, and practical die replacement protocols are possible.

Study objective The context stated above allows for a direct comparison of the performances of TCHP dies and WC dies in the tire filament drawing and stranding processes. This comparison was the objective of this program, and the results and implications are presented below.

Results and discussion/testing overview The results referenced in this paper were gathered over a period of seven weeks of continuous high-speed drawing and stranding of high-carbon steel tire cord filament. (The scheduled testing timeframe was eight weeks, and this was completed with an 85% machine uptime efficiency.) The results of two lines were compared. One line was a “Control” line with PCD entry dies, WC central dies, and PCD finish dies. The other line was a “Test” line that replaced the WC dies with TCHP dies. Schematic representations of these two lines are set forth in Fig. 3. The results of these two lines and the plant-wide averages during the same period were also compared. The wire diameter and surface finish of the wire were checked daily and recorded, and representative scanning electron micrographs are shown in Fig. 3. The parameters tracked throughout this test were the overall die life in a wet-drawing operation, and stranding performance of drawn wire in the secondary cabling operation. The overall die life was calculated by dividing the total mass of drawn wire by the total number of central section dies used during the testing timeframe. Similarly, stranding performance was determined by dividing the total mass of stranded wire by the number of ruptures during stranding. That is:

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titanium carbonitride Ti(C,N) core particles to provide higher thermal conductivity along with high hardness in a tungsten carbide and cobalt matrix. Fig. 2 shows microstructural photos of this material. The Ti(C,N) TCHP grade is beginning to demonstrate significant performance advantages over the alumina TCHP in high-speed wiredrawing where high heat generation at the die-wire interface rapidly wears WC-Co dies. Allomet continues to develop additional TCHP grades as this group of new materials expands to meet performance demands of more applications.

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Test results At the completion of the scheduled test timeframe, the line segment with the TCHP die sequence showed an increase in overall die life of greater than 85% compared to the corresponding WC dies in the conventional WC control line. Tracking showed that the wire diameter was consistent after each die throughout its service life. Analysis of the tested TCHP dies showed only minor wear, and future testing will be extended to determine the critical drawing time for these TCHP dies. Beyond this, the TCHP-die-containing test line reduced the number of stranding breakages by over 55%. In other words, the mass of stranded wire per break more than doubled (increased by a factor of 2.21). This reduction in wire breaks during stranding is a significant benefit to the tire cord manufacturer due to: a) significant reductions in stranding operation downtime; b) increased product yield; and c) improved strand quality. That is, each break represents either a segment of time where an operator is dedicated to welding and re-stringing the machine, or scrapping the remaining spool. (If the required amount of stranded

wire on a spool is small, it may not be cost effective for an operator to bother restringing the machine in order to complete the spool.) Moreover, the stranded wire is more valuable to an end user with fewer or no welds and other inconsistencies that could potentially increase downtime at their facility.

Potential factors affecting steel tire cord wire breakage For the TCHP dies, the increased die life and decreased number of stranding breaks reflect advantageous conditions at the wire-die interface during the central drawing, and this improvement must be attributed to the unique composite of TCHP at the interface. A comparison of the as-drawn wire surface characteristics (see Fig. 3) suggests that, in this instance, the frictional conditions do not change much when TCHP dies are used. However, a strong argument can be made, through the use of Finite Element Modeling (FEM) , that the temperature at the wire-die interface is not as high when TCHP dies are used. FEM has been utilized to analyze the thermal performance benefits of using TCHP dies over conventional

Fig. 3. Schematic representation of “Test” and “Control” lines, together with scanning electron micrographs of the as-drawn wire surfaces. 66 | WIRE JOURNAL INTERNATIONAL

instead of WC dies seems to have had little effect on the friction conditions, even though the TCHP dies are more wear resistant. Surface heating is also related to tensile residual stress development at the wire surface. This is unlikely to be a factor with stranding breaks, since the residual stress pattern is wholly re-established with each pass, and at stranding will surely reflect drawing through PCD dies. The phenomenon that seems most compatible with the observed behavior is that of dynamic strain aging near the steel wire surface. Dynamic strain aging is very sensitive to temperature and strain rate, with the maximally strain aged steel having a greater strength, together with reduced toughness. In principle, either factor (strength or toughness) could be fundamental for reducing the vulnerability to stranding breaks, since any changes in the mechanical properties generated during central die drawing could carry through to the finish-drawn condition. Actually, at the high strain rates involved with wiredrawing, drawing temperature reduction can be associated with reduced strain aging4, and greater toughness, and this seems likely to be the dominant factor. In any event, a full understanding will require further basic studies.

Looking forward/new TCHP material grades Allomet is currently developing new grades of TCHP materials that address specific market needs. The most recent addition to the TCHP portfolio is a diamond “core” particle coated with an outer shell of tungsten

Fig. 4. Comparison of die cross section temperature profiles for the cases of a WC die, a TL-3 TCHP die, and a diamond TCHP die. (Shown is the model used in Finite Element Modeling simulations to determine the temperature profile throughout the die cross section.)

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WC-Co material. Fig. 4 shows the TCHP die configuration used in the thermal-linear simulation. In the case of the modeling of the WC-Co die, the disk geometry was replaced with an R-2 nib. A constant heat flux was applied on the die-wire contact interface while convection cooling was applied to all of the exposed die faces. During this analysis, a steady state temperature profile throughout the radial component of the wire die monitored. Using ambient temperature as a “zero” reference base, Fig. 4 shows that a TL-3 TCHP grade wiredrawing die has an estimated operating temperature at the die-wire interface that is roughly 10% lower than that of a conventional WC-Co die. This operating temperature could be reduced even further, by over 50%, through the use of a diamond-core TCHP material. This heat reduction at the wire-die interface may be fundamental to improved resistance to breakage during stranding. Suggestions regarding a possible effect of die-wire interface temperature must be regarded as preliminary at the point and should not obscure the strong empirical evidence that TCHP dies are very advantageous in the manufacturing and stranding of tire filament. That having been said, some important points can be made. Temperature effects in fine wire drawing are often discounted because the high surface-to-volume ratio of the wire allows for substantial interpass cooling. The wire surface can get quite hot during the pass, particularly as the wire approaches the exit of the drawing zone. This undoubtedly affects the behavior of the lubricant. However, in this study, the use of TCHP dies

TECHNICAL PAPERS

carbide, and subsequently, cobalt. This new TCHP composition, along with several others that are in the development pipeline, allows Allomet to produce specific mechanical and thermal properties in order to address specific applications. In the case of wiredrawing, this diamond TCHP grade will have a toughness well above that of standard PCD, and a hardness and thermal conductivity that far exceed any conventional tungsten carbide dies. These targeted material properties should increase the robustness of standard PCD dies and also lead to significantly lower operating temperatures than those of conventional tungsten carbide dies. As the portfolio of TCHP materials grows, Allomet will strive to continue addressing technical market challenges and pushing the envelope on material development.

Conclusions A study has been undertaken to evaluate the use of TCHP dies in the drawing of high-carbon steel filament, preparatory to its stranding en route to tire cord manufacture. The results of two different lines were compared. One line was a “Control” line with PCD entry dies, WC central dies, and PCD finish dies. The other line was a “Test” line with TCHP dies in the central locations instead of WC. At the completion of the scheduled test timeframe, the line segment with the TCHP die sequence had an overall die life increase of greater than 85% compared to the corresponding WC dies in the conventional

WC control line. The wire diameter was tracked after each die and was consistent throughout its service life. Actually, an analysis of the tested TCHP dies showed only minor wear, and future testing will be extended to determine the critical drawing time and full life for these TCHP dies. Beyond this, the wire from the TCHP-diecontaining test line displayed over a 55% reduction in stranding breakages or an increase in the mass of stranded wire per break at a factor of 2.21. The observed behavior is consistent with dynamic strain aging near the steel wire surface. Finite Element Modeling reveals that TCHP dies experience reduced heating at the die-wire interface, which should increase the toughness of the near-surface wire metal. The development of diamond TCHP dies will even further decrease the die-wire interface temperature. 

References 1. J. M. Keane and R. N. Wright, “Drawing Steel with Long-Life TCHP Dies,” Wire & Cable Technology, 2009, Vol. 37, No. 5, p. 52-54 2. J.M. Keane and R. N. Wright, “Commercial Evaluation of TCHP Dies,” Wire Journal International, August 2012, pp. 72-77. 3. Steel Wire Handbook (Robert M. Shemenski, ed.), The Wire Association International, Inc., Guilford, CT, USA, pp. 1045-1102. 4. M. E. Donnelly, M.S. Project, Rensselaer Polytechnic Institute, 1982.

John M. Keane

Dan Cunningham accepts the Silver Certificate Award at Wire Expo 2014. 68 | WIRE JOURNAL INTERNATIONAL

Roger N. Wright

Dan Cunningham is manager, applications engineering & new product development for Allomet Corporation, North Huntingdon, Pennsylvania, USA. He holds a master’s degree in engineering mechanics and a bachelor’s degree in aerospace engineering, both from Pennsylvania State University. John M. Keane is president and vice president of technology for Allomet. He has been with the company for over 10 years. He holds Ph.D. and B.A. degrees in chemistry and an MBA, and has received several academic awards. Roger N. Wright is a professor of materials engineering at Rensselaer Polytechnic Institute and president of Roger N. Wright, Inc. Prior to joining Rensselaer in 1974, he worked at Allegheny Ludlum Steel Corporation and at Westinghouse Electric Corporation. He has been widely active in the metallurgy and metals processing sector, as a teacher, researcher, and consultant. He holds Sc.D. and B.S. degrees in metallurgy from Massachusetts Institute of Technology. This paper, which was presented at WAI’s 83rd Annual Convention, Atlanta, Georgia, April 2013, won the Silver Certificate Award in the General Sector.

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TECHNICAL PAPERS 70 | This presentation appeared in the proceedings of the 62nd IWCS Conference

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PRODUCTS & MEDIA

PRODUCTS AT WIRE 2014 as seen at wire düsseldorf

Dynamic dancer controls allows cable wrapping to meet strictest tolerances

Affordable extruder is efficient producer of medium voltage products

At wire Düsseldorf, Italy’s W.T.M. Srl displayed working horizontal and vertical versions of its wrapping technology designed to meet the requirements for the most sophisticated cable products. It reported the following about its systems for tape or yarn wrapping.

At wire Düsseldorf, Maillefer introduced the MXI 150, an air-cooled extruder that provides output of 300 kg/h with a low melt temperature that ensures production of good medium-voltage cable durability. The generated homogenous melt results in high insulation quality. The MXI 150 is easy to operate, has low maintenance needs, and is part of a medium voltage catenary continuous vulcanizing line. Designated as the EPL 30/ Enter, the line is a compact quality solution for more sustainable production that is cost-effective. Just as important, the line is intended to be easy to start and maintain in different production environments. The Maillefer medium-voltage catenary continuous vulcanizing line is designed for continuous insulation of XLPE insulated cable cores. It can process cables to 60 mm in diameter with a cable weight of 7 kg/ min. The product range is 10-35 kV, with a conductor cross section of 25-630 sq mm (copper) and 25-800 sq mm (aluminum). The conductor is insulated by proven XLPE extruders and triple crossheads. The combination of the advanced Autocure line control system, triple crosshead and X-ray dimensional measurement makes it possible to minimize start-up scrap and material over-consumption during a cable production run. Contact: Product Manager Jorma Leppänen, Maillefer, tel. 358-40-504 8308, jorma.leppanen@maillefer.net, www. maillefer.net.

A dancer is the most efficient way for creating a perfect synchronization between a payoff and a take-up, when unwinding/winding wires. The reason is clear: it is direct! The control of the tension through a dancer is accurate because the dancer touches the wires and feels directly the pulling strength applied, regulating consequently the speeds to avoid any stress of the material. W.T.M. has applied this principle to its wrapping equipment, which is available in both vertical and horizontal systems. While the tape or yarn to be laid on the cable are unwound from their spools, W.T.M.’s dynamic dancer controls--in real time--the tension onto the materials being wrapped. Further, it applies the set tensioning and maintains it constant in any situation, including those cables having a square or rectangular section. There is the only way to handle the tension on the tapes/yarns to achieve the same precision. The horizontal line featured two taping modules wrapping polyimide + PTFE, typical application for aerospace cables. They were equipped, respectively, with new 150 mm and 220 mm taping heads for cross wound spools that can run to speeds of up to 3000 rpm, fitted with a traditional WTM proprietary high-sensitivity tape tension control by DYNAMIC dancer. The vertical taping line was suitable for an innovative mica tape for the fire-resistant and fire-retardant cables. It features no tape-flacking effect, maximizes tape use, increases production capability in the following extrusion process and allows use of thinner external insulating material, all of which results in greater cable installation efficiency in cable installation by saving material and increasing the extrusion speed. It also helps in installation thanks to the easiness in stripping, the smaller diameter, for the same cross section, and higher flexibility. Contact: Aldo Zanirato, W.T.M. Srl, tel. 39 347 0753636, azanirato@wtmachinery.com, www.wtmachinery.com. 72 | WIRE JOURNAL INTERNATIONAL

Bender offers versatility, high output and easy maintenance At wire Düsseldorf, U.S.-based AIM presented the SYNCHRO bender, the newest addition to the company’s AFM equipment line. The patented model, AFM 3D8-S, offers unmatched versatility, fast output and low cost maintenance, deploying hybrid forming technology that provides the user with the competiveness needed in today’s ever-changing marketplace. The Synchro system can process complex, shaped wire and tubing off coil as well as form round wire. It comes with a standard two-year warranty, DXF importation, an animation simulator and ease of programming. Optional capabilities include inline drilling, chamfering, press operations, marking, part numbering and more.

PRODUCTS & MEDIA AIM offers upgraded and updated 2D and 3D CNC wire bending solutions, including single- and double-bending head machines with Fanuc robotics integration and complete automated systems. These completely automated work cell solutions that take wire from coil, form, weld and systematically arrange the finished parts. In all instances, wire can be fed directly from a coil, straightened, bent and cut using a software package that provides flexibility and simplicity in programming and is offered in all universal languages. Contact: AIM, Inc., tel. 630-458-0008, cg@aimmachines.com, www.aimmachines.com.

Fewer dusty roads to travel in mills with new lubricant line At wire Düsseldorf, U.S.-based H.L. Blachford Corporation noted that it has spent the last four years working with wiredrawers to help them control and mitigate risk associated with combustible dusts, a focus that stemmed from a 2008 U.S. factory explosion where a single spark destroyed six facilities and caused 13 deaths. Blachford’s new low-dust lubricants reduce the amount of dust created during all aspects of the steel wiredrawing operation. These are not simply beaded or pelletized products, but instead are reformulated lubricants that interact with wire differently. Lubricants can create dust when they are poured, agitated in the drawing line, and when they detach from the wire after it exits the die.

The first two modes can be easily reduced or eliminated by using a beaded product or by installing a soapbox lid, but the third cause, the biggest challenge, is where Blachford’s new lubricants help. When wire is drawn into a die, it pulls lubricant into the die and it heats up. At the higher temperature the lubricant softens, becomes tacky, and attaches into the wire as a cohesive film. But when the wire exits the die, it starts to cool, which causes the lubricant film to cool also and become brittle. When the wire is subsequently bent around a capstan the brittle lubricant can fall away from the wire surface resulting in liberated lubricant, which can become airborne and create a dust hazard. Blachford’s new low-dust dry lubricants adhere better at cooler temperatures and resist falling away from the wire when it is cooled and bent. This result in less detached lubricant, lowering the risk of dust creation in the wire drawing environment. Contact: Dan Howard, H.L. Blachford Corporation, Ltd., tel. 815-464-2100, dhoward@blachford.com, www.blachford.com.

Draw-peeling system designed for special uses, optimal chip disposal At wire Düsseldorf, Germany’s Kieselstein International GmbH displayed one of the company’s draw-peeling systems that can be used for specialized purposes.

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The upgraded system employs an FEM optimized design and adjustment of the flux flow during chipping treatment. It has modules for flexible adjustment of the chip breaker position in order to realize an optimal chip breaking, and offers increased driving speed of the chip

cally reduce dust in the working environment, cut lubricant consumption and eliminate product waste. Offering greater lubrication than traditional products, the lubricant film is fully soluble in water and has increased thermal stability with a final melting point above 300°C. The lubricant runs very freely in the lubrication box and in the die. At the Fairgrounds, Tecnovo launched TECNOLUBRE FM/195, a new calcium-based lubricant that is 100% free from titanium dioxide, which is suspected of being dangerous to humans. As demonstrated by rigorous tests conducted by leading companies, this substance causes serious difficulties with subsequent wire treatments including pickling, annealing, coating and wet wiredrawing, and it also exerts a severe abrasive action on capstan coatings. Another Tecnovo innovation is its SINTEK FL line of emulsifiable and liquid compounds for wet wire drawing made from natural products and renewable sources. This product line is top of the range in the market, subject to constant improvement and with a broad range of

breaker for higher digit rate during draw-peeling in combination with an optimized bearing. The model has been designed for optimal chip disposal of the draw-peeling unit, guaranteeing desired temperature conditions, and additional cooling spots have been added. Finally, an additional drawing die has been integrated to accommodate the specifics of processing nonferrous metals. The correspondent designed draw-peeling unit can be integrated into various lines and applications. Besides a standalone solution, the integration into existing drawing machines is also possible. A process integration of the draw-peeling unit in front of a wire rod drawing machine or a rolling mill as well as integration in drawing benches is possible. Kieselstein has two complete draw-peeling lines at its facilities in Chemnitz that are used for testing of customers products, small production for clients with smaller needs on shaving as well continuous R&D on the technology of draw-peeling. Its expertise has made possible a new concept that offers significant advantages for particular fields of application, such as superconductors or nonferrous wire. Such draw-peeling applications require particular mechanical engineering requirements and very precise chip removal. Contact: Kieselstein International GmbH, tel. 49-3719104100, info@kieselstein.com, www.kieselstein.com.

products for all wiredrawing applications. Topping off TKT’s products lines are KONER’S PRESSURE DIES K.340, which are specially constructed and designed to greatly improve lubrication and drawing performances, reducing costs and improving quality. The above-cited technology, integrated with a new cleaning system named ECOCLEAN and a full range of auxiliary products, provide amazing and outstanding steps forward for the steel wiredrawing industry. Contact: Fabio Bellina, TKT Group, tel. 39-025456396, fabio.bellina@tktgroup.it, www.tktgroup.it.

Lubricants cut dust and consumption while eliminating product waste

Trio of new compounds offer multiple advantages for cable manufacturers

At wire Düsseldorf, Italy’s TKT Group, with its leading companies Tecnovo and Koner, showcased advanced lubricants designed to improve lubrication while making conditions safer for employees. The company’s TECNOLUBRE FM/913 and FM/915 are incomparable sodium-based drawing lubricants, 100% free from borax, boron derivatives and nitrites. They drasti-

At wire Düsseldorf, Borealis and Borouge, suppliers of innovative, value-creating plastics solutions, launched three new products, including Borlink™ LS4201EHV for power cables. Borlink™ LS4201EHV brings the benefits of Supercure technology to extra-high voltage (EHV) applications. Building on the excellent record of Borlink LS4201S and

74 | WIRE JOURNAL INTERNATIONAL

gy worldwide, transmission lines must be refurbished and replaced. As energy shifts towards renewable sources such as wind and solar, these must be integrated into existing grids. Borealis and Borouge are helping the industry meet this demand with high quality, innovative polyolefin compounds, cutting-edge facilities and reliable global supply.” Contact: Borealis AG, tel. 43-1-22-400-335, www. borealisgroup.com.

A sound measuring approach can reduce maintenance charges At wire Düsseldorf, one of the focuses at the booth of Swiss-based Zumbach Electronics AG was how the company’s line of UMAC® RZ65 ultrasonic eccentricity and wall thickness scanners for cable insulations, tubes and hoses can help manufacturers avoid outrageous maintenance charges. Thanks to the completely new design, the transducers can synchronously be adjusted within seconds to the best possible measuring position. The scanners cover an outside diameter range from up to 65 mm (2.5 in.). They represent a smart and simple solution for fully non-contact, in-line eccentricity and wall thickness measurement. Benefits include: quick centering, thanks to the eccentricity measurement and adjustment from the very first second, regardless of the materials’ temperature; completely automatized process monitoring and quality control; easy and product

There are many cold welder companies to choose from... So why should you buy from Huestis Industrial? a. Quality b. Performance c. Dependability d. Reputation e. Pricing

PRODUCTS & MEDIA

outstanding cleanliness of Borlink LE4201EHV, it provides improved processing (scorch performance) and faster production cycles (lower degassing burden) for cable manufacturers. Borealis XLPE grades and the proprietary Borstar® technology also support recycling of plastics in the cable industry. Although XLPE waste cannot be reprocessed as a 100% ingredient, it has been shown that a mixture of virgin PE and up to 60% XLPE waste can be reprocessed with good mechanical properties and can be used, for example, in injection molding. Recycling of cable waste in certain applications is also a possibility with jacketing. The companies also announced that they are strengthening their global leadership in the industry through two major Borlink investments: the expansion of the crosslinked polyethylene (XLPE) production in Stenungsund, Sweden; and the ongoing Borouge 3 project in Abu Dhabi. The 20 kilotonne capacity increase in Sweden will be applied directly to Borlink EHV high voltage direct current and high-voltage polyethylene compounds produced in closed or controlled loop processes. “With rising demand for ener-

WJI 1/2 PA HORIZ

non-blee 6.775”x

f. Delivery g. Warranty h. Customer Service i. All of the above

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From superfine to rod, standard and custom sizes. Huestis machines — Our performance is legendary!

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For more details or to place an order, call us at 800-972-9222, or email us at sales@huestis.com

www.huestisindustrial.com Air Wipes, Pay-offs, Take-ups, Buncher Pay-offs, Accumulators, Spoolers, Cold Pressure Welders, Cable Jacket Strippers, Custom Machinery 2C_HUESTIS_CPW_ManyCompaniesToChoose_WJI_halfHoriz_ISOlogoFix_v9_05132014_press.indd 1

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PRODUCTS & MEDIA

change within a few seconds, thanks to a quickly removable segment; quick and easy symmetrical positioning of all transducers, centrally adjustable; availability of four- and six-point measurement; large measuring range with the same scanner; no readjustments, no tools, no change of transducers; fully non-contact, uncritical centering; no wear parts; 100% construction of non-corrosive materials for maintenance-free long-life operation under water; important material savings; and return on investment within few months. All ultrasonic UMAC systems offer flexible mounting options including inside cooling troughs and spray tanks, or in a separate installation tank provided by Zumbach. By means of further components, such as proven WALLMASTER data acquisition, processing and display systems, ODAC® or MSD diameter and ovality gauges, KW lump and neckdown fault detectors, etc., a UMAC®

WALLMASTER system can be extended for any case, for the highest possible productivity and product quality. These systems provide you with flawless SQC /SPC reports of the final product. Contact: Zumbach Electronics Corp., sales@zumbach. com, www.zumbach.com.

