India Outlook

WIRE JOURNAL FEBRUARY 2011

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India Outlook

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

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

CONTENTS

Volume 44 | Number 2 | February 2011

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . . 24 Fastener Update . . . . . . . . . . 27 Copper update . . . . . . . . . . . . . . . .20 Fiber Watch . . . . . . . . . . . . . 28 WAI News . . . . . . . . . . . . . . 30

John Gross, a metals industry consultant and the publisher of the Copper Journal, shares his thoughts on the continued volatility of copper prices.

Chapter Corner . . . . . . . . . . . 38

Feature: India Outlook

Technical Papers . . . . . . . 58-77

This article on the outlook for India was written by Huned Contractor, the editor of WAI’s quarterly newsletter, WIRE BULLETIN, who presents a home perspective. It also includes a wrapup of the 2010 wire India trade show as well as an interview with WCISA President Rahul Sachdev about the importance of the world’s largest democracy.

Products. . . . . . . . . . . . . . . . 78 Classified . . . . . . . . . . . . . . . 83

. . . . . . . . .44

Career Opportunities . . . . . . . 83 Advertisers’ Index . . . . . . . . . 86

T ECHNICAL P APERS Mordica Lecture: A twist on heavily drawn wires Prof. Javier Gil Sevillano . . . . . . . . . . . . . . . . . . . . . . .58

Next issue March 2011

Fire-induced damage in prestressing steel José Miguel Atienza and Manuel Elices . . . . . . . . . . . .71 Effect of water quality on wiredrawing lubricants Frank J. Solitario . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

• Preview of Interwire 2011

Cover: Long viewed as a region with incredible growth potential, India as a country has begun turning opportunity to reality. This report notes that the proof can be seen in the activity at a recent trade show and the commitments foreign companies are making to serve this market. See p. 44.

FEBRUARY 2011 | 3

INSIDE THIS ISSUE EXHIBIT FIRSTS

. . . . . . .31

INDIA OUTLOOK . . . . . . . . . . . . .44

CONTENTS

INTERWIRE

More than 60 companies have signed up to exhibit at Interwire 2011 for the first time. Has demand improved?

Is it the return to Atlanta? WJI asked some of those exhibitors why they will come, and their replies, well, speak for themselves. Pictured above are Mountville Rubber Sales Manager Mike Coffing, President Bud Paulk and VP of Technical Service John Smith.

4 | WIRE JOURNAL INTERNATIONAL

Activity at recent trade shows reflect just how much potential India has, as exhibitors have reported good discussions with wire and cable companies seeking to make further improvements. The trade shows are just one element of the India story, the focus of this feature, which was written by Huned Contractor, editor of WAI’s quarterly publication WIRE BULLETIN.

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EDITORIAL WIRE JOURNAL

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EDITORIAL

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

In India, a sense of belief and direction The feature in this issue (see p. 44) talks of India’s future, and I can tell you that this very question is being bandied around in many of our television talk shows, where the topic is whether the country is on its way to becoming a superpower. Those in favour note that India enjoyed 6 per cent growth from 1980 to 2002, and 7.8 per cent growth from 2002 to 2005, and that from 2004 until 2010, India’s average quarterly GDP growth has been 8.40 per cent. These numbers speak of success, and while they slowed some during the global economic recession, they did not slacken as much as they did for strongly developed nations.

This is a story that has been a long time coming, but many believe that it was inevitable that such would happen, that it could have been no other way. Consider that in 2010, India rose to the position of the fourth largest crude steel producer. Construction contributed about 8 per cent to India’s GDP in 2009, and though the speed slackened, the government’s focus on awarding projects under different infrastructure segments has once again put air in its bellows and fire in its belly. Our government has gone all out to promote infrastructure development and industry, and with such support the outlook for India’s momentum is good for many years to come. This is good for India and for wire and cable demand, offering more opportunity for both domestic companies as well as foreign companies.

However, this is not to say that all the major challenges have been overcome. A country that is democratically ruled faces the possibility of a change in governance after every election and any change in leadership could tilt the equation. Moreover, the creation of wealth among a small percentage of the population is leading to a huge imbalance and this is something that the government needs to pay attention to. But the one obvious element in this success story is that the growth has been organic and therefore sustainable. Unlike China, which is a state-induced success, India is a success despite the state. In time to come, this new status of the country will provide it with additional power in the corridors of global politics.

Other nations now look forward to investing in India because it is being seen as the fastest growing market, especially for consumer goods. The fact that international giants of the automobile industry have set up production plants (Mercedes Benz, Volkswagen, etc.) in India is a testimony to this new confidence. As reported in the feature, demand continues to grow, and plans are in place that will keep the wire and cable industry busy for many years to come. As many different plans and efforts go forward, the one thing India needs is a new image, that of a nation sans bureaucratic bungling and corruption. When that happens, India will have truly arrived, and the paving will have begun for its road to being a superpower.

Mahesh Poddar, director MIKI Wire Works Pvt. Ltd. Jharkhand, India 6 | WIRE JOURNAL INTERNATIONAL

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

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

203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail 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. © 2011 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.

CALENDAR

CALENDAR March 14-16, 2011: AWPA Annual Meeting Orlando, Florida, USA. This event will be held at the Hilton Bonnet Creek in Orlando, attached to the WaldorfAstoria. Contact: www.awpa.org, tel. 703-299-4434.

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.

March 31-April 1, 2011: Polymers in Cables 2011 Miami, Florida, USA. This event, organized by AMI and to be held at the Hilton Miami Downtown, brings together cable producers, raw materials suppliers and equipment manufacturers. Contact: Marissa Hann, tel. 610 478 0800, mh@amiplastics-na.com.

April 7-9, 2011: Cable & Wire, Electric & Energy Fair Istanbul, Turkey. To be held at the at CNR Expo IstanbulTurkey, this event, organized by Media Force Fuarcýlýk with the support of Conductor Industry Association, includes wire and cable, wiring harnesses, insulating materials and equipment. Contact:Contact: Media Force Fuarcýlýk, tel. 90-212-465-6545, info@mediaforceonline.com.

April 19, 2011: NESMA Trade Show Plantsville, Connecticut, USA. This New England Spring & Metal Stamping Association event will be held at the Aqua Turf Country Club. Contact: Cindy Scoville, tel.

860-314-2101, c.scoville@centralctchambers.org, or go to www.nesma-usa.com. See p. 12.

May 2-3, 2011: Wire Rod Supply Chain Conference Atlanta, Georgia, USA. In partnership with WAI, the American Wire Producers Association (AWPA) and other trade associations in the supply chain will once again sponsor this unique industry event for ferrous rod, wire and wire products manufacturers. Contact: AWPA, tel.

703-299-4434, www.awpa.org. See p. 11.

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. 52-53.

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.

W IRE ASSOCIATTION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.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.

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May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. See main listing.

2012: Wire Expo 2012 Dallas, Texas, USA. See main listing.

Sept. 13-15, 2011: wire Southeast ASIA Bangkok, Thailand. Organized by Messe Düsseldorf, this event will be held at the Bangkok International Trade & Exhibition Centre (BITEC). Contact: Messe Düsseldorf North America, erowe@mdna.com, tel. 312781-5180.

Sept. 19-21, 2011: The National Wire Electrical Manufacturing and Coil Winding Expo Nashville, Tennessee, USA. To be held at the Gaylord Opryland Resort & Convention Center.

Contact: Expo Productions, Inc., tel. 262-367-5500, www.expoproductionsinc.com.

held at the Centro de Exposicoes Imigrantes. Contact: Cipa LTDA. Correia de Lemos, tel. 55-11-55854357, fax 55-11-55854359.

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.

2012: Wire Expo 2012 Dallas, Texas, USA. WAI will hold this event, which will include its 82nd Annual Convention, for the first time in Dallas, the exact dates and location to be decided. ■

Oct. 4-6, 2011: MetalTech 2011 São Paulo, Brazil. This event, for the metal drawn wire, rolled products and related machinery industries, will be

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FEBRUARY 2011 | 9

CALENDAR

June 19-23, 2011: JI Cable 2011 Versailles, France. To be held at the Versailles Congress Centre, this event presents a comprehensive forum about power cables and exhibits. Contact: JI Cable 2011, www.jicable.org.

INDUSTRY NEWS

INDUSTRY NEWS LS Cable receives $100 million order from Indonesian National Police South Korea’s LS Cable announced that it has won a $100 million contract from the Indonesian National Police that calls for it to engineer and install an integrated wired and wireless communications network and a control center for 135 police stations and six police agencies as well as equip police vehicles with IT equipment such as laptop computers and communication devices.

A press release said that the company, in essence, is providing a complete communications network and integrated control center, a project that represents “the first remarkable outcome of LS Cable’s solution-centered business model innovation.” The completed communications network will integrate police stations across the entire densely populated island of Java and also build an integrated control center for efficient field supervision, it said. The authorities, it noted, will get capabilities that include automatic address search, reporter position tracking, electronic map and vehicle location tracking solutions specialized to the local conditions. “The Indonesian National Police anticipate that once this project is completed, their abilities to respond to and handle accidents, distress calls and terror incidents will improve significantly,” it said.

This order was possible because LS Cable was highly evaluated for the successful completion of an information access center implementation and ICT education center installation in Indonesia respectively in 2006 and 2007, the release said. “We will actively attack the global market by achieving innovation of our business model centering on solutions rather than individual products,” said LS Cable President Jong-Ho. LS Cable has been succeeding in its overseas SI business endeavors as of late, centering on Asia and the Middle East, including receiving an order for an open access optical network project from Bangladesh in May. The business has been expanding recently into the Central and South American regions.

Chinese bid for Draka withdrawn A recent Chinese offer to buy Dutch cable maker Draka NV has been withdrawn. The one billion euro bid from Tianjin Xinmao S&T Investment Corp. Ltd., which had topped a previously accepted offer from Prysmian, had shocked the industry. The problem with the Chinese bid, wire reports said, included questions about funding and the time frame as well as logistical problems that reportedly could require getting as many as seven regulatory approvals from Chinese authorities. Draka said it would now move ahead with the agreed-upon Prysmian deal.

Interwire 2011 report The Interwire event returning to Atlanta this May does so with renewed energy on the show floor (see p. 30) and three days of “theme” technical programs (see p. 34) designed by wire and cable manufacturers as well as a unique forum on continuous casting (see p. 52). The March WJI preshow issue will present those elements and much more.

NEC Corp. part of group that lands $362 million undersea cable contract Bloomberg reports that NEC Corp., Japan’s largest maker of phone-network equipment, has won a $326 million order from a group led by Nippon Telegraph & Telephone Corp. to supply undersea cables.

The story, which notes the deal had not been made public, says that the order calls for fiber-optic cables to be laid that will connect Japan with Southeast Asia. It cited increased bandwidth demand, such as video downloads from Google Inc.’s YouTube and the popularity of smartphones, as reviving the market for undersea cables. It added, “NEC is vying with Alcatel-Lucent SA and Tyco Electronics Ltd. for contracts in a $2.6 billion market that researcher Frost & Sullivan Inc. estimates will grow as much as 9 percent a year through 2015.”

LS Cable wins US$20 million order for optical fiber network for Qatar South Korea’s LS Cable Ltd. has won a deal worth more than US$20 million to build and maintain a communication network in Doha, the largest city in Qatar.

BloombergBusinessweek.com reports that the contract includes an $18 million project, from Vodafone Qatar, that calls for LS Cable to establish broadband networks using optical cables to provide fast Internet service in the city. The order also includes a project worth $2.5 million for network maintenance, it said.

New Zealand contract goes to consortium that includes nkt cables A consortium with the nkt cables and Balfour Beatty/UGL Limited as participants, has won a cable contract in New Zealand from Trans Power worth about 47 million euro.

A press release said that nkt cables’ part of the contract is worth about 20 million euro. UGL Infrastructure and Balfour Beatty Utility Solutions have been working

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

10 | WIRE JOURNAL INTERNATIONAL

Nexans to supply 440 km of fiber optic cable to Chinese company Nexans announced that it has won a major contract that calls for it to deliver 440 km of submarine fiber optic cables for use under the Mediterranean Sea. The contract, from Huawei Marine Networks Co. Ltd., will be used for a high-profile communications project, the Libya Silphium link across the Mediterranean Sea, a press release said. The Silphium system, it noted, will provide route protection for Libya’s existing international communication channels and also offer bandwidth improvement designed to satisfy increasing demand for multi-national communications.

Huawei Marine is constructing the link on behalf of the Libyan International Telecom Company (LITC). The cable will cross the Mediterranean Sea, connecting Damah, in Northern Libya with Chania, Greece, and will have an initial capacity of 7 x 10 Gbps and a maximum theoretical capacity of 1.2 Tbps, it said. The cable, it said, will be installed at sea depths of down to 3,700 meters.

The cable, for unrepeatered fiber optic systems, will be manufactured at Nexans’ factory in Rognan, Norway with delivery in spring 2011, the release said.

“This very significant submarine cable contract in the Mediterranean Sea is the result of almost a year’s careful planning between Nexans and Huawei Marine,” said Tom Birkeland, vice president for Nexans’s telecom and building cable division in Norway. “It reinforces the successful cooperation between the two companies developed over a number of high profile projects such as the Hannibal link between Tunisia and Italy and the T-E project connecting the coastal cities of Libya, Tobruk and Emasaed.”

Prysmian Cables & Systems reports 2 contracts worth 60 million euro Prysmian Cables & Systems reports that it has won two contracts worth more than 60 million euro for a project in Europe and one in Turkey.

A press release said that the company has an order from Energinet.dk to supply a 500 kV cable system for the Skagerrak 4 HVDC link between Norway and Denmark, which represents a new interconnection between the two countries that it said will enhance the Nordic electricity market. The contract includes the supply, jointing and testing of 92 km of 500 kV mass-impregnated underground cable system and related accessories, with a trans-

AWPA report: new rod supply chain conference to colocate with Interwire Did you miss the Long Products Supply Chain Symposium held in Milwaukee last May? The program was outstanding and attendee feedback was FANTASTIC. Sponsored by 16 companies and 11 ferrous wire-related trade associations, this event was attended by CEOs and senior executives from rod, wire, and wire products companies. The programming had just begun for the 2011 event and the major sponsors are already signed on, along with many new sponsors.

The event has a new name but the content will once again provide participants with important and timely information from top quality speakers.

You will have The rod supply panel in 2010 included, opportunities to l-r, Matthew Brace, executive v. p. of meet with supplisales & marketing, CMC Americas; ers, customers Jim Kerkvliet, v.p. commercial sales, and colleagues to Gerdau Ameristeel; David Brooks, gain insightful senior v.p. of American Metal Market; information about H. Woltz, chairman/CEO, Insteel the marketplace.

Industries; and Jack Lynch, sales Plan to attend manager, Charter Steel. the Wire Rod Supply Chain Conference May 2-3, to be held in Atlanta, Georgia, just prior to the Interwire exhibition.

Is the recession over? What is the extent of the manufacturing sector’s recovery? Which of the key wire and wire products markets are back: Commercial Construction, Housing, Autos? The program will include two high-level industry keynote speakers; a general economic picture of the recession and recovery; a construction outlook; a steel industry forecast; a scrap/metallics analyst; and the popular wire rod supply panel. The wire rod supply panelists will discuss the market from the point of view of domestic and international rod suppliers, a stainless rod supplier and a major wire producer.

Sponsorships are available and provide a great public relations opportunity for your organization, and include complimentary registrations for representatives from your company. Consider the breadth of participants in the supply chain and your opportunity to reach potential new customers. Last year’s event brought 300 of the top executives from all strata of the wire rod supply chain.

Commit early for the best exposure.

Contact Emily Bardach at the American Wire Producers Association, ebardach@awpa.org or 703-299-4434.

FEBRUARY 2011 | 11

INDUSTRY NEWS

together since 1982 as a joint venture called, BBUGL, which designs, supplies and constructs overhead and underground electrical transmission and distribution systems. The contract calls for the NKT/BBUGL consortium to manufacture and install an 18 km cable that is part of a major upgrade of the electricity grid in New Zealand, it said. “The consortium was chosen because they are all extremely experienced in the production and installation of extra-high-voltage cables,” it noted.

INDUSTRY NEWS

NESMA to hold 30th anniversary event on April 19 in Connecticut The New England Spring and Metal Stamping Association (NESMA) will hold its biennial trade show on April 19, at Aqua Turf Country Club, in Plantsville, Connecticut, where the organization will celebrate the 30th anniversary of the trade show for the spring industry, which has expanded in recent years to include metal stamping.

At the NESMA website, the organization—whose membership includes more than 60 companies, many of them in region but also from outside New England—notes that the trade show is an excellent way “to see what is new in the industry, to renew old acquaintances and to network with new business partners. … We encourage management to offer employees access to the daytime events and if possible, the evening program as well,” it said, adding that, “We all know that many changes have occurred over the 30 years, but we should take pride in knowing that each of us continues to be a strong member of NESMA carrying on the original objectives of this organization.”

The event starts at 1 pm and concludes at 6 pm. It will also include an array of seminars during the day.

Following a cash bar reception at 6 pm, dinner will be served at 7 pm. It At the 2009 NESMA show, Wafios will feature Machinery Corp.’s Al Clement explains a speech the performance of a CNC machine.

by ESPN founder Bill Rasmussen, which promises to be colorful whether one is a sports fan or not.

NESMA was created by a few owners of spring companies in the Bristol, Connecticut, area back in 1956, who recognized the need for a trained, skilled work force.

The event originally was called the New England Spring Manufacturers Association but in later years changed to The New England Spring and Metal Stamping Association as many members were involved with both spring and metal stamping.

The event is free to attend, and tickets for dinner are $70, $55 for NESMA members. To register and for more details, including hotel rooms, go to the NESMA website at www.nesma-usa.com, or contact Cindy Scoville at scoville@centralctchambers.org, or at tel. 860-314-2101.

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mission capacity of 700 MW, that will be made at Prysmian’s manufacturing facility in Arco Felice (Naples), Italy, it said, adding that the project is scheduled for completion by late 2014.

“Northern Europe represents a strategic market for Prysmian, with a number of projects currently ongoing and already accomplished,” said Prysmian Powerlink CEO Marcello Del Brenna. “The upgrade of interconnections in the area will further strengthen also the development of the offshore wind power, which is one of the key focuses of the Group. In this area, in particular, the Group is deeply involved in the development of offshore wind farms for the exploitation of energy from renewable sources.”

The company also reported that its Turkish subsidiary, Turk Prysmian, has two new projects worth a total of 20 million euro that calls for it to supply and install 52 km of high-voltage cables and 78 high-voltage joints and terminations. The new connection in Istanbul will replace the existing transmission line which will be removed following completion of the Umraniye-Vaniköy cable project, it said. The cables, it added, will be manufactured at Prysmian’s Mudanya facility, with the projects to be completed early in the first quarter of 2012.

Rockwood sells AlphaGary plastics compounding business to Mexichem Rockwood Holdings Inc. announced that it is selling its plastic compounding business to Mexichem SAB de CV for US$300 million. The sale includes AlphaGary US, AlphaGary UK Ltd. and AlphaGary Canada business units. The closing of the sale is expected to take place in the first quarter of 2011.

AlphaGary manufactures specialty plastic compounds for the wire and cable business as well as medical applications and other uses. The AlphaGary operations, which represent the largest division in Rockwood’s Specialty Compounds segment, were sold as part of Rockwood’s plans to concentrate “our portfolio on high-margin specialty chemicals and advanced materials businesses,” a press release said. Rockwood Chairman and CEO Seifi Ghasemi said that the company expects to use the proceeds of the sale to reduce debt.

“AlphaGary will continue to provide high standards of service to customers and we believe this combination with Mexichem will enhance our position in the markets we serve,” a press release said.

Mexichem, which was described as the only vertically integrated chemical manufacturer in Mexico and the largest vertically integrated hydrofluoric acid producer in North America, was said to have annual sales of approximately US$1.2 billion and exports to more than 50 countries. Its operations include two production chains: the vinyl-chlorine chain, which comprises Unin Minera del Sur, Cloro de Tehuantepec, Pennwalt, and Primex; and the fluorine chain, which includes Mexichem Flor.

Sister companies Canterbury and GENCA report that 27 wire and cable customers from eight different countries attended a recent two-day extrusion seminar at their operations in Clearwater, Florida, where the program was presented in both English and Spanish.

The event, held in early December last year, focused on the company’s expertise in injection and extrusion screws as well as cross heads and tooling for extrusion. CEO Paul Cusolito welcomed the attendees, who heard Spanish translations of talks by Joe Chapin, Jim Scott and Joe Fleiss, experts in extrusion, tooling and screws. The presenters explained basic, intermediate and advanced information, with topics ranging from calculation tips to how to select cross heads and extrusion screws.

Attendees from outside the U.S. came from Chile (PD Cocesa), Columbia (Centelsa, Nexans Columbia and Procables), Costa Rico (PD Conducen), Mexico (Aceros Camesa, Conductores Monterrey, Conductores del Norte, Mexichem and Pisa Pharmacy), Peru (Brande), Puerto Rico (RD Medical) and Venezuela (Elecon).

GENCA Managing Director Jasmin Sehovic was joined

INDUSTRY NEWS

Attendees from 8 countries attend Canterbury/GENCA extrusion seminar

The fine points of extrusion technology were presented at GENCA’s recent extrusion seminar.

by Michael Maduro and Antonio Ayala, Latin America sales managers, who answered questions and helped solve specific problems for each customer. The customers and GENCA staff also enjoyed a visit to Bush Gardens.

“This kind of seminar is a very good way to share our experience and technical information as well as offer customers a chance to speak with staff that has expertise with different equipment brands as well as new materials in the market,” Ayala said.

The Big One — Cable Raw Material Savings When your cable compacting dies lose tolerance by 0.1mm, you are wasting very valuable raw material. For a typical 240 mm² Copper cable, up to $10,000 of wasted raw material goes out the door of your factory for every 100 Km of cable that you produce.

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FEBRUARY 2011 | 13

INDUSTRY NEWS

Acquisition talks spurned, Coleman Cable offers $38 million for business

Alcan Cable establishes a new company entity in Mexico

U.S.-based Coleman Cable, Inc., announced that it has made an offer to the board of directors of Technology Research Corporation (TRC) to buy the company for US$38 million.

A press release noted that the company took the action because TRC would not meet with them. “We have attempted to engage TRC’s board of directors on a number of occasions and we are disappointed that rather than engaging in constructive dialogue with (us), TRC’s board instead adopted a ‘Poison Pill’ to block a transaction that is clearly friendly to its shareholders,” said Coleman President and CEO Gary Yetman.

The release noted that Coleman Cable’s offer for TRC’s outstanding shares represents a premium of 46% to the average closing share price for the 20 trading days before the offer was made public.

At its website, Technology Research Corporation, based in Clearwater, Florida, notes that it specializes in power distribution and power management solutions for military and commercial customers, with its core focus on supplying electronic control and measurement devices.

Alcan Cable, a business of Rio Tinto Alcan, announced that it has created a new legal entity for its cable operations in Mexico that will be known as Alcan Cable de México.

Rio Tinto Alcan has undergone significant divestments in recent years, including the composites division of the Engineered Products business, but it has maintained its ownership of Alcan Cable, which has now strengthened its identity. That, company officials said, will allow the business to expand its sales and technical support to the major metropolitan areas of Guadalajara, Monterrey and DF, and to facilitate business transactions in local currency.

Alcan Cable de México’s corporate office is located in Monterrey.

14 | WIRE JOURNAL INTERNATIONAL

Carlyle Group completes $3.9 billion acquisition of CommScope Inc. The Carlyle Group announced that it has closed its $3.9 billion acquisition of CommScope Inc., a global supplier of cables as well as wireless technology. A press release

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

Q: Why did you join WAI? A: To network and connect with like-minded business professionals and enhance my career development through WAI technical programs and contacts. I also like the ability to meet many suppliers in one location.

Q: Why do you renew your membership?

A: To stay abreast of the latest technologies for a competitive edge and keep in touch with friends and colleagues from around the world. I am at the point in my career that I would like to give back to the WAI and our industry by being a voice for manufacturing.

Q: What would you be doing if you hadn’t become involved in the wire industry?

A: I’d be in the metals industry. I like metallurgy and molten metals.

Q: What do your co-workers say about you?

A: They think I am always trying to improve something, innovative, very knowledgeable of copper continuous casting, results oriented, outspoken, and fair.

Gary Spence

Q: What did your most valuable WAI contact help you do?

A: Many helped further my professional development and assisted me in achieving product and process improvements. I now have global contacts to communicate with via the Internet at anytime.

VP Nonferrous Metals | Encore Wire Corp.

Member Since: 1980

Meet Gary Spence.

One of WAI’s worldwide members.

One compelling story.

You’ll find Gary where innovation and old-world ethics collide. Continuously improving. In 40 years he’s gathered more information on copper continuous casting than most will ever learn. Until May 2011, that is, when he will join a casting call of his international colleagues at Interwire for a global copper continuous casting forum of his design.

He’s an expert. An optimistic leader. And, he’s emblematic of the knowledge base accessible through WAI. Gary’s profile reveals key themes familiar to all distinguished personalities, namely:

Q: Who was your mentor?

A: My parents; they instilled a strong work ethic. I have also been fortunate to work for three outstanding companies all with strong, innovative leadership.

Q: What is something that few people know about you?

A: I do not have a cell phone.

Q: Who is the most famous person you’ve met?

A: I met Brooks Robinson—the Baltimore Oriole third baseman with a golden glove—at a ball game in San Francisco.

Q: What do you do for leisure?

A: You can find me at a health club or by the water somewhere.

Bold Optimism | Intrepid Innovation | Achievement | Hot Metal | Cool Mettle | Moving Ahead | Giving Back A global networker without a cell phone. Trust us. He stays connected. And when you meet Gary be sure to ask him what he’s working on. He’s clearly advancing but he’s always ready to give back.

MNEMONIC TIP: GARY SPENCE. GARY SPENDS TIME ON INNOVATION.

Q: What is your lifelong ambition?

A: In business to be recognized as an expert by my peers.

To be the best I can be at whatever I pursue.

Q: What is your greatest accomplishment?

A: I am optimistic the best is yet to come.

Meet your peers. Achieve your goals. Join WAI’s community 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

RI S

The Wire & Cable Manufacturers’ Alliance (WCMA) announced that eight industry veterans will be honored at its 27th annual Awards Dinner and Investiture Ceremony on April 16 at the Connecticut Convention Center in Hartford, Connecticut.

A press release said that the newest inductees include: Jim Anixter, president, A-Z Industries, Inc.; Ray Baril, president, TempFlex Cable, Inc.; Randall Crenshaw, executive vice president & chief supply officer, CommScope; Jim George, business manager/cable materials, NEPTCO Inc.; Stew Later, vice president of sales and marketing, Comtran Cable LLC; Robert Raiti, president, Owl Wire & Cable, Inc.; Bill Reichert, vice president, operations, Champlain Cable; and Peter Sheehan, CEO, Cobra Wire & Cable, Inc. The Wire & Cable Manufacturers’ Alliance continues the tradition of recognizing industry professionals that was started in 1985 by the late Dick and Harriet Callahan, founders of the Wire & Cable Clubs of America.

Following a nomination process, a Selection Committee of over one-hundred prior award recipients votes on the candidates. After a review of the ballot results, the former recipients on the WCMA Board of Directors select the new yearly recipients of strong character and credibility who have made significant commercial or technical contributions over a minimum 25-year industry career.

WCMA, established in 2004 as the successor organization to the Wire & Cable Clubs of America, is a corporate membership organization for manufacturers of con-

TO C A SE DA K T Y FR UP EE A TR IA

WCMA award winners to be honored in April

ductor, insulated wire, cables, fiber optic cables and connectivity products with an established manufacturing base in North America, as well as industry suppliers and service providers. For more information, contact Deb Mathiasen at tel. 860-873-2311 or mrcdm@snet.net, or go to www.wcmainc.org.

NO SEAMS NO SPLICE NO FAILURES

Catroll Belts for Caterpuller, Capstan and Haul-Off Units have been developed specifically for the wire and cable industries. Catroll will eliminate short belt life, cover separation, tracking and other belt problems.

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FEBRUARY 2011 | 17

INDUSTRY NEWS

said that Marvin S. Edwards Jr., CommScope’s current president and COO, has been named president and CEO, succeeding Frank M. Drendel, who will stay on as chairman.

INDUSTRY NEWS

An industry marketing first? Company says its product has no (scrap) value It’s rare that a company will admit that its products are anything less than sterling, but given the problems with wire and cable being stolen for its copper content, Fushi Copperweld has introduced a product that it is declaring in print has no value, in terms of scrap, that is.

The company’s new anti-theft product, Copperweld®

HIDE™, is a copper-clad steel wire jacketed in a steelgrey colored PVC coating. A press release notes that it performs the same function as pure copper wire in electrical grounding, railroad signaling and many other applications highly exposed to theft, but it is primarily made of steel, and as such, of minimal scrap value to plunderers.

“Furthermore, the grey PVC makes it look from a distance like plain galvanized steel wire,” the release said.

“HIDE is a quadruple-threat to copper thieves,” Joe Longever, CEO of Fushi Copperweld, said in the release.

The value of Copperweld’s latest product relates to its lack of value...to would-be thieves, that is.

“First, it looks like steel until you’re very close to it,” Longever said. “Second, it is made of genuine high-strength Copperweld — much harder to cut than copper wire—which should be the first tip-off to would-be thieves that they are going after the wrong material. Third, if they do decide to cut, they will be sorely disappointed when the time comes to cash in, because the metal is of very little scrap value. Finally, Fushi Copperweld is even imprinting this message on the jacket itself, in both English and Spanish in the American market, to go one step further in letting copper thieves know to move on.”

PolyOne acquires Brazilian supplier of thermoplastics PolyOne Corporation, a U.S.based global provider of specialized polymer materials, services and solutions, reports that it has

18 | WIRE JOURNAL INTERNATIONAL

closed, there had been nearly 250 employees. …

Andrew Solutions, a division of CommScope, Inc., that specializes in wireless communications systems and products, has been named In-Building Wireless Vendor of the Year in this year’s Telecom Asia Readers’ Choice Awards.

A press release said that the award was given based on nominations from a panel of more than 60 wireless industry analysts, consultants and service providers as part of an annual event recognizing the innovations and contributions to the industry of the top telecom vendors operating in Asia Pacific. ■

News in brief Poland’s TELE-FONIKA Kable reports that it won the Eminent Exporter 2010 Award at the 7th Congress of the Polish Exporters’ Society, which took place on Nov. 25, 2010, in the Warsaw Mariott Hotel. The competition, which promotes exporters from all businesses and regions in Poland, is open to all Polish exporters. The Polish Exporters’ Society includes more than 300 Polish exporters from all trades and regions. … EUROMADEM Spain announced that it has been awarded PEFC “Green” certification for manufacture of wooden reels. The company notes that it is the largest wooden reel supplier in Spain and Portugal. PEFC (Programme for the Endorsement of Forest Certification Scheme) is the world’s largest forest certification organization, promoting sustainable forest management that is socially beneficial and economically viable through independent third party forest certification. … The furnaces have been fired up at the ArcelorMittal steel mill in Georgetown, South Carolina, for the first time in about 18 months.

TheSunNews.com reports that small batches of steel have been made for test runs for the nearly 264,000 tons of wire rod expected to be annually produced at the mill, which has the capacity to produce about 480,000 tons. The company said that it had more than 700 applications for the 187 positions it hopes to fill. When it FEBRUARY 2011 | 19

INDUSTRY NEWS

acquired Uniplen Industria de Polimeros Ltda. (Uniplen), a Brazilian producer of specialty engineered materials and distributor of thermoplastics.

“The Uniplen acquisition provides PolyOne with local expertise in specialty engineered materials as well as an attractive position in the Brazilian thermoplastics distribution market,” said Stephen D. Newlin, chairman, president and chief executive officer. “The combination of Uniplen and our previously announced acquisition of Polimaster firmly establishes our specialty product offering and overall customer service capabilities in Brazil.”

ANALYSIS

Copper – the challenge continues

By John E. Gross The market is bullish, and why not?

Over the past two years, following the financial meltdown of 2008, copper has not only recovered all lost ground, but has also risen to record highs in a record amount of time.

Virtually everywhere you look, forecasts call for continued global economic growth that will require more copper There is little point with expectations in trying to outguess that production will not keep up with the market; it can’t demand, thereby be done consistently. drawing down already low inventories. Further, if industrial demand is expected to keep prices aloft, it is thought the introduction of Exchange Traded Funds to meet investor demand will have markets soaring. Thus, almost to a person, the outlook remains positive, with many if not most calling for higher prices throughout 2011.

On the numbers, it is hard to disagree with conventional wisdom. After copper hit a low of $1.25 in 2008, the market climbed $2.08, or 166% to close 2009 at $3.3275. 2010 saw more of the same with the spot price on Comex closing out the year at a record high $4.4395, with the full year also averaging a record high $3.4251, up 45% from the $2.3542 average in 2009. Correspondingly, inventories of copper held in Comex and London Metal Exchange warehouses fell 156,000 metric tonnes, or 26%, during 2010, to close out the year at 436,166 mt. (See chart on opposite page.)

In large part, the decline of inventories reflects a market in deficit that is expected to continue supporting prices going forward. Based on recent statistics from the International Copper Study Group, the global copper market generated a 436,000 mt deficit through September as compared to a 56,000 mt shortfall during the first nine months of 2009.

Although production of refined copper rose 707,000 mt, or 5.2% through September to 14.24 million mt, it was not enough to keep up with consumption that climbed 1.09 million mt, or 8% from the year ago period to 14.68 million mt.

Looking ahead, it is anticipated that consumption will outpace production again in 2011, with the market being in deficit by another 440,000 mt and paving the way toward

20 | WIRE JOURNAL INTERNATIONAL

higher prices. Indeed, a consensus of opinion among analysts predicts that copper will average $3.75 in 2011, up almost 10% from 2010.

Expectations of continued economic growth in major industrial economies as well as emerging markets also support the positive outlook. Gross Domestic Product is forecast in 2011 to grow 2.6% in the United States; Germany +2.2%; Japan +1.3%; China + 8.9%; India +8.6%; Russia +4.0% and South Korea up 3.9%.

Collectively, these countries account for approximately 70% of global consumption.

There is another side to the story, however, one that is considerably more sobering. The bullish argument is certainly a logical one based on current fundamentals prospects, but in the world of commodities logic is often in short supply and expectations can change in an instant.

John E. Gross On July 2, 2008, the copper spot price on Comex traded at a high of $4.0775, and the outlook was for further gains. But as we now know, the economic crisis changed the equation entirely as commodity prices crashed, with copper falling a mind-numbing $2.83, or 70% to $1.25 just six months later.

To state the obvious, just as we can’t predict changing winds, neither can we know what will cause the markets to shift course, or when it will occur. To this point, China, the world’s largest consumer of copper is working to transform its economy from being export dependent to one based more on domestic consumption, and is also now attempting to limit rising inflation. Thus, for the second time in three months, interest rates were increased, with further tightening anticipated. If these changes result in a slower consumption rate, the world will see more metal moving into inventory.

Also, while no statistics are available, some analysts believe that China is already holding significant quantities of unreported stocks.

On the European side, we saw the impact of the sovereign debt crisis during the second quarter when Greece had to be rescued causing markets to shudder throughout the world, with copper falling 85¢ before recovering. Since then,

ANALYSIS Copper prices have outpaced inventory changes.

Ireland also had to be bailed out, and it is thought that Portugal, or possibly Spain, will be facing a similar fate.

As we’ve already seen, any crisis of confidence, regardless of the source can have a swift and severe impact.

Within the United States, fears of a double-dip recession seem to have receded, but our economy has yet to see any meaningful recovery in the building and construction sector that represents almost 50% of domestic demand.

Construction spending overall is running at an $815 billion annualized rate through November, down 30% from $1.167 trillion posted in 2006, while housing starts which came in at an annualized 555,000 in November are off almost 75% from the peak of 2.068 million during 2005.

From a different point of view entirely, and completely unrelated to the fundamentals, one proprietary technical indicator with more than fifty years of history and a record of 78% accuracy indicates prices will fall this year rather than reach a new high annual average.

Thus, with copper currently trading at record highs and some analysts eyeing the $5.00 level, we would be remiss to ignore the potential pitfalls. Further, if nothing else, the past five years have clearly demonstrated an unprecedented level of volatility that poses an unprecedented level of risk for any organization dependent upon copper and other metals.

It necessarily follows, therefore, that your organization must have a plan in place that can be implemented when necessary, to mitigate price risk exposure. There is little point in trying to outguess the market, it can’t be done consistently. What can be done, however, is to properly manage purchases and sales, and protect inventory valuations.

This is the key to maintaining profitability, regardless of whether the market rises or falls.

John Gross, the publisher of The Copper Journal, is a metals industry consultant with a focus on price risk management. For more information on his company’s services, go to www.copperjournal.com. ■

FEBRUARY 2011 | 21

ASIAN FOCUS

ASIAN FOCUS India, not China, is the electronic focus of Wikipedia’s plans for major growth Think of expansion and growth, and China is likely first to come to mind, but Wikipedia, the provider of a wellknown and much used global online encyclopedia, has high hopes for continued growth of its free service, with India expected to be a key to its goal of topping a billion users within five years.

A Reuters article said that the San Franciso-based nonprofit organization currently has 410 million unique visitors a month, the fifth most of any website, and that with a rela-

she noted that the company will have 316 events in 104 nations marking Wikipedia’s 10th anniversary, with 60 scheduled in India.

“Our main strategic focus right now is on India and other countries in the developing world. Massive numbers of people are starting to get connected to the Internet, mostly through mobile phones but also through traditional PCs,” Gardner said.

The article notes that, while just about anyone may add or alter entries without oversight, the journal Nature reported in 2006 its accuracy was close to that of Encyclopedia Britannica. The company has some 100,000 regular contributors who work for free, with the general public writing and editing articles in 270 languages, it said, noting that the site carries 17 million articles in English, adding 1,100 per day.

Leoni establishes plant in India

Wikipedia is looking to India as a driver for its goal of achieving a billion users. tively low budget of US$20 million a year, most of which comes from donations, it has announced that it is seeking to more than double its activity through increased activity in India, as well as Brazil.

The article said that Wikipedia’s goal is to attract additional users, but it has not moved any servers into China yet because it would mean accepting government limitations on publishing. “With the Chinese market essentially cut off and Western markets maturing, India and Brazil present attractive growth opportunities,” it said.

This year, as the organization celebrates its 10th year of being in operation, it will open its first overseas office, in India, where it will work to increase readership and articles in English and many Indian languages, Wikipedia Executive Director Sue Gardner said. In an interview with Reuters,

Germany’s Leoni, which specializes in cables and cable systems for the automotive sector and other industries, has established a wiring systems manufacturing facility in India, in Pirangut, located near Pune, that has begun to supply diesel engine harnesses to Tata Cummins Ltd. An announcement from the company said that it expects “annual sales of double-digit millions of euros” by 2012.

It said that TCL is a joint venture between the Indian car maker Tata Motors Limited and the American engine manufacturer Cummins Engine Company Inc. The factory was officially opened in December by Uwe H. Lamann, a member of the company’s Executive Board who is responsible for the Wiring Systems Division at Leoni.

“India is a major growth area of the global automotive market and is therefore strategically important for Leoni,”

Uwe H. Lamann officially opened the new wiring systems plant in Pirangut near Pune.

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

22 | WIRE JOURNAL INTERNATIONAL

ASIAN NEWS BRIEFS Expanded production begun by Cords Cable Cords Cable Industries Limited announced that it has commenced initial commercial production at its new manufacturing facility in Rajasthan, India. The new facility has a potential to double the companyâ&#x20AC;&#x2122;s cable production capacity, it said.

Cords, founded in 1987, produces high quality customized cables. The company notes that its products

include: LV power & control cables, instrumentation cables, thermocouple extension cables, compensating cables, telephone cables, panel wires and customized cables. Cords quality management system is ISO 9001:2000 certified. Its Occupational Health & Safety Management System is certified through BS OHSAS 18001:2007 and Environmental Management System is certified through ISO 14001:2004.

New aluminum product made by Japanâ&#x20AC;&#x2122;s Kyowa Steel Guru reports that a new solderable aluminium wire product has been launched by Kyowa Electric Wire Company, a division of Furukawa Electric Company of Japan.

The story noted that the product â&#x20AC;&#x153;targets a significant new market in building wiring,â&#x20AC;? as conventional aluminium wire cannot be soldered because it has a strong oxide layer. The new product uses a tin-alloy layer that is plated onto the aluminium wire for easy soldering. Aluminium wire has long been used by utility companies in power grid applications, but because of higher copper prices it has seen more usage for building and housing applications, it said. â&#x2013;

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ASIAN FOCUS

Lamann said. â&#x20AC;&#x153;This new plant and our engineering and customer support in Pune emphasises our position as a leading global supplier of automotive wiring systems and demonstrates Leoniâ&#x20AC;&#x2122;s commitment to supporting our customers in India.â&#x20AC;?

The factory area is about 1,300 sq m, with the potential to expand to more than 6,000 sq m in support of the planned growth of the business, the release said. â&#x20AC;&#x153;The management structure of the Pune facility is in place and ongoing recruitment in support of planned business growth is expected to result in a headcount of around 240 by the end of 2011.â&#x20AC;?

PEOPLE

PEOPLE Dr. Christoph MüllerMederer is the new sales and marketing director on the board of directors for Wafios, responsible for its sales agencies around the world. He and Dir. for Development and Design Dr. Uwe-Peter Weigmann will share Egon Reich (l) has passed the leadership of the four baton at Wafios AG to Dr. Wafios divisions. Müller- Christoph Müller-Mederer.

Mederer will work on the further development of new markets, industries and customers, with special focus on the expansion of business in China and Asia as well as optimization of existing processes in the sales area. He replaces Egon Reich, who will retire after more than 40 years of service, but be available as a delegate of the board of directors through 2013 as well as a resource for Dr. Müller-Mederer in his new post. Based in Reutlinger, Germany, Wafios AG is a global supplier of wire and tube processing technology.

John Laskowsky has been named president and CEO of C&M Corporation. He most recently was president and CEO of Barry Controls, and prior to that he was at the Eaton Truck Group. He holds a BSEE degree from the University of Missouri and an MBA from Pepperdine University. Based in Wauregan, Connecticut, USA, C&M Corporation is an integrated manufacturer of bulk cable,

coil cords, and cable assemblies (both molded and mechanical).

BASF Corporation has named Serge Rogasik as vice president, plastic additives in North America.

He joined BASF in 2006 and was its director of corporate strategy in North America since 2009. He previously worked with Colgate Palmolive in Belgium as well as several chemical and plastic companies in Europe and the U.S. BASF Serge Rogasik Corp., based in Florham Park, New Jersey, is the North American affiliate of Germany’s BASF SE, a supplier of additives and pigments for the plastics industry.

As part of a restructuring, Milliman Extrusion Tool and Design Inc. reports two personnel appointments. The operations manager is Ryan Otenberger, who served three consecutive tours in Operation Iraqi Freedom and Operation Enduring Freedom, where he suffered combatrelated injuries and was later awarded a Purple Heart and Bronze Star. The lead machinist is Brian Baker, who has extensive knowledge of machining and extrusion tooling.

A graduate of Southern Illinois University, where he studied industry-related machining, he holds two associate degrees as well as a bachelor’s degree. Based in Orlando, Florida, USA, Milliman Extrusion Tool and Design Inc., a veteran owned and operated business, supplies custom and standard extrusion tools and tooling.

OBITUARIES 2 WAI members killed in plane crash Davis-Standard Corporation announced that one of its employees and one of its independent sales representatives, both WAI members, were killed in a plane crash in Texas on Wednesday morning, Jan. 5, 2011.

The crash took the life of Steve Vannais, 58, a 16-year company veteran who worked out of his home office in Mooresville, North Carolina, representing customers in the southern U.S. and Eastern Europe. He was a 1975 graduate of Kent State University with a B.S. Steve Vannais degree in architecture. A regional

24 | WIRE JOURNAL INTERNATIONAL

sales manager for the company, he traveled extensively, including numerous trips to China, Russia, Thailand and India. Prior to joining Davis-Standard, he worked in management and engineering positions with Northampton Machinery Co., Nokia-Maillefer Inc., Reichhold Chemicals and TRW/Holyoke Wire and Cable.

Vannais was a very active WAI member, and was a key founding member of the Southeast Chapter. He was highly respected in the wire and cable industry, and outside of wire, was very active with the Boy Scouts, with his son, Eric, one of eight that he helped attain Eagle Scout status.

James Polewchak He is survived by his wife of 38

years, Elizabeth “Beth” Pierson Vannais; a son, Eric Ryan Vannais; a brother, Jeffrey Vannais; sister, Nicolette Vannais; and many nieces and nephews.

Also lost in the crash was the pilot, James Polewchak, 40, the president of Midloathian, Texas-based JP Industrial Technologies, Inc., which represented equipment for the plastics industry. He held B.S. degrees in business and atmospheric physics from Miami University of Ohio and one in electrical engineering from the University of Cincinnati.

He had gone scuba diving in the tropics, sailed the Caribbean, rode a zipline in Costa Rica, backpacked through China, climbed a volcano in Colombia and traveled the country on his motorcycle. A long-time aeronautic enthusiast, he earned his private pilot rating in 1992, and had run a sight-seeing aviation company. Since 2003, he had been Davis-Standard’s wire and cable representative for Arkansas, Kansas, Louisiana, New Mexico, Oklahoma and Texas. He also represented Clinton Instrument and Beta LaserMike. He had joined WAI in 2010.

He is survived by his wife, Kelly; father, James L. Polewchak Sr.; mother, Carla (Jerry) Farone-Haupt; sister, Dr. Jennifer (Jason) Bellman; and two nephews.

“For all of us, it was a terrible loss,” said Tim McElhany, Tulsa Power, a friend of both men. He said that he has known Vannais for some 20 years. “Steve was inspirational to everyone. Whether it was work or his church or the Boy Scouts, he never did anything half-way, it always was ‘all in’ effort-wise.” He and Vannais had co-chaired the chapter’s golf tournament for all nine years, and Steve was a key to making the logistics work, he said. He added that “Jim was another good guy. He was one of the younger guys in the industry, and he had the same drive and infectious smile that Steve had.”

Woody Holland, Clinton Instrument Co., who also knew both men, said he was still stunned by the news as he had flown with Polewchak and believed that he was a very good pilot flying a very good plane. “What a loss,” he said. “Steve was a true friend and was well respected by customers and competitors alike, and Jim might not have been as well known as Steve, but he was equally dedicated to the industry in the short time that he was in it.”

“The passing of these men will be a loss not only to DavisStandard, but to the entire plastics extrusion industry,” the release said.

FEBRUARY 2011 | 25

PEOPLE

OBITUARIES (cont’d.)

PEOPLE

OBITUARIES (cont’d.)

Lawyer turned founder of major U.S. wire manufacturer dies at age 85 Howard O. Woltz, Jr., who began his career in law and later followed a path in industry that resulted in his creating a wire business that ultimately became Insteel Industries, Inc., one of the largest such domestic companies in the U.S., died Jan. 2, 2011, at age 85.

Following his earning a degree from the University of Virginia School of Law in 1948, Woltz prac- Howard O. Woltz, Jr. ticed law in Mount Airy, North Carolina, until 1954. In 1953, Woltz had entered a concrete block business that later evolved in the early 1970s into what eventually become Insteel Industries, Inc. Under his stewardship over the next 25 years, Insteel achieved national prominence as a supplier of reinforcing materials for the construction industry. He served as board chairman until February 2009. During his career, Woltz held numerous industry leadership positions and was recognized a national level. He joined the American Wire Producers Association (AWPA) in the mid ‘80s, and was an active member on its board of directors.

“It was my great pleasure to work with him,” said AWPA Executive Director Kimberly Korbel. “He was the epitome of a Southern gentleman, with all the grace and charm embodied in the title. At the same time, he was clearly an astute businessman, while dedicated to the well-being of his family, employees and community.” In his own words, he believed “in making a better world, in addition to making a living.”

Over the course of his life he consistently contributed to his community and took genuine interest in the welfare of other people.”

His son, H.O. Woltz, III, today runs Insteel and serves on the AWPA Board of Directors.

Woltz, an Eagle Scout, was involved in numerous community organizations. In 1991 he was named Citizen of the Year by the Chamber of Commerce of Greater Mount Airy. He is survived by four children: Louise Woltz; Joanie Robins; H.O. Woltz III; and Ed Woltz; and 13 grandchildren.

Radix Wire Company president dies Charles “Chuck” VerMerris, the president and CEO of Cleveland, Ohio-based Radix Wire Company, died on Dec. 18, after a day of cross-country skiing with his wife, MaryLou, and friends. He was 68 years old.

A company announcement noted that he had served “Radix and the wire industry with great distinction for over 45 years.

We have all lost a true friend.”

A graduate of Michigan State University, VerMerris moved

26 | WIRE JOURNAL INTERNATIONAL

to Radix Wire, a manufacturer of high-temperature, high-performance wire and cable, in 1968. In 1995, Radix was presented the Governor’s Award for Export Excellence. In 1997, he bought out the last remaining partner and acquired a majority of the stock. That same year he was a recipient of the Wire & Cable Manufacturers’ Alliance Distinguished Charles “Chuck” Career Award. The July 1999 issue of VerMerris Smart Business Cleveland cited his dedication, noting that “In an industry in which he has seen competitors get rolled up into large conglomerates, Chuck VerMerris vows fiercely to remain independent.” In response to a question to explain his company’s success, VerMerris replied, “The whole commitment to independence is probably what makes this company tick. We believe that we can continue to lead the transition of this company to whatever level it needs to go, to be better, quicker, faster, more effective than the competition. They will have their advantages, but our innovativeness, which is our real weapon, is what’s going to hold this together. We preach it.

We teach it. We practice it. That’s what’s going to pull it off.”

In addition to his wife, MaryLou, and his children, Scott and Morgan, he is survived by his mother, Marjorie VerMerris; father-in-law and mother-in-law, John and Helen Gillengerten; sisters, Barbara Joan Eardley and Judy Cooper; brother-in-law, John (Nancie) Gillengerten, and many cousins, nieces and nephews.

Jeffrey C. Wagner, an account manager at Carris Reels, died December 18, 2010, while skiing at Jiminy Peak Ski Area in Hancock, Massachusetts. He was 62 years old.

Wagner, a 1970 graduate of the University of Vermont, started with Carris Reels in 1986 and worked for many years at its plant in Rutland, Vermont. He relocated to its plant in Jeffrey C. Wagner Enfield, Connecticut, in 1999, representing Carris in North Carolina, Vermont, Virginia and Connecticut.

“He was a trusted, knowledgeable customer advocate who knew histories of companies (past and present) as well as people,” said David Ferraro, v.p. of sales and marketing, Carris Reels. “He was organized, committed to customers and dependable, and had immense respect for the Carris employees who supported his efforts. He was on the manufacturing floor on a regular basis and knew most everyone.”

He is survived by his son, Sean Wagner; a brother, William Wagner; a sister, Susan Wright; his former wife, Joanne (Burditt) Wagner; and many nieces and nephews. ■

Deadline extension sought for appeal to WTO for E.U. duties on fasteners

Russia body considering antidumping duties for imported steel fasteners

The European Union and China are jointly seeking an extension of the deadline to lodge an appeal in a World Trade Organization (WTO) dispute panel ruling condemning EU duties on Chinese screws and bolts, Reuters reported.

The article said that the extension was sought to give WTO’s “overworked appellate division” the time it needed for the dispute settlement body “to agree to extend the deadline to make an appeal to March 25, and that neither party would lodge an appeal before March 22.”

Delays have occasionally been requested by WTO members in the past to make life easier for the appellate body, which has to rule on appeals within 90 days, the story said.

The article said that the fasteners case “was a victory for China in the first WTO dispute it had launched against the European Union and was a setback to the EU’s handling of imports from countries that it considers are not market economies.”

The Ministry of Industry and Trade of Russia has offered to introduce antidumping duties of US$282 per metric ton for fasteners imported to Russia.

Kommsersant, a Russian on-line daily, reports that Rosmetiz corporations (those members of the Rosmetiz Association of some 60 hardware sellers and manufacturers) are against this measure, as wire products market participants are concerned about increases in fastener prices.

“However, Russian manufacturers seem to be unable to produce high quality fasteners without protective measures,” it said.

The duty can be applied to screw bolts and washers and nuts other than fasteners produced in Belarus and developing counties which use a special preference system of Russia. The investigation, the story said, was initiated in Russian by Magnitogorsk Steel and Wire Works MMK METIZ and Severstal Metiz in May 2009. ■

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FASTENER UPDATE

FASTENER UPDATE

FIBER WATCH

FIBER WATCH Corning reports Australian contract U.S.-based Corning Inc. announced that it has won “the first major contract for the 36 billion Australian dollar (US$35.6 billion) national internet broadband network project that the government hopes will improve broadband speed across Australia.”

Dow Jones reports that Australian government-owned NBN Co. has awarded three equipment contracts for network infrastructure over the next five years with the largest worth up to A$1.2 billion, going to Corning. Italy’s Prysmian SpA and Melbourne-based Warren & Brown Technologies won smaller orders worth up to A$300 million and A$110 million, respectively, it said.

The orders are related to Australia’s largest infrastructure project, which is planned to reach over 13 million homes and businesses within a decade, the report said.

At the Corning website, it notes that NBN intends to pass 93 percent of Australian homes and businesses (roughly 10 million) with an open-access network providing download speeds of 100 megabits per second within the next 10 years.

“Having participated in Australian FTTH builds since 2005 including the launch of NBN in Tasmania, Corning Cable Systems Australia has crafted a country-specific solution set that will be able to withstand the various environments found throughout the Australian landscape,” it said. “Use of the FlexNAP™ terminal distribution system with RPX™ ribbon cable for aerial installations and ALTOS® ribbon cable featuring the industry’s best performing enhanced low-loss ITU-T G.652.D compliant SMF-28e+® LL fiber for underground installations will ensure a successful deployment.”

“This is a very significant day for NBN,” Mike Quigley, NBN’s chief executive, was quoted as saying. “Part of our purchasing strategy is to make a substantial up front purchase commitment to encourage suppliers to invest in their Australian supply chain ramp-up as we head to volume rollout.”

Corning, the story said, will invest about A$25 million at its Melbourne facility while Prysmian plans to spend an extra A$13 million on plant and equipment in Sydney, it said. The initial contracts, it noted, will create 400 new manufacturing jobs in Australia.

NBN Co. is negotiating many deals in relation to the network, the main one being with Australia’s largest telecommunications company Telstra Corp. (TLS) to access its infrastructure, the story said. The company, it said, has already awarded contracts to Nokia Siemens Networks worth up to A$400 million over 10 years and an initial deal with AlcatelLucent worth A$70 million.

Leoni sells 2 subsidiaries to euromicron Germany’s Leoni announced that it has sold two business units, one in Austria and the other in The Netherlands, to euromicron holding GmbH, a provider of “all-in solutions” for communication, data and security networks.

28 | WIRE JOURNAL INTERNATIONAL

A press release said that the moves are part of a “step up collaboration” by Leoni and euromicron in the Fiber-to-theHome (FTTH) growth market.” It identified one of the two subsidiaries as Leoni NBG Fiber Optics GmbH, which will be called euromicron NBG. The company, it said, covers a broad spectrum of passive system components such as glass fiber cable, empty conduit systems as well as connection technology and provides planning, engineering, project management as well as installation services in the FTTH segment, primarily so in the German-speaking region. Leoni WCS Benelux B.V. operates as a sales and distribution company in the Benelux countries, it said, adding that the two companies employ a total of about 60 people.

With this strategically motivated takeover of these two businesses, euromicron will expand its development and production know-how in the field of glass fiber-based passive components, further enhance its expertise in the FTTH solutions market and strengthen its presence in Austria and Benelux, the release said. “Leoni and euromicron regard the deal as the start of greater collaboration in the FTTH business and expect this closer linking of their skills and market access to strengthen their combined market position.

The companies see opportunities for joint endeavour in other segments as well.”

Fiber optic system launched by Airtel Bharti Airtel has launched its IMEWE (India-Middle EastWestern Europe) cable system, an ultra high capacity fiber optic submarine cable system to deliver better connectivity requirements of Middle East and European countries to Asia transiting through India.

In a report by The Economic Times, the company said, “IMEWE will open a second gateway for Airtel’s customers to the European market from Asia via Mumbai.” The report said that the project will provide alternate routes for meeting the bandwidth requirements and diversity needs of the customers. “The commencement of IMEWE cable system will significantly enhance the connectivity from Asia to Western Europe and Middle East by offering high speed and diverse connectivity,” it said.

Per GK News Networks, the completion of the fiber optic submarine cable that stretches from India to Europe is the work of a consortium of nine partners. “The 13,000 km long, three-pair fiber optic cable has a design capacity of 3.84 terabits per second, and is also the most advanced cable connecting India in South Asia to Italy and France in Western Europe via the Middle East with landings en route in Pakistan, UAE, Saudi Arabia, Egypt and Lebanon,” it said.

“The deployment of the cable system will enable the company to deliver the much anticipated capacity to meet the connectivity requirements of Middle East and European countries to Asia transiting through India and vice versa,” the story said. ■

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WAI NEWS

WAI

NEWS

First time Interwire exhibitors: why we plan to be in Atlanta this May The exhibit floor at Interwire will feature more than 60 new exhibitors. WJI asked them why they will be there, and below are some of the responses.

Saco Polymers, Inc., U.S. Some of us have exhibited at Interwire in â&#x20AC;&#x153;past lives,â&#x20AC;? but felt that the show had lost some ability to draw wire and cable customers. This was especially evident at the show we attended in Cleveland.

Interwire seems invigorated with its return to Atlanta and our customers are talking about it more.

Encouraged by this, we also felt that it was a great opportunity to promote our new name and face to the industry and to improve the visibility of our products and services. We are looking forward to it. Dean Jenne, product specialist, Saco Polymers Inc., www. sacopolymers.com.

Dixie Converting Corporation, U.S. The opportunity to participate in this event for the first time is very exciting for our company. Dixie Converting Corporation has been a major supplier of paper cable wrap and filler to the wire and cable industry in the U.S., Dixie Converting Corporation President Mexico, and Chris Dixon.

Canada since 1978. We believe the Interwire Trade Exposition will be an ideal format to showcase our products and potentially increase our sales outside of North America. Utilizing high-performance extensible kraft paper, the cable wrap we produce is primarily used in non-metallic sheathed cable and our twisted paper fillers are used in the construction of portable or flexible cords. As a supplier to the wire and cable industry, we are looking forward to seeing old friends and making new ones at the 2011 Interwire Trade Exposition. Chris Dixon, president, Dixie Converting Corporation, www.dixieconverting.com.

WAI Q&A New Interwire sponsorship options This occasional section covers a topic of general interest involving WAI. This one is answered by WAI President Dominique Perroud.

Q: In addition to traditional exhibiting opportunities, are there any other marketing options associated with the upcoming Interwire Trade Exposition?

Perroud: As an active volunteer within the Association, I am pleased to see the pieces coming together for the upcoming Interwire Trade Exposition. This is something that the organization has been working towards for a number of years and I hope that the industry takes full advantage of this terrific resource.

At the core of the event is the 100,000 sq ft of exhibitions, and the 400 companies occupying that space. But, the event is much more than an exhibition. It is a forum designed to connect the industry that not only relies on the exhibition but the willingness of the industry leaders to share their experience and knowledge.

Expanding on the approach of connecting the industry,

30 | WIRE JOURNAL INTERNATIONAL

there are two new marketing opportunities that are not exclusively for the exhibitors: event sponsorships and theme session sponsorships. As the articles in this section indicate, the return to Atlanta has sparked the exhibits while volunteers from wire and cable producers have helped design and produce techniPerroud cal programs that are truly superior. These are events that any company should want to be associated with. At the time this article was written, there were two sponsors; Southwire Company as an event sponsor and Gem Gravure as the sponsor of the Best Practices theme session.

In my opinion, these sponsorships are a great way to put your name in front of the industry with plenty of notice in the advance promotion and during the event.

For more details on sponsorship opportunities, contact Robert Xeller or Anna Bzowski, sales@wirenet.org.

When the age of change comes to us, everyone must find his/her own efficient way to deal with the market, and all hidden risks. Therefore, we join the Interwire 2011 for the first time and present our brand-new automatic welding machine for construction company owners, a new way to make the business more than sustaining. The original idea is to save more money from purchasing different forms of concrete reinforcement meshes and even more, get extra profit from it. It is believed that Golden Spot SSA series wire mesh welding machine can help many entrepreneurs with vision grow their business. The image shows the stroke line of an SSA series machine. Alon Chen, Global Partnership Manager, Overseas Dept., Golden Spot Industry Inc., www.goldspot.com.tw.

Magnum Manufacturing, Inc., U.S. We will be exhibiting for the first time in order to have more exposure to the customer base we are trying to reach. We will be displaying a variety of products we currently manufacture, for a number of industries. We will be discussing the savings associated in cold heading manufacturing versus traditional manufacturing. Steve Goodwin, Magnum Mfg., steve7597@bellsouth.net.

Steve Goodwin, Magnum Mfg.

Mountville Rubber, U.S. At Mountville Rubber we have increased the capacity of our custom mixing business to 100 million pounds of annual capacity by adding a new 268 liter mixing line at our colored rubber mixing plant. Our available capacity and the

ability to offer strained or unstrained compounds leads us to seek additional business in CPE, EPDM, CSM, NBR, SBR, NR, EVA, Butyl and polychloroprene compounds. With a history From l-r, Mountville Rubber’s Sales Manager Mike Coffing, of supplying wire and cable companies we see President Bud Paulk and VP of Technical Service John Smith. the Interwire Trade Exposition as a great opportunity to introduce ourselves to prospective new customers requiring quality compounds and timely, reliable service. Bud Paulk, president, Mountville Rubber, www.mountvillerubber.com.

Enercon Industries, U.S. Enercon is exhibiting at Interwire for the first time to share its breakthrough atmospheric plasma surface treating technology, which is enabling wire and cable producers competitive advantages by breaking through traditional production and performance barriers associated with the bonding of aqueous inks, coatings and adhesives. It will be demonstrating the company’s in-line surface treating capabilities for increased adhesion for wire and cable applications.

Treatment is effective on a wide variety of polymer materials used in the wire and cable industry and enable “green” process advancements and reduced production costs when compared to existing manufacturing technologies. Also, Enercon’s Rory Wolf will present a technical paper detailing the treatment effectiveness of air plasma, chemical plasma and flame plasma treatments for specific

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.

FEBRUARY 2011 | 31

WAI NEWS

Golden Spot Industry, Inc., Taiwan

wire and cable materials. Mark Plantier, v.p. marketing, Enercon Industries, www.enerconind.com.

WAI NEWS

Metalloid Corp., U.S. Metalloid Corp. will exhibit at Interwire because there is a need in the wiredrawing market for new and improved lubricant technology to address the global issue of our environment. Our “green chemistry” offers alternatives to petroleum-based lubricants, powder soaps and greases. Our lubricant alternatives are formulated with American-made, renewable resources that eliminate hazardous ingredients while providing the ultimate in lubricity. They are bio-stable, environmentally friendly, safer to use and offer new solutions to current manufacturing concerns. Our strategy focuses on combining problem solving skills with new concepts that meet the needs of the market and address environmental concerns. Rick Strapple, v.p. sales & marketing, Metalloid Corp., www.metalloid.com.

Bytewise Measurement Systems, U.S. Bytewise has decided to exhibit at Interwire so it can introduce its new in-line, laser-based, profile measurement technology to cable, wire and magnet wire manufacturers. It will display a new profile measuring system, the Profile360, for monitoring dimensional properties of rectangular and profiled wire, including magnet wire, on-line. Profile360 employs four laser line sensors to digitize the wire profile

Golf tourney to be part of WAI’s return to Atlanta for Interwire 2011 The Frog Golf Club, located in beautiful Villa Rica, Georgia, and considered a top Atlanta golf course, will host a charity golf tournament on Monday, May 2, 2011.

The event will include prizes being awarded: $10,000 Hole-In-One, top teams, long and accurate drives, Closestto-the-Pin, and more! The tournament is limited to the first 120 golfers to sign up. The schedule calls for players to depart by bus from the Omni Hotel at 7:30 am. Check-in and continental breakfast is at 8 am, and the shotgun start event begins at 9:30 am, followed by a BBQ buffet at 3:30 pm (approximately), and the bus leaves for the Omni at 4:30 pm (approximately).

Registration is $125/per player registration fee covers greens fees, cart, range balls, continental breakfast, and BBQ buffet lunch. Non-golfers may attend the lunch for $25. Net proceeds from the event will go to the Vanderbilt Cancer Research Center.

32 | WIRE JOURNAL INTERNATIONAL

into 4000 points which are automatically analyzed to extract key parameters such as thickness, width, corner radius, radius tangential fit, and cross-sectional area. Measurements are done at frequencies up to 15 Hz. Profile360 is employed as a tool for quality control monitoring and process control.

Jim Williams, sales director, Bytewise Measurement Systems, www.bytewise.com.

KP America, Inc., U.S. We see Interwire as an excellent opportunity to connect our technical and commercial staff with existing and potential customers, during a concentrated three-day event which focuses on the wire business. We have been helping customers grow their business for more than 100 years.

Our high-performance wiredrawing oils are designed to increase productivity by maximizing wire quality and with a zero tolerance on breakages. While others have been cutting resources, we continue to increase our investment in people, R&D and technical know-how. Our philosophy is to listen to our customers, so we can continue to be the product and solution providers for emulsion control, maintenance and best practices. Gert B. Larsen, country manager, KP America, Inc., www.roloil.com.

Corporate Hole sponsorships are $100 a hole, and an assortment of premium sponsorships are available. All sponsors will receive recognition in the Interwire Show Program, the WJI, and a sign with the The Frog Golf Club will host a company’s name at golf outing during Interwire 2011. the event.

The registration deadline is April 18, 2011, after which there will be no refunds for cancellations. For more information contact: Jeffrey Swinchatt (jswinchatt@sikora-usa.com) or Molly Hardegree (mhardegree@sikora-usa.com) at tel. 770-4861233 or WAI’s Steve Fetteroll at tel. 203-453-02777, ext.

132, sfetteroll@wirenet.org.

Zeus Techno, South Korea

Having already taken part in the past at this fair with the name of Pittini Impianti, Promostar Srl participates for the first time to this event with the purpose of consolidating its presence in American country, for meeting again the consolidated Promostar’s customers in the USA, and for introducing oneself to the new clients of Central and North America. In 2005, Promostar inherited from Pittini Impianti the know-how and production technologies for the machining of steel wire, adding to its long experience in technological innovation and the specialization of equipments that is customized to satisfy any client’s needs. Thanks to the synergy with MEP group, Promostar is able to offer complete solutions for the realization of complete production lines, turnkey plants, machines equipments and accessories for the production of concrete reinforcing wire (cold rolling, straightening and cutting, stretching process etc., with cassettes or dies), thin steel wire (wire drawing process), lattice girder and electrowelded mesh lines for different industrial application.

Lorenzo Zontone, sales department, Promostar Srl, www.promostar.it.

Zeus Techno constantly invests in R&D of new technology and innovative thinking to produce reliable machines capable of the processes needed by leading manufacturers in the wire and cable industry. We try in all ways to support our customers to meet their demands and requirements, a process that is one of mutual development and mutual benefit. We plan to introduce our RT-20T model, a bolt-threading and rolling machine that provides: high-speed, precise bolt threading and thread rolling by fine cam drive; has a high-efficiency internal cooling system for dies for long tool lie; and offers fast setup and easy maintenance. Sean Baek, overseas sales development, Zeus Techno, www.zeus-techno.com.

bogimac, Belgium We come to the Interwire to present our strategy about why and how dynamic material fatigue testing could

Tailor-made to your particular requirements, our high-precision rolling mills process all kinds of material into every possible shape.

ai 2011 Interwire 03 – 05 M Mai 2011 Wire Russia 23 – 26

FEBRUARY 2011 | 33

WAI NEWS

Promostar Srl, Italy

WAI NEWS

improve manufacturing leadership. Our product portfolio covers high performance fatigue bending, compression/tension, torsion and wear test machinery. To ease new material innovations, early warning monitoring is done at a stage where the initial sample degradation can be precisely observed. We are dedicated to supplying fatigue testing equipment for flexible materials worldwide to cable, cord, wire and rope products makers. Further improvements in quality control, product liability assurance and material innovation can be achieved by extending material testing beyond static characterization. Philippe van Bogaert, bogimac, www.bogimac.com/

Interwire 2011: 3 unique days of industry-designed tech programs Designed by representatives from more than two dozen wire and cable manufacturers, Interwire 2011 will present three days of technical programs, each day featuring specific themes as well as a centerpiece event.

The program was planned by the 25 members of WAI’s recently formed Conference Programming Committee, a

group of industry veterans from large and small, ferrous and nonferrous wire and cable manufacturers, which focused on topics that would be of interest to the industry as a whole.

The programming centerpiece each day will be a 90-minute featured event in the morning. “It’s like having a different keynote every day,” said WAI’s Director of Education and Member Services Marc Murray. “We’ve built each day to be full of programming centered on a different major topic that we hope will make the overall conference feel a little like three one-day events rolled together.”

Day 1: Tuesday, May 3: Metals & Materials The program day begins with a futuristic look at materials science as Prof.

Robert L. Snyder, Chair of the School of Materials Science & Engineering at Georgia Tech, discusses “The new world of materials science & engineering: nano & bio technology.” The two most important events in materials in the past 20 years have been the introduc- Robert L. Snyder tion of surface free energy as a tool for creating new materials and the cracking of the genetic code of the biosphere which opens paths to nanoscale manufactur-

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WAI NEWS

ing. These two events are intertwined at the most fundamental level. This talk will explore their impact on the future with a focus on the production of 1D wires at the nanoscale.

Snyder is professor and chair of the School of Materials Science and Engineering at The Georgia Institute of Technology. He has won numerous awards and holds eight patents and has published 300 technical papers.

Day 2: Wednesday, May 4: Manufacturing Best Practices Join a panel of wire and cable manufacturers and compliance experts at the Safety Roundtable as they tackle the challenges of maintaining high safety standards in their own operations. Panelists will discuss their experiences and field questions from the audience and each other about raising the bar on safety.

Following a Q&A, attendees are invited to approach panelists for one-on-one conversation. Panelists include Rob Gaines, U.S. Compliance Corp.; Nick Johannes, Leggett & Platt; Kevin Porath, Coleman Cable; and Tim Wampler, General Cable. Theme sessions later in the day will take another look at the individual approaches of different companies to safety as well as lean and six sigma strategies.

Day 3: Thursday, May 5: Green Initiatives The future of the U.S. electrical power supply is the focus when U.S. Dept. of Energy Assistant Secretary Patricia A. Hoffman asks, “Where is the electric grid going?” This talk addresses the critical steps needed to meet the growing demand for reliable electricity by overcoming the challenges of the country’s aging electricity transmission Patricia Hoffman and distribution system and addressing the vulnerabilities in its energy supply chain.

Hoffman was named assistant secretary for the Office of Electricity Delivery and Energy Reliability (OE) at the U.S. Dept. of Energy (DOE) in 2010 after serving as principal deputy assistant secretary since 2007.

Other presentations that day will address what makes “green” cable, recycling for fuel at a wire facility, Leadership in Energy and Environmental Design (LEED), and mitigating the environmental impact of wire operations. ■

36 | WIRE JOURNAL INTERNATIONAL

CHAPTER CORNER

CHAPTER CORNER Full slate of technical papers to be offered at Polish conference More than 50 presentations are scheduled for a biennial technical conference to be held March 3-5, 2011, in Zakopane, Poland, that includes members of WAI’s Poland Chapter among its organizers.

Poland Chapter President Jan Pilarczyk reports that the biennial event, to be held again at the ANTAŁÓWKA Hotel, will have presentations in four sessions (ferrous, nonferrous, electrical and special products) and a poster session. In addition to Poland, scheduled speakers will come from Sweden, Spain, Japan, South Korea, U.S., Russia and the Czech Republic.

“This conference is international in scope, including representatives from many countries from both the West and East,” Pilarczyk said. He noted that the conference program has strong support from the most important schools in Poland, universities that provide education in wiredrawing science, as well as support enterprises, he said, noting that the conference is held every other year, with a smaller event, a seminar, held the other years.

Beyond the technical program, the 2011 event will include tabletops, an opening reception and a gala dinner with folk music as well as special lectures presented

Participants at the 2010 seminar in Poland, l-r, included: Wojciech Szulc, award presenter; Andrzej Prajsnar (who accepted award for his father, Tadeusz Prajsnar); Edwards Zgłobicki, award recipient; Stefan Augustyniak, award recipient; Bogdan Golis, award presenter; and Jan W. Pilarczyk, Poland Chapter president. by 2011 Schneider Memorial Award recipients Prof.

Kazunari Yoshida, from Tokai University, Japan, and Eugeniusz Filipczyk, past president of Drumet, Poland.

Suppliers should want to take part in the tabletop displays, Pilarczyk said. “There should be a good showing from participants from Russia, Poland and Czech Republic due to the relatively low fee and travel cost,” he said, adding that the event will also have good accompanying programs, with local folk specialties and music and mountaineer traditional dances. To request a list of the technical papers, send an e-mail to editorial@wirenet.org.

For more details, including how to get a tabletop or to 38 | WIRE JOURNAL INTERNATIONAL

Prof. Kazunari Yoshida, WAI’s 2011 Mordica Memorial Award winner, joins performers at a reception at the 2009 Polish conference in Zakopane. register, contact: Dr. Sylwia Wiewiórowska by e-mail at wiewior@wip.pcz.pl, or go to the event website, www.konferencja.wip.pcz.pl

Members of 3 WAI chapters can seek a college scholarship for their children Three Wire Association International chapters, in conjunction with the Wire Foundation, are seeking applications from the children of chapter members in good standing for their 2011 Scholarship awards. Members of the New England, Midwest and Southeast chapters will receive letters this month, inviting applications. Submissions must be postmarked no later than Thursday, March 31, 2011.

The chapter scholarship program got its start in the New England chapter in 2006, and the Midwest and Southeast chapters offered their first scholarships in 2008. The Wire Foundation connection allows donations to support the chapter scholarship funds to be tax deductible.

For both the New England and Midwest chapters, eligible candidates for the awards are graduating high school seniors who will be continuing their education in college. The Southeast Chapter also allows continuing college students to apply.

“The scholarships provide a special connection between the Association, the Foundation, and the applicants, in that all are committed to education,” said WAI Executive Director Steve Fetteroll. “The chapters work hard to accumulate the resources necessary to fund the programs and everyone enjoys the golf tournaments, which are the primary revenue generator.”

Each chapter’s scholarship committee reviews the applications and forwards the recommended choices to the Wire Foundation for their review and vote. The scholarship payments are made after the student’s begin their fall semester.

Non-members of WAI who have students who would be eligible to apply for the scholarships are welcome to join WAI and their respective chapter. First-year chapter dues are free for new members. For more information about the scholarship programs or WAI membership, contact Fetteroll at (001) 203-453-1777 or sfetteroll@wirenet.org. ■

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Your best days in wire and cable

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Introducing INTERWIRE 2011.

METALS &

MATERIALS

D AY

D AY

MANUFACTURING GREEN INITIATIVES BEST PRACTICES

N E W V E N D O R S . N E W O P T I O N S . N E W E N E R G Y.

