Auxiliary Equipment

WIRE JOURNAL NOVEMBER 2012

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

Auxiliary Equipment OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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WIRE JOURNAL

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

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

CONTENTS

Volume 45 | Number 11 | November 2012

F EATURE

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 18 People . . . . . . . . . . . . . . . . . 20 Fiber Watch . . . . . . . . . . . . . 22 Fastener Update . . . . . . . . . . 26 WAI News . . . . . . . . . . . . . . 28 Chapter Corner . . . . . . . . . . . 36

Auxiliary Equipment . . . . . . . . . . .40 This feature showcases some of the less-heralded suppliers to the wire and cable industry: those who provide process essentials, from straighteners and welders to air wipes and bows, and more.

Technical Papers . . . . . . . 54-68 Products. . . . . . . . . . . . . . . . 70

T ECHNIC AL PAPERS

Classified . . . . . . . . . . . . . . . 75

Manufacturing highly loadable helical springs through optimization of tempering processes in both spring steel wire and spring production Rüdiger Lux, Ulf Kletzin and Peter Beyer . . . . . . . . . .54

Career Opportunities . . . . . . . 75 Advertisers’ Index . . . . . . . . . 79

Next issue

Dynamic recrystallization of continuous cast copper wire rod and the rapid tensile test Tadeusz Knych, Andrzej Mamala, Beata Smyrak and Monika Walkowicz . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

December 2012 • Green: Part 2 • wrapup: wire China

Cover: An assortment of auxiliary equipment and support parts from top, l-r: Amacoil Inc.; Krollman GmbH; Queins Machines GmbH; Sealeze, a unit of Jason; Niagara Composites International; and Witels Albert USA. See p. 40.

NOVEMBER 2012 | 3

INSIDE THIS ISSUE 4-FOLD FOCUS AT CHAPTER MEETING . . . .36

Attendees inspect some of the equipment that was on display during an Open House at SAMP Shanghai’s new plant in Malu Town. The 4,500-sq-m plant is double the size of the original plant and includes more than 3,800 sq m dedicated to the workshop. The investment, which represents an important milestone for the Italian parent company, was heralded by notables at the event, which included the mayor of Malu Town and the consul general of Italy in Shanghai.

Steven Stoll, a senior technical sales representative for the TPU business of Huntsman Polyurethanes, was one of four speakers at an Oct. 11 education program put on by the New England Chapter at the Holiday Inn Boxborough in Boxborough, Massachusetts. The event—which drew more than 50 attendees and included dinner and a networking reception—presented four experts in areas that were of both direct and indirect interest for the wire and cable industry.

CONTENTS

SAMP SHOWCASES CHINESE RESOURCES . .18

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EDITORIAL WIRE JOURNAL

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EDITORIAL

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

U.S. elections: drama and predictability Publisher | Steven J. Fetteroll

As this issue arrives, the citizens of the United States will have elected their president for the next four years. Two weeks out, the race is too close to call, and pending a stumble by one of the candidates, election night is likely to have lots of drama.

While almost half of WJI’s readership resides outside of the United States, this is a global world that causes us all to be interested in U.S. politics—as well as in Greece’s debt, China’s currency and Syria’s power struggles. The global interest in the U.S. presidential election seems to equally reflect the power of the media and the intellectual curiosity of the world.

Politics are personal. We pick sides and want our candidate to win, even if we are watching via CNN in Mumbai. The tallying and projections will keep many of us up late in front of the television or computer until a winner is determined. However, the real drama will be in the days, weeks and months that follow. Regardless of the election outcome, there will be considerable tax, regulatory and economic implications that will need to be digested by individuals, businesses and markets. In one scenario, the National Association of Manufacturers warns that 70% of the U.S. manufacturers could experience a significant tax increase as soon as Jan. 1, 2013. Couple the various tax concerns with a fragile economy and unemployment could quickly rise.

Companies have been surviving, but not flourishing, following the 2008 economic downturn and continuing global challenges. They recognize that taxes cannot be decreased, yet they can’t afford further expenses unless they are needed for production enhancements. Still, there is reason for concern, but also a basis for hope. Both candidates campaigned as advocates for business and jobs, and once we, the voters, have our say, we will find out soon enough how committed they are to their campaign promises.

Manufacturing wire and cable is very challenging due to intense global influences, an ever-changing human resources landscape, fluctuating raw material pricing and the need to fully utilize technology. All manufacturing segments, including ours, need a pro-business approach at every level of government, but they also need predictability from Washington. Regardless of the outcome on Nov. 7, the positive aspect is that the results will provide some semblance of predictability for four more years.

Steve Fetteroll WAI Executive Director

Editor-in-Chief | Mark Marselli Senior Graphic Designer | Bill Branch Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing & Corporate Communications | Janice E. Swindells Graphic Artist | Adrienne E. Simpson Proofreader | Livia Jacobs Publications Advisory Board Ferruccio Bellina | TKT Group/President ACIMAF, Italy Malcolm Michael | AWIA Australia Don Schollin | Q-S Technologies, USA Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA Technical Advisors John Drummond | Scotia Group R. M. Shemenski | RMS Consulting, Inc.

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

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

Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2012 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700.

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

6 | WIRE JOURNAL INTERNATIONAL

Visit us at the IWCS 2012 - booth 409 www.sikora.net/spark6000

» This innovation is highly electrifying. « Stephanie Imöhl, Head of Procurement & Logistics at SIKORA AG

WLAN (WiFi) ready

SPARK 6030 HF

New: The SPARK 6030 HF is a high-frequency high-voltage sparktester for online detection of pin holes and bare patches in the cable insulation.

SPARK 6030 HF • Integrated display with keypad • Integrated function test and calibration system for: • High-voltage accuracy • Max. short-circuit current • Function and sensitivity test • Corona level detection • Log file for detected break downs and self-test according to EN61010-1:2010

Free SIKORA App for iPhone* and other smart phones: operating page including test certificate ready to be transmitted by e-mail to quality management *iPhone is a trademark of Apple Inc., registered in the U.S. and other countries. App Store is a service mark of Apple INC.

We work for your success.

CALENDAR

CALENDAR Nov. 11-14, 2012: 61st IWCS Conference™ Providence, Rhode Island, USA. This event, to be held at the Rhode Island Convention Center, was rebranded last year as the International Cable • Connectivity Symposium. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990.

Nov. 15-18, 2012: Cable & Wire Fair Istanbul, Turkey. To be held at the CNR Expo Center, this event, organized by CNR Holding, includes cable accessories, cable realignment, electrical insulation materials, equipment and machines. Contact: Esra Aydin, CNR Holding, tel. 90-0212-465-74-74/2-22, esra.aydin@cnr.net, www.cnrexpo.com or www.cnrcablewire.com.

Nov. 27-28, 2012: Wire & Cable Asia 2012 Shanghai, China. This new event is being organized by U.k.-based Integer Research, www.integer-research.com.

See ad on p. 69.

Oct. 8-13, 2013: wire South America 2013 São Paulo, Brazil. Messe Düsseldorf and its partner Grupo Cipa will stage this new fair for the Brazilian market. The new event will be held in parallel with TUBOTECH at the Imigrantes Exposicoes Exhibition Centre in São Paulo. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

April 7-11, 2014: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

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.

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

May 23-26, 2013: wire Russia 2013 Moscow, Russia. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

Sept. 17-19, 2013: wire Southeast Asia Bangkok, Thailand. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

8 | WIRE JOURNAL INTERNATIONAL

WIRE A SSOCIATION INT’L EVENT For more information, contact the WAI, USA. Tel. 001203-453-2777; fax 001-203-453-8384; www.wirenet.org.

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

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INDUSTRY NEWS

INDUSTRY NEWS Nexans is considering the sale of its Berk-Tek business in U.S. Nexans reports that, “following receipt of expressions of interest,” the company is considering the possibility of selling its Berk-Tek copper and fiber cable activity in the U.S. It noted that Berk-Tek, which focuses on cables for local area network applications, generates annual sales of approximately $200 million.

At its website, the company notes that Berk-Tek produces twisted-pair copper cabling at its plant in New Holland, Pennsylvania; fiber optic cabling at its plant in FuquayVarina, North Carolina; and high-pair count copper cabling at the Nexans Electronic Cabling facility in Elm City, North Carolina.

Nova buys Coast Wire; plans to grow business, may pursue acquisitions U.K. based Nova Capital Management Ltd. (Nova), which specializes in acquiring corporate and private equity portfolios, announced that it has acquired five companies in the U.S. from Latshaw Enterprises, Inc., including one of which it has plans to grow and expand.

A press release said that the companies that Nova acquired include: Coast Wire & Plastic Tech Inc, a manufacturer of custom electronic wire and cable products, for the medical, instrumentation and commercial electronic industries, based in Carson, California; MC Electronics Inc, which specializes in the assembly of custom electronic cables, harnesses, electro-mechanical assemblies and full system integration, based in Hollister, California; Wescon Products Company, an OEM manufacturer of mechanical controls, cable assemblies and screw machined components primarily for the lawn & garden sector, based in Wichita, Kansas; Wescon Plastics LLC, a manufacturer of custom plastic injection molded parts using highly-engineered resins primarily for the battery and heavy duty truck industries, based in Wichita, Kansas; and Anderson & Forrester Inc., a manufacturer of orifices, fittings and gauging tools for the natural gas and propane industries, based in Wheat Ridge, Colorado.

“We are delighted to have completed this portfolio acquisition,” said Tom Leader, a Nova investment partner. “It fits perfectly with our strategy of buying groups of companies in a single transaction, which are well managed and have strong market positions but where we feel we can accelerate their growth through the deep operational and international experience which we can bring to bear. This is our third deal in the USA and we believe that this will open up other opportunities for us.”

Asked for further details about Coast Wire, Leader told WJI that the company will be developed as a standalone entity with its current management team continuing. He said that the company has been profitable and that the plan is not to put it up for sale. “We are long-term investors and seek to grow and develop our portfolio companies over many years.” One goal is to bolster international sales, which now accounts for less than 10% of revenues for Coast Wire. “We intend to grow Coast Wire organically within and outside of the U.S., and will be adding new sales resources to enable this. We are also interested in exploring acquisition opportunities for the company.”

U.S. Commerce Department confirms decision on wire rod from Mexico The U.S. Department of Commerce (US DoC) has made its final determination in the anti-circumvention inquiry of small diameter carbon and certain alloy steel wire rod from Mexico, confirming its preliminary determination that 4.75 mm to 5.00 mm wire rod from Deacero SA de CV “constitutes merchandise altered in form or appearance in such minor respects that it should be included within the scope of the order on wire rod from Mexico.”

Steel Guru reported that the US DoC determination applies only to Deacero, and not Ternium Mexico SA de CV, because Ternium has not shipped wire rod with those diameters. The effective date of this determination is June 8, 2011. “Thus, (the identified wire rod)...produced and or exported by Deacero and entered into the United States on or after June 8th 2011, will be subject to potential dumping duties.”

US DoC, the story said, “will instruct US Customs and Border Protection to continue to suspend liquidation of entries of such small diameter wire rod from Deacero and to require cash deposits of 20.11% for all entries that were made on or after June 8th 2011.”

Some certifications for UL 2196 on hold now for fire-resistive cables Underwriters Laboratories (UL) reports that, for now, it will not offer certification for fire-resistive cable, electrical circuit protective systems, and circuit-integrity cable testing conducted in accordance with UL 2196 Test for Fire Resistive Cables.

A press release said that “the abrupt decision was based on UL’s internal test results taken from a wide array of current products and systems originally certified to UL 2196.”

Results, it said, showed inconsistencies in achieving the two-hour fire resistive ratings of UL 2196. Further, UL was not able to confirm any reaction between the zinc found in

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

10 | WIRE JOURNAL INTERNATIONAL

Silica has been the material of choice for optical fiber for so long that it has been a given. After all, what could be a more practical substance to work with than purified beach sand? However, a team of researchers from Clemson University and the University of Illinois believe that they have found a better ingredient: sapphires.

A project headed by Clemson University Professor John Ballato, the director for the Center for Optical Materials Science and Engineering Technologies (COMSET), has found that sapphires can be a practical and cost-effective improvement to silica, which, he said in an article in Science Daily, has been pushed to its limits. The problem, he explained, is that Stimulated Brillouin Scattering (SBS), an interaction between light and sound waves in the fiber that causes frequency conversion and reversal of the propagation, has become more problematic as WDM systems have proliferated and the fibers themselves are carrying more and more information and power (intensity). “Silica has done remarkably well over time, it is now being pushed to its limits for faster and cheaper data and new functionality. It has gotten to the point where there is so much light packed in fiber cable that the silica material essentially can’t handle the intensity and has actually begun interacting and rebelling.”

In the article, Ballato said that one reason that sapphires had not been given serious consideration is that their crystalline structure “is not amenable to making into optical fiber using commercially accepted methods.” The Clemson University research team developed a way to make the sapphire fiber withstand greater intensity and be more useful for high-energy applications than typical commercial fibers.

Aided by testing and modeling by University of Illinois Prof. Peter Dragic, Ballato believes that the results show that sapphires can offer much better performance as well as a lower cost. Following, he discusses the potential for the semi-precious gems.

Photo of sapphire-derived fibers purposefully excited to scatter out green light. Photo by Peter Dragic.

INDUSTRY NEWS

Optical fiber advance represents a semi-precious approach to materials

From l-r, the Clemson University research team of John Ballato, Stephanie Morris and Thomas (Wade) Hawkins.

W JI: Just how much better capacity-wise are sapphires as a replacement for silica?50%? 100%? 1000% or more?

Ballato: “Capacity” means different things to different people. In our case, we focused our studies on certain nonlinear optical effects that limit the performance of optical fibers in telecommunication and high energy laser systems.

This nonlinearity on which we were focused, Stimulated Brillouin Scattering (SBS), is well known to be the main issue restricting the operation of fibers at higher powers. So, specific to SBS, the very first (unoptimized) fibers exhibited enhancements to the SBS properties of about 20 dB, or 100 times (10,000%), over conventional silica fibers. We are working on other systems now were we hope for 30-50 dB enhancements, which would be 1,000 to 100,000 times better and essentially remove from practical consideration this limitation.

WJI: Would the use of sapphire-based optical fiber be practical for deployments where SBS is not considered a problem?

Ballato: Sapphire-derived fibers are expected to offer other enhancements, such as in optical fibers tailored specifically for distributed sensing where Brillouin scattering is used. Further, they may have lower Raman gain, less loss further in the infrared and, as such, may be good for transmitting light from Tm-doped fiber lasers/amps as an example.

WJI: How much more demanding is the process to prepare the sapphire for use as a replacement? Would this require specialized equipment or could a system that now processes silica work for this with only modest changes?

Ballato: The fabrication of the sapphire-derived optical fiber employs the same general process and instrumentation used to make silica fiber. This was important to us because it is hard enough to bring a new material to market; having also to bring a new manufacturing method greatly reduces the likelihood of commercial implementation. In one way of thinking, it requires less complexity. Silica optical fiber is drawn using a fiber draw tower from a bulk glass rod (preNOVEMBER 2012 | 11

INDUSTRY NEWS

form) containing the core and clad. This preform is made on a chemical vapor deposition lathe which is itself a major capital expense and typically costs more to buy and maintain than the draw tower. So, in order to make silica fiber, one needs both the lathe and the tower. In our case, we bought the commercial sapphire (more on that below) and a tube of high-quality silica, and sleeved the sapphire rod into the silica tube, thus creating the core/clad structure. No lathe was required. At the temperature where the silica glass cladding draws into fiber, the sapphire core melts, partially chemically reacts with the silica glass, and results in an allglass optical fiber with greatly enhanced properties over conventional silica-based fibers.

WJI: Sapphire may be semi-precious, but it still has to be more expensive than sand: can it offer enough of a capacity increase to make it viable for commercial production?

Ballato: This is a great question and you’ll not believe— possibly even laugh at—the answer: this fiber is considerably cheaper than conventional SBS-reducing fiber. While sapphire is “semi-precious” you are thinking about the cut gemstones, which carry a great premium because people will pay for it. Sapphire has a lot of industrial uses, such as in abrasives and as scratch-resistant windows (the window over which you slide your groceries at the check-out counter is made from sapphire). The industrial-grade sapphire (we) used ... cost $175 for a 4.2 mm diameter x 100 mm long rod (equivalent of 27.5 carat), so industrial sapphire is very reasonable. So, including the glass cladding tube, the first fiber cost us about $2,000 to make. Obviously, one needs the fiber draw tower, technicians, etc., but if you make optical fiber, you need this infrastructure anyway.

Fibers specifically designed for SBS reduction will easy cost over $50,000 based on all the structuring that goes into those fibers. Interestingly, those fibers have far less SBSsuppression. So not only is it a simpler process but the performance is better and the cost is lower; a trifecta.

WJI: If you research goes forward as hoped, could this direction still be decades away from commercialization?

Ballato: No, we believe that the relative simplicity of the process, especially given the marked improvements in performance, coupled with market need could see such intrinsically-low Brillouin fibers commercialized within a few years. Most likely, they would go into laser or sensor systems first as that is where the greatest value for the enhanced performance lies.

WJI: Have you worked with or had much contact with potential optical fiber customers?

Ballato: A few but the publication is relatively recent so visibility is still growing. We have received a number of inquiries so we anticipate that will continue as our work continues.

Editor’s note: For more information on this project, Ballato can be contacted at jballat@clemson.edu.

12 | WIRE JOURNAL INTERNATIONAL

rigid metal conduit and fire-resistive and circuit-integrity cables. “As a result, manufacturers are no longer authorized to place the UL mark on fire-resistive cable and circuitintegrity cable. UL has removed its certification directory, Electrical Circuit Protective Systems constructed with Fire Resistive Cable.”

Certification will remain on hold while UL’s relevant technical committee (UL 2196 STP) determines appropriate next steps, the release said, noting that UL will offer an interim certification program for fire-resistive cable and circuit-integrity cable in accordance with UL 2196. “The interim certification does away with representative testing.

Testing for each cable construction will be based on five samples and all five samples must achieve compliance to be considered eligible for certification.”

Namibia joint venture seeks to create major African wire manufacturer Groot Group and Partners announced that they are forming a joint venture business called Hakahana Wire and Cable (Pty) Ltd., that plans to develop a wire and cable plant in Namibia that it said could develop into the largest such plant in Africa.

A press release said that the goal is to create the Hakahana Wire and Cable Manufacturing Plant (Hakahana W&C) in Windhoek, Namibia. The new business, it said, will focus on “producing wire, cable, connectivity and networking products for the transmission of signals for data, sound and video applications for use in broadcast, automotive, telecommunications, aerospace, enterprise, transportation, industrial, energy and consumer electronics for the whole of Africa and the world markets.”

The project is budgeted at more than US$1 billion and is expected to create more than 1,500 new direct jobs and more than 7,500 new indirect job opportunities throughout Namibia, the release said.

Groot Group CEO Simon Kapenda said in the release that it intends “to partner with some of the world’s largest wire and cable manufacturing equipment makers, technology processes, and suppliers for the development and commissioning” of the proposed plant. “We’re currently exploring the opportunity to acquire all the Ramatex Buildings in Windhoek...but if we don’t reach an amicable agreement with the parties involved, then we will look at developing and constructing new infrastructure buildings elsewhere in the Windhoek or Okahandja area,” he said.

He identified the SDS Group as one of the part owners forming the joint venture, “and we seek more partners.”

The release said that the Groot Group has partnered with some of the leading Namibian entrepreneurs and local gov-

In terms of financing, he said that it is being structured on a syndicate debt and equity financing basis.

The Groot Group was identified as “a Namibia-based premier rapid industrial development and foreign direct investment management company which focuses on implementing applied neuroeconomics and systems dynamic to efficiently explore, develop, and manage self-sustained ecosystems for the slow-developing and stagnant economies.�

LS Cable & System holds official opening for U.S. power cable plant South Korea’s LS Cable & System held the official ribbon-cutting ceremony for its new U.S. power cable plant of Superior Essex on Oct. 9 in Tarboro, North Carolina, USA, where more than 200 guests attended the ceremony, including Chairman & CEO Christopher Koo, President & CEO Jong-Ho Son, President and COO Ja-Eun Koo, Superior Essex CEO Stephen Carter, state officials, customers and plant employees.

A press release said that the company invested a total of $64 million dollars in the new Superior Essex Energy, Inc., manufacturing facility, which is approximately 140,000 sq m, with production capacity of 20,000 tons of signal and control cables (300V~600V), low-voltage power cables (600V-2kV) and medium-voltage power cables (5-35kV) per year. The production facility has an effective inventory

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ernments; such as Otavi Town Council and Tses Village Council and some of the world’s largest companies, providers, and investment powerhouses such as Danieli, ABB, Aurecon, Mott MacDonald, Siemens, and more, for the development and construction of Otavi Steel, Tses Glass, and Sitentu Power Plant in Namibia.

Asked by WJI why Namibia was chosen, Kapenda replied in an e-mail, “Namibia is one of the peaceful democratic countries in the world with a diverse mineral based economy.�

Regarding the timeframe, Kapenda said that he was optimistic based on the Groot Group’s experience setting up Tses Glass Manufacturing Plant and Otavi Steel. “It took us less than three months to find partners for Tses Glass and we expect to take about two to four months to ink a partnership deal for our planned wire and cable factory in Namibia.� He noted that Namibia has ample resources of copper and other raw materials for making wire and cable products, making it a prime location for any company seeking to expand their boundaries by manufacturing wire and cable “in one of the most stable and fast growing economies in the world. Namibia is beautifully open for business.� The goal is to finish the bankable feasibility study for Hakahana W&C within the next six months, and for operations to begin within eight months thereafter, given success in negotiating the former Ramatex buildings in Windhoek, he said.

INDUSTRY NEWS

management system that will make it possible to proactively and promptly respond to key customers’ demands for products, and early production lines—which were completed in December 2011 in an adjacent manufacturing facility—and have already been producing 300V and 600V signal and control cables, it said.

Superior Essex will concentrate on producing low to medium-voltage distribution cable products in the initial stages and develop high-value-added products, such as high-voltage cables for transmission and power solution

replacement work is projected to “remain at a low level for many years to come.”

The company’s shareholders were identified in the story as: Showa Denko K.K. (17%); Fujikura Ltd. (17%); Hitachi Cable, Ltd. (17%); SWCC Showa Cable Systems Co., Ltd. (17%); Furukawa Electric Co., Ltd. (17%); Tokyo Electric Power Company (13%); and Kandenko Co., Ltd. (2%). A resolution to dissolve the company will be adopted at the end of September 2013, it said, adding that it will be liquidated by the end of December 2013.

USI returns to a once-stalled steel rolling mill project in the UAE

From l-r, LS Cable & System Chairman and President Christopher Koo and CEO Jong-Ho Son tour the new plant with Superior Essex CEO Stephen Carter.

products, the release said. “With the creation of this new U.S.-based energy division, there will be synergies that make it possible to supply LS Cable & System’s extrahigh-voltage and submarine cable products to the North American market. Presently, the U.S. has more than 3,500 generation, transmission, and distribution utility companies.

As of the end of 2011, its installed capacity is projected at 1,072 GW, which makes the United States the number-one producer and consumer of electric power. The U.S. electrical system is going through a transformation where existing grids are being redesigned with new technology. The plan is to cover 20% of its total power consumption with renewable energy by 2030.”

“The completion of the energy plant is one of the most important moments in the 50-year history of LS Cable & System,” said Chairman & CEO Christopher Koo. “LS Cable & System will truly become a global player.”

Plans call for Japanese company to be closed next September Citing JCN Newswire, Bloomberg reports that Showa Denko K.K. (SDK) plans to dissolve its affiliate, Tokyo Aluminum Wire Co., Ltd. (TAW), on Sept. 30, 2013.

The story said that TAW, founded in 1965, will close because demand for the aluminum wire electric cables and rough drawing wire it produces for new construction or

14 | WIRE JOURNAL INTERNATIONAL

Saudi-based United Steel Industries (USI) has chosen U.K.-based Turner & Townsend as project manager for the construction of a new steel rolling mill in the UAE emirate of Fujairah that will produce wire rod and straight rebar for the construction industry.

A story in BigProjectme.com said that the project, located in the Fujairah Free Economic Zone, was initially started in October 2006 before being put on hold in November 2008 following the global economic crash. It said that the rolling mill, 145,000 sq m in size, will be the biggest steel rolling mill in the UAE, having the capacity to produce one million metric tons a year for sale in the UAE market and exported abroad.

In the article, Turner & Townsend said that the revival of the project indicates the return of confidence in the region’s construction industry. “The UAE was no different from the rest of the world in suffering from market decline in 2009 after the property and construction boom went bust. But the UAE’s rapidly growing and urban young population constantly fuel demand across the real estate, infrastructure and utilities segments of the market. It seems the construction industry is on the up once more.”

Queins reports multiple contracts Germany’s Queins Machines GmbH reported on several projects, one of which is a recently finalized planetary strander that it said is now being assembled at a customer’s facility.

A press release said that the customer, in South America, already has other Queins’ machines working in the same factory, and that the new planetary strander will be used for producing umbilicals. The strander is designed to operate with up to 24 spools and with a spool capacity of up to 30 tons. It noted that a second order, for a rigid strander for 800 mm bobbins, was recently commissioned. That machine, which is designed for 24 spools with 1200 kg (2645 lbs) copper or 480 kg (1058 lbs) aluminum, will manufacture large sections of aluminum conductors, it said.

The company noted that it is also filling orders for delivery later this year for a 91-wire strander and a 37-wire rigid strander for customers in the United States and Mexico.

These machines, the release said, will be used for round, sector shaped or Milliken section conductors for cable

ADB supports submarine cable project in the Solomon Islands The Asian Development Bank (ADB) has approved $7.5 million grant and $10.5 million loan for the $60 million Solomon Islands Broadband for Development Project, which will build a submarine cable system that will deliver high-speed internet services at affordable prices to the people of Solomon Islands.

An announcement said that the loan will be made available to the Solomon Oceanic Cable Company, which is also seeking private sector loans, including from ADB’s private sector wing. The submarine cable system, it said, will connect Solomon Islands to an existing international submarine cable network that runs between Guam and Sydney, Australia. It added that the cable system is expected to be in place by December 2013. “The development of the new submarine cable system is a critical step in Solomon Islands international connectivity

and will effectively open up efficient and reliable telecommunications access to the country’s population,� said ADB Pacific Department Director General Xianbin Yao. The underwater fiber optic cable will provide the Solomon Islands population of 550,000 cheaper, accessible, reliable information and communication technology (ICT) services, the release said. It noted that lack of access to markets and services, combined with high transport and communication costs, leaves much of the geographically isolated portion of Solomon Islands economically isolated from national and regional markets.

DoC affirms antidumping duties on steel wire hangers from Taiwan The U.S. Department of Commerce (DoC) issued an affirmative final determination in the antidumping duty (AD) investigation of imports of steel wire garment hangers from Taiwan, finding that producers and exporters from Taiwan sold steel wire garment hangers in the U.S. at dumping margins that range from 69.98% to 125.43%.

If the U.S. International Trade Commission (ITC), which is scheduled to make its final determination on or before Nov. 23, finds that the steel wire garment hangers from Taiwan materially injure, or threaten material injury to the

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INDUSTRY NEWS

domestic industry, ITC will issue an AD order. If it does not agree, the investigation ends.

The petitioners for the investigation are: M&B Metal Products Company Inc, Innovative Fabrication LLC Indy Hanger and US Hanger Company LLC. The merchandise subject to this investigation are steel wire garment hangers fabricated from carbon steel wire. In 2011, imports of steel wire garment hangers from Taiwan were valued at an estimated US$12 million, the announcement said.

The proposed margins were 69.98%, with Taiwan Hanger Mfg., Co., Ltd., receiving a final dumping margin of 125.43% because it did not respond to the questionnaire.

News briefs U.S.-based T&T Marketing has established the Bob Rowland Scholarship Fund in honor of longtime T&T employee Bob Rowland, a well-known wire and cable industry veteran and beloved employee, who passed away earlier this year. The scholarship fund will assist qualified candidates: students between ages 18 to 25 in a four-year college or university who are pursuing a degree in either engineering or one of the sciences, have a GPA of 3.0 or better, and have a parent currently working in the wire and cable industry. The application deadline is March 31, 2013.

To receive a copy of the application and additional information about the program, contact Jessica Hoogendoorn at

T&T Marketing at jhoogendoorn@ttmarketinginc.com, tel. 610-438-1452. ... U.S.-based AMSC has introduced a new class of Amperium® superconductor wire for power cable applications that it said is expected to lower the cost of superconductor power cables and expand the global addressable market for these systems. The brass-laminated 4.4 mm Amperium wire, it said, has demonstrated current carrying performance up to 200 amps, which it noted is industry-leading performance for high-volume second generation (2G) high temperature superconductor (HTS) wire and compares with AMSC’s existing line of 70-100 amp wires. ... U.S.-based Keystone Steel & Wire, manufacturer of Red Brand® fence, reports that it recently was chosen to receive the 2012 Steel Manufacturers Association Achievement in Environmental Stewardship and Recycling Award. “Recycling is in our DNA, and to be recognized by our peers for our efforts is a great honor,” said David Cheek, CEO of Keystone Consolidated Industries, Inc. “Many already know that we recycle about 800,000 tons of scrap metal at our Peoria, Illinois plant each year,” he said, adding that recycling efforts have been expanded to include materials used throughout the company’s facilities.

By implementing a company-wide effort, from the manufacturing floor to administrative offices, over 60 tons of packaging materials are now diverted annually from landfills and sent to recycling centers, he said.

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ASIAN FOCUS SAMP celebrates its new facility in China with colorful grand opening SAMP Shanghai celebrated its new plant in Malu Town in Shanghai with a dazzling Grand Opening on Sept. 26 that saw several hundred guests from 20 different countries visit the building, designed for the manufacturing of machinery and equipment for the wire and cable industry.

The decision to further strengthen SAMP presence in China, investing in a new state-of-the-art production unit to efficiently and safely produce high-quality machinery and equipment, was taken in 2011, after almost 12 years of direct and successful presence in Shanghai. The 4,500-sq-m plant, double the original SAMP Shanghai plant, includes more than 3,800 sq m dedicated to the workshop.

realize our aggressive growth plans for the Asian market.”

The ribbon-cutting ceremony was conducted in an appropriate way: instead of the ceremonial ribbon, the dignitaries declared the building open for business by cutting copper wire, the final product of the machines manufactured in the Shanghai plant. Following the ceremony, all guests took part in the Gala Dinner at the Marriott Hotel in Jiading, where traditional Chinese music shows and dances livened up the evening. Among the guests was WAI Executive Director Steve Fetteroll.

Commenting later on the bolstered resources, Perroud said that the new plant will further SAMP’s ability to reduce its costs while providing customers with high-quality machinery that does not need to be imported. He also explained that the importance of customer service cannot be overstated.

“China is a big territory, and fortunately for us a lot of the customer base is concentrated in very specific areas that we can easily cover from Shanghai,” Perroud said. “Service is very critical for Chinese customers and the level of technical support expected here is in fact much higher compared to what we typically experience in North America or Europe. In order to fully respond to those needs we have technical experts who moved from Italy and are now here in China. We have also developed and trained a team of Chinese technicians. Obviously the language barrier requires many times the presence of both our resident Italian technicians with our Chinese staff.”

ASIAN NEWS BRIEFS The Sept. 26 Grand Opening Ceremony at SAMP Shanghai’s new plant was heralded as a milestone for the Italian parent company.

The investment in the new SAMP Shanghai plant, an important milestone for the Italian parent company, was heralded by notables speaking at the event, including Wang Chun, governor of Malu Town; Vincenzo De Luca, consul general of Italy in Shanghai; Dominique Perroud, managing director of SAMP Shanghai; and Antonio Maccaferri, president of the SAMP Group.

“In recent years, SAMP has experienced an exceptional period of development in China, thanks to our customers’ continuous trust and the hard work of our employees, their dedication and expertise,” Perroud said. “Today, a large and absolutely avant-garde production plant brings in a new phase of growth. We aim at giving our customers what they most need and value, in a cost-effective and sustainable way. This new flexible plant will give us the capacity to

Nippon Steel & Sumitomo Metal Corp merge operations in Thailand as part of overall plans Nippon Steel & Sumitomo Metal Corp. announced that they will merge two subsidiaries in Thailand to create the largest Japanese-affiliated bar and wire processing company in Southeast Asia.

Steel Processing (Thailand) Co. and Nippon Steel Bar & CH Wire (Thailand) Co. signed a merger agreement on Oct. 1 to be completed in January next year, the announcement said. The integrated company will be called Nippon Steel & Sumikin Steel Processing (Thailand) Co., and will become a consolidated subsidiary of Nippon Steel & Sumitomo Metal. The production capacity will be 84,000 tons a year of steel wire for cold heading and cold forging and 18,000 tons a year of cold-finished steel bars, the company said.

The announcement stems from a business plan of Nippon Steel and Sumitomo where they outline their initiatives, including integration of operations, to establish global production capacity of 60 million to 70 million tons.

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

18 | WIRE JOURNAL INTERNATIONAL

India’s Torrent Power energizes India’s first ACCC conductor tranmission line

Hu An Cable Holdings announced that it has secured an order, worth approximately US$15 million, from Shanghai Municipal Electrical Power Company, a subsidiary of State Grid Corporation of China.

A report in Singapore Business Review said that the deal calls for the company to supply 325 km of low-voltage power cables for use in various municipal projects in Shanghai, China. The new order was signed under the Group’s wholly-owned subsidiary Wuxi Hu An Wire and Cable Co. Ltd. Around 80% of the deliveries are expected to take place in 2012 and the balance in 2013.

In other news, Singapore Business Review reported that Hu An Cable has named Zhou Jian Jun as vice president, responsible for the Group’s marketing and sales functions as well as for the overall management and operation of Wuxi Hu An Wire & Cable Co., Ltd., a subsidiary of the company. Previously, he worked for Wuxi Hu An Wire & Cable Co., Ltd., and for Yixing Longteng Huanbao Mechanical Equipment Co., Ltd.

U.S.-based CTC Global reports that Torrent Power Ltd. has energized the first ACCC® conductor transmission line installed in India.

A press release said that the ACCC 629 kcmil (318 sq mm) Lisbon size conductor was installed to double the capacity of an existing 132 kV transmission line between two substations in Ahmedabad, one of the major cities in the western part of India, in the state of Gujarat.

The ACCC composite core, the release said, was produced by CTC Global in Irvine, California, and the finished conductor was manufactured by Sterlite Technologies, Ltd., which is one of CTC Global’s 10 international manufacturing partners. The project was delivered by Sterlite Technologies, Ltd., on a turnkey basis, under the guidance of CTC Global.

Tom Walton, installation supervisor for CTC Global, said that, “Power demand is heavy in this highly industrial area, but we doubled line capacity without having to modify or reinforce the existing lattice towers. With ACCC, Torrent Power can keep the power flowing at a high capacity through its transmission lines, as well as reduce the number of line losses, which is important in a city of this size.”

NOVEMBER 2012 | 19

ASIAN FOCUS

Hu An Cable wins order for 325 km of power cables, names new vice president.

PEOPLE

PEOPLE Cable Components Group, LLC, has named Paul McLaughlin as sales & marketing manager, responsible for direct sales interactions with existing customers as well as establishing new customers and support for new product introductions. He has 30 years of sales and business experience, most recently serving for eight years at NEPTCO as national accounts manager. Before that, he spent more than 20 years with International Paper and Georgia Pacific, concentrating on flexible packaging, coated and laminated films, and custom laminated products.

Paul McLaughlin He holds a B.A. degree in economics from the College of the Holy Cross.

Based in Pawcatuck, Connecticut, USA, Cable Components Group, LLC, supplies plastic extruded products for wire and cable, fiber optic and other markets.

U.S.-based Alps Wire Rope Corporation reported several recent personnel moves. Jeff Pyzyna has joined the company as district sales manager, Western region, based in Saint Charles, Illinois. He has a background in wire

rope sales and most recently was a national account manager for a manufacturing company. It said that Ross Benner has returned as customer service and purchasing manager. He had worked with Alps from 1988 to 2004. The company also announced the promotion Jeff Pyzyna of Elizabeth Beddow to controller. She attended Western University of Illinois and Ross Benner joined the company in 2005, working closely with Bob Zader, who recently retired as vice president and controller. Based Elizabeth Beddow in Saint Charles, Illinois, USA, Alps Wire Rope Corporation supplies a wide range of wire ropes and related products.

OBITUARY Memorial Medal from the Association of Iron and Steel Lifelong steel mill manufacturer Paul S. Morgan, Engineers in 2002.

Duxbury, Massachusetts, died Sunday, Sept. 23, 2012, at Under Paul Morgan’s leadership, the company entered age 88. into a number of mergers, acquisitions and licensing From 1965 to 1986, Paul Morgan served as president agreements with companies in the U.S.—as well as of Morgan Construction Company, the rolling mill equipEngland, Japan, Italy, Germany, Switzerland and China— ment engineer and manufacturer, based in Worcester, and opened new markets and expanded existing Massachusetts, USA, and continued as chairproduct lines, such as universal joint spindles, man until his retirement in 2004. He was the non-ferrous tube drawing and continuous fourth generation of Morgans to lead the rolling, cutting and coiling of nonferrous company founded in 1888 by his great-grandrods. The company’s first overseas subsidiary, father, Charles Hill Morgan. During his Morgan do Brasil, opened in São Paulo in 1981. tenure as president, he oversaw the introducPaul Morgan laid the foundation for the U.S. tion of two significant technical developments company’s transition from global market particfor the production of high speed steel rods: ipant to a truly global organization. After 120 the No-Twist Mill and the Stelmor cooling years as a world leader in rolling mill technoloprocess. The No-Twist finishing mill was gy, Morgan Construction Company was developed by Morgan engineers between acquired in April 2008 by Siemens AG. Its 1960 and 1963 and tested at the American Worcester operations continue today as part of Steel & Wire operations of U.S. Steel, while Paul S. Morgan the Siemens VAI Metals Technologies business. the Stelmor process represented the joint Paul Morgan is survived by his wife, Anne; efforts of Morgan and Steel Company of sons, Philip and his wife, Gale, and Daniel and his wife, Canada (Stelco) announced in 1962. Both innovations Mayo; daughters, Margaret and her husband, Nick, and were first installed together for Stelco in 1966. In recogAnne; six grandchildren; and three great-grandchildren. nition of these major contributions to the steelmaking process, Paul Morgan received the Tadeusz Sendzimir 20 | WIRE JOURNAL INTERNATIONAL

USA Wire & Cable, Inc. (USAWC), has named Trey Sitterle as an account manager, responsible for sales through electrical distributor accounts in parts of Texas, Oklahoma, Colorado, Wyoming, Nebraska, and North and South Dakota. He previously worked for the U.S. Dept. of Agriculture, Sysco Food Services and Ranger Marketing. He holds a degree Trey Sitterle in agriculture economics from Texas A&M. Based in Austin, Texas, USA, USA Wire & Cable, Inc., supplies the power and industrial markets with a full line of wire and cable products as well as cable management services.

Bruce Chantry has been promoted to director of marketing, North America, for Lincoln Electric. He has been with the company for 17 years, the last four as a portfolio manager for welding equipment. Before that, he served as a product manager for advanced welding equipment and as a regional manager for the company’s Sub-Saharan Africa region, and also spent time in two of its U.S. sales offices. He holds a B.S. degree in electrical engineering from The Colorado School of Mines and graduated from the Thunderbird School of Global Management’s International Consortia Program. Based in Cleveland, Ohio, USA, The Lincoln Electric Company is a global supplier of welding technology.

RETIREMENT

Theresa Bill, the co-founder and long-time secretary treasurer of Pelican Wire Co., Inc., recently retired. Along with her late husband, Larry Bill, she co-founded Pelican Wire in 1969, starting out in a basement in Wonderlake, Illinois. Today, the company is a leading producer of resistance and thermocouple wire and cable, with 55 employees at its 33,000-sq-ft facility in Naples, Florida.

Theresa’s son, company President Ted Bill, recalled his mom’s efforts in the early years. “Pelican was literally a ‘Mom and Pop’ organization when it began. Dad ran wire in his spare time on the weekends and weekdays, and she handled the shipping and the bookkeeping while also holding down a full-time job. When I was born in 1970, she took on the job of mom and did it all. I can still remember being in the old pole barn on Stateline Road, wrapped up in a blanket, watching them doing a spool change on our enameling line.”

At her retirement party, Pelican Wire co-founder Theresa Bill (right) with her sister, Mary Hayden, and company President Ted Bill, her son.

Ted said that his mom’s positive presence, “can do” mentality and focus to customer service was a key to the company’s success. “Her ‘customer first’ mentality really rubbed off on her co-workers and was the guiding force behind the strong Pelican Wire culture that is still in place today,” he said. In 1975, the company relocated to its current base in Naples, Florida. She continued to serve full time until Larry became very ill, at which point taking care of him became a full-time job. In 2008, shortly after the passing of Larry Bill, Pelican Wire Co., Inc., officially converted to an ESOP (Employee Stock Ownership Plan), a direction that she fully supported because she believed that everyone should feel like an owner and benefit from the company’s success.

Ted said that his mom worked part-time her last two years with the company, coming into the office one or two days a week. She was an active member of the executive committee, and remains active today as a member of the Board of Directors. He added that his mom says she plans to be an active board member “as long as you can wheel me up to the table!”

NOVEMBER 2012 | 21

PEOPLE

Dave Henninger was recently promoted to the position of technical director for Bridon American Corporation.

He has worked in the wire industry for most of his professional career, a total of 27 years. He joined Bridon seven years ago as a wire rope engineer and four years later became director of technical services. He had previously worked for Paulsen Wire Rope Corporation for 15 years, starting as a quality control engineer then as chief engineer for the last 13 years, then became engineering manager at Arcos Alloys, a manufacturer of stainless steel and high nickel weldDave Henninger ing wire and electrodes. He holds a B.S. degree in mechanical engineering from Pennsylvania State University and is a member of ASME and the Wire Rope Technical Board. He replaces Dave Sleightholm, the company’s long-time technical director, who retired in September. Sleightholm, who will continue with the company in a part-time role, was recognized for lifetime achievement at a recent standards meeting of The Wire Rope Technical Board. Based in Wilkes-Barre, Pennsylvania, and part of the U.K.’s Melrose Group, Bridon American Corporation supplies a wide range of wire and wire rope used for lifting for sectors such as oilfields and mining.

FIBER WATCH

FIBER WATCH Seaborn tabs Alcatel-Lucent to build U.S.-Brazil submarine cable network Seaborn Networks announced that it has signed a contract with Alcatel-Lucent to build Seabras 1, a new 10,700 km submarine cable system that will connect the New York metropolitan area and São Paulo, with a branch that lands in Fortaleza, Brazil.

A press release said that the Seabras-1 system will provide a direct route between New York and São Paulo in Brazil, with a branch to Fortaleza, Brazil. It noted that Seaborn Networks and Alcatel-Lucent have already commenced the permit acquisition and marine survey work for the project.

A map showing the route of the Seabras 1 submarine cable system.

The 100 gigabit per second system will deliver new capacity on primary route for internet, data and voice traffic between South America and the rest of the world as well as support a wide variety of consumer and business broadband services between two of the world’s most connected societies, the release said. It noted that, by providing low-latency communication via a 10,400 km segment directly connecting São Paulo and New York, and route diversity via a 350 km branch to Fortaleza, Seabras-1 will also enhance traffic protection in the region.

“Seabras-1 will be the first direct route between New York and São Paulo and also the longest 100G transoceanic link to date,” the release said. “Once deployed, it will contribute with other ongoing initiatives to enhance trans-continental connectivity, for the benefit of the global consumer and business community,” said Philippe Dumont, president of Alcatel-Lucent Submarine Networks.

The Alcatel-Lucent technology for the project includes an integrated 100G wet plant of cable and high bandwidth repeaters, power feed equipment, and its 1620 Light Manager (LM) submarine line terminal, equipped with advanced coherent technology and the flexibility to increase direct connectivity between countries, the release said.

22 | WIRE JOURNAL INTERNATIONAL

INTERWIRE 2013 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

April 23-25, 2013 | Georgia World Congress Center | Atlanta, Georgia, USA

INTERWIRE 2013 LEADING WIRE & CABLE BUSINESSES IN THE AMERICAS. WHY INTERWIRE? When industry professionals look for new wire and cable technology they choose Interwire, the benchmark for wire business in the Americas.

Information is exchanged at Interwire. Machinery is debuted, reviewed, and sold at Interwire. And the promise of international networking on the Americas’ stage continues to excite visitors to this vital marketplace.

Location: Atlanta, Georgia.

Interwire returns to the city of its origin where it was introduced in 1981.

Compact: 3 full days of exhibits.

Interwire 2013 offers a concentrated show schedule.

Operating equipment.

Interwire is a machinery show. Visitors will see operating equipment.

Renewed energy.

Attendance at Interwire 2011 surged with a 19% uptick. Visitors came from 53 countries. More than 400 companies exhibited making Interwire the largest trade show of its kind in the Americas for the wire and cable industry.

Complete technical program.

The conference will feature technical and operational presentations, panel discussions, and guest speakers. Preliminary topics include: green initiatives; cost reduction; health and safety issues; and human resources.

Fully supported.

Show management continues to work with allied organizations, supporting sponsors, and educational supporters to interest a growing number of international participants in the show. Event news is communicated to Wire Journal International readers in 100 countries worldwide.

Learn more about exhibiting and speaking opportunities at 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

EXHIBITING COMPANIES — As of October 2012 — Esteves Group USA Etna Products Inc. Eurolls SpA EuroWire Magazine George Evans Corp.

Evolution Products Fabritex Inc. FIB Belgium SA Fil-Tec Inc. Filtertech Inc. Fine International Corp.

Fisk Alloy Wire Inc. Flymca & Flyro FMS USA Inc. Foerster Instruments Inc. Fort Wayne Wire Die Inc. Fortune Machinery OM Frigerio Frontier Composites & Castings Inc. Fuhr GmbH & Co. KG Gauder Group Inc. Gavlick Machinery Corp.

GCR Eurodraw SpA Gem Gravure Co. Inc. Genca Gimax SRL GMP Slovakia sro Guill Tool & Engineering Co. Guney Celik H. Folke Sandelin AB Hall Industries Handuk Ultrasonic Hangzhou JR Exhibition Co. Ltd. Heacock Metal & Machine Co. Inc. Heany Industries Inc. Hearl Heaton - Pentre Group Heatbath Corp.

HENRICH Maschinenfabrik GmbH Heraeus Noblelight LLC Heritage Wire Die Inc. Howar Equipment Huestis Industrial ICE Wire Line Equipment Inc. IDEAL Welding Systems Ideal-Werk iim AG Measurement & Engineering INHOL LLC InnoVites Cable ERP Software Inosym International Wire Group International Wire Machinery Association (IWMA) InterWire Products Intras Ltd. IWE Spools & Handling GmbH IWG High Performance Conductors Inc. Joe Tools Inc. Jouhsen - Bundgens Inc. Kalmark Integrated Systems Keir Manufacturing Inc. Kieselstein GmbH KMK KP America Inc. Kyocera Industrial Ceramics Lämneå Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. OM Lesmo Group Lesmo Machinery America Inc. Lloyd & Bouvier Inc. Lubrimetal Corp.

The Lubrizol Corp.

LUKAS Anlagenbau GmbH Magnetic Technologies Ltd. Maillefer SA Manner Plastics LP Markem-Imaje USA Mathiasen Machinery Inc. Messe Düsseldorf North America Metavan nv MFL USA Service Corp. - Frigerio The MGS Group MGS Manufacturing Inc. Micro Products Co. Microdia USA Mid-South Wire Morgan-Koch Corp.

Mossberg Associates Inc. Nanjing Capatue Chemical Co. Ltd. Nano-Diamond America Inc. Niagara Composites International Niehoff Endex North America Inc. Northampton Machinery Co. (USA) Numalliance North America Oklahoma/Iowa Steel & Wire OMA USA Inc. OMCG North America Inc. OMCG SpA P&R Specialty Inc. P/A Industries Inc. Paramount Die Co. Parkway-Kew Corp.

Pave Automation Design Petig AG Phifer Wire Inc. Pioneer Machinery USA Pittsfield Plastics Plas-Ties Co. Plymouth Wire Reels & Dies Inc. PolyOne Polytec Inc. POURTIER-Gauder Group Precision Die Technologies Inc. Premier Wire Die Pressure Welding Machines Ltd. PrintSafe Promostar srl Properzi International Inc. Proton Products QED Wire Lines Inc. QUEINS Machines GmbH Radyne Corp.

Rainbow Rubber & Plastics Rautomead Ltd. Redex SA Reel Options by Vandor Corp.

Reel-O-Matic Inc. Refractron Technologies Corp.

RG Attachments Ltd. RichardsApex Inc. Rizzardi Rockford Manufacturing Group FELM Rosendahl Nextrom Technologies Roteq Machinery Inc. RTO Manufacturing S&E Specialty Polymers SAMP SpA SAMP USA Inc. SAMPSISTEMI Sark-USA Inc. Sarkuysan AS Schlatter North America SETIC-Gauder Group

Shanghai Pudong International Exhibition Co. Sictra Srl SIKORA International Corp.

SIMPACKS Sivaco Wire Group Sjogren Industries Inc. SKET Verseilmaschinenbau GmbH Smeets SA Joe Snee Associates Inc. Sonoco Reels Spirka Schnellflechter GmbH SPX Precision Components FENN Division STAKU-Anlagenbau GmbH Stolberger KMB - Maschinenfabrik GmbH Strecker USA Sylvin Technologies Inc. T&T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Tecnofil SA Tecnoherramental SA de CV Teknikor Teknor Apex Tensor Machinery Ltd. Titan Strapping Systems LP Tonar Plastics Tramev SRL Traxit North America LLC Troester GmbH & Co. KG Tubular Products Co. Tulsa Power Inc. United Wire Co. Inc. UNITEK Uniwire International Ltd. US Synthetic Wire Die Reel Options by Vandor Corp.

Vitari SpA Vollmer America Inc. vom Hagen & Funke GmbH WAFIOS Machinery Corporation Stolberger Inc. dba Wardwell Braiding WCISA - Wire & Cable Industry Suppliers Association Web Industries Weber & Scher Mfg. Co. Inc. Windak Inc. Wire & Cable ASIA Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp.

The Wire Association International, Inc. Wire Forming Technology Wire Journal International Wire Lab Co. Wire Machine Systems Inc. Wire Technology Machinery WireCo WorldGroup WiredIn USA Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. YuConn Electronic Inc. Zumbach Electronics Corp.

INTERWIRE 2013 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Ace Metal Inc. ACM AB Advaris GmbH AEB International Inc. AIM Inc. All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American & Efird Inc. American Kuhne Amexstra Inc. Anbao Wire & Mesh Co. Ltd. AW Machinery LLC AXIS Computer Systems Inc. Axjo America Inc. Aztech Lubricants LLC B&H Tool Co. B&Z Galvanized Wire Industry Inc. Bartell Machinery Systems LLC Baum’s Castorine Co. Bekaert Corp.

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

Bock GmbH & Co. KG Bogimac Engineering BOW TECHNOLOGY-Gauder Group Boxy SpA Breen Color Concentrates Inc. Buhler Wurz Kaltwalztechnik GmbH Buttwelders USA Caballe SA Cable Consultants Corp.

Calmec Precision Ltd. Canterbury Engineering Co. Carris Reels Inc. Cary Compounds LLC Cemanco LC Central Wire Industries Ltd. CeramTec AG Chase/NEPTCO Chase Wire and Cable Materials Cimteq Ltd. Clayton Industries Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. CN Wire Corp.

Collins & Jewell Co. Inc. Cometo SNC Commission Brokers Inc. Condat CONDUCTIX WAMPFLER Conneaut Industries Inc. Continuus Properzi SpA Cortinovis Machinery America Inc. CPA Wire Technologies GmbH Custom Machining & Fabrication LLC DALOO-Gauder Group Davis-Standard LLC Design & Engineering LLC Die Quip Corp.

Domeks Makine Ltd. Sti Ebner Furnaces Inc. EJP Maschinen GmbH Electron Beam Technologies Inc. Enercon Industries Engineered Machinery Group Inc. Er-Bakir Elektrolitik Bakir Mamulleri A.S. ERA Wire Inc.

FASTENER UPDATE

FASTENER UPDATE Study: global demand looks strong for industrial fasteners through 2016 A new study from The Freedonia Group, Inc., a U.S.based industry market research firm, predicts that there will be strong global demand for industrial fasteners through the year 2016, with growth coming at an annual rate of 5.2%.

A press release about World Industrial Fasteners, a 482page study, said that Freedonia expects that growth from 2012 to 2016 will occur at a faster pace than from 20062011. By 2016, it said, the global market for industrial fasteners will reach $82.9 billion.

In 2011, the OEM motor vehicle sector was the largest market for industrial fasteners, and this market will post the largest gains through 2016 in value terms, the release said.

The Asia/Pacific region, it said should record the fastest demand gains from 2011 to 2016, averaging 7.4% per year, driven primarily by the strong Chinese market, which will continue to advance despite moderating from the 2006-2011 rate, the release said. Rising demand in the smaller Indian market will complement these gains, as sales in this country will climb at the most rapid pace worldwide through 2016.

The release said that increases in industrial fastener

Projections of global industrial fastener demand through 2016. Chart courtesy of Freedonia Group. demand in economies in the U.S., Western Europe and Japan were much slower than in industrializing countries between 2006 and 2011, and predicted that sales gains in most developed nations will continue to be subpar through 2016. “However, recoveries in motor vehicle production and construction expenditures following a period of decline will result in faster fastener market advances going forward.”

For more information, contact: The Freedonia Group, Inc., tel. 440-684-9600, pr@freedoniagroup.com, www.freedoniagroup.com.

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WAI NEWS

WAI

NEWS

Website makes it easier than ever to sign up or renew WAI membership As previously reported, members of The Wire Association International (WAI) can now renew their membership online. This option represents a critical step in a much larger project to strategically utilize technology in support of the operation.

Eligible member must have a unique email address on file as the renewal notification is emailed to members and receipts are automatically generated after payment.

Members with expiration dates in the 4th quarter of 2012 are the first to be given the opportunity to use the electronic payment option with the entire membership being phased in as their expiration dates come due.

The goal of the project is to help streamline the renewal process by removing paper invoices and multiple processing steps. “In this era of lean, the traditional steps to processing a renewal invoice involved far too many touches

The following individuals recently joined WAI. Alberto Aguilar Vice President Production Carris Reels Inc Corinne Allendorf Director Human Resources Nexans Canada Inc Kamal Baid Director Human Resources GEM Electro Mechnl Pvt Ltd Joseph F Barry Director Engineering Comtran Cable LLC Greg Bates Technical Support Engineer Gem Gravure Co Inc Kathy Beaudoin Director Sales Comtran Cable LLC

and as with manufacturing, each step adds time and opportunities for mistakes,� states Steve Fetteroll, Executive Director.

Members process their payments online as they would many other online transactions. The system allows for payments via credit card or Paypal, and provides the highest level of security.

Security was critical on two fronts as the system was established by WAI Information System Manager Chuck Szymaszek. First, the legislation surrounding the management of financial data relating to customers including members is very onerous and the Association knew that the best way to protect our customers was to utilize a well established third party expert that encodes the data throughout the process. Second, technology allows members to manage their own passwords and this system ensures that the password is truly private.

The Association Management System that was deployed in 2010 provided the necessary foundation for offering

Allen Bishop Accounting Manager Sonoco Reels

Andrew Carr Ins Plant Manager Coleman Cable Inc

Scott Blackwood Manager Operations Coleman Cable Inc

Kyle Carter Inside Sales Supervisor Encore Wire Corp

Alain Blezy Plant Manager Nexans Energy USA Inc

Clif Carty Process Engineer General Cable Corp

Gary Bliss VP Product Development Encore Wire Corp

Matthew A Carver Department Manager Southwire Co

Ron Bolhofner Quality Assurance Mgr General Cable Corp

Richard Chamberland Techical Sales Engineer Gem Gravure Co Inc

Howard Borkholder Technical Process Engrg Mgr Coleman Cable Inc

Allen Chong Chemical Engineer Coleman Cable Inc

Lisha L Brantley CSR Southwire Co

Cao Chuba Manager Plastics Division Encore Wire Corp

Cynthia Brooks Dir of Strategic Sourcing Southwire Co

Dale Clary General Manager Carris Reels Inc

Billy Brown Plant Manager Encore Wire Corp

Todd Clayton Plant Engineer Encore Wire Corp

Scott Calahan Plant Manager Coleman Cable Inc

Brian Connell Director Carris Reels Inc

28 | WIRE JOURNAL INTERNATIONAL

Peter Cook Environmental Health & Safety Manager Gem Gravure Co Inc Marcia A Cook Quality Control Manager Coleman Cable Inc Mark R Cunningham President Huber & Suhner NA Michael F Curran President Carris Reels Inc William J Curtin Materials Manager Nexans Energy USA Inc David Daisy Ins Plant Manager Coleman Cable Inc Brandon R Dalton Process Engineer General Cable Corp Melvin Debord VP Maintenance Encore Wire Corp Imari J Dellimore Process Engineer General Cable Corp Ron Deter Engineer Coleman Cable Inc

Eric Gay Process Engineer Southwire Co

Timothy N Jensen Engineering Manager General Cable Corp

Patrick McEnery Engineer Nexans Energy USA Inc

Chris J Dixon President Dixie Converting Corp

Brian D Gemelli Sales & Marketing Eng Gem Gravure Co Inc

Jon Jensen Regional Service Manager Gem Gravure Co Inc

Chad Mercer Supervisor Southwire Co

Rufus M Dixon CEO Dixie Converting Corp

Kevin Gilbert Technical Support Engineer Gem Gravure Co Inc

Kevin M Kieffer VP Sales & Marketing Encore Wire Corp

Matthew C Merrill Process Engineer Special Metals

Tim M Dixon Executive VP Mfg Dixie Converting Corp

John Glendenning Facilities Manager General Cable Corp

Ken Knuth VP Administration Encore Wire Corp

Shaun Miller Engineering Manager General Cable Corp

John Doherty System Sales Engineer Davis-Standard LLC

Denis Godin Vice President Engineering Wire & Plastic Machinery Corp

Deana M Lagana Human Resources Manager Nexans Energy USA Inc

Brian R Montgomery Technical Sales Rep Gem Gravure Co Inc

Jim LaGuire Project Manager General Cable Co

Michael Monti VP Manufacturing General Cable Corp

Christine E Lippert Manager Quality & Eng General Cable Corp

Andrew R Moore President & General Mgr Sterling Steel Co

Robert F Lizon Supervisor Southwire Co

Justin V Morgan Supervisor Southwire Co

William K Locke Sales Representative Hussey Copper

Isaac Muller Application Engineer Nexans Canada Inc

Dustin Logston Sales Development Mgr Encore Wire Corp

Jean-Sebastien Nadeau Process Engineer General Cable Corp

Daniel Lopez Quality Control Technician Encore Wire Corp

Eshan Narang Salesman Wire & Plastic Machinery Corp

Ronald O Dunn Process Engineer General Cable Corp Shaun W Elton Process Engineer Southwire Co Adrianna Everhart Sales Carris Reels Inc Kimberly Ferguson Vice President Mfg Hefner Reels LLC Lee Ferguson Plant Manager Coleman Cable Inc David Fitz-Gerald Chief Financial Officer Carris Reels Inc Chad E Fleury Production Manager Carris Reels Inc

Terry Gooch Senior Process Engineer Berk-Tek Inc Ricky Greathouse Sales Dixie Converting Corp James Grey Process Engineer Gem Gravure Co Inc Daniel Groulx Plant Manager General Cable Corp Scott Hansen Process Engineer Manager Cerro Wire LLC Dwight G Harder General Manager & Sales Carris Reels Inc Vernon Hartsell MV Unit Manager General Cable Corp

Audi Luna Chemist Gem Gravure Co Inc

Pierre Niquette Quality Assurance Mgr General Cable

Jeffrey B Fountain Environmental Health & Safety Specialist Southwire Co

Robert Henderson Techical Sales Rep Gem Gravure Co Inc

Greg Malcervelli Vice President Sales Wire & Plastic Machinery Corp

John C Frederick Maintenance Manager General Cable Corp

Terry R Henderson Supervisor Southwire Co

David A E Mancini Process Engineer Nexans Canada Inc

Adam Paiz R&Development Chemist Gem Gravure Co Inc

Paul Furtado Plant Manager General Cable Corp

David C Hoddinott Chief Engineer Davis-Standard LLC

John D Marshall Quality Assurance Supv Nexans Canada Inc

Kyung Seok Park Marketing Director Reentech Co Ltd

Jose Garza Plant Manager Encore Wire Corp

Patti M Hodgkinson Human Resources Manager Nexans Canada Inc

Mike Marshall President Roteq Machinery Inc

Dharmendra Patel Process Engineer General Cable Corp

Robert Gaskins Supervisor Southwire Co

Greg C Hundley Manufacturing Manager General Cable Corp

Jimmy R Massanelli Unit Manager General Cable Corp

Erik Perks Value Stream Manager General Cable Corp

Tim Gause Plant Manager Encore Wire Corp

Karim Ibrahim Engineering Manager Nexans Canada Inc

Michael J McDonald Vice President International Southwire Co

Wayne G Popowich Human Resources Manager Nexans Canada Inc

Frank Onofrio Maintenance Manager Nexans Energy USA Inc

NOVEMBER 2012 | 29

WAI NEWS

Jose Diaz Engineer Coleman Cable Inc

WAI NEWS

Kevin Porter Elec Eng Quality Control Encore Wire Corp

Janet Sander Vice President Purchasing Encore Wire Corp

Donald Spurgin Vice President Sales Encore Wire Corp

Jessica Utter Customer Care Rep Carris Reels Inc

Janet Porter Customer Care Rep Carris Reels Inc

Don L Schmidt Process Engineer General Cable Corp

Jaclyn L Stempowski Industrial Engineer Southwire Co

Bodewijn Vandromme President B W C Technologies

Michael Prasad Western Tech Service Mgr Gem Gravure Co Inc

Corey Schultz Plant Manager Cerro Wire LLC

Jimmy R Stevens Engineering Manager General Cable Corp

Scott A Warren Plant Manager Encore Wire Corp

Paul S Purewal Engineering Manager General Cable Corp

Robert M Senenfelder Mfg Systems Mgr Tappan Wire & Cable Inc

Edward Stikeleather Plant Manager IBC Corporation

Tim Waters Advanced Engineer General Cable Corp

Daniel F Raposo Machinist AFC Cable Systems

Dolores Sevilla Moldes y Exhibidores SA de CV

Bob Strunk Operations Manager Gem Gravure Co Inc

Nicky C Welborn Plant Manager Encore Wire Corp

Brad Rattan Distribution Manager Encore Wire Corp

Leann Sexton Accounting Manager Carris Reels Inc

Paul Szeplaki Plant Manager J Hamelin Industries

Hal Wells Sales Standridge Color Corp

Chris Raynor Engineering & Quality Assurance Manager Berk-Tek Inc

Sandra Sharpe Human Resource Manager Southwire Co

Glenn Tessmer Process Engineer United Copper Industries

Paul White Vice President Engineering Roteq Machinery Inc

Rusty G Shields Process Engineer General Cable Corp

Bijo K Thomas Lead Engineer Tappan Wire & Cable Inc

John M Williams Process Engineer Nexans Energy USA Inc

Varun Shrivastava Process Engineer Nexans Canada Inc

Tammy Thompson Customer Care Rep Carris Plastics

Christopher M Wooten Southwire Co

Frederick H Simmons Engineering Supervisor Nexans Canada Inc

Trevor Thompson Industrial Engineer Southwire Co

Andrew S Small Plant Manager General Cable Corp

Todd M Trivisani Process Engineer Nexans Energy USA Inc

Kenneth C Smith Manufacturing Manager General Cable Corp

Garret Turbyfill Production Manager Carris Reels Inc

Tim Spivey Engineering Manager General Cable Corp

Christopher W Usry Controller Southwire Co

Agustin Rodriguez Quality Control Technician Encore Wire Corp Clemente Rodriguez Plastics Mill Operations Manager Encore Wire Corp Tara R Rolley Continuous Improvement Eng Nexans Energy USA Inc Brian D Roth Process Engineer General Cable Corp Nick Roth Accounting Manager Pittsfield Plastics Eng Inc Kenneth J Rowe Systems Analyst Nexans Canada Inc

Randie Yoder Prod Dev Associate Eng Berk-Tek Inc William Yost Engineer Dynamet Inc Dr Alexander Zheltkov Principal Specialist Mechel Steel Group

Sheaves - Pulleys Cable Guides ProcessSheaves.com 866-344-6774 30 | WIRE JOURNAL INTERNATIONAL

WAI NEWS Renewing your membership and shopping at the WAI Store is now much easier through the “my WAI” page of wirenet.org.

Members scheduled for renewal will be directed to the screen above to securely renew their membership online. online service options. In addition to renewing online, members can also update their mailing address and purchase products from the WAI Store.

In December, the Association’s website,

www.wirenet.org, will be re-launched with a completely redesigned format that will integrate the new online renewal and bookstore functionality.

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NOVEMBER 2012 | 31

WAI NEWS

WAI honored with “Gold” and “Best in Show” at PRSA Mercury Awards Following up on its 2011 Silver Mercury Award for creative tactics, the Wire Association International earned multiple honors at the Public Relations Society of America (PRSA) Connecticut Chapter’s 2012 Mercury Awards competition. The annual presentations recognize outstanding work in the public relations, communications, and marketing professions.

Both Mercury Awards—a “Gold” in the Strategic Campaign category for “Marketing Products and Services” and a “Best in Show” distinction—were in acknowledgment of the WAI Operations Summit & Wire Expo 2012 campaign.

Nationally-known emcee Michael Buckley—a recent guest co-host on WABC-TV’s Live! With Kelly—presented the honors to Janice E. Swindells, WAI’s Director of Marketing and Corporate Communications, and Adrienne E. Simpson, Graphic Artist and Marketing Assistant.

“We certainly share these achievements with WAI’s volunteers and staff all of whom deserve recognition for their dedication to the planning process. They help provide the resources that ultimately interest our audience, and give our marketing efforts direction and traction.

“That said, it’s great fun when creative ideas and strategy come together and develop into an effective marketing campaign,” said Swindells.

The first, most challenging goal of the campaign was to attract interest in a program for which substantive content was yet undetermined, but developing simultaneously.

Timing and message creation became critical factors in the marketing campaign.

Part of WAI’s strategy was to use print media to build general awareness of known event elements such as dates, location, and participating exhibitors and sponsors; to reach and attract specific individuals through direct mail and sales promotion pieces; to use the flexibility and immediacy of electronic media to describe the program that was developing in real time; to regulate the flow of newsworthy event details to industry press as available; and to ensure that the campaign was visually consistent across all media.

“That’s when the cactus theme evolved. We needed a visual hook; something green, in Texas, that would provide

Tactical pieces from the WAI Operations Summit & Wire Expo 2012 campaign.

32 | WIRE JOURNAL INTERNATIONAL

WAI’s Adrienne Simpson (l) and Janice Swindells (r) accept the PRSA “Best in Show” Mercury Award from emcee Michael Buckley. a creative link to other wire manufacturing concerns like material handling and water conservation,” said Swindells.

Similar to an advertising agency but on a smaller scale, WAI’s in-house marketing team handles both the strategic and tactical elements of each campaign. Communications functions in both traditional and digital formats include brand identity, creative conceptualization, copywriting, design and production, direct marketing, public relations, sales promotion, advertising, media planning and purchase, and web content and design.

While such a broad range of activities typically requires the attention of numerous agency specialists, this year’s ceremonies spotlighted the benefits of an effectively streamlined marketing operation, and the advantages of close teamwork.

“We spoke with agencies in the competition that employ 20 people or more,” Simpson noted. “In our department, it’s just the two of us.”

Among associations and communications agencies in the competition, some of the more notable represented Connecticut Food Bank (Best in Show-Tactical), YaleNew Haven Hospital, Stamford Hospital, and United Illuminating Co. (UI).

The 2012 Mercury Awards competition, now in its 17th year, is hosted annually by the Connecticut Valley, Southern Connecticut, and Westchester/Fairfield chapters of the Public Relations Society of America. PRSA’s three Connecticut chapters reach throughout the state, into Western Massachusetts, and into the Westchester County and Lower Hudson Valley regions of New York. This year’s awards were judged by a PRSA sister chapter in Tulsa, Oklahoma, USA. The world’s largest and foremost organization of public relations professionals, PRSA is an individual membership professional society of more than 21,000 public relations and communications practitioners.

Renee Earley, a 22-year-old process engineering intern with Fort Wayne Metals, Inc. (FWM), received a scholarship in August from The Wire Foundation, an annual award that is given to individuals in the wire and cable industry who are furthering their education.

“I was very excited to get the scholarship,” said Earley, who is scheduled to graduate next May from the Fort Wayne branch of Purdue University with a degree in mechanical engineering. She heard about the Wire Foundation scholarship and applied for it, and winning it was one more step in a career path that has moved forward with machine-like precision. She has been an intern at FWM for about a year-and-a-half, balancing 24 to 30 hours a week there with her schoolwork. She previously had an engineering internship with DePuy Orthopaedics, and said that the experiences to date have confirmed her decision to be a mechanical engineer. “I always liked taking things apart and seeing how they work and was good at math and science. In high school, I didn’t know what to do, and my parents suggested this path.”

The combination of school and hands-on work has been an amazing experience, Earley said. There’s more to engineering than just the technical end, she observed. A “people

person” at heart, she said that she has found that mindset to be helpful because good communication is important for knowing what is needed and why for a given task. “I learn something new every day, and the time goes by quickly.”

One part of her education at FWM is learning how industry works. “I’ve learned so much at Fort Wayne Metals, things I never would have learned at school. Not only is

Renee Earley, an engineering intern with Fort Wayne Metals, Inc. (FWM), with (l-r) Larry Kay, FWM director of technology; Pat Sheean, FWM engineering manager; John Drummond, president, Scotia Group Inc./president, Wire Foundation; and Jacob Boomershine, FWM senior engineer.

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NOVEMBER 2012 | 33

WAI NEWS

Fort Wayne Metals intern is awarded scholarship from The Wire Foundation

Everything I needed to know about networking I learned at Wire Expo.”

I renew my WAI membership to stay on top of industry trends and new technology.”

Aaron Nolan

Andrew P. Helffrich

I can help WAI members learn more about copper, continuous casting, and process innovation.”

WAI’s networking summits propelled me to peak performance.”

Christine Lovett

WAI’s resources helped put the fun into hard work.

Seriously.”

Dane G. Armendariz

I can help WAI members look at operations today and see ahead to tomorrow.”

Bill Reichert

If you’re serious about a career in wire and cable, all signs point to WAI membership.”

Erik A. Macs

I joined WAI for the member discount on a technical conference and the investment paid off.

No regrets!”

Gary Spence

I can help people solve technical problems and improve their careers.”

Dr. Horace Pops

Paola D’Oria

DISCOVER WAI. Some things you know as well as your name. Other times it takes a little searching to find—or learn— what you need, especially if you are new to the wire and cable industry or plan to keep pace with its innovative advances.

Wire Association International (WAI) is the place to start.

As a WAI member it’s easy to stay informed. Likewise, you won’t have to dig too deeply to uncover the industry’s rich history and accepted certainties.

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

When you consider that wire making can be traced on one timeline from the golden threads in ancient Egyptian jewelry—through telephony, countless creature comforts, and modern infrastructure— toward yet unimagined applications, you can appreciate your vital role in the wire manufacturing continuum.

WAI members represent a living history of the industry. Whatever your direction, if you earn a living with wire, cable, supplies, or equipment you’ve earned a place in WAI’s global network.

MEET YOUR PEERS. ACHIEVE YOUR GOALS. JOIN WAI TODAY. L E A R N

M O R E :

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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

WAI NEWS

Fort Wayne Metals a great place, a lot of the products we make are for medical, so you also feel that you're contributing to society. It’s definitely a rewarding job and I hope that when I graduate I will be offered a full-time position.”

“Renee is the kind of person we want to help,” said Scotia Group Inc. President John Drummond, who doubles as president of The Wire Foundation. “She’s got the enthusiasm and desire that the wire and cable industry needs.” He encouraged companies that could use someone like Renee to consider sending a tax-deductible donation to the Wire Foundation, which is an independent body from the Wire Association International, “so we can help future Renees in their career path.”

The Wire Foundation can be contacted by e-mail at jdrummond@scotiagroupinc.com or via WAI’s David LaValley at dlavalley@wirenet.org.

Last call for Nov. 14 Parkway-Kew webinar on ways to improve drawing It’s only a few days away, so now’s the time to sign up for WAI’s Nov. 14 webinar by Parkway-Kew Corporation (PKC), “How to Improve Your Wiredrawing Process and Gain a Competitive Advantage.”

The webinar, scheduled for Wednesday, Nov. 14, at 11:00 am EST, is being presented by PKC President Gene Klein, Sr. It will address concepts for improving the speed of wiredrawing machinery as well as product quality. It offers solutions particularly for operations whose wire on the drawing blocks is not three quarters of the way up the drawing surface. It addresses the use of taper, radius and water cooling.

The webinar will discuss practical strategies such as proper use of coatings for capstans, pulleys, and tuner and guide rolls, as well as recording common-sense feedback on capstan performance. It will discuss priorities for diagnosing and correcting problems like overlapping and wire separation, and possible problem sources such as heat problems or incorrect number of wraps.

Webinars are free to WAI members and $55 for nonmembers. Members also have free access to the online archives of past webinars. For more details, go to www.wirenet.org/events/webinars.

ne n-li ic i e l n ilab tra so a v l u wa No h GEO : W wit ning NE a cle

Final spots on exhibit floor for Interwire 2013 being filled Interwire 2013 is still about a half year away, but the vast majority (more than 90%) of available exhibit space has already been taken. It may be possible to expand the available space, but at this point there Companies wishing to exhibit that have not done so already should WAI’s sales department to secure a booth.

To date, more than 90,000 net sq ft of exhibit space have been sold for Interwire 2013, to be held April 23-25 in Atlanta, Georgia, USA. For more details on exhibiting at Interwire 2013, contact WAI’s Bob Xeller or Anna Bzowski at tel. 203-453-2777. sales@wirenet.org.

NOVEMBER 2012 | 35

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CHAPTER CORNER New England Chapter program covers multiple topics, draws 50+ attendees The New England Chapter took a different approach to educational programs on Oct. 11 with a multi-speaker event that presented four experts in areas that were both direct and indirect for the wire and cable industry.

The event, held at the Holiday Inn Boxborough in Boxborough, Massachusetts, started with Bruce Hamilton, president of GBMP, a Boston-based non-profit provider of lean technology. He noted that Lean methodology can be a challenge, but he insisted that it can help, and that no organization is so unique it cannot benefit by it. He did not focus on the tools of lean but instead on understanding how and why waste exists. “When’s the last time you went home after work and said, ‘Wow. Everything went perfect today.’

We tend to turn a blind eye to all our problems (there).

What are problems? They are things that get in the way of work. Lots of little anonymous (things) we haven’t decided are problems yet.” It is essential to talk to and to listen to the operators who do the actual work, he said. “Waste eats away from the soul of your organization. ... Develop people and take steps to reduce waste.”

Up next was Liz Harriman, deputy director of the Massachusetts Toxics Use Reduction Institute (TURI) at the University of Massachusetts Lowell, who discussed new developments in chemical restrictions and policies. She warned the audience that the EU’s REACH directive for restricting use of hazardous substances is continuing to add new Substances of Very High Concern, which may require authorization to use. In addition, the EU RoHS Directive restricting the use of hazardous substances in electrical and electronic equipment has been updated to include currently

GBMP President Bruce Hamilton discussed the practical reasons for attaining a “lean” approach at work.

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Chapter President John Rivers, center, with speakers (l-r) Bruce Hamilton, Liz Harriman, Steven Stoll and Jacob Lahijani. exempt equipment like medical devices, and will be likely restricting more substances. Some existing exemptions, including cables sold separately, will no longer be exempt, and they will also have to be labeled with the CE mark, she said.

The event also saw two technical presentations. The first was by Jacob Lahijani, a senior research scientist with DuPont Fluoropolymer Solutions, who discussed the development of high-performance perfluoropolymer materials for wire and cable and semiconductor applications. He spoke about DuPont’s™ ECCtreme™ ECA 3000 perfluoropolymer resin. He discussed its electrical and physical properties and its potential applicability at temperatures up to 300°C, even when exposed to harsh environments.

The final presentation, by Steven Stoll, a senior technical sales representative for the TPU business of Huntsman Polyurethanes, covered the development and commercialization of a halogen-free, flame-retardant TPU for the wire and cable market that passes stringent VW-1 flammability testing. He showed a short video that displayed a cable made from IROGRAN® performing well in flame tests, noting that the TPUs were developed to meet stringent European regs.

Brian Holden, Carris Reels, Inc., and Roy St. Andre, EIS Wire & Cable, were the co-chairs for the educational event.

Also working on the program was chapter President John Rivers, Delaware Marketing Services, who said he liked the way it combined good information and networking. The multi-speaker format offers more diversity, but fewer speakers with more allotted time might work even better, he said, also thanking Dave Fisher for arranging for the venue.

The event drew more than 50 attendees, including three people who became members of WAI. The chapter’s next event will be its 19th annual meeting, which will be held at the Mohegan Sun Resort Conference Center at a date to be set soon. For more details about the meeting, including sponsorships, contact WAI’s Anna Bzowski, tel. 203-4532777, ext. 126, abzowski@wirenet.org.

The Poland Chapter reported that the technical seminar it held Sept. 20-22 in Zakopane, Poland, saw good participation from European companies and educational institutions.

CUT Associate Prof. Sylwia Wiewiórowska discussed a new-generation of TRIP wires.

The program, “High Carbon Steel Wires and Ropes: Technology and Properties,” included technical presenta-

tions presentations, tabletops, an awards ceremony and more. Chapter President Jan Pilarczyk said that the seminar, held at the Antalowka Hotel, was opened by Professor Jerzy Wysłocki, vice dean of the faculty of materials processing technology and applied physics at Czestochowa University of Technology (CUT). The awards ceremony was led by Professor Tadeusz Knych, the WAI chapter’s vice president.

During the banquet, the prestigious Prof. M. Schneider Prize was awarded to three people, including WAI President Nicholas Nickoletopoulos, Andrzej Stupiński and Wojciech Gorak. Nickoletopoulos presented Silver Certificates from the WAI to Prof. Golis and Justyna Adamczyk from CUT, and Dr. Jan Krnac from ŻDB Bohumin, Czech Republic, for papers they had presented at Interwire 2011 in Atlanta.

He also gave a plaque to Prof. Pilarczyka for the chapter’s extensive technical contributions to the WAI. Following the awards ceremony it was time for songs and dance. The entertainment included a performance by the musical group “No Name” and a Zorba dance lesson by Nick Nickoletopoulos.

During two sessions on Friday, Sept. 21, there were 10 presentations which were described in the August 2012 issue of WJI. The proceedings included the Mordica Lectures of Prof. Etienne A.D. Aernoudt, Prof. Van Houtte and Prof. Sevillano as well as the award of the Prof. M. Schneider Prize.

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Poland Chapter reports good results for its technical seminar in Zakapone

CHAPTER CORNER From l-r, Prof. Zbigniew Muskalski, president of the scientific committee; Prof. Bogdan Golis, Silver Certificate winner; WAI President Nicholas Nickoletopoulos, Wojciech Górak and Andrzej Stupiński, all winners of the Schneider Prize; Chapter Vice President Tadeusz Knych; CUT Associate Prof. Sylwia Wiewiórowska, president of the organizing committee; CUT Vice Dean Jerzy Wysłocki; Prof. Etienne A.D. Aernoudt, Dept. of Metallurgy and Materials Engineering, KULeuven, Belgium; and Poland Chapter President Jan W. Pilarczyk.

Pilarczyk said that there were 55 participants from 29 companies and institutions from Poland, Italy, Czech Republic, Belgium, Slovakia and the U.S. The seminar was sponsored by Polskie Liny, Gama Metal from Poland and DEM Costruzioni from Italy, and saw widespread participation from the following Polish companies: Techmat

38 | WIRE JOURNAL INTERNATIONAL

Przedsiębiorstwo Handlowo-Usługowe, Chemetal Polska Sp. z o.o., Centrum Badań i Dozoru Górnictwa Podziemnego Sp. z o.o., Sag Sp. z o.o., Nota Zakład Mechaniki Precyzyjnej, Przedsiębiorstwo Produkcyjno Handlowe “Staldrut,” Stalex s.c., Fabryka Przewodów

WAI President Nicholas Nickoletopoulos explained the function and goals of the Association.

Energetycznych S.A., Met-Prim Sp. z o.o., Degropol Ośrodek Badawczo Rozwojowy, Wolco Sp. z o.o., ATS S.A. Toruń, Zakład Wyrobów Złącznych, Shymko, Centrala Zaopatrzenia Górnictwa S.A., Gama Metal, Polskie Liny Sp. z o.o., Premco S.C., Fabryka Drutu Gliwice Sp. z o.o., Przedsiębiorstwo Wielobranżowe, Pawlak Producent Drutu.

Representatives were also there from six other European companies: ZDB Group a.s., the Czech Republic, Lubrimetal SpA and DEM Costruzioni Speciali, Italy; Bekaert Bohumín/Petrovice sro, the Czech Republic; Bekaert Hlohovec, AS, Slovakia; and Traxit International GmbH, Germany. Lubrimetal and DEM also displayed products at a tabletop display.

Scientists took part from the following three universities: Czestochowa University of Technology (CUT), Poland; AGH Science and Technology University, Krakow, Poland; and KULuven Department of Metallurgy and Materials Engineering, Belgium.

"I found the presenters and attendees to be highly energetic and truly excited about our industry,” Nickoletopoulos said. “The strong relationship between industry and academia was clearly evident and a definite driving force of the seminar and peripheral events. The seminar was a tremendous success; everyone is encouraged to attend future events by the Poland Chapter.”

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Joe Snee Associates, Inc. PO Box 236, Seekonk, MA 02771 Tel: 774-991-0504 Email: joe@jsnee.com

At the tabletop display of Polskie Liny Spólka z o.o., l-r, are Rafał Hadera, management board vice president; Jacek Czarczyński, managment board president; Roman Glik, technical director, CTO; and Stanisław Parysiewicz, director of sales offices, SAG Sp. z o.o.

Pressure Pressure Welding Welding Machines Ltd Bethersden, Kent England TN26 3D 3DY DY Te el: +44 (0) 1233 820847 Tel: Fax: +44 (0) 1233 820591 Fax: E-mail: pwm@btinternet.com W Welders elders and dies available from PWM or authorised distributors only only..

NOVEMBER 2012 | 39

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Powerful…

FEATURE

Auxiliary Equipment A

process is only as good as its weakest link, which is why the role of auxiliary equipment/components and replacement parts is not to be undervalued. Here, suppliers discuss what they have to offer as well as some thoughts on their specific niche.

Amacoil/Uhing U.S. Amacoil/Uhing has reengineered their FA flange detection system. The FA-II system utilizes laser sensor technology for expanded functionality and simpler operation. The FA-II is PLC-controlled and requires none of the tedious adjustments associated with the previous version. Whereas the original system worked only on spools having straight flanges, the new FA-II may be used with spools having either straight or tapered flanges. During spool changeovers, it is often the case that a new spool is not placed on the mandrel in the exact same position as the spool being replaced. This means that a worker must readjust the end stops on the traverse to make sure the traverse reverses at the correct points. The FA-II saves valuable time by eliminating this step thereby enabling operators to manage more winding stations which helps boost production.

Furthermore, winding accuracy is improved because the laser sensor is a more accurate means of locating the spool

Amacoil’s FA II flange detection system.

40 | WIRE JOURNAL INTERNATIONAL

flange edge than the human eye. In its original version, the FA relied on a steady beam of light to trigger reversal of the traverse. The FA-II system employs a laser sensor mounted to the traverse. The sensor continually references the distance from the spool core up to the highest point that wire or other material will be spooled. When the sensor detects the spool flange, the reading is not within the acceptable variance and a signal is sent to a pneumatic cylinder which reverses the traverse. Amacoil, Inc., Bob Eisele, www.amacoil.com.

Cemanco LC U.S. Cemanco provides the wire industry with hard-coated drawing tools and components that save cost and maintain product quality. The surface quality of drawing tools and guide rollers or pulleys plays a substantial role for the quality of products and manufacturing costs. A dense and finely polished surface reduces friction, protects the material, saves energy costs, prolongs the useful life of a tool, reduces machine downtime and, finally, helps to avoid production problems.

Most notable are chromium oxide or aluminum oxide ceramic-coated pulleys, rollers and step cones that are used in machines from makers such as Steel cones offered by Cemanco LC. Niehoff, SAMP,

Cometo Snc Italy Lesmo Machinery America U.S. Italy’s Cometo Snc, represented in the U.S. by Lesmo Machinery America, offers its MTF straightening and cutting machine as a practical system that can process material diameters from 0.6 mm to 5.0 mm. To cover this range, the machine is equipped with more than one wire straightening module. The feed rollers are made from plastic polymers without grooves (see photo), so there is no need for feed roller change when processing a new wire diameter. The

Cometo’s MTF straightening and cutting machine.

pressure on the feed rollers is electronically controlled and this readout is displayed on the touch-screen. The length of the pieces to be cut is controlled by an external encoder that allows 0.1 mm accuracy. The straightening accuracy is 1 mm on a one-meter length. The cutting unit is driven by a brushless motor-reducer and consequently the noise level is very low. The bar/material collector tray is modular, with each module being 1 meter long. With this type of configuration, the machine is capable of cutting/processing 50 x 1 meter lengths per minute. This Cometo product design makes it possible to configure a machine that can cut up to a max of 10 mm material diameter. The cutting unit and the pressure on the feed rollers can be pneumatically or hydraulically controlled (shown is electronic version). The

Beyond the product, what do suppliers offer to customers?

Amacoil adds value to customer transactions by making sure the Uhing traverse will work for the specific application before the sale takes place. Understanding that angled bearings on a rotating shaft result in linear motion is easy. But some aspects are not so easy to understand: how the wrong mounting screws can prevent the traverse from reversing Bob Eisele direction; how to correctly attach a payload; which lubricants will cause slipping and which will enhance traverse performance; and so forth. Amacoil helps customers decide if the Uhing traverse is the right solution. If it is, then we help them optimize traverse performance. Bob Eisele, Amacoil, Inc. The working alliance of Niagara Composites International, Inc., CoorsTek and Talladega Machinery & Supply Co, was formed about a year ago. Each company’s vision is to provide high-quality, face-to-face service, providing customers with a complete suite of products with a focus on excellent customer service, price and on time deliveries. By consolidating our customers and their individual requirements we can reduce the annual operating costs of the factories through enhanced machine rebuilds, high quality ceramics and composite products. High product quality being paramount, however, having the right parts on hand is vitally important as well. With TMS being a major supplier to the wire and cable industry, both CoorsTek and Niagara maintain a variety of inventory available for the customers within 24 hours in the U.S. and Canada. These inventory levels continue to grow as our customers’ needs grow. Our customers have benefited from our alliance in many ways.

By combining our services we have reduced cost, lead times and regularly provide onsite support to each customer’s needs.

Having the ability to draw on the resources of each company 24/7 ensures all of our cusFrom l-r at wire Düsseldorf: Niagara tomers’ Composites’s Steve Boldebuck, ceramics factories division; Niagara President Roy Rymer and operate at TMS Sales Manager Gerry Runyan.

NOVEMBER 2012 | 41

FEATURE

Henrich, etc. We stock a large variety of hard-coated pulleys and are pleased to introduce our new line of tungsten carbide-coated drawing tools, guide rollers and pulleys, with coating thicknesses up to 1 mm with a high-gloss, diamondpolished finish. Using tungsten carbide-coated components is an economical way to take advantage of the excellent price-performance ratio of this material. We will manufacture components per your specifications and small quantities are no problem. Choosing the right supplier for drawing tools is essential to manufacturing the finest quality finished product during wet wire drawing, Call us and we will help you with a cost-effective and long-lasting solution.

Cemanco LC, Ranier Lashofer and Beliza Bermudez, www.cemanco.com.

FEATURE

peak efficiency. We provide complete engineering services on the individual product lines and regularly work together for the customers. We have many overlapping customers in the field and are able to provide multiple solutions to complex machine and manufacturing issues.

CoorsTek/Niagara Composites International, Inc., www.niagara.com; TMS, tmsc.com.

KEIR Manufacturing differentiates itself by offering not just quality products, but a partnership with each customer to create solutions of real value to meet their specific needs. Our total process improvement approach provides unexpected value by analyzing an entire process rather than selected components. Our creative team collaborates and quickly responds to any opportunity with immediate turnaround.

Mike Walters, Keir Manufacturing.

Witels Albert USA takes pride in providing its customers with a superior level of customer service. We never use phone menu systems and personally answer a1l calls and only use voice mail when all lines are busy. E-mails are answered usually within one hour and if research is needed we will follow closely until the customer’s request is 100% answered. We take the extra steps needed to keep customers informed about their order status and delivery.

Our motto is the customer is our boss! Bob Flower, Witels Albert USA, Ltd. As long-standing, specialist manufacturers and suppliers of cold welding equipment, we ensure customers choose the right machine and get the best value from their investment.

Our products are made inhouse, in the U.K., to stringent standards, so customers know they can rely on consistent Steve Mepsted quality. We offer customers an efficient technical support service via our worldwide network of experienced agents and our long-serving U.K.based team is always happy to advise on cold weld techniques and applications. Steve Mepsted, PWM Ltd. We offer special value to customers by designing welders with one unique principle: simplicity of operation. The design keeps pace with technology but the pri-

42 | WIRE JOURNAL INTERNATIONAL

machine can be customized to customer requirements.

This allows the machine performance to vary according to the configuration requirements. The operator panel is identical on any machine configuration. Units available without collector’s tray for inclusion into any line or layout design of your choice. The company further complements its range of wire-handling equipment with wire straighteners, wire guides, replacement straightener and guide rollers, traversing units, rotating dies and straightening machines for rebar processing. Lesmo Machinery America, Harish Panchal, panchalh@comcast.net www.lesmoamerica.com.

CoorsTek (Wire & Cable Division) U.S. The CoorsTek product is renowned for its performance and high quality standards. CoorsTek recently appointed Niagara Composites International, Inc., as its master distributorship in North America for all its wire and cable ceramic products. Niagara’s Steve Boldebuck, who worked for CoorsTek for 30 years in its Wire & Cable Division, has the expertise to deliver the right solution at the right price. A lot of ceramic is sold into the wire market without proper technical support. With our knowledge of the ceramics products, we are able to work closely with each end user. Steve will work directly with your maintenance managers and engineers to deliver the correct solution. Not only do we provide the ceramic product, we also offer complete evaluations of your ceramic needs. By doing this we can fit your machines with the correct product, solve technical issues and provide 24/7 support for each part sold. This approach ensures minimal down time, and high efficiency in wire production. In combination with Talladega Specialties Manufacturing and Niagara (see sidebaron p. 41), CoorsTek is well represented and supported in our market by the Niagara Composites Ceramic Division. CoorsTek/Niagara Composites International, Inc., www.niagaracomposites.com.

Heany Industries Inc. U.S. At Heany Industries Inc., we specialize in custom designs While we have been around for over 80 years supplying industry standard ceramic components (eyelets, pulleys, rods and tubes), our engineering and sales staff is always ready to work with you to create a new product for your specific requirements. All design and custom fabrica-

A range of Heany replacement parts.

KEIR Manufacturing, Inc. U.S. KEIR Manufacturing is an American-based manufacturer of high-purity 99.8% alumina ceramic guides, the Frontiersman™ line of air wipes, and composite flyer bows serving the global wire and cable industry. We are dedicated to making products that enable manufacturing processes to run more efficiently and productively through the application of leading edge materials. Our solutions are focused on continuous process improvement, energy savings, and longer operating life. KEIR’s patented SureShot and SplitShot Air Wipes provide a far more effective drying method that does not depend on high-volume air consumption. Our efficient design yields effective drying using a very low volume of compressed air and lasts much longer

Huestis Industrial U.S. The ceramic-lined “air miser” air wiper was designed and developed by customer demand. For years, manufacturers have been plagued by poor centering and alignment of product as it goes through the air wiper causing premature wear and damage to the plastic air wiper bodies. In most cases not only does it damage the body, but also the product as it rubs and cuts into the plastic. Over the years, many manufacturers’ approaches to this issue have been tried from ceramic eyelets and partial ceramic inlet guides leading into the canal or cavity of the air wiper.

Most of these designs were abandoned due to lack of performance, breakage, and cost. Later versions of full bodied inserts resulted in much higher costs as well as less than stellar performance.

In answer to this problem, Huestis Industrial decided that it had to be built exactly as a standard air miser. It had to A Huestis ceramic air wiper. have a full bodied ceramic insert. It must perform exactly as the standard air miser, and it must be “Huestis tough.” Thus we began our design work, ceramic search, and testing in the field. The results were outstanding! Not only did it fill all of the customers needs, and use less air than other air wipers, it is “Huestis rugged” to be able to stand up to the rigors of daily wear and tear of manufacturing activities. It performs as well and delivers the same economy in air usage as our standard air misers (some say better) and it takes away the need for centering guides and frequent supervision and adjustment. The ceramic air miser is offered in the most popular sizes up to 1 in. (25.4 mm). Huestis Industrial, Howie Fancher, www. hfancher@huestis.com.

KEIR Manufacturing’s Mike Wallace. than other brands due to the rugged ceramic insert lining the wire path. We also offer special configurations that can incorporate other process functions. This equates to over 25% reduction in compressed air usage and an operating life of years versus months. KEIR’s triaxially braided composite standard and BackBone™ flyer bow constructions have greater durability than layered/laminated designs and are able to take more hits and endure higher stress yielding increased operating life and less machine downtime. The more aerodynamic BackBone™ design functions at lower power consumption and higher TPM with improved wire quality and a further reduction in bow breakage. Up to 40% less energy (amps) is used along with a decrease in wire scrapped. Keir Manufacturing, Mike Walters, sales@keirmfg.com, www.keirmfg.com.

Krollmann GmbH & Co. Germany Morgan Koch Corporation U.S. Friedr. Krollmann GmbH & Co. KG, represented in the U.S. by Morgan Koch Corp., produces a full line of roll pointing machines, including pointing/ stringing/welding combinations for a wide range of wire sizes. Its products include swaging machines, point milling machines and tube pointing presses. Roll pointing machines are used to produce drawing points on round, square, flat and other profiles. The DW U-3-D machine, used for pointing wires up

NOVEMBER 2012 | 43

FEATURE

tion work takes place at our Scottsville, New York, USA facility. We can tailor your design to meet your needs in terms of material choice (heanium, zirconia), surface finish and tolerances. Our goal is to provide our customers prototype design assistance with an affordable end result. To compliment our ceramic division, our coatings department is devoted to lengthening product life, improving performance, and controlling costs. A working combination of properly selected coatings in effective application processes virtually guarantees optimum results. Our engineering staff can help you select the ceramic(s) or coating(s) best suited for your specific applications. Heany Industries Inc., Kathie Carl, kathiec@heany.com or Cliff Rabidoux, cliffr@heany.com, www.heany.com.

FEATURE

mary concern is making the welders easy to operate by not adding bells and whistles that make the design more complex without any benefits to customers. This unique design principle has served Micro-Weld customers well for over 80 years for continuous processing of wire, rod and cable. William Banks, Micro Products.

William Banks

In addition to providing products and machinery for customers’ needs, we provide process engineering assistance, working with customers on individual problems and issues. We look out for the best interests of our customers, and if we could not provide the correct answer or specific product for their needs and thought some other company might have the answer, we would tell the customer.

No one company can solve every technical challenge that can come up, Howard Fancher but you certainly can go that extra step because it is the right thing to do.

Howard Fancher, Huestis Machine Corporation.

We understand that customers at times need help locating items that we don’t offer. It is these times that our service stands out, by listening and hearing our customers, we are able to pass them along to others in the industry that carry what they need. By doing this not only do we help our customers, but we are continually building relationships with other suppliers and building a larger network. It is these relationships between the suppliers that opens doors for them to not only receive opportunities but to send opportunities to us when they get the same request. Andrew Stromer, Howar Equipment, Inc. In addition to our 60+ years servicing the wiredrawing industry with the repair and coating of capstans, we are problem solvers, we work with our customers to help maximize their wire production output, minimize equipment changeovers and reduce down-time, and improve quality. This is the valuedadded that we provide, and why we are the “One Stop Shop” for all our customers’ wiredrawing needs.

Parkway-Kew Parkway-Kew Corp’s Robert Galperin Corporation. and Mark Patrizza.

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to 15 mm in diameter, offers a unique operating feature where the part of the machine containing the forming rolls continuously swings between the two positions shown in Krollman GmbH’s DWU-3D pointing the photograph. machine.

The distinct advantage for pointing large diameter wires is that between each step of the pointing cycle, the operator must only transfer the end of the wire to the next smaller groove.

Also, because the rotating portion is in continuous movement, the wire is rolled on several planes resulting in a neat and round point as compared to machines with a horizontal and a vertical roll pair. The machines can be equipped with a shear and an option is available for a portable base.

Krollmann GmbH, www.krollmann.de; Morgan Koch Corporation, Robert Strauss, straussrl@morgan-koch.com.

Micro Products Company U.S. The AD Series of Micro-Weld butt welders from Micro Products Company is gaining popularity in several markets all over the world for sleeveless welding of stranded copper and aluminum conductors. Micro-Weld welders have been made in Peoria, Illinois, USA, since 1928. The AD models have been well received for welding a wide range of sizes of stranded non-ferrous conductors including large diameters without sleeves. They also weld solid material. It saves cable companies a lot of time for continuous processing in their production line. The unique design has fewer moving parts, so very few adjustments have to be made over the entire range of the welder. Changing the welding dies is easy and fast. The design also makes it easy to operate these welders. Welding die sets have been designed with special “Stellite” inserts for accurate alignment and clamping and prevent slippage.

These models feature pneumatically controlled heavy duty clamping mechanism for positive positioning and unique two-stage upset (low to high pressure) mechanism.

The heavy duty transformers used in these welders are all built inA butt welder from Micro Products Co.

Niagara Composites International Inc. U.S. With roots dating back to the early 1970s, Niagara Composites International has grown to become a vibrant company serving the wire and cable industry worldwide.

Our success has been based on hearing the needs of the customer and providing each with a custom solution to their bow needs. All machines operate differently. By matching these requirements with small or large adjustments, Niagara can manufacture the right bow for the right machine enabling the end user to maximize performance. Many of our customers are currently using the supply chain management concepts whereby inventories of bows are maintained either in the customer’s factory or Niagara’s. This simply reduces lead time and drives down the overall costs to the end users. Under this scenario, a delivery is made within 24 hours to the factory. If we see an excessive use of particular product, we will review our processes and work with the customers to reduce Replacement bows overall consumption of the prod- offered by Niagara uct. High consumption of bows is Composites Int’l. one indication of a possible machine problem. Niagara will review these issues with the customer and offer solutions to better serve the needs and drive operating cost down for them. Niagara’s partnering with TMS and Coorstek Ceramics (see sidebar on p. 41) has been overwhelmingly popular with our customers due to our joint commitments of delivery, price and support. Niagara Composites International, Inc., www.niagaracomposites.com.

Parkway-Kew Corporation (PKC) U.S. Parkway-Kew Corp. (PKC) has historically been known for the restoration, coating, and fabrication of blocks and capstans for the ferrous and nonferrous wire industry.

Drawing on over 60 years of experience enables us to help companies improve quality, and increase production speeds in their drawing process. The recent addition of a proprietary CNC machining process, along with robotic technology allows us to provide more solutions to the industry. PKC can now work with materials such as solid carbide and our line of fused tungsten carbide coatings, allowing for alterna-

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s WWW LLOYDBOUVIER COM SALES LLOYDBOUVIER COM 3TERLING 3T s #LINTON -!

NOVEMBER 2012 | 45

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house. The models for larger diameters come with SCR electronic weld heat control for precise heat settings and other models can be equipped with the same control. Over 50 models of ferrous and non-ferrous Micro-Weld welders are available, ranging from butt welders for very fine wire to flash welders for large diameter steel rods. Micro Products Company, info@micro-weld.com.

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tive cost effective solutions and longer wear life. PKC now repairs and fabricates dancer and guide rolls, pulleys, sheaves, descaler sheaves and step cones. Dancer and guide rolls are available from stock for many of your newer high-speed drawing equipment, such as Morgan-Koch and Frigerio, as well as a variety of parts for Niehoff, and Bongard down-coilers. PKC also offers a number of innovative solutions to your wet drawing and fine wire needs.

Wet drawing rings can be resurfaced or fabricated from existing steel rings. Solid ceramic rings can be reground or furnished new. Our newest product uses solid carbide replaceable rings for stepcones which provides longer wear life. These new products and capabilities make PKC your “One Stop Shop� for all your ancillary part needs.

Parkway-Kew Corporation. Mark Patrizzia, mpatrizzia@parkwaykew.com or Robert Galperin, rgalperin@parkwaykew.com.

PWM/Joe Snee Associates Inc. U.K./U.S. U.K.-based British PWM Ltd., represented in the U.S. and Canada by Joe Snee Associates, Inc., has been at the forefront of cold weld technology for over 25 years, and has designed and developed a range of energy efficient rod welders to provide manufacturers with an economical method of welding large nonferrous rod sections up to 30 mm in diameter. The P1500 machine, PWM’s largest model, has recently been upgraded to provide a quieter, smoother weld operation. Like all PWM cold welders, the

PWM Ltd.’s Steve Mepsted with a company welder.

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E-mail: fukaseco@ja2.so-net.ne.jp http://www.fukase.co.jp

Queins Machines GmbH Germany Queins Machines GmbH is offering a new preforming head for 84 or more steel wires as its latest solution for customer’s requirements. The preforming head, which can process wire from 2 mm to 9 mm, is installed in one of the world’s biggest wire rope stranders, consisting of a rotating payoff with a 150 tons capacity and a traversing take-up

Preformer technology from Queins Machines GmbH.

Sk Bldg #1 2-10-10 Makuhari-Hongo, 2- 6 -1 Hamada Mihama -Ku Hanamigawa-Ku, Chiba, Chiba Bhiba-Ken 261-0025, Japan 262-0033 Japan Tel : +81-43-276-0630 FAX Fax :81-43-276-0463 +81-43-276-0463 TEL 81-43-276-0630

NOVEMBER 2012 | 47

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P1500 produces strong, reliable welds every time, improving production, reducing downtime and material wastage.

The P1500 is very cost-effective to operate, since the only power required is an 11Kw supply for the electric motor that drives the hydraulic pump. The weld cycle takes approximately five minutes and the welded rod requires only minimal cleaning to make it ready for processing. The new version of the P1500 is equipped with an improved hydraulic operating system, and a new user-friendly keypad, making it even simpler to use. As well as large freestanding rod welders, PWM also makes smaller portable cold welders for medium wire sizes. The newest model is the HP200, an air/hydraulic-powered machine mounted on a trolley that enables an operator to wheel it quickly to the work area. The HP200 has a solid steel welding head for added strength and stability, and is designed for wire/strip sizes 2 mm to 6.50 mm. Powered by an air/hydraulic intensifier, the HP200 is quick and easy to operate and requires minimal maintenance. PWM machines and dies, standard or custom made to suit round or profile wire and rod, are precision engineered in the company’s own workshops, ensuring total quality control and accountability. Video of PWM’s P1500 and HP200 cold welders can be viewed at the PWM website. PWM Ltd., www.pwmltd.co.uk; Joe Snee Associates, joe@joesnee.com.

FEATURE

with a capacity of 300 tons. The rear cage section consists of 36 and the front cage section of 48 bobbins of 710 mm.

The machine produces spiral strands up to 200 mm for the mooring of offshore oil installations, as well as large strands of six-, eight- and nine-strand ropes. The preformer shown in the photo is laid out for 84 steel wires. The roller distance between the outer rollers is steplessly adjustable by electric motor. The outer discs are changing the position synchronously. The motorized middle part can be steplessly adjusted with all wires engaged. Queins Machines GmbH, info@queins.com.

Rainbow Rubber & Plastics Inc. U.S. Rainbow Rubber & Plastics, Inc., has been a supplier to the wire and cable market for over a decade, solving the problems with caterpuller, capstan and haul-off belts. The company’s single-piece construction has no seams or splices, which eliminates common belt failures that have plagued manufacturers for years. Short belt life, cover separation and tracking issues can be reduced by using the proper belt structure and rubber compound. All of Rainbow Rubber & Plastics’s belts are designed specifically for the wire and cable industry. It has developed compounds that address problems with oil on the armoring lines and wear issues on CV lines as well as a belt structure with a breaker

DESIGNERS S & MAN MANUFACTURERS NUFACTURERS ISO9001 OF PAYOFF & TENSION CONTROL SION C ONTROL REGISTERED EQUIPMENT FOR WIRE & CABLE CABLE

A belt from Rainbow Rubber & Plastics in action.

fabric that eliminates lengthwise splitting issues. Breaker fabric is a ply of fabric inserted in the middle of the belt that dissipates the down pressure across the entire width of the belt. This reduces centerline pressure that cause belts to wear and split. Combined with Rainbow Rubber & Plastics’ technical experience, manufacturers can be assured that they have the proper belt the first time, a basis that has helped the company gain customers such as Southwire,

With suppliers With all all of of the the suppliers out out there...why there...why should should you you call Wyrepak Industries Industries for manufacturing your manufact uring needs?

Quite simply simply,, Wyrepa Wyrepak ak is a name you can trust for reliablee and dependable products. products. With With our our many many years years of of experience in creating creatinng cost-effective manufacturing manufacturing applications, applications, backed backed by by a solid solid guarantee guarantee and and excellent excellent service has it all! customer ser vice – Wyrepak W For more details on any oof our manufacturing product solutions, call uss at 800-972-9222 or email sales@wyrepak.com sales@wyrepak.co y p om

WYREPAK PA INDUSTRIES INDUSTRIES — A Huestis Industrial Indu us u strial Company s WWW 792%0!+ COM s WWW 792%0!+ COM "UTTONWOOD 3TREET "RISTOL 2HODE )SLAND 53! s TEL OR FAX "UTTONWOOD 3TREET "RISTOL 2HODE )SLAND 53! s TTEELL OR FAX

48 | WIRE JOURNAL INTERNATIONAL

Sealeze, a unit of Jason U.S. Sealeze manufactures a range of brushes in Richmond, Virginia, that are used in a variety of areas in wiredrawing and forming operations to increase process effectiveness

and efficiency. By removing excess scale or lubricants, the brushes improve drawing and bending machine performance and reliability, extend die life, improve uniform lubricant adhesion, and optimize surface finish and brightness.

Additionally, when used in conjunction with chemical descaling, they can speed processes and lower costs by extending the life of the bath. Sealeze has been manufacturing brush solutions for industrial applications for over 30 years. The company’s brush products are found in applications ranging from shielding on machine tools to guides on conveyor systems. The custom-forming capabilities enable them to make shapes and designs specific to the needs of the application. Sealeze, a unit of Jason, industrial@sealeze.com, www.sealeze.com.

Sheaves Inc. U.S.

Brush technology from Sealeze, a unit of Jason.

Sheaves offers standard, custom and semi-custom sheaves and pulleys for manufacturing wire and cable and other linear products. We have announced two new product lines: SX Polymer© custom sheaves and SX Polymer replacements for the discontinued BOMCO product line. SX Polymer is stronger than UHMW, has better wear characteristics than cast nylon, and is tougher than both. SX Polymer resists denting and chipping. It is also can withstand temperatures up to 250º F (120ºC). Off white is the standard color, but other colors are available upon request. A custom design can

NOVEMBER 2012 | 49

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Okonite, Nexans, General Cable and Tyco, to name a few.

Rainbow Rubber & Plastics, a leader in belting for the wire and cable industry, also offers on-site surveys and technical assistance to help reduce belt expenditures and increase machine up time. Rainbow Rubber & Plastics, Mark MacKimm, mackimm@rainbowbelts.com.

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be built in two to three weeks.

Once the first run is complete, subsequent deliveries take five to 10 days. Pricing is much better than with UHMW and cast nylon.

The discontinued lines of BOMCO sheaves are now available in the same SX Polymer. Although the sheave A replacement pulley looks different than the spun offered by Sheaves Inc. aluminum hardcoat design, care has been taken to maintain the dimensions as close as possible. If your present BOMCO sheaves are not subjected to temperatures over 250ºF, these SX polymer substitutes should meet your requirements. Some sizes are now in stock, with others in the process of being manufactured for stock. Sheaves also offers a line of economical cable guides, box rollers and accessories. These products are made with a fabricated steel construction that is suitable for ferrous and nonferrous rod, wire, strand and insulated wire.

Most of these items are in stock and ready for immediate delivery. Sheaves is geared to provide its customers not only

with great products, but with technical design services and support. Our engineers have extensive experience in the wire and cable business. The entire range of our product line can be seen at our website. Sheaves Inc., Stewart Walton, sales@processsheaves.com. www.processsheaves.com.

August Strecker GmbH Germany To satisfy the request of many of our customers for reliable welding machines for cable cross-sections of 1,600 to 2,000 sq mm, August Strecker GmbH presented the new dual-upset butt-welder, type MK 300-3P, at the Düsseldorf tradeshow in 2012. The machine welds copper cable from 185 sq mm up to a maximum cross-section of 2,500 sq mm, which translates to an outside diameter of about 65.5 mm. As is the case with all the machines of the MS and MK series, these cables are also deflashed fully automatically after welding. Especially when welding cables with large cross-sections, power consumption, or the so-called Strecker’s MK 300-3P butt “short-term peak load” is a welder. concern, as the customer must ensure adequate power supply. Providing a separate transformer for the welding machine is not only expensive, but also approaches the limits of what is physically possible. The MK 300 3P system has a nominal capacity of 800 KVA with a three-phase direct current transformer. This drastically reduces the current required, nearly cutting it in half. The biggest advantages of the system are: lower current load for each individual phase; balanced load for all three phases; and higher capacity/higher secondary voltage. August Strecker GmbH, sales@strecker-limburg.de.

Talladega Machinery & Supply Co. U.S. Established in 1986, Talladega Machinery & Supply Co. is one of the fastest growing wire and cable service centers in North America.

TMS, which has dedicated facilities and staff serving the wire industry for over 25 years, can handle most jobs effectively whether big or small. From complete rebuilds Line art of a TMS safety device for a to refurbishing Syncro FX-13. machinery, the 50 | WIRE JOURNAL INTERNATIONAL

An assortment of Tramev cutters offered by Lesmo Machinery America. and aluminum alloys and different grades of steels and galvanized steels can be cut by these cutting tools. Various

Tramev Italy Lesmo Machinery America Canada Tramev, represented in the U.S. and Canada by Lesmo Machinery America, Inc., provides two different types of cutting heads. Open-face scissor-type or closed-face, shear-type operated either by rechargeable battery pack or a hydraulic power pack. Diameters up to 180 mm can be safely and easily cut by using appropriate cutting head. Custom cutting heads are also available for specific needs. Cutting large cables using manually operated shears is not only unsafe but also time consuming.

Operator fatigue also should be a consideration. Tramev cable cutters are ergonomically designed, generating high pressure to easily cut through large cables. Cutting heads are designed to cut various types of cables such as uninsulated conductors, insulated and jacketed conductors as well as armored cables. Various metals like copper and copper alloys, aluminum NOVEMBER 2012 | 51

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expertise of the TMS Wire & Cable Machinery Division is delivered each day. TMS is able to evaluate the correct solution by closely working with customers. Our expert staff can provide the technical and cost data to support choices between rebuilding, refurbishing or buying new. Our rebuilt machinery includes wiredrawing machines, bunchers, stranders, annealers, take-ups, rewinders, re-coilers and accumulators. Most rebuilds are furnished with new OEM parts built by TMS that often exceed the OEM’s original quality standards. It provides solutions, such as a pneumatic door opening and closing safety device for older model wire breakdown machines, such as the Syncro FX-13. This TMS designed assembly will raise and lower the protective pullblock access door safely, avoiding heavy lifting by the operators.

It includes an air safety check valve and a self-locking mechanical safety latch, providing a redundant safety system to eliminate accidental closures.

With this modest upgrade, companies can further protect their employees from harm, a very worthwhile investment. TMS is further bolstered by its partnership with Niagara Composites International, Inc., and Coorstek (see sidebar on p. 41).

Talladega Machinery & Supply Co., wire@tmsco.com, www.tmsco.com.

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other electro-hydraulic or hydraulic tools are also available for other cutting, bending, straightening and hole punching needs. Tramev, www.tramev.com; Lesmo Machinery Aemrica, Inc., Harish Panchal or Allan Brown, sales@lesmoamerica.com.

Unitek Austria Howar Equipment, Inc. Canada Extrusion crossheads expert Unitek of Austria, represented in the U.S. and Canada by Howar Equipment, Inc., is leading the way in crosshead technology by focusing on listening, collaborating, and adapting ideas from its customers.

For 33 years Unitek has known that listening to its customers is the key to its success. It is exactly this philosophy that Unitek has used to develop improvements to existing crossheads as well as entirely new products. One such development was to bring to market a crosshead that offers the same micro adjustment capabilities as their low temp Micro adjust crosshead to high temp fluoropolymer products as well. With the addition of a micro adjustment crosshead for fluoropolymer, Unitek is once again leading the way in meeting this demand for today’s high tech customers. Just like its low temp Micro adjusts crosshead, the crosshead is a fixed center crosshead that gives the customer the ability to adjust the concentricity very slightly in some cases adjusting from 1% to 2%. For customers manufacturing products for medical as well as communications, the ability to adjust just 1% is 2% makes the difference between scrap and a quality product. As with all Unitek crossheads and products, durability and precision are the foundation. Unitek can offer solutions for crossheads, color change systems, and tooling based on experience as well as work with the customer to develop crossheads based on their needs. Unitek, www.unitek.at; Howar Equipment, www.howarequipment.com.

Witels-Albert USA U.S. A wire straightener for round wire usually consists of two straighteners connected with a bracket. The axes of the rolls on one straightener are vertically oriented, while the axes on the other straightener are oriented horizontally. To achieve good, consistent results, the configuration of the straightening equipment must be tailored specifically to the direction of flow of the material and to the position and direction of rotation of the wire coil. It is essential that the roll axes on

52 | WIRE JOURNAL INTERNATIONAL

Witels-Albert’s newly designed wire straightener. the first straightener are aligned with the axis of orientation of the coil and that the axis of the first straightening roll in the direction of flow of the process material is located on the side of the axis of the coil. That is the only way of ensuring proper deformation of the process material in the plane of curvature at the first straightener. Eight different versions of the connecting bracket and a large variety of parts are needed to configure straighteners which meet this requirement. In the past, the connecting brackets consisted of as many as five separate pieces excluding the bracket mounting parts. By redesigning the bracket (photo and www.witels-albert-usa.com/video.php), the part count has been reduced to two. The new design offers additional advantages such as continuous adjustment of the angle between the straighteners, and the zero line can be set up correctly between the straighteners for a specific wire diameter. Alternatively, guides and a standardized protective cover can be mounted on the brackets which are located at each end of a straightener. Due to the simplicity of the design, the user can remove the connecting brackets at any time and reassemble the individual pieces to configure a different version of the bracket. Witels Albert USA, www.witels-albert-usa.com, info@witels-albert-usa.com.

Wyrepak Industries U.S. Wyrepak Industries, which specializes in payoff systems and tension controls, also manufactures a wide range of machinery and ancillary equipment for the wire and cable and other industrial markets. Founded in 1954 in Bridgeport, Connecticut, it has a reputation for rugged, simple designs that work and are longlasting. In 2012, the company was purchased by Huestis Machine Corporation and relocated to Bristol, Rhode Island, where its equipment is sold as a separate product line complementing those offered by its Huestis Industrial business, offering customers more choices in machines and ancillary equipment to meet their manufacturing needs. Wyrepak's products include reinforced plastic guide pulleys that are highly durable. They have replaceable contact rings and are ideal for guiding or redirecting all types of wire. The flanges are bolted together, so individual parts can be replaced when worn or damaged.

Each can come with single or double bearings. The replaceable contact ring is available in hardened rubber, tungsten

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carbide coated steel or ceramic coated steel. The nitrile (rubber) has high abrasive resistance and reduces vibration.

The pulleys come in sizes from 2.5 in./89 mm to 16 in./445 mm. It also offers small “no torque” pulleys that have a ceramic contact ring mounted on tough, reinforced plastic flanges. Each pulley comes with a single bearing. They come in sizes ranging from 15.0 mm to 50.0 mm. Wyrepak Industries, www.wyrepak.com.

Yield Management Corporation U.S. Wire and cable manufacturers now have a fail-safe method of detecting wire breaks in cabling lines of all types. Yield Management Corporation (YMC) has developed a product line that continuously monitors individual spool rotation on planetary, rigid frame and tubular stranding machines. The spool monitoring system reliably detects wire breaks 100% of the time using photo-optic sensors to monitor spool rotation. All sensors and wiring are located outside the machine’s rotation eliminating the need for slip rings and maintenance. The system detects a broken wire in four or less machine revolutions enabling the machine to be stopped before the broken wire reaches the next section. In most cases the cabling line is stopped before the broken wire reaches the collecting die. Early detection allows for repair and preservation of the finished cable. Users of the system report significant reduction, and/or elimination of material scrap and short lengths.

Applications range from power cable to fine wire. Manufacturers stranding insulated wire, glass or textile rely on the YMC system because traditional ground techniques do not work. The system features an HMI touchscreen for user-friendly operation. Additional features include failed sensor alarms

YMC President Robert Brown demonstrates a company’s strand counter at Wire Expo. and auto detection of rotating spools. YMC supports installations throughout the world and has installed the spool monitoring system in six continents. Yield Management Corporation, Robert Brown, bbrown@yieldmanagementcorp.com.

Sheaves - Pulleys Cable Guides ProcessSheaves.com 866-344-6774 NOVEMBER 2012 | 53

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Manufacturing highly loadable helical springs through optimization of tempering processes in both spring steel wire and spring production

M

TECHNICAL PAPERS

TECHNICAL PAPER

Tests found that adjusting the tempering processes for wire and spring production can improve strength and forming behavior characteristics.

By R端diger Lux, Ulf Kletzin and Peter Beyer

In recent years, specifications for wire products have steadily become more demanding. Industry requires components that will take ever greater loads while becoming lighter in weight. One example of this phenomenon is helical compression springs, which are required to be designed for higher loads, both thermal and dynamic. The Wire and Spring research group at Ilmenau University of Technology has cooperated in recent years with wire and spring manufacturers on a number of projects. In the investigations carried out into wire hardening and spring tempering, reserves have

Fig. 1. Qualitative diagram of the stages of the hardening process and the tempering of the spring or component.

54 | WIRE JOURNAL INTERNATIONAL

been found which can enhance the spring parameters. The results, however, have made it clear that any progress requires extremely accurate knowledge of material strength properties and how to target these specifically to improve them.

Demands on spring steel wire In accordance with applicable standards, wire types used for springs are classified according to their tensile strength Rm. However, the dimensioning of helical compression

Fig. 2. Schematic of experimental hardening plant.

TECHNICAL PAPERS

springs is carried out according to the permitted torsional stress:

Eq. (1)

For the proof of strength, the permitted torsional stress τt zul is a necessary parameter. This being the case, DIN EN 13906 is applied and the tensile strength Rm is converted into τt zul using a certain factor, which is set in the standard for preset helical compression springs as τt zul/Rm = 0.56.

One way of increasing the load-bearing strength of helical compression springs is to raise the permitted torsional stress τt zul. See Fig. 1. Reducing τt vorh, by optimizing the geometry of the springs, for instance, is not the subject of the present paper.

Eq. 1 makes it clear that the wire should have high permitted torsional stress τt zul so that the spring will have maximum capacity for energy storage, optimal installation space and the most efficient use of material.

To achieve specific raising of the yield point under torsional stress by optimizing the crucial processes in the manufacture of both wire and spring requires exact measurement.

The Wire and Spring research group at Ilmenau TU has developed such a testing station to record torsion characteristic curves with a precision shear recorder1. This unique measuring technology has been used to prove that the yield point under torsional stress can be raised by optimizing the tempering procedures during wire and spring manufacture.

It has also been able to prove that there is no fixed relationship between the nominal strength values in tensile testing (yield point Rp0.2 and tensile strength Rm) and the values in torsion testing (yield point under torsional stress τt0.04 as

The goal was to increase the load capacity of helical compression springs by optimizing the tempering processes at the wire and the spring manufacturing stages.

The heat treatment of the wire, also known as hardening,

Fig. 4. Tensile strength Rm from austenitization curves for 65SiCrV6 SC of d = 4.5 mm.

0.04

Fig. 3. Heating curves at 880°C and 940°C Sample wire 65SiCrV6 SC of d = 4.5 mm.

τt zul and maximum torsional strength τtmax). The relationship between the strength values is dependent on the wire material, how the wire is heat-treated and how the spring is heat-treated2.

Wire hardened by different wire manufacturers to the same Rm may show a wide variation in yield point under torsional stress τt zul. When the wire is used to make springs, these variations result in springs which vary in capacity and may thus be the cause of early failure of a component.

Increase in load capacity of springs

Fig. 5. Technical yield point under torsional stress τt from austenitization experiments on 65SiCrV6 SC of d = 4.5 mm.

NOVEMBER 2012 | 55

TECHNICAL PAPERS Fig. 6. Maximum tensile strength Rm in relation to tempering regime, without spring tempering of the 65SiCrV6 wire, d =4.5 mm.

Fig. 7. Maximum tensile strength Rm in relation to tempering regime, with spring tempering of the 65SiCrV6 wire, d =4.5 mm.

takes place in two stages: the hardening of the material and the subsequent tempering. A simplified view is that the hardening is dependent only on the austenitizing temperature and time and the quenching temperature and time. The tempering is, again, dependent on the temperature and time spent in the tempering medium which is, in most cases, lead. There is further tempering after the springs have been created. The entire sequence is shown in Fig. 1.

To improve the strength properties of a wire it is necessary

to fine-tune the eight relevant and independent parameters in the treatment process shown in Fig. 1 (four temperatures and four periods of time). As this would require a great number of variation, it was not possible to apply the passage tempering method used in industry. For this reason, the hardening and tempering plant shown in Fig. 2 was developed by the research group. This apparatus has the additional advantage of not being tied to the sequence followed in industry and the periods spent by the wire in the individual process stages,

Fig. 8. Technical yield point of torsional stress Ď„t 0.04 in relation to tempering regime, without spring tempering of the 65SiCrV6 wire, d 5 mm.

Fig. 9. Technical yield point of torsional stress Ď„t 0.04 in relation to tempering regime, with spring tempering of the 65SiCrV6 wire, d =4.5 mm.

Raised load capacity from setting and dynamic fatigue experiments.

56 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Fig. 10. Technical yield point under torsional stress τt0.04 from spring tempering experiments on passage tempered wire, d =4.5 mm, material SiCrV6 SC. that are dependent on each other because of the building and construction constraints (austenitizing furnace, oil bath, lead bath, water bath). The hardening and tempering possible in the laboratory equipment thus offers the only possibility of varying the parameters completely and independently for all tempering stages.

Complete austenitization—the conversion of the ferrite structure of steel into austenite—is a crucial prerequisite to the succeeding setting of wire strength. The experiments therefore began with austenitization. First, heating curves

Fig. 11. Tensile strength Rm from spring tempering experiments on passage tempered wire of diameter d = 4.5 mm, material 65SiCrV6 SC.

were recorded for wires of d = 4.5 mm at furnace temperatures of 880°C and 940°C (Fig. 3). These curves were used to identify the period of time during which the structural change took place as the wires (with their various austenitization times) were hardened at the stated temperatures. The times were varied at 10 second intervals. The samples were quenched in an oil bath at 50°C. The tensile and torsional characteristics of these samples (see Figs. 4 and 5) were evaluated, as were the metallographs, so that optimal austenitization parameters could be established.

Fig. 12. Pre-setting values for springs made of 65SiCrV6 SC with d = 4.5 mm.

NOVEMBER 2012 | 57

TECHNICAL PAPERS Fig. 13. Weibull lifetime analysis of springs that were tempered at 420°C for 30 min made of 65SiCrV6 SC 4.5 mm wire. Red: normally hardened wire; green: optimized 1. Taukh stress range of 1100MPa.

Fig. 14. Weibull lifetime analysis of springs that were tempered at 420°C for 30 min made of 65SiCrV6 SC 4.5 mm wire. Red: normally hardened wire; green: optimized 1. Taukh stress range of 1180MPa.

After austenitization and quenching, the wire is tempered in a lead bath. The strength of the wire—and thus its susceptibility to reshaping during spring manufacture—is set using the parameters from the austenitization and the hardening/tempering process. Good forming behavior will reduce the strain on the coiling machine. Therefore, it is necessary to determine the tensile and torsional characteristics of the material even at the stage following austenitization and tempering. The next experimental step is to simulate the tempering of the spring or component, and this can be carried out on the wire. A commercially available fan oven is used for this heat treatment. Parameters for the temperature and time are varied, and tension and torsion nominal values are established for these samples. Comparing samples made of hardened material with those made of hardened then tempered material makes it possible to state the increase or decrease in the strength parameters caused by the heat treatment in the spring manufacturing stages. The parameters selected for the hardening and tempering were close to those already used by industry: tempering times between 0.5 min and 5 min at temperatures of 420°C to 460°C (for the wire manufacture) combined with spring tempering times between 15 min and 60 min and temperatures for spring tempering of 300°C to 400°C. The goal of the experiments was to find hardening parameters in both wire and spring manufacture that would lead to the best material properties in the finished spring. In relation to the wire from which the spring is to be made, a low yield point should first be set at the wire works to minimize the forces and wear suffered by the coiling pins when the springs are being coiled. To produce a helical compression spring that will cope with demanding static, dynamic and/or thermal stress, the necessary high strength is set by targeted influencing of the τt zul during tempering of the spring. The parameters of the wire

production were comprehensively combined in the experimental plant presented with those of the ensuing heat treatment of the springs. Tensile strength and torsional strength tests then established the properties of the wire. Simulating the spring tempering process on the wire and then determining the nominal strength values to be expected in the spring made from it both increases strength and facilitates more precise dimensioning and manufacture of springs.

Figs. 6-9 show the technical yield point under torsional stress τt 0.04 and the tensile strength Rm. These levels were determined from samples of 65SiCrV6 material of d = 4.5 mm that were austenitized at a temperature of 880°C for 2.5 min. For the tempering time and temperature, a number of variants were used. Figs. 6 and 8 show the nominal values for the relevant samples immediately after hardening.

Figs.7 and 9 show the same nominal value for samples that also received component tempering. It can be clearly seen that the yield point under torsional stressτt 0.04 is considerably more influenced by the spring tempering (up to approximately 10%) than is the tensile strength Rm (approximately 0 % to 2.5%). The experiments also show that the increase in strength to be achieved by spring tempering to be higher than the hardening temperature set previously during the wire manufacture.

By using the researchers’ hardening and tempering plant for about 5000 hardening experiments, it was possible to find optimal parameter combinations for wire hardening and spring tempering. These experimental results were then computed to fit industrial wire manufacture, using thermal substitution models and applied to passage tempered wires.

This produced wire material with optimal strength properties (see Figs. 10 and 11) that could be used for the production of experimental springs. The experimental springs were compared with versions produced identically from material

58 | WIRE JOURNAL INTERNATIONAL

Conclusions Test stations developed by the research group and a newly developed experimental hardening and tempering plant made it possible for the first time to imitate in the lab all the heat treatment procedures—from wire works to finished spring—using completely independent parameter variation, and from that data improve the strength properties of the finished springs. The research group is able to find the optimum tempering processes for other wire products and provide industry with the results without a high expenditure of time and money. Conclusions can be drawn for the design and operation of new passage tempering plants to be used in wire manufacture and for the selection of process parameters at the spring tempering stage.

The knowledge obtained—that heat treatment processes calculated in combination for wire and spring manufacture will enable shaping and strength properties to be specifically improved—is promising for improved manufacture and more accurate dimensioning of heavily loaded springs. It was proved that the hardening and tempering parameters have varying effects on yield points and ultimate tensile strength. The nominal value for the yield point under torsional stress, τt zul, which is particularly important for the

materials used in helical compression springs, can be increased by up to 10% by optimally tuned wire hardening and component tempering parameters. It is possible to achieve reduction of maximum material strength to improve capacity for coiling after the wire works and then to set the desired high strength level during the manufacture of the spring. It was also clear that static and dynamic strength cannot be simultaneously optimized but that the heat treatment must be set at all stages to meet the use to which the spring is to be put.

Acknowledgment This research project, ref. no. AiF 15463 BR of the Gemeinschaftsausschuss Kaltformgebung e.V., has been funded from the budget of the BMWI (the federal German ministry for industry and technology), channelled through a scheme under the aegis of the German Federation of Industrial Research Associations (AiF). It has been actively supported by the Eisendraht- und Stahldrahtvereinigung e.V. and its project supervision committee.

References 1. V. Geinitz, Genauigkeits- und auslastungsoptimierte Schraubendruckfedern, Dissertation, TU Ilmenau, 2005.

2. R. Lux and U. Kletzin, Optimierung des Vergüteprozesses SiCr-legierter Federstahldrähte in Verbindung mit der Wärmebehandlung daraus zu fertigender hoch belastbarer Federn Abschlussbericht zum gleichnamigen AiF-Forschungsvorhaben, 15463, BR., TU Ilmenau 2011.

Rüdiger Lux provides scientific assistance to the wire and springs research group of the Department of Machine Elements of Ilmenau University of Technology (IUT), Ilmenau, Thuringia, Germany, and is the head of Wire Technology at the Steinbeis Transfer Centre in Ilmenau. He holds the equivalent of a master’s degree in mechanical engineering from IUT. He served as the head of the department of special engineerLux Kletzin Beyer ing at Zander GmbH from 2006 to 2008, before joining IUT. Professor Ulf Kletzin is the head of the Department of Machine Elements at IUT Ilmenau University of Technology, Department of in Germany and one of the heads of Springs Technology at Machine Elements Study of information technology. He the Steinbeis Transfer Centre. He holds a master’s degree previously was group leader of the quality assurance staff in mechanical engineering from IUT and received his doc- at VEB Relaistechnik Grossbreitenbach, a supplier of torate in 2000. From 1997 to 2000, he was an FEM-engi- inspection, measuring and test equipment. This paper, neer at Brose Fahrzeugteile GmbH & Co. KG, Coburg, which was presented at the WAI’s 81st Annual Germany, and from 2000 to 2005 was CEO (head of devel- Convention, Atlanta, Georgia, USA, May 2011, won the opment) at Friendly Sensors AG, Jena, Germany. He Allan B. Dove Medal Award for the best paper in the ferjoined IUT in 2006. Peter Beyer is a laboratory engineer at rous division.

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that came from a non-optimized lot. It is clear from Fig. 12 that springs made from material with an optimized yield point under torsional stress show significantly lower pre-setting values. Further, springs made of optimized wire achieved longer life both for time and fatigue strength (see Figs. 13 and 14).

D

Dynamic recrystallization of continuous cast copper wire rod and the rapid tensile test

LV E R ATE C I F I CERT AW AR

SI

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The volume of impurities and the temperature at which annealing was done was found to result in different elongation results by the rapid tensile test, an alternative methodology to the traditional SE test.

By Tadeusz Knych, Andrzej Mamala, Beata Smyrak and Monika Walkowicz The quality of a copper wire rod used for electrical purposes in accordance with effective standards and worldwide trends is currently being evaluated by manufacturers through the characteristics of two properties: electrical conductivity and annealing susceptibility. While the former property unambiguously evaluates the chemical quality of the cathode from which a copper wire rod is made, the latter material property is a function of both chemical composition and condition of the material.

The production cycle has three stages that shape the chemical constitution and state of material strengthening. The first stage involves the determination of the final total content of elements of impurities, which are related to the type of copper ore or concentrates used in the production of cathodes.

The second stage is the part of the cycle for producing wire rod during which the last metallurgical interference in the chemical composition of copper takes place through adding oxygen and, at the same time, developing the state of charge material for processing through casting and then hot rolling.

The chemical composition and the condition of charge material are very important in terms of final product quality. The third stage is the multi-stage drawing process and the multi-

ple annealing treatment the material undergoes before it is a final product.

Analysis of the above stages reveals three processes— strain, dynamic recrystallization and static recrystallization— which, with the assumed chemical composition, determine the chances of obtaining the appropriate properties of the final product.

Analysis of the problem Copper currently produced worldwide has a high chemical purity of 6N and 8N. The above grades are usually achieved through the method of vacuum cast and are used in niche areas of technology. Analysis of commercial scale copper grades shows that the copper usually has a purity of 3N, 4N or 5N. Both for economical and technological reasons, it is not possible to produce copper with higher chemical purity in currently used industrial systems for constant melting, casting and rolling (Contirod®, Southwire®, Properzi®). The quality of cathode and copper wire rod has been defined by the following standards: ASTM B49 - 92 and BS – 1036, as well as Polish standards PN - 77/H - 82120, PN - 76/H 93672 PN - 83/M – 80003. Apart from chemical composi-

Fig. 1. Scanning photographs of broken copper wire rods with different impurities content.

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tion, producers of cathodes and wire rods use the electrical conductivity and annealing susceptibility of the material as the main index determining the quality of the product. While the first of the mentioned properties results directly from the basic use of a copper wire rod for electrical purposes, the requirements for annealing susceptibility result from technological discipline during the process of drawing with multi-speed machines. The guarantee of the annealing potential of wires during the multi-stage process of drawing is a basic requirement for copper wire rod. Fig. 1. shows SEM photographs of broken copper wires obtained from wire rods with various contents of impurities.

Copper for electrical purposes requires high chemical purity, so standards for its chemical composition are very rigorous.

Table 1. Total impurities reported in cathodes produced by various Currently, global and domestic standards manufacturers and the requirements of the London Stock Exchange. require manufacturers of CATH1 cathodes to limit the content of admixtures in copper to a few dozen ppm (according to LME - 45 a mandrel (20-mm diameter, 2-mm stroke) and loaded with a ppm, excluding silver). Table 1 shows the comparison of total stress of 7Mpa. The spring elongation can then be observed. impurities in cathodes produced by different manufacturers If the spring elongation of the material is lower than 40%, it and the requirements authorized by the London Stock is assumed that the wire rod meets the requirements of the SE Exchange. Leading manufacturers, which include KGHM test.

Polska Miedź S.A, produce copper cathodes that do not Many copper manufacturers have changed the parameters exceed an impurity level of 20 ppm (excluding silver). for conducting an SE test or even prepared their own for However, a cathode can have a low level of copper impuriquick classification of copper. Belgium’s Metallurgie ties yet still be susceptible to annealing problems in hot and Hoboken Overpelt-Olen (now AURIBIUS)3 has introduced cold working. The copper should have such annealing kinetthree versions of intermediate annealing in the procedure ics that provide for the fastest possible transition of the mate(SE): 600°C for copper with lower purity, 850°C for copper rial from the strengthened to soft state. See Fig. 2. with higher purity (obtained using the Contirod® method) The red curve represents the kinetics of annealing material and without annealing for consumers who do not anneal wire with good recrystallization susceptibility, while the blue rod4. France’s SCCC has developed its own method for curve reflects material with poor susceptibility. The fundadetermining annealing susceptibility through a quick elongamental difference between the materials is the time of transition from the strengthened to soft state. Good annealing susceptibility is closely related to the actual conditions for annealing wires during the process of drawing multi-speed drawing machines.

From the early 1950s, testing directed at preparing a method for determining the annealing susceptibility of copper has been developing dynamically. The most precise and widespread method for evaluating susceptibility of copper wire rod to recrystallization is the spring elongation method prepared by Dialektra AG1 and patented in Germany in 1952.

The method was later modified by Sweden’s ASEA and AB Svenska Metallverken and eventually became a standard2.

During the Spring Elongation (SE) test, a spring made of copper wire is measured during elongation for susceptibility of copper to recrystallization during specific heat-treatment conditions. The wire rod is annealed at 700oC for 1 h and then used to form a 2 mm wire that is then placed in an oil Fig. 2. Qualitative analysis of copper grades from the bath at 200oC for 2 hours. It is then is coiled into a spring in point of view of their annealing susceptibility.

TECHNICAL PAPERS Table 2. Characteristics of tests evaluating the annealability of copper wire rod used worldwide. tion test called the rapid tensile test whereby an 8-mm wire rod is drawn to 6.4-mm wire in one operation and then annealed in an oil bath at 260oC for 10 min. The heat-treated wire undergoes a uniaxial drawing test with the initial length of the measuring base being 200 mm. The drawing test determines elongation of the material during breakage. If the value of this parameter is not lower than 30%, it is assumed that a wire rod has met the requirements of the rapid tensile test.

The rapid tensile test is stricter than the SE test in which after 40% cold strain, the material undergoes testing of structure improvement; therefore, the material has a lower propelling force in comparison with the SE test. Consequently, its result tells us more about defects in the structure of wire rod formed in the process of hot rolling. This structure is a result of the processes of strain and dynamic recrystallization occurring simultaneously in rolling stands and the static recrystallization that takes place between them. The material is present in the strain gap from a few seconds in first rolling stands to thousandths of a second in last stands at a temperature between 800–400°C. Such a strict technological regime needs to reveal the influence of this group of admixture elements which impede dynamic and static recrystallization.

Table 2 shows the test parameters while Table 3 compares the results of the SE test and the rapid tensile test. The classification in Table 3 however, does not apply to all cathodes and wire rods. Manufacturers note that an SE test can have a positive result for a sample that gets a negative result on for the rapid tensile test.

The influence of the low content of admixtures on the recrystallization temperature is the function of many factors.

An analysis on recrystallization shows that the most intense

influence of admixtures can be seen when their content is at the level of hundredths of a percent, and the higher the purity of copper, the greater the influence. Two groups of elements can generally influence the temperature of recrystallization in a different way depending on the level of affinity for oxygen. The first group included elements strictly related to oxygen that occur only in the form of oxides (Sn, Fe, Co, P). The second group includes elements not formed below the melting point of cupric oxides that result from a lower affinity for oxygen than for copper. It includes elements from group VI of the periodic classification of elements, i.e. selenium, tellurium, sulphur.

A key to analyzing the annealing susceptibility of copper is the solubility of impurities in the matrix. For soluble elements, the influence is higher when the differences in the atomic diameters of a dissolved element (impurities) and a dissolvent (matrix) are higher and the solubility of the element in metal is lower. The influence of admixtures is less significant when their content is higher8,9. The recrystallization process requires the possibility of nucleation and migration of grain boundaries. For admixtures that are soluble in copper, they are usually incorporated into the matrix of cells located at grain boundaries, i.e. in places which are good for nucleation of the material after strain in favourable conditions. The influence of soluble admixtures is more intense during the migration of grains than during their nucleation.

The influence of non-soluble elements has not been explicitly resolved, and the predominant opinion is that they play a key role during the process of nucleation, i.e. in the first stage of recrystallization. Table 4 shows the results of analysis of the influence of each element separately on the temperature of recrystallization (value of elongation in a spring elongation test)5.

From Table 4, it can be seen that the difference in the content of Se, Te and Bi already at the level of 1 ppm leads to the greatest decrease in spring elongation from among the analyzed elements. Taking into consideration the reactions between impurities, this leads to Table 3. Wire rod classification on the basis of the rapid tensile test and SE test.

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the change of their influence on the properties of copper and, therefore, annealing susceptibility.

Table 5 shows the results of tests conducted at the Rokana Division of Nchanga Consolidated Copper Mines6 for the influence of impurities in copper on annealing susceptibility. From this, it can be seen that, generally, an increase in the level of impurities leads to a decrease in elongation in Table 4. Influence of individual admixtures on the temperature of recrystallization the SE test. The lowest and elongation in a spring elongation test of annealed copper. value of the spring (51 mm) is obtained with copper from the most impure cast The above results of different tests show that the metallur(No. 800), in which the total impurities amount to 56.1 ppm, gical purity of copper is a basic factor deciding the temperawhereas in cast No. 628, it is at a level of 14 ppm, and the ture of recrystallization. This temperature is measured by the spring is 447 mm long. The evaluation of the influence of elongation of the spring, but there is no simple relation individual elements is not explicit, which is mostly a result of between them with reference to individual elements. The other possible reactions between them. Table 6 shows the influence of these elements on the decrease in spring length results of the calculation of the percentage share of individis most significant in the case of copper with a high level of ual impurities with reference to their total within individual purity. casts and the percentage decrease in spring length with referFrom the literature10-11, it can be stated that the total conence to cast No. 628, which has been treated as a reference 7.9 tent of impurities determines the level of the recrystallization cast . This analysis method has made it possible to see the temperature of copper. However, this is not synonymous with influence of interaction between individual elements on the the notion of the annealing susceptibility of copper, which is length of the spring. Analysis of the causes of decline in the determined by the kinetics of the annealing process. length of the spring in individual casts may indicate the folResearch13 shows that, in spite of a low total content of impulowing interrelations: rities in copper, the wire rod does not meet the requirements • comparison of casts Nos. 628 and 656 clearly indicates of the rapid tensile test. Figs. 3-7 show the influence of imputhe influence of Se on the contraction of the spring, even rities on AR test results. though the content of other elements decreases; • comparison of casts Nos. 180 and 177 clearly indicates the influence of Se, S and Pb; and • comparison of casts Nos. 189 and 800 with others clearly indicates the high content of total impurities.

Similar observation can be made on the basis of the results of the analysis conducted

by AB Svenska Metallverken. See Table 5. Chemical composition of high purity casts of copper according to the tests of the Table 7.

Rokana Division of Nchanga Consolidated Copper Mines.

TECHNICAL PAPERS

tion of individual elements in their total number is more beneficial (Fig. 7.) as opposed to the distribution of elements seen in Fig. 6, which presents the predominant share of one element, lead, with a 47% share.

This provides a basis for testing a new approach to the analysis of the influence of elements of admixtures in copper on its physical and chemical properties, and in particular on its susceptibility to improvement of the structure in static and Table 6. Percentage share in total impurities for tested samples. dynamic conditions. It can be therefore stated that minimization of the total conFig. 9 presents the breakdown of individual elements of tent of elements of impurities in copper is a necessary condiimpurities in a copper wire rod, which, in the rapid tensile tion, but it does not guarantee good annealing susceptibility test, receives a rating of 12%. This, in accordance with the of the material. data presented in Table 3, classifies the material as having average annealing susceptibility, even though the total conObjective and research program tent of impurities here amounts to only 14.76 ppm.

A copper wire rod with very good annealing susceptibility Another case of chemical composition13 displays a positive should guarantee the possibility of full recrystallization of result of the rapid tensile test (rapid tensile = 41%) conductwires during the process of drawing with multi-speed ed with a wire rod, in which the total content of impurities machines. Hence, the objective of this paper is to determine amounts to 26.69 ppm. In spite of the high level of impurithe influence of the initial state of two Cu-ETP wire rods on ties, the rapid tensile test could classify such a wire rod as annealing susceptibility of wires. having very good annealing susceptibility.

Table 8 shows the specific chemical composition for two Figs. 6 and 7 present detailed analysis of the chemical comCu-ETP wire rods made in the same continuous casting and position of copper that draws attention to the percentage hot-rolling system with different total content of impurities. share of individual elements and not to the total content of The wire rod oxygen content was about 160 ppm. impurities. From the point of view of obtaining material with Fig. 8 shows the result of a rapid tensile test of the mechansuperb annealing susceptibility, it seems that equal distribu-

Table 7. Analysis of the influence of chemical composition, temperature of annealing on elongation in the test of the spring and the electrical conductivity of copper.

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TECHNICAL PAPERS Fig. 3. Influence of Se content on the wire rod elongation and AR test results.

Fig. 4. Influence of Fe content on the wire rod elongation and AR test results.

ical properties of the wire rods. The authors notice that the results for the rods was different. The AR for copper wire rod (A) = 33% and for copper wire rod (B) = 18%.

Simultaneously. spiral elongation test result for analyzed materials is SE=455 mm.

Wire rods A and B were preheated at 100-900째C. Then, the prepared wire rods were tested according to the AR procedure (deformation in the process of drawing with a draft of 40%, wire heating in an oil bath at 260째C for 8 min., determination of the total elongation in tensile test).

Examination results and their analysis The test results were divided into two parts. The wire rod annealing results were analyzed to find out whether the wire rod is actually soft after the line of continuous melting, casting and rolling. Typical mechanical properties of copper wire rod are as follows: Rm=225 MPa. R0.2=120 - 140 MPa. A250=45 %. The above values classifies this product as part of a group of materials in soft state. However, based on examinations conducted for this research, it may be that for wire rod annealing, especially at higher temperatures, only a value of proof stress has changed. See Figs. 9-11.

Fig. 6. Percentage share of individual elements of impurities in all impurities in copper (excluding silver), rapid tensile = 12%.

Fig. 5. Influence of Te content on the wire rod elongation and AR test results.

On the basis of the Figs. 9-11, one may notice that the CuETP wire rod still has residual strengthening, which results from great diversification of the value of yield point that may vary from a few to even several dozen percent depending on the annealing temperature. The above diversification of the yield point with simultaneous preservation at the same level of annealed wire rods tensile strength changes the character

Fig. 7. Percentage share of individual elements of impurities in total impurities in copper (excluding silver), rapid tensile = 41%.

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Table 8. Chemical composition of copper used for examinations. of material strengthening during tensile test. The value of this strengthening changes from a few to several dozen MPa. Based on the above results, it may be stated that Cu-ETP wire rod after plant processing still has residual strengthening, as can be seen in the microstructures in Figs. 12-13.

The second part of the analysis regards the Cu-ETP wire rod annealability evaluation test. Fig. 14 shows an overall comparison of AR test results that was carried out on wire rods with various initial state. As the minimum elongation of a wire after the AR test should reach 30%, it was seen that this criterion is only met by wire rod A after initial heat treatment consisting in annealing at 100°C. However, for wire

made from wire rod B, it may be noticed that the same annealing parameters do not cause recrystallization, which may be explained by the greater amount of impurities present in this wire rod.

In the next phase of the research, an assessment of materials annealability was made through calorimetric examination. It also shows certain diversification of examined materials properties. Fig. 15 and 16 present the results of wire rod A and B examinations. It may be noticed that recrystallization temperature reaches about 219°C, whereas the beginning of softening process is observed in the temperature of approximately 180°C. An analysis of the above results allows one to state that wire rod B is characterized by different annealing kinetics, which is proved by the wider range of process temperatures.

This range is for wire rod B approximately 60°C, while for wire rod A it is only 35°C. See Fig. 16. This difference is primarily caused by different impurities contents. However an analysis of the above problem must also take into account contents of oxygen. It is well known that higher level of oxygen positively influences AR test results. See Fig. 17.

Another important parameter is the structural state of material that is being directly shaped on continuous casting and rolling line. In particular, rolling speed has a decisive influence.

Conclusions Fig. 8. Stress–strain characteristics of tested copper wire rods and wires 6.3 mm after rapid tensile test.

Fig. 9. Comparison of characteristics of tension of ETP copper wire rod (variant A) annealed at a temperature of 20, 100, 400 and 900ºC. 66 | WIRE JOURNAL INTERNATIONAL

This report found that diversification of the AR test results of studied wire rods results mainly from different content of impurities. That occurs as a result of the preparation of vari-

Fig. 10. Comparison of characteristics of tension of ETP copper wire rod (variant B) annealed at a temperature of 20, 100, 400 and 900ºC.

TECHNICAL PAPERS

ous structural states of the wire rods by annealing at different temperatures, resulting in different elongation results. For wire rod A, increasing the annealing temperature caused elongated extension in the AR test, while for wire rod B, the initial heat treatment did not lead to higher values.

References 1. G.A. Smith,” The Spiral - Elongation Test for Copper Annealability: An Examination of Same Controlling,” Journal of the Institute of Metals, Kitwe, Zambia, No. 1, 1971, pp. 325-334.

2. S. Metallverken, SM-Norm, 22, 34, 01, E, “Spring Elongation Test.”

3. G. Amstrong, “Some observations on the electrical conductivity of commercial electrorefined copper,” Journal of the Institute of Metals, Vol. 100, 1978.

4. F. Humphreys and M. Hatherly, “Recrystallization and Related Annealing Phenoma,” Elsevier, 2004.

Fig. 11. Overall comparison of percentage difference between tensile strength and proof stress of wire rods annealed in various temperatures.

Fig 12. Microstructure of Cu-ETP wire rod in the state after plant processing.

Fig. 13. Microstructure of Cu-ETP wire rod after annealing at 900°C for 1h.

Fig. 14. Overall comparison of rapid tensile test results of singled out materials in the function of wire rod initial annealing temperature.

Fig. 15. Calorimetric curve – wire rod A.

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TECHNICAL PAPERS Fig. 16. Calorimetric curve – wire rod B.

5. Y.V.R.K. Prasad and K.P. Rao, “Influence of oxygen on the processing maps for hot working of electrolytic tough pitch copper,” Materials Letters, Vol. 60, 2006, pp.

2786–2790.

6. S. Aoyama. M. Onuki. Y. Miyake and R. Urao, “Effects of lead on annealing properties of cold-drawn copper wire,” Journal Of Materials Science, Vol. 26, 1991, pp. 3775-3779.

7. S. Fujiwara and K. Abiko, “Ductility of Ultra High Purity Copper,” Journal de Physique 111, Vol. 5, November 1995.

Fig. 17. Influence of oxygen content on the rapid tensile test result.

8. D. Markovich, I.D. Guskovich and I.A. llich, Effect of stresses in annealing a on its technological properties copper wire, Metal Science and Heat Treatment, Vol. 39. November 1997.

9. J. Schamp, B. Verlinden and J. Van Humbeeck,” “Primary Recrystallization and Grain Growth of Tough Pitch Copper Wire,” Journal de Physique 111, Vol. 5, April 1995.

10. J.L. Magana and E.F. Godinez, “Rapid tensile test elongation study for measuring the annealability of copper rod,” Wire Journal International, February 2009, pp. 76-79.

Tadeusz Knych is a research-didactic fellow in the Nonferrous Metals Department at AGH University of Science and Technology (AGH-UST), Krakow, Poland. He holds many patents in the area of materials Smyrak Knych Mamala Walkowicz and technologies for overhead electricity zines and has supervised more than 30 master’s theses. and rail. He has authored or co-authored numerous Monika Walkowicz is a Ph.D. student in the Nonferrous papers, and has supervised more than 100 master’s and Metals Department at AGH-UST. She is a specialist in doctoral theses. Andrezej Mamala is an associate procopper metallurgy and materials engineering. She fessor in the Nonferrous Metals faculty at AGH-UST. earned her M.Sc. degree in management and producBeata Smyrak is an associate professor in the tion engineering from AGH. She is the author or coNonferrous Metals faculty of AGH-UST. She specialauthor of more than 20 papers. This paper, which was izes in the broader theory, technology, and application presented at WAI’s 81st Annual Convention, Atlanta, of cables for overhead power lines. She earned her Georgia, USA, May 2011, won the Silver Certificate Ph.D. degree in metallurgy from AGH. She has written Award in the nonferrous category. in more than 70 in national and international maga-

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PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS System offers combination diameter measurement and lump detection Germany’s Sikora AG, represented in the U.S. by Sikora International Corp., reports that its TIGER LASER 6010 XY system provides high-speed diameter measurement as well as simultaneous lump detection of cables.

A press release said that the system’s gauge head offers extremely precise and reliable inspection of the cable surface for lumps and neckdowns for cables from 0.004 in. to 0.39 in. (0.1 to 10 mm). The TIGER LASER 6010 XY can be combined with a device from Sikora’s ECOCONTROL series to visualize detected faults, it said, noting that this option provides cable manufacturers with the clear information needed to properly evaluate faults. It added that this approach also makes it possible to store the pictures with the ECOCONTROL processor system.

The release said that the measuring principle of the TIGER LASER 6010 XY is based on the analysis of two high-resolution image sensors that measure and inspect the surface profile of the cable from two measuring planes. Due to the high measuring rate, the TIGER LASER 6010 XY detects lumps with utmost detection probability. In particular with the visualization of the product surface the lump can be assessed, without a labor- or time-intensive rewinding process.

Contact: Sikora AG, sales@sikora.net, www.sikora.net; Sikora International Corp., sales@sikora-usa.com, www.sikora.net.

Melt-processable foamed resins meet the need for ultra-thin gauge wire U.S.-based DuPont Fluoropolymer Solutions has introduced a melt-processable foam resin that it reports is “an answer to the electronic and communications industries’ demand for an insulator designed for ultra-thin gauge wire.”

A press release said that DuPont™ Teflon® fluoropolymer foam resin, FFR 880, provides superior dielectric-toconductor adhesion for micro coaxial designs, producing cable with increased data transmission speeds with least 70 | WIRE JOURNAL INTERNATIONAL

possible distortion and exceptional signal return loss and attenuation performance. The resin, it said, allows electronic manufacturers to continue development of innovative compact devices that require high-speed cable performance. It noted that, in testing, microcoaxial cables using the FFR 880 foam resin had a conductor size of 28 AWG or smaller and a wall thickness of 0.002 inches or greater, with void content up to 55%, and providing similar electrical performance to cables made with expanded PTFE tape.

The increased versatility, the release said, offers an alternative to expanded PTFE tape. High processing speeds ease the manufacturing process, and when used with a gas-injection port on the extruder and installation of a nitrogen gas system, the nucleating package in the foam resin forms uniform foam cells in the insulation, a critical factor in resin stability and electrical performance, particularly in thin-wall applications, it said.

“DuPont is providing greater flexibility for the wire and cable industries with a product that is easily incorporated into current manufacturing technologies,” said Frenk Hulsebosch, global business manager, DuPont Fluoropolymer Solutions. “FFR 880 offers a new level of wire and cable performance in micro applications.”

Contact: DuPont Fluoropolymer Solutions, www.dupont.com/FFR880.

VFD cable line has flexible version U.S.-based Alpha Wire has expanded its Series V VFD cable line with the addition of the “V-Flex,” a flexible version that is compatible with systems from all major VFD manufacturers.

A press release said that the V-Flex cables are approved to CSA CIC Control and TC and UL TC-ER, 1000 V Motor Supply Cable, and Sunlight Resistance and is suitable for use in NFPA 79 applications. The cable has a TPE jacket and is available in sizes ranging from 16 AWG to 4 AWG, with a temperature range of -40°C to +90°C. The cables, it said, use a double shielding system, a combination of aluminum/polyester/aluminum foil and copper braid with 85% coverage, to provide maximum EMI protection over a wide frequency range.

Featuring both UL and CSA tray cable ratings, a low tem-

ance and stability – proprietary manufacturing processes provide a smooth surface finish, making it ideal for automatic applications on formed truck panels.

The release said that the wire “offers excellent performance on high-speed groove welds in formed truck panel applications, as well as robotic fillet welds on trailer tanks, requiring minimal post-weld clean up.” The product is available in standard sizes (.035 in., 3/64 in. and 1/16 in.) on 1 lb and 20 lb plastic spools as well as 16 lb steel spools.

Contact: The Lincoln Electric Company, tel. 888-3553213, www.lincolnelectric.com.

New aluminum MIG welding wire designed for trailer manufacturing

Switzerland’s Zumbach Electronic AG, represented in the U.S. by Zumbach Electronic Corp., has expanded its PROFILEMASTER® line with the addition of three profile and shape measurement systems.

A press release said that the PROFILEMASTER® PMM 30, 50 and 80 profile and shape measurement systems use Light Section principle and Machine Vision technology that provides the best price/performance ratio for all profiles, tubes, cables made of plastic, rubber, metal, steel and other materials. The measuring

U.S.-based Lincoln Electric has introduced a new product to its line of welding wires: SuperGlaze® 5356 TM™, an engineered aluminum alloy GMAW wire designed specifically for applications in the trailer manufacturing industry.

A press release said that the engineered alloy system provides optimal puddle clarity and arc action, as well as excellent wetting for both semi-automatic and high productivity automatic applications. It said that it provides the following advantages: superior wetting—unparalleled bead profile and appearance are critical for groove and fillet welds; enhanced puddle clarity and control—engineered chemical composition outperforms standard ER5356 electrodes, giving the operator unprecedented control; and maximum arc perform-

3 profile and shape models have been added to measuring system line

NOVEMBER 2012 | 71

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perature rating of -40°C, and a bend radius that is five times that of standard VFD cable, the V-Flex offers the best combination of ruggedness and routability in the market, the release said. The cable’s cross-linked polyethylene insulation offers superior resistance from corona discharge, low capacitance for longer runs, and excellent low temperature properties to -40C°, it said.

A premium TPE jacket can hold up to everything from corroding solvents (UL Oil Res I/II) to intense sunlight, the release said. The five-x static bend radius allows the cable to be used in tight corners, greatly improving ease of installation, it said, adding that the round, symmetrical design also reduces the cable diameter and increases its flexibility for easier routing and handling. “We designed the V-Flex to be the most complete VFD cable on the market,” said Alpha Wire Product Manager Kristen Berard. “The XLPE core is far superior to PVC and allows for longer cable runs. ... The UL and Canadian tray ratings expand the market for this product, making it ideal for everyone from machine builders in the U.S. to oil refineries in Western Canada.”

Contact: Alpha Wire, tel. 800-522-5742), www.alphawire.com.

PRODUCTS & MEDIA

field is 1.18 in. for the PMM 30, 2 in. for the PMM 50 and 3.15 in. for the PMM 80 models, with repeatability up to +/- 0.002 mm (+/- .00008 in.), it said. The light source is a VLD (Visible Laser Diode) red, class 3R, the cameras are CCD Megapixel Gigabit Ethernet, the line speed has no limit and the operating system is Windows™ XP embedded, it said.

The PROFILEMASTER® PMM 30/50/80 models “fulfill the demands of the market for a compact, industrialproof and cost-effective system,” the release said, citing the following benefits: increased accuracy of end product; improved process control; reduced scrap; savings on raw material and post processing costs; increased product quality that results in higher customer satisfaction; quick and easy installation on existing production lines; and seamless integration of the PC-based system with a company’s network.

Contact: Zumbach Electronic AG and Zumbach Electronic Corp., www.zumbach.com.

Type A C(UL) and UL tray-rated cable have been added to product line U.S.-based Belden, Inc., reports that it has expanded its line of FOUNDATION Fieldbus cables with Type A

C(UL) and UL tray-rated cable that offer reliability that end-users need for in harsh environments such as the oil sands of Canada and other oil, gas and petrochemical operations.

A press release said that the cables comply with both Canadian and U.S. regulatory requirements and meet the Fieldbus IEC 61158-2 (ISA/SP-50) specification.

Standard single and multi-pair cables are available with an easily identifiable orange jacket, or a blue jacket for Intrinsically Safe (IS) applications, it said, noting that the cables are UL-approved for direct burial, are oil- and sunlight-resistant, RoHS compliant and CE approved. It added that the XLP insulation provides additional physical enhancements of the conductors, including better cut through and chemical resistance.

The Fieldbus cables, designed for temperature extremes and harsh environments, have a C(UL) CIC Type TC rating in 300V and 600V as well as UL 600V TC-ER Tray rating and 300V PLTC/ITC-ER rating in 18 AWG and 16 AWG and suitable for use in Class 1, Div. 2 applications, the release said. They have CMG, FT4 and IEEE1202 flame ratings and a temperature rating of -55°C cold bend and -40°C cold impact to 105°C, it said.

Contact: Belden, Inc., tel. 800-235-3361, www.belden.com.

Drive unit uses feed belts to provide better material handling Germany’s Witels-Albert GmbH, represented in the U.S. by WitelsAlbert USA, reports that its NAK 160 Z drive unit provides superior performance.

A press release said that the NAK 160 Z drive unit, which can be horizontally or vertically mounted, uses two feed belts designed to process cable, tube and profiled shapes. The feed belts, it said, offer better friction coefficients and exert less surface pressure on the material than do conventional feed rolls. At given contact pressure and torque, it noted, belts generate higher feed force than rolls and are gentler on the product.

Feed belts generally have a shorter service life than feed rolls, and to compensate for this a new type of coating, Max Grip 25, is applied to the back of the belts on the NAK 160 Z, significantly extending service life at the same friction coefficient, the release said. The drive unit also features centric clamping of the process material, with the two feed belts

72 | WIRE JOURNAL INTERNATIONAL

410-228-8383, info@witels-albert-usa.com, www.witels-albert-usa.com.

Glass strength member is flexible yet has wear-resistant charactertistics At IWCS 2012, Denmark’s Roblon A/S will display a new lightly coated glass strength member, Ultra Lightflex, pictured, that offers very high wear resistance with a minimum of coating (less than 2%).

A press release said that the product, named for its very low weight and flexible appearance, “offers a unique coating formulation to maintain the soft and flexible behavior of a glass roving, but with highly improved wear resistance properties.” Ultra Light-flex, it said, “is ideal for high-speed production and all types of machinery and is available in standard and water-blocking versions.”

The company said that another new product, ultra low-

System Solutions Drives NADV Straighteners Rolls Guides Preformers

Advanced feeding units for material sizes up to 40 mm.

Are your feeding units powerful enough to transport large process material sizes safely?

The design of NADV feeding units allows a constant or an intermittent process material transport in close tolerances with forces up to 5 kN!

WITELS-ALBERT USA Ltd. Phone: 410 228 8383, FAX: 410 228 1813 info@witels-albert-usa.com, www.witels-albert-usa.com

NOVEMBER 2012 | 73

PRODUCTS & MEDIA

mounted on a moveable insert that can be positioned with a pneumatic cylinder to clamp the material in the direction of movement of the cylinder, it said.

The inserts, the release said, are adjusted in the open position using a wedge while a spindle mechanism and mechanical position indicator are provided to ensure reproducible adjustment.

The unit can be used to clamp and feed process materials which have varying diameters or symmetrical cross-sections in thickness between 0.6 mm and 40.0 mm while maintaining a defined, identical zero line, it said.

Belt tension, it added, can be set exactly by using an adjustable toothed pulley and the associated pneumatic cylinder.

Contact: Bob Flower, Witels Albert USA, Ltd., tel.

PRODUCTS & MEDIA

shrinkage polyester binder yarn (0.60% at 190C), is ideal for compact cable designs and binding of flexible loose tubes. The product minimizes the footprint of the binding yarn and thereby the risk of attenuation on the optical fibers, it said.

Contact: Roblon A/S, tel. 45-96-20-33-00, info@roblon.com, www.roblon.com.

MEDIA Company literature details custom tool wire fabrication capabilities U.S.-based Northern Wire LLC has introduced new corporate literature detailing the company’s custom tooled wire fabrication capabilities that can be accessed at its website by clicking on “Literature Download.”

A press release said that literature covers the scope of the company’s full service capabilities, including its straighten-and-cut, automated forming, welding and press departments as well as its cold heading operations, secondary capabilities and plating department. It said that the company offers design assistance and complete quality assurance. A member of the Elgin Fastener Group, Northern Wire LLC notes that it is an ISO 9001:2008 certified manufacturer for large OEMs, as well as small- to medium-size companies, and

74 | WIRE JOURNAL INTERNATIONAL

processes material from .080 in. to .750 in. in diameter, in lengths from 6.0 in. to 12 ft.

Contact: Northern Wire LLC, tel. 715-536-9551, info@northernwire.com, www.northernwire.com.

Video series focuses on the safe handling and use of industrial gases Germany’s Linde Group, whose U.S. business is Linde North America, has created a new on-line series of videos on the safe handling and use of several of its gases: oxygen, nitrogen, carbon dioxide and hydrogen.

A press release said that the videos are available in DVD for customers, for download from the company’s website and viewable on Linde’s YouTube channel. Each video, it said, covers safety guidelines in working with the gases, including basic properties and behavior and how they are piped and stored as well as safety concerns such as prevention of low temperature burns from cryogenic products, the potential dangers of oxygen enriched atmospheres and how to avoid oxygen deficiency when working with nitrogen, carbon dioxide and hydrogen.

“The new videos represent state-of-the-art know-how on how to handle them safely and we wanted to make them accessible in a variety of viewable forms, particularly in the social media where so many of our customers and employees are accustomed to accessing information,” said Tim Wren, head of Safety, Health, Environment and Quality for Linde North America. “Safety is the number one priority at Linde and we have decades of experience with these products in all their forms.”

Contact: The Linde Group, www.thelindegroup.us/en/index.html.

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 on-line classifieds at wirenet.org (20-word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category.

PAYMENT POLICY: All ads must be pre-paid.

CAREER OPPORTUNITIES SALES REPRESENTATIVE IS NEEDED IN TEXAS AND OKLAHOMA. Manufacturer of flat, square, and shaped wire looking for sales representation in Texas and Oklahoma.

For inquires, please contact Bob Swanson @ 800.840.9481.

TECHNICAL SALES ENGINEER. As a leading importer of European machines for the wire and cable industry we are seeking a proven technical sales engineer. The ideal candidate would have a mechanical or electrical engineering degree, 2 to 3 years experience as a project engineer in a cable manufacturing facility and possibly 1 to 2 years in sales and reside in the OH, IN, PA, NC or GA area. A broad knowledge of the wire and cable manufacturing process is essential. Extensive travel throughout the USA and Canada is required to fulfill our sales and marketing philosophy of personal selling and relationship building with existing and new customers. After initial training in NC and NY the candidate would be home based. Salary is commensurate with experience. Please email resume with salary expectations to: Fritz@Carolina.rr.com.

PERSONNEL SERVICES “LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors and managers.

Contacts: Peter Carino, pcarino@ wireresources.com or at www. linked in.com/in/petercarino1, or Jack

DEADLINES: Copy is due a full month in advance.

Contact: classified@wirenet.org for more details.

Cutler, jcutler@wireresources.com.

Wire Resources Inc, 522 E Putnam Ave, Greenwich, CT 06830, tel. (203) 622-3000 or (800) 394-WIRE. Visit our website at 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) 226-1508 or 1 (508) 226-0946 E-mail: apollodie@comcast.net

ANCILLARY EQUIPMENT TRAVERSES, GUIDES AND STRAIGHTENERS. Lowest prices Longest Warranties on High Quality Products! Call YR Products at 708-2051194.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, color-o-meters and pointers). Tel: 727-

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

FOR SALE

1 - CEECO 37-Wire 30” Rigid Strander Line 1 - NIEHOFF Model SPH801.1.G.E.A Automatic Spooler 2 - WARDWELL 24-C Braiders 2 - NEB 48-C #2 Harness Braiders, Long Legs, Motor 1 - NEB 12-C #2 Braider, Long Legs, Motor 3 - TMW 24-Carrier Cable Braiders, 6” Horn Gears 1 - EDMANDS 18-Wire, 6+12, 16” Planetary Cabler Line 2 - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 1 - SYNCRO F13 Rod Breakdown, refurbished 1 - DAVIS STANDARD 4.5” 24:1 L/D Extruder 2 - DAVIS STANDARD 2” 30:1; 2.5” 24:1 L/D HiTemp Extruders 1 - DAVIS STANDARD 1.5” 24:1 L/D Extruder 1 - DAVIS STANDARD 1.25” 24:1 L/D Vertical Extruder 1 - HALL 40” Motorized Payoff w/Dancer 1 - CLIPPER DF6 Dual Cone Flyer Payoff (24” Reels) w/Reel Jacks 1 - BARTELL 12-Bay B64 Tubular Strander 1 - ROSENDAHL 630mm Parallel Axis Dual Reel Take-up, never used

1 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-up, 1997 1 - SPHEREX 18” Dual Reel Take-up, refurbished 1 - CLIPPER Model SP16 Dual Spooler 2 - AL-BE Model MS12 Respoolers, 12” Reels 1 - REEL-O-MATIC Model RD-5 Rim Drive Takeup w/Coiling Head 1 - WEMCO 84” Take-up, Model 8284B, w/Mobility Package 1 - TEC Model DTC630 D.T. Twister 2 - ENTWISTLE 4-Wire 24” D.T. Twisters, Model 4WDT24 1 - KENRAKE Model TWD101 Twister 1 - FINE Preheater, Model IP4000-180-1, 2007 1 - EUBANKS Model 4000-04 Cut and Strip Machine 3 - CARPENTER Strippers, Model 70-B 1 - MICRODIA Crosshead, Model M9000/10XFL 1 - DCM Electronic Switching System, Model ES350PC 1 - FORMULABS ‘Codemaster 5’ Spiral Striper, w/5’ Oven 1 - KENRAKE Respooler, Model WTR-656 1 - REEL-O-MATIC Model SP-HJ/K5 Take-up 1 - REEL-O-MATIC Model ILB12X Dual Respooler

Contact: Martin Kenner

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

NOVEMBER 2012 | 75

CLASSIFIEDS

CLASSIFIEDS

CLASSIFIEDS

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

BLIND BOX? YES____ NO ____

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

863-4700 or by e-mail, please send to urbassoc@verizon.net.

MEDIA ELECTRICAL WIRE HANDBOOK SET. Focusing on the special needs of the insulated wire and cable industry, these books examine materials, equipment, and products. They

include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire, and other applications. The set is divided into three separate handbooks. Part 1 is Wire and Cable Production Materials; Part 2 is Wire and Cable Production

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.

Processes, and Part 3 is Types of Cables. While the updated handbook includes the latest information available, the new format allows for more frequent future updates. Parts 1 and 2 are now available. The price is $99, $59 for WAI members, plus shipping. To purchase, go to wirenet.org and click on the WAI Bookstore.

Surplus assets due to plant consolidation of

Seminole Wire and Cable Facilities

WIRE & CABLE EQUIPMENT Online Auction

Bidding open: Wed., December 5th, 2012 at 7:00 AM EST Lots closing from: Thurs., December 6th, 2012 at 12:00 PM (Noon) EST Location of assets: 35 Industrial Drive, East Longmeadow, Massachusetts 01028 Inspection: By appointment only Dynamex 24" S.T. Cabler Line, Davis-Standard 2-1/2" & 3-1/2” 24:1 Thermatic Extruders, Complete 2" 24:1 Extrusion Line, Entwistle Dual Cone 30” Flyer Payoff, Genca 3/4” 24:1 Pedestal Extruder, Davis-Standard 24” Dual Wheel Capstan, (4) Davis Electric & Hall Vertical Dancers, (3) Northampton 24” Dual-Powered Payoffs, Progressive Dual Spooler, Wardwell 16-C Braiders and Bobbin Winders, Clipper SP16 Dual Spooler, Coilers, Heat Tunnel, Air Compressors, Chillers, Huestis Tape Head, Tulsa Oscillator, Welders, Grinders & More

Auctioneer & License: MA – David S. Fox #AU2798 For further information, please contact:

BRYAN GOODMAN Tel: (443) 796 4235 Email: bryan.goodman@go-dove.com For more information and terms of sale, please visit

www.go-dove.com

in conjunction with:

Lloyd & Bouvier, Inc.

76 | WIRE JOURNAL INTERNATIONAL

Catch your prospects all season with an ad in the 2013 WJI Reference Guide

SPACE RESERVATION DEADLINE: November 12, 2012 ANNUAL BUYER’S GUIDE FEATURES: wire • cable • supplies • equipment 1,100 Products | 3,000+ Company Profiles Contact WAI Sales at 001-203-453-2777 ext. 119 or 126.

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

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

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

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

GoIndustry DoveBid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Bergandi Machinery Co . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Howar Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8, 71

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

Howar Equipment/Unitek . . . . . . . . . . . . . . . . . . . . . . . . . .74

Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16, 26

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

Integer Research/Wire & Cable Asia 2012 . . . . . . . . . . . .69

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

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

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

Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . . . . .27

FIB Belgium sa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Lesmo Machinery America Inc/Tramev . . . . . . . . . . . . . . .53

Flymca & Flyro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Lloyd & Bouvier Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

T Fukase & Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Morgan-Koch Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

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

Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Gem Gravure Co Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

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

NOVEMBER 2012 | 79

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE Parkway-Kew Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Jan. 2013 WJI

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .39 Queins Machines GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Sealeze A Unit of Jason Inc . . . . . . . . . . . . . . . . . . . . . . . .17 Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30, 53 SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

• India Outlook • Wrapups: IWCS and wire & Cable India • New WAI officers

August Strecker GmbH & Co KG . . . . . . . . . . . . . . . . . . .33 Talladega Machinery & Supply Co . . . . . . . . . . . . . . . . . . .4 Tulsa Power Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 US Synthetic Wire Die . . . . . . . . . . . . . . . . . . . . . . . .Cover 3 Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .79 Witels Albert USA Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .22 Wyrepak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13, 48

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-25 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 WAI Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

WIRE JOURNAL

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

NORTH AMERICA

EUROPE

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

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

80 | WIRE JOURNAL INTERNATIONAL

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

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