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Wire Expo 2008 Short Course: Fundamentals of Wire Manufacturing - Part II - Practices Saturday and Sunday, June 7 and 8 Get back to the basics on Saturday and Sunday with WAI's two-day course, "Fundamentals of Manufacturing - Practices." You’ll learn the central practices of wire manufacturing as shared by a team of eight instructors who are experts in their respective disciplines. Four general topics (two hours each) will be covered on the first day that apply to everyone in the wire and cable industry. On the second day, instructors will cover sector-specific topics in ferrous and nonferrous/electrical disciplines (four hours each), and then the entire group will reassemble in the afternoon for a combined session featuring general discussion and a question-and-answer forum with all presenters on hand. Note: The Carrie Furnace Hard Hat Tour of the former U.S. Steel furnace is included for course participants. General Topics | Instructors Ferrous Track | Instructors
Sunday Nonferrous/Electrical Track | Instructors
Wiredrawing Machine Design Principles Marco Gerardo, SAMP USA Inc. This presentation focuses on the major technological developments of the past thirty years in the wiredrawing industry. It traces design principles from older wiredrawing equipment to modern equipment, including design features and criteria to be used when selecting a machine for a specific application. Topics include single-wire machines vs. multiwire machines, main design principles for rod breakdown machines and multiwire machines, take-up and payoff solutions, and process consideration for downstream operation. Marco Gerardo is sales and marketing manager for SAMP USA Inc., Williamsport, Maryland, USA. He joined the company in 1991 as a sales area manager. In 1997 he was named export sales manager with direct responsibilities for territories in Mexico and Canada. He was promoted in 2000 to his current position, which also requires him to work closely with the product development and marketing group at SAMP in Italy. Prior to joining the company, