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WIRE JOURNAL DECEMBER 2010

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The recovery

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WIRE JOURNAL

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

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

CONTENTS

Volume 43 | Number 12 | December 2010

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 24 People . . . . . . . . . . . . . . . . . 26 Fiber Watch . . . . . . . . . . . . . 30 Wrapup: Monterrey ITC Fastener Update . . . . . . . . . . 32 WAI News . . . . . . . . . . . . . . 33

. . . . . . . . .40

The return to Monterrey, Mexico, for the 2010 staging of WAI’s International Technical Conference showed that the venue remains a good place for the wire and cable industry to meet.

Chapter Corner . . . . . . . . . . . 38 Technical Papers . . . . . . . 56-69 Products. . . . . . . . . . . . . . . . 68 Classified . . . . . . . . . . . . . . . 76 Career Opportunities . . . . . . . 76 Advertisers’ Index . . . . . . . . . 78

Next issue January 2011

Industry trends: the recovery

. . . . .46

In the U.S., the official view is that the “recession is over,” but has that translated to better times for the wire and cable industry, much of which has had a tough go of it for the last two or so years?

T ECHNICAL P APERS Effect of parameters of extrusion on strain and stress states in the manufacturing process of wire from alloy CuAg15P5 Rafał Włudzik, Marcin Knapinski, Jan W. Pilarczyk, Stanisław Ksiezarek and Zbigniew Smolarczyk . . . . . .56 Overview of zinc coating monitoring and automatic control system achievement Ian R. Zoellner and Michael D. West . . . . . . . . . . . . .64

• GREEN FOCUS: compounds, colorants and marking inks Cover: Market conditions may be improving somewhat, and in the U.S., at least, the populace has been told that the “recession is officially over,“ but the months ahead likely will continue to be tough going for most wire and cable manufacturers. See p. 46. DECEMBER 2010 | 3

INSIDE THIS ISSUE THE

INDUSTRY CYCLE (FEATURE )

. . .46

Delphi Guadalupe III Plant Manager Quirino Anaya Gutierrez takes ITC attendees through the labor-intensive process of preparing wire harnessess during the tour of the Ensamble de Cables y Componentes factory that is part of the Delphi Packard Electrical/Electronic Architecture division. The plant’s customers include automakers Ford, Hyundai and Kia.

Fig. 3. This chart shows the traditional industry cycle for the wire and cable industry in mature economies. It reflects expectations for an economy as it contracts from a peak point to a downturn and climbs through a recovery stage back to prosperity. The theory still holds, but “other conditions” have impacted the results to date, reports Integer Research, which provided the chart.

CONTENTS

MONTERREY ITC . . . . . . . . . . . . . .40

4 | WIRE JOURNAL INTERNATIONAL

Extrusion • Corrugation • Optical Fiber • SZ-Stranding

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EDITORIAL WIRE JOURNAL

EDITORIAL

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

Looking back, looking ahead In May, I said at the WAI’s Annual Meeting at Wire Expo 2010 that “the WAI was stronger today than it was a year ago, and that it would be stronger a year from now than it is today. You have my word on it.” At the time, the economy was suffering and our industry was continuing to shrink, and while we now know we have “officially” been out of the recession for some time, conditions remain harsh. I have had my share of doubts about my pledge, but looking forward I feel confident that we are, indeed, moving to a better place. One of the drivers that has made a difference came from the very concerns that faced us. I heard more than one person ask, “Where are the new Horace Popses, Bob Shemenskis, Tom Renners, John Drummonds and David Richardses? For readers who don’t know those names, they are a few of our Association’s key long-time volunteers, as unique a set of industry experts as one could imagine. WAI Executive Director Steve Fetteroll said that more such input was needed, and that as the industry continues to be pressed, the area to hone in on was from our target audience: manufacturers. Who better to help design programs that will result in well-attended technical conferences, build our Interwire and Wire Expo trade shows into vibrant events and grow our membership than those who get it done? Over the past year, Fetteroll met with dozens of key executives at wire and cable manufacturers, asking what they wanted the WAI to be to them, and asking if they would help create it. The result is that WAI’s Conference Programming Committee now has representatives from more than two dozen wire and cable manufacturers. In a matter of months, Southwire Company’s Richard Miller had great success finding new members and new exhibitors. Encore Wire’s Gary Spence single-handedly created an incredibly ambitious technical program for Interwire 2011. Beyond that, WAI staff is making major advances to the Association’s website, which will be seen in 2011, and our new publication, WIRE BULLETIN, is firmly establishing itself as an industry presence in India. Exciting things are happening. To my WAI mentor, Sandy May, a man who expects a lot, I can say, “I think we’re getting ‘er done!” It was an honor being your representative this year and I fully expect my successor for 2011, Dominique Perroud, will do an excellent job. I want to thank my employer, Henkel Corporation, for letting me travel for a slew of WAI projects during the year. And I especially want to thank my wife, Karen, for her support and understanding. Remember, behind every successful man is a woman rolling her eyes. May God bless you and your families, and keep you safe.

Dane G. Armendariz WAI President

6 | WIRE JOURNAL INTERNATIONAL

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). 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. © 2010 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.

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CALENDAR

CALENDAR March 15-17, 2011: Cables 2011 Cologne, Germany. The 11th staging of Cables will be held at the Maritim Hotel. Contact: Applied Market Information Ltd., tel. 44-117-924-9442, fax 44-117-9892128, info@amiplastics.com. March 15-18, 2011: CABEX-2011 Moscow, Russia. This event for cables, wires, fastening hardware and accessories and installation technologies (CABEX) will be held at the EcoCentre. Contact: Natalia Medvedeva, tel./fax 7-495-925-34-82 or 995-05-95, ext. 260, mns@mvk.ru. Show site is www.cabex.ru. May 2-5, 2011: Global Continuous Casting Forum Atlanta, Georgia, USA. This event, to be held at Interwire, is designed to be the most comprehensive program ever for continuous casting. See p. 36-37. May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show, technical programs and the Association’s 81st Annual Convention as well as the Global Continuous Casting Forum. WAI, tel. 203-4532777, www.wirenet.org. May 18-19, 2011: National Electrical Wire Processing Technology Expo Milwaukee, Wisconsin, USA. Organized by Expo Productions, Inc. (EPI), this event will be held at the Frontier Airlines Center. Contact: EPI, tel. 800-367-5520, www.expoproductionsinc.com/wire_home.htm. May 23-26, 2011: wire Russia Moscow, Russia. Organized by Messe Düsseldorf, this event will be held along Tube Russia at the ZAO Expo

Centre Krasnaya Presnya. Contact: Messe Düsseldorf North America, erowe@mdna.com, tel. 312-781-5180. June 15-17, 2011: Wire & Cable Expo, China Tianjin, China. To be held at the Tianjin International Exhibition Center, the 15th staging of this event will include a conference, exhibition and featured events. Contact: AIT Events Co., Ltd., tel. 86-10-85868930, www.bvents.com/event/389490-wire-cable-expo. June 19-23, 2011: JI Cable 2011 Versailles, France. This international conference, which has multiple organizers and was last held in 2007, will present a comprehensive forum about power cables and exhibits. Contact: JI Cable 2011, www.jicable.org. Sept. 13-15, 2011: wire Southeast ASIA Bangkok, Thailand. Organized by Messe Düsseldorf, The International Wire & Cable Trade Fair for Southeast Asia (wire Southeast ASIA) will be held at the Bangkok International Trade & Exhibition Centre (BITEC). Contact: Messe Düsseldorf North America, erowe@mdna.com, tel. 312-781-5180. Nov. 6-9, 2011: 60th IWCS Conference™ Charlotte, North Carolina, USA. To be held at the Charlotte Convention Center. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990. March 26-30, 2012: wire Düsseldorf 2012 Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, erowe@mdna.com, tel. 312-781-5180. ■

WIRE ASSOCIATION I NTERNATIONAL E VENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. January 26, 2011: New England Chapter Meeting Uncasville, Connecticut, USA. The chapter will hold its 17th annual meeting at the Mohegan Sun Resort Conference Center. Contact: Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org. March 3-5, 2011: Modern technologies & modelling of drawing/manufacturing processes of metal products Zakapone, Poland. WAI’s Poland Chapter members are among those organizing this event. Contact: Dr. Sylwia Wiewiórowska, wiewior@mim. pcz.czest.pl, www.konferencja.mim.pcz.czest.pl.

8 | WIRE JOURNAL INTERNATIONAL

May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show, technical programs and the Association’s 81st Annual Convention as well as the Global Continuous Casting Forum. WAI, tel. 203-4532777, www.wirenet.org.

INDUSTRY NEWS

INDUSTRY NEWS WireCo WorldGroup acquires rope manufacturer in Portugal

Tyco to sell majority interest in its electrical/metal product unit

U.S.-based WireCo WorldGroup Inc. (WireCo), a supplier of specialty wire ropes, announced that it has acquired Grupo Oliveira Sá “and certain other assets comprising its worldwide business.” Based in Maia, Portugal, and founded in 1825, Oliveira Sá manufactures wire ropes for the crane and fishing markets as well as synthetic ropes for mooring line and towing applications, a press release said. “The Oliveira acquisition is the continuation of our strategy to strengthen our leadership in our core markets, to bring access to new geographic and end markets, and to expand our synthetics capabilities,” said WireCo CEO Ira Glazer. He said that Oliveira “has a strong position in the global wire rope aftermarket for cranes, which we believe will further enhance our leadership in that segment.” Beyond that, he said, the deal will strengthen WireCo’s range of high-performance synthetic ropes as those made by Oliveira serve marine markets that are highly complementary, including for offshore oil and gas and fishing. Glazer said that Oliveira’s existing management team is expected to remain with the company, as has been the case with previous WireCo acquisitions. WireCo plans to maintain Oliveira’s manufacturing operations in Maia and Paredes and hopes to expand the utilization of both facilities, which would require investment in plant and equipment and create the potential for additional jobs, he said.

Tyco International Limited will sell a 51% stake in its electrical and metal products business to buyout firm Clayton, Dubilier & Rice for $720 million. The company said that it plans to use the proceeds for part of a $1 billion share repurchase program. The deal, which includes 37 manufacturing and distribution facilities worldwide that generated revenue of $1.4 billion in 2010, was described as part of Tyco’s previously announced plans to focus on burglar alarms and fire-detection systems. The electrical and metal products unit,which manufactures steel tubes and pipes, electrical conduit, and armored wire and cable, will operate as a stand-alone entity under the name Atkore International, a press release said.

Plot twists continue in bid for Draka as Chinese company submits highest offer At press time, the hierarchy of the cable industry was shaken in a major way: shortly after Draka Holding AG announced that it agreed to support a buyout offer of 840 million euros from Prysmian SpA—topping a prior offer by Nexans that had been rejected as undervalued—a Chinese business has made an offer for about 1 billion euros. Reuters identified Xinmao Science & Technology (Xinmao) as saying that its parent company, the Xinmao Group, was offering 20.5 euros a share for Dutch cable maker Draka, exceeding the 16.76 euro share offer from Prysmian, which had topped the offer from Nexans. The story noted that, while Xinmao has a market capitalization of just over $400 million, Xinmao said that financing would be provided by Tianjin Xinmao S&T Investment Corp. Draka had supported the Prysmian’s offer, but it allowed the company to opt out if it received an offer worth at least 15% more. Prysmian had indicated that it would not increase its bid. Look for more details in future issues.

Champlain Cable Corporation acquires Berkshire Electric Cable Company Champlain Cable Corporation announced that it has bought the assets of Berkshire Electric Cable Company, a deal that it described as a “strategic acquisition (that) will complement Champlain’s product line and channel of distribution.” “This deal gives us the foundation for future growth,” declared Champlain Cable Corporation President Richard Hall, who said in a press release that the company is “pleased to have Berkshire’s experienced workforce and lineage of quality irradiated products expand our capacity, capabilities and product mix.” The ability to expand the company’s capacity for irradiated products was a key to the deal, and there are synergies that should bolster the outlook oputlook for both operations, he said. Berkshire, a custom wire and cable manufacturer based in Leeds, Massachusetts, manufactures cable products that have UL, military and marine approvals. It has 26 employees and will function as an independent division of Champlain Cable, he said. All Berkshire employees were retained, and there are plans to add a second shift, he said. Champlain Cable, a manufacturer of high performance wire and cable to industries such as automotive, industrial, military and data sectors, is based in Colchester, Vermont, and has a factory in El Paso, Texas.

Japan’s Fujikura to double its workforce at its plant in Romania Japan’s Fujikura plans to double its current workforce of 630 at its Romania factory based in Cluj-Napoca, which makes automotive wiring at its location that is northwest of Bucharest.

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

10 | WIRE JOURNAL INTERNATIONAL

Prysmian to supply cables for research project into ‘tidal power’ generation Prysmian reports that it selected together with International Telecom by the Fundy Ocean Research Centre for Energy (FORCE) as a partner in an innovative project aimed at exploring the potential of tidal power generation. A press release said that Prysmian will design and supply the submarine composite cables for the connection of four tidal current turbines in the Bay of Fundy (Nova Scotia, Canada). Once the underwater cables are installed and oper-

its high predictability, it said. The FORCE project is a new application for submarine power transmission and distribution cable systems. Tidal power has not gotten the attention of wind farms and solar farms because the underwater conditions have proven to be quite difficult to withstand. Matt Lumley, Fundy FORCE, told WJI that in-stream tidal “is still an emerging technology, and we expect it will be a few years before we see large scale development.” He explained that FORCE is “technology neutral, so we don’t endorse any specific design. Rather, we are putting in common infrastructure and monitoring to reduce the costs of entry for developers.”

Belden to buy communications business unit from Thomas & Betts U.S.-based Belden Inc. announced that it has agreed to acquire the Thomas & Betts Communications Products Business, for $78 million in cash, in a deal that it said would further strengthen the company’s position as an end-to-end solution provider within the broadband/CATV, security, and audio/video markets. A press release said that the business includes SnapNSeal® drop connectors, LRC® hardline connectors, Diamond® hardware & grounding products and telecom enclosures & connectors, including the Kold-N-Klose® enclosure system. “By adding these established brands and market-leading Radio Frequency (RF) connectors to its extensive portfolio of audio, video and security cables, Belden will expand its end-to-end solution offering and leverage its existing channels,” it said.

Draka plans to locate a cable assembly plant site in U.S. to supply Siemens Prysmian cables will be used in efforts to harness tidal power. ating, the generated electricity will be transferred to the shore and connected to the Nova Scotia power grid, it said. The Bay of Fundy, it noted, has been identified as the best site in North America and one of the best in the world for tidal power generation, with a resource potential as high as 2,000 megawatts, enough power for about 750,000 homes. Specifically, Prysmian will provide about 11 km of 3-core ethylene propylene rubber (EPR) insulated 34.5 kV composite submarine cables for the connection of tidal current turbines, the release said. The work will be done at the Group’s submarine cable facility in Arco Felice, Italy, it said, adding that installation will be done by International Telecom next summer. The release said that the scope of the FORCE project is to test tidal energy devices and their effects, if any, on the environment and explore the potential of a cleaner, renewable source of energy. After wind and sun, tides are the ultimate frontier of renewable power that shows great potential due to

The Kansas Dept. of Commerce announced that Draka will open a site in Hutchinson, Kansas, USA, that will supply the local Siemens energy plant, which builds housings for the generator, transformer and gearbox for wind turbines. A press release said that Draka, based in The Netherlands, plans to open the plant with up to 10 employees, with that number expected to double within a year. Local officials said that they expect other companies to locate operations there as the Siemens operation gears up. Kansas, it said, ranked second in the nation for wind energy potential.

Southern Steel & Wire to close, production to cease by year’s end Southern Steel & Wire plans to close its 280,000-sq-ft plant in Arkansas, reports The City Wire, which wrote that the longtime member of the manufacturing community in Fort Smith had notified the city that it will cease production beginning Dec. 22. “As a result of this cessation of production operations, 117 employees will be permanently laid off with the majority leaving in the anticipated 14-day period from Dec. 22, 2010, through Jan. 5, 2011,” it said. DECEMBER 2010 | 11

INDUSTRY NEWS

ACT News reports that the announcement was made at a news conference by Ignacio Ibarra Fujikura, president for the company’s operations in Europe and South America. The expansion, planned to take place in the first quarter of 2011, stems from a new contract with auto producer Volkswagen that was said to be more than €10 million over at least three year, it said. The story said that the Cluj-Napoca factory opened in 2001, with 30 employees at that time. It also noted that Fujikura has a second production facility in Romania, located in Dej, that opened in 2006 and has 1,200 employees.

INDUSTRY NEWS

WCJ Pilgrim Wire expands by purchase of wire business from Stanley Bostitch U.S.-based WCJ Pilgrim Wire (WJC), which notes that it is already the largest manufacturer and distributor of wire used in the box stitching and printing industries in the

Americas, reports that it has further expanded via its purchase of the Stanley Bostitch wire business encompassing box stitching, bookbinding stitching and Thredlok wire. A press release said that WCJ had been working in conjunction with Stanley Bostitch on different levels for years. That business relationship, it said, expanded when Stanley closed its wire mill in Clinton, Connecticut, and WCJ began supplying Stanley Bostitch customers. “WCJ Pilgrim Wire has considerable product and industry knowledge in relation to all our customers already, as well as an extensive inventory to serve their needs with little or no lead times.” The story said that all open orders are being transitioned to WCJ Pilgrim Wire. The company told WJI that WCJ Pilgrim Wire bought the machines, customer list and inventory, no physical plants. Also, that the company had some 300 customers that generate an approximate volume of 600 tons.

Venezuela’s leader nationalizes steelmaker Venezuelan President Hugo Chavez plans to nationalize Sidetur, an affiliate of Venezuela’s biggest private steelmaker, Sivensa, that processes scrap and manufactures rebar “along with wire rod or construction cable.” The announcement, reported by multiple media sources, notes that Chavez said that the expropriation was made because the company was guilty of price-gouging, “and the next day the military occupied at least three of Sidetur’s six plants.” The Latin American Herald Tribune reported that the operations director of Sidetur denies the claim. “We reject the measure decreed by the president because our products have been regulated since 2006,” Gourmetts said on Union Radio in Caracas. The Venezuelan Confederation of Industries claims that the Chavez government has nationalized 200 companies to date in 2010.

12 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

Superior Essex buys wire distributor U.S. based-Superior Essex, Inc., announced that it has acquired Piremag Corp., the exclusive distributor for PPE Fios Esmaltados (PPE), a producer of magnet wire. A press release said that via its Essex Group Inc. (EGI) subsidiary, the company has acquired the assets of Piremag Corp., which for 26 years has distributed magnet wire made by PPE, which was formally known as Pirelli, in North America, Central America and the Caribbean. “This agreement will allow PPE to use Essex Brownell’s extensive network of sales professionals and distribution centers to reach

a wider range of customers and grow its share in the North American market,” the release said. As part of the deal, EGI has signed a long-term distributor agreement with PPE to sell magnet wire in North America, Central America and the Caribbean. EGI will market PPE magnet wire through its Essex Brownell subsidiary.

Chinese supplier reports order for high-speed wire rod production line Taiyuan Mining Machinery Group Co., Ltd., a Chinese state-owned manufacturer of heavy-duty machinery products and coal mining machinery equipment, announced that it has received an order worth approximately US$31 million to build a two-strand, high-speed wire rod production line. Steel Orbis reports that the order, for a line with annual capacity of one million metric tons, is for Chinese steelmaker Zhengfeng Iron and Steel Co., Ltd. The company, which is located in the county of Liujiaying, Fengrun district, Tangshan, Hebei Province, has two plants in other counties of the Fengrun district with annual production capacity of 2 million mt of steel and wire rod, it said.

Lincoln Electric to buy Russian company U.S.-based Lincoln Electric Holdings, Inc., has agreed to acquire Mezhgosmetiz-Mtsensk OAO (MGM), a privately held welding wire manufacturer based in the Orel Region in Russia. A press release said that the acquisition will provide Lincoln its first manufacturing operation in Russia as well as established distribution channels to serve the growing Russian and Commonwealth of Independent States (CIS) welding markets. MGM, it said, has annual sales of approximately $30 million and employs over 200 people. “MGM...will complement our imported products offering and significantly expand our commercial presence in the region,” said Lincoln Electric Chairman and CEO John Stropki, who added that his company already has solid brand recognition in Russia. 14 | WIRE JOURNAL INTERNATIONAL

requiring multiple parallel fibers per port (8 for 40 Gbps and 20 for 100 Gbps), it said, adding that newer “plug n’ play” fiber products that provide this parallel fiber approach will be needed. Contact: Frank Murawski, FTM Consulting, Inc., tel. 717-533-4990, ftm.consulting@verizon.net. (continued on p. 18)

The data center cabling market looks as if it will be one of the strongest growth applications for the next few years, per a report from U.S.-based FTM Consulting. In “Data Center Cabling Systems Market,” it projects that the market will grow from $1.6 billion in 2010, at an 18.9% rate, to $3.8 billion by 2015. A press release said that, compared to the total structured cabling systems market’s projected growth of 13.1% over the next five years, “the data center cabling market offers one of the highest growth applications.” “The recent analysis on this market revealed a surprising finding: the copper cabling segment will be larger than the fiber cabling segment during the forecast period,” said FTM President Frank Murawski. “There now are, and will be, a larger number of smaller data center sites requiring copper cabling than the larger sites, which use fiber cabling. Even though most of the recent product introductions targeting this market have been fiber-based, our analysis indicates that by 2015, there will be 2.6 billion servers at large sites being cabled, compared to the small sites with 5.8 billion servers,” he said. “Prior to the TIA 942 data center cabling standard, many sites were a rat’s nest of cabling: disorganized, with no provisions for data center upgrades,” Murawski said. “As these sites grow because of adding storage, a point will be reached when it is no longer feasible to handle this in a piecemeal manner. There will be the need to put in place a structured cabling system to manage current expansion and future growth.” The release said that a significant technology development will be the higher speeds (bandwidths) needed at data centers. Currently, 10 Mbps Ethernet is the highest speed being implemented, but in ISO 9000:2000 AS9100 Registered the near future, both 40 and 100 Gbps will start to be deployed,

Bomco Inc. 125 Gloucester Avenue Gloucester, MA 01930-2294 978-283-9000 Fax 978-283-2882 e-mail custserv@bomco.com

DECEMBER 2010 | 15

INDUSTRY NEWS

Study: data center cabling has strong outlook, and copper a surprising role

INTERWIRE 2011 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Convention Dates: May 2-5, 2011 | Exhibit Dates: May 3-5, 2011 Georgia World Congress Center | Atlanta, Georgia, USA

INTERWIRE 2011 IS ALIVE WITH POSSIBILITIES. IT IS RENEWED, INVIGORATED, AND TAKING A NEW TACK. WHO’S AT THE HELM? Senior executives from more than 25 key corporations are skillfully guiding major changes to the show. Their interest in Interwire—the largest wire and cable marketplace in the Americas— is resolute. Interwire affects their business and is clearly worth their personal time. The result is a series of carefully considered and nimbly integrated transformations to better Interwire. Location: Atlanta, Georgia. Relocated and familiar, Interwire returns to the city of its origin where it was introduced in 1981. Compact: 3 full days of exhibits. Interwire 2011 offers a concentrated show schedule.

Special industry theme days. Look for presentations, technical papers, and executive discussions to orbit around these central themes: Metals & Materials Manufacturing Best Practices Green Initiatives Also NEW: The Global Continuous

More operating equipment. Interwire is a machinery show. Visitors can count on more operational equipment in 2011. Renewed energy. Exhibitor participation is on the upswing showing a 14% increase between the 2007 and 2009 events. Networking opportunities, ranked as the #1 reason to attend the show, will be part of the landscape. Expect to see production solution demonstrations and other attendance-building activities on the exhibit floor.

CC Casting Forum.

Uniting worldwide copper continuous casting practitioners for networking, technical and operational presentations and workshops. 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 108 countries worldwide.

“Having all or most of the vendors in one location for a face-to-face has always had unmeasured value and still does, especially when times are tougher for travel and the like. Our company believes in the future of the business and that means get out there and find out what is going to take us into new future markets. I’ve already recommended that we return in 2011.” Ed Kozlowski, Senior Design Engineer W.L. Gore & Associates

SAVE THE DATE: MAY 2-5, 2011 AND LEARN MORE ONLINE AT WWW.WIRENET.ORG Interwire 2011 is organized by 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

INTERWIRE 2011 EXHIBITING COMPANIES — AS OF NOVEMBER 2010 EuroWire Magazine George Evans Corp. EVG Inc. Fabritex Inc. FIB Belgium SA Fil-Tec Inc. Filtertech Inc. Fine International Corp. Fisk Alloy Conductors Flymca Flyro FMS USA Inc./FMS AG Foerster Instruments Inc. H. Folke Sandelin AB Fort Wayne Wire Die Inc. Fortune Machinery Frontier Composites & Castings Inc. FSP-One Fuhr GmbH & Co. KG Fushi Copperweld Garg Sales Co. Ltd. Gauder & Co. Gauder Group Inc. Gavlick Machinery Corp. GCR Eurodraw SpA Gem Gravure Co. Inc. Genca/Canterbury Engineering W. Gillies Technologies Gimax SRL GMP-Slovakia Golden Spot Industry Inc. Guill Tool & Engineering Co. Hafner & Krullmann GmbH V. Hagen & Funke Hagener Feinstahl Hall Industries Heacock Metal & Machine Co. Inc. Heany Industries Inc. Heatbath Corp. Henkel Corp. Henrich Maschinenfabrik GmbH Heritage Wire Die Inc. Howar Equipment Inc. Hudson Color Concentrates Huestis Industrial Huettner Maschinenfabrik GmbH ICE Wire Line Equipment Inc. IDEAL Welding Systems Ideal-Werk INHOL LLC Inosym InterWire Products Intras Ltd. Italian Trade Commission ITO-SIN (Deyang) Wire & Cable Equipment Co. Ltd. IWE Spools & Handling GmbH IWG High Performance Conductors Inc. IWMA - International Wire & Machinery Association JMS Machinery Joe Tools Kalas Manufacturing Kalmark Ltd. KEI Industries Ltd. KEIR Manufacturing Inc. Kieselstein GmbH King Steel Corp. Ernest Koch GmbH & Co. KG Albert Krenn Friedrich Krollman GmbH & Co. KG Lamnea Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. OM Lesmo Lesmo Machinery America Inc. Lloyd & Bouvier Inc. J.J. Lowe Associates LUKAS Anlagenbau GmbH M + E Macchine + Engineering Magnetic Technologies Ltd. MAGNUM Mfg. LLC MAGPOWR

Maillefer SA Mapre Belgium SA Merritt Davis Metavan NV MFL USA Service Corp. - Frigerio The MGS Group (MGS-HallNorthampton) MGS Manufacturing Inc. Micro Products Co. Microdia USA Millennium Steel & Wire Inc. Morgan-Koch Corp. Mossberg Associates Inc. Mountville Rubber Co. MPI Machines Ltd. NEPTCO Inc. Nextrom Oy Niagara Composites Industries Inc. Niehoff Endex North America Inc. Maschinenfabrik Niehoff GmbH & Co. KG NIMSCO LLC/SB2C Northampton Machinery NUMALLIANCE Oklahoma Steel & Wire OMA SRL OMA USA Inc. OMCG North America OMCG SpA Pamica Electric Material Panchmahal Steel Ltd. Paramount Die Co. Parkway-Kew Corp. Pave Automation Phifer Wire Inc. Pinnacle Metals Inc. Pioneer Machinery Co. Ltd. Pittsburg Carbide Die Co. Pittsfield Plastics Eng. Inc. Plasmait GmbH Plastic Equipment LLC Plymouth Wire Reels Polytec Inc. Pourtier - Gauder Group Power Sonics LLC/Magnus Equipment Precision Die Technologies Inc. Premier Wire Die PrintSafe Promostar srl Properzi International Inc. Proton Products QED Wire Lines Inc. Queins & Co. GmbH Raajratna Metal Industries Ltd. RAD-CON Inc. Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Reel-O-Matic Refractron Technologies Corp. RG Attachments RichardsApex Inc. Rizzardi Rockford Manufacturing Group FELM Rosendahl GmbH Rosendahl Nextrom Technologies Roteq Machinery Inc. S&E Specialty Polymers Saarsteel Inc. Saint-Gobain Ceramic Materials SAMP SpA SAMP USA Inc. SAMPSISTEMI Sark USA Inc. Sark Wire Corp. Sarkuyasan AS Schlatter Inc. Schmidt Maschinenbau GmbH Schunk Graphite Tech Sealeze A Unit of Jason Inc. Service Thread Mfg. Co. Setic SAS Shaoxing Kaicheng Mica Material Co. Ltd.

Sictra Srl SIKORA International Corp. SIMPACKS Sirio Wire Srl Sivaco Quebec Sjogren Industries Inc. Skaltek Inc. SKET Verseilmaschinenbau GmbH Smeets SA Sonoco Reels Spirka Schnellflechter GmbH SPX Precision Components FENN Division STAKU-Anlagenbau GmbH Stamm Feindrahtwerk Stema/Pedax Steuler Anlagenbau Stolberger Inc. (dba Wardwell Braiding Co.) Stolberger KMB Maschinenfabrik GmbH Sylvin Technologies Inc. T & T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Team Meccanica Srl Teknikor Teknor Apex Co. Tenova Core Tensor Machinery Ltd. Teurema Thermcraft Inc. Tips & Dies Inc. Traxit North America LLC Tri Star Metals Troester GmbH & Co. KG Paul Troester Maschinenfabrik Tubular Products Co. Tulsa Power Inc. UMC United Wire UNITEK Uniwire International Ltd. UPCAST OY US Reel US Synthetic Wire Die Vandor Corp. Vitari SpA Vollmer America Inc. Wafios Machinery Corp. WAI Connection WCISA - Wire and Cable Industry Suppliers Association Weber & Scher Mfg. Co. Inc. Windak Inc. Wire & Cable Asia Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp. wire 2012/Messe Düsseldorf North America The Wire Association International, Inc. WIRE BULLETIN Wire Forming Technology Wire Journal International Wire Lab Co. Wire Machine Systems Inc. Wire World Internet WireCo WorldGroup WiTechs Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Woywod GmbH & Co. KG/ Plasticolor WTC Wuhan Sunni Electric Wire & Cable Co. Ltd. Wyrepak Industries Inc. Ya Sih Technology Yield Management Corp. Zeus Inc. Zumbach Electronic AG Zumbach Electronics Corp.

INTERWIRE 2011 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

A. Appiani Ace Metal Inc. ACM-KSM AFL Agape Industry Inc. AIM Inc. Ajax Turner All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American Kuhne AW Machinery LLC AXIS, A Consona ERP Solution Axjo Plastic AB Aztech Lubricants LLC B & H Tool Co. Inc. Balloffet Die Corp. Bao Zhang Galvanized Iron Wire Co. Bartell Machinery Systems LLC/ Ceeco Machinery Bekaert Corp. Bergandi Machinery Co. Besel Basim San Tic Ltd. Sti. Beta LaserMike Blachford Corp. Maschinenfabrik Bock GmbH & Co. KG Bogimac Bongard Machines USA LLC Boockmann GmbH/The Slover Group Breen Color Concentrates Brookfield Wire Co. Bühler-Würz Kaltwalztechnik Butt Welders USA Caballe SA Cable Consultants Corp. Calmec Precision Inc. Carris Reels Inc. Cary Compounds LLC Cemanco LC Chase Coating and Laminating Chemetall Oakite CJI Group Ltd. Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. CN Wire Corp./Er Bakir Collins & Jewell Comapac Wire Machinery Srl Cometo SNC Commission Brokers Inc. Condat Corp. Conductix Delachaux Group Conneaut Industries Inc. Continuus-Properzi SpA Cortinovis Machinery America Inc. CRU North America Inc. Dalian Tongda Equipment Technology Development Co. Daloo Machinery Davis-Standard LLC Dem Costruzioni Speciali Srl Deyang Dongfang Zhouyue Electrotechnical Equipment Die Quip Corp. Dixie Converting Corp. Domeks Makine Ltd. Sti Dynamex Corp. Ebner Furnaces Inc. Egyptian Galvanized Steel Plant Co. EJP Maschinen GmbH Elektrisola Inc. Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Estane Engineered Polymers/ Lubrizol Esteves Group USA Etna Products Inc. Etna-Beechem Lubricants Ltd. Eurodraw Energy SpA Eurolls Group Srl

INDUSTRY NEWS

Good showing reported at Rosemont for 2010 staging of SPRINGWORLD Organizers of SPRINGWORLD described the 2010 staging at the Rosemont Convention Center in Rosemont (Chicago), Illinois, USA, as a success, with attendance of 2,237, about 10% higher than the 2008 event. “The tone on the floor was upbeat,” said Thomas Renk, executive vice president of the Chicago Area Spring Manufacturers (CASMI), which puts on the biennial event. He observed that while the economy remains sluggish, there were positive indications from attendees, which included both spring-making and wire-forming companies. “Some were saying orders were up, they had added employees and some had added second shifts. They were still cautious about expectations, but generally, attendees were saying they could see and feel the uptick.” The attendees included more regional attendance coming from the Midwest than in prior years, but there was also a strong international contingent of exhibitors coming from China, Japan, India, Taiwan and European countries, Renk said. While the number of attendees was up, there was a decrease in numbers for exhibitors, with such staff down about 8% from 2008, he said. Evaluations from the 98 exhibiting companies consistently rated the 2010 event as being a success, Renk said.

18 | WIRE JOURNAL INTERNATIONAL

“Exhibitors reported quality leads, indicating that, despite the condition of the economy, they were happy with the quantity and quality of the leads and contacts made at this year’s show. By the end of the show, 16% of this year’s exhibitors had reserved their space for 2012 before they had finished taking down their booths, and those numbers went up the last few weeks.” Renk said that a new educational component on the show floor also went well. “The new format was originally suggested by an exhibitor who had a story they wanted to tell. For a first effort, and with only the one education room on the show floor, we often had standing room only.” He said that a variety of sessions were offered, including topics such

Activity on the show floor at SPRINGWORLD 2010.

INDUSTRY NEWS

tional two-day exhibitor move-in, which had been reduced to one day for 2010. Contact: Tom Renk, CASMI, tom@casmi-springworld.org or tom@associationenterprise.org.

Belden to sell Trapeze Networks business to Juniper Networks

SPRINGWORLD saw a first-time educational program on the show floor. as new products, processes and software options, and were repeated during the show. “Attendees seemed to appreciate the educational program offerings,” Renk said. The goal is to repeat the program in 2012, adding a second classroom, only with a hard-wall setup and a better microphone, he said. One other popular event, he said, was the All Industry Reception on opening night, hosted by the Spring Manufacturer’s Institute (SMI), which participated in the education programs. SPRINGWORLD will return to Rosemont for the next staging, which has a tentative date of October 17-19, 2012. Renk said that the plan at this time is to return to the tradi-

Belden Inc. announced that it has agreed to sell its Trapeze Networks business, which specializes in enterprise wireless local area network (WLAN) systems and management software, to Juniper Networks in a deal worth about $152 million. A press release said that the acquisition will bolster Juniper’s growth via Trapeze Networks’ innovative WLAN technology, which it described as being highly complementary to Juniper’s campus and branch switching, routing and security business. It noted that Trapeze Networks currently holds 17 awarded patents, more than any other WLAN provider, with 49 more patent filings pending. “This agreement enables our organization to remain focused on the long-term growth opportunities for wireless technology in our core markets, including the nascent industrial networking market,” said Belden President and CEO John Stroup.

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INDUSTRY NEWS

The role of wire in the October rescue of 33 trapped Chilean miners The October rescue of the 33 Chilean miners trapped 2,000 feet below ground was a tremendous effort that took teamwork and collaboration from around the world. Those efforts included at several companies from the wire and cable industry. Austria’s Teufelberger supplied a 1,000-meter-long stretch of its Evolution TK 16 rope. Per the company, the rope had to be non-rotating to prevent any rotation of the capsule during the rescue. Östu-Stettin GmbH, which provided the specialized elevator winch system, asked Teufelberger to supply the rope. Days later, the rope, which weighed almost three tons, was air-lifted to Chile, said Florian Teufelberger, director of the Teufelberger Group. “We are proud to have been able to contribute to the rescue of the miners,” he said. Another contributor was Prodinsa, a rope specialist and a joint venture company of Bekaert, which provided the backup rope for Geotech Boyles Brothers SA, one of four drilling companies involved in the rescue effort. It supplied a 24 mm Prodinsa Izaflex wire rope and its wire ropes were used by Codelco, which developed a shower system for the mineworkers.

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One indirect contributor was Unitek of Austria, represented in North America by Canadian-based Howar Equipment Inc., which reported that the cable that was used was insulated with a thin layer using Unitek’s UXH70 SC fixed-center crosshead, which is capable of insulating up to 70 mm cable insulation diameters. It also supplied special extrusion tooling for this application and custom made cable.

News briefs The Edge in Singapore reports that Hu An Cable Holdings, a top wire and cable manufacturer in China, has won a contract worth an estimated US$2.2 million from Guodian Hefeng Wind Power Development Co. The cables, it said, will be used for the Daqingbei Wind Power Project Phase 1 in the Huachuan County of Heilongjiang Province, which will have an installed capacity of 49.5MW per annum. It said that Hu An Cable will provide its patented low temperature and twist-resistant wind power cables that are used between the generator and transformer of the wind turbine. ... U.K.-based Webster & Horsfall will invest an initial £1m in a new production plant and equipment for its Birmingham operation. Insider Media Limited reports that the Hay Mills company plans to expand production. The company, the report said, expects that its overall plans, worth

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INDUSTRY NEWS

£3.4 million, will “safeguard” 19 jobs and add eight more. At its website, the company notes that its product range includes carbon steel spring, music and rope wire; stainless steel spring, forming and welding wires; and low alloyed steel spring wire and strip for springs, clips and pressings. Company Finance Director Robert Horsfall said that the new plant and machinery includes state-of-the art wiredrawing machinery, a new electric furnace, specialized testing equipment and a highly efficient thermal-fluid heating system. The new technology “will also ensure we reduce our carbon footprint,” he said. ... U.S.-based Videojet Technologies reports that it has acquired the Mexican coding business of F. Armida y Cía, which has represented Videojet in the country for more than 20 years. The deal gives Videojet a direct presence in Mexico through the business, which is now called Videojet Technologies México, it said. Eduardo de la Torre, general manager of Videojet Technologies México, said that the goal was to invest and expand the company’s geographic coverage to offer customers better service. ... Germany’s SMS Meer officially opened a new production site in Singapore on October 25. A press release said that the company, a business of the SMS Group, invested approximately US$27 million in the site. The company produces a range of

SMS Meeer held an official opening of its new production site in Singapore on October 25. equipment that includes wire rod and bar lines. The release said that the Shanghai site will manufacture complete machines for the Chinese market and components for customers around the world, while SMS Meer’s engineering and design operations will continue to be based in Europe. ■

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ASIAN FOCUS

ASIAN FOCUS ‘Smart’ China growth trend: more R&D Centers, more interaction China has moved to a leadership position as a land where commodity products can be made at lower prices, but increasingly, companies that have been doing business are looking beyond that level. One reflection of that evolution can be seen in the increase in R&D Centers by multinational companies, which a spokesman for the Ministry of Commerce said numbered more than 1,200. An article by Jianmim Jin, economic research center, Fujitsu Research Institute, notes that as of the end of 2009, there were 465 multinational R&D centers that have the approval of the Ministry of Commerce. Those centers, he wrote, represent a total investment of more than US$12.8 billion, with registered capital of US$7.4 billion. The centers are mainly concentrated in Shanghai, Beijing, Guangdong, Jiangsu and Zhejiang, but one article observed that more are now being located in provincial cities. The focus of such R&D Centers has expanded from a traditional domestic focus to regional Asia-Pacific and even global centers, the article said. “Western and other foreign companies are beginning to comprehensively use China for not only low-cost manufacturing and as an attractive market, but also for basic research and reverse innovation supported by high-quality human resources. This trend is only accelerating in China, which achieved V-shaped recovery from the financial crisis,” it said. China has encouraged such growth as part of its goals to be an “innovative and creative nation,” the article said, by offering tax exemptions on equipment imports and government R&D subsidies; strengthening intellectual property protection; and giving preferential treatment to products developed domestically and independently (including by foreign companies) through government procurement. The R&D Centers, however, are not necessarily an end unto themselves. Companies are reaching out to become more involved in the local communities as well as furthering their image in China. One wire and cable company that has gone that route is South Korea’s LS Cable. The company notes that its current activities in China “center on LS Hongqi Cable, launched in December 2009, after the takeover of Hubei Yongding Hongqi Electric, an electric power manufacturer, from Yongding Group of China in August 2009.” LS Cable, it said, completed its composite business portfolio by adding Hongqi Cable, which makes electric power cable joints, bus ducts, automobile cables and machine cables, etc., to its Wuxi office in Jiansu. The company’s Tianjin office in Hubei, it added, offers winding wire made by SPSX, which it took over in 2008. In a press release, LS Cable CEO & Chairman Christopher Koo said that his company has an agreement

with the Investment Office of Wuhan, in Hubei Province, China to establish a local R&D Center that will develop products customized to the Chinese market for the purpose of reinforcing product competitiveness. “This … is an important turning point in LS Cable’s business strategy for the Chinese market,” said VP Cho Joon-Hyeong, who is in charge of R&D for LS Cable. “LS Honqi Electric is planning to strive to increase sales by developing customized cable products as well as contributing to the economic growth of Wuhan.”

The LS Cable/LS Hongqui booth at EP China 2010. Beyond the R&D Center, LS Cable plans to reach out to the local community as well as increase its recognition in the country. It said that it has plans to “foster local talents and develop state-of-the-art products” as well as reinforce marketing “by participating in professional exhibitions and social contribution activities.” The company has also organized seminars, targeting key customers, to display its 22.9 kV and 154 kV super conducting cable system application and its large-capacity electric power solution for green energy. “These seminars were attended by approximately 1,000 key personnel from the electric power industry of China,” it said. “Moreover, LS Cable actively publicized the company’s corporate image by organizing additional events to introduce the company’s vision and business activities.” Together with its LS Hongqi Cable subsidiary, LS Cable took part in the International Exhibition on Electric Power Equipment and Technology 2010 (EP China 2010) and was scheduled to be at the 25th World Battery, Hybrid and Fuel Cell Electric Vehicle Symposium and Exhibition as well. The company also arranged for some Chinese college students to go the Shanghai Expo and some of the company’s production facilities, and plans “to continue to be engaged

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

24 | WIRE JOURNAL INTERNATIONAL

ASIAN NEWS BRIEFS KEI Industries inaugurates high-voltage plant KEI Industries reports that it has inaugurated its ExtraHigh-Voltage (EHV) cable manufacturing facility ranging from 66 kV to 220 kV at its Plant at Chopanki, District Alwar Rajasthan, in India. The plant is under a technical collaboration agreement with Swiss-based Brugg Kabel AG, a specialist in manufacturing high-voltage/extra-high-voltage cable. KEI Industries manufactures high and low tension cables (EHT, HT and LT), control and instrumentation cables, house wires and stainless steel wires.

Hu An Cable to provide cables for wind farm China’s Hu An Cable Holdings, which notes that is one of the country’s top 10 wire and cable manufacturers, reports that it has won a contract worth US$2.2 million from Guodian Hefeng Wind Power Development Co. The contract, reported The Edge in Singapore, is for cable

to be used for the Daqingbei Wind Power Project, Phase 1, in the Huachuan County of the Heilongjiang Province. The project, it said, will result in an installed capacity of 49.5 MW per annum. Hu An Cable will provide its patented low temperature and twist-resistant wind power cables, which are to be used in-between the generator and transformer of the wind turbine, the article said. It added that the company has a total order book value of about US$75 million, with about 12% of that coming from renewable energy industries.

Lapp India turns to InnoVites for technology InnoVites B.V. reports that Lapp India Pvt. Ltd., Bangalore, India, has selected it to implement CableBuilder© design and quotation processes technology developed by U.K.-based Cimteq Ltd., an industry partner of InnoVites, which is its exclusive reseller in India. A press release said that Lapp India, a manufacturer of cables, connectors and other products, “invests in intense R&D to stay ahead of times,” which led to its choosing CableBuilder to “further support and strengthen their innovation capabilities.” InnoVites B.V., which is based in The Netherlands (www.innovites.com), has an office in India, which it has targeted as a growth area. ■

DECEMBER 2010 | 25

ASIAN FOCUS

in marketing activities in China...including donations for scholarship fund.” As one article noted, companies looking for business in China are expected to offer more than low-paying jobs.

PEOPLE

PEOPLE Coleman Cable Inc. has named Howard Strauss as vice president of wire & cable distribution to lead its wire and cable and security home technology business units. He has more than 25 years of industrial and low-voltage product experience, working at Lake Cable, Genesis Cable and Houston Wire and Cable as well as at Coleman Cable, where he previously held various positions in sales, marketing and business development. Based in Waukegan, Illinois, USA, Coleman Cable Inc. manufactures electrical and electronic wire Howard Strauss and cable products. SAMP USA, Inc., has named Orlando Martinez as its sales area manager, North America. He has 15 years of experience in the wire and cable industry, most recently working with Zumbach Electronics Corporation as area sales manager for its Southeast, Mexico and Caribbean region. He holds a B.S. degree in industrial engineering from the University of Puerto Rico, and an MBA degree from the University of Phoenix. Based in Williamsport, Maryland, USA, SAMP USA, Inc., is a division of Italy’s SAMPSISTEMI, a global supplier of wire and cable Orlando Martinez equipment. The Prysmian Group has created two new positions, effective January 2011, as part of its new “customer-centric” organizational model. Massimo Battaini will be the Chief Commercial Officer (COO,) responsible for the entire supply chain (purchasing, operations, logistics). He has worked for the company for 23 years and is currently the CEO of Prysmian UK. Fabio Romeo will be the CCO, responsible for sales and marketing activities, covering both the energy and telecom businesses. He has worked for the company for 10 years and is currently director of the energy business. Based in Italy, the Prysmian Group is a global supplier of cables and systems for energy and telecom applications. Effective Jan. 1, 2011, Kyle Spader will be promoted to president of IEWC’s U.S. Division. Spader joined the company in 2000 as controller and eventually became Chief Financial Officer (CFO). He was involved in many aspects of IEWC’s business, including acquisitions, greenfields, systems and process improvement. He will retain his current responsibilities as CFO. The company notes that it has become increasingly global the last five years, with a division president overseeing its activities

26 | WIRE JOURNAL INTERNATIONAL

in Canada, Mexico, Europe and Asia. The new duties for Spader will allow President & CEO David Nestingen to focus on the company’s broader global initiatives. Based in New Berlin, Wisconsin, USA, IEWC is a global supplier of wire, cable and wire management products to OEMs and sub-assemblers. Jeff Marterella has joined Alps Wire Rope Corporation as its eastern region manager/director of crane rope sales. He has 30 years of experience, both on the manufacturing and sales support side in the wire rope industry, with extensive knowledge of the specialty crane rope products, the U.S. market place and a thorough understanding of general purpose and Jeff Marterella elevator ropes. Based in Glendale Heights, Illinois, USA, Alps Wire Rope Corp. markets a wide range of products through its seven warehouses and sales offices. Fushi Copperweld Inc. has named Craig H. Studwell as Chief Financial Officer (CFO). He has more than 35 years of experience in banking and corporate finance in the U.S., Asia and Europe. He takes over from company President Wenbing Christopher Wang, who has served as interim CFO since March 2010. Through its subsidiaries, China-based Fushi Copperweld Inc. is a global supplier of copper-clad bimetallic wire for telecom, utility, transportation and other electrical applications. WireCo WorldGroup announced a number of personnel changes that were made as part of a new management structure to streamline its sales management. Senior Vice President Miguel Gomez will manage sales efforts for all markets in the Western Hemisphere. He will also lead non-steel rope industry directors, including high-carbon wire, electromechanical cable and synthetic ropes. He served as the Commercial Director for Aceros Camesa before its acquisition by WireCo in 2005. He relocated to the corporate headquarters in 2006 and has led the sales of Camesa wire, wire rope and electromechanical cable since that time. Wolfgang Oswald will take on a new role as senior vice president of global sales where he will lead a team of international market directors for wire rope products and maintain sales management responsibility for Europe, Africa and Asia. He will retain his role as managing director at CASAR, where he has led the sales team, and also spent time overseeing Paulsen Wire Rope in the U.S. Other changes include the formation of a team of global market directors who will be responsible for key market segments and also engage in business development activities. John Josendale, senior vice president,

bridge contractors and DOTs across the U.S. and Canada. He will expand efforts to pursue the structure sector globally. Dr. Frank Jauch, who joined WireCo WorldGroup earlier this year and is a recognized expert in the OEM sector and crane markets, with more than 20 years of experience working in the European wire rope industry, will now lead all global efforts in the crane industry. He holds a Ph.D from the University of Dresden. Based in Kansas City, Missouri, USA, WireCo WorldGroup, a business of Paine & Partners LLC, supplies wire, wire rope, wire rope assemblies and electromechanical cable. (continued)

Scott Higgins, WAI past president, dies at age 50 Scott S. Higgins, a big man both literally and figuratively in the wire and cable industry, died Saturday, October 30, at a hospital in Cherry Hill, New Jersey, days after suffering a heart attack while working nearby for Seminole Wire and Cable Company. He was 50 years old. A New Hampshire resident, Higgins entered the industry in 1983, and worked at, among others, General Cable

Scott Higgins with a fellow underwater enthusiast.

Corporation, Capital Wire & Cable, Hendrix Wire & Cable, IGC Advanced Superconductors and Autac, Inc. In recent years, he continued to work as an industry consultant, but also pursued his lifelong passion for boating and scuba diving, working as a boat captain and a scuba instructor, while remaining an active member in WAI, which he joined in 1989. Higgins, who attended Indiana State University, served on just about every Association volunteer body, and was president in 2002. He was a founding member of the New England Chapter, where he was both a director and presi-

dent, and represented WAI at events from Germany (wire Düsseldorf) to Australia. He served as a moderator on numerous occasions for WAI technical programs, and was honored with WAI’s Donnellan Memorial Award in 2004. “Scott was a presence wherever Scott S. Higgins he went,” observed Dave Richards, RichardsApex, who as WAI’s president in 2003 spent a lot of time with him on the executive committee. “Scott ‘Bubba’ Higgins will truly be missed by the Wire Association family of employees, volunteers and members.” He said that Scott epitomized the true definition of a loyal and dedicated volunteer leader. Sandy May, who served as interim executive director of WAI from 1999-2000, said that Scott was an essential resource to him. “When I took over headquarters, and even before, Scott was my biggest supporter. I couldn’t have done it without him.” “Scott was a special resource that contributed to the Association over the span of 20 years. We will miss his ideas, support, and friendship,” said WAI Executive Director Steve Fetteroll. Beyond his official activities, Higgins was involved in the nitty-gritty work. He helped rewrite the chapter formation manual, revise the WAI Bylaws and work procedures, and update the interview process for prospective WAI employees as well as provide substantial input for WAI’s technical programs, for which he also served as a moderator. He was active behind the scenes, making fre-

DECEMBER 2010 | 27

PEOPLE

will take on the role of oil & gas market director. He has more than 33 years of sales management experience and a deep knowledge of the industry. He will lead all marketing endeavors in this key strategic market, with particular focus on the Middle East and the Pacific Rim regions. Blake Chandler, who joined the company six years ago, will lead global mining efforts. He has become an expert in the surface and underground mining markets around the world and has developed new opportunities throughout Asia for the company. Prior to joining the company, he had 14 years of international industrial sales experience. Richard Humiston, who has served in various sales management roles with the company since 1986, has assisted

PEOPLE

OBITUARIES ...

(contâ&#x20AC;&#x2122;d.)

quent phone calls and personal visits to encourage others to take part in WAI activities. He is survived by his parents, A.S. and Margaret Hodge Higgins; a daughter, Jessica Higgins; a brother, Shaun Higgins, and his wife, Lori; and his longtime companion, Robin Mason.

In lieu of flowers, contributions in his memory may be made to The Wire Foundation, Inc., for the Jessica Higgins Scholarship Fund, C/O Wire Association International (WAI), 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437.

Petar Erdeljan, an industry veteran for three decades, died Sept. 21, 2010, in Victoria Hospital in London, Ontario, Canada, at age 70. He was born in Kikinda, Yugoslavia, and attained his higher education at Leicester School of Technology and Commerce in the U.K.; The Academy of Commerce in Belgrade, Yugoslavia; and the University of Subotica in Yugoslavia. In 1968, after completiing his military duties in Yugoslavia, he started work with Wogau Engineering, a U.K.-based agency that represented companies that sold equipment to the Petar Erdeljan

Soviet Union and Eastern Bloc companies. His linguistic talents led him to represent and then be employed by the General Engineering (Radcliffe) Co. Ltd. group of companies, which included Trafalgar Engineering, with responsibilities for the Eastern Bloc countries. He worked in that position for more than 20 years. In March 2010, he joined Roteq Machinery, Concord, Ontario, as area sales manager, and he was a full-time employee at the time of his death. Many of his years in the industry were spent conducting business in Eastern Europe and the Far East. A member of the Wire Association International, he was highly respected in the industry and known for possessing an easy charm. He is survived by his son, Dr. Petar Erdeljan, and daughter-in-law, Dr. Meivys Erdeljan, and his brother, Lazar. â&#x2013;

28 | WIRE JOURNAL INTERNATIONAL

FIBER WATCH

FIBER WATCH Prysmian reports fiber milestone, activity at Russia production plant

New Zealand government plans to pay for education broadband

Prysmian Cables & Systems reports that it has attained a significant milestone in Russia, where its latest project for its VertiCasa™ FTTH cable system has driven total deliveries in the country past the 1000 cable kilometer mark. A press release noted that Russia “is currently playing a leading role in the adoption of Fibre to the Home/ Building (FTTH/B).” It cited that data from the FTTH Council Europe shows that more Russian subscribers were connected to fiber than in any other European country during the second half of 2009. “In fact, according to the Council, Russia is the leading European country among the G20 economies in terms of subscriber fiber penetration.” The release observed that many Russians live in cities, and that the company has been busy meeting orders and training local installation teams to deploy the systems. It noted that Prysmian recently established its first production facility in the country, in the city of Ribinsk, where it manufactures energy cables.

New Zealand officials have pledged that the government will provide the necessary fiber infrastructure so schools will be able to access the ultra-fast broadband network (UFB). The National Business Review reports that Education Minister Anne Tolley and Communications and Information Technology Minister Steven Joyce have announced that the logistics will be handled, from the street to school buildings, so schools will have broadband access. The story noted that schools had been required to contribute to the cost of connecting. It cited Steve Fuller, chief executive of Christchurch fiber operator Enable Networks, as saying that the government’s decision was an “excellent outcome,” one that would make it possible for even smaller schools to get fiber. Tolley described the government’s commitment as “an important step in ensuring equitable access” to the benefits of ultra-fast broadband. The government’s goal, the article said, is to see ultrafast broadband available to 97% of schools within six years. The remaining 3% of schools will be served by wireless or satellite technology, it said. The cost for project is estimated at $1.35 billion to $1.5 billion.

Nokia Siemens test shows lots of life in last leg of plain old copper At this year’s Broadband World Forum event in Paris, Nokia Siemens Networks reports the success of its Phantom DSL technology, which it said was able to transmit 825 Mbps over 400 meters of copper wire. A press release said that the technology, which also sustained 750 Mbps over 500 meters of copper wire, “holds the promise of delivering broadband Internet to homes using existing copper wire infrastructure, rather than having to lay new fiber or cable-based connections.” Eduard Scheiterer, head of broadband access business lines for Nokia Siemens Networks, observed in the release that laying optical fiber to the home is a definite solution for long-term bandwidth requirements, but the “innovative use of technologies such as phantom circuits helps operators provide efficient last-mile connectivity with existing copper wires.” He noted that current peak DSL offerings max out at about 40 Mbps, and in the U.S. it’s not unusual for residential customers to see DSL service peak at 1.5 Mbps or lower. “Overall, Nokia Siemens estimates the Phantom DSL technology could lead to bandwidth increases of 50 to 75 percent over existing bonded copper lines,” he said. 30 | WIRE JOURNAL INTERNATIONAL

Fiber rollout in Iraq leads to Internet deal for Russian business Russian national operator Rostelecom plans to extend its internet infrastructure to Iraq, in a deal that was made possible by a Russia-Iran-Azerbaijan venture to improve fiber connectivity in the Caspian Sea region that was launched late last year. TeleGeography reports that Rostelecom signed an agreement with Iraqi company IQ Network, and will partner Iran’s Telecommunication Infrastructure Company (TIC) and Azerbaijan’s Delta Telecom in the project. The planned system is expected to handle Europe-Asia voice and data transmission as part of a wider program to improve internet service delivery in the Caspian region. If the pilot project is successful, Rostelecom plans to substantially increase the volume of internet traffic transferred through the region, it said. The article said that the plans to improve fiber connectivity include Russian long-distance operator Synterra and Azerbaijan’s AzTelekom, which formed a joint venture with private company Iran Mobin, using the TIC backbone to connect to a new regional fiber ring. “Russian and Iranian state and company officials signed joint venture documents, whilst TIC also signed an agreement with Rostelecom, to share international transmission links, which it is assumed led to the newly announced rollout in Iraq,” it said. ■

*2,1*)253(5)(&7,21 www.eurollsgroup.com

Straightening machines

Multiwire drawing machines

Cold rolling lines with cassettes

PC strand machines

Spooling equipment

WIRE MACHINERY DIVISION

FASTENER UPDATE

FASTENER UPDATE Organizers report that fastener event had very good results in Las Vegas Organizers of the National Industrial Fastener Show reported a very good showing by attendees at its Nov. 8-10 event at the Mandalay Bay Convention Center in Las Vegas, Nevada. A press release said that approximately 4,096 people registered, including 1,033 distributors, 329 manufacturers, 151 independent sales reps, 113 importers, 63 manufacturers’ reps and hundreds of others who visited the 3-day expo and conference. The registered attendee base included people from 35 countries, it said. “We have received a number of very positive comments from exhibitors and show visitors alike who are saying the show was busy and productive,” said Show Manager Susan Hurley. “We are now looking ahead to 2011, when just about everything about our 31-year old event will be new. The October 19-21 dates are much earlier, keeping us well in advance of and avoiding any conflict with STAFDA. The earlier dates will also afford our exhibitors more time to follow up on show-generated leads before the holidays.” In addition to earlier time, the 2011 expo will be at a new location, with a new name and features, the release said. “Our new location at the Sands Expo & Convention Center will put us in the very heart of the Las Vegas Strip and open up a variety of hotels with different price points ranging from luxury at the Venetian and Palazzo to economy at Harrah’s,” it said. The new name for the event will be the National Industrial Fastener & Mill Supply Expo, the release said. The new name reflects the addition of many multi-line distributor products such as abrasives, air tools, cutting tools, drills, hand tools, safety and plant maintenance supplies and more, it said. “Finally, our Machinery & Tooling section has been greatly expanded to accommodate more exhibitors and larger machinery,” said Jim Bannister & Mike McGuire, general partners. For more details, contact the National Industrial Fastener & Mill Supply Expo, tel. 614-895-1279, info@fastenershows.com, or go to the Expo web site at www.fastenershows.com.

Recovery seen well underway for Taiwan’s fastener industry Taiwan’s fastener industry has seen a solid resurgence, with annual output expected to return to the levels it enjoyed prior to the recession, reports CENS Publications. At the publication’s website (cens.com), it notes that statistics compiled by the Industry & Technology Intelligence Service (ITIS) show that the industry’s total output was worth NT$28.2 billion in the second quarter of 2010, up 17% from the first quarter and equal to more than 35% of last year’s annual total of NT$75.8 billion. 32 | WIRE JOURNAL INTERNATIONAL

Another encouraging sign is that the industry increased second-quarter exports to NT$25.5 billion, the story said. Exports, it noted, have grown steadily for four consecutive quarters, beginning when global economic prospects began looking somewhat better in the second half of last year. Breaking down the fastener production, the ITIS statistics show that, during the first five months of 2010, 35% of Taiwan-made fastener exports went to the U.S., 8% to Germany, 5% to Japan, and 4% each to The Netherlands and China. Collectively, those overseas markets accounted for more than half of such shipments, the report said. In terms of quantity, Taiwan’s exports to the U.S. increased 46% year-on-year during the second quarter but were still 18% less than the figure for the same period in 2008, the story said. While the U.S. figures were low, shipments to the EU shot up 80% and were nearly 20% higher than the same period in 2008, it said. ITIS attributed that growth to EU policy that included punitive tariffs on Chinese fasteners. In terms of imports, Taiwan’s were valued at around NT$900 million in the second quarter, about equal to the first quarter of 2010, with more than half (52%) coming from Japan, 15% from the U.S., 11% from China, 6% from Germany, and 3% from Vietnam. “This indicates, to some extent, that although Taiwan ranks among world’s top five fastener producers by output and has managed to go upmarket for years, the island still has to import top-end fasteners from advanced countries such as Japan,” it said. “ITIS believes that 2010 will mark the beginning of years of continuous growth for Taiwan’s fastener industry, especially in view of the International Monetary Fund’s July prediction that global GDP growth will reach 4.6% this year and 4.3% in 2011,” the report said.