Tangential taping machine accurate at high speeds At wire Düsseldorf, U.K.-based Ridgway Machines Limited showcased its HTM-4T high-speed horizontal taping machine, which it noted can provide accurate taping at speeds of up to 60 meter/minute.

The system represents a cost-effective solution that can allow wire and cable manufacturers to simultaneously apply up to four tapes at speeds to 1000 rpm. It is designed to process conductor sizes from 6 sq mm to 1100 sq mm, applying materials that include paper, Nomex®, mica, polyester, aluminum/Mylar®, PTFE and Kapton®. The model uses high-capacity tape pads that require fewer changes, thus increasing production, with consistent results via the latest servo drive technology that provides accurate head control. Non-contact photo-electric sensors monitor low pad and tape break conditions while a strobe light provides a “freeze frame” view of the taping process for accurate adjustment. The unit, which offers bi-directional rotation, is HMI controlled, with an easy-to-operate control panel that offers fine adjustment of the taping lap, strobe light settings and jog as well as a display of line status in-formation. Multiple machines can be used to apply further tapes and bunching facilities and the complete lines include high capacity payoff/take up drum stands and caterpillar traction control for smooth feeding of the conductor to ensure high quality product with minimal process downtime. Remote diagnostics is also possible by using the machine/line IP address, allowing Ridgway Engineers to provide worldwide support at any time as required. The result of all the above features is a system that allows manufacturers to increase productivity while ensuring that accuracy and consistent taping. Contact: Tony Cuttill, Ridgway Machines Limited, tel. 44-116-289-9199, ext. 212, tcuttill@ridgwayeng.com, www.ridgwayeng.com. 76 | WIRE JOURNAL INTERNATIONAL

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), P.O. Box 578, Guilford, CT 06437-0578 USA.

CLASSIFIED AD RATES: • $1.30 per word for WJI and

PAYMENT POLICY: All ads must be pre-paid.

FORon-line SALE classifieds at wirenet.org (20-word minimum). • Blind

box numbers, add $25. • Boldface headlines, add $6 per line (up24-Carrier to 18 characters per line). Specify category. A Model DF24 Braider

WELL 24-Carrier Braiders CAREER OPPORTUNITIES C #2 Braider, Long Legs, Motor 64-C Horizontal Braider PROCESS ENGINEER: Burton C CB-1 CableWire Braider & Cable is a small family manufacturing facility in 560mm D.T.owned Twisters Hooksett, NH Capstan producing low volt-MATIC 24” Caterpuller age electric cables. We are seek22”, 30” Caterpuller Capstans ing a plastics processing engineer. D 36” Closer Desirable candidates should have 5+ years in a Cablers plastic manufacturWire 8” Vertical Planetary ing setting and be familiar with the D 30” S.T. Closer extrusion process. Responsibilities TANDARD 4.5” Extruder 2009 would24:1 include processLine, improvement TANDARD 3.5” Rubber Extruder and efficiency, helping maintain process and product specifications, TANDARD 2.5” Hi-Temp Extruder new product development, evalTANDARD 2.5” 24:1 Extruder Line,and 2009 uation of new raw materials and TANDARD 1” 24:1 Extruder involved in incoming quality control 1800mm Gantry Payoff, ModelPlease SPF1800 of raw materials. forward resumes Model to BurtA16-4K Hyman at Burton K 1600mm Payoff, Wire Model & Cable, 4 Brookside West, EX Tape Payoff, TPB30-2-D Hooksett, NH +3 630mm Bow Strander Line, 2009 K MP360Pure Packaging LineDIE CUTTING DIAMOND WIRE & POLISHING CONSULTANT. DAHL 630mm P/A Dual Reel Take-up A large stainless steel, nickel alloy EX 18” Dual Reel Take-up, refurbed and carbon steel wire manufacturer R Model SP16 Dual Spooler wishes to engage the services of a Model MS12 Respooler, 18” consultant Reels in the fi well-experienced 36” Rewind Line eld of diamond wire die cutting and polishing. R Model ME301 3-Head Winder del DTC630 D.T. Twister The consultant must have “hands on” STLE 4WDT24 4-W 24” Twister experience andD.T. be qualifi ed to teach CO 16” D.T. Quadders die cutting and polishing techniques for C a large diePrinter, room supporting NIC AlphaJet Inkjet 2005 fine wire drawing operation from .0030” odel EP500 Rod Welder (0.07mm) to .0320” (0.80mm) diamape Accumulator eter wire. ICK “Chalkmaster” Talc Applicator Our plant located in Monterrey, KS Model 4000-04 C/SisMachine Mexico. Travel to Mexico is manUNIGER Model UC3750 Cutter datory. UNIGER Model ES9320 EcoStrip UNIGER Model HS4500 Hot Stamper Requirements • TheCT32, ability CT42 to teach and communiUNIGER Model Crimpers cate withPart current operators (one-on Model STP Stripper, #45-930

