Interwire 2019

13th to 16th May, 2019

When

13th to 16th May, 2019 07:00 am - 07:30 pm

Website: Interwire 2019

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Where

Georgia World Congress Center
285 Andrew Young International Blvd NW, Atlanta, GA 30313
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Monday, 13th May 2019

Time Room A411 Room A403 Room A412
8:30 am Mechanics of Wiredrawing
Link

Mechanics of Wiredrawing

This course presents fundamental engineering principles and process calculations that are used to design, analyze, and improve metal rod and wiredrawing operations. Topics include a basic overview of wiredrawing mechanics with respect to material behavior and process parameters. Die angle and reduction will be addressed in light of the Delta-parameter and its practical application. Drawing limits, friction and lubrication, work-piece heating, and temperature effects are also discussed.

By:
Frank F. Kraft
May 13, 2019, 8:30 am to 9:15 am
Hall: Room A411 Track: Fundamentals of Wire Manufacturing Type: Session
   
8:35 am    
8:40 am    
8:45 am    
8:50 am    
8:55 am    
9:00 am    
9:05 am    
9:10 am    
9:15 am Dies
Link

Dies

This course presents the basics of die technology, material science, and application. It begins with a review of basic die geometry and the importance of all geometric attributes and how these attributes affect drawing performance. Then it reviews the pros and cons of different die materials (carbides and ciamond). And finally it moves into the science behind draft profiling, including how pressure clearances should be determined for maximum drawing performance. This course familiarizes all participants with a wide array of die terminology, theory, and practical information.

By:
Joao Noroña
May 13, 2019, 9:15 am to 10:00 am
Hall: Room A411 Track: Fundamentals of Wire Manufacturing Type: Session
   
9:20 am    
9:25 am    
9:30 am    
9:35 am    
9:40 am    
9:45 am    
9:50 am    
9:55 am    
10:00 am Fundamentals Break at Level 4 Common Area    
10:05 am    
10:10 am    
10:15 am Lubrication in the Wiredrawing Process
Link

Lubrication in the Wiredrawing Process

Wiredrawing requires lubrication between the wire reduction system and the wire surface to successfully perform the deformation process. The selection and type of lubricant used must consider various factors in order to achieve optimal quality, efficiency, production costs, and EH&S concerns. Understanding the material type, surface preparation, processing, and end use application is critical in the determination of lubricant selection. Knowledge of lubrication principles, lubrication systems, and operational mechanics form the basis for lubricant selection..

By:
Brad Andrews
May 13, 2019, 10:15 am to 11:00 am
Hall: Room A411 Track: Fundamentals of Wire Manufacturing Type: Session
   
10:20 am    
10:25 am    
10:30 am    
10:35 am    
10:40 am    
10:45 am    
10:50 am    
10:55 am    
11:00 am Wire Breaks and Surface Damage
Link

Wire Breaks and Surface Damage

This course presents a classification of wire breaks from a perspective that compares material defects to process-related problems. Rod defects will include both casting and rolling issues such as internal voids, foreign contaminants, rolled-in scale, hot cracks, and surface porosity. The effects of wiredrawing speed and lubrication will be discussed with respect to generation of fines, shaving, galling, and other surface defects.

By:
Horace Pops
May 13, 2019, 11:00 am to 11:45 am
Hall: Room A411 Track: Fundamentals of Wire Manufacturing Type: Session
   
11:05 am    
11:10 am    
11:15 am    
11:20 am    
11:25 am    
11:30 am    
11:35 am    
11:40 am    
12:00 pm     Fundamentals of Wire Manufacturing Luncheon at Room A412
12:05 pm    
12:10 pm    
12:15 pm    
12:20 pm    
12:25 pm    
12:30 pm    
12:35 pm    
12:40 pm    
12:45 pm    
12:50 pm    
12:55 pm    
1:00 pm Stranding and Cabling
Link

Stranding and Cabling

This presentation documents the stranding process for nonferrous conductors, specifically bare copper and tinned wire, as well as assembly of multi-conductor cables. Different processes that are addressed include bunching and concentric constructions, silicone blocked stranding, as well as cable assembly techniques, and rationale for each type. Specific applications include industrial and energy sectors, electronics and data communications, the automotive industry, consumer products, and appliances.

By:
Peter Blackford
May 13, 2019, 1:00 pm to 1:45 pm
Hall: Room A411 Track: Fundamentals Nonferrous Elect Track Type: Session
Fundamentals of Ferrous Metallurgy
Link

Fundamentals of Ferrous Metallurgy

This introductory course is designed to provide a general understanding of ferrous metallurgical concepts, including phase equilibrium, transformation, strengthening mechanisms, heat treatment, and an overview of steelmaking, and their relevance to wire technology.

By:
Anand Bhagwat
May 13, 2019, 1:00 pm to 1:45 pm
Hall: Room A403 Track: Fundamentals Ferrous Track Type: Session
 
1:05 pm  
1:10 pm  
1:15 pm  
1:20 pm  
1:25 pm  
1:30 pm  
1:35 pm  
1:40 pm  
1:45 pm Extrusion
Link

Extrusion

This course starts with a discussion of the basics of the various polymers used for wire and cable insulation. This is followed by discussion of the construction aspects of rubber and thermoplastic extruders. The remaining components of typical extrusion lines are reviewed and include payoffs, dancers and accumulators, preheaters, crossheads, cooling troughs, capstans, online measurement and testing equipment, online printing, take-ups, and operator control systems.

By:
Erik A. Macs
May 13, 2019, 1:45 pm to 2:30 pm
Hall: Room A411 Track: Fundamentals Nonferrous Elect Track Type: Session
Cleaning and Coating of Rod and Wire
Link

Cleaning and Coating of Rod and Wire

This course presents the fundamentals of cleaning, pickling, and coating of ferrous wire and rod in preparation for drawing and processing. Proper control and handling in these areas ensures quality of the finished product. The design of these processes impacts the economics of the operation. It is imperative that rather than individual stages, this department should be viewed as a whole as it is critical to success. The course deals with zinc phosphate processes and the advantages and limitations as well as specialty coatings such as salt carriers, lubricants, dry film polymers, and new technologies on the horizon.

By:
Neil C. Lowdon
May 13, 2019, 1:45 pm to 2:30 pm
Hall: Room A403 Track: Fundamentals Ferrous Track Type: Session
 
1:50 pm  
1:55 pm  
2:00 pm  
2:05 pm  
2:10 pm  
2:15 pm  
2:20 pm  
2:25 pm  
2:30 pm Break  
2:35 pm  
2:40 pm  
2:45 pm Fundamentals of Electrical Testing
Link

Fundamentals of Electrical Testing

This fundamentals course is geared to providing a general overview of electrical testing. The course highlights key terms, standards, and tests that are common to the wire and cable industry for conductors and insulations, and highlights specific concerns of various industries and product types.

By:
Peter Blackford
May 13, 2019, 2:45 pm to 3:30 pm
Hall: Room A411 Track: Fundamentals Nonferrous Elect Track Type: Session
Ferrous Testing and Properties
Link

Ferrous Testing and Properties

This course discusses tensile, coiling, wrap, reverse bend, torsion, fatigue, and hardness testing procedures. It illustrates interpretation of test results in terms of sample properties.

By:
C. Richard Gordon
May 13, 2019, 2:45 pm to 3:30 pm
Hall: Room A403 Track: Fundamentals Ferrous Track Type: Session
 
2:50 pm  
2:55 pm  
3:00 pm  
3:05 pm  
3:10 pm  
3:15 pm  
3:20 pm  
3:25 pm  
3:30 pm Marking and Printing
Link

Marking and Printing

This presentation addresses the equipment and processes for marking, printing, and guiding insulated wire and cable in addition to precise positioning of wire and cable relative to processing and gauging equipment. It discusses flexible turn-key designs suitable for a variety of applications on a product range from 28 gauge up to a 6-in. diameter. Equipment can be located in-line during extrusion, off-line during take-up and payoff, barrel-fed for wire and harness processing, and used for short runs for wire and cable distribution.

By:
Mark Spencer
May 13, 2019, 3:30 pm to 4:15 pm
Hall: Room A411 Track: Fundamentals Nonferrous Elect Track Type: Session
Ferrous Heat Treatment
Link

Ferrous Heat Treatment

This course focuses on heat treatment of ferrous metals. It includes basic heat treating principles applicable to many metals with specific examples related to heat treatment of steel rod and wire.

By:
C. Richard Gordon
May 13, 2019, 3:30 pm to 4:15 pm
Hall: Room A403 Track: Fundamentals Ferrous Track Type: Session
 
3:35 pm  
3:40 pm  
3:45 pm  
3:50 pm  
3:55 pm  
4:00 pm  
4:05 pm  
4:10 pm  
4:15 pm Fundamentals Q & A
Link

Fundamentals Q & A

All the instructors for the Fundamentals courses get together at the end of the program for an open session of questions and answers with the audience. The 45-minute session immediately follows the end of the last class.

By:
Anand Bhagwat, Brad Andrews, C. Richard Gordon, Erik A. Macs, Frank F. Kraft, Horace Pops, Jack McAfee, Joao Noroña, Mark Spencer, Peter Blackford
May 13, 2019, 4:15 pm to 5:00 pm
Hall: Room A411 Track: Fundamentals of Wire Manufacturing Type: Session
 
4:20 pm  
4:25 pm  
4:30 pm  
4:35 pm  
4:40 pm  
4:45 pm  
4:50 pm  
4:55 pm  
7:15 pm GCCF Social Hour (7:30 pm - 9:00 pm) at STATS Brewpub  
7:20 pm  
7:25 pm  

Tuesday, 14th May 2019

Time Sonoco Theater [Exhibition Hall] Room A411 Room A312 Room A401
7:00 am       GCCF Authors' Breakfast at A401
7:05 am      
7:10 am      
7:15 am      
7:20 am      
7:25 am      
7:30 am      
7:35 am      
7:40 am      
7:45 am      
7:50 am      
7:55 am      
8:00 am   Welcome to GCCF!
Link

Welcome to GCCF!

By:
TBD
May 14, 2019, 8:00 am to 8:10 am
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
   
8:05 am      
8:10 am   Aluminum Welding Wire Technology
Link

Aluminum Welding Wire Technology

Two new Properzi lines, based on a new technology and process, are currently operating in China processing special aluminum alloy wires. This innovation transforms the aluminum welding wire production process by going from ingot to continuously cast 6 mm wire and subsequent cold rolling to 2.2 mm wire. Remarkable savings in annealing steps and overall production are illustrated.

By:
Giuseppe Marcantoni, Vladimir Djukic
May 14, 2019, 8:10 am to 8:40 am
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
   
8:15 am      
8:20 am      
8:25 am      
8:30 am      
8:35 am      
8:40 am   Operational Advancements in Continuous Rod Systems
Link

Operational Advancements in Continuous Rod Systems

As an operator of a single copper rod system and three aluminum rod systems, SCR is intensely focused on maximizing quality and reliability while minimizing operating costs. This presentation focuses on on-going improvements to the SCR process in copper and aluminum rod production from the perspectives of both an operator and an equipment supplier.

By:
Jeffrey Ainsworth
May 14, 2019, 8:40 am to 9:10 am
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
   
8:45 am      
8:50 am      
8:55 am      
9:00 am   Opening - Keynote
Link

Opening - Keynote

By:
W.T. Bigbee
May 14, 2019, 9:00 am to 9:05 am
Hall: Room A312 Track: Interwire Conference Type: Session
 
9:05 am   Keynote: The Future of Wires and Cables in a Connected World
Link

Keynote: The Future of Wires and Cables in a Connected World

The number of “things” connected to the Internet surpassed the number of people on the planet more than 10 years ago. This colossal change is creating tremendous challenges and unheralded opportunities. Massive experimentation today will redefine our future and influence how we work, communicate and live. As we usher in a digitized, datafied world, the next industrial revolution is unfolding before us all and forever changing our businesses.

By:
Shawn G. DuBravac
May 14, 2019, 9:05 am to 9:45 am
Hall: Room A312 Track: Interwire Conference Type: Keynote
 
9:10 am   Casting High-Conductivity Oxygen-Free Copper Rod From Scrap: Myths and Reality
Link

Casting High-Conductivity Oxygen-Free Copper Rod From Scrap: Myths and Reality

High conductivity oxygen free copper rod is the most ductile of all copper grades, and its utilization brings important efficiency advantages in high speed multiwire drawing and magnet wire applications. In order to preserve its properties, special care must be taken when it is produced either entirely from scrap or from a cathode/scrap combination. This presentation describes the effect of some melt pollutants on conductivity and drawability.

By:
Juan Carlos Bodington
May 14, 2019, 9:10 am to 9:40 am
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
 
9:15 am    
9:20 am    
9:25 am    
9:30 am    
9:35 am    
9:40 am   GCCF Break at Level 4 Common Area  
9:45 am   State of Manufacturing
Link

State of Manufacturing

Changes in the manufacturing landscape foretell a marked difference in how wire and cable plants will operate in the future. Hear insight from Karl G. Glassman, President and CEO of Leggett & Platt.

By:
Karl G. Glassman
May 14, 2019, 9:45 am to 10:15 am
Hall: Room A312 Track: Interwire Conference Type: Session
 
9:50 am    
9:55 am    
10:00 am   Continuous Casting of Dilute Copper Alloys for Drawing to Wire in Specialist Applications
Link

Continuous Casting of Dilute Copper Alloys for Drawing to Wire in Specialist Applications

Many modern industrial applications of copper-based conductor wires call not only for high electrical conductivity, but also for other matching physical properties, including high tensile strength, high softening temperatures, creep resistance, abrasion resistance, and corrosion resistance, while also maintaining good ductility. This paper shows examples of dilute copper alloys offering these properties and techniques and equipment which have been developed by Rautomead for reliable, continuous production to narrow chemical tolerances.

By:
Michael Nairn
May 14, 2019, 10:00 am to 10:30 am
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
 
10:05 am    
10:10 am    
10:15 am   Global Wire & Cable Market Outlook
Link

Global Wire & Cable Market Outlook

Mr. Radbourne will share the latest developments in the wire and cable sector and discuss key trends that will impact demand in the nonferrous, electrical sectors. Integer Research is a subsidiary of Argus, a leading energy and commodity price reporting agency providing data, news and insights.