BE Aerospace to buy fastener distribution business from Satair Satair AS, a Danish aerospace firm, announced that it is selling its OEM fastener activities to U.S.-based B/E Aerospace for $162 million. AP reports that Satair’s fastener business distributes products to European and Asia Pacific aerospace manufacturers and their suppliers. The deal, it said, will expand BE Aerospace’s product offerings in its consumables business. Those products will now include expanded metric fasteners, adhesive fasteners, latches, cables, struts, tooling and lighting products. Demark.dk, the official website of Demark, reported that, “Due to consolidation in the segment in recent years and falling (OEM) revenue streams, the company’s board decided that a sale of the unit and its employees was the best decision for both Satair and the unit itself.” Satair has operations across Europe, North America, the Middle East and the Far East. ■

WAI

NEWS

It was not quite business at usual for the WAI, but its second series of business meetings, which used to be called “Reconvene,” proved to be an efficient forum for planning the Association’s direction. Instead of volunteers on WAI committees and boards meeting at one site, often the location for a future Association trade show, meetings were held based on what timeframes worked best for the participants. The idea was to make it simpler for attendees to participate, although there is still a desire to hold face-to-face meetings, if it is considered feasible. The meeting began on a sad note, with a moment of silence in remembrance of WAI Past President Scott Higgins, who died at age 50. See p. 27. One of the key decisions made at the “on-line” meeting, which was run from WAI headquarters, was that the board of directors voted to hold Wire Expo in Dallas in 2012. Some sites are under consideration, but the location itself was well regarded, especially as board member Gary Spence of Encore Wire said that the company would host a plant tour of its facility in McKinney. WAI Sales Director Bob Xeller reported to the board that booth sales for Interwire 2011in Atlanta are going well, and that the goal of 100,000 sq ft of net floor space should be reached by year’s end. He noted that there are about 30 new exhibitors. The board also voted to return to Atlanta in 2013, a decision that WAI The board also voted President Dane Armendariz to return to Atlanta in described as 2013, a decision that “a smart one at this time.” WAI President Dane The American Wire Armendariz described Producers as “a smart one at Association, which co-located with this time.” Wire Expo earlier this year in Milwaukee, has committed to co-locating at Interwire 2011, and has indicated that it is willing to co-locate at the 2012 event and possibly in 2013. WAI Executive Director Steve Fetteroll reported that the Association will work with two other industry organizations in Brazil to take part in an event in Sao Paulo in 2011. He said that the Association will also support a conference being produced by IWMA in 2011 in Düsseldorf. During the meeting, WAI Director of Education Marc Murray reported that the WAI’s webinar programs have continued to do well. He said that a total of 11 have been

WAI NEWS

November business meetings cover a wide range of Association interests

An update on WAI’s webinar programs was one of many topics discussed during the Association’s recent business meetings. held so far, and that feedback from participants has been good. Attendance has been as high as 90, including some companies that had more than 10 employees sit in at a single webinar, which are free to WAI members. “This has proven to be a very good membership benefit,” he said. The board of directors was also updated on the Association’s website, which has been undergoing considerable change and will go live in mid-2011. WAI Director of Marketing & Corporate Communications Janice E. Swindells outlined some of the improvements that are being made for the new website, which will be launched next year. In terms of current activity, WAI Manager of Information Technology Chuck Szymaszek said that the forums at wirenet.org have now exceeded a quarter-million hits, and that there is increasing demand for banner ads on the site. Fetteroll also updated the board on WIRE BULLETIN, a publication published by the Association’s India subsidiary, which has increased both in size and circulation, and was expected to get a big boost from being showcased at the Wire India trade show in November. He added that the subsidiary, which has become financially stronger, continues to reach more readers and draw more advertisers who want to reach the flourishing market. The board was given an update on the Continuous Casting Forum (see p. 36-37), which is a very ambitious program at Interwire 2011 that is led by Encore Wire’s Gary Spence. “There is a lot of good stuff going on,” Armendariz observed. In other meetings, the WAI’s Member Relations Committee met by webinar and conference call on Nov. 2. Among the strategic discussion items were a report of the growth task force initiatives; the webinar program and archive offerings, which are free to members; social netDECEMBER 2010 | 33

WAI NEWS

WAI HOW TO How can I find WAI on social networks: WAI Forums, LinkedIn, Facebook? Technical | Join the WAI wirenet.org Forums Wirenet.org Forums are an avenue for the free exchange of technical information among members of the wire and cable industry where manufacturing issues are discussed on general, ferrous, nonferrous, electrical, and fiber optic topics. Start or join a technical discussion using the following steps. 1. Go to www.wirenet.org/forum/register.cfm – Click “Agree.” 2. To create an account – create a user name; enter your email address; create a password – click the “Submit my Information” button.

3. View the current discussions in the discussion pane. You may search previous discussion topics by keyword. After registering you can view the profiles of the contributors to the discussions. Interaction on the wirenet.org forum pages is a practical and timely way to share information with like-minded colleagues around the world.

Educational | Join WAI’s Education Center Group on LinkedIn WAI’s LinkedIn group provides a forum for authors, instructors, attendees, and anyone else who’s interested, to discuss WAI’s educational programs. You must have an account (which you can create at www.linkedin.com) to access the group discussion. Find WAI’s Educatin Center Group 1. Locate the search bar in the upper right-hand corner of any LinkedIn page. 2. Select “Groups” from the drop-down menu as your search category, and type in “WAI Education Center.” 3. Once you see the group summary, click on the gold “Join Group” bar to sign up. 4. The group page automatically opens to a “Discussions” tab to list the most recent and most popular topics. The group is open to anyone using LinkedIn; it is not limited to WAI members. Like, Comment, and Share in Discussions When your mouse hovers over a given discussion, icons

appear at the bottom of the entry including “Like,” “Comment,” and “Share.” 1. Like – Click the icon to like/agree with the information. 2. Post a Comment – Click on the word bubble icon for “Comment” – Type your comment and click the “Share” button to post comments 3. Starting a New Discussion – is just like sending an e-mail – Type a subject line and the text of your message into the blank boxes at the top of the list of discussions; click the “Share” button at the bottom to post your new discussion In addition to the “Discussions” tab, LinkedIn offers other tools like a listing of all group members, and a “More” tab that allows you to view subgroups. The WAI Education Center has added smaller discussion groups dedicated to specific programs such as webinars. Be sure to check back as new groups are added that may interest you.

Social | Join WAI on Facebook Find Us on Facebook & “Like” Us 1. Create an account by going to www.facebook.com; provide your first name, last name, email address, sex, birthday, and create a password 2. In the search box, type in: The Wire Association International, Inc. 3. Go to the page by clicking on the search result for The Wire Association International, Inc. 4. “Like” us by clicking the “Like” button next to the page name How to Post a Comment on the Wall or Event 1. On the Wall – Click in the box that says “Write something…” and share your thoughts by clicking the “Share” button

34 | WIRE JOURNAL INTERNATIONAL

2. On an Event – Click on the “Events” tab, to view the list of WAI upcoming events – Click on the individual event and post a comment by clicking in the box that says “Write something…” and share your thoughts by clicking the “Share” button Starting a Discussion | Replying to a Discussion 1. Once on The Wire Association International, Inc.’s page, click the “Discussion” tab 2. Click the “Start New Topic” button 3. Enter a topic name 4. Type in the “Post” box 5. Click the “Post New Topic” button 6. To Reply to a Discussion – Type in the “Reply” box and click the “Post reply” button.

segment-specific tracks in the afternoon. They will reassemble the next day for two more general topics in the morning. The committee also approved a slate of six Production Solutions on-floor demonstrations and one all-day workshop on productivity. Other topics discussed included WAI’s growing webinar program and updates to WAI technical handbooks and reference materials. The Exhibition Planning Committee (EPC) met on Nov. 4 via teleconference. Two important agenda items discussed and recommended were: that Interwire will remain in Atlanta in 2013, confirming WAI’s plans to return to Atlanta for a two-cycle venue beginning in 2011. Discussion followed as to venues for 2015 and beyond but were tabled. A second item was a recommendation to pursue Dallas as the venue for Wire Expo 2012. WAI staff will pursue a request for bids from the city and inform the EPC of possible choices. There was also some discussion to venues beyond 2012. Both of those items were voted on and approved as described above. The WAI’s operating budget was approved by the board of directors. The January WJI will present the Association’s officials for 2011 as well as the winners of the Mordica Memorial Award and the Donnellan Memorial Award. ■

DECEMBER 2010 | 35

WAI NEWS

working options including WAI Forums, LinkedIn and Facebook; and the introduction of a new testimonial advertising campaign in which members are highlighted and encouraged to participate. The Education Committee met on Nov. 3, focusing on finalizing the educational programming at Interwire A second item was 2011. The group a recommendation made some adjustments to the to pursue Dallas as schedule for the the venue for Wire Fundamentals of Wire ManuExpo 2012. WAI staff facturing course, will pursue a request but maintained the for bids from the city full slate of topics that includes four and inform the EPC general topics, two of possible choices. ferrous, and two nonferrous/ electrical. The new schedule calls for a full day of courses on Monday, May 2, the day before the opening of Interwire. Attendees will have two general courses in the morning, then split into

NETWORKING TECHNICAL & OPERATIONAL PRESENTATIONS WORKSHOPS

G L O B A L

CONTINUOUS

CASTING —

F O R U M

—

WAI’s new forum raises the bar on copper continuous casting May 2-5, 2011 | Atlanta, Georgia, USA Information will flow. It’s hot. Molten hot. It’s pervasive. And it’s a new forum for copper continuous casting practitioners in which every major process is well represented: SCR | Contirod | Properzi | Upcast | ESSEX It’s a total immersion in a think tank where industry gurus will greet you. Experts will enlighten you. Legends will lead you. It’s high-viscosity learning that’ll stick with you because you have to be present to access it. Given its fluid format, no matter your level, you’ll leave with a rock solid understanding of what’s new and innovative in continuous casting today. Here. There. And everywhere copper bar and rod is processed—worldwide. It’s a big idea that’s much more than theory. One forum—over four days— at Interwire 2011. It’s convenient. Comprehensive. Compulsory. It’s engineered for you. Go with the flow and learn more 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

U P D A T E :

T E C H N I C A L

P A P E R S

Go beyond bar graphs. See past pie charts. Access the best in copper continuous casting. USER NAME: PROCESS IMPROVEMENT PASSWORD: INNOVATION It’s true that the combined experience of the leaders at the Global Continuous Casting Forum is off the charts. With years of research and practice in the field, these folks know more about copper continuous casting than most will ever learn. Until May 2010, that is, when they’ll change how much you already know about copper continuous casting—whether you are a competent practitioner, a supplier, or are new to the industry—because there’s a lot of new information to share. From bag house fires to scrap melting; and furnace burner combustion to surface oxide testing; these technical topics are part of a larger picture covering operational presentations, expert discussion panels, and workshops. KEYWORD: NETWORKING. No more casting about for answers to your most pressing questions. When you interact with the world’s most distinguished experts in copper continuous casting, you’re sure to become one of them. Technically speaking about continuous copper casting:

WEDNESDAY, MAY 4

TECHNICAL PAPER EXPERTS

“Investigation into Baghouse Fires,” by Gary L. Spence, Encore Wire Corporation, USA “Maerz Direct-to-Wire® Technology – Optimized FRHC Copper Production,” by Timm Lux and Joerg Koehlhofer, Andritz Maerz GmbH, Germany Spence

Lux

Garcia

“Scrap Melting Technology,” by Miquel Garcia, La Farga Lacambra SA, Spain “Continuous Casting: A Matter of Continuous Innovation,” by Juan Carlos Bodington, Upcast OY, Finland “Furnace Burner Combustion Ratios and Influence on Dissolved Oxygen,” by John Hugens, Fives North American Combustion Inc., USA

Bodington

Hugens

Baker

THURSDAY, MAY 5 “New Improvements for Surface Oxide Testing of Copper Rod,” by Gil Baker and Tim Stahlhut, Confident Instruments Inc., and Dr. Horace Pops, Horace Pops Consulting Inc., USA

Stahlhut

Pops

CHAPTER CORNER

CHAPTER CORNER Western Chapter gets glorious day for its annual golf outing

New England Chapter’s annual meeting will be held on January 26

The formula is simple: the Western Chapter had a good golf course, helpful staff and decent weather, all of which made for a thoroughly enjoyable setting for the chapter’s 10th Annual Wild West Shootout, which was held at the Las Verdes Golf Course in Rancho Palos Verdes, California. “It was another wonderful day of golf and sunshine along the ocean, with great views of Catalina Island on most holes,” said event organizer Michael Howard, Coast Wire. “For a day where I left the house with my raincoat and umbrella it turned out that I just needed my sunscreen and as I looked out over the crowd at the awards dinner so did everyone else.” The winning team, golfing friends of Michael Weiss, Whitmor Plastic Wire, was the foursome of John Gunson, Todd Mayne, Darrell Belisle and John Van Diepen, which collectively shot 10 under par. They were Enjoying a great day is the team, from tied with the l-r, of Gordon Gunn, Tony Sanders and team of John Eric Maks. Stevens and Derrick Stevens, both of Engineered Machinery, Rod Ambrose of Cinc and Ken Rea of Nevada Bob’s Golf, but were declared the winners based on card comparison. Third place went to Michael Weiss and Brian Bouvier. Howard said that 32 golfers played, with five more people joining for dinner. He also thanked the sponsors for the event, which included: Commission Brokers, Lloyd & Bouvier and Whitmor/Wirenetics (19th Hole Reception), James Monroe Wire & Cable and Whitmor/Wirenetics (long drive holes) and James Monroe Wire & Cable (most accurate drive). Corporate hole sponsors included: Beta LaserMike, Fred Camarena Inc., Champlain Cable, Chromatics, Engineered Machinery, Gem Gravure, Harbour Industries, Leoni Wire, James Monroe Wire & Cable, Neptco Tapes, Q-S Technologies, Silver State Wire & Cable, Thermax and Whitmor/Wirenetics. The chapter is scheduled to return to the Las Verdes Golf Course for its 11th Annual Wild West Shootout on Monday, October 24, 2011.

The New England Chapter will hold its 17th annual meeting on Wednesday, January 26, at the Mohegan Sun Resort Conference Center in Uncasville, Connecticut, USA. The event, which will see the introduction of the chapter’s new officers for 2011, starts with a reception at 5 pm, followed by dinner. The event will also include a guest speaker.

38 | WIRE JOURNAL INTERNATIONAL

At its 2010 annual meeting, the New England Chapter heard from motivational speaker Alden Davis. to be announced. Once details are finalized they will be uploaded to the New England Chapter’s page at www.wirenet.org. For more details, contact WAI’s Anna Bzowski, tel. 203453-2777, ext. 126, abzowski@wirenet.org.

Still time to register for wiredrawing seminar supported by Poland Chapter Poland Chapter President Jan Pilarczyk reports that now is a good time to register for the upcoming wiredrawing seminar that the chapter once again is supporting. To date, nearly 50 technical papers have been received for the biennial event, which will be held once again at the ANTAŁÓWKA Hotel, on March 3-5, 2011, in Zakopane, Poland. The event will include tabletops, an opening reception and a gala dinner with folk music as well as special lectures presented by 2011 Schneider Memorial Award recipients Prof. Kazunari Yoshida, from Tokai University, Japan, and Eugeniusz Filipczyk, past president of Drumet, Poland. There will be presentations in four sessions (ferrous, nonferrous, electrical and special products) and a Poster Session. In addition to Poland, scheduled speakers come from Sweden, Spain, Japan, South Korea, U.S., Russia and the Czech Republic. For more details, including how to get a tabletop, go to the event website at www.konferencja.wip.pcz.pl. ■

I’ve met many influential leaders through WAI including a U.S. President. Q: Why did you join WAI? A: Because of its reputation as the leading organization for the wire and cable industry.

Q: What are the most valuable benefits you receive through WAI? A: I maintain contacts in the industry through networking and participating in trade shows like Interwire and Wire Expo, chapter events, and educational opportunities. My WAI committee work is a way to give back to the industry. Q: Why do you renew your membership? A: At this point, the WAI community seems like my extended family. It has provided me with the opportunity to meet many colleagues and stay informed.

Q: How did you get involved in the wire industry? A: My father was one of the original partners when Duncan M.

Mark Spencer Executive VP | W. Gillies Technologies Member Since: 1981

Meet Mark Spencer. One of WAI’s worldwide members. One compelling story. Leaders of all kinds comprise the spotlight of WAI’s membership community. And a glance at Mark Spencer’s personal profile reveals key themes familiar to all extraordinary personalities namely:

Gillies Co., Inc. was formed in 1955, the year I was born. I entered the family business immediately after college. So I have been involved in the industry, in some shape or form my entire life.

Q: Who was your mentor? A: My father. At age 13 he had to quit school to support his family. He served in World War II, built his house by hand after the war, raised his own family, and became a very successful businessman. Through his many hardships he maintained true balance between business, family, and pleasure. He was a real role model and I appreciate everything that he did for me. He was my very best friend.

Q: What is your greatest accomplishment? A: My greatest accomplishment is still to come.

Hard Work | Reputable Practices | Honoring History | Staying Informed | Giving Back | Involvement Listen in on Mark’s story to find your common ground. And when you meet Mark in person— or through WAI’s Facebook page—be sure to ask about his presidential introduction. Since he’s

Q: What would you be doing if you hadn’t become involved in the wire industry? A: I would have been a biologist or involved in medical research.

been making an impressive mark with committee

Q: What do your co-workers say about you? A: I hope good things. Some think that I work too hard and need

involvement, who knows, you may just be meeting

to delegate more.

a future president.

MNEMONIC TIP: MARK SPENCER. MARK SELLS MARKING EQUIPMENT.

Q: Who is the most famous person you’ve met? A: One of my favorite memories from Interwire involved a chance encounter with former President Carter, a close friend of the family, outside of the convention center in Atlanta.

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FEATURE Keynote speaker Geoffrey Bogart talks to attendees about the importance of the U.S. and Mexico relationship.

ITC report: success on more than 1 level By Mark Marselli, editor-in-chief The good news is that the WAI’s return to Monterrey, Mexico, for the 2010 staging of its International Technical Conference proved to be successful. The even better news is that, while the final

Event Organizer Antonio Ayala, Latin America Sales Manager, Canterbury/Genca (CanGen), welcomes attendees to the conference.

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attendee numbers of 215 did not quite match those of the 2008 staging—which had about 250—the 2010 event had to contend with two concerns the prior event did not. Fortunately, all went well. “I am happy that we had so many visitors to the ITC in Monterrey from many coun-

Sergio Montes, Viakable, served as both a moderator and a technical paper presenter.

Geoffrey Bogart, the U.S. Commerce Department’s principal commercial officer at its consulate office based in Monterrey, Mexico, had a message for the attendees at the WAI’s International Technical Conference.

Discussions at the Esteves tabletop display. Attendees had multiple opportunities over two days to meet with company representatives. tries,” said Antonio Ayala, Canterbury/Genca, who spearheaded the efforts for the event, which he had also led in 2008. The former WAI President said that he was worried that overall attendance and company participation in the tabletops could be reduced because of the considerable bad publicity about increasing violence in Mexico, including Monterrey, as well as the stunning amount of destruction to the region caused by Hurricane Alex on July 1. Earlier this year there were many reports about the violence, but relatively little was heard outside the country about the significant infrastructure damage caused by the hurricane. Despite those two challenges, the results were quite positive, Ayala declared, “There was attendance by many companies, including a very large group from Conductores Monterrey. The show was good, the papers were of good quality, the plant tour of Delphi was really first class and the Mexican food was excellent. In general, the ITC went as planned, and I look forward to having

More than 20 technical presentations, ferrous and nonferrous, were offered to attendees.

Geoffrey Bogart, principal commercial officer, U.S. Consulate Monterrey. “If you remember anything from this speech, it is that the integration of the U.S. and Mexican economies is a driving force in our relationship, that there are great business opportunities in both markets, that good news doesn’t sell many newspapers, and that when times are tough, the tough get going,” he said in his opening comments. Bogart highlighted the importance of trade between the two countries, He noted that Mexico is the third largest trading partner of the U.S. and second for exports. He also praised the contributions of NAFTA, which he said has helped both

Trade between the U.S. and Mexico represents significant activity for both countries. Chart courtesy of U.S. Department of Commerce. DECEMBER 2010 | 41

FEATURE

Keynote speaker: the relationship between the U.S. and Mexico offers value to both

FEATURE

countries in terms of having better access to each other’s goods/services/markets. NAFTA, he said, represents the world’s largest free trade area, with 442.4 million people and $15.4 trillion in gross domestic product. Tariffs on U.S. exports to Mexico were eliminated as of 2008, and the rules of trade have been clarified and simplified, Bogart said. Further, NAFTA has provided protection for Intellectual Property Rights (IPR) and investment as well as a mechanism for resolving disputes, he said. NAFTA, which was signed into law by President Clinton on Dec. 17, 1993, and went into effect on January 1, 1994, has continued to be a source of controversy for some, but Bogart focused on the results that have stemmed from it. The U.S.-Mexico trade has grown faster than the infrastructure that handles it, he declared, citing a 465% increase from 1993, when it was $88 billion, to $409 billion in 2008. The latest numbers support the continued progress, Bogart said. From January through August in 2010, U.S. exports to Mexico were $104 billion while U.S. imports from Mexico were $149 billion. “Trade in 2010 has really picked up, and will no doubt pass 2009 by a significant margin,” he said, adding that 2011 “could be a different story.” The current security conditions in certain parts of Mexico do create challenges for private industry and attraction of new business, with border cities particularly vulnerable, Bogart said. However, international businesses still want to invest in Mexico, and in particular, Monterrey, which he noted is a strategic market, and a major producer of items for both manufacturing as well as consumers. Some of those highlights are listed below.

another such event in Mexico. The 2010 ITC, co-sponsored by Mexican wire association Asociación Nacional de Transformadores de Acero A.C. (ANTAAC), featured some 20 technical paper presentations, the tabletop exhibits (Suppliers Market), a reception and a plant tour of Delphi Guadalupe III facility. The technical presentations, both ferrous and nonferrous, were made over two days, with attendees able to visit the Suppliers Market during breaks as well as during a reception held the first night in the tabletop area. Comments from attendees were quite positive, with one summing up the collective experience of what was offered at the ITC. “I would emphasize the quality of the material presented and mastery of the presentations by the exhibitors,” wrote Vidal Valdes, process engineer, Sadosa/Esdtico, S.A. de C.V. He noted that through the technical sessions, the welcome dinner and the round table, “I was able to increase my networking with suppliers; share best business practices with my colleagues; learn about other ways

Monterrey manufacturing highlights

At the tabletop displays (l-r) are: Hans Jaekel, Rosendahl; Jose Zamudio, Conductores Monterrey; and Victor Muñiz and Ethem Edas, both of Beta LaserMike.

• 75% of Mexico’s glass containers • 60% of Mexico’s cement production • 60% of Mexico’s synthetic fibers production • 60% of Mexico’s household appliances • 50% of Mexico’s beer production • 50% of Mexico’s ceramics production • 45% of Mexico’s automotive parts • 40% of Mexico’s production of basic steel

The growing Hispanic market in the U.S., which includes some 45 million people and an estimated S$1 trillion in purchasing power, continues to be a great market for Mexican exporters, Bogart said. Newspapers don’t report good news, but there is much good news to be found, he said. For instance, he said, Mexican investment in the U.S. has led to the creation of some 60,000 jobs. Despite the challenges, the big picture of what NAFTA has meant and the value of the continued relations between the two countries should not be taken for granted, he said.

42 | WIRE JOURNAL INTERNATIONAL

of addressing the issues of quality, cost, productivity, service, environment and ecology; and (hear more) about issues such as energy efficiency utilization, noise reduction, water pollution, reducing usage of toxic raw materials and increasing consumption of (renewable) energy and raw material sources.” Companies that took part in the tabletops also reported largely favorable experiences. “I liked the mix of attendees at the conference,” said Joe Memmott, US Synthetic Wire Die. “They were very genuine in looking for solutions to challenges they face. The proximity to several large drawing mills made the conference that much more valuable.” “Our reasons for attending this show (were twofold): we want to expand our customer base in Mexico, and we have two big customers in Monterrey,” said Dennis Swing, Lear Engineering. “The scheduling was good,” said Tino Corral, Fort Wayne Wire Die, Inc. “I thought that the cocktail hour in

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FEATURE Attendees at the tour of the Delph Guadalupe III facility, led by Plant Manager Quirino Anaya Gutierrez (center) got to see how automotive harnesses are processed. the exhibit room was a good idea, as was dinner at the hotel.” “Sikora has a large number of good customers in Mexico, and we will always support any program there,” said Jeff Swinchatt, Sikora International Corp. “I thought the event was well worth the time and money,” said Mark MacKimm, Rainbow Rubber & Plastics Inc. “The lunches/dinner allow for great networking opportunities.” “We would be there (for a return to Monterrey),” said Robert Wild, Niehoff Endex North America. “I would sign up again for Monterrey,” said Kirk Prosser, Rockford Manufacturing Group Inc./Fastener

Attendees enjoyed lunch at the Crowne Plaza Hotel.

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Engineers & Lewis Machine. “The Crowne Plaza Hotel as a venue for this year’s ITC (was) a perfect location,” said Mark Patrizzia, Parkway Kew. “Condat would attend a 3rd edition in Monterrey,” said Clément Barrat, Latin America, Condat. One of the highlights of the ITC was the plant tour, on Wednesday, October 20, of the Ensamble de Cables y Componentes plant, Guadalupe III, which is part of the Delphi Packard Electrical/Electronic Architecture division. Attendees got to see just how labor-intensive production can be at the Nuevo Leon plant, where the company manufactures components and systems for the automotive industry. Its main product is automotive harnesses for customers such as Ford, Hyundai and Kia. Plant Manager Quirino Anaya Gutierrez led the group around the plant, which started operations in 1999. The ISO-9000 and ISO 14001-registered plant has been a recipient of the Q1 Ford Award and the Industria Limpia Award, among others. The plant has some 1,300 employees, and attendees got to see how vital those staffers are because of the degree that the process requires hands-on work. In 2011, the WAI plans to support a technical conference being produced by IWMA in Düsseldorf. More details will be provided in future issues. ■

FEATURE

Industry trends — the recovery T

he wire and cable industry in mature western economies has long been viewed

as a cyclical entity, with up and down periods that are viewed as, if not pre-

dictable, at least inevitable. That’s not the case for developing markets, where it could be decades before supply catches up with demand, but the last two years have been especially tough on many levels for mature economies. There is hope that the industry downturn—further bottomed out by factors from the banking and credit woes to high unemployment and a weak housing sector—is easing some, but where from here?

Are better times here or still ahead? It may not seem so to a lot of cable manufacturers, but Philip Radbourne, a director at U.K.-based Integer Research, believes the global outlook for wire and cable is better, if not ideal. At an October 6 Open House at Niehoff Endex North America, he told guests that the wire and cable industry is still recovering from the disastrous fourth quarter of 2008, which saw volume drop 12%. “We don’t normally see this kind of shock,” he said, noting that what made this period different from past down cycles is that it was not limited to a sector, such as fiber optics, but largely across the board in all sectors. “For some producers, it almost felt as if there was no business for six months from late 2008,” he declared. “Right now it might not seem like we’re recovering, but it’s in that phase,” he said, citing several indexes that point to positive things happening. See Fig. 1. Looking at the North American market, Radbourne said that the wire and cable recovery continues, although it has been tough going for a number of factors, with sluggish employment a drag on progress. He said he does expect that investment in key areas in North America will recover, and with it the wire and cable industry. Some of the drivers, both on a North American and global level, will be renewable energy, which for the U.S. requires development of a “smart grid” that will be able to transfer power generated from wind farms and solar farms to where the energy is needed. Despite a recent federal okay for an offshore wind farm in Massachusetts, he said he does not view that as a key development as inland technology is

46 | WIRE JOURNAL INTERNATIONAL

Integer Research’s Philip Radbourne speaks to guests at the Niehoff Endex North America Open House. more practical and cost-effective. However power is generated, it will require a lot of extra-high-voltage cable, said Radbourne, citing investments by both Prysmian and ABB in that capacity. He also looks for more investment in RF coaxial cables, electric vehicle cable systems, bare overhead conductors and nuclear power cables, among others. Radbourne said that the price of copper price is a very good indicator of supply and demand for the copper cable industry. Asian and Middle Eastern demand in growth has absorbed the slack that emerged after the 2008 crisis in North America and Western Europe, which is why copper prices are back up where they are, he said. On a global level, Radbourne said that while China has

FEATURE Fig. 1. U.S. cable production and the Purchasing Managers Index (PMI) have both showed positive movement in 2010. firmly taken over leadership positions in wire and cable, the importance of domestic manufacturers there is only now being seen. He noted that the top 30 cable companies in the world in terms of 2009 revenues today include seven Chinese companies (Far East Holding Group, #12; Wanda Group, #16; Shanghai Shenghua, #19; Wuxi Jiangnan, #20; Xing Yue, #25; and HengTong, #28). Speaking later, Radbourne discussed other topics, including the challenge for cable manufacturers to be able to operate at an appropriate level of capacity utilization. He said that the goal for commodity products, such as building wire and enamelled wire, is to run at more than 80%, a level at which production should cover all direct costs and overheads and result in a net profit. For products with higher margins, such as EHV power cables, submarine power cable and products that require e-beam

technology for cross-linking, manufacturers can be profitable at 70%, he said. While China clearly has become the largest driver in most wire and cable categories (see Fig. 2.), a depressed U.S. still represents the world’s second largest cable market, a not insignificant chunk of business, Radbourne said. Looking forward, Western Europe is likely to be more challenged in the short to medium term, which may further press merger and consolidation activity in the sector, he said. Finally, asked about whether the current economic conditions represent significant change from prior low points, Radbourne observed that, to some degree, the wire and cable industry is following a classic pattern (see Fig. 3. in Table of Contents, p. 4). That said, it has been stretched by the sheer magnitude of other factors that have slowed the recovery/return to prosperity phase, he explained. To a degree, what happens from here depends on how governments respond, he said. “If governments cut spending, in the short run, there will be a fall in fixed investment in an economy, and this will cause cable demand to fall. However, if in the long run reduced government spending leads to increased private sector activity, and wealth creation, that should result in higher demand for wire and cable.” Based in the U.K., Integer Research provides research, data, analysis and consultancy services to global commodities markets that include wire and cable. Company Director Philip Radbourne can be contacted at philip.radbourne@integer-research.com, tel. 44-207-503-1265.

Fig. 2. The numbers show the importance of China to the world’s wire and cable industry. DECEMBER 2010 | 47

FEATURE

The U.S. recession is officially over: so, what does that mean now for industry? In an industry outlook in the Dec. 2008 issue of WJI, Brian Hirt, a business analyst for U.S.-based IEWC, concluded his report by writing, “In these times of trial, purge what is misallocated in your life and in your business, and prepare yourself for the economic recovery to come. Things will get worse before they get better, but they will get better.” What follows is his current outlook. As you may have heard, the recession that began in the U.S. in December of 2007 officially ended in June of 2009 as of September 20, 2010. Let me explain. The National Bureau of Economic Research (NBER), the Massachusetts-based organization with the traditional responsibility for marking the beginning and end of recessions in the U.S., released a statement in September explaining that the U.S. economy stopped declining and began to grow in June of last year. It took them more than a year to decide that the recession was over simply to be sure – economic data is often revised months after the initial release. If nothing else, it is an important reminder for the national psyche that the economy is indeed growing again. The end of the recession, however, does not indicate a return to normal. Reading the most recent data

available, the U.S. has recovered only 69% of the total loss in gross domestic product, and unemployment remains at 9.6%. More relevant than any official definition of the recession or its end is the current performance and future expectations for the wire and cable industry. As part of my regular monthly newsletter, Hot Wire, I recently conducted a survey of my readers which provided some interesting insights into where growth in the industry has occurred and where it is likely to occur in the future. My readership and survey respondents primarily includes individuals on the OEM side of wire and cable, with more than 50 individuals from wire and cable manufacturers, sub-assemblers and harness manufacturers, and equipment manufacturers weighing in. Most individuals reported a 2010 YTD growth rate of more than 20% for their company. Nearly one in five reported growth in excess of 40% between 2009 and 2010. Only eight respondents suggested that their company was flat or down for the current year. Compare that to the roughly 3% growth rate for the overall economy during the past year, and it’s clear that the recovery for manufacturers is better than average (though the downturn was worse). The bulk of the responses came from individuals who identified North America as their company’s primary customer base. For those companies who claimed a global customer base, 2010 growth rates were lower than those companies with a North American base. This trend

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highlights the stabilizing effect of a more geographically diversified customer base—surely it was the same global companies whose 2009 growth outpaced those based mostly on North America. Most of the respondents listed multiple industries for their markets served, but narrowing the list to companies involved in certain market verticals showed a few interesting trends. Companies selling into the off-highway, construction and agriculture equipment market reported the highest growth rates (on average) in 2010, while also citing some of the lowest expectations for 2011. Companies involved in the medical equipment industry reported the second highest growth rates for 2010, but still held better

FEATURE

than average expectations for 2011. Companies with customers in the military and aerospace market reported slightly below-average growth in 2010, with average expectations for their company in the coming year. Some of the lowest (but still growing) growth rates were reported by those companies involved in the mining, oil and gas, or construction industries—no surprise coming from the two industries most closely linked to the pre-recession bubble and the collapse that followed. Companies in the mining, oil and gas market were among the most optimistic about their company’s performance next year, while those companies exposed to the construction industry reported the lowest growth expectations for 2011. Examining each company’s role in the supply chain also revealed distinct trends for 2010 growth. As shown in the graph below, those companies doing sub-assembly and contract manufacturing work reported the highest growth rates of the bunch, while the OEMs reflected more modest growth rates. These growth rates suggest the impact of companies rebuilding inventories. Looking back at my 2009 survey, it was the sub-assemblers who reported a slight excess in inventories and the largest decline in business activity. Such meager conditions in 2009 have now set up the same group of companies up for faster growth in 2010 as their OEM cus-

Results of survey on outlook for business growth. Chart courtesy IEWC. tomers seek to satisfy new orders and rebuild inventories. Although the employment situation in most regions of the US is still rather weak, the survey suggests that the industry has already begun to add new jobs and appears poised to add even more next year. 42% of respondents said that their company has increased headcount and/or capacity in the last 12

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52 | WIRE JOURNAL INTERNATIONAL

months, while 52% expect their company to add to their ranks in the next 12 months. When asked about their own pulse on the economy and the probability of recession in the next 24 months, individuals gave a mix of responses. Fortunately, no one predicted an imminent recession, but almost half suggested that the probability of recession was greater than 40%. The most common response was a 20-40% chance of recession, while a third of respondents felt that a recession was most certainly not on the horizon. I didn’t take my own survey, but if I did, I also would have suggested a 0-20% chance of recession (if you pressed me further, I’d say 15%). Brian Hirt is a business analyst for U.S.-based IEWC, a U.S.-based global stocking supplier of wire, cable and wire management products as well as author of a monthly industry newsletter called Hot Wire®. He can be contacted at tel. 262-957-1118, bhirt@iewc.com.

2010 snapshot: wire rod rides the coattails of scrap, for better or worse Wire rod, an industry staple for steel wiredrawing manufacturers, is a significant cost factor. Below, Katie Memmel, the content manager and editor-in-chief of Prime magazine, published by SteelOrbis, comments on the current market. Like spotting animals or other objects in a nebulous tuft of clouds, much can be interpreted looking at pricing charts from years past. The trend for shredded scrap prices in 2009, for example, resembled a mountain range—dizzy high peaks and devastating low valleys. So far, 2010 has more closely resembled a roller coaster—less intense ups and downs, but still reflecting measurable volatility—and the steel products derived from shredded scrap, namely wire rod, have been beholden to its pricing whims. Instead of price fluctuations based on demand, 2010 has primarily seen wire rod prices based on scrap costs—a situation that not only makes many in the industry nervous, but can be partially blamed for the lack of confidence in the market. At the start of 2010, the seasonal shortage of scrap resulted, as it usually does, in higher raw material costs for wire rod mills. In early January, mills announced a sizeable $60/nt ($3.00 cwt.) price increase based primarily on scrap, and wire drawers and mesh-makers did not exactly respond with enthusiasm. Inventories were being kept purposefully low, and demand, which is usually sluggish in the winter, took a blow in February when intense storms crippled construction activity throughout much of the U.S. In fact, as of February 13, snow was on the ground in 49 out of 50 states (Hawaii being the obvious exception). Nevertheless, many looked forward to the upcoming spring season, when new construction activity on the horizon usually coincides with significant inventory

FEATURE

build-up. However, stockists seemed determined to wait until the spring thaw brought both increased availability of scrap and the resultant lower prices. Imagine how shocked they were in early March, when shredded scrap jumped $50/long ton and mills reacted with another $60/nt price increase. Because demand from the construction sector had not picked up yet, the automotive sector was still the primary source of significant demand. But the ramp-up of automaking in the aftermath of the “Cash for Clunkers” program began to wane in the first quarter, and demand levels overall began trending down. Meanwhile, scrap pricing’s upward momentum continued.

Price chart for wire rod, domestic and imports, as well as scrap steel. Chart courtesy of SteelOrbis. The faster spring approached, the faster wire rod customers realized that if they wanted to prepare inventory levels for the spring surge of construction activity, they would have to start paying what the mills were asking. By the end of March, spot prices inched closer to mill asking prices ($32-$33 cwt. and $33-$34 cwt. respectively), as buyers got off the fence amid loud proclamations in the industry that scrap was likely to keep rising throughout the summer. But the very next month, scrap pricing went sideways to everyone’s surprise, and wire rod buyers responded by pushing for deals with mills, who could no longer point to the virtual “scrap rocket” as justification for higher prices. Import activity followed a similar pattern in the first quarter, with rising export scrap prices in the U.S. affected Turkish mill offerings for wire rod to the U.S. In addition to higher raw material costs, Turkish mills boasted about sizzling construction activity in the Middle East. However, the hype turned out to be nothing more than a mirage—the illusion of actual demand combined with lower scrap prices overseas resulted in import offers tumbling down at the end of April and bottoming out in midJune. Many traders and other wire rod buyers took advantage of the situation while they could, but by the time import prices recovered later on in the summer, domestic prices had dropped as well. Imports were too expensive to gain much attention from U.S. buyers, who preferred to stick with domestic wire rod as long as the forecast for domestic prices remained unclear and lead times made imports too much of a gamble.

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DECEMBER 2010 | 53

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Back on the domestic front, spring came and went without the long-awaited improvement in construction activity. Wire rod purchases for the sole purpose of beating further price increases ground to a halt, and mills, now relying on actual end-use demand to drive their sales, found themselves in a precarious position. Construction demand wasn’t terrible, experiencing growth spurts week after week, but consistency remained the key to a sustained recovery in the steel industry; small spikes in demand may have excited the market temporarily, but what it really needed was slow, steady growth. Additionally, shredded scrap’s $40/lt decrease in May put pressure on mills to lower prices—they didn’t, deciding to instead keep prices level. At the time, mills were still operating at around 60-65 percent capacity, putting them in no posiKatie Memmel, SteelOrbis. tion to give up the gains they achieved with first-quarter price increases. Their efforts toward temporary stability were crushed in the next couple months, however, when shredded scrap dropped a meager $5/long ton in June followed by a hefty $40/lt in July. Spot prices had already started to slip, by about $0.50 cwt., before the July decrease was announced, so by the time mills decided on a $1.00 cwt. drop in transaction pricing, they took it off market prices of $31.50-$32.50 cwt. instead of the official range of $32.00-$33.00 cwt. that they had been holding onto for months. By the end of the summer, it became clear that the longawaited recovery in the steel industry was not panning out as many optimists predicted in the beginning of the year. Even healthier end-use markets for wire rod started to slip, with automotive sales waning and appliances suffering a post-rebate program slump. After the President of Whirlpool’s North American operation predicted that appliance demand would remain depressed for the remainder of the year (in a second quarter conference call), it was disheartening to many wire rod customers when August shredded scrap pricing jumped $32/lt, followed by another $28/lt increase in September. As expected, mills increased transaction pricing for wire rod, but unexpectedly, pricing for September deliveries varied among mills: Gerdau Ameristeel and Keystone announced a $1.50 cwt. increase, while Nucor boosted prices by $1.75 cwt. However, none of the mills found much acceptance to the new prices, and by the end of September, spot prices were still at pre-increase levels. Naturally, when shredded scrap dropped in October by $30/lt, mills responded by lowering offers, but not by the

DECEMBER 2010 | 55

FEATURE

full scrap decrease—domestic wire rod offers only dropped by about $1.00 cwt. Demand for wire rod remained neutral— not terrible, but not impressive—and buyers hoped that by not trying to absorb the full scrap decrease, mills were aiming for stability in prices to match the tenuous demand situation. Those hopes were dashed in November, when scrap pricing continued on its rollercoaster trend—increasing by $20/lt, followed quickly by mill announcements of comparable transaction price increases. Some mills, such as Keystone, even attempted to recoup some of the recent losses by raising prices for December deliveries by $1.25 cwt. Wire rod is both a staple and a challenge for the ferrous wire industry. If it wasn’t overwhelmingly clear before, it became painfully obvious that mills had one do not necessarily support another 750,000 annual tons of thing, and one thing only in mind when determining wire rod (Georgetown’s pre-shutdown production level), monthly prices: scrap. Demand for wire rod, which everybut on the other side of the coin, more competition in the one who doesn’t live in a cave knows is the most honest market could potentially have a tempering effect on the indicator of what prices should be, seemed to have no scrap-driven price rollercoaster. role in the decision-making process. Many wire rod buyTrade legislation will not likely influence the US wire ers wonder, and rightfully so, why mills are so quick to rod market much in 2011, considering that most trade add demand into the pricing equation when demand is up, action is directed at China, and China has been a spotty at but ignore it completely when it’s low. best source of imported wire rod. In fact, even including Even overseas wire rod markets seemed to understand an unusual spike of 9,964 metric tons shipped in July of this—when Turkish wire rod mills were paying more for this year, China has only accounted for approximately 0.9 scrap over the summer and early fall, they resisted raising percent of total U.S. wire rod imports in 2010, according their prices because they knew they wouldn’t be accepted to the U.S. Department of Commerce. Even when (the Turkish lira’s strength over the U.S. dollar had a part demand levels increase in the U.S., China will likely to play, as well). They knew that regardless of their raw remain on the sidelines (at least until they become more material situation, demand for imported wire rod in the “honest” in their pricing policies and/or discontinue their U.S. did not warrant price increases. Heck, demand for AD/CVD circumvention shenanigans). domestic wire rod in the US didn’t warrant price increasAlready, market forecasters predict healthy growth in es either, yet there they were. And with predictions of the steel industry as a whole by the end of 2011, but any another scrap increase in December already looming, optimism must be taken with a grain of salt. Economic there doesn’t seem to be any hope of reconciling the recoveries do not happen overnight, and part of the frusdemand-price disparity anytime this year. tration with the US economy in 2010 sprang from expecSo the question remains: What about next year? Many tations of faster improvement. The best that wire rod buyin the steel industry predict more of an improvement in ers can hope for next year is a measure of price stability. 2011 than 2010, even though forecasts in the first quarter Unfortunately, aside from a marked uptick in demand levpointed to a rosier outlook than what actually occurred. els, this would only be achieved through a collective mill What many agree on, however, it that the worst is defieffort to not let scrap dominate their pricing decisions. nitely behind us. During the year, wire companies on the And the chance of that occurring is about as likely as whole did not exactly enjoy soaring profits or rapid invenChina labeling a wire rod shipment with the correct countory turnaround, but most saw steady sales and financials try of origin. back in the black after several quarters in the red. Developments in the works, such as ArcelorMittal’s SteelOrbis provides steel news, sector analysis, trade Georgetown wire rod mill’s imminent reopening, could statistics on steel, market pricing and more as well as turn out to be a double-edged sword. In mid-October a secure e-trade platform for steel buyers and sellers. maintenance workers returned to the mill, which was Katie Memmel, SteelOrbis’ content manager and editoridled in July 2009, and according to James Sanderson, in-chief of Prime magazine, has a lengthy background president of the local United Steel Workers union, proin the publishing field and her steel-based writing duction will resume as early as January 2011. While this focuses on long products (wire rod, rebar, merchant bar, is doubtlessly a much-needed shot of confidence in the beams). She can be contacted at tel. 713-589-6049, market, many industry insiders are not sure more wire rod www.steelorbis.com. ■ supply is what the market needs right now. Demand levels

Effect of parameters of extrusion on strain and stress states in the manufacturing process of wire from alloy CuAg15P5

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It is possible to replace high-silver content brazes with an alloy that uses less silver, but it is important to control the strain rates of deformation and the low and high temperature rates. By Rafał Włudzik, Marcin Knapinski, Jan W. Pilarczyk, Stanisław Ksiezarek and Zbigniew Smolarczyk

Copper-phosphorus brazes that include an addition of silver (Cu-Ag-P) can pose difficulties in the cold deformation process. These brazes used for copper, brass, bronze and others alloys (copper and silver) as well as for tungsten and molybdenum. In most cases, these brazes consist of P 5-7%, Ag 2-18% and the remainder copper. The solid and liquid

temperatures for these brazes range from 644°C to 825°C. Table 1 lists copper-phosphorus brazes according to EN1044:1999 and ANSI/AWS A5.8-921-5. These brazes with an addition of a silver have replaced higher silver-content brazes because they cost less. With a high phosphorus content, these alloys are very fluid at the brazing temperature, which

Table 1. Chemical composition of copper-phosphorus brazes per EN1044:1999 and ANSI/AWS A5.8-92. 56 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Table 2. Properties of selected copper-phosphorus brazes.

makes it possible to use them to make joints without needing a flux application. Adding phosphorus also hardens the alloy and increases its resistance to wear and corrosion. Joints made with such Cu-P-Ag brazes are tight, and form a high quality joint. They are applied in thin brazing layers for high thermal loading and variable mechanical loading in cooling and heating devices, air conditioning as well as in gas and sanitary installations. Considering that there is increasing concern for protecting the environment and eliminating lead from brazing, this creates growing global demand for Cu-Ag-P alloys. Producers try to develop brazes with precisely defined prop-

erties for use with a specific type of materials. Those materials can range from round wire in diameters from 1 to 3 mm and wire with square or rectangular sections. The final dimension of brazes depends on its destined applications6-7. Table 2 shows the most important properties of selected brazes1-3.

Fig. 1. Effect of temperature on mechanical properties (elongation A and contraction Z) of casted alloy CuAg15P58.

Fig. 2. Effect of temperature on mechanical properties (tensile strength Rm and yield strength R0.2) of casted alloy CuAg15P58.

Material and tools tests Investigations were carried out on an alloy CuAg15P5. Table 1 shows the chemical composition for the alloy, which was manufactured in the Institute for Non-ferrous Metals in Gliwice, Poland, by continuous casting of a 90-mm ingot. For a determination of the hardening curves a physical simulation

DECEMBER 2010 | 57

TECHNICAL PAPERS Fig. 3. Effect of temperature on mechanical properties (elongation A and contraction Z) of extruded alloy CuAg15P58.

Fig. 4. Effect of temperature on mechanical properties of extruded alloy CuAg15P58.

of the process has been performed with Gleeble 3800 at strain rates of 0.154 s-1, 0.62 s-1 at a deformation temperature of 450°C and strain rates of 0.01 s-1, 0.04 s-1, 0.154 s-1, 0.62 s-1 at deformation temperatures of 500°C and 550°C. The test specimens have diameters of 12 mm and lengths of 10 mm.

Figs. 1 and 2 show the relationships of the mechanical properties for the casted alloy versus temperature as determined by research carried out by the authors at the Institute for Non Ferrous Metal. Fig. 1 shows a rapid increase of elongation and contraction above temperature of 100°C. Tensile strength and yield strength (see Fig. 2) decreased with the increase of temperature but they were still relatively high at a temperature of 200°C. Extruded material that was tested exhibited higher elonga-

tion and contraction compared to the cast alloy, although the differences in tensile strength and yield strength are small (see Figs. 3-4). At an ambient temperature, elongation of the extruded material reaches 27% and increases to 63% at a temperature of 150°C. At higher temperatures, the alloy becomes superplastic, and the elongation value is higher than 300%. The tensile strength and yield strength values are very small at those temperatures. The ingot’s mechanical properties are relatively homogeneous. The alloy underwent a rapid increase of deformability at a temperature of 100°C. At a temperature of 20°C and using a torsion device, the alloy showed a very low ability for deformation. Fractures of the tested specimen were brittle. For higher temperatures, a relation of elongation versus temperature was observed, with one peak (see Fig. 3) that is related to dynamic recrystallization.

Fig. 5. Hardening curve of alloy CuAg15P5 at temperature 450°C.

Fig. 6. Hardening curve of alloy CuAg15P5 at temperature 500°C.

Mechanical properties

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TECHNICAL PAPERS Fig. 7. Hardening curve of alloy CuAg15P5 at temperature 500°C.

Fig. 8. Scheme of eight hole dies with a diameter 2.4 mm for drawing copper-silver phosphorous alloys.

Research results Figs. 5-7 show flow (hardening) curves determined at a . strain rate ε equal to 0.154 s-1 and 0.62 s-1 at a deformation . temperature of T=450°C (Fig. 5) and at a strain rate ε equal to 0 .01 s-1, 0.04 s-1, 0.154 s-1 and 0.62 s-1 at a deformation temperature of T=500°C (Fig. 6) and T=550°C (Fig. 7). On the basis of data placed in Figs. 5-7, it can be stated that strain rates and temperatures of a deformation greatly influence the value of a flow stress. The shape of the hardening curves at temperature 550°C has a different character in relation to the curves determined at temperatures of 450°C and 500°C. At a deformation strain rate equal to 0.62-1 at 550°C, the maximal value of the yield stress drops about 42%, compared to the same values at 450°C. At 500°C, the same yield stress value is 22% higher than at 550°C. The maximal yield

Fig. 9. Distribution of longitudinal stresses on the material section heated to 500°C during extrusion process with a speed of 0.15 mm/s.

Table 3. Parameters of Henzel-Spittel’s function for approximation of results of research for determination of hardening curves for an alloy CuAg15P5.

stress values are as follows: 93 MPa at 550°C, 121 MPa at 500°C and 170 MPa at 450°C. The mathematical relationship from the values of the yield . stress σp and parameters of a deformation (T, ε and ε) results obtained from the Gleeble Simulator were calculated by using the Henzel-Spittel’s9 function (see Table 3) as follows:

Fig. 10. Distribution of flow rate of material on the section of extruded material heated to 500°C during extrusion process with a speed of 0.15 mm/s. DECEMBER 2010 | 59

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Fig. 12. Measurements points for calculation of stresses and temperatures in the axis of extruded material and at its surface. Fig. 11. Distribution of temperature on section of material heated to 500°C during extrusion process with a speed 0.15 mm/s. Eq. (1)

where: . ε = strain intensity, ε= strain rate, T = temperature, and A1, A2, A3, A4 = coefficients related to properties of tested material. Fig. 8 shows a schematic of a die that was used for extrud-

ing the wire (alloy CuAg15P5) to 2.4 mm. The entrance diameter of the eight dies was equal to 10 mm. FORGE 2 D software10 was used for the numerical simulation of extruding the wire. The initial material was a 90-mm billet. Simulations were carried out for three different process temperatures (450°C, 500°C and 550°C) and three different extrusion speeds (0.15 mm/s, 0.20 mm/s and 0.30 mm/s). To reduce the time for calculations, a die model was simplified to 1/8 of the “total” die with one hole. (This can be done as all eight holes are placed centrically.) Parameters of function from Table 3 were used to calculate the yield stress of the test alloy. Figs. 9-11 show the exemplary distributions of longitudinal

Table 4. Temperature at the surface and in the axis of extruded material. 60 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Fig. 13. Distribution of temperature at the surface and in the axis of extruded material for material heated to 450°C.

Fig. 14. Distribution of temperature at the surface and in the axis of extruded material heated to 500°C.

stresses, flow rate and material temperature on the section of the extruded material obtained from finite element method simulation of the extrusion process. Fig. 12 shows the points that were measured to derive the quantitative estimation of the differences of the considered process parameters values of stresses, flow rate and temperatures obtained by the FEM simulation for different sections of the die. In the actual extrusion process, the die is heated to 450°C, so that temperature was assumed for the simulation. For all considered parameters of the extrusion process, the maximal temperature of the material are noticed during the last stage of the extrusion, where superposition of the heat from deformation and friction occur. On the basis of the temperature distribution data in Table 4, it can be stated that at a temperature of 450°C and an extrusion speed of 0.15 mm/s, the axis temperatures from the beginning to the end of the deformation zone range from

447°C to 515°C. Increasing the extrusion speed from 0.15 to 0.20 mm/s has resulted in a range increase of 459°C to 557°C, and at a speed of 0.30 mm/s the range is 494°C to 596°C. For higher temperature of initial material (500°C) those same ranges are as follows: 0.15 mm/s (462°C to 532°C); 0.20 mm/s (482°C to 589°C); and 0.30 mm/s (516°C to 613°C). For the highest temperatures of initial material, those ranges were as follows: 0.15 mm/s (506°C to 572°C); 0.20 mm/s (506°C to 572°C); and 0.30 mm/s (543°C to 627°C). Those results confirm the significant effect that extrusion speed has on the temperatures of extruded material. Too high a temperature increase for the highest extrusion speed can result in overheating of the alloy, which in turn can damage the surface of the extruded wires. The limit is related to the melting temperature of a given alloy at which extrusion becomes impossible. In the case of extrusion of the material heated to 550°C, the cooling effect of the material at the zones of contact with a

Table 5. Longitudinal stresses on the surface and in the axis of extruded material. DECEMBER 2010 | 61

TECHNICAL PAPERS Fig. 15. Distribution of temperature at the surface and in the axis of extruded material heated to 550°C.

cooler die (450°C) is observed. This resulted in the formation of dead zones of deformation (metal is not deformed), which are caused by a lack of the temperature increase that is needed in those zones for proper deformation. Comparing temperatures of the extruded material in the axis and at the surface (see Fig. 13) calculated for zones A and B, which corresponds with the entrance and half length of the last stage extrusion die, it can be stated that at all considered extrusion speeds they are slightly higher in the axis than at the surface. For zones C and Dm temperatures at the surface and axis are the same for all considered temperatures and extrusion speeds. Table 5 presents the results of calculation of longitudinal stresses at the surface and in the axis of the extruded material for all considered parameters of the process. From Table 5, it can be said that only at the die entrance are those stresses higher in the axis of the drawn material as compared to the stresses at the surface for all temperatures and speeds considered in analysis. For others zones marked in the Fig.12 as B, C and D, the opposite relation is found. Longitudinal stresses at the surface are higher than in the axis for all considered temperatures and extrusion speeds. The highest stresses are for the lowest temperature of heating and the highest speed of extrusion. At the halfway point of the die length, those stress-

Fig. 17. Distribution of longitudinal stresses at the surface and in the axis of the material heated to 500°C.

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Fig. 16. Distribution of longitudinal stresses at the surface and in the axis of extruded material heated to 450°C. es are approximately 20 MPa higher than at the exit from the deformation zone.

Conclusions Strain rates in the range 0.01 to 0.62 1/s applied in the work significantly influence the flow stress of the considered alloy CuAg15P5 for all temperature of heating (450°C, 500°C and 550°C). FEM simulation of the extrusion process of tested alloy has confirmed that cooling of the extruded material occurs in the plastic zone at its external layers. Inner layers of the material have a higher flow rate than external ones that are close to the die surface, which result in non-homogeneity of strain distribution on the cross section of the extruded material. Longitudinal stresses in the external layers of the extruded material are relatively large, and for material with a low ability for a deformation can lead to circumferential surface cracks. Increasing the extrusion speed in the range 0.15 to 0.30 mm/s significantly increases the temperature of the extruded material in all the tested samples of initial material. For the highest extrusion speed (0.30 mm/s) and initial temperature (550°C) applied in the extrusion process, the increase

Fig. 18. Distribution of longitudinal stresses at the surface and in the axis of material heated to 550°C.

References 1. H. Hackiewicz and K. Bukat, Lutowanie bezołowiowe, Wydawnictwo BTC, Warszawa 2008, Poland. 2. ANSI/AWS A5.8-89: Specification for filler metals for brazing and braze welding. 3. Polish standard PN-EN 1044: Lutowanie twarde. Spoiwa. 4. J.F. Lancaster, Metalurgia procesów spawalniczych. WNT, Warszawa 1967, Poland. 5. M. Schwarz, Brazing, ASM International, Ohio 2003. 6. P. Villars, A. Prince and H. Okamoto, Handbook of

Rafal Włudzik and Jan Pilarczyk accepting their award at Wire Expo 2010.

ternary alloy phase diagrams, ASM International, 1997. 7. T. Sheppard and H.L. Yiu, “Microstructure and properties of some extruded copper-phosphorus alloys,” Metal Science, vol. 18, September 1984. 8. Ł. Marchewka, J. Stobrawa, B. Cwolek and E. Hałasik, Badania wpływu temperatury, pr dko ci i stopnia odkształcenia na struktur i własno ci trudnoodkształcalnych stopów CuPAg, Rudy i metale nie elazne Nr 6, SIGMA-NOT, 2007, Poland. 9. A. Henzel and T. Spittel, Rasciet energosilovykh parametrov v processakh obrobotki metallov davlenijem, Metalurgija, Moskva 1982, s. 360. 10. Forge 2D v2.9. Users guide. TRANSVALOR, Sophia Antipolis, France, January 2000. ■

Knapiński

Rafał Włudzik works at Yawal S.A., a manufacturer of aluminum profiles system for windows, doors and curtain walls in Poland. He holds a Ph.D. degree in specialty plastic working of metals obtained in the department of materials processing technology and applied physics at Czestochowa University of Technology (CUT). He specializes in the wiredrawing, silver brazing and extrusion of aluminum profiles. A WAI member, he is the author or coauthor of more than 20 technical papers. Jan W. Pilarczyk is a professor in the department of materials processing technology and applied physics at CUT. He works on the development of new technology for wiredrawing and metal products. He holds a Ph.D. degree and a degree in specialty plastic working of metals from Czestochowa. He is the author or co-author of more than 170 technical papers. He is currently president of the WAI’s Poland Chapter. Stanisław Księżarek is chief process engineer of the Institute of Nonferrous Metals (INMET) processing plant in Gliwice, Poland. He graduated from the School of

Księżarek

Smolarczyk

Mechanical Engineering of Silesian Technical University, Gliwice, and from the School of Nonferrous Metallurgy of the University of Mining and Metallurgy (AGH), Krakow. He later received a Ph.D. degree for his thesis on the application of vacuum metallurgy in the process of melting nickel-based magnetically soft materials. He is particularly interested in the micro-processing of silver, copper, and nickel-based alloys. Zbigniew Smolarczyk is an assistant professor at the Institute of Non-Ferrous Metals (INMET) in Gliwice, Poland. He previously was chief of development at Duo-Stal, Ltd.’s mini mill in Bytom, Poland. He worked at the Institute for Ferrous Metallurgy for 20 years, spending seven years as a scientific worker. He specializes in the plastic deformation of metals and has co-authored more than 30 research articles. This paper, which was presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, April 2009, won the Silver Certificate Award in the nonferrous division.

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in the temperature of the extruded material can lead to it surpassing the alloy’s melting temperature, preventing further extrusion.

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TECHNICAL PAPER Overview of zinc coating monitoring and automatic control system achievement This presentation, which traces the industry’s transition from gas to nitrogen wiping, focuses on the importance of monitoring and control systems, and presents related results in the production of Galfan® coated wire. By Ian R. Zoellner and Michael D. West

From the time that South Africa’s Cape Gate first started producing galvanized wire in 1967, three different wiping methods have been used to produce fully galvanized wire. This paper summarizes those experiences, starting with the method types, and presents some of the lessons that have been learned from shop floor application. Charcoal Wipe. The first method was a charcoal wipe invented in the early 1900s. This method employed charcoal mixed with transformer oil, later replaced by wax. The mixture is floated on top of the molten zinc and the wires are drawn vertically through it. There are two main disadvantages: the moving wires agitate the charcoal, causing the coating thickness to vary greatly; and production speed is limited to between 20 to 30 meters a minute. Gas Gravel Wipe. During 1983, the charcoal wipe method was replaced with the A.W.I. Gas Gravel Wipe process. This method uses a bottomless, lidless steel box that is filled with small, round uniformly sized pebbles placed on the zinc surface. The wires are drawn vertically through these pebbles in much the same manner as the charcoal wipe. A mixture of 1.33% hydrogen sulphide and 98.66% natural gas is blown into the gravel bed to form a sulphide meniscus around the wire, which smoothes the wire surface and restricts the quantity of zinc applied to it. The wires are able to run at around 80 to 90 meters a minute. However, a trial-and-error method of manual raking is used to agitate the pebbles to control the coating, which still allows a large variation in coating thickness. Jet Wipe (Nitrogen Wipe). In 1998, “Jet Wiping” was introduced into the Cape Gate galvanizing lines. This technology was already successfully being used in Europe and Australia

Editor’s note: Due to space restrictions, Tables 1 and 2, Photos 2 and 6, and Figs. 6 and 10 are not included. For a PDF of the complete set of figures, e-mail a request to editorial@wirenet.org. 64 | WIRE JOURNAL INTERNATIONAL

and it was believed to be the right course to follow. Cape Gate’s system was developed in-house from basic principles and experimentation and ongoing improvements are still being investigated and tested as part of its continuous improvement strategy. With this method, each wire is passed vertically through its own individual wiping nozzle that uses nitrogen gas to wipe the excess zinc off the surface. Nitrogen was chosen as the wiping medium because it is an inert gas and does not form oxidation on the wire surface, ensuring an improved appearance. It is also environmentally friendly, unlike hydrogen sulphide. Speeds of up to 160 meters a minute are achievable with this system, depending on the wire diameter.

Jet Wiping system experience Initially it was thought that the Jet Wipe system was an uncomplicated, simple wiping technique. It was believed that if the wire speed, the nitrogen flow and the zinc bath temperature were all kept constant it would deliver a wire with a constant zinc coating thickness. However, it was soon discovered that this was not so; the coating thickness tended to vary over time albeit much less than the gas gravel system. Identical nozzles required different pressures to produce the same coating thickness on the same diameter wires, and required much manual intervention as the control valves required periodic adjustments. It appeared as if a nitrogen flow versus coating weight relationship tended to develop for each individual nozzle, especially as the nozzle started to age. After trying many different cleaning and operating techniques, it was found that exact control was still an impossible task to achieve and some kind of device was required to do this automatically. Problem solution. Literature searches revealed there was a “closed-loop system” available that was able to automatically measure and control the deviation in coating thickness during production. The method of control is achieved by passing

TECHNICAL PAPERS

each wire through a sensor, and with the aid of a process control computer, the zinc coating thickness is measured. The computer then estimates how much the nitrogen flow should be increased or decreased to obtain the correct coating thickness, and regulates each wire’s flow control valve accordingly. Automatic adjustments are made several times a minute to achieve accurate coating thickness control. During May 2002, the first units were fitted and commissioned. Live analysis of the actual laboratory tests has also been introduced in the form of flow charts to form a continuous feedback so that corrections can be made when necessary. Jet Wipe advantages. The Jet Wire process has been found to offer many advantages. These include: • the coating thickness of each wire can be adjusted to a customer’s needs by varying the volume of nitrogen applied; • automatic controls result in less variation in coating thickness; • it produces a more concentric zinc coating on the wire surface; • fewer rejects and diverted products means fewer quality problems; • fewer destructive tests to check coating weights means longer production runs without welds or joints; • less coating thickness variations equals big savings in zinc costs; • less scrap means there is less cleaning of nozzles; • exposure of ferrous surface to nitrogen atmosphere (See WAI’s Ferrous Wire Handbook, Vol. 1, p. 534) appears to help zinc adherence. A thinner alloy layer can result in better ductility; and • the system is compatible with the production of Galfan®. Setting standards. Most standards only specify a minimum coating weight, thus from practical experience with this system, it has been possible for Cape Gate to set its own standard, one that complies with both the relevant specification and supplies the customer with an acceptable quality coating weight on the wire. Management decided that a

Fig. 1. Zinc deviation, first transition period, for a 2.70 mm wire, fully galvanized minimum coating weight, 260g/m2. Number of samples: 1102.

Fig. 2. Zinc deviation, second transition period, for a 1.96 mm wire, fully galvanized, minimum coating weight of 245 g/m2. Number of samples: 177.

Fig. 3. Zinc deviation for a 3.15 mm wire, fully galvanized, minimum coating weight, 270 g/m2. Number of samples: 246. DECEMBER 2010 | 65

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coating thickness of 30 g/m2 above the minimum specified weight and a maximum of 60 g/m2 above the specified weight would ensure a good quality product is supplied. If maximum coating weight is exceeded, the quality system detects it and the necessary measures can be taken to rectify it. However, these specifications are unique to Cape Gate’s requirements and can be made more or less stringent if required. They can also be tailored to each individual product and customers’ requirements if necessary. The transition period. Fig. 1 shows the actual test results done over the transition period when the first controller was installed in May 2002. It shows that the variation in coating with jet wiping alone and then later with the closed-loop controller installed. The data presented here are actual laboratory test results for all coils of 2.70 mm wire produced for the period from May 13, 2002, to June 6, 2002. Without the control, the coating weight ranged between 190 g/m2 and 520 g/m2.

With the controller, the cutoff is almost immediate, dramatically reducing the range to between 240 g/m2 and 350 g/m2. Fig. 2 illustrates the second transition period, where the company’s last gas gravel wipe system was removed and replaced by a controlled jet wipe system in December 2008. The monitored period is from Sept. 1, 2008, to May 20, 2009. The data were collected over the commissioning period in January 2009. As before, the presented data are from actual laboratory test results. The gas gravel wipe data returned an average coating weight of 348 g/m2 with a relative standard deviation of 17.24% while the controlled nitrogen wiping returned an average coating weight of 267 g/m2 with a relative standard deviation of 5.61%. It is evident that the gas gravel wipe tends to produce wire with heavy zinc coatings as most of the coating weights were above the mean, thus giving away more zinc than the uncontrolled jet wiping shown on Graph 1.

Fig. 5. Zinc deviation for a 1.25 mm low-carbon, fully galvanized wire. minimum coating weight of 195 g/m2. Number of samples: 119.

Table 3. Information pertaining to Fig. 5.

Table 4. Information pertaining to Fig. 6. 66 | WIRE JOURNAL INTERNATIONAL

Performance analysis and adjustments Analysis of product performance. Fig. 3 and Table 1 provide a detailed analysis of a single product simultaneously produced by a seven wire, low-carbon galvanizing line. Fig. 3 shows the plotted actual test results from the quality control mainframe computer system from Jan. 9 to May 21, 2009, for a 3.15 mm fully galvanized wire with a minimum coating thickness of 270 g/m2. These graphs can be automatically generated for any chosen period. Fig. 3 shows the average coating weight to be 301 g/m2 and the standard deviation 11, which equates to a relative standard deviation of 3.6%. The horizontal red line on Fig. 3 is set at 330 g/m2 which is the maximum coating thickness allowed, the blue horizontal line is set at 270 g/m2 which is the minimum coating allowed. The horizontal green line is the mean which is set at 300 g/m2. The plotted data line moves around the mean between the red and the blue line, only touching each line once. The highlighted areas in Table 1 show that out of 246 samples, only two samples were out of specification. One was below the minimum and the other above the maximum. These points are also evident

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where they intersect the red and blue lines on the graph. Both the graph and the table illustrate how well the coating thickness is controlled. Correction of a coating thickness. Fig. 4 reflects quality tests for 119 samples of 1.60 mm low-carbon, fully galvanized product produced from February 19, 2009, to May 4, 2009. This is a typical graphical representation of where an adjustment was made to bring the coating weight into line after using the live quality analysis system. Table 2 shows the data used to produce this graph. The highlighted area is the 11-day period (Feb. 25 to March 2), 2009, where the plotted line on Fig. 4 moves between the median and the minimum lines, and not around the median, suggesting that the controller was controlling the coating weight at a too lower level. Fig. 4 and Table 2 both show that in the same period three of the samples tested on and between March 5-7 had coating weights considerably below the minimum. If an average of the 17 highlighted values in the â&#x20AC;&#x153;Test g/m2â&#x20AC;? column in Table 2 is calculated, the average coating weight for this period is 235 g/m2 and produces a relative standard deviation of 9.78%. However, if the same column is averaged up to the end of the table after the rectification was made, the average coating weight increased to 252 g/m2 and the relative standard deviation decreased to 5.95%. It can be clearly seen on the graph how the adjustment brought the coating weight back into specification between the maximum and minimum lines. Coating thickness and concentricity. Coating weight concentricity and uniformity was a problem with both the charcoal and gas gravel wipes. The photos on this page of cross sections of random samples of controlled jet wipe products were taken by a laboratory microscope at Cape Gate. When looking at these cross sections, note that the wire is centered in the nozzle purely by the naked eye, and not by means of a measuring instrument, thus concentricity can be affected. Fig. 5 and Table 3 depict the results for the controlled coating weight of a low-carbon 1.25

Photo 1. 1.25 mm fully galvanized cross-sectional area.

Photo 3. 3.15 mm fully galvanized cross-sectional area.

Photo 4. 4.0 mm fully galvanized cross-sectional area.

Photo 5. 2.70 mm fully galvanized cross-sectional area.

Fig. 7. Zinc deviation. 3.15mm low carbon fully galv. minimum coating weight 270 gm2.

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Table 5. Information pertaining to Fig. 7.

Table 6. Information pertaining to Fig. 8.

Fig. 8. Zinc deviation. 4.00 mm low carbon fully galv. minimum coating weight 290 gm2.

Fig. 9. Zinc deviation. 2.70 mm low carbon Galfan速 minimum coating weight 244 gm2.

Table 7. Information pertaining to Fig. 9. 68 | WIRE JOURNAL INTERNATIONAL

mm wire. Photo 1 shows the cross sectional area of the same wire, magnified 50 times. The concentricity was measured in four places 90o apart around the circumference of the cross sectional area. On the horizontal plain, the zinc coating measured 0.04 mm on the left and 0.05 mm on the right, and on the vertical plain, 0.04 mm at the top and 0.06 mm at the bottom. Fig, 6 and Table 4 show plotted results for the controlled coating weight of a 2 mm low-carbon wire. Photo 2 shows the cross-sectional area of the same wire magnified 50 times. Photo 2 shows as before the coating thickness was measured at 90o around the circumference in four different places. Other than the small protrusion and dip at 45o to the right and left of the horizontal, concentricity is good, measuring 0.05 mm, 0.04 mm, 0.05 mm and 0.05 mm respectively. The two deformations are very small and could be caused by dirt on the mating faces of the nozzles. Fig. 7 and Table 5 show the results for a 3.15 mm low-carbon wire. Photo 3 is the cross-sectional area of the same wire measured at a magnification of 50 times. The total circumference is not visible because it does not fit in the frame. However, the sample concentricity was good, measured at 0.05 mm, 0.05 mm, 0.05 mm and 0.07 mm. Fig. 8, Table 6 and Photo 4 reflects the results for a 4.00 mm low-carbon wire. Concentricity was 0.05 mm, 0.04 mm, 0.06 mm and 0.04 mm, respectively. Galfan速. The process used by Cape Gate to produce Galfan速 is a double-dip process. The wire is initially pad-wiped by passing it through a normal zinc bath to form a zinc alloy layer on the steel. It is then dipped for a second time in a bath filled with Galfan, which consists of 95% zinc and 5% aluminum plus rare earth mischmetals. The jet wipe process is used to wipe off the excess Galfan to obtain a coating similar to a fully galvanized product. Fig. 9 and Table 7 shows the results obtained from test done on a 2.70 mm low carbon Galfan coated wire. Photo 5 is

the cross sectional area of the 2.70 mm wire. The above illustrates that Galfan coatings can be controlled equally as well as ordinary zinc coatings. The coating concentricity measured 0.05 mm, 0.03 mm, 0.04 mm and 0.05 mm, respectively. Concentricity and higher carbon wires. Wire stability plays a large role in the galvanizing of higher-carbon products as the helix forms a memory in the wire, caused by the drawing process, and is not easily removed during the galvanizing process. Tension rollers are fitted at the zinc bath entry to apply back-tension to the wires. That helps remove some of the movement, although the fact that the nozzle barrel diameter has very little clearance in relation to the wire diameter makes the smallest movement of the wire critical. Also, without these tension rollers the wire would touch the side of the nozzle barrel. One must appreciate that if too great a back-tension is exerted to thinner wires, elongation or breakage can occur, and it is virtually impossible to remove the helix from thicker wires, thus instability is even more imminent. Photo 6 clearly shows that the wire movement in the nozzle has affected the concentricity of the zinc coating. The wire tends to spiral in the nozzle barrel and form thicker and thinner areas where the molten zinc is displaced. This is caused by uneven pressure due to the closer proximity of the wire to one side of the nozzle barrel. Critical variables involved with nitrogen wiping. To achieve proper coating weight control, one cannot just rely on the controller system alone to do the work. There are certain key issues that have to be addressed by the galvanizing operator to ensure that the controller can do its job properly. The below items are critical to proper nitrogen wiping control: • using the correct barrel diameter nozzle for the wire that is to be galvanized; • ensuring that the nozzle is cleaned frequently and that the orifice is not blocked with zinc; • the nozzle must be aligned properly with the wire running in the center of the barrel; • constant nitrogen supply pressure supplied to the controller; • the zinc or Galfan® bath temperatures must be correct; • frequent and proper drossing of the zinc and Galfan tanks; • the flux pH must be at the correct specification; • the correct amount of cooling water must be applied to the wire; • acid strength must be within specification in the in line pickling; • worn out nozzles must be replaced; • line vibrations must be removed as wire stability is important;

• the zinc or Galfan bath levels must be kept as constant as possible; • the zinc or Galfan bath surfaces must be kept as clean as possible in the nozzles wiping area; • wire speeds differ for identical wires when making fully galvanized products to that of Galfan products as the viscosity of the two molten metals differ; and • the Galfan bath concentration must be maintained at the zinc and 5 % aluminum. ■

Zoellner

West

Ian R. Zoellner is a process development technologist with Cape Gate (Pty.) Ltd., Vanderbijlpark, South Africa. He has been with the company for 30 years, and has specialized in the development of galvanizing processes for the last 14. During this time he was deeply involved with jet wiping and the controlling thereof. He holds degrees in engineering and management accounting. Michael D. West is an operations manager at Cape Gate’s Vanderbijlpark facility. He has been with the company for 14 years. He started out as a product development technologist and headed the Process Control Department for two years. He then moved into production and has managed wire drawing, galvanizing, and CO2 welding wire production facilities. He has a degree in metallurgical engineering, a Fundamental Management Program certificate in management, and is currently working on his M.B.A. This paper was presented at WAI’s International Technical Conference, Istanbul, Turkey, November 2009.

DECEMBER 2010 | 69

TECHNICAL PAPERS

Table 8. Information pertaining to Fig. 10.

PRODUCTS & MEDIA

PRODUCTS & MEDIA PROD DUCTS Measuring gauge can offer both accuracy and flexibility The SPEEL 3000, a new length and speed measuring gauge from Zumbach Electronics, features a flexible design that enables it to process a wide range of applications and production speeds. A press release, which said that the SPEEL gauge is available with a measuring distance of 300 mm and a depth of field of +/- 15 mm, noted the following characteristics. The sensor system uses a high-speed line scan camera that detects light reflected from the object being measured. Data processing is achieved by advanced algorithms running on a powerful signal processing platform. The sensor system thus shows a high degree of adaptability, and can be used on a wide range of industrial surfaces. It is possible to detect lack of motion or direction-change in the object being measured, which are then taken into account in the measurement of distance covered. Using built-in diagnostic LEDs, an RS-232 interface, and appropriate software, extensive configuration and diagnosis possibilities are available for users, thus facilitating the start-up as well as enabling preventive maintenance. The release cited the main advantages as including: a non-contact optical measurement principle; a compact, heavy-duty and industrial design; speed range up to 3000 m/min; accuracy < 0.05 % or better; detection of standstill and direction; start and end recognition; allows deviation of the measuring distance; works on smooth and rough surfaces; long-life LED illumination; and maintenance-free. Contact: Zumbach Electronics Corp., sales@zumbach, www.zumbach.com.

Zero-tolerance compacting and stranding dies offer fast ROI Sanxin Dies reports that its line of Nano Dies for compacting and stranding can hold a zero tolerance that translates to potential savings of up to $10,000 in copper for every 100 km of 240 sq mm compacted copper cable. The report emphasizes that $5,700 is the maximum observed in the field so far, but thatthe company believes additional savings are available. A press release said that, unlike tungsten carbide (TC) 70 | WIRE JOURNAL INTERNATIONAL

or PCD dies that continue to wear until they are out of tolerance, the Nano Dies, which have a very thin layer of nanocrystalline diamond particles applied to the working surface of the nib, hold a zero tolerance for their entire working life. The key, it said, is that the diamond particles, in the nanometer size range, are all the same size and locked together in a pattern that results in exceptional hardness and strength. “When a Nano Die finally fails, it is due to collapse of the diamond surface caused by metal fatigue in the tungsten carbide foundation material,” said Doug Thornton of Sanxin Dies. He added that for compacting and stranding applications, a Nano Die might produce as much 1,000 km of cable, but typical die life is in the 500800 km range. Thus, lifetime savings are five to eight times as great as indicated for a 100 km run, he said. The result, the release said, is that the Nano Die “provides astonishing savings in raw material.” For instance, a good tungsten carbide die that compacts a 240 sq mm copper cable to 18.4 mm can open up by 0.1 mm in 100 km of cable compacted, it said. Based on current copper prices, the observed raw material (copper) savings using the Nano Die with a +0 tolerance are up to US$5,700, it said, noting that the practical and theoretical foundation for this result can be seen at the Sanxin website. Potential savings are even higher, the release said, as the Nano Die typically holds a +0 tolerance for 500, 600 and even up to 800 km. Thus, it said, lifetime savings “are spectacular,” adding that the Nano Die imparts a better quality surface finish than aTC die while also using less energy, which makes it a “green” die as well. Contact: Doug Thornton, Sanxin Wire Die, Inc., tel. 434-906-2340, www.sanxinamerica.com, admin@sanxinamerica.com.

Laser scan micrometer excels at detecting shorter-length flaws U.S.-based LaserLinc reports that it has introduced a new laser scan micrometer, the Triton331™, that offers exceptional ability to detect shorter-length flaws as well as provide accurate measurement of hexagonal or other product shapes that incur oscillation, and measurement of non-constant diameter products, such as corrugated tubing. A press release said that the Triton331 has a 30 mm measurement window, like LaserLinc’s Triton330, but is much faster, with a rate of 12,000 measurements per second (4,000 per axis). Because of its speed, the Triton331 is exceptional at detecting flaws, it said, adding that the basic Triton331 model has a standard measurement rate of 4,800 per second, with 12,000 as an option.

Semi-automatic system makes die finishing process simpler U.S.-based Die Quip Corporation has introduced a new machine, the Die Flex MA, a semi-automatic angle polishing and sizing system that it reports provides reliable, precision die finishing. A press release said that once the operator places the die into the machine, an automatic cycle runs either the angle polishing or bearing calibration programs. The Die Flex MA automatically finds the approach angle so different diameter dies with the same angle can be polished without changing the machine settings, making the Die Flex MA easy to use for removing die wear, it said. The dies are held in a three-jaw adjustable chuck to ensure die concentricity, which reduces out-of-round wire, it said. Like all Die Quip machines, it added, the Die Flex MA is built on a sturdy

Few cold welders are this versatile

Fast, reliable and easy to operate, our portable HP100 air/hydraulic machine can be wheeled quickly to the work area. The welding head can be detached to fix breaks in confined spaces, and the HP100 is also available with an automatic setting, offering effortless welding at the touch of a button. For full details, call +44 (0) 1233 820847 or visit www.pwmltd.co.uk. PWM. Precision you can depend on. All inquiries within North America for machines, spares and dies, contact: AMARAL AUTOMATION ASSOCIATES PO Box 7816, Cumberland, RI 02864 Tel: 401 405 0755 / 774 991 0504 Fax: 401 405 0757 E-mail: joe@amaralautomation.com www.amaralautomation.com Welders and dies available from PWM or authorised distributors only.

DECEMBER 2010 | 71

PRODUCTS & MEDIA

The Triton331 works well with the company’s new Lobex™ system for in-process lobing measurement on centerless ground products, including centerless ground wire, the release said. As with all LaserLinc scanners, the Triton331 links (via the TLAser400™ micrometer interface card) to a PC running the company’s sophisticated Total Vu™ software, which provides an operator-friendly, measurement/data processing package that runs on any Windowsbased PC. The software, the release said, provides inprocess tolerance checking, trending, SPC, feedback control, data logging, recipes, and other features. LaserLinc micrometers are covered by a four-year warranty on all parts and labor and lifetime support, which includes the option of remote desktop interface with company support staff to pinpoint and solve difficult problems. Contact: LaserLinc, tel. 937-318-2440, www.laserlinc.com.

PRODUCTS & MEDIA

steel base with industry standard parts for long heavyduty work and long production life. “The machine is perfect for die shops that produce a small number of dies per size where automation takes too long to set up,” the release said. Combined with a manual or semiautomatic grinding machine, it said, the Die Flex MA will increase the productivity of any die shop. Contact: Die Quip Corporation, tel. 412-833-1662, diequip@diequip.com.

that ensures cost-effective operations and excellent reliability, it said. A touch-screen makes it easy to navigate and allows for quick setup of nail parameters while tooling changeovers and maintenance routines are simple because of the user-friendly machine design, it said.