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

one or classroom setting) the proper techniques of cutting dies is required. • The ability to teach the proper use of equipment for polishing either natural, SCS, or PCD diamond wire drawing dies to specifi ed requirements. • The ability to teach the proper use of inspection equipment, including micrometers, microscopes, laser mics and other related equipment. • The ability to teach supervisory personnel how to provide feedback to the wire drawing department.

Length of assignment and compensation negotiable. If interested, please contact: ACS Industries, Inc. One New England Way Lincoln, RI 02865 Tel. (401) 769 4700 Attn: Darlene Lachance Email: dlachance@acsind.com M A N U F A C T U R E R ’ S REPRESENTATIVE. Established international manufacturer of drawing lubricants, pre-coatings, chemicals, equipment and tools is seeking representation in the US. Through our innovative practices and respon-

FOR SALE 1 - HACOBA Model DF24 24-Carrier Braider 2 - WARDWELL 24-Carrier Braiders 1 - NEB 72-C #2 Braider, Long Legs, Motor 1 - TRENZ 64-C Horizontal Braider 1 - NEB 24-C CB-1 Cable Braider 7 - KINREI 560mm D.T. Twisters 1 - REEL-O-MATIC 24” Caterpuller Capstan 2 - FARRIS 22”, 30” Caterpuller Capstans 1 - ALLARD 36” Closer 2 - NEB 12-Wire 8” Vertical Planetary Cablers 1 - ALLARD 30” S.T. Closer 1 - DAVIS STANDARD 4.5” 24:1 Extruder Line, 2009 1 - DAVIS STANDARD 3.5” Rubber Extruder 1 - DAVIS STANDARD 2.5” Hi-Temp Extruder 1 - DAVIS STANDARD 2.5” 24:1 Extruder Line, 2009 1 - LESMO 1800mm Gantry Payoff, Model SPF1800 1 - SKALTEK 1600mm Payoff, Model A16-4K

1 - SKALTEK MP360Pure Packaging Line 1 - ROSENDAHL 630mm P/A Dual Reel Take-up 1 - SPHEREX 18” Dual Reel Take-up, refurbed 1 - CLIPPER Model SP16 Dual Spooler 1 - AL-BE Model MS12 Respooler, 18” Reels 1 - TULSA 36” Rewind Line 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 - METRONIC AlphaJet C Inkjet Printer, 2005 1 - PWM Model EP500 Rod Welder 1 - HALL Tape Accumulator 1 - WARBRICK “Chalkmaster” Talc Applicator 1 - EUBANKS Model 4000-04 C/S Machine 1 - SCHLEUNIGER Model UC3750 Cutter 1 - SCHLEUNIGER Model ES9320 EcoStrip 1 - SCHLEUNIGER Model HS4500 Hot Stamper

1 - DYNAMEX Tape Payoff, Model TPB30-2-D 1 - MALI 1+3 630mm Bow Strander Line, 2009

1 - SCHLEUNIGER Model CT32, CT42 Crimpers 1 - IDEAL Model STP Stripper, Part #45-930

1 - DAVIS STANDARD 1” 24:1 Extruder

Commission

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JUNE 2014 | 77

CLASSIFIEDS

WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME_________________________________________________________________________ TITLE ��

CLASSIFIEDS

COMPANY �� ADDRESS �� CITY_________________________________________STATE________________POSTAL CODE______________________ COUNTRY �� PHONE______________________________ FAX________________________________ EMAIL �� AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail_____________________________________ NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

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

siveness to customer’s needs we have rapidly achieved a leading role in international markets and are currently pursuing highly motivated and results oriented reps to develop the US market. If you are enthusiastic with tremendous initiative and ambition this ground floor opportunity is right for you. Competitive commission structure and marketing support are provided. Please respond by e-mail to classified@wirenet.org. PLANT/MANUFACTURING MANAGER. MA-based privately held custom cable manufacturer seeks manufacturing manager due to pending retirement of current one. Extensive background and experience in Wire & Cable industry is required. We are a smoke & drug free EOE offering excellent pay, benefits and room for personal and professional growth for the right candidate. Send Resume to: generalwire@aol.com PERSON-