By:
Philip Radbourne
May 14, 2019, 10:15 am to 10:45 am
Hall: Room A312 Track: Interwire Conference Type: Session
 
10:20 am    
10:25 am    
10:30 am   compacROD®
Link

compacROD®

The new compacROD® plant for ETP copper rod production combines the know-how of CONTIROD® with the advantages of a small copper rod production plant. The mix of a proven shaft furnace with a cost-efficient wheel/belt casting system and the single driven roll stands of the SMS module system from CONTIROD® leads to an attractive new solution in the segment of copper rod production for capacities of 5-7 t/h. This paper gives an overview of the system and its design features as well as product quality to be produced.

By:
Thomas Schatz
May 14, 2019, 10:30 am to 11:00 am
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
 
10:35 am    
10:40 am    
10:45 am   Interwire Conference Break at Level 3 Common Area  
10:50 am    
10:55 am    
11:00 am   Use of OEE in Optimization of Maintenance Schedule
Link

Use of OEE in Optimization of Maintenance Schedule

According to some studies, 50% of all precautionary maintenance is futile. If the maintenance schedule is optimized, it does not only reduce the cost of the maintenance, but also improves the factory throughput. This paper aims to explore the possibilities of using modern mathematical methods for utilizing OEE measurement for achieving the best possible maintenance plan through the use of IIoT. This leads to a maintenance schedule which is dynamically adjusted rather than keeping the standard cyclical schedule.

By:
Aleksandar Bukvić
May 14, 2019, 11:00 am to 11:30 am
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
Sector Insights/Forecasts
Link

Sector Insights/Forecasts

Three speakers take turns in this session, each offering an individual perspective on one of the following segments of the wire and cable market: automotive, defense and medical, and petrochemical.

By:
Bill Reichert, Luis Adame, Paul Wagner
May 14, 2019, 11:00 am to 12:00 pm
Hall: Room A312 Track: Interwire Conference Type: Session
 
11:05 am    
11:10 am    
11:15 am    
11:20 am    
11:25 am    
11:30 am      
11:35 am      
11:40 am      
11:45 am      
11:50 am      
11:55 am      
12:00 pm   GCCF Lunch at Room A412    
12:05 pm      
12:10 pm      
12:15 pm      
12:20 pm      
12:25 pm      
12:30 pm      
12:35 pm      
12:40 pm      
12:45 pm      
12:50 pm      
12:55 pm      
1:00 pm Mordica Memorial Lecture: Trends and Challenges in Steel Wire Technologies
Link

Mordica Memorial Lecture: Trends and Challenges in Steel Wire Technologies

Global industry trends are well known: innovation and innovation speed, cost reduction, digitalization, automation, reduced energy consumption, environmental protection … . These are also the trends observed in the wire industry and many of the technology projects at Bekaert are linked with these issues. This paper highlights some of the developments and challenges in the area of wire deformation and coatings such as higher strength and sound ductility of high-carbon wires, improved corrosion resistance, and endurance. It also discusses more novel approaches like smart machinery for more robust processing, newly developed test techniques, and challenges to comply with fast-changing regulations.

By:
Walther Van Raemdonck
May 14, 2019, 1:00 pm to 1:40 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Mordica Lecture
Cost-Saving Opportunities Panel: Management
Link

Cost-Saving Opportunities Panel: Management

By:
Roberto Duralde, Martin LeCours, Florin Teglas
May 14, 2019, 1:00 pm to 1:50 pm
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
   
1:05 pm    
1:10 pm    
1:15 pm    
1:20 pm    
1:25 pm    
1:30 pm    
1:35 pm    
1:40 pm The Effect of Bearing Length on the Surface Quality of Drawn Wire
Link

The Effect of Bearing Length on the Surface Quality of Drawn Wire

In wiredrawing, the geometry of drawing dies influences the performance of the wire process. This study investigates the effect of bearing lengths on the surface quality of the drawn wire. Wiredrawing tests were done using an industrial wiredrawing machine utilizing drawing dies with different bearing lengths. The influence of bearing length on surface quality is discussed.

By:
Joakim Larsson, Lars Pejryd, Patrik Karlsson
May 14, 2019, 1:40 pm to 2:00 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
   
1:45 pm    
1:50 pm Wire & Cable Outlook and Global Aluminum Markets
Link

Wire & Cable Outlook and Global Aluminum Markets

This presentation examines the current state of the wire and cable market with a special focus on aluminum as used in overhead lines globally and insulated cable.

By:
Philip Radbourne
May 14, 2019, 1:50 pm to 2:30 pm
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
   
1:55 pm    
2:00 pm Weld Button Defect in Resistance Butt Welding of High-Carbon Steel Wires
Link

Weld Button Defect in Resistance Butt Welding of High-Carbon Steel Wires

A metallurgical investigation of weld failure was done to identify the defect and arrive at the source of defect generation. Spark generation at the annealing jaws produces a hard spot near the HAZ (heat affected zone) which is quenched rapidly and produces a hard phase resulting in a button-shaped defect after drawing. The results indicate that measures of weld joint preparation and weld annealing procedure plays a key role in avoiding the defect and associated wire failure.

By:
Amit Agarwal, Satish Kadu
May 14, 2019, 2:00 pm to 2:20 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
   
2:05 pm    
2:10 pm    
2:15 pm    
2:20 pm Use of Open Circuit Potential for Measurement (OCP) Technique for Arriving at Optimal Pickling Time of Carbon Steel Wire Rods
Link

Use of Open Circuit Potential for Measurement (OCP) Technique for Arriving at Optimal Pickling Time of Carbon Steel Wire Rods

HCl acid pickling is widely used for steel wire rod due to advantages like lower cost along with faster and complete cleaning before subsequent drawing. Optimizing the pickling operation for higher productivity and lower WPL generation are major challenges for the wire industry. Existing methods used to identify pickling time are time-consuming and experienced based. This paper explores the possibility of using the OCP technique for determining wire rod pickling time.

By:
Swapnil Kor, Kedar Bhave, Dinesh Gudadhe, Shishir Desai
May 14, 2019, 2:20 pm to 2:40 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
   
2:25 pm    
2:30 pm Global Copper Market Outlook
Link

Global Copper Market Outlook

Although the global copper market has been in a deficit position for a number of years, the price has been falling most recently. It is widely assumed that the rising dollar, coupled with international trade issues, is weighing on prices. This presentation addresses this apparent contradiction and lays out how the author believes the market will evolve going forward.

By:
John Gross
May 14, 2019, 2:30 pm to 3:00 pm
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
   
2:35 pm    
2:40 pm Wiredrawing Lubricant Dust Reduction
Link

Wiredrawing Lubricant Dust Reduction

Steel wiredrawing normally uses soap powder lubricants. This type of lubricant poses a major problem: dust. Its origin is not only due to the chemistry of the lubricant but often linked to its improper use or use in unsuitable conditions. Different dust generation factors are addressed along with solutions to significantly reduce the problem and methods that improve working conditions and limit the fire risk while reducing the global cost of using this type of lubricant.