Oil-spill absorbent offers great capacity, has ‘green’ characteristics U.S.-based Telm Sales announced that its representation lines have expanded beyond drawing lubes for the wire and cable industry with a unique “green” oil-absorbent product, FLOOR GATOR, that it said excels at containing and eliminating floor spills. A press release described FLOOR GATOR, from Gator International, as a premium oil absorbent product manufactured from natural recycled agricultural products (cotton husks) that can absorb up to six times their own weight in oil or oil-based products. FLOOR GATOR totally encapsulates a spill, and enables the floor to be swept clean and dry, it said, adding that customers report that one 30-lb bag can replace from eight to 24 bags of standard clay-based absorbents. The product, the release said, is engineered for safe, fast and economical oil spill pick up, and aids in meeting EPA 1996 mandate to reduce waste by 50%, it said. Floor Gator products have been endorsed by the AARC, USDA and Federal Register: Office of Federal Procurement Policy; Acquisition of Green Products 10 CFR Part 490.2 December 28, 2007, and meets the EPA CPG Recovered Materials used as an absorbent under other organics in oil- or oil-based products, it said. Contact: Telm Sales, tel. 815-245-2214, telmsales@gmail.com.

In-line rotary system offers highest rates of production for nail output Denmark’s ENKOTEC A/S reports that its in-line system for producing nails, using the company’s rotary forming principle, offers the highest output-per minute-rate in the market while providing stable production. A press release said that the company’s in-line nail manufacturing system (see diagram), which consists of a high-volume rotary nail machine with an integrated payoff, a magnetic conveyor and a thread rolling machine, offers multiple advantages. The systems are thoroughly proven, equipped with high-quality, durable precision tooling 72 | WIRE JOURNAL INTERNATIONAL

Specifically, the Enkotec systems can produce up to 2,000 nails per minute for nail dimensions of 1.8-4.2 x 32-127 mm length. The company’s thread-rolling machine is specially designed to make screw shank or annular nail profiles at production speeds of up to 2,500 nails per minute, it said. Managing Director Bent Petersen notes that the system’s rotary forming principle allows for low-noise automated nail manufacturing, and that once the nail dimensions are set, production can take place unmanned, with only limited staff required for changeovers and maintenance. Customers benefit because ENKOTEC is the total supplier of its in-line manufacturing solutions, and therefore guarantees the performance of the complete lines. Further, by having only one supplier, the customers will benefit from ENKOTEC’s extensive service concept, including quick supplies of spare parts, technical support at all levels, and customized training programs. Contact: Bent Petersen, ENKOTEC A/S, tel. 45-8652 4444, sales@enkotec.dk, www.enkotec.com; in the U.S., Jan Sorige, Enkotec Company, Inc., tel. 440-349-2800, sales@enkotec.com.

Lubricant line provides ‘green’ solution for wiredrawing technology needs U.S.-based Metalloid Corporation reports that it can provide the wiredrawing industry with environmentally friendly practical alternatives to conventional petroleum-based wire drying lubricants. A press release said that its ADDVANCE™ line of lubricants is formulated with natural, American-made renewable resources that eliminate chlorine, oil and other hazardous ingredients while providing the ultimate in lubricity, cleanliness and biodegradability. “Metalloid’s wire rawing lubricants are formulated with a focus on your work, your people and your environment,” it said.

Nothing fishy about this wire product European-based Luvata has introduced anti-fouling wire alloys that it believes will “revolutionize fish farming” by significantly reducing the cleaning and maintenance costs associated with this usage. A press release said that the company has developed three new copper alloy wires that not only reduce operating expenses for fish farms, but also provide “superior exclusion of predators, prevention of escapes, and increased fresh water flow, improving the health and the environment for the fish.” Seawire™, it said, is resistant to organisms including barnacles, algae and many other organisms that often disrupt the flow of water and offer a breeding ground for diseases and infections in the aquaculture. The alloys, the release said, offer a thin, weldable solution that is 100% recyclable and can be used in a smaller diameter wire, which is lighter in weight when compared with conventional copper wire-based solutions, delivering additional savings on raw material and downstream transportation costs. The product, it said, creates a natural protective surface oxide on the wire that is effective against biofouling, while also providing increased water flow. It described the potential market as “huge,” with end-uses from lobster and crab traps to cages for all imaginable types of aquaculture including some species that were previously unsuitable for farming. Contact: Luvata, www.luvata.com.

Solid cords optimize performance The U.S. business of Siemon reports that the company has introduced a line of innovative Cat. 6A Z-MAX solid cords terminated to 23-22 AWG copper conductors for use in high-performance consolidation points and cross connects as an equipment cord. A press release said that the solid conductor single and double-ended modular cords feature Siemon’s Z-MAX’s patented PCB-based RJ-45 Smart Plug technology. Available in both 10 Gb/s Cat. 6A shielded and UTP con-

figurations, the new solid cords are designed to provide enhanced signal-tuning capabilities in a precisely tuned printed circuit board (PCB). Z-MAX’s PCB-based plug design enables it to be terminated to either stranded or solid, shielded or UTP category 6A cables. The release said that the new Z-MAX 6A modular solid cords extend the distance reach from consolidation points and cross-connects compared to stranded cords, which must be de-rated per industry standards due to their inability to accept the larger-diameter solid cable conductors. With the Z-MAX plug, the cable conductors are terminated to the PCB at the rear of the plug rather than directly to the plug contacts, as in traditional plugs, which both supports larger conductor sizes and minimizes pair untwisting that can cause transmission issues in standard plugs, it said. Contact: Brian Duval, Siemon, tel. 860-945-4380, brian_duval@siemon.com, www.siemon.com.

Stainless steel cable ties can handle the toughest conditions U.S.-based Del City reports that its new line of stainless steel cable ties can serve the purpose in the toughest of conditions. A press release said that the stainless steel cable ties can withstand harsh, corrosive and saltwater environments because they are resistant to chemicals, radiation exposure and temperatures up to 572°F. Each cable tie, it noted, is manufactured from #304 stainless steel, which produces little to no oxidation, making them the ideal choice for clean environments. The cable ties, it added, feature a self-locking ball mechanism that meets low insertion force requirements, while maintaining a 100 lb tensile strength. The release said that the company’s cable-bundling lines also include the Cable Wraptor™, precision lock cable ties and Grip Strip™ cord organizers, all of which can be seen in a catalog at the company’s website. Del City notes that it has been a direct source for professional grade electrical supplies since 1947, with product lines that include the following: automotive wire, wiring, cable, electrical terminals, connectors, clamps, grommets, circuit breakers, fuses, switches, testers, cable ties and loom as well as thousands of other electrical products, all backed by personal service. Contact: Del City, tel. 800-654-4757, www.delcity.net. (continued)

DECEMBER 2010 | 73

PRODUCTS & MEDIA

It said that two of its “green” products include: ADDVANCE MD C-WD, a bio-stable wiredrawing lubricant that eliminates the need for biocides and other costly additives, is ideal for drawing copper, copper-clad and galvanized wires, with long sump life and low maintenance, making it ideal for central systems; and ADDVANCE MD 5130HV, an oil-free wiredrawing lubricant for drawing aluminum, copper or cladded rod and wire in any gauge, using an anneable formulation that optimizes die life and reduces tears and scratches, replacing messy soap lubricants. Contact: Metalloid Corporation, tel. 800-686-3201, www.metalloidcorp.com.

PRODUCTS & MEDIA

MEDIAA Alpha Wire launches Spanish website U.S.-based Alpha Wire has unveiled a Spanish version of its website to reach an increasingly diversified customer base, as well as plans to add other languages. A press release said that Spanish-speaking customers can now access all the company’s existing website functions,

including product filters, data sheet searches, sample requests, and product brochure downloads, in a more user-friendly manner. The full-service website offers multiple product filter and search capabilities “for unparalleled ease-of-use,” the release said, noting that it includes “Online Tools” functions and an “Engineer’s Room.” To access the Spanishversion, go to www.alphawire.com and select “Spanish” from the language drop-down box. The company also plans Chinese-, French-, and German-language versions. Contact: Alpha Wire, tel. 908-587-4012, jdubow@alphawire.com.

Steel statistical yearbook free online The World Steel Association (worldsteel) has published the 2010 Steel Statistical Yearbook, which is now available on the website of the Belgium-based organization. The yearbook, the release said, presents a cross-section of steel industry statistics, including comprehensive statistics for 2009 on crude steel production by process, steel production by product, steel trade by product, apparent steel use, and production and trade of iron ore. It can be downloaded for free, and printed copies can be ordered. Contact: World Steel Association, www.worldsteel.com. ■

74 | WIRE JOURNAL INTERNATIONAL

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking positions are entitled to free “Position Wanted” classified ads. Limit: one ad per issue, three ads per year. This benefit is not transferable to nonmembers or to companies. 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. 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. PAYMENT POLICY: All ads must be pre-paid. DEADLINES: Copy is due a full month in advance, i.e., it must be received by March 1 for publication in the April issue. Classifieds booked on-line, run for at least one-month on-line, from the date of booking. Wire Journal International “Print classifieds” booked on-line as an “add-on” to an “online classified” booking will run in the next available issue.

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POSITION WANTED. Exec Sales Manager/GM with 20+ years of success in the areas of industrial sales, sales/business management, strategic planning and business development. Global orientation with balance of sales, organizational, managerial and interpersonal skills; relentless, resultsdriven leader with strong record of building highly effective teams, business start up with minimal resources, and turnaround situations in low growth markets. Specialties include sales management and training, business development, building/managing distribution network, strategic planning, supply chain, business management. Please respond to Box 11-01.

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

CAREER OPPORTUNITIES SALES PROFESSIONAL: NY based company seeking a proven sales professional with a Bachelors degree in engineering discipline to cover the southern region of the U. S. The ideal candidate should have a minimum of 5-7 yrs experience in Industrial/Technical Sales with knowledge of Wire/Cable (or Steel) a plus.. A broad knowledge of of the wire and cable manufacturing process is essential. Extensive travel is required. We offer a challenging working environment, and competitive compensation and benefits program including 401(K), medical, and dental. Confidential resumes and salary requirements will be accepted by e-mail only. Attn: Carolyn Edwards at cedwards@zumbach.com

salary assessment functions. For the professional exploring a new opportunity, we provide career evaluation and guidance. Our services are performed in absolute confidence. Contact: E-mail Peter Carino at pcarino@wireresources.com or Jack Cutler at jcutler@wireresources.com, or visit the Wire Resources website at w w w. w i r e r e s o u r c e s . c o m . Wi re Resources, Inc., 522 E. Putnam Ave,

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

FOR SALE

1 - HALL 500’ Vertical Accumulator, 1997 3 - NEB 48-Carrier CB-1 Cable Braiders 7 - WARDWELL 12-Carrier Braiders 10 - NEB #2 Braiders, 12-C, 16-C, 44-C 1 - FRIGECO 800mm D.T. Buncher 13 - LESMO 630mm D.T. Bunchers 1 - WATSON 36” Rotating Cabler Line, Model RT-36 2 - EDMANDS, WMCA 37-Wire 16” Planetary Cabler Lines 2 - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 1 - CEECO 6-Bobbin 60” Closer w/ 96” Caterpuller, 120” Take-up 1 - WATSON 6+1 48” Cabler 1 - DAVIS ELECTRIC Model CAT-TRAK 22 Caterpuller Capstan 1 - FARRIS Model E500VT Caterpuller Capstan. 1 - VITECK 24” Horizontal Belt Wrap Capstan 2 - NEIHOFF Model MMH121 MultiWire Drawers, 14 and 16-Wire 3 - DAVIS STANDARD 3.5”, 2.5” 24:1 L/D Extruders 2 - D/S 2.5” 24:1 L/D, 2” 30:1 L/D Hi-Temp Extrusion Lines 1 - D/S / KILLION 1” 24:1 Extruder L/D, 2001

2 - TULSA 24” Motorized Shaftless Payoffs, Model HSPO-1, 12/02 1 - EJR 18” Motorized Payoff, Model 260FWPPO 1 - EUBANKS 6415 Prefeeder, Model 6415-03 1 - WATSON 61-Wire, 6+12+18+24, 22” Rigid Strander Line 1 - NEB 54-Wire, 12+18+24, 22” Rigid Strander Line 2 - MGS 18-Bay 10” Tubular Stranders, outside string-up 5 - DAVIS STANDARD Dual Reel Take-ups, 36” (1), 30” (4) 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 5 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-ups 1 - CLIPPER Model SP16 Dual Spooler 1 - DAVIS ELECTRIC Model CRS30 Respooler 2 - WATSON/AFA 84” Rewind Lines, 6,600lb cap. 2 - TEC Model 24STC Hi-Speed Twisters, rated 1300rpm w/2-Wire Payoffs 1 - TEC Model DTC630 D.T. Twister 1 - SCHLEUNIGER PS9500RS Rotary Stripper, 2005 1 - ZOLLER & FROLICH AI-01 Stripper, 2005

Contact: Martin Kenner

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

DECEMBER 2010 | 75

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DIES MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904388-3654. SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service. 60+ years of quality products and service to the wire industry. Contact Bill Drumm at 1-800-332-0747, or E-Mail at sales@sancliff.com. APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette,

Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ wmconnect.com.

PURGING COMPOUNDS AMERICA’S OLDEST SUPPLIER. Since 1948, we’ve supplied millions of pounds so we know a little bit about JIT deliveries an customer satisfaction. We sell for less because our costs are less. BUY SMART - WE DO. Alan Plastics Co., Inc. PH: (781) 828-0700. FX: (781) 828-2087. Contact: E-mail: alphas@aol.com, www.alplastic.com

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & Non-ferrous; Marldon Rolling Ring Traverses) and Used Wire & Cable Equipment. Available (Cleaned, painted & checked operational) Buttwelders: Micro

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.

Models E1S, J4S, J5S, J6S, THD, J45C, GP-0 and AD-5. Coldwelders: Koldweld Models KBM-5 & KBM-9. Babcock Models CBW-2, CBW-10 & CBW-20. Printers: Gillies Models GS500 & GS100HD. Roll Pointers: Morgan Models #250 and Hand Operated. Inquire on other used equipment. Please contact by telephone at 727-863-4700 or by e-mail at urbassoc@verizon.net. EQUIPMENT FOR SALE: • 1 ea. 20-tube strand annealing furnace. • 1 ea. 20-stainless tube cooler. • 1 ea, 20-2" spindle take up with individual electronic drives. • 10 ea. round wire header drums for the take up. • payoff frames for 20 ea. 30 reels with 2" spindles. • 12 ea. lazy susan pay offs for round wire top hats (wire stems). • 91 ea. 30" reels for the take up.

WANTED TO PURCHASE – KINREI BUNCHERS AND CABLERS Kinrei of America wishes to purchase used Kinrei Bunchers and Cablers in good condition. We will quickly provide a quotation on any of our equipment and we feel we can offer the best pricing in the industry. Please feel free to contact Mitch Jacobsen at mjacobsen@kinreiusa.com or 973Ͳ 494Ͳ6143. 76 | WIRE JOURNAL INTERNATIONAL

MEDIA ELECTRICAL WIRE HANDBOOK. Focusing on the special needs of the insulated wire and cable industry, this three softcover book set examines materials, equipment, and products. The original version remains available while the revised Electrical Wire Handbook is divided into three separate handbooks: Part 1 - Wire and Cable Production Materials, Part 2 - Wire and Cable Production Processes, and Part 3 - Types of Cables. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. List Price: $99, WAI Member Price: $59. Go to wirenet.org, and click on The WAI Bookstore.

FERROUS WIRE HANDBOOK. The most recent in a series of handbooks published by WAI, this comprehensive hard-cover book is a new, definitive industry resource for ferrous wire written by members of the Association and edited by former WAI President Robert M. Shemenski. List Price is $235, $195 for WAI members. THE BOOK OF WIRE & CABLE TERMS. Learn the A to Zs of wire and cable with this essential reference source. Published in 2003, this 350page soft-cover book covers both ferrous and nonferrous terminology. More than 5,000 entries are offered. Each entry was reviewed by a panel of industry experts with further input from more than 50 specialists within a wide range of disciplines. A musthave resource for anyone in the wire and cable business from the shop

floor worker to the chairman of the board, Price $75, $50 for WAI members, plus shipping. COLORING OF PLASTICS: FUNDAMENTALS. Edited by Robert A. Charvat, 2004, 402 pages, bound and indexed. This latest edition offers an updated introduction to color as a science. It describes the basic families of colorants, along with their properties, and examines how statistical analysis can improve the consistency of colored polymer production runs as well as the colorants used to match the color. It is intended to give polymer and colorant manufacturers, plastics compounders, and coating and synthetic fiber industries a greater appreciation of the complex technological issues a colorist must consider. List Price: $125.00, WAI Member Price: $105. ■

NEW MACHINES, shortly available Ref. no. 12-6038 QUEINS, high speed bow strander for 7 wires, type QSS 1+6/630, max 1400 rpm, new machine Ref. no. 12-5651 QUEINS, bow twister for stranding insulated conductors, type QRL 1+3 or 1+4 or 1+5/1600 (63“), reel ø 1600 mm (63“), new machine Ref. no. 32-7573 QUEINS, extrusion line for XLPE, 3-layer crosshead, extruders 65/25D, 150/25D, 90/25D, new machine Ref. no. 61-7546 QUEINS, rod drawing machine for Cu, 13 dies, inlet ø 8 mm (0,31“), outlet ø 1,2 - 4 mm (0,04 - 0,15“), annealer, double spooler, new machine Ref. no. 61-7557 QUEINS, rod drawing machine for Al and Al alloys, 13 dies, inlet ø 12 - 9,5 mm (0,47 - 0,37“), outlet ø 1,7 4,5 mm (0,06 - 0,18“), double spooler, new

Pre-owned machines still installed in a German cable factory, promptly available! Ref. no. 13-7612 HENRICH, double twist buncher, take-up bobbin 630 mm, with 7 flyer-type pay-off ’s (2 machines available) Ref. no. 61-7619 HENRICH, copper rod drawing machine model 30R13, 13 dies, inlet 8,0 mm, finished ø 1,4 mm, continuous annealer, dual spooler AR 1000 for bobbins 630 mm ø, plus bundle packer / static coiler for bobbins 1250 mm ø Ref. no. 66-7600 NIEHOFF, 8-wire drawing line, type MMH 101, 21 dies, inlet 1,5 mm ø, finishing size 0,2 – 0,30 mm, continuous annealer R 160, automatic static coiler for 630 mm bobbins Further medium and fine wire drawing machines as well as drawing lines for copper alloys and flat wire.

QUEINS & CO. GMBH

Hans-Georg-Weiss-Straße 12 52156 Monschau GERMANY

Tel.: +49 2472 8080 Fax: +49 2472 3014 Email: info@queins.com www.queins.com

DECEMBER 2010 | 77

CLASSIFIEDS

Contact: Conn-Weld, tel. 304-320-5485 or 540-577-8833, conn-weld.com.

ADVERTISERS’ INDEX

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

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

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

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

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .74

Enkotec Co Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

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

Eurolls SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Bomco Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Bongard Trading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Force Measuring Systems (FMS) . . . . . . . . . . . . . . . . . . .50

Cable Consultants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Fushi Copperweld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18, 20

Chase Coating & Laminating . . . . . . . . . . . . . . . . . . . . . . .49

Inhol BV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

MIND THE GENERATION GAP

Great minds are developing. Engineers. Metallurgists. Innovators. The future of the industry depends on them. Find them online. Connect with them. Influence them. And meet them halfway through WAI.

78 | WIRE JOURNAL INTERNATIONAL

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

Jinyoungtech Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . . . . .21

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Kinrei of America LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Rainbow Rubber & Plastics Inc . . . . . . . . . . . . . . . . . . . . .12

Kos America Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Rosendahl Maschinen GmbH . . . . . . . . . . . . . . . . . . . . . . .5

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Sealeze A Unit of Jason Inc . . . . . . . . . . . . . . . . . . . . . . . .19

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

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

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .14

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Power Sonics LLC/Magnus Equipment . . . . . . . . . . . . . .25

Talladega Machinery & Supply Co . . . . . . . . . . . . . . . . . .35

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .71

Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DECEMBER 2010 | 79

ADVERTISERSâ&#x20AC;&#x2122; INDEX

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

ADVERTISERS’ INDEX

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

February 2011 WJI

Tubular Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

• India outlook

Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .79

Advertising Deadline: Jan. 1, 2011

Witels Albert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Wyrepak Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 4

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17 Global Continuous Casting Forum . . . . . . . . . . . . . . .36-37 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 WAI Webinars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52, 54

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 P.O. Box 103 D-82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

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

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

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

email: amacoil@amacoil.com

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

ZUMB.707.0105.U_WJ SEP.10

w True Length Measurement Even Down To Zero Speed

The Achilles heel of non-contact speed and length measurement has always been the detection of Zero speed or the period change from and to zero speed. Whether going through a change in direction or start/stop operation. These areas of concern have now been eradicated in the new Zumbach SPEEL 3000.

Ask us for additional information: askme@zumbach.ch

Switzerland, Argentina, Benelux, Brazil, China, France, Germany, India, Italy, Spain, Taiwan, UK, USA www. zumbach.com