NEL SERVICES SALES REPRESENTATIVE – TECHNICAL. Saint-Gobain Ceramics – High Performance Refractories/ Metallurgy Non-Ferrous Metals, is part of Saint-Gobain Ceramics & Plastics, Inc., a technical leader in advanced and industrial ceramics. Our constant aim is to develop ceramic products and technologies to better serve the kiln furniture, foundry, primary metals, energy, mining/mineral processing (wear), and military armor markets. Job Goals: The candidate will act as the technical resource for product selection, installation method and 78 | WIRE JOURNAL INTERNATIONAL

operational suggestions for customers as required and present proposals designed to improve their operation or secure new business. Use design and analysis software to support sales activities. Identify new opportunities and undertake product development projects designed to satisfy the requirement to ensure continued growth of sales and customer base. Provide direct supervision of installation/application of products at customer’s facilities to ensure installation according to required instructions. Supervise distributor activities and coordinate sub-contracting of installers or products. There is some flexibility to the physical work location for this position; the incumbent will work from home. Skills and Requirements: Skills equivalent to a Technical/ Engineering Degree are required and 2-4 years of relevant experience in Non Ferrous Metals/Copper Market would be advantageous. Strong technical, application and personal selling skills, along with some technical and working knowledge of internal product manufacture are also necessary. No phone calls please. An Equal Opportunity Employer. To apply for this position, you must apply through the Saint-Gobain Internal Open Job. Please copy and paste the following into your browser: http://saint-gobain-northamerica.com/ Experience/home.asp

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.

Reference Code: 512998 Or fax to: (508) 795-5175 Human Resources Saint-Gobain Ceramics & Plastics, Inc.

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.

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

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: 727863-4700 or by e-mail, please send to urbassoc@verizon.net. n

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

AlphaGary Corp . . . . . . . . . . . . . . . . . . . . . . . . . C2

Nano-Diamond America, Inc . . . . . . . . . . . . . . 13

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . 14

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . 29

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

Pressure Welding Machines Ltd . . . . . . . . . . . 17

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . C4

Proton Products Ltd . . . . . . . . . . . . . . . . . . . 9, 32

Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Commission Brokers Inc . . . . . . . . . . . . . . . . . 77 Esteves Group USA . . . . . . . . . . . . . . . . . . . . . 33 George Evans Corp . . . . . . . . . . . . . . . . . . . . . . 17 Fort Wayne Wire Die Inc . . . . . . . . . . . . . . . . . . 25 Howar Equipment . . . . . . . . . . . . . . . . . . . . . . . 55 Huestis Industrial . . . . . . . . . . . . . . . . . . . . . 8, 75

Queins Machines GmbH . . . . . . . . . . . . . . . . . 15 Rainbow Rubber & Plastics Inc . . . . . . . . . . . . . 2 SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sjogren Industries . . . . . . . . . . . . . . . . . . . . . . . 45 August Strecker GmbH & Co KG. . . . . . . . . . . 19 Teknikor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Inosym Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . 53, 73

TMS Specialties Manufacturing Co Inc . . . . . . . 4

KEIR Manufacturing Inc . . . . . . . . . . . . . . . . . . 11

Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . 5

JUNE 2014 | 79

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX PEOPLE

ADVERTISER ............................ PAGE WAFIOS Machinery Corp . . . . . . . . . . . . . . . . . C3 Wire & Plastic Machinery Corp . . . . . . . . . . . . 79 Witels Albert . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Woodburn Diamond Die . . . . . . . . . . . . . . . . . . 22

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

August 2014 WJI • Industry Focus: evolving industry standards

Wyrepak . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 28

WIRE ASSOCIATION INTERNATIONAL ADS . . . . . . . . WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . 23 Interwire 2015 . . . . . . . . . . . . . . . . . . . . . . . . 30-31

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

SALES OFFICES NORTH AMERICA

EUROPE

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

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

ASIA/ WAI INDIA OFFICE

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

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

80 | WIRE JOURNAL INTERNATIONAL

Advertising Deadline: July 1

B Series Precision CNC Wire Bending Machines Economical, Compact, Profitable! B3 Working range .079 - .256 in ø 2.00 - 6.50 mm ø

B4 Working range .118 - .315 in ø 3.00 - 8.00 mm ø

B5 Working range .157 - .394 in ø 4.00 - 10.00 mm

Basic execution includes 6 CNC axes

WEB SERVICE Call • Connect • Immediate Support

Designed for the production of 2D and 3D wire parts

Optical control capability for process monitoring bend Provides automatic optimization of CNC program sequences for superior output rates

User-friendly WPS 3 operator interface with intuitive graphics for plain-text programming of part lengths, angles or coordinates

wire Simulation and Quoting Software

Engineered for What’s Next Spring Coiling & Forming Machines

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