Convention: May 2-5 | Exhibits: May 3-5 Georgia World Congress Center Atlanta, Georgia, USA Co-located: WAI’s Global Continuous Casting Forum AWPA’s Wire Rod Supply Chain Conference

The only time and place in the world this year to experience a peer-defined program this vast. Face-to-face dialog. Direct questions and answers. And the support of an international community led by 25 industry pioneers who joined our team to inspire yours. Expert forecasts. Industry intelligence. Staff development. 300 stands.

All organized into three productive days. Look forward to the possibilities.

At Interwire everything clicks. www.wirenet.org SPONSORS: Southwire Co. | GEM Gravure Co. Inc. Interwire 2011 is organized by The Wire Association International, Inc.

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

INTERWIRE 2011 EXHIBITING COMPANIES — AS OF JANUARY 2011 A. Appiani Ace Metal Inc. ACM-KSM AFL Agape Industrial Inc. AIM Inc. Ajax Turner All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American Kuhne Anbao Wire & Mesh Co. Ltd. Anhui Changjiang Jinggong Wire & Cable Machinery Co. ASMAG UK Ltd. AW Machinery LLC AXIS, A Consona ERP Solution Axjo Plastic AB Aztech Lubricants LLC B & H Tool Co. Inc. Baicheng Fujia Mechanical Manuafcture Co. Ltd. Balloffet Die Corp.

Bao Zhang Galvanized Iron Wire Co. Bartell Machinery Systems LLC/ Ceeco Machinery Baum’s Castorine Co. Inc. Beijing Holland Trading Co. Ltd. Bekaert Corp.

Beneke Wire Co. 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 GmbH Butt Welders USA Bytewise Measurement Systems Caballe SA Cable Consultants Corp.

Calmec Precision Inc. Carris Reels Inc. Cary Compounds LLC CEIA USA Cemanco LC Central Wire Industries Ltd. Chase Coating and Laminating Chemetall Oakite China Electronics Technology Group Cimteq CJI Group Ltd. Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd.

CN Wire Corp./Er Bakir Coats North America Coding Products Inc. 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 Danyang Steel Wire Plant Davis-Standard LLC DCM Industries Dem Costruzioni Speciali srl Deyang Dongfang Zhouyue Electrotechnical Equipment Die Quip Corp.

Dixie Converting Corp.

Domeks Makine Ltd. Sti Dongguan Zhangli Machine Fitting Co. Ltd. Dongjiagang Mechanical & Electrical Equipment Co. Donnelly Reels Dynamex Corp.

Ebner Furnaces Inc. Egyptian Galvanized Steel Plant Co. EJP Maschinen GmbH Elektrisola Inc. Enercon Industries Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Estane Engineered Polymers/Lubrizol Esteves Group USA Etna Products Inc. Etna-Beechem Lubricants Ltd. Eurobend SA Eurodraw Energy SpA Eurolls Group Srl 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 GH Induction Atmospheres 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. Hearl Heaton Heatbath Corp.

Henkel Corp.

Henrich Maschinenfabrik GmbH Heritage Wire Die Inc. HMP Heinrich Muller Maschinenfabrik GmbH Howar Equipment Inc. Hudson Color Concentrates Huestis Industrial Huettner Maschinenfabrik GmbH IBA ICE Wire Line Equipment Inc. IDEAL Welding Systems Ideal-Werk INHOL LLC InnoVites 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 Integrated Systems KEI Industries Ltd. KEIR Manufacturing Inc. Keystone Steel & Wire Co. Kieselstein GmbH King Steel Corp.

Kinrei of America

Ernest Koch GmbH & Co. KG KP America Inc. Albert Krenn Friedrich Krollman GmbH & Co. KG Kyocera Industrial Ceramics Corp.

L-S Industries 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 Macromeric - A Div. of Saco Polymers Magnetic Technologies Ltd. MAGNUM Mfg. LLC MAGPOWR Maillefer SA Mapre Belgium SA Marubeni Specialty Chemicals Inc. Mathiasen Machinery Inc. Merritt Davis Metavan NV MFL USA Service Corp. - Frigerio The MGS Group (MGS-Hall-Northampton) MGS Manufacturing Inc. Micro Products Co. Microdia USA Mid-South Wire 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 NTB Hitech Ceramics NUMALLIANCE Ohio Rod Products Oklahoma Steel & Wire OMA SRL OMA USA Inc. OMCG North America OMCG SpA P/A Industries Pamica Electric Material Panchmahal Steel Ltd. Paramount Die Co. Parkway-Kew Corp.

Pave Automation Penn Machinery Co. Phifer Wire Inc. continued on next page

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

INTERWIRE 2011 EXHIBITING COMPANIES — AS OF JANUARY 2011 Pinnacle Metals Inc. Pioneer Machinery Co. Ltd. Pittsburg Carbide Die Co. Pittsfield Plastics Eng. Inc. Plas-Ties Co. Plasmait GmbH Plastic Equipment LLC Plymouth Wire Reels PolyOne Polytec Inc. Pourtier - Gauder Group Power Sonics LLC/Magnus Equipment Powerbase/Juhua China Precision Die Technologies Inc. Premier Wire Die Pressure Welding Machines PrintSafe Promostar srl Properzi International Inc. Proton Products QED Wire Lines Inc. Qinhuangdao Yanda-Guohai Stainless Steel Co. Ltd. Qual-Fab Inc. Queins & Co. GmbH Raajratna Metal Industries Ltd. RAD-CON Inc. Radyne Corp.

Rainbow Rubber & Plastics Rautomead Ltd. Redex SA Reel-O-Matic Refractron Technologies Corp.

RG Attachments RichardsApex Inc. Rizzardi Rockford Manufacturing Group FELM Roloil Rosendahl GmbH

Rosendahl Nextrom Technologies Roteq Machinery Inc. S&E Specialty Polymers Saco Polymers Inc. Saint-Gobain Ceramic Materials SAMP SpA SAMP USA Inc. SAMPSISTEMI Sanxin Wire Die Inc. 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 Shanghai SETI Enterprise International Co. Ltd. Shanghai Shenchen Wire & Cable Equipment Co. Ltd. Shanxi Tianxiang Machinery Co. Ltd. Shaoxing Kaicheng Mica Material Co. Ltd. Shijiazhuang Kingway Metal Products 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 SunWyre Inc. Sylvin Technologies Inc. T & T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Team Meccanica Srl Techalloy Welding Products Teknikor Teknor Apex Co. Tenova Core Tensor Machinery Ltd. Teurema Thermcraft Inc. Thermoplastics Engineering Corp.

Tianjin Zhaohong Metal Product Co. Ltd. Tips & Dies Inc. Traxit North America LLC Tri Star Metals Troester GmbH & Co. KG Paul Troester Maschinenfabrik Tubular Products Co. Tulsa Power Inc. Ultimate Automation Ltd. UMC United Wire UNITEK Unitrading (LianYunGang) Ltd. Uniwest Uniwire International Ltd. UPCAST OY US Reel US Synthetic Wire Die Vandor Corp.

Videojet Technologies Inc.

Vitari SpA Vollmer America Inc. Wafios Machinery Corp.

WAI Connection Watson Machinery 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 Yangzhou Qunye Electrical Machinery Factory Yield Management Corp.

Zeus Techno Inc. Zhejiang Litai Metal Co. Ltd. Zhejiang Rongtai Electric Material Co. Ltd. Zhengzhou Yifang Cable Co. Ltd. Zumbach Electronic AG Zumbach Electronics Corp.

INTERWIRE 2011 | HOTEL RESERVATION INFORMATION Deadline: April 6, 2011 Two hotels are offering special Interwire 2011 rates. Reservations may be made by either calling hotels directly, or by booking online using the direct links provided below. Online reservations may also be made at www.wirenet.org.

IMPORTANT: If making hotel reservations by phone, remember to ask for the special INTERWIRE rate (shown below).

If making reservations online, use the customized links below to ensure you receive the special INTERWIRE rate.

HOSPITALITY SUITES: Please call hotels directly for options, availability and suite rates.

OMNI HOTEL AT CNN CENTER 100 CNN Center, Atlanta, Georgia 30303 | Phone: (001) 404-659-0000 RATE: US$179 per room night, plus tax, single or double Online Reservations: http://www.omnihotels.com/FindAHotel/AtlantaCNNCenter/MeetingFacilities/Interwire2011.aspx THE WESTIN PEACHTREE PLAZA HOTEL 210 Peachtree St. NW, Atlanta, GA 30303 | Phone: (001) 404-659-1400 RATE: US$164 per room night, plus tax, single or double Online Reservations: http://www.starwoodmeeting.com/Book/interwire

ADVANCE REGISTRATION FORM Georgia World Congress Center | Atlanta, Georgia, USA | Convention Dates: May 2-5, 2011 1. COMPLETE AND MAIL OR FAX THIS FORM TODAY

1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Tel.: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org Note: Please print neatly and complete all information to ensure accurate registration. If you choose to mail this form, make sure you keep a photocopy.

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2. BUSINESS INFORMATION (These two questions must be completed for proper processing.)

A. Which ONE of the following best describes your company’s type of business? PLEASE CHECK ONLY ONE. WIRE MANUFACTURING 10 ❏ Aluminum & Al. Alloys (Rod/Bar, Bare Wire) 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire) 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire) 40 ❏ Other Metal (Rod/Bar, Bare Wire) 50 ❏ Electrical (Insulated Wire) 53 ❏ Communication (Insulated Wire) 55 ❏ Fiber Optics

FASTENERS, WIRE FORMING, FABRICATING 61 ❏ Fastener Manufacture 62 ❏ Four-Slide Forming 64 ❏ Hot and/or Cold Forming and Heading 66 ❏ Spring Manufacture 68 ❏ Wire Cloth Mesh Screening 69 ❏ Other Forming and Fabricating Please Specify ______________________________

WIRE END-USER 11 ❏ Appliance 12 ❏ Communications (Voice/Data) 13 ❏ Computer 14 ❏ Construction/Building 15 ❏ Electrical (Equip./Components/Power) 16 ❏ Transportation/Vehicular 17 ❏ Wire Formed Durable Goods

SUPPLIERS TO THE WIRE INDUSTRY 72 ❏ Machinery 74 ❏ Process, Accessories, Materials

OTHER 80 ❏ Service Cntrs, Distrib. & Warehouses 90 ❏ Consultants 92 ❏ Govt., Library, Others Allied to Field

B. Which ONE of the following best describes your primary job function? CHECK ONLY ONE. 10 ❏ General & Administrative Management 20 ❏ Engineering and/or Operations and/ or Production 30 ❏ Technical and/or Research & Development and/or Quality Control 40 ❏ Purchasing 50 ❏ Sales & Marketing 90 ❏ Other Please Specify _______________________________

3. EVENT REGISTRATION (This section must be completed for proper processing.) *advanced (on or before APRIL 8, 2011) on-site (after APRIL 8, 2011)

Please Print Your WAI Member Number ________________________________ *advance New Member

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SOUTHWIRE PLANT TOUR (PT) Monday, May 2 Individual registrations subject to approval.

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4. TOTAL REGISTRATION FEES, U.S. $ 5. REGISTRATION FEE IS PAID BY: ❏ Check enclosed payable to THE WIRE ASSOCIATION INTERNATIONAL, INC. (Checks must be in U.S. dollars drawn on U.S. bank)

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FEATURE

India Outlook: en nt ti ia al li is sn no ow wr re ea al li it ty y po ot te p

ndia has long been viewed as a land of much potential, but often the question was

I

when it would be there for the wire and cable industry. By many gauges, it indeed

has arrived, and it is fitting that this feature is written by Huned Contractor, the editor of WIRE BULLETIN, WAI’s quarterly newsletter in India. The tone and style may be different, but at its essence, his report, which includes a wrapup of wire India, speaks of progress, of action and of a brighter future for the world’s largest democracy.

By Huned Contractor WIRE BULLETIN editor the next two years. For the cable industry, from previous In spite of the worldwide recession that impacted global year’s moderate growth, the cable sector has posted an avereconomy in 2008-09, the Indian growth story has been an age 15 per cent growth in 2010-11 mainly due to the amazing one, translating into huge business opportunities increase in demand from industrial projects, as revealed by for almost every industrial sector. There’s so much to cheer an industry report published by the Indian Electrical & and toast about that it seems this is going to be a rather Electronics Manufacturers Association (IEEMA). never-ending party. The reference is to the India growth story – a tale that has been filling up not only the local newspapers and magazines but has also begun to attract global interest. In terms of figures, the year 2011 will witness a surge in India’s GDP growth to 8.3 per cent, driven by robust industrial growth and the resilient performance of the service sector.

According to trade reports, the elements that will support the growth in industrial production will include the prospect of a rebound in investment activity, increased thrust of the government on infrastructure projects, and the renewed growth of exports. The question therefore is: How will all this reflect on the performance of the wire and cable sectors in India?

On a broader front, consider the Fitch ratings that predict a stable outlook for Indian steel producers for 2011. “The stable outlook is supported by an expected increase in the domestic steel demand during the year due to growth in automobiles, white goods, and construction sectors coupled with the continuous thrust of the Indian government on infrastructure spending,” the The India presence can increasingly be seen at trade shows where recently published report states. Fitch expects strong economic growth has translatd to serious business discusIndia’s steel demand to grow at 7-9 per cent over sions, such as this one at wire Düsseldorf.

44 | WIRE JOURNAL INTERNATIONAL

FEBRUARY 2011 | 45

FEATURE

year were mining and quarrying (10.6 per cent), manufacturing (10.8 percent), electricity, gas and water supply (6.5 per cent), construction (6.5 per cent), trade, hotels, transport and communications (9.3 per cent), and financing, insurance, real estate, and business services (9.7 per cent).

According to a study conducted by the Associated Chambers of Commerce and Industry in India (ASSOCHAM), the Indian real estate industry is expected to reach USD 60 billion by the end of 2010.

The increasing number of special economic zones (SEZs) would also contribute to this robust growth. Further, as per a report by the Automotive Component Manufacturers Association The shop floor at Ravin Cables, one of Indiaâ&#x20AC;&#x2122;s busy wire manufacturers. of India (ACMA), the turnover of the auto component industry was estimated at more than USD 19.2 billion in 2010.

Wire sector The report states that 31 per cent of the auto component industry is dominated by engine parts, 19 per cent by drive The steel wire manufacturing industry in India accounts transmission and steering parts, and 12 per cent each by for an annual turnover of more than Rs 8,000 crore and the suspension & braking parts and body & chassis. This will production of approximately 2.5 million tonnes of steel positively impact the wire industry, especially players supwires per annum. It employs around 10,000 workers and plying wire harnesses and other such components to OEMs. staff. The steel wire industry is a basic infrastructure indusThe increasing intake by the construction, automobile, try producing various types of steel wires, which have highend critical applications in infrastructure, auto industry, power distribution, defence, and other critical industries. The development of this industry is directly linked to the growth of the infrastructure, automobile, and power sectors. The industry caters to both the domestic and export markets. â&#x20AC;&#x153;Given this background it is but natural for us to assume that there exist tremendous growth opportunities for the wire industry in India primarily because of the expected momentum in those particular sectors that are dependent on steel wire,â&#x20AC;? points out Varun Kapoor, Director, Sarvasv Machinery & Equipments, a company that manufactures machines for stranding, copper annealing, wire drawing, armouring, and other applications. Economic activities which showed significant growth rates in 2009-10 over The Gateway of India is a landmark in Mumbai, which hosted the wire India trade the corresponding period last show last November.

FEATURE India’s burgeoning auto production has contributed to the country’s healthy growth rate.

and manufacturing sectors has helped major steel companies like the state-run Steel Authority of India Ltd. (SAIL) and Vizag Steel post excellent sales of wire rods as reflected in the financial results of 2010. In fact, SAIL achieved its best-ever July-September quarter sales of 3.17 million tonnes (MT) on account of this demand. “In comparison to sales in the previous quarter (Q-1), SAIL achieved a growth of 30.8 per cent,” the company said in a statement. The steelmaker said the sale of wire rods during the period increased by 60 per cent compared to the corresponding period last year, besides higher sales of other products like bars, sheets, and coils. Meanwhile, the cumulative production of saleable steel comprising wire rods, rebars, rounds, re-rollables, and structurals at Vizag Steel’s Visakhapatnam rose to 1.5 million tonnes during the first half of 2010.

Given the scenario, companies in India currently engaged in the production of wire rods and associated products and equipment are now getting into a frenzied mode of scaling up their capacities, indulging in foreign collaborations, and

India’s growth will require more power, another growth area.

46 | WIRE JOURNAL INTERNATIONAL

investing huge amounts of money for their expansion projects. For example, Bedmutha Industries, one of the leading steel wire manufacturers in western India, has plans to set up a 36,000 tonnes per annum (TPA) manufacturing facility for low relaxation pre-stress concrete (LRPC) wire and spring steel wire with installed capacity of 18,000 TPA. LRPC wires, which are in much demand, are used in prestressed concrete girders for roads, railway sleepers, and flyovers.

Another example that can be cited is that of Switzerlandbased Maillefer SA, with expertise in providing extrusion and winding solutions to the wire, cable and pipe industries, opening an office in India. Commenting on this initiative, Manuel Felder, Executive Vice President (Sales & Marketing), says, “As being part of the BRIC countries, India is seen as a rapidly growing country with a strong potential for investments in infrastructure. With its manufacturing solutions for cables and pipe, Maillefer is in a good position to be one of the leading equipment suppliers to the leading players in this infrastructure development. The target is to be closer to our customers from the commercial and service point of view.”

This can be further substantiated with the view of Harry Prunk, CEO of Sikora AG of Germany, manufacturers of measuring, controlling, and testing equipment for the wire, cable, plastics, and rubber industry.

“We are one of the leading suppliers of Harry Prunk, Sikora AG. measuring and control technology in India and we are planning to further expand our business,” he states. Taking it a point further, Raj Kumar Tyagi, CMD, Assomac Machines, a company that manufactures wire machinery, says, “The 11th (2007-08 to 2011-12) and the 12th (2012-13 to 2016-17) plans of India have worked wonders in boosting the economy of the country through industrial and infrastructural development. This momentum will now continue because investments are being made in the right sectors and the demand for housing, commercial construction, automobiles, power, etc., is going to rise Raj Kumar Tyagi. further with the increasing spending power of the consumers.”

“We think that the India market for cable business will grow in the next ten years and it’s an important region for mutual business cooperation.”

Jonathan Yang, CEO, Chengdu Centran Industrial Co Ltd, China.

“Already for several decades now Medek & Schoerner has been offering its high-performance cable marking machines to companies of the Indian cable industry and has been extremely satisfied with the success and the huge interest of Indian customers in our cable marking products. Our Indian customers are very quality conscious but of course also hard bargainers.” Werner Lichtscheidl, CEO (Commercial), Medek & Schoerner GmbH, Germany.

“As an expanding market, India offers great potential for our products, particularly for wire and cable manufacturers seeking a safe, clean, ‘green’ alternative to electrical welding—and for those who want reliable, well-designed machines that deliver accurate results.” Steve Mepstead, Managing Director, Pressure Welding Machines (PWM) Ltd, UK. “With the India market growing, we visualise big potential for measuring instruments used in India’s wire industry.” Mathias Köhr, Managing Director, H Schmidt & Co GmbH, Germany.

“The importance of the Indian market cannot be underestimated with many experts predicting that in the future India’s economy will rival that of China.” Stephen Wood, Chairman, International Wire & Machinery Association, UK.

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FEATURE

Industry perspectives of India

FEATURE

Cable sector More than the wire sector, it is the cable industry in India that is expected to post an impressive performance in the coming years. The reasons are simple. One of them can be attributed to the power sector that will grow at least 1.8 to 2 times that of the GDP, translating to an addition of generation capacity by nearly 18,000 to 20,000 MW each year. It is estimated that nearly 3 to 3.5 per cent of investment per MW goes towards power cables. Therefore, with an approximate investment of Rs 40 million per MW, the demand for cables will be in the range of Rs 1.2 to Rs 1.4 million. The estimated market size of the Indian power cables and conductors segment (including unorganised players) was estimated to be around Rs 120 billion in 2008-09. Around 70 per cent of the industry is organised, while the remaining accounts for the unorganised and regional sector.

Further, the Indian telecommunications network with 621 million connections (as on March 2010) is the third largest in the world. The sector has been growing at a speed of 45 per cent during the recent years. The Indian Telecom Analysis (2008-2012) report by RNCOS Industry Research Solutions shows that the mobile telecom segment has surpassed all the other segments in the Indian telecom sector.

Its growth has been forecast at a compound annual growth rate of around 15 per cent between 2010 and 2014. The report also indicates that the advance of services such as Internet Protocol Television (IPTV) and 3G are adding the right elements to the growth of the Indian telecom sector.

This certainly bodes well for the cable industry.

Further, with 10.34 million broadband subscribers in the country as on September 30, 2010, the Indian government is actively working on the formulation of a ‘National Broadband Plan,’ and the Telecom Regulatory Authority of India (TRAI) is holding consultations with stakeholders on the subject. The National Broadband Plan would address broadband connectivity to all the villages, including through optical fiber cable, as required. However, no final decision has been taken in the matter so far. “In an effort to increase the penetration of broadband connection in the country, 3G and BWA services in the private sector have been allocated spectrum through auction. This will facilitate the prolifera-

48 | WIRE JOURNAL INTERNATIONAL

tion of broadband through mobile handset and wireless technology,” informs Sachin Pilot, Minister of State for Communications & Information Technology.

Given this scenario, the developments taking place in the cable industry are tremendously India Minister Sachin Pilot. brisk-paced.

Consider, for example, a presentation made in December by Prysmian, a global player in the energy and telecommunications cables industry, and Ravin Cables Ltd., its Indian JV subsidiary. “The group’s initial plan is to invest in a new high voltage cable manufacturing unit of up to 220 kV as well as to improve Ravin’s product offer in the industrial cables market in sectors that include automotive, mining, and renewable energies,” Fabio Romeo, COO, Prysmian Group, said.

Meanwhile, electrical and power equipment major Havells India has doubled its cable and wire manufacturing capability at an investment of Rs 120 crore. The company, with a market share of 10 per cent of the Rs 12,000 crore cable and wire industry in India, expanded its manufacturing plant at Alwar in Rajasthan to make Rs 2,400 crore worth of electrical goods. “The expansion is in line with the demand the market is witnessing in both the domestic and international markets,” states Sunil Sikka, President, Havells India. The company expects the demand of its cable and wire products to hit Rs 1,800 crore by 2012 from the organised construction sector and independent home builders.

Delhi-based Shilpi Cable Technologies, a radio frequency (RF) cables manufacturer, is planning to set up a wire and cable assembly shop, expand its product portfolio, and manufacture low voltage power cables and cable accessories. A family-owned venture with over three decades of experi-

3rd International Wire & Cable Trade Fair for Southeast Asia

FEATURE

ence, the company bought out its joint venture partner, Rosenberger Hochfrequenztechnik GmbH & Co KG, for Rs 22 crore in 2008. “The JV was set up to manufacture RF cables but our partner wanted a majority stake which we were not willing to concede,” the company’s director Manish Goel said in the course of an interview to the media. The company caters primarily to the telecom sector and its products are used in telecom towers.

In another instance reflecting the growth in the Indian cable sector, Sterlite Technologies, provider of transmission solutions for the power and telecom industries, and CTC Cable Corporation have announced a strategic relationship wherein the former would manufacture specialty ACCC power conductors for the Indian market, using CTC’s patented ACCC conductor technology. “Sterlite has been engaged in actively exploring the latest technologies to make it easier, faster and more cost-effective for utility companies to build power infrastructures. India needs to rapidly increase the current carrying capacity on its grid to keep pace with its economic development. ACCC conductors would offer India a unique ability to increase the current carrying capacity of the existing lines and to significantly improve the overall economics on new lines,” says Rajendra Mishra, COO (Power), Sterlite Technologies.

Incorporating :

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The challenges This is not to say that the road ahead is without bumps.

“To accelerate growth in the wire industry there is an urgent need to devise policies that will increase the export of wires. If such policies can be put in place, the wire industry in India has the potential to grow at a rate much higher than the current Tirthankar Banerjee. rate of 7-9 per cent per annum. For one thing, according to the Indian Customs Tariff, steel wires (the finished products) continue to be classified with semi-finished and raw steel items i.e., wire rods. It is an anomaly, which should immediately be done away with. Also, a reduction in the rate of duty on wire rods from 5 per cent at present to 0 per cent would give a huge boost to the steel wire industry,” points out Tirthankar Banerjee, Secretary, Steel Wire Manufacturers Association of India (SWMAI).

According to a study reported by the International Cablemakers Federation, China will continue to hold its position as the world’s top wire and cable supplier. The growth of China’s wire and cable industry has been achieved as part of the country’s transition from a centralised economy to a market economy, as well as its transition from a rural agrarian economy to an urban industrialised economy.

No other country is likely to duplicate this feat. India is trying hard though to get to the top slot. “It definitely will,” predicts Raj Kumar Tyagi, CMD, Assomac Machines.

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FEBRUARY 2011 | 49

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India visibility on rise at trade shows both home and abroad The fact that Indian players in the wire and cable industry are all geared up to make an international mark was more than driven home by the trade shows in 2010 held in India and abroad.

This could be seen in Düsseldorf, Germany, not just outside its cafe-lined streets and by the riverfront but also on the sprawling campus of the Messe Düsseldorf Fairgrounds that April 12-16 hosted its wire show, the world’s largest wire and cable event. More so, because you could see for yourself how Indian companies operating in the wire and cable space have now emerged as key players on the international front. For the 60-odd participants who had booked their stalls there, this was not just about showcasing their products but also to establish the fact that Indian technology is now at a level of competence that continues to climb higher.

Commenting on the event, S.K. Sengupta, GM (Technical Services), Kalpena Industries Ltd., said: “This was our second participation after the year 2008 and it was a nice experience. More than 200 customers from all parts of the world, including Indian cable manufacturers, visited our stall and participated with fruitful technical/commercial discussions.” Similar was the experience of Shubhendu J Taly, Marketing & Sales Manager, JLC Electromet. “More than 100 new and potential customers came to visit us. It proved to be a far-reaching platform for us to touch base with the latest in the industry and meet people with common objectives,” he said.

Later, the third international exhibition and conference for the wire and cable industry hosted by Messe Düsseldorf at Mumbai in November 2010 was a clear indicator of the fact that India is now a major draw for foreign companies.

Organizers Messe Düsseldorf report that a total of 286 exhibitors from 24 countries showcased their latest products and technologies to 5,600 trade visitors at Wire & Cable India 2010, India’s largest and most important trade fair for the wire and cable industry. The number of exhibitors grew by almost 30% compared to the 2008 event and gross exhibit space rose by 50%. This increase is a clear indication of a promising market with continued growth in buying power and the need of India’s diverse industries for the latest innovations and state-of-the-art technologies. The positive results were no surprise to many exhibitors given the fast pace of developments in India and the large interest by overseas exhibitors in India’s growth potentials.

For the companies exhibiting their products and technologies at this show, this turned out to be a perfect meeting ground with existing and potential clients. The presence of the foreign companies easily overshadowed those from India. There were 172 foreign exhibitors as compared to 109 Indian companies. The signal was clear: India is now a ‘happening’ country when it comes to the wire and cable sector.

It should be no surprise then to find foreign players mak-

50 | WIRE JOURNAL INTERNATIONAL

ing a beeline to India. “In recent times the Indian government’s emphasis has been on improving the infrastructure and allocating a huge budget, and this is indeed good news for all the wire and cable players. Also, because of the growth in India’s telecom sector, the need for power cables will be on the rise. As such, India is definitely an important country for us as of now,” said Frank Waets, Senior Technical Manager, Borouge. As providers of value-creating

Messe Düsseldorf, organizers of the wire trade show in Germany, are expecting its recently acquired event in India to become increasingly important. plastics solutions to the wire and cable industry across the world, Borouge and Borealis had on display advanced insulation, semi-conductive, and jacketing materials while promoting their Visico solutions for low and medium voltage cables offering reduced complexity versus other silane cross-linking technologies.

Interestingly, even as the foreign companies are setting up their sales offices on Indian turf, there is also a scramble by Indian companies to take advantage of this freeway and tie up with leading foreign players to not only gain branding mileage but also enhance their production processes and technologies. Scouting at the exhibition for quality vendors, Zoeb Chitalwala, Director, Zarhak Steels Limited, said, “The entry of the foreign companies has changed the perception of quality. It has now become very important to have quality control benchmarks of international standards because anything that is sub-standard will no longer find a market. As such, this is indeed a good thing to happen to India. Also, the space has expanded. Our company, for example, is now looking at the growing auto sector with interest.”

The best example of this shift of focus to India is that of InnoVites from The Netherlands that was perhaps one of the first few companies to have realised the vast potential that lay here. InnoVites has established a technical competence center at Hyderabad and is an exclusive re-seller for Cimteq’s CableBuilder, a software solution for

Silvio Piller, Area Sales Manager.

Given this situation, collaborations between Indian and foreign players are in full swing. While Walson Woodburn Wire Die is one example of a perfect understanding between an Indian and an American company to produce natural diamond wire dies, Enkotec of Denmark is another.

This is a company that makes rotary nail machines with a modernised tooling system and touch screen for data display, machine adjustments, and trouble-shooting. “We have tied up with an Indian partner to launch this machine in February,” revealed Bent Just Petersen, the company’s managing director.

Moreover, foreign companies are now setting up permanent base stations in India in anticipation of the long-term prospects. Switzerland-based Maillefer SA, with expertise in providing extrusion and winding solutions, is one such that has set up its operations here. Commenting on the market potential in India, Abraham Joseph, Sr. Sales Manager, Maillefer Extrusion India, said, “The market will be buoyant for the next few years based on the initiatives and projections by the government in the power, telecom, and agriculture segments. We foresee investments in both private and government projects which will have a positive impact on the manufacturing sector.”

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cable manufacturers. “We offer enterprise resource planning (ERP) software that helps cable manufacturers improve business performance. India is one of our biggest markets and we have ambitious plans to expand our activities here,” said Albert Groothedde, the comAlbert Groothedde, pany’s CEO. Zumbach Electronics AG, a InnoVites.

Switzerland-based company that provides online monitoring and control equipment, is yet another one that has found the Indian soil fertile for its operations. “We started as an agency outfit in India almost three decades ago and then set up our own office eight years back. However, since the last four years Zumbach Electronics is now an independent Indian company. The reason for this development is obviously the increasing demand for our products and the need to provide a professional level of service support. We have already started assembling the products here and may even start full-scale manufacturing with localisation of vendors,” informed

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Putting all such developments in a nutshell, Dr. Kurt Eder, President, Eder Engineering, Austria, said, “This rapid opening up of the Indian territory in the wire and cable sector can primarily be attributed to the growth of Indian economy and the huge investments in the infrastructure, telecom, automotive, Kurt Eder, President, Eder power and other sectors Engineering. and two, the change in the mindset of the Indians. Earlier, quality was not such an important factor but now it is and therefore Indian companies are increasingly joining hands with established foreign companies to avail of the best products and technology.”

The synergy is definitely worth taking note of. For example, as part of its worldwide expansion strategy in high growth countries and in the high-tech cables and systems sector, Prysmian acquired a 51 per cent stake in India-based Ravin Cables early in 2010, thus entering into a joint venture agreement with the Karia family that now controls 49 per cent of the company. Ravin Cables’ Board of Directors appointed Luigi Sarogni as chief executive officer and Vijay Karia as chairman and managing director of the Board of Directors. “Thanks to the integration with Prysmian, we will be able to bring to India state-of-the-art cable technologies that were scarcely available before,” Karia said.

However, there was another factor that came to the fore.

For one thing, India is still being looked upon as a good place to sell but not to produce. “Yes, it is true that not many of the foreign companies have started to manufacture their products here for the wire and cable industry, unlike what is happening in the automotive sector where giants like Mercedes-Benz, Volkswagen, General Motors and others have already invested huge amounts in the local manufacturing of their vehicles. That may be because everyone is still studying the scenario with caution. Manufacturing operations can be started only when there is a guarantee that the wire and cable sector will witness long-term growth,” explained Dr. Eder.

Another obstacle is that the Indian bureaucracy continues to be a nightmare for most of the foreign companies. “What is most annoying is that the policies change with any change in the government, which is not the case in most of the other countries. As of now the policy is in favour of FDIs and industrialisation but this could shift if another political party with a different agenda takes over,” Dr. Eder said. However, given the potential in store, these are considered as challenges that can and should be overcome. “This may just be the beginning of a new growth cycle and surely no one wants to or can afford to ignore it,” is how Ashwin Gupta, Chairman, India Steel Works, puts it.

54 | WIRE JOURNAL INTERNATIONAL

WCISA and India: a first (but not last) experience One of the first-time exhibitors at Wire & Cable India was WCISA®, the Wire and Cable Industry Suppliers Association, a nonprofit corporate membership association that represents about a hundred North American suppliers of machinery, materials and accessories used for making all types of wire and cable. It promotes its members’ products and services through representation, networking/social outings and services at wire and cable trade events and conferences. Its new president, Rahul Sachdev, Wire & Plastic Machinery Corp., spoke with WJI about its presence in India.

WJI: Why did WCISA take part in the Wire & Cable India event for the first time, and what was the event like?

Sachdev: This was WCISA’s first show in India, and we plan to be back and support the next show. We had a halfdozen companies in our North American pavilion, and this was probably one of the better shows we’ve been to in terms of projects and activity. These are exciting times in India.

Everybody seems to have expansion plans. There were attendees there from a broad spectrum, including top-level management as well as general managers, plant managers and maintenance managers.

WCISA President Rahul Sachdev talks business at the Wire & Plastic Machiney Corp. booth at wire India.

WJI: How important is India as a venue for your members? How hard it is it for them to do business here?

Sachdev: As I said, India is an exciting place to be. I would compare India to where China was 15 years ago.

There’s only one way for it to go, and that is up. GPD is going up to 10 percent and the growth cycle could be 10-15 years. Everyone is very upbeat here. You come away feeling extremely positive. The key is that this is a long-term opportunity, not a three- or four-year growth cycle, like what happens in the U.S. It’s important for companies to be here, and

WJI: How did the India show further that goal, and what are your expectations for the next staging?

Sachdev: You could look at the show and on one level find it very lacking compared to longestablished shows, but it provided a good venue WCISA’s pavilion at wire Düsseldorf. WCISA President Rahul for contacts to be made, and that value cannot be Sachdev has high hopes for members at future India shows. underestimated. WCISA was not involved in the event until a few months before it was held, when it was bought by Messe Düsseldorf, which organvenues. WCISA regularly polls its membership and izes the world’s largest wire and cable event as well as other supports shows that its memberships finds relevant in ones in Asia. It was too late for the event to be upgraded to today’s world. the level that Messe shows are held, but we fully expect that the next one will be much better in terms of logistics, which For more information on the Wire and Cable Industry were difficult, including getting back and forth from the Suppliers Association, go to www.wcisaonline.org. venue in Mumbai. We understand that Messe is encouraging the site owners in Mumbai to upgrade their facility.

Looking to 2012, given the proper marketing and advertising, we expect a fairly large portion of our membership will be looking to tap into the global market, and we definitely expect that our North American pavilion will be much larger.

WJI: What does WCISA do for its members that they can’t do on their own?

Sachdev: Logistics are always a challenge, and when you sign up with us, you don’t have to deal with a lot of it, such as finding local contractors. This was a different experience for us as we came into it so late, but we have worked well with Messe for years and expect to be able to offer more practical help in 2012, including holding a networking reception that we weren’t able to do this time.

WJI: As globalization has forced companies to be active in more parts of the world, has WCISA changed what it does?

Sachdev: Being an exhibitor myself, I like to think how we can make this process easier for members. We’re looking into doing more, not just in India, but in our overall approach to what we do. We are now an active sponsor for all the major international shows and we think we could serve our members better by forging alliances with other international groups. Today, you cannot function as a single entity. It’s a shared responsibility, and if we are part of an international group, then we all can participate in discussions that relate to staging of future shows and alternative

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those willing to invest will be rewarded. It’s not hard to be in the India market. It is a democracy, it’s English-speaking and laws are based on British rules. Yes, there are infrastructure problems but rapid improvements are being made.

What’s important is that business is being done here, now is the time to establish relationships.

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

Editor Huned Contractor has been tasked with making WIRE BULLETIN a practical information network for the wire and cable industry in India. The WAI quarterly publication, officially launched in January 2010, has completed a successful first year of operations. Below, he discusses what has happened.

Somerset Maugham, the celebrated author of short stories who loved twists in his tales, would probably have been inclined to use the Düsseldorf situation in one of his works.

In April 2010, just as the Messe Düsseldorf show for the wire and cable industry was about to wind up, a volcano called Eyjafjallajoekull in Iceland decided to give vent to its fuming anger and spilled out dense plumes of smoke and ash that eventually closed down the airspace over Europe.

Those who had come to the show from outside Germany were left with no option but to keep watching the sky and pray for it to clear so that they could return to their homes. I was one of those trapped in this rather precarious situation and hitched up with a group of Indian wire manufacturers to wait for the airlines to begin their operations.

Sitting in a hotel’s courtyard at Frankfurt, our discussions generally veered toward the wire and cable sector in India and how it presented a great growth opportunity in the years to come. “As Huned Contractor looks at a recent such, WIRE WIRE BULLETIN issue.

BULLETIN couldn’t have been launched at a better time,” commented R.K. Tyagi, CMD, Assomac Machines. He was referring to the quarterly 16-page publication started in India by the Wire Association International January 2010. And now, reflecting on what has transpired over the past year, I can say that Tyagi was right.

WIRE BULLETIN has grown in strength from one issue to the other, so much so that it has now been expanded into a 24-page publication to accommodate more industry-related news and informative features that can be of value to the industry leaders.

What has helped along the way is the earnestness of the players in the Indian wire and cable sector to network with each other, keep abreast of the changing technologies, search for suitable collaborations with foreign partners, improve processes and designs, and be in the loop. This has been reflected through the increasing editorial participation

by Indian companies who have begun to share news about

their companies with the publication as also the advertisers that are now growing in number. Almost all of them have renewed their advertising contracts for 2011 and this includes Supermac Industries, Cable Tech Machines, and others even as fresh entrants such as InnoVites India and Sarvasv Machinery & Equipments have come on board for the entire year.

What matters for a publication of this kind is the outreach.

Here, WIRE BULLETIN has been able to maintain a steady trot of increasing its number of subscribers and ensuring that it reaches the right people in the industry. CEOs, production managers, analysts, engineers, research and development professionals make for a major portion of this circle of readers and the numbers have multiplied especially after showcasing it at the prestigious Messe Düsseldorf shows at Germany and Mumbai in 2010.

To date, WIRE BULLETIN has presented news on established and fledgling companies, done interviews with company officials and provided news about the industry in India while also telling readers of events happening elsewhere.

It includes technical information and has experts who can advise producers. As momentum continues, WIRE BULLETIN will do more, and plans call for greater frequency as it serves its mission to keeping people in the wire and cable industry informed.

“A publication like WIRE BULLETIN helps provide a platform for the industry and keeps everyone informed about what’s new in this space,” is what Shivaji Katke, Director, Arihant Group, once told me during a meeting.

That certainly is sweet music to the ears. As for what lies in store, WIRE BULLETIN will have its own web portal very soon and there are plans to revive the activities of the association in India. In short, it’s going to be a busy and fruitful year for us in India—just as busy and profitable as it’s going to be for the manufacturers who are riding the high tide of the India growth story.

For a free sample copy (PDF) or rate card for WIRE BULLETIN, e-mail a request to Huned Contractor at hunedc@gmail.com or to sales@wirenet.org ■

FEBRUARY 2011 | 57

FEATURE

WIRE BULLETIN chronicles India’s thriving wire and cable industry

MORDICA LECTURE

MORDICA LECTURE A twist on heavily drawn wires This Mordica Lecture focuses on the absolute upper limits of tensile strength of heavily drawn wires, noting that a key is understanding that the stress state of of many wire producs is not purely tension but a combination of tension and torsion.

By Javier Gil Sevillano

I was first confronted with the mechanical properties and microstructure of metallic wires at the start of my PhD work, and thanks to the guidance and inspiration of Prof.

E. Aernoudt, I learned to never idealize the pure materials science aspects and properties of drawn wires in isolation from the constraints imposed by their industrial processing and by their final technological application. It is thus a great honour to be selected by the Wire Association

Javier Gil Sevillano accepted the Mordica Memorial Award at the Awards Ceremony at Wire Expo 2010 in Milwaukee, Wisconsin, USA. He later delivered this Mordica Lecture.

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International as the recipient of the Mordica Memorial Award 2010. My lecture will be devoted to their maximum achievable mechanical strength.

The tensile strength of some heavily drawn metallic wires can reach absolute values that cannot be matched nowadays by any other commercially available continuous and inexpensive filamentary material. In fact, they can reach strength values quite unusual for bulk engineering metallic materials of any kind. Moreover, after heavy cold drawing and possessing such high strength, ultra-high strength wires often still retain enough ductility and toughness to be shaped and used in multiple ways for structural or functional applications without previous annealing: in ropes, as reinforcing material in tires, in medical devices, in high-strength electrical conductors or in low-temperature superconductors.

The main part of this paper makes an inquiry about the static tensile strength limit of heavily drawn wires. That limit is experimentally and theoretically well established for some but not all material families, which leaves a good margin for speculation. Understanding the strength after cold work by drawing and its actual or conjectural limit requires paying attention to the strain-induced changes of the internal structure of the materials. The strength is merely a response of the material structure to a mechanical stimulus. Structure is taken here in a wide sense, including the hierarchy of lattice defects (grain boundaries, interfaces, dislocation patterns, dislocation lines, etc.), the crystallographic texture and the internal stresses. Heavily cold drawn wires often become nanostructured materials or nanocomposites which locates their fundamental study at the forefront of current Materials Science research interest.

The final part of the paper deals with the behavior of highly drawn wires under torsion or, more in general under mixed tension-torsion states, because the stress state of many wire applications is not a pure tension. Key to the heavily cold drawn wires response to out-of-axis loading states is, besides their intense crystallographic texture, the

portant relative to its value; such materials behave in a brittle manner at room temperature and are purposeless from the wiredrawing point of view.

For metallic materials with BCC structure (or HCP except for basal slip, akin to FCC behavior), τp increases greatly at low temperatures but above some critical temperature the contribution of τp to the strength, if not negligible like in FCC metals, is only one more among other possible components of the plastic flow stress. For instance, the

Tensile strength limit of heavily drawn wire: single-phase stress-strain behavior The two extreme plastic strength limits. For crystalline materials, the extreme limits of mechanical strength paradoxically correspond to two structural states that only differ in a small detail. The upper bound is associated to the supreme order: an infinite crystal without any lattice imperfection. It can only fail either by homogeneous elastic collapse of the lattice when an unstable distortion is reached (at 0° Kelvin) or by homogeneous nucleation of dislocations at finite temperature, under the so-called “ideal shear stress, (τc) max = τi, a critical resolved shear stress in a crystallographic plane (usually one of the atomically densest lattice planes). The lower bound does not correspond to total disorder, but to an infinite crystal also infinitely perfect but for a mobile dislocation line. Gliding of that solitary dislocation is only impeded by the lattice friction: the critical resolved shear stress needed for driving the core of the dislocation line through the periodical internal energy landscape it experiences as it moves along its slip plane, (τc)min = τp, the so-called Peierls-Nabarro stress1-2.

The Peierls stress is highly temperature and strain rate dependent.

The Peierls stress is negligibly small for FCC metals (Cu, Ni, Al, etc.) and alloys: less than 10-5G*, with G* the appropriate shear elastic modulus for a dislocation line3, e.g., τp<0.42 MPa for copper at room temperature (G* = 42.1 GPa). By contrast, it is so high for some materials (e.g., most ceramics at low temperatures) that it approaches their ideal strength, all possible strengthening mechanisms being unim-

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extreme directionality of their internal structural patterns, that leads to peculiar strength anisotropy and failure modes. Elastic or plastic anisotropy of most technical materials is mainly dictated by crystallographic texture, with deep-drawing ability of steel sheets being the paradigm for this behavior; however, in heavily drawn wires, the mechanical anisotropy is in a great measure ruled by their structural directionality. Strength and failure under axial loading, collinear with the directional structural patterns, are mainly controlled by the transverse microstructural size. Under out-of-axial loading, the ultra-fine structured wire behaves akin to nano-layered materials or the so-called kinking non-linear materials: a high density of finely spaced parallel internal boundaries facilitates axial shear but also makes the wire’s failure by compressive kinking and by longitudinal delamination easier. The “delamination syndrome” in fact often puts a lower bound to the usable tensile strength of wires below their absolute tensile strength limit.

This paper revisits the subject of the limit strength of heavily drawn wires after two previous attempts in 1987 and 19911-2.

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Peierls stress of the iron lattice (BCC steels) is about 15 MPa at room temperature and moderate strain rate3, i.e., it contributes with about 45 MPa to the tensile plastic flow stress of ferritic steels on the assumption of the following orientation factor:

For pure FCC metals, the ratio τi/σicl , is so small that the inequality (2) is never met (but for iridium) at any temperature. In short, the absolute bounds for the maximum tensile strength of a metallic crystalline material are given by Eq. (3)

Its contribution to the plastic flow stress at room temperature of refractory metals (W, Ta, etc.) can indeed be much higher. To have an idea of the maximum value such a contribution can reach, the order of magnitude of the zero Kelvin limit of τp of BCC or HCP materials is 5·10-3 G* 3; for BCC iron, such limit is τp ≅ 365 MPa (i.e., a contribution of about 1 GPa to the tensile flow stress of ferritic steels at 0° Kelvin).

The ideal shear stress ti can only be quantitatively predicted using atomistic numerical calculations. It turns out that results of rigorous atomistic calculations4-7 lead to near the same value obtained from the classical order of magnitude calculation of Frenkel8: Eq. (1)

For <111> simple shear of BCC iron at room temperature, G* = 64 GPa3, and atomistic calculations yield τi = 6.4 GPa5. Similarly, for simple shear of FCC copper, τi = 4.2 GPa6,7.

Summarizing, there is plenty of room between the lower and upper bounds of the tensile strength of ductile metals, . For FCC copper and BCC iron at room temperature, the available ranges are 1.2 MPa< <12.6 GPa and 45 MPa< <19.2 GPa, respectively.

The contingent limit of homogeneous brittle fracture. For materials that cleave, as BCC metals, brittle fracture can establish a strength limit at stresses smaller than the ideal stress for dislocation-less plastic flow4,7,9. For such materials, a critical ductile-brittle transition temperature, DBTT, can be defined as the temperature for which the tensile stress normal to the weakest crystallographic direction for homogeneous cleavage (<001> for BCC materials), sicl , is smaller than the ideal tensile plastic flow stress in the same crystallographic direction Eq. (2) For BCC metals, σicl ≅ 0.08E<001>, where E<001> is the elastic modulus in the direction normal to the cleavage plane7,9. For iron at room temperature, this ideal fracture stress is 10.8 GPa, smaller than its ideal tensile plastic flow stress in <001> direction, 15.7 GPa ( ). In an iron polycrystal a grain with the weakest orientation for cleavage will constitute the weakest-link for brittle failure under tensile stress; consequently, the available strength range for iron at room temperature is 45 MPa< <10.8 GPa and the upper bound strength would be limited by brittle fracture.

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The limit strength of disordered metallic lattices. Now, a word concerning another structural state limit of a solid metallic material: the total absence of long-range order, i.e., the metallic glass state below the glass-transition temperature. Metallic glass alloys (MG) can today be made in bulk form (BMG) and BMG wire drawing has been performed10,11. At low temperature and high stress, plastic deformation of MG occurs by superposition of the shear of localized groups of atoms, known as “shear transformation zones.” Plasticity of MG is confined to a small number of very thin shear bands where the local strain and strain rate are very high12-14. The ideal shear strength of a MG for shear nucleation without recourse to any geometrical defect or compositional heterogeneity is only accessible to atomistic calculations. The conditions of incipient plastic shear under the contact surface of a MG with a blunt nanoindenter approximately reproduce experimentally the ideal shear strength scenario. Results for several Zr- and Fe-based MG15 indicate that (τi )MG ≤ 7 -10-2GMG, a value smaller than the ideal shear strength for the crystalline state. On account of its isotropy, the maximum MG tensile plastic flow strength would be twice such value, Eq. (4) The subscript of the modulus is meant to indicate that it is the modulus of the glassy metal, slightly smaller than the isotropic average modulus of the polycrystalline metal, G. The ideal tensile strength for homogeneous cleavage of the metallic glass, assuming the relationship valid for crystals also to hold for MG, would be σicl ≅ 0.08EMG ≅ 0.2GMG. Consequently, in tension, MG alloys would fail after plastic shear instead of by brittle fracture from the elastic state, as confirmed by tensile experiments of small and smooth (near “perfect”) MG samples, e.g., ref.11.

A reinterpretation of the experimental nanoindentation results leading to the upper-bound (4) and new theoretical estimates of the ideal shear strength of MG16,17 both lead to (τi) MG = 2.7.10-2GMG, a value about three times smaller than the upper-bound. The current estimate of the tensile flow strength of MG is thus Eq. (5) The predicted values for, respectively, copper and iron are 2.48 GPa and 4.48 GPa (using here their respective isotropic polycrystalline shear elastic modulus G for the

Eq. (6)

at “low” temperature (T<0.3TM, TM being the absolute melting temperature of the material) changes irreversibly the internal structure of a metal. The common result from that internal change is that the metal hardens: its plastic flow stress (its instantaneous elastic limit for its current deformed state) increases as plastic strain increases.

Each wire drawing pass imparts a significant amount of plastic strain to the wire and after several passes the accumulated strain can be very high, much higher than the maximum uniform strain attainable in a tensile test, u, limited by the necking instability, seldom reaching a value of 0.5. In terms of the initial and final wire diameters, the true strain neglecting any redundant strain components (the true axial elongation) is Eq. (8) For instance, In crystalline materials at low/moderate temperature, the main internal mechanism of plastic deformation is dislocation glide. Dislocation lines move through the slip planes of the crystalline structure under the action of a critical resolved shear stress acting on the slip plane in the slip direction, τc. Each dislocation line carries a shear displacement b (the modulus of its Burgers vector); when a line has crossed a grain of size D of a polycrystalline metal, the grain has been deformed in terms of resolved shear strain in that active slip system. The external and internal stresses and strains are related through the orientation-dependent factor

For the sake of clarity the possibility of ductile fracture has been omitted (this could be partially justified by the condition that ductile fracture requires concomitant plastic deformation). The brittle fracture condition below the ideal tensile cleavage stress occurs when the stress intensity factor associated to a crack-like defect of size a under the tensile plastic flow stress reaches the toughness value of the material in its current structural state, s, chemical composition ch, dislocation density ρ, any internal distance λ interfering with the dislocation mean free path (grain boundaries, interfaces in two-phase materials, inter-particle distance in precipitation-hardened metals, etc.

Eq. (9) means that the macroscopic or external measures of the flow stress and the plastic strain, respectively and , have as internal or orientation-independent counterparts τc and The order of magnitude of the tensile orientation factor is and the order of magnitude of b is the interatomic distance, b » 0.25 nm. This means that in a drawing pass of say = 0.25 a grain of size D=10 μm has been crossed by about N=105 mobile dislocations:

Eq. (7)

Eq. (10)

Some of the structural parameters from the s set are plastic deformation-dependent: for single phase materials (or for the matrix of a two-phase composite), the dislocation density ρ and the size, morphology and orientation of the grain boundaries or other interfaces are the most prominent. The orientation factor entering in the tensile flow stress expression is deformation-dependent too, as the crystallographic texture evolves with the applied plastic deformation; its change is however most often secondorder with respect to the stress-induced alteration of the critical resolved shear stress.

Effect of moderate drawing strains. Plastic deformation

This is indeed a heavy traffic!

Those dislocations are linear objects oriented differently in the three-dimensional space domain of the grain where other dislocation lines are already stored in a three-dimensional network that must be crossed by the mobile lines.

Dislocations are not inert geometric lines signalling defective regions of the crystal lattice; they are regions of high energy density and they have associated elastic stress fields that can be of a very high level in their neighborhood18. So it is no wonder that if they react repulsively or attractively when they cross themselves traffic jams result where part of the dislocation lines carrying the strain become captured

Eq. (9)

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calculation).

Limits for real materials. Real materials are neither infinite perfect or quasi-perfect pure single crystals nor, in our context, bulk metallic glasses: they are finite in size, defective, impure and usually polycrystalline, i.e., they are bounded by free surfaces with roughness and geometrical defects, they are impure or purposely alloyed, constituted by an aggregate of grains of different orientations separated by grain boundaries and they contain some density of linear dislocations and point defects inside the grains. They contain non-desired solid inclusions in some proportions and often second phases of variable size. All those structural items constitute “defects” with respect to the infinite perfect or quasi-perfect single crystal and, in general, enhance the low temperature flow stress above its absolute lower-bound, the strength corresponding to the Peierls stress. Most of them, on the other hand, act as stress raisers or void or micro-crack nuclei, promoting ductile or brittle fracture below the absolute strength upper-bounds expressed above. Representing the set of structural items of a real material by s (composition, grain size, initial dislocation density, etc.), the bounds for the maximum tensile strength of a real material are now narrower than those provided by the inequalities (3):

MORDICA LECTURE

inside the grain. This causes the density of the stored dislocation network ρ to increase at every strain increment, making the glide of new mobile dislocations increasingly more difficult. This is the essence of work hardening in most cases19,20.

Dislocation density is measured as the length of the dislocation lines per unit of volume. The mean distance between two dislocation lines of a 3-D dislocation network of density ρ amounts to roughly A mobile dislocation has to cross such a network for producing slip and the shear stress to make it possible depends on the network density. That dislocation-dependent part of the strength of

the crystal scales with the inverse of such characteristic distance Eq. (11) where G* is the shear elastic modulus in b direction and a* ≅ 0.05. For dislocation densities after moderate strains, a ≈ 0.3.

The initial dislocation density of a well annealed polycrystal is about 1011 m-2. Plastic strain can multiply this value by more than three orders of magnitude. The plastic strain dependence is well described, at least for moderate strains, by the Kocks-Mecking (KM) kinetic relationship Eq. (12) Eq. (12) manifests a competition between dislocation storage (some length of the mobile dislocation remains inside the crystal, the first term) and dislocation annihilation (dynamic recovery, the second term; some of the previously stored dislocation length is eliminated at the passage of the mobile dislocation: encounters of mobile dislocation lines with stored dislocation segments of opposite sign eliminate dislocation length from both the mobile and the stored dislocation densities). Experimental results and theoretical calculations yield a universal value C1 ≈ (1.30b), quasi independent of the material, temperature or strain rate19,20. Then, in the absence of the second term, the first term of Eq. (12) combined with Eq. (11) would produce a linear strain hardening with a slope Eq. (13) However, the dynamic recovery term of Eq. (12) progressively weakens the dislocation storage capacity as dislocation density increases, asymptotically leading to a saturation dislocation density ρσKM = (C1/C2)2 that, through Eq. (11), represents a saturation of the strain hardening θ. The dynamic recovery parameter C2 depends on the temperature and strain rate: dislocation annihilation responds to a thermally activated process. For a given temperature and strain rate, neglecting the dependence of a on the dislocation density,

Fig. 1. Strain hardening rate Θ = dσ /dε vs. tensile flow stress σ (both relative to the shear elastic modulus, G*) in wire drawing of: (a) copper (FCC, G* = 42.1 GPa, TM = 1356 K, Stage IV approximated by a Voce behaviour, as Stage III) and (b) niobium (BCC, G* = 44.3, TM = 2741 K), from ref. [2] In (b) the copper curves have been also included for comparison. Notice the scale change with respect to (a). Niobium maintains a work hardening rate Θ ≅ 2.3 . 10-3 G* up to very large strains and stresses. See also Fig. 4.

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Eq. (14) Eq. (14) is the so-called Voce equation in differential form, Fig. 1a. Strain hardening rate continuously decreases until a saturation stress is reached. The parameter C2 is related with the long-range cross-slip ability of the mobile dislocations driven by the applied resolved shear stress on the cross-slip system. Its quantitative theoretical prediction is still debated21. For, respective-

Eq. (15) where D is expressed as the mean linear intercept. Grain size strengthening beyond the yield point comes from an extra storage of dislocations on top of the storage occurring in the absence of grain boundaries (given by the first term of Eq. (12)). Its importance decreases as plastic deformation increases to large values19,22,23. As a first approximation, the dislocation density equivalent to the strengthening given by Eq. (15) can be taken as initial dislocation density using Eq. (11). Then, the strength limit determined by Eq. (14) would not be affected by grain size. Similar considerations can be made on the effect of dispersions of fine precipitates; their effect on strain hardening fades-out for very large strains.

Large wiredrawing strains: regular behavior. The strain hardening behaviour after large plastic strains, > 1, easily reached after several wire drawing passes, deviates rather abruptly from the behaviour extrapolated from small-moderate strains, the Voce equation (the strain range covered by the uniform elongation in a tensile test of a ductile material, a range more often fitted with a Hollomon equation for practical reasons). The saturation stress is surpassed in practice: when the decreasing hardening rate falls to about

mated above for the apparent saturation stresses for copper and BCC ferrite, the approximate true saturation tensile equivalent stresses for these two materials would, respectively, be 405 MPa and 540 MPa on top of their respective tensile yield stresses prior to any plastic deformation (the chemical composition dependent part of the yield stress, Δ τc(ch) from Eq. (7)).

Although there is no complete scientific agreement on the origin of Stage IV, the most plausible explanation is that it corresponds to a persistent work weak hardening contribution completely overlooked by the mainstream scientific studies of plastic deformations focused on small and moderate strains until the eighties19,20,22. This situation has changed with the current interest on the so-called “severe plastic deformation” SPD processes24. The source of Stage IV must be linked to the storage of a particular dislocation density rather immune to the dynamic recovery processes governing the KM stage. The physical origin of its termination when the true Δ(τc)s is reached is still debated.

An important remark for the wire drawing community is necessary here. The above description of the strain hardening and tensile equivalent maximum strengths attainable by unlimited plastic deformation of a metallic polycrystal is the canonical or general behaviour found in dislocationmediated plasticity … with a very important exception: wire drawing of BCC and some HCP metals.

Large wiredrawing strains. The exceptional behavior of BCC and HCP metals. It is well known since the sixties and in particular since the seminal works of Embury et

Eq. (16) a strong deviation from the KM behaviour is observed, Fig. 1b. The hardening rate θIV remains almost constant or slowly decreasing until a true saturation stress is reached on the order of Eq. (17) The subscript IV refers to the name given to this deformation stage in scientific jargon. In terms of strain, because θIV is relatively small, “StageIV” can be very long. It must properly be considered as the “large strains deformation stage”. By taking into account Eqs. (9), (16) and (17), Eq. (18) Because the KM stage in polycrystals lasts until » 1, Eq. (19) indicates that the true saturation stress in plastic deformation is not reached until total tensile equivalent deformations > 4.

From Eqs. (9) and (17) and on account of the values esti-

Fig. 2. Shear modulus compensated work-hardening rate of several BCC and HCP polycrystalline materials largely strained by axisymmetric wire drawing versus homologous deformation temperature2.

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MORDICA LECTURE

ly, copper or iron at room temperature, represents approximately 90 MPa and 120 MPa19,20,22.

Grain size at moderate strains contributes to the strength through the well-known Hall-Petch relationship valid for conventional grain sizes

MORDICA LECTURE

al.25, Langford and Cohen26 and Biswas and Cohen27,28 that BCC metals (ferritic steels, refractory metals and other BCC alloys) as well as HCP aTi alloys or Be highly deformed by axisymmetric wire drawing (or, more in general, by any process of axisymmetric elongation) deviate in a rather extraordinary way from the regular behavior just described: at large strains they show a constant (or slightly increasing) strain hardening rate up to very high drawing reductions ( >10). The tensile stress-strain slope is of the same order of magnitude when normalized by the temperature-dependent shear modulus, , little dependent of the crystal structure or homologous deformation temperature (Fig. 2). The behavior is associated to a peculiar morphology of the grains in the cross-section of the wire, a “Van Gogh sky” structure of curled grains29,30, morphology explained by the <011> wire texture of BCC wires or the wire texture of HCP metals like Ti or Be that prefer to deform by prismatic glide27,31. In both cases the orientation of the available slip directions makes plane strain elongation of each <011> or grain much easier than axisymmetric elongation; after large strains, the grains become flat co-axial ribbons that need to bend around each other in order to maintain continuity of the aggregate. Bending implies plastic gradients across the grain thickness in a cross section and plastic gradients imply storage of “geometrically necessary dislocations” GND32, very difficult to annihilate by dynamic recovery processes, Fig. 3. As this process goes on as far as wire drawing deformation accumulates, the dislocation density of GND steadily increases and is believed to be responsible for the observed near-constant strain hardening rate, as attested by numerical simulations of crystal plasticity30,33.

Is there any limit to the strengthening of single phase BCC or HCP wires by GND accumulation before the strength limit is imposed by the ideal stress or a brittle fracture stress, the upper limits presented in Eq. (6)?

For hardening by statistically stored dislocations, as both

signs of any type of dislocation lines are on average equally present in a grain, the limit is imposed by a critical density that makes impossible the storage of any new dislocation segment or loop because they would be near enough to a previously stored line or loop of opposite sign for their immediate mutual annihilation. As this cannot happen when dislocations of a neighbourhood are all of the same sign, the limit must be related to the maximum admissible lattice disorder, i.e., by the reaching of a structure akin to the metallic glass state. The strength limit would then be given by Eq. (5), ( max)MG ≅ 0.054G*. This amounts to 4.48 GPa for ferritic steels. The maximum value reported for ferritic wires is, to my knowledge, 2.5 GPa34, for a Fe-6% Si solid solution alloy drawn to ≅ 10, i.e., 0.039G*. For HCP A70 titanium, Biswas27 reports 2 GPa after ≅ 4.5, that amounts to 0.046G*. In both cases no level off of the stress-strain curve was still observed. Finally, for BCC niobium, Spitzig and co-workers35,36 show that its strain hardening by wire drawing stops between 10< <12 with a tensile saturation stress of 1.38 GPa that represents, with G*=44.3 GPa3, 0.031G*.

Thus we have, for wire drawing of different BCC or HCP single phase polycrystalline materials measured maximum strengths in the range 0.031<( max)G*<0.046. The lower bound corresponds to a pure metal, the upper bound to an impure one. It appears that the maximum disorder a lattice can tolerate exclusively on the basis of increasing the dislocation density is far from the amorphization limit and a terminal crystalline structure is achieved by a process other than crystal-glass solid state transformation. However, if the dislocated lattice is additionally distorted by a high concentration of foreign atoms in solid solution, the limit strength approaches the metallic glass limit. In fact, crystalline alloys of favourable composition for glass formation by cooling from the melt can be amorphized by effective severe plastic deformation (for instance, by mechanical high-energy milling37,38 or by high-pressure torsion, HPT24,39. Partial amorphization by heavy wire drawing has been observed in NiTi-base alloys or in multi-phase Cu-Nb-Ag or Fe-Fe3C alloys40,42.

It is interesting to estimate the maximum dislocation density that corresponds to the pure Nb wire drawn to its saturation strength, max=1.38 GPa = 0.032G*. From Eq. (11), a dislocation density 6·1016 m-2 is obtained43. This means that this BCC metal drawn to saturation of its strength contains 60000 km of dislocation lines per mm3, one and a half the circumference of the earth!

Tensile strength limit of heavily drawn wires: two-phase stress-strain behavior Fig. 3. (a) Sketch of a section of a bent ribbon-shaped grain of a highly drawn BCC wire (for a Ti, Be or Zr HCP wire, the corresponding orientations would be // 3 and (0001) // 1). (b) Net density of geometrically necessary dislocations for a bending curvature Κ according to Ashby32.

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Strengthening mechanisms in composite wires. The origin of the strengthening of single-phase FCC, BCC or HCP metallic wires by drawing is the resistance to a forest of dislocation lines to be crossed by a mobile dislocation gliding on its slip plane, approximately proportional to the square root of the dislocation density, Eq. (11). We have just seen that the maximum recorded values of such strength

Eq. (19) Such a limit can be overcome by wire drawing ductile two-phase materials with a fine initial structure (Fig. 4) because, particularly after large strains, new mechanisms take control of the plastic strength2: composite strengthening and constrained slip strengthening.

The morphology and size evolution of the microstructure of two-phase materials are essential for understanding their strength. After ≈ 1, the second phase particles are elongated, axially oriented and the matrix and inter-particle spacings have been reduced because of the diametric contraction, i.e., the wire material is being progressively converted in an axially oriented composite. The orientation and spacing refinement are more effective as deformation accumulates (shear-lag effect) and most effective if both phases or at least one of them is BCC or HCP (they impose an internal deformation of the phase units intermediate between the axisymmetric and plane-strain elongations, the fingerprint of such effect being the curled aspect of the microstructure in the cross section of the wire). Once the two ductile phases are axially oriented and with a high aspect ratio (quasi-continuous in the axial direction), the scaling of the average spacings with the drawing strain, in absence of fragmentation or destabilisation of one of them (dissolution, phase transformation), will be Eq. (20)

als or alloys, like Cu-Ag., e.g.44. The lower bound corresponds to internal deformation by perfect plane-strain elongation, requiring curling of the ribbon-like grains around the wire axis. Actual evolution of the spacings will be intermediate between the two relationships when one or the two composite wire components are BCC or HCP. Cases of FCC-BCC mixtures, like Cu-Nb wires for low-T superconductors or high-strength electrical conductors for high magnetic field coils45,46 will be close to the upper bound. Composite wires of BCC or HCP pairs of alloys or BCC-HCP pairs are expected to evolve closer to the lower bound as well as pearlitic steel wires with about 88 % of BCC ferrite in volume. However, at least for pearlitic wires, despite the characteristic “Van Gogh sky” pattern of its interphase boundaries in the cross section, the dependence of the average pearlitic spacing on strain does not deviate too much from the upper bound47. The αTi- NβTi filaments of superconductor composite wires are an example of BCC-HCP composite nanostructured by drawing48-49.

Once their structure is well developed, the strength of the composite wires is given by the law of mixtures: Eq. (21) In principle, the strength of both components, A and B, will evolve with strain. If their initial microstructural sizes were conventional, i.e. of the order of tens of μm, they would follow their corresponding single-phase strain hardening law for dislocation-mediated plasticity. But when their initial or current spacing is smaller than some critical size, their CRSS is no longer governed by forest dislocation crossing but by the resolved shear stress necessary for either pulling their mobile dislocation lines through the free space of their slip plane confined between two het-

The upper bound corresponds to spacing scaling with wire diameter. It will hold for composite wires of two FCC met-

Fig. 4. Stress-strain behaviour of Cu (FCC, G* = 42.1 GPa, TM = 1356 K), Nb (BCC, G* = 44.3, TM = 2741 K) and an in situ Cu-20% Nb composite deformed by axisymmetric drawing at room temperature. Replotted data from35, 36, 46.

Fig. 5. From (a) to (c), critical configurations for propagation (a) or multiplication (b,c) of dislocations gliding on the plane of the figure if their slip planes are confined by an impenetrable second phase. The multiplication mechanism (c) is the “scolopendra source” devised and observed by Janecek et al. [49]; it requires discontinuity of the second phase (e.g., deformation-induced fragmentation). Configuration (d) corresponds to simultaneous glide across both phases beyond some critical condition for unconfined slip.

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lay in the range 0.03 <( max)exp/G*<0.05 for BCC or HCP metals and we have estimated an upper limit for strengthening by dislocation interactions, in absence of brittle fracture amounting to a maximum total tensile strength for a single-phase metallic material of

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erophasic boundaries or for activating dislocation sources within such constrained space, Fig. 5. Such CRSS range is approximately limited by the so-called “Orowan stress” that must be applied in excess of the Peierls and other possible “friction” components for critically bowing a dislocation to either a radius equal to the phase spacing or equal to half of it, e.g. for the A phase50-53 Eq. (22)

By a combination of Eqs. (20-22) an exponential strain hardening is predicted, in agreement with experimental observations (e.g., Fig. 4). The cross-over between strength control by dislocation density or by confined slip will take place when Eq. (23) For a dislocation density ρ = 6 . 1016 m-2 (a plausible absolute limit for the average dislocation density, see above), the cross-over occurs for a confining space of 200b ≅ 50 nm measured on the slip plane, Fig. 6. This interphase spacing is smaller than the initial spacing used to process most of the composite wire materials cited above

Fig. 6. Dislocation strengthening (forest hardening) as a function of the interdislocation distance (in units of the modulus of the Burgers vector, b), eq. (11) or strengthening by slip confinement in a phase, eq. (22), as a function of the spacing on the slip plane limited by the other phase (also relative to the modulus of the Burgers vector). The absolute strength limit (the ideal stress), is depicted in the figure too.

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but it can often be reached after a modest drawing deformation on account of the exponential decrease given by Eq. (20). For instance, the initial lamellar structure of pearlitic wires obtained by patenting has a true spacing of about 100 nm, the spacing of the cementite lamellae being about 1/8 of it.

For dislocation densities below the saturation limit, the control by the bowing mechanisms will occur for larger spacings. Also in this respect it is important to notice that dislocation storage in confined spaces is reduced or even suppressed: dislocation storage requires a minimum meanfree-path of the mobile dislocations in order to take place54. Consequently, such high dislocation density levels will not be reached in composite wires (with the possible exception of the interfaces) and the cross-over will occur for larger spacings than 200. In short, the critical bowing stress for confined slip, Eq. (22), will easily take control of the strength of finely structured metallic composite wires.

Strength limits for composite wires. If we started with the two phases of a ductile composite with a very fine structure or after enough drawing strain, it seems that Eq. (22) should exponentially lead us to composite wires with the ideal strength Eq. (24) This is in part true: neutron or synchrotron diffraction residual stress measurements or in situ experiments of plastically deforming Cu-Nb composites or fine pearlitic wires indicate that, after heavy drawing strains, the Nb nanofilaments or the cementite lamellae, the finer components in those composites, deform under very high CRSS55-58. However, the maximum strengths experimentally measured for such two-phase wires are 2.2 GPa for Cu-20%Nb composite wire after ≅ 1245, 46 and 6 GPa for a patented pearlitic wire after = 659. Impressive values, although they are far from their respective hypothetical upper limits, 12.7 GPa and 19.2 GPa, calculated according to Eq. (24) and assuming Eq. (1) for their ideal shear stresses (cementite and ferrite elastic constants have rather similar values and the same happens with copper and niobium). The maximum tensile strength reported for the dual-phase steel wire Scifer60,61, a highly-drawn composite of α ferrite and α′ martensite, is 5.5 MPa, of the same order but smaller than the maximum strength reported for pearlitic wires.

The large gap that separates the maximum strengths reported for composite wires from their ideal strengths means that at least one of their constituent phases is still deforming under a CRSS determined by dislocation glide.

In the Cu-Nb case, the final spacings of the Cu and Nb were about 125 nm for Cu and 25 nm for Nb45,46. Thus, according to Fig. 5, in the strongest Cu-Nb wire neither Cu nor Nb should be close to its ideal strength, the plasticity of both phases being still controlled by confined slip and the strength of the wire explained by the corresponding

deformation , i.e., there is a linear shear strain gradient with zero strain at the axis and maximum strain at the free surface. A corresponding linear shear stress gradient is built during elastic torsion loading and plastic yield occurs first at the surface and gradually penetrates towards the axis as torsion twist ϑ increases.

The axially oriented structure, optimal for tensile strength, is badly suited from the point of view of resisting plastic flow and failure in torsion: it is a nanolayered structure optimally oriented for preferential plastic flow or fracture by intra- or inter-lamellar simple shear in the longitudinal direction (a “deck-of cards” mode of deformation already conjectured by Langford71), Fig. 7. The structure presents thin alternating soft layers constituted by the matrix material and hard layers constituted of dense dislocation regions, grain boundary regions or second phase lamellae or fibres, also regions of preferred brittle fracture paths. At the nanoscale, interfacial regions can also contribute with localized slip or other interface-related mechanisms to the shear displacement. Because of their oriented microstructure, strong wires underperform in torsion with respect to what would be expected from their tensile behaviour if only their crystallographic texture was taken into account and they are also prone to suffer from surfacenucleated longitudinal delamination failure in torsion.

Fig. 8 shows shear stress-shear strain curves of twophase pearlitic or Cu-20%Nb wires derived from torsion tests at room temperature after different amounts of drawing. The behavior of the two systems is qualitatively very

High strength wires in torsion The strongest wires we have been talking of fail in tension by a ductile mechanism, with noticeable necking before fracture. Their internal structure of grain or interphase boundaries is fully aligned with the wire axis and the structural spacings are of a nanometric scale in the cross section. Such homo- or hetero-phase boundaries constitute obstacles resisting the propagation of a tensile brittle fracture70. However, torsion strength is required for practical applications of the wires.

If we consider any tubular element of the wire under torsion, its stress-strain state is a circumferential/axial simple shear in cylindrical coordinates. After a twist increment ∂ϑ each tubular element of length endures a simple shear

Fig. 7. Possible local shear modes in a surface element of wire with axially oriented structure of alternating hard and soft phases or zones in a torsion test72.

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rule of mixtures. There is room for further strengthening, although perhaps not too much room after all!: an investigation of the strength of nanometric Cu-Nb multilayers obtained by PVD indicates that their strength is controlled by the confinement of slip (in good agreement with Eq. (22)) for spacings larger than 1 nm but saturates at » 2.6 GPa at about 1 nm of layer thickness. The limit strength is believed to be set by a transition from slip confined in each phase to a regime of interface crossing by dislocation lines that glide simultaneously in both phases62,63.

In the highly drawn pearlitic wire of maximum reported strength, the spacings were about 10 nm for ferrite and a few nm for cementite59. According to Fig. 6, cementite shear strength should have reached its ideal shear stress value 0.1G* or should be close to it and ferrite should contribute with a CRSS of about 0.03G* because of slip confinement: in all, predicted » 7.5 GPa, even without accounting for the Peierls and other dislocation-independent strength contributions. This predicted tensile strength value is rather higher than the measured one, measured » 6 GPa. Fragmentation and strain-induced partial dissolution of cementite64-66 doubtless contribute to the discrepancy and much discussion on this subject is going on. Alternatively, the measured value can be simply explained on account of the actual limit strength of cementite being smaller than 0.1G*. Experimental measurements of pearlitic cementite strength from in situ diffraction during tensile deformation of drawn wires or deduced from residual stresses provide values in the range of 4 GPa to 5 GPa 55,68,69, much less than the value 19.2 GPa expected from the average cementite elastic constants, Eq. (1).

Whether this difference is due to an anomalous small ideal strength of cementite with respect to metals or to the easy emission of cementite dislocations from the interface (as in the finest Cu-Nb nanolayers62) deserves further investigation. Anyway, presently, with max ≅ 6 GPa= 0.1G*, highly drawn patented steel wires hold both the absolute or relative records of tensile strength among metallic wires. If the transition from the confined slip mechanism to the interface cutting mechanism has already occurred for the finest pearlite drawn to » 6, there would be no more room for further challenging this record.

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similar: a lower than expected yield stress, a high initial strain hardening rate that scales with the yield stress and, after some plastic deformation, a transition to another strain stage with a decreasing hardening rate. Fig. 9 shows the ratio of the tensile to torsion yield stresses (3.2 for the pearlitic wires, 2.6 for the Cu-Nb composites, to be compared with the ratios 2 or respectively expected for Tresca or Von Mises isotropic materials). The behaviour can be explained by an initial torsion deformation internally resolved by a heterogeneous deck-of-cards mode of plastic flow of the oriented structure, followed by a transition to an approximately uniform deformation equal to the macroscopic strain72. The yield and flow stresses are in fact commanded by the shear yield stress of the softer regions of the aligned structure (shear parallel to the oriented ferritic lamellae in the pearlitic wires), until rotation because of the tangential deformation makes easier the uniform simple shear of the composite. The first high hardening stage of the torsion of highly drawn wires is mainly a

geometrical contribution. The deformation mechanism of this initial stage has been termed “cable mode”73 because of its obvious analogy with the torsion behaviour of a bundle of individual filaments, in contrast with the “bar mode” that occurs afterwards, the expected behaviour of a solid bar.

At least in the case of the pearlitic steels, the “deck of cards” plastic deformation in torsion takes place in a heterogeneous manner, with localization of intense shear bands longitudinally aligned when formed. Localization is favoured in the steel case by the dynamic strain aging of the carbon steel wires with its associated negative strain rate sensitivity but in general localization is expected because of the observed transient work softening associated to abrupt strain path changes in deformed materials. The intense shear bands quite often lead to failure by brittle longitudinal splitting, favoured by the profusion of oriented, weak interfaces, either by direct brittle fracture under mode II or from crack nuclei formed by crossing of new shear bands with older shear bands inclined with respect to the axial direction by the shear deformation74,75. Internal tensile residual microstresses transverse to the axial direction, inherent to the axisymmetric drawing of BCC or HCP wires, are thought to be decisive in their delamination failure in torsion76.

Shear bands and crack nuclei in torsion are triggered by surface defects, their density being dependent of the raw material cleanliness, the starting structure for drawing and the design and quality of the drawing process. That nuclei being randomly distributed in the wire surface, they introduce a strong size effect in the brittle failure stress in torsion that

Fig. 8. Shear stress-shear strain curves from torsion tests of highly drawn (a) pearlitic wires (supplied by Bekaert; symbols indicate failure of individual tests) and Cu-20% Nb wires (supplied by W.A. Spitzig, Ames Laboratory).

Fig. 9. Ratio of the tensile strength of highly drawn Cu20% Nb or pearlitic wires to their back-extrapolated shear yield stress in torsion (data from Fig. 8). The slopes and 2 respectively correspond to the Von Mises and Tresca ratios for isotropic materials.

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for ISO standard). The empirical tensile strength to diameter Ď&#x2020; relationship can be interpreted by assuming a Weibull weakest-link statistics80 for the maximum available torsion strength typical of brittle fracture triggered from surface defects. In its simplest form, the cumulative probability F of delamination failure of wires of constant length to diameter ratio, assuming a constant surface density of randomly distributed failure nuclei reads Eq. (25)

The exponent m is the Weibull modulus of the brittle fracture of the wire by delamination in torsion and Ď&#x2020;0 and are material and process dependent parameters.

Selecting an acceptable limit for the probability of delamination in torsion to occur at the yield stress, eq. (25) leads to the following expression for the maximum equivalent tensile stress as a function of the diameter of the wires Eq. (26) where C is a proportionality factor. See Fig. 10. The twist of the wire has thus the final word in the maximum strength of the wires in the real (technical) world!

alloys are in the range 0.031< max/G*<0.046. Their extra strengthening relative to FCC wires is due to the accumulation of geometrically necessary dislocations (of the same sign at short range) because the internal deformation of their grains differs from the macroscopic deformation imparted by drawing. Such behaviour is specific to the <011> BCC or HCP wire textures. An absolute limit for the strength of BCC or HCP wires is tentatively established at by a dislocation limit leading to their amorphization.

In highly drawn two-phase wires, the strengthening mechanism is the confinement of dislocation glide by the interfaces. The interfacial spacing is continuously reduced by drawing and the strength can increase above the limit imposed by dislocation-dislocation interaction as far as either the two phases do not totally dissolve (partial deformation-enhanced out-of-equilibrium dissolution occurs) or a transition to a regime of interfacial crossing slip (loss of confinement) takes place. The limit strength set by dissolution is bound by the strength of the glassy alloys of the base metal, . The limit imposed by the simultaneous slip in the two phases depends on the crystallographic nature and elastic constants of the two components. For Cu-Nb the limit is estimated in 0.06G* from experimental indentation experiments, although such limit has not been reached by wire drawing. For fine pearlitic wires, 0.1G* is a maximum wire strength that has never been surpassed. It probably lays close to the strength limit of highly drawn pearlitic wires at room temperature.

The torsion strength of highly drawn wires, two-phase wires in particular, is peculiarly decided by the mechanical

Conclusions The broad picture of the strength limits of metallic wires looks as follows: Metallic FCC wires display a decreasing work hardening rate and their strength saturates after accumulated drawing strains in the range 5< <10, at the end of the so-called Stage IV of deformation. Their strengthening mechanism is the interaction of mobile dislocations with the stored dislocation density. The saturation value of FCC wire tensile strength is determined by a limit density of the statistically stored dislocations that depends on the stacking-fault energy of the alloy, the homologous temperature and the strain rate. For pure copper drawn and tested at room temperature the saturation stress is about 0.01G*. The absolute (athermal) limit of FCC metallic wires is estimated to be 0.033G* (the Stage IV saturation strength extrapolated to 0 K).

Cold drawn BCC and HCP alloys display a nearly constant strain hardening rate little dependent on the material or deformation conditions. They do not show signs of reaching a saturation stress up to â&#x2030;&#x2C6;10. In one case (pure Nb at room temperature) saturation at 0.031G* occurs after drawing to 10< <12. The maximum room temperature tensile strengths quoted for several BCC and HCP metal or

Fig. 10. Maximum shear strength in torsion of pearlitic wires with finite torsion ductility as a function of the wire diameter, for torsion samples of length 50 times the diameter (higher strengths determine delamination failure with zero plastic strain). The plot is compatible with a Weibull distribution of failure nucleated from surface defects with a modulus m 13.5. Re-plotted from Kanetsuki and Ogawa, 198177.

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puts a practical conventional limit to the tensile strength of the strongest wires: the maximum tensile strength of a commercial wire of a given quality is a decreasing function of the wire diameter (e.g.,77-79), because the torsion tests standards for its qualification impose a fixed length to diameter ratio of the torsion sample of fine wires (geometrical similarity:

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anisotropy induced by the axially oriented fibrous nanostructure evolved by drawing. Longitudinal simple shear is favoured against circumferential simple shear at the beginning of a torsion test. A lower than expected torsion yield stress ensues together with longitudinal shear instabilities capable of nucleating the fearful delamination failure.

Acknowledgements I gratefully acknowledge the Wire Association International for my selection for receiving the Mordica Memorial Award and Profs. E. Aernoudt and J.W. Pilarczyk for my nomination. Prof. Etienne Aernoudt open for me forty years ago the research field of large plastic strains that has since then offered me a lot of work, intellectual pleasure and rewarding discussions with many colleagues that friendly shared their wisdom with me: P Van Houtte, L. P. Kubin, F. Kocks, A. Kelly, H. Mughrabi, D. Embury, G. Langford to name but a few. W.A. Spitzig kindly provided me with samples of Cu-Nb wires for the torsion tests of Fig. 8b. The collaboration along several years with Bekaert provided me with the industrial counterpoint for anchoring academic reveries to reality and I would like to mention here the names of A. Martín Meizoso from CEIT and I. Lefever, U. D’Haene, W. Van Raemdock and P. Dambre from Bekaert CVO, Zwevegem (Belgium).

Editor’s Note: Due to the length of this paper, the references have not been included. E-mail editorial@wirenet.org to request a PDF of the rerferences.

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Prof. Sevillano accepts the Mordica Memorial Award from WAI Second Vice President Nick Nickoletopoulos.

Prof. Javier Gil Sevillano, the winner of the 2010 Mordica Memorial Award, is a prolific technical paper author, researcher and a full professor at the Technological Campus of the University of Navarra (TECNUN) in San Sebastian, Spain, where he has headed the school’s Department of Materials Engineering since 1994. He received his PhD in engineering from the Materials and Applied Metallurgy Department of the Khatolieke Universiteit Leuven (Belgium) in 1974. His research has focused on the mechanical stress-strain response, structural evolution, texture development and fracture of materials undergoing large plastic strains. He has specialized on torsion behavior of high strength pearlitic steel wires and to the origin of their delamination failure.

Some of Gil Sevillano’s research has included sizeeffects in plasticity of small volumes with applications to micro/nanotechnology. He has taken part in 40-plus research projects, many international and in collaboration with industry, and published more than 130 scientific papers. He is a recipient of the Silver Medal of the Grupo Español de Fractura, the Europe Prize of the Centre for European Studies, University of Navarra and the Honour Plaque of the Asociación Española de Científicos.

The Mordica Memorial Award is named for John Mordica, the WAI’s first president, and signifies “contributions to the industry’s knowledge base through research, development, innovation or other technical contributions.” This lecture was presented at WAI’s 80th Annual Convention, Milwaukee, Wisconsin, USA, May 2010. ■

Fire-induced damage in prestressing steel A fire may cause damage to a structure that cannot be detected by a visual inspection yet can be significant enough to undermine the structural integrity of prestressing steel.

By José Miguel Atienza and Manuel Elices

When fire occurs either in buildings or bridges, depending on the relative severity of the fire, there is a possibility of fireinduced damage that affects the performance of the structures, even if no collapse happens. The extent of damage depends on the very intensity and duration of the fire, as well as the geometry, materials used in construction and load intensity. After a fire, the question that cannot be avoided is whether the structure should be replaced or whether it is still possible to use it, either as-is or after some partial repairs. In many cases, the structural members can be restored through repairs. However, before undertaking such repairs an assessment of the load-bearing capacity of the structure has to be carried out, even if it seems that no repairs are needed, since a misjudgment at this point can lead to unsafe situations.

The financial aspect is an important issue and may, in some cases, lead to the decision of destruction rather than repairing the damaged structure. However, the essential question that the engineers have to face is whether the structure is still safe.

What is the load-bearing capacity of the structure now? How has it been affected by the fire? Appropriate knowledge of the behavior of construction materials after a fire is of major importance for answering these questions.

Much experimental work on the characterization of the mechanical properties of steels at high temperatures, aiming at structural fire design, has been done in the past decades1-7.

However, less work has been performed in the characterization of the mechanical residual properties after a fire. Correct knowledge of such properties is of major importance for the assessment of the residual load-bearing capacity of the structure. In this work, the behavior of prestressing steel after fire is studied, examining the two main factors which can affect the security of the structures: • The permanent deterioration of the material properties, especially the strength and elastic limit; and • The modification in the distribution of actions and loads due to the increase in the stress relaxation losses of prestressing steels produced by the exposure to high temperatures.

This can reduce the prestressing load after fire, with a subsequent reduction in the safety of the structure.

Fire simulation A prestressed wire has been subjected to a fire scenario to simulate the effects of a fire on the mechanical behavior of prestressing steel wires when the structure does not collapse.

The key feature of the fire relevant to the prestressing steel behavior is the temperature-time curve endured by the material. Structural steel has a high thermal conductivity coefficient; when directly exposed to a fire it immediately acquires the fire temperature. However, as concrete surrounds steel wires and has low thermal conductivity, its thickness protects steel wires, delaying the values of temperature reached inside the structural elements. Standards provide curves to predict the temperature inside concrete elements during the nominal fires.

The time-temperature curve (Fig. 1a) used in this work represents a realistic and conservative fire scenario, even considering the bearing capacity of the wire is not surpassed. The heating velocity is around 3ºC/min, representing a typical temperature curve inside concrete elements during the nominal fires. Maximum temperature is reached at the end of the fire, three hours after the beginning.

An additional aspect should be considered to model the effects of fire: temperature produces a dilatation of the structural members which, in general, could not expand freely due to the external constraints. Standards distinguish between “restrained” and “unrestrained” assemblies. The term restrained means that thermal expansion of the specimen is restricted during the fire test. If a fire occurs beneath a portion of a large structure, the heated portion will expand and push against the surrounded unheated portion. In turn, the unheated portion exerts compressive forces on the heated portion, altering the service load during the fire. In the case of unrestrained assemblies, the dilatation of the element is free.

Fig. 1a shows the time-temperature curve endured by the steel wire during the fire simulation, and Fig. 1b shows the evolution of prestressing load during the fire simulation.

For this test case, the length of the specimen remains con-

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stant during the fire. This is a typical case of a restrained assembly, in which the service load would diminish during the heating because of the constrained dilatation. The fire scenario was simulated following the next steps: • The prestressing steel wire (specimen length: 1.2 m) is loaded at 20ºC. The initial load has been 70% of the maximum load, the value proposed by standards for the stress-relaxation tests. The curve load-time is continuously recorded.

• Once the majority of the stress relaxation losses have occurred, after five days, the effects of fire are simulated using a furnace (size: 0.7 of the specimen length). The fire duration was about three hours. Then the furnace was turned off and left open, so that the wire would cool in air. The curve load-time is recorded continuously during the whole process.

• The test continues five more days at room temperature.

Again, the curve load-time is continuously recorded.

• After that, conventional tensile and stress relaxation tests were performed on the final wire at room temperature to study the residual properties.

Fire-induced damage Fig. 1b shows the evolution of the prestress load before, during and after a fire. It can be observed that during the fire there is a significant reduction of the bearing load, as a consequence of the restrained dilatation and the increase of stress relaxation at high temperatures. When cooling, the part of this lost load due to the constrained dilatation is recovered, but not the stress relaxation losses. Although the wire has successfully supported the fire without any visible damage, the prestressed load after fire has been considerable reduced.

Additionally, the results of the conventional tensile and stress relaxation tests at room temperature showed that the residual strength has been affected (20% less than the origi-

Fig. 1. Residual mechanical properties at room temperature after a fire (four-hour duration, loaded at 70% maximum strength) as a function of the maximum temperature reached during the fire.

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nal value) as well as the relaxation rate (five times larger than the typical for a “low relaxation” wire).

In summary, even though the fire has not produced visible damage, the strength of the wire and its prestressed load were reduced, with the subsequent reduction of the residual loadbearing capacity of the structure.

Characterization of prestressing steel residual behavior after fire Stress relaxation losses at high temperatures. By definition, stress relaxation refers to the decrease in stress at a constant deformation. In prestressed concrete structures, steel tendons in tension provide compressive stresses to the concrete.

Throughout the life of the structure there should not be an appreciable loss of tension, because a reduction in prestressing loads would affect the structural safety. Design codes place limits for keeping the relaxation losses within safe margins. Stress losses are measured according to a standardized test (ASTM E328, ISO15630/3) and the figures should be provided by the manufacturer for the acceptance of the steel tendons; those with a figure of stress losses of less than 2.5% of the initial stress—after 1000 hours, at room temperature, when stressed at 0.70 of the tensile strength—are called “low relaxation” tendons, and are those used in prestressing at present8.

Temperature has a great influence on stress relaxation; an increment of temperature produces a large increase in stress relaxation losses. During a fire, the wire temperature increases and, depending on the boundary conditions, initial wire load can decrease due to the restrained dilatation. Since no results under such conditions were found in the literature, a detailed experimental study on the effects of temperature on the stress relaxation losses of the wires was performed. Stress relaxation tests at different temperatures and at different initial loads were carried out. The duration of the tests was four hours, longer than the duration of the conservative fire scenarios proposed by standards (EC1 2002, EC2 2005).

Temperatures studied were: 20ºC, 100ºC, 200ºC, 300ºC, 400ºC, 500ºC and 600ºC. Initial loads considered were: 10%30%-50%-70%-90% of the tensile strength.

In Fig. 2, the time-stress relaxation losses curves are depicted as a function of temperature and initial loads. It can be seen that as temperature increases the stress relaxation losses increase significantly, and, consequently, the prestressed compressive loads provided to concrete decreases. Clearly, this is a fact to be considered when assessing the fire-induced damage after cooling.

Residual mechanical behavior at room temperature. After a fire, even if no collapse happens and no effects can be visually seen in the structure, damage can be induced in the materials due to previous exposure to high temperatures. The term “residual” will be used here to indicate the properties that the prestressed steel exhibits after a complete cycle of heating and cooling.

In the authors’ work, to simulate the effects of fire, wires were subjected to a complete cycle of heating and cooling (four hours), while loaded at 70% of their tensile strength.

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The effects of fire will depend upon the fire duration and the loading of the wire; in this case, testing conditions are a conservative simulation since the duration of the fire is longer than the nominal fires (BS811, EC1, EC2), and the load is the maximum load experimented for the wires in service.

Temperature was raised at a rate of around 20ºC/min and the different maximum temperatures studied were the same as the rest of this work: 20ºC, 100ºC, 200ºC, 300ºC, 400ºC, 500ºC and 600ºC. After cooling, tensile tests and stress relaxation tests at room temperature were performed to obtain the residual mechanical properties of the wires.

Table 1 shows the variation of the tensile strength, the yield stress and the stress relaxation losses after 250 hours for the different maximum temperatures reached during the fire simulations. The reference values of the original wires (control samples without thermal treatment) at room temperature have also been included. The values of the residual tensile strength for the tested prestressing steel remain approximately constant up to temperatures around 300ºC. If the wire suffers higher temperatures during fire, the residual strength, the elastic limit and the stress relaxation behavior are affected.

Summary Fire safety should consider not only the performance of the structure during the fire but also the behavior of the structure after cooling. Even if a fire does not give rise to apparent damage in the prestressed structure, mechanical properties of materials as well as load distribution can be affected. After a fire, a verification of residual loadbearing capacity is necessary to determine if the structure can be maintained in use. The extent of damage in prestressing steels depends on the intensity and duration of the fire, the temperatures reached in the wires, as well as the load intensity they bear during a fire.

In this work, the authors have highlighted possible non-visible fireinduced damage that can be produced

Fig. 2. Stress-relaxation losses as a function of temperature, for different initial stresses. The relative values are given as stress loss/strength.

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in prestressing steels after fire: • Reduction of the prestressing loads due to the increment in the stress relaxation losses during the exposure to high temperatures.

• Damage of the mechanical properties of steel wires produced by the exposure to high temperatures: residual strength and stress relaxation behavior at room temperature depend on the maximum temperature reached in the wire during fire.

Acknowledgements The authors gratefully acknowledge the support of the Ministerio de Fomento in Spain, by means of the “Durability of prestressed concrete tendons” grant. They are also indebted to Luis del Pozo, from Emesa Trefilerías, and Mariano Ortez, for their highly beneficial comments and help with the material and the tests.

Table 1. Residual mechanical properties after a fire (four-hour duration, loaded at 70% maximum strength).

References 1. T.Z. Harmathy and W.W. Stanzak, “Elevated temperature tensile and creep properties of some structural and prestressing steel,” Fire Test Performance, ASTM STP 464, American Society for Testing and Materials, pp. 186-208, 1970.

2. British Standards Institution BS8110: Part 2, 1985, Structural use of concrete, Code of practise for special circumstances, BSI, London.

3. CEB (Comité Euro-International du Beton), “Fire design of concrete structures,” Bulletin 208, Comité EuroInternational du Beton (CEB), Laussane, Switzerland, 1991.

4. A.H. Cristofano and L.D. Martin, “Design for fire resistance of precast prestressed concrete,” Second Edition, Prestressed Concrete Institute (PCI), 1989.

5. EC1 2002, Eurocode 1: Basis of design and actions on structures, Part 2.2: Actions on structures exposed to fire, EN 1991-1-2: 2002, November 2002.

6. EC2 2005. Eurocode 2: Design of concrete structures – Part 1-2: General rules–Structural Fire Design EN, 1992-1-2: 2002, February 2005.

7. FIB (Federation Internationale du Beton) 2007, Working Party, 4.3-1, Fire design of concrete structures–materials, structures and modelling. State of art report, FIB Bulletin 38.

8. J.M. Atienza and M. Elices, Role of residual stresses in the stress relaxation of prestressed concrete wires, Journal of Materials in Civil Engineering, 19(8), pp. 703-707.

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Atienza

Elices

José Miguel Atienza teaches in the materials science department at Madrid Polytechnic University, Spain, where he started as a researcher in 1998. His areas of scientific interest include steel wire for prestressed concrete and biomaterials. He holds a Ph.D. degree in civil engineering from Madrid Polytechnic. Manuel Elices is a full professor of materials science and technology at Madrid Polytechnic and dean of the faculty for materials science and engineering. His professional and research work has been centered mainly on cracking and fracture of materials. This paper was presented at WAI’s 80th Annual Convention, Milwaukee, Wisconsin, USA, May 2010.

Effect of water quality on wiredrawing lubricants Water may be thought of as a simple ingredient, but the proper choice of water is essential for a wiredrawing lubricant to be effective.

By Frank J. Solitario

There are a number of companies that supply wiredrawing lubricants for industrial use. These products have been developed using laboratory resources and customer resources for field trials, and are fully functional when diluted with water. Production batches of these lubricants usually go through vigorous quality control before release to the customer. Yet, in contrast, the quality of the water does not have similar controls in many instances. Since water is a major component in a water-soluble drawing lube, this author will attempt to clarify the parameters that affect water quality, and in turn, how these can affect the performance of the lubricant.

Water quality can be described through the measurement of certain parameters that can vary depending up the water source. Specifically, they are pH, hardness, conductivity, alkalinity and concentration of certain anions (Cl-, SO4-, PO4-) as well as biological activity, all of which will have an effect on the performance of a water-soluble lubricant.

Water quality parameters pH. This is the measure of hydrogen ion concentration, and can be described as acidic, neutral and basic. An acidic pH is within the range of less than 7, a basic PH is greater than 7 and a neutral pH is 7. The optimum pH for lubricant performance is generally in the range of 8.0–9.0.

When a lubricant sump is freshly charged, the pH is usually within the optimum range due to the additives package within the lubricant itself. Over time, under dynamic conditions, there will be a decrease in the pH of the lubricant solution. Reasons for why this happens include biological activity, dissolved carbonates and lubricant breakdown. An increase in the pH of the lubricant can be expected from the addition of biocides, buffering additives and other “package additives.”

Adjusting the pH either up or down from the optimum

range can have several adverse effects on the lubricant itself. Lowering the pH l can loosen the emulsion or create a larger particle size, especially with soluble oil and semisynthetic type lubricants. This may cause too much slip, or result in some active lubricant additives plating out in the system. An increase in the pH can cause reduction in lubrication and cause tension breaks and premature wear to the mechanical system. The pH of a lubricant will have an effect on its foaming characteristics, and on its detergency and cleanliness.

Water hardness. This is a term used to describe the concentration of calcium and magnesium salts in water, and is independent of the anions present. Water varies in hardness based on geographical location and by mineral deposits and rain run-off. This parameter can be the common denominator for a majority of the lubricant problems, and can usually be traced to the formation of hard-water soaps.

Hardness will have a dramatic impact on the foaming characteristics of a wiredrawing solution and can have a significant effect on the stability of the sump. Increased water hardness can “loosen” an emulsion, or have a negative impact on the emulsion stability, as well as lower the pH, and can reduce the solubility of the active lubricant components, especially with synthetic wiredrawing compounds. Hard water will reduce the foaming tendency of the solution; as hardness decreases, foaming tendency increases.

Conductivity. This is an indication of the total level of dissolved solids in water. Unfortunately, this parameter is not able to differentiate between the types of dissolved solids.

An increase in dissolved copper will show an increase in conductivity just as will an increase in free alkalinity.

Generally, as conductivity increases, water quality decreases as this is an indication of dissolved foreign material.

The effect of an increase in conductivity on soluble oil,

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TECHNICAL PAPERS

TECHNICAL PAPER

TECHNICAL PAPERS Photo 1. Effect of sulfate (75 ppm) on copper in a synthetic wiredrawing solution.

Photo 3. Differences in foaming characteristics of lubricant in soft (DI) and in hard (135 ppm) water.

semi-synthetic or synthetic-type drawing lubes will be dependent on the type and nature of the dissolved solids.

Alkalinity is the measure of carbonate and bicarbonate ions in the water. It can be expressed as free and total alkalinity. Free alkalinity is that amount which reacts with acid to an end point of pH = 8.2, and Total Alkalinity (also known as “M” Alkalinity) is that which reacts with acid as the pH is reduced to a methyl orange endpoint – about pH = 4.2.

Alkalinity will have an effect on pH, and can cause pitting of copper and staining of other nonferrous metals such as aluminum. These effects would hold for any of the three

76 | WIRE JOURNAL INTERNATIONAL

Photo 2. Differences in solubility for synthetic lubricant @ 8% in soft (DI) and in hard (135 ppm) water.

Photo 4. Wiredrawing solutions in DI water, all at 8% concentration. From l-r are: a soluble-oil type, a semi-synthetic and a synthetic solution. The picture illustrates the different emulsion particle sizes of the soluble versus the semi-synthetic, versus the true solution for the synthetic.

types of wiredrawing lubricants.

The anions most commonly found in make-up water are chloride, sulfate and phosphate. Both sulfates and chlorides are corrosive to both ferrous and nonferrous metals.

See Photo 1. In some cases, a sulfate can act as nutrient material for certain types of bacteria. Phosphate can contribute to total alkalinity, and can also stimulate micro-biological growth.

Biological activity or the presence of micro-organisms can cause problems with wiredrawing lubricants.

Generally, bacteria at a level higher than 10^3 organ-

TECHNICAL PAPERS

isms/ml can begin to utilize the actives in the lubricant as nutrient material. When this occurs, the bacteria metabolic by-products are fatty acids which will lower the pH of synthetic, semi-synthetic and soluble-oil type lubricants. In all cases, they can be corrosive, promote a disagreeable odor and can clog the lines and filter. In the case of semi-synthetics and soluble-oil type lubricants, bacteria metabolism can cause instability of the emulsion.

Types of water Parameters that affect water quality are described above.

This paper now focuses on the types of water encountered when charging a water-soluble lubricant. Generally, the types can be described as softened, soft, hard, de-mineralized and municipal water. See Photos 2 and 3.

Softened water. This ingredient is not to be confused with soft water. Softened water is usually produced by passing hard water over an ion exchange that replaces the calcium and magnesium ions with sodium ions. Some issues associated with softened water include that it can contain a relatively high concentration of sodium ions, and as such, can have high conductivity. High concentrations of sodium ions can destabilize soluble oil type emulsions.

Soft water. This is water whose hardness is less than 60 ppm as calcium carbonate. The use of soft water in wire drawing solutions will cause foaming issues. Conversely, hard water is water whose hardness is greater than 125 ppm of elements known as calcium carbonate. Utilizing hard water can promote the formation of insoluble soaps and “hard water scum.” These soaps can have a negative impact on emulsion stability.

De-mineralized water is accomplished by deionization or reverse osmosis. In its simplest form, water is forced through a selective membrane with pressure. Large molecules and ions are retained on the membrane allowing purified water to pass through. Disadvantages to this process include cost and efficiency. Additionally, post treatment is required for sterilization.

For information purposes only, Photo 4 illustrates the relative particle size of three types of lubricant (soluble oil, semi-synthetic and synthetic) appear in the same water (DI).

Lastly, municipal water can be used for lubricant makeup. Generally, municipal water is low in microbiological activity, but can vary in mineral content and hardness From a lubricant standpoint, optimum water quality is free from minerals and extraneous ions, is low in alkalinity and will be of low to moderate hardness. In addition, the water should have a neutral pH and be low in biological activity. However, one must consider available water sources. Based on analysis of the water prior to charging the lubricant concentrate, many deviations from optimum can be overcome with pre-treatment or additives.

Note: The author would like to thank Dean DeVenzio for his able assistance with the photos in this document. ■

Solitario Frank Solitario is manager of product quality and performance for RichardsApex Inc, Philadelphia, Pennsylvania, where he previously held the position of manager of research and development. Prior to joining RichardsApex in 2005, he spent 20 years working for The Harry Miller Corporation as quality coordinator and as a formulations chemist. He is a member of the Society for Tribologists and Lubrication Engineers, and holds a B.S. degree in biochemistry from the University of Scranton, Scranton, Pennsylvania. This paper was presented at WAI’s International Technical Conference, Monterrey, Mexico, November 2010.

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PRODUCTS & MEDIA PROD DUCTS Central stranders offer both high speeds and dependability With more than a hundred of the company’s rigid central stranders in operation around the world, Germany’s SKET GmbH reports that its proven technology is exemplified by two of its models: the MKZ 700 and the MKZ 250.

A press release said that the MKZ 700, which it described as being “at the very top of the tree,” employs unique technology that enables production of stranded conductors at speeds of up to 500 rpm and linear throughput speeds of up to 180 m/min. Equally important is the consistency in conductor quality, it said, adding that the key to this is controlled process tension that ensures “not only the high output of the system but also significant savings in material costs.” The company’s new MKZ 250 model, available as a single or twin machine, is particularly suited to the needs of aluminum wire stranding and overhead conductor production, the release said. It offers a stranding product volume of 245 dm³ (three times the volume of a 630 mm DIN bobbin), special wire guides and a hybrid bobbin braking system. (Shown is the MKZS 1+6+18+24x245 version.)

The release said that the company’s rigid central strander, introduced in the 1970s, faced a skeptical industry audience but over time earned its acceptance in a fiercely competitive marketplace. Today, SKET central stranders, available in a wide range of machine arrangements and sizes, are an essential part of efficient cable production, it said.

Contact: SKET GmbH, tel. 49-4055814, www.sketvmb.de.

Radiopaque composite wire excels for medical applications U.S.-based Anomet Products, Inc., is offering custommanufactured clad composite radiopaque wires for use with catheters, stents, implantable coils and related devices.

A press release said that the wires feature platinum and 78 | WIRE JOURNAL INTERNATIONAL

platinum-iridium, tantalum and tantalumtungsten and similar alloys in clad composite with high strength wires such as 316LVM stainless steel, nitinol and MP35N®. These clad compo-site wires, it said, are an effective alternative to solid wires with marker bands, and greatly improve visibility under fluoroscopy.

The radiopaque alloys in the Anomet radiopaque wires are metallurgically bonded to the core wires with 2% or more cladding thickness, and offered in sizes from 0.002" to 0.060" O.D., the release said. The clad composite wires have a smooth, consistent finish and are supplied on spools and manufactured to precise OEM specification, it said.

Contact: Daniel Lambert, Anomet Products, Inc., tel.

508-842-3069, dlambert@anometproducts.com.

Certification tests confirm Cat. 6A cabling products exceed parameters Siemon reports that ETL testing has confirmed that both shielded and UTP versions of Siemon’s Z-MAX 6A connectors and cable exceed all Cat. 6A component performance parameters for 10Gb/s copper cabling systems.

A press release said that ETL found that the Siemon components met the requirements of the newly published amendment 2 of ISO/IEC 11801, 2nd ed. and both IEC 60603-7-51 and IEC 61156-5 for Cat. 6A connecting hardware and cable. As the ISO/IEC Cat. 6A component performance requirements are more stringent than those set for Cat. 6A components by TIA-568-C.2, achieving ISO/IEC compliance is considered a stronger indicator of overall Cat. 6A system performance capabilities, it said.

The Z-MAX 6A shielded and UTP connecting hardware and cable showed performance headroom for NEXT loss, return loss, insertion loss, FEXT loss, TCL, TCTL, DC resistance, DC resistance unbalance, PSANEXT loss, and PSAFEXT loss performance, the release said. “Along with the ISO/IEC and TIA Cat. 6A channel test results, this ETL confirmation of component compliance further cements Z-MAX performance leadership,” said Robert Carlson, vice president of global marketing. “Z-MAX has remained the highest-performing, fastest to terminate shielded or UTP Cat. 6A system since its launch in

Extrusion control systems now have remote access capability U.S.-based Davis-Standard reports that its EPIC III supervisory control system just got smarter via recent upgrades that have equipped EPIC with extensive remote access capabilities that allow plant engineers and technicians to monitor multiple lines via a computer or cell phone from any location.

A press release said that instant notification about line conditions, alarms, events, and other changes are sent directly to e-mail accounts or cell phones to provide real-time updates. This upgrade, it noted, is available on all new EPIC III systems and for retrofit on systems sold in the past three years.

“Companies have fewer engineers and technicians to support multiple lines,” said Davis-Standard Electrical Engineering Manager John Clemens, shown in the photo demonstrating how the new EPIC enables an extrusion line to be monitored via a cell phone. “This technology enables access to several lines in different plants so that one engineer, regardless of location, can effectively monitor them. It facilitates troubleshooting and can help customers avoid costly repairs and downtime,” he said.

The company noted that it also offers customer support via Remote ACcess Technology (ReACT), a service that enables Davis-Standard process engineers and technicians to support customers worldwide in real-time without a service call.

With ReACT, the service team can remotely and immediately view process conditions at a customer’s plant during a production run and make a diagnosis without stopping the line.

Contact: John Clemens, Davis-Standard, jclemens@davis-standard.com, www.davis-standard.com.

WHEN IT COMES TO TROUBLE-FREE

MULTI-WIRE STARTUPS,

WOODBURN IS THE PERFECT MATCH!

FEBRUARY 2011 | 79

PRODUCTS & MEDIA

launch in January 2009,” he said.

Contact: Brian Duval, Siemon, tel. 860-945-4380, brian_duval@siemon.com.

PRODUCTS & MEDIA

Supplier offers both equipment and expertise for compacting conductors Germany’s Stolberger KMB, which notes that it has decades of experience in providing systems to efficiently compact aluminum and copper conductors, reports that it now is also supplying manufacturers with the expertise to best deploy the technology.

A press release said that Stolberger’s “know-how package” includes all the data necessary for compacting in conformity with international standards. That, it said, includes: the number and diameter of wires; compacting rollers of suitable sections, including those for other makes; stranding die inside diameter information; and all calculations assumed as a basis. “Under such a know-how transfer, Stolberger will also assist with the manufacturing process as customers may require,” it said.

Stolberger’s compactors, including idle-roller models that are equipped with two, three or four pairs of rollers to compact round conductors, with one or two pairs of rollers used when producing straight and pre-spiralled sector-shaped conductors. It also offers combination-type compacting units that equipped with up to four pairs of rollers can be used in producing round or straight sector-shaped conductors as well as pre-spiraled, sector-shaped conductors. The complete equipment is available for compacting round conductors up to 1,000 mm² and sector-shaped conductors for Milliken conductors up to 2,400 mm², it said. Pictured is the company’s VG 18/3 model compactor.

Contact: Stolberger KMB-Maschinenfabrik GmbH, tel. 49-2402-86558-0, info@stolberger.com, www.stolberger.com.

Addition made to company’s 10 gb/s cabling solution line U.S.-based CommScope, Inc., reports that it has added the Uniprise Ultra® 10 Unshielded Twisted Pair (UTP) structured cabling system to its line of cost-effective 10 gigabits per second (Gb/s) infrastructure solutions for communications networks.

A press release said that the new UTP system extends bandwidth without degrading internal channel transmission performance 80 | WIRE JOURNAL INTERNATIONAL

by suppressing interference from external pairs to eliminate alien crosstalk at frequencies up to 500 MHz. It joins the company’s Uniprise Ultra 10 Foiled Twisted Pair (FTP) copper and Uniprise Ready™ fiber solutions to deliver a full range of Uniprise 10 Gb/s media solutions, it said. The technology was described as being ideal for value-oriented environments that are heavily adopting 10 Gb/s applications, such as small-to-medium-sized enterprises, data center-equipped intelligent buildings, local and municipal government buildings and primary and secondary educational campuses.

The release observed that demand for bandwidth-intensive applications like streaming video, online media sharing, and virtual file storage that require 10 Gb/s connectivity has been growing at a faster rate than most mid-size enterprise IT budgets. “Combining quality, reliability and performance, the Uniprise Ultra 10 copper systems provide cost-effective, extended bandwidth functionality to help businesses evolve network capabilities and prepare for emerging applications while maximizing IT spending.”

Contact: CommScope, Inc., www.commscope.com.

Power cable stranding line offers an attractive quality-price ratio Daloo, a wire and cable machinery manufacturer based in China that was launched by the Gauder Group in 2008, notes that it offers a comprehensive line of rigid stranders for MV, HV and EHV power cable.

“With already six rigid stranding lines sold to four renowned cable makers, Daloo...forges itself an international reputation for the delivery of low-cost equipment based on European experience,” a press release said. It noted that the company’s line of rigid stranders provides “basic functions, simple design and steady quality.” The 630 model, which is able to strand up to 91 wires, as well as provide steel wire armoring and copper wire screening, is offered in a main shaft (KZ630) or independent motors (KM630) version, it said, adding that options include a side-loading carriage or tilting loader. Shown is a Daloo KM630-12 rigid strander.

Daloo, the release said, “offers best quality-price ratio machinery” for extrusion lines, screening/ armoring lines, rigid stranding lines, taping lines, rewinding lines and payoffs and take-ups as well as pulling caterpillars.

Contact: Daloo Machines, tel. 86-519-8548-0553, sales@daloo-machines.com, www.daloo-machines.com.

U.S.-based Applied Plastics Co., Inc., announced that it has introduced a new line of nichrome resistance wire that is coated with DuPont Teflon® to create a non-stick surface for use at high temperatures.

A press release said that APC’s Teflon-coated Nichrome wire provides a non-stick surface in a variety of plastics and packaging processing applications and is capable of 500°F continuous and 600°F intermittent use.

The product is suitable for use in a wide range of packaging, sealing, shrink wrapping, plastic sheet and styrofoam cutting, and acrylics bending equipment, it said, The wire, it noted, will outlast plain nichrome resistance wire and prevent melted plastic. The product comes on spools from stock in standard 0.018", 0.020" and 0.036" sizes; other sizes upon request, and is priced according to size and quantity, with samples and price quotations available upon request.

Contact: David Ring, Applied Plastics Co., Inc., tel. 781-762-1881, davering@appliedplastics.com, www.appliedplastics.com.

A press release said that the kit “includes everything an engineer might need to test the EMI/RFI shielding capabilities of different materials before time and money is spent in prototyping. Specifically, it will enable them to consider different materials, which can include foil tapes, metal-filled elastomers and wire mesh used for EMI gaskets, before they are ordered, “saving time and money,

Kit is an aid to design engineers U.S.-based Fabrico has introduced an EMI/RFI Testing “Survival Kit” intended to help engineers investigate and test materials in the early phases of design.

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New nichrome resistance wire offers longer life, has non-stick surface

PRODUCTS & MEDIA

and ensuring a more knowledgeable and effective material selection.”

The kit includes: a magnetic field probe; an electric field probe, an EMI/RFI demo fixture, materials samples and cables and probes.

Sample materials include: nickel on copper-plated polyester fabric tape with conductive adhesive, embossed foil tape, aluminum foil tape with conductive adhesive, tinplated copper foil tape with conductive adhesive, EMI absorber and gasket materials and polyester laminated aluminum foil tape with conductive adhesive as well as samples of die-cut materials for EMI/RFI shielding.

Contact: Fabrico, tel. 800 351-8273, www.fabrico.com.

material, more inspections, work-arounds, troubleshooting, reduced productivity/capacity due to slow line speed, downtime, and lost business due to inferior product quality.) “Hidden operating costs are the enemy of profit, and most companies mask them, rather than fix them,” it says.

For a copy, go to the B&H website and click on “articles and tech briefs,” to find this article as well as others.

“We feel that offering this kind of information is another way B&H Tool can better serve customers, making them more aware of their options,” said company President Peter Neville, shown in the photo.

Contact: B&H Tool Company, tel. 800-272-8878, www.bhtool.com.

New website offers customers a wealth of process control information U.S.-based Process Control Corporation reports that its new website, www.process-control.com, makes it easier than ever for users to navigate through a site that has been designed with industrial buyers in mind.

MEDIAA Tooling’s role in good extrusion results is the focus of tech piece A two-page article by Walter Freischlad, consultant to U.S.-based B&H Tool Company, focuses on the potential consequences that can come from cutting corners on extrusion tooling.

In “High Quality Tooling or RockBottom Cost?,” Freischlad reports that he has seen many expensive mistakes over the years that could and should have been avoided. “I spent the first 21 years of my career in electrical wire manufacturing, heavily involved with every aspect of melt and paste extrusion. What I have observed in those two decades, and what I’ve seen since I started consulting several years ago, is that most companies have forgotten just how much tooling directly impacts – for better or worse – their bottom line,” he wrote.

The article cites specific topics, such as using substandard tooling increases many operating costs, some in visible ways (scrap and extra labor costs for frequent cleanings) and others not so apparent (such as use of excess

82 | WIRE JOURNAL INTERNATIONAL

A press release said that the new primary feature is an integrated product catalog that allows users to search and compare process control equipment and technical data.

Product details are directly visible on the website without the need to download a specification sheet. The website also features a profile of the company, its management team and a full listing of its U.S. sales representatives.

Overall, the site makes it simple for processors in the plastics industry to find products and information to meet their auxiliary equipment needs.

Established in 1967, Process Control Corporation notes that its product lines include the first continuous gravimetric blending system.

Contact: Tim O’Haren, Process Control Corporation, tel, 770-449-8810, ext. 219, toharen@process-control.com. ■

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.

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CAREER OPPORTUNITIES WIRE & CABLE PROCESS ENGINEER. T & T Marketing Inc. seeks a skilled process engineer to assist our customers in optimizing their extrusion conditions in the use of the compounds we supply. The ideal candidate would

Metallurgical Engineer Central Wire Industries Ltd., North America’s leading stainless steel and nickel alloy wire manufacturer has a metallurgical engineering opportunity working with our Union, Illinois and Fond du Lac, Wisconsin locations.

An individual with a degree in material science or metallurgy along with five to ten years metallurgical experience in a manufacturing environment has the opportunity to provide various metallurgical services related to processing standards, raw material specifications, quality department corrective action investigations as well as technical services to customers and training to operations.

It is important that the candidate be a selfstarter, strong problem solver, organized and able to work independently. As this position interacts with internal and external customers, strong interpersonal as well as verbal and written communication skills are a must.

The candidate must be proficient with Microsoft Office. Occasional travel to customers is required.

We offer a competitive salary and benefits package. Send cover letter with resume and salary history/requirements to: resume@centralwire.com.

An equal employment employer, M/F/D/V.

appears in print or on-line), P.O. Box 578, Guilford, CT 06437-0578 USA. PAYMENT POLICY: All ads must be pre-paid.

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have 20 years experience processing polyolefins and PVC. Other duties include process support to compound manufacturing, quality assurance support, HSE support, material inspection and testing. Respond to Paul Lorigan at plorigan@ttmarketinginc.com

POSITION WANTED A CHEMICAL PHARMACEUTICAL BIOLOGIST with a Master’s degree in experimental science and with experience in lubricant sales in the W&C market in Mexico, Central and South America desires a full time

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

FOR SALE 1171211121111111-

HALL 500’ Vertical Accumulator, 1997 NEW ENGLAND BUTT 24-Carrier Model CB-1 Cable Braider WARDWELL 12-Carrier Braiders OMA 24-Carrier Braider, Type 24/1 104 w/Payoff and Take-up OMA 24-Carrier Braiders, Type 24+24/140TCH/EORIZ, 1996 w/Capstans SPIRKA 24-Carrier Braider, Model 24N4 SPIRKA 16-Carrier Braider, w/500mm Take-up and Payoff NEB 12-C #2 Braider, Long Legs, Motor NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 DAVIS STANDARD 3.5” 24:1 L/D Extruder, Model 350HII DAVIS STANDARD 2.5” 24:1 L/D Nylon Extruder, Model 250SII D/S 2.5” 24:1 L/D Hi-Temp Extrusion Line D/S 2” 30:1 L/D Hi-Temp Extrusion Line ENTWISTLE 1.5” 24:1 L/D HiTemp Extruder, Model EC1500-24 SPHEREX 18” Dual Reel Take-up, completely refurbished CLIPPER Model SP16 Dual Spooler

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HALL Dual Spooler/Coiler w/36” Powered Payoff and Dancer AFA 72” Roll-Thru Take-up, Model TU62-460 WATSON/AFA 84” Rewind Lines, 6,600lb REEL-O-MATIC Model PRR1 Rim Drive Powered Reel Roller REEL-O-MATIC Model Rd-5 Rim Drive Take-up w/Coiling Head TEC Model 24STC Hi-Speed Twisters, rated 1300rpm w/2-Wire Payoff TEC Model DTC630 D.T. Twister ARTOS CS600 Wire Processing Machine w/Tinning Unit ARTOS CS327 Cut/Strip Machines ARTOS CS27 Cut/Strip Machines FINE Preheater, Model IP4000-180-1 TENSOR Dual Binder Head MOLEX TM3000 Crimping Machine, Type 63801-7200 - HEARL HEATON 22” x 13.25” OAW” x 11” x 2.25”, Plastic - CYBERLAN 24.75” x 15” OAW” x 9.75” x 2.25”, Plastic

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

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position with an international company. For additional information, please send an e-mail to Antonio Ayala Jr. at antonioayalas@gmail.com.

DISTRIBUTORS/AGENTS S A L E S AG E N T S WA N T E D .

DS Hai, LLC is a new and growing diamond die maker with locations in the United States and Korea. We can supply high quality Diamond and PCD dies at very competitive prices. A few of our specialities are dies for high performance bunching (silver/nickel etc.), dies for hard drawing material, and dies that combine Carbide coating with PCD which can be very efficient on a long order for big cables.

DS Hai services wire manufacturers in the United States as well as Internationally. We also provide very competitive recutting services. We are looking for sales agents both domestic and international to assist in our growth. Attractive commissions. Please contact Simon at tel. 860 574-4771 or tel. 860-884-1270, or by e-mail at Simon@dshaidies.com.

MACHINERY MACHINERY FOR DIES. Used Ultrasonic And Wire Recut/Polisher machines for sale, Good condition and attractive prices! New machines are also available. Please Contact Simon (860) 574-4771 or (860) 884-1270, Simon@dshaidies.co WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, color-o-meters and pointers). Tel: 727863-4700 or by e-mail, please send to urbassoc@verizon.net

MACHINERY WANTED MACHINERY WANTED. Dytron Corporation is looking for a straightening and cutting machine for small diameter wire. Down to at least .010" and maybe .005. Fax information to 1-586296-6771 or please send an email to sales@dytroncorp.com.

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MEDIA

“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

FERROUS WIRE HANDBOOK. The most recent in a series of handbooks published by WAI, this comprehensive hard-cover book is a definitive industry resource for ferrous wire written by members of the Association and edited by former WAI President Robert M. Shemenski, this 1,168 page hardcover book wsa published in 2008. It is

84 | WIRE JOURNAL INTERNATIONAL

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org.

For more details, you can call her at 203-453-2777, ext. 116.

a modern-day reference tool for those working directly in the steel wire or manufacturing, engineering, or operations sectors of the industry. The publication’s comprehensive 36 chapters cover a broad range of topics including many of the equipment types, processes, and specialty applications of steel wire manufacturing. The book begins with a history of the steel industry and the evolution of ferrous steel manufacture and is followed by details on: continuous casting; controlled rod cooling; rod defects; pickling and coating; mechanical descaling; deformation in cold drawing; wiredrawing theory, machinery, and finishing equipment; lubrication; heat treatment; stress relief; annealing; oil tempering; patenting; corrosion; galvanizing; statistical process control; bridge rope and strand; and nails, barbed wire, mechanical springs.

Appendices and a complete index are included in the handbook. List Price is $235, $195 for WAI members.

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 indus-

THE BOOK OF WIRE & CABLE TERMS. Learn the A to Zs of wire and cable with this essential reference source. Presented in a clear, practical manner over 350 pages, The Book of Wire & Cable Terms is an indispensable publication covering both ferrous and nonferrous terminology, including a special section for fiber optic terms.

More than 5,000 entries are offered. It also features a listing of industry-related organizations and associations with corresponding web site addresses. 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 must-have resource for anyone in the wire and cable business from the shop floor worker to the chair-

man of the board, The Book of Wire & Cable Terms spells it out for everyone.

List Price: $75, $50 for WAI members.

Ships in one to two business days.

ELECTRICAL WIRE HANDBOOK SET. Focusing on the special needs of the insulated wire and cable industry, these books examine materials, equipment, and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire, and other applications. The 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.

While the updated handbook includes the latest information available, this new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. The intent of these handbooks is to provide basic but meaningful information to those people working in the wire and cable industry-especially those who are new to the field. Produced by the WAI’s Electrical Management Committee, these books are intended to serve as a valuable reference tool for members of the industry to help keep up with today’s rapidly changing technology.

Price $99, $59 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

More than 1,200 second-hand machines in stock Reconditioned 6 block double capstan drawing machine

New machines designed for your production New Bongard drawing line for trolley wire

e-mail Dave.Evans@george-evans.com

Bongard Machines USA LLC Suite 160 · 6920 Pointe Inverness Way Fort Wayne, IN 46804, USA Phone +1 260 225 4510 Fax +1 260 225 4513 E-Mail chris.z@bongard.us www.bongard.us

FEBRUARY 2011 | 85

CLASSIFIEDS

tries a greater appreciation of the complex technological issues. List Price: $125.00, WAI Member Price: $105.

ADVERTISERS’ INDEX

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

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

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

Gimax Srl . . . . . . . . . . . . . . . . . . . . . . .insert, between 16-17

Anbao . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

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

Howar Equipment Inc/GMP Slovakia . . . . . . . . . . . . . . . . .21

Bongard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27, 51

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Inhol BV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Cemanco LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Kinrei of America LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .83

Lamnea Bruk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Lesmo North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Karl Fuhr GmbH & Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Madem S.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

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.

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

86 | WIRE JOURNAL INTERNATIONAL

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

Messe Düsseldorf Asia (Bangkok) . . . . . . . . . . . . . . . . . .49

Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

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

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .19 Power Sonics/Magnus Equipment . . . . . . . . . . . . . . . . . . .23

Interwire 2011 reminder

Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . . . . .39

Exhibitors: if you have not sent your

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

booth description in yet, we need it by

Rainbow Rubber & Plastics Inc . . . . . . . . . . . . . . . . . . . . .17

(or before!) Tuesday, March 1, to make sure that it gets in the April WJI and

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

the official Show Program.

Sanxin Wire Die Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

FEBRUARY 2011 | 87

ADVERTISERS’ INDEX

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

ADVERTISERS’ INDEX

April 2011 WJI ADVERTISER . . . . . . . . . . . . . .PAGE

Tubular Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

• Dies • Interwire 2011 update

Tulsa Power Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Advertising Deadline: March 1, 2011

Talladega Machinery & Supply Co . . . . . . . . . . . . . . . . . . .4

Unience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2 Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Windak Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .87 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .79 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 4

WIRE ASSOCIATION INT’L ADS WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Interwire 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-43 Global Continuous Casting Forum . . . . . . . . . . . . . . .52-53

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

88 | 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

Ne

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