By:
Mike Bowen, Pascal Cossu, Brad Andrews
May 14, 2019, 2:40 pm to 3:00 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
   
2:45 pm    
2:50 pm    
2:55 pm    
3:00 pm Improved Payoff Performance Using Constant Tension Systems
Link

Improved Payoff Performance Using Constant Tension Systems

Tension control accuracy in payoff systems affects product quality. Solutions used in industry range from crude, improvised methods to precise, closed-loop microprocessor controlled systems. The degree of accuracy required for a specific application dictates the selection of payoff system. In this paper, authors explore the spectrum of tension control systems and their appropriate uses ranging from constant torque brakes to powered payoffs. Authors highlight a recently developed controller that provides a simple, integrated control system.

By:
Alan Doucette, Howard Schwerdlin
May 14, 2019, 3:00 pm to 3:20 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
GCCF Break at Level 4 Common Area    
3:05 pm    
3:10 pm    
3:15 pm    
3:20 pm Electrical Linear Resistance Versus Weight Measurement of Conductors – What Benefits Can We Expect?
Link

Electrical Linear Resistance Versus Weight Measurement of Conductors – What Benefits Can We Expect?

Measuring the linear electrical resistance of conductors is the standard method of IEC for ampacity determination. This paper discusses the benefits of such a measurement compared to weight calculation/measurements described in ASTM standards. Among them, the possibility of high-accuracy “on-the-line” measurement without cutting the conductor is detailed. Progress in the current distribution homogenization of off-line measurements and their application to watertight and Millikan conductors are also presented.

By:
Boris Dardel
May 14, 2019, 3:20 pm to 3:40 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
Global Scrap Markets
Link

Global Scrap Markets

By:
David Golman
May 14, 2019, 3:20 pm to 3:50 pm
Hall: Room A411 Track: Global Continuous Casting Forum Type: Session
   
3:25 pm    
3:30 pm    
3:35 pm    
3:40 pm Envirosafe and Cost-Effective Additives to Protect Wire and Cables From Pest Attacks
Link

Envirosafe and Cost-Effective Additives to Protect Wire and Cables From Pest Attacks

This presentation describes an eco-friendly, US- and EU-regulatory-compliant solution to prevent pest damages. The globally patented and trademarked products Rodrepel™, Termirepel™, and Combirepel™ are polymer additives which are extremely low-toxic and low-hazard and are not harmful to the environment. These products do not kill; they just repel the pests. They can be incorporated in wire and cable as masterbatches while they are extruded, thus making the cables pest-repellent.

By:
Chaitanya Joshi
May 14, 2019, 3:40 pm to 4:00 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
   
3:45 pm    
3:50 pm Cost-Saving Opportunities Panel: Technology
Link

Cost-Saving Opportunities Panel: Technology

By:
Kiran Manchiraju, Andrea Peviani, John Quinn, Willem Sundblad
May 14, 2019, 3:50 pm to 4:40 pm
Hall: Room A411 Track: Global Continuous Casting Forum Type: Panel Discussion
   
3:55 pm    
4:00 pm Fiber Ribbon Dimensional Measurement and Color Sequence Verification
Link

Fiber Ribbon Dimensional Measurement and Color Sequence Verification

Fiber optic ribbon is increasing in popularity in the United States and other countries as a method of grouping different fiber strands together. Ribbon cable needs to have consistent geometry to tightly stack multiple ribbons with the high fiber density that is one of the ribbon’s primary benefits. Taymer’s Ribbon Inspection system (RI) is a high-speed tool that allows fiber optic cable manufacturers to improve quality of their fiber optic ribbon production process and avoid creating hundreds or thousands of meters of poor quality ribbon.

By:
Craig Girdwood, Max Fondyga
May 14, 2019, 4:00 pm to 4:20 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
   
4:05 pm    
4:10 pm    
4:15 pm    
4:20 pm Wire and Cable Manufacturing Problem-Solving
Link

Wire and Cable Manufacturing Problem-Solving

This presentation is a demonstration of problem-solving techniques used to solve real challenges faced in the wire and cable industry. Actual scenarios are used to challenge attendees to think beyond the obvious symptoms and find the root cause. Lean Six Sigma problem-solving strategies are utilized as the course walks through each problem until the cause is identified. The audience is encouraged to participate in this interactive program.

By:
Stacy Martin
May 14, 2019, 4:20 pm to 5:00 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Session
   
4:25 pm    
4:30 pm    
4:35 pm    
4:40 pm      
4:45 pm      
4:50 pm      
4:55 pm      
6:30 pm Interwire Welcome Reception (6:30pm - 8:30pm) at Chick fil A College Football Hall of Fame Interwire Welcome Reception (6:30pm - 8:30pm) at Chick fil A College Football Hall of Fame  
6:35 pm  
6:40 pm  
6:45 pm  
6:50 pm  
6:55 pm  

Wednesday, 15th May 2019

Time Sonoco Theater [Exhibition Hall] Room A411 Room A403 Room A312 Room A313 Room A401
7:00 am           GCCF Authors' Breakfast at A401
7:05 am          
7:10 am          
7:15 am          
7:20 am          
7:25 am          
7:30 am          
7:35 am          
7:40 am          
7:45 am          
7:50 am          
7:55 am          
8:00 am WAI Member Rewards Breakfast at Room A313 ETP vs. FRHC Copper Rod: Correlation With ASTM Standards
Link

ETP vs. FRHC Copper Rod: Correlation With ASTM Standards

This presentation discusses influence of residual impurities and alloying elements for both ETP and FRHC copper rod with an emphasis upon annealability and both mechanical and electrical properties. Major effects of oxygen content, thermal-mechanical processing variables, and continuous casting factors are linked to recent changes to ASTM and European standards and will be summarized with an emphasis upon fire refining and resulting rod requirements.

By:
Horace Pops
May 15, 2019, 8:00 am to 8:30 am
Hall: Room A411 Track: GCCF Copper Track Type: Session
Overview of Furnace Aspects of Recycling of Aluminum
Link

Overview of Furnace Aspects of Recycling of Aluminum

This paper focuses on the efforts the secondary aluminum industry is making toward recycling aluminum in a green way by saving 170 million tons of greenhouse gas from being released to the atmosphere by recycling aluminum. Two forms of recycling, in-process scrap and market scrap, are discussed together with how furnace equipment is adapted to treat the different requirements of the two recycling streams. Energy conservation drives the industry, but productivity improvements and the means to improve metal yield also need to be added to the “green” accomplishments of this segment of the industry.

By:
Patrick Bryan, Jens Hebestreit
May 15, 2019, 8:00 am to 8:30 am
Hall: Room A403 Track: GCCF Aluminum Track Type: Session
     
8:05 am      
8:10 am      
8:15 am      
8:20 am      
8:25 am      
8:30 am Inline and Offline Concepts for FRHC Copper Rod
Link

Inline and Offline Concepts for FRHC Copper Rod

FRHC copper is either cast directly from the fire refining furnace into products using inline solutions or via offline solutions using FRHC ingots or blocks as cathode substitutes. This paper discusses the advantages and disadvantages of both variants and the different furnace concepts used. Further, it shows a new TBRC fire refining concept, which allows a reduction in natural gas consumption of up to 40% for FRHC copper.

By:
Hans-Jörg Krassnig, Rolf Degel, Timm Lux
May 15, 2019, 8:30 am to 9:00 am
Hall: Room A411 Track: GCCF Copper Track Type: Session
Determining the Effect of Aluminum Wire Alloys on Cement and Phosphate Bonded Castables
Link

Determining the Effect of Aluminum Wire Alloys on Cement and Phosphate Bonded Castables

Utilizing aggressive aluminum wire alloys (8177,1350,6201, and 5154) as well as 7075 as a control and the addition of a salt flux, 86% alumina cement-bonded castables as well as 88% alumina phos-bonded castables were tested at more than 2100°F for 72 hours in precast and dried cups. The cups were sectioned in half and the penetration of alloy was measured and photographed. The test showed that phos-bonded castables resist penetration by wire alloys better than cement-bonded castables as a whole.

By:
Bryan Nelson
May 15, 2019, 8:30 am to 9:00 am
Hall: Room A403 Track: GCCF Aluminum Track Type: Session
     
8:35 am      
8:40 am      
8:45 am      
8:50 am      
8:55 am      
9:00 am   The Effect of Flame Intensity on the Shaft Melting of Copper
Link

The Effect of Flame Intensity on the Shaft Melting of Copper

The intensity of shaft furnace burner flames influences melting performance in many ways. Actual results contrast with handbook predictions of performance in terms of furnace thermal efficiency and product metallurgy.

By:
John Hugens
May 15, 2019, 9:00 am to 9:30 am
Hall: Room A411 Track: GCCF Copper Track Type: Session
Combustion Systems and Environmental Emissions
Link

Combustion Systems and Environmental Emissions

This presentation offers a brief discussion of burner design and furnace operating parameters impact on emissions (NOx, CO, CO2, and particulate). It includes general discussion on levels to be expected and techniques for reducing levels emitted. The information is based on natural gas operations.

By:
Don Whipple
May 15, 2019, 9:00 am to 9:30 am
Hall: Room A403 Track: GCCF Aluminum Track Type: Session
Operations Innovation Panel
Link

Operations Innovation Panel

The four panelists will cover a lot of turf, offering their observations on the role of innovation, where it comes from, and where it is headed.

By:
Ali Shehab, Tom Heberling, Dave Hawker, Richard Wagner
May 15, 2019, 9:00 am to 10:00 am
Hall: Room A312 Track: Interwire Conference Type: Panel Discussion
   
9:05 am      
9:10 am      
9:15 am      
9:20 am      
9:25 am      
9:30 am   Evaluation of Monolithic Refractories Used in Anode Shaft Furnaces as Well as Transfer Launders and Process Equipment in Rod and Tube Mills
Link

Evaluation of Monolithic Refractories Used in Anode Shaft Furnaces as Well as Transfer Launders and Process Equipment in Rod and Tube Mills

This study explores finding the best monolithic refractory to resist corrosion and penetration by anode, rod, and tube mill slags. It is a continuation of work presented at the 2015 Forum. The work expands now to include the search for an optimum refractory system for the working lining of shaft furnaces as well as the metal transfer and processing equipment downstream of the taphole. The study expands to include evaluation of colloidal silica bonded castables as well as cement bonded castables.

By:
Bryan Nelson
May 15, 2019, 9:30 am to 10:00 am
Hall: Room A411 Track: GCCF Copper Track Type: Session
Installation of an FFD at Prysmian General Cable, Lapointe Works
Link

Installation of an FFD at Prysmian General Cable, Lapointe Works

Québec-based Lapointe Works (Prysmian Group) and STAS share a long history of collaboration. Twenty-five years ago, STAS provided the rod producer with one of its first Aluminum Compact Degassers (ACD) to process molten aluminum with the use of chlorine. Flux injection trials were performed on it to validate metallurgical performance (hydrogen, alkali, and inclusions) vs. the use of chlorine gas and to confirm the cable produced has the same quality specifications. This paper presents an overview of the metallurgical performance achieved while addressing the positive impact this approach may have on aluminum rod production.

By:
Dominic Vézina, Eric Pilote, Bruno Maltais
May 15, 2019, 9:30 am to 10:00 am
Hall: Room A403 Track: GCCF Aluminum Track Type: Session
   
9:35 am      
9:40 am      
9:45 am      
9:50 am      
9:55 am      
10:00 am Factors Affecting Wire Production From Precoats to Lubricants
Link

Factors Affecting Wire Production From Precoats to Lubricants

There are many issues in the production of wire and many factors affecting high-quality wire production even after cleaning. These include selection and maintenance of the non-reactive precoats and lubricants, followed by identifying key drawbench parts/systems that have immediate impact on the lubricant performance. Many of these parts require minor fixes that minimize downtime. Everything working together improves wire quality and production efficiency.

By:
David Gzesh
May 15, 2019, 10:00 am to 10:20 am
Hall: Sonoco Theater [Exhibition Hall] Track: Production Solutions Type: Session
3-D Printed Filters in Copper Production
Link

3-D Printed Filters in Copper Production

Filtration via strainers or reticulated foam have been incorporated in many applications to achieve improvements in copper quality. Due to the low quality improvement or strainers and foam reticulates pore size restriction, many applications have been left without a path forward. This presentation explores the development of 3-D filters and their use in copper production. The flexibility and repeatability of a 3-D structure with the oxide removal of a reticulated foam has the potential to offer the best of both worlds in copper filtration.

By:
David Heckman
May 15, 2019, 10:00 am to 10:30 am
Hall: Room A411 Track: GCCF Copper Track Type: Session
  Intelligent Industrial Automation: Using Your Process Data to Solve Quality, Downtime, and Production Problems in the Wire & Cable Manufacturing Industry
Link

Intelligent Industrial Automation: Using Your Process Data to Solve Quality, Downtime, and Production Problems in the Wire & Cable Manufacturing Industry

As Industry 4.0 gains momentum in the wire and cable industry, many are calculating the risk-reward ratio of becoming early adopters. To truly understand the urgency of starting an Industry 4.0 project, consider what you’re losing by not innovating, specifically: the cost of poor quality, downtime, and competitiveness. This session discusses why the process data and analytics provided by Industry 4.0 solutions are the most important part of industrial automation and how they can help solve these production problems.

By:
Willem Sundblad
May 15, 2019, 10:00 am to 10:30 am
Hall: Room A312 Track: Interwire Conference Type: Session
   
10:05 am      
10:10 am      
10:15 am      
10:20 am        
10:25 am        
10:30 am DMAIC Problem-Solving for Wire and Cable
Link

DMAIC Problem-Solving for Wire and Cable

By:
Steve Pinnix
May 15, 2019, 10:30 am to 10:50 am
Hall: Sonoco Theater [Exhibition Hall] Track: Production Solutions Type: Session
    Break    
10:35 am        
10:40 am        
10:45 am     Tariffs & Trade - Steel Wire Impact
Link

Tariffs & Trade - Steel Wire Impact

Mr. Wolz will give an update on the AWPA activity relative to the Proclamations 9704 and 9705 on adjusting imports of steel and aluminum, under section 232, that were put into place in March 2018. Insteel Wire Products operates 10 plants throughout the U.S. and is the U.S.'s largest manufacturer of steel wire reinforcing products for concrete construction applications.

By:
H.O. Woltz III
May 15, 2019, 10:45 am to 11:15 am
Hall: Room A312 Track: Interwire Conference Type: Session
   
10:50 am          
10:55 am          
11:00 am Determining Root Causes of Issues Attributed to the Cleaning and Coating Operation
Link

Determining Root Causes of Issues Attributed to the Cleaning and Coating Operation

Everyone talks about running an operation perfectly, but where do you start looking when an issue arises? This presentation briefly covers identifying the root cause of issues that can develop during cleaning and coating. It discusses determining if the source is possibly from different processes in the production cycle such as heat treatment, cleaning, or drawing. In some cases, simple tests can be run on site to help point you in the right direction. An example would be: “is that red hue on the rod surface coming from copper plating or hematite scale?” Questions and discussion are welcome during the presentation.

By:
Neil C. Lowdon, Paul Kulongowski
May 15, 2019, 11:00 am to 11:20 am
Hall: Sonoco Theater [Exhibition Hall] Track: Production Solutions Type: Session
       
11:05 am        
11:10 am        
11:15 am     Positioning for Future Challenges and Opportunities
Link

Positioning for Future Challenges and Opportunities

The world is changing rapidly. It is flatter, leaner, and more innovative than at any point in history. This trend will not relinquish. As manufacturers, we have proven that we are not intimidated by the environment we find ourselves, but most importantly we need to embrace the opportunities that are on the horizon. Mr. Sofia will discuss the shared dynamics that push and pull our organizations and why he is confident in the business of wire and cable.

By:
Giacomo Sofia
May 15, 2019, 11:15 am to 12:00 pm
Hall: Room A312 Track: Interwire Conference Type: Session
   
11:20 am          
11:25 am          
11:30 am Wire Breaks
Link

Wire Breaks

How do you identify possible causes of wire breaks? Is it the process or the material? Learn to distinguish between both issues that can result in wire breaks. A detailed analysis of central bursting (cuppy wire) will include causes, prevention, and correction.

By:
Horace Pops
May 15, 2019, 11:30 am to 11:50 am
Hall: Sonoco Theater [Exhibition Hall] Track: Production Solutions Type: Session
       
11:35 am        
11:40 am        
11:45 am        
11:50 am          
11:55 am          
1:00 pm Why Buy New Equipment – If Existing Machines Are Still Running (and Are Written Off)?
Link

Why Buy New Equipment – If Existing Machines Are Still Running (and Are Written Off)?

With the latest advances in technology in the wire and cable industry, is the cable manufacturer able to justify the purchase of new equipment? This presentation explains advances in wire processing technology and their benefits compared to existing (old) machinery. It discusses whether savings in energy, labor, and material, coupled with quality improvements, can justify the investment in new and modern technology. Focusing on wiredrawing and double-twist stranding, it presents ROI calculations for real production examples in the wire industry.

By:
Bernd Lohmüller
May 15, 2019, 1:00 pm to 1:20 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
Coiler Modernization at Sarkuysan’s SCR Plant
Link

Coiler Modernization at Sarkuysan’s SCR Plant

Global metals producer Sarkuysan operates a copper mill with a Southwire SCR system, producing up to 70,000 tpy of 8.0 mm, 11 mm, and 16 mm ETP wire rod. The coiler needed upgrading as free-falling rings led to irregular coil shapes that were difficult to control, with tangling risks during high-speed payoff. Any changes would affect plant production. The four project partners coordinated a two-stage process with a mill shutdown of only eight days.

By:
Bruce V. Kiefer, David Gow, , Süleyman Sinan Selvi
May 15, 2019, 1:00 pm to 1:30 pm
Hall: Room A411 Track: GCCF Copper Track Type: Session
Modification of Aluminum Alloy Filler to Improve Arc-Welding Performance
Link

Modification of Aluminum Alloy Filler to Improve Arc-Welding Performance

Al-Mg alloys are widely used as GMAW and GTAW filler electrode for their high strength and compatibility with a large variety of aluminum grades. Compared to 4000-series filler alloys, Al-Mg alloys have less favorable welding characteristics such as spatter, fume, arc stability and puddle fluidity due to their high magnesium content. Low levels of alloying elements were added to AA5356 and these modified chemistries welding performance were assessed in GMAW and compared to the unmodified alloy. The modified alloys have shown significantly lower spatter, higher arc stability and better puddle fluidity than the baseline alloy. The improved welding performance is likely due to the effect of the alloy addition on metal transfer and surface tension.

By:
Shenjia Zhang, Janusz S. Sekunda, Mike Beckman
May 15, 2019, 1:00 pm to 1:30 pm
Hall: Room A403 Track: GCCF Aluminum Track Type: Session
     
1:05 pm      
1:10 pm      
1:15 pm      
1:20 pm Effect of Al Content on the Mechanical Properties of Alternately Cold-Drawn Magnesium Alloy Wires
Link

Effect of Al Content on the Mechanical Properties of Alternately Cold-Drawn Magnesium Alloy Wires

For the purpose of this research, six different magnesium alloy wires were cold drawn using conventional and alternate drawing methods. After reaching the drawing limit, the drawn wires were tested and a reciprocal connection between the aluminium content in the wire, the drawing limit and the increase in tensile strength of the wire was established. The results were summarized and the effectiveness of the method for the different magnesium alloys was established.

By:
Kazunari Yoshida, Vladimir Stefanov Hristov
May 15, 2019, 1:20 pm to 1:40 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
     
1:25 pm      
1:30 pm Silicon Carbide Linings for Copper Melting Shaft Furnaces
Link

Silicon Carbide Linings for Copper Melting Shaft Furnaces

This paper reviews a wide breadth of refractory innovations made in copper shaft furnaces.

By:
John Hugens, Julio Spadaccia
May 15, 2019, 1:30 pm to 2:00 pm
Hall: Room A411 Track: GCCF Copper Track Type: Session
Development of New High-Performance Aluminum Conductors Produced by Continuous Casting
Link

Development of New High-Performance Aluminum Conductors Produced by Continuous Casting

This paper presents a micro-alloying approach to develop new high-performance aluminum alloys to achieve an improved and optimized combination of strength, electrical conductivity, and thermal stability. The micro-additions create nanoscale strengthening precipitates which are distinct from the traditional strengthening phases, such as β-Mg2Si and Al3Fe, and have a much higher thermal stability and coarsening resistance. This study demonstrates this micro-alloying modification concept in 1000-, 6000-, and 8000-series aluminum conductor alloys and discusses their mass-production scalability by the continuous casting process.

By:
David C. Dunand, Francisco Flores, Janusz S. Sekunda, Nhon Q. Vo, Shenjia Zhang
May 15, 2019, 1:30 pm to 2:00 pm
Hall: Room A403 Track: GCCF Aluminum Track Type: Session
     
1:35 pm      
1:40 pm Drawing of High-Strength Aluminium Alloy Wire by Using a Cryogenic Wiredrawing Method
Link

Drawing of High-Strength Aluminium Alloy Wire by Using a Cryogenic Wiredrawing Method

In this research, three different aluminium alloy wires were drawn to their drawing limit by using conventional drawing and cryogenic wiredrawing, and the changes in the mechanical properties of the wires were examined. By using cryogenic wire, higher-strength wires were attained and better surface, due to the use of lubricant in this process, was achieved. The effectiveness of this method was confirmed.

By:
Chihiro Takuma, Kazunari Yoshida, Trisna Ardi Wiradinata
May 15, 2019, 1:40 pm to 2:00 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
     
1:45 pm      
1:50 pm      
1:55 pm      
2:00 pm Improving the Technological Plasticity of Material in Dieless Drawing Processes
Link

Improving the Technological Plasticity of Material in Dieless Drawing Processes

This paper explores a method for increasing technological plasticity of material in the dieless drawing process. The proposed method is based on the implementation of a multi-pass process. The authors have theoretically and experimentally investigated two dieless drawing processes. The difference was related to the heating systems, induction heating and laser heating. FEM simulations and experimental tests were performed for two materials, magnesium alloy and pure copper. It was shown that the more effective increase in plasticity can be achieved using laser dieless drawing.

By:
Andrij Milenin, Piotr Kustra, Tsuyoshi Furushima
May 15, 2019, 2:00 pm to 2:20 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
New Dual-Layer Refractory Material for Burner Blocks in Copper Melting Shaft Furnaces
Link

New Dual-Layer Refractory Material for Burner Blocks in Copper Melting Shaft Furnaces

Copper melting shaft furnaces can develop extremely hot areas around the burner block mountings that cause deformities and breaks in the furnace shell over time. Saint-Gobain has addressed this problem with a new proprietary dual-layer refractory system named Twinfrax. This Twinfrax material is working successfully on burner blocks and has potential beneficial applications throughout the refractory system.

By:
Ethan Weikleenget, Julio Spadaccia
May 15, 2019, 2:00 pm to 2:30 pm
Hall: Room A411 Track: GCCF Copper Track Type: Session
How to Run a RBD Line With Integrated Annealer for Cu and Al in the Most Efficient Way
Link

How to Run a RBD Line With Integrated Annealer for Cu and Al in the Most Efficient Way

For running a Cu or Al RBD machine with an integrated annealer, many paramters have to be carefully considered. This presentation gives an overview about the theoretical basics of the calculation of the drawing process, including drawing forces, DDS, annealing power, and achievable wire speed. It also covers design of the machine in order to provide the most sophisticated process, e.g. individual drives, capstan diameter, cooling and drying, special coating of deflection, and contact rolls. Other topics include impact of slippage, lubrication, drawing dies, filtration system, and predictive maintenance.

By:
Stefan Nixdorf
May 15, 2019, 2:00 pm to 2:30 pm
Hall: Room A403 Track: GCCF Aluminum Track Type: Session
     
2:05 pm      
2:10 pm      
2:15 pm      
2:20 pm Production of Zn-Mg Wire for Biomedical Application
Link

Production of Zn-Mg Wire for Biomedical Application

This paper deals with the problem of obtaining wire from zinc alloys in order to obtain dissolved surgical threads. Three types of materials were analyzed – pure zinc, zinc with the addition of 1% magnesium, and bimetallic wire based on zinc and magnesium. A workpiece for the drawing process (diameter 2 mm) is obtained using an extrusion process. The wiredrawing is performed at room temperature up to diameters of 1.0 and 0.3 mm. Mechanical tests, including relaxation tests, were performed on the obtained wire.

By:
Andrij Milenin, Piotr Kustra
May 15, 2019, 2:20 pm to 2:40 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Technical Paper
     
2:25 pm      
2:30 pm          
2:35 pm          
3:00 pm         Inaugural Meeting - WAI Operations Forum
Link

Inaugural Meeting - WAI Operations Forum

For those in the nonferrous/electrical sector, the Association will be launching a new forum specifically for invited plant/operations managers. This forum is intended to support the educational and networking needs of these key individuals charged with day-to-day management of the plants.

By:
Ali Shehab
May 15, 2019, 3:00 pm to 3:45 pm
Hall: Room A313
 
3:05 pm          
3:10 pm          
3:15 pm          
3:20 pm          
3:25 pm          
3:30 pm          
3:35 pm          
3:40 pm          
4:00 pm The Champion’s Code: Building Relationships Through Life Lessons of Integrity and Accountability from the Sports World to the Business World
Link

The Champion’s Code: Building Relationships Through Life Lessons of Integrity and Accountability from the Sports World to the Business World

This program is based on more than six years of research that resulted in two critically acclaimed series of sports-business books. The first examines how and why certain teams win world championships, while the other chronicles the unwritten and unspoken rules in the world of sports, or “codes” as they are known, which explores the fine line between cheating and gamesmanship — and the consequences involved when that line is crossed. Bernstein interviewed more than 1,000 professional athletes and coaches for his six books and along the way he saw some fascinating patterns, metrics, and trends develop among certain individuals who possessed a very unique DNA. For these individuals, or “champions,” it wasn’t always about winning, it was about following their moral compass in order to play the game the right way — with respect and integrity — in order to achieve success. In his presentation, Bernstein identifies upwards of 100 unique characteristics and traits that are common among champions, which he then ties into poignant life lessons and inspirational stories that relate back to industry.

By:
Ross Bernstein
May 15, 2019, 4:00 pm to 5:00 pm
Hall: Sonoco Theater [Exhibition Hall] Track: Technical Program Type: Session
         
4:05 pm          
4:10 pm          
4:15 pm          
4:20 pm          
4:25 pm          
4:30 pm          
4:35 pm          
4:40 pm          
4:45 pm          
4:50 pm          
4:55 pm          
7:05 pm   GCCF Dinner (7:00pm - 9:00pm) at Ventanas      
7:10 pm        
7:15 pm        
7:20 pm        
7:25 pm        

Thursday, 16th May 2019

Time Room A411 Room A403 Room A313 Room A401
7:00 am       GCCF Authors' Breakfast at A401
7:05 am      
7:10 am      
7:15 am      
7:20 am      
7:25 am      
7:30 am      
7:35 am      
7:40 am      
7:45 am      
7:50 am      
7:55 am      
8:00 am Running a Copper Rod Line: Tricky Business
Link

Running a Copper Rod Line: Tricky Business

User-friendly continuous casting copper rod lines are the result of combining three different processes: melting, casting, and rolling, which in the past were separate processes that may have even been located in different buildings. Although complex, the modern lines do provide a high level of automation that would normally enable a smooth transformation of the raw copper materials into bright coils of quality rod. This paper addresses hidden issues and variables which make CCR lines so tricky to operate and provides a few hints to achieve better results on a consistent and repeatable basis.

By:
Andrea Peviani
May 16, 2019, 8:00 am to 8:30 am
Hall: Room A411 Track: GCCF Automation and Safety Track Type: Session
Copper Rolling Lubricants: The Future
Link

Copper Rolling Lubricants: The Future

Nonferrous rolling lubricants have been built around soluble-oil emulsion technology. What works in aluminum rolling applications may not always provide the desired results/benefits for copper rolling applications. This presentation reviews the various copper rolling lubricants utilized and provides insight into the attributes that new technologies can deliver. By making use of new chemical technology, next-generation rolling lubricants can be developed that provide improvements in consistency of operation, improvements in lubrication properties, and improvements to metal surface finish.

By:
Robert Blithe
May 16, 2019, 8:00 am to 8:30 am
Hall: Room A403 Track: GCCF Lubrication and Testing Track Type: Session
   
8:05 am    
8:10 am    
8:15 am    
8:20 am    
8:25 am    
8:30 am Hazelett® Twin-Belt Caster – Past, Present, and Future
Link

Hazelett® Twin-Belt Caster – Past, Present, and Future

This presentation gives an overview of the Hazelett® twin-belt caster and its past, present, and future use in the production of ETP copper rod. The technology was developed in the 1940s for casting lead strip and later adapted for use in the production of ETP copper rod. Today, there are over 40 active copper casting installations. The straight-through design, coupled with a tapered mold, offers an inherent advantage for casting alloyed or recycled copper products.

By:
Rob White, Wojtek Szczypiorski
May 16, 2019, 8:30 am to 9:00 am
Hall: Room A411 Track: GCCF Automation and Safety Track Type: Session
Controlling Bacteria in Soluble Oil Systems with the use of UV Light
Link

Controlling Bacteria in Soluble Oil Systems with the use of UV Light

RH2O Engineering, Inc. has developed a patented UV light system for controlling bacteria in very opaque liquids. This non-chemical treatment system has been successfully used in continuous casting systems that use soluble oil in milling operations to control bacteria counts to less than 100 cfu/ml. The use of this UV light system eliminates the need for hazardous biocide feed and allows for more consistent soluble oil performance.

By:
Mike Robertson
May 16, 2019, 8:30 am to 9:00 am
Hall: Room A403 Track: GCCF Lubrication and Testing Track Type: Session
   
8:35 am    
8:40 am    
8:45 am    
8:50 am    
8:55 am    
9:00 am Advanced Continuous Rotary Extrusion of Copper and Its Alloys
Link

Advanced Continuous Rotary Extrusion of Copper and Its Alloys

ASMAG has further developed continuous rotary extrusion technology with a focus on improving product quality, process control, and operational reliability. The findings of the development have been patented, and ASCON extruders using those innovative solutions are in continuous operation at leading copper semi manufacturers. The innovations include features to minimize and keep constant the process scrap during operation and to produce high-quality oxygen-free copper products.

By:
Johannes Sieberer-Kefer
May 16, 2019, 9:00 am to 9:30 am
Hall: Room A411 Track: GCCF Automation and Safety Track Type: Session
Hot Rolling Fundamentals - Managing Rolling Lubricants for Optimum Copper Rod Quality
Link

Hot Rolling Fundamentals - Managing Rolling Lubricants for Optimum Copper Rod Quality

The ever-increasing volume of copper rod being manufactured on continuous copper rolling plants globally is driving rod producers to improve their copper rod quality due to increased competition. The downstream demand by wire producers to manufacture consistent quality wire outcomes is driven by the quality of the copper rod produced by the rod plant. This paper discusses the tools and process requirements required by the rod plant to successfully manage the key parameters of copper dust, oxide and surface finish, and how the rolling mill lubricants play a part in supporting improved quality outcomes during the copper rod rolling process.

By:
Kyle Craft
May 16, 2019, 9:00 am to 9:30 am
Hall: Room A403 Track: GCCF Lubrication and Testing Track Type: Session
   
9:05 am    
9:10 am    
9:15 am    
9:20 am    
9:25 am    
9:45 am Business Challenges for Copper Continuous Castings
Link

Business Challenges for Copper Continuous Castings

Based on long experience, years in the business, and management of three continuous casting operations with different technologies, La Farga shares its vision of the future challenges for the sector, with special emphasis on the challenge of eco-sustainability, and describes how the soft skills of the organization have to coexist with technological know-how for the business model to be successful.

By:
Carles Camprubí
May 16, 2019, 9:45 am to 10:15 am
Hall: Room A411 Track: GCCF Automation and Safety Track Type: Session
Caster Water Filtration
Link

Caster Water Filtration

In the process of continuous casting copper rod, acetylene soot or graphite is applied to the caster wheel or belts as a release agent and insulator, optimizing heat transfer. The amount of soot or graphite that remains in the water is critical to the process and relates directly to line speed, component life, and product quality. This presentation provides information on a system using proprietary clay chemistry to manage the amount of soot or graphite in the caster water.

By:
Lawrence El-Hindi, Jamal El-Hindi
May 16, 2019, 9:45 am to 10:15 am
Hall: Room A403 Track: GCCF Lubrication and Testing Track Type: Session
   
9:50 am    
9:55 am    
10:00 am Manufacturing Management Workshop
Link

Manufacturing Management Workshop

The work environment has been called the most crucial factor in employee satisfaction. This seminar takes a look at why work atmosphere is important, how you can recognize the signs that the atmosphere isn’t as good as it should be, and how to fix it! Speaker Ed Krow of Ed Krow LLC, works with executives and business owners who are struggling with people problems.

By:
Ed Krow
May 16, 2019, 10:00 am to 12:00 pm
Hall: Room A313 Track: Workshop Type: Workshop
 
10:05 am  
10:10 am  
10:15 am Safety Culture
Link

Safety Culture

SDI LaFarga has inherited and further develops a strong safety culture within the company. This session shares some of the company’s activities in the hope of starting a collaborative discussion on improving safety throughout the industry.

By:
Matt Reinoehl
May 16, 2019, 10:15 am to 10:45 am
Hall: Room A411 Track: GCCF Automation and Safety Track Type: Session
Continuous Cast Copper Rod Coolant Filtration
Link

Continuous Cast Copper Rod Coolant Filtration

It’s in no doubt at this point that the removal of copper or aluminum oxides from the rod mill coolant is essential to a quality rod, increased mill rolls life, and increased production, in addition to maintaining the coolant quality and coolant service time resulting in less waste-cost and reduced environmental impact. A correctly sized and designed filtration system is a must to accomplish this. This presentation provides the most recent information to the copper rod producer about coolant filtration system design, sizing, and component preference.

By:
Lawrence El-Hindi, Jamal El-Hindi
May 16, 2019, 10:15 am to 10:45 am
Hall: Room A403 Track: GCCF Lubrication and Testing Track Type: Session
 
10:20 am  
10:25 am  
10:30 am  
10:35 am  
10:40 am  
10:45 am   High-Speed Eddy Current Testing of Round, Ovate, and Fine Wire
Link

High-Speed Eddy Current Testing of Round, Ovate, and Fine Wire

This presentation focuses on new technology that allows high-speed eddy current testing of round and non-round wire while improving flaw detection and minimizing false rejects. The systems can be incorporated in-line to be used during production, or adapted for off-line testing use.

By:
Mario Di Bello, Martin Schilling
May 16, 2019, 10:45 am to 11:15 am
Hall: Room A403 Track: GCCF Lubrication and Testing Track Type: Session
 
10:50 am    
10:55 am    
11:00 am    
11:05 am    
11:10 am    
11:15 am      
11:20 am      
11:25 am      
11:30 am      
11:35 am      
11:40 am      
11:45 am      
11:50 am      
11:55 am      

Legend

 GCCF Lubrication and Testing Track Scheduled Lunches Fundamentals of Wire Manufacturing Scheduled Breaks
 Global Continuous Casting Forum Technical Program Production Solutions Workshop
 Interwire Conference Fundamentals Nonferrous Elect Track Fundamentals Ferrous Track GCCF Automation and Safety Track
 Scheduled Breakfast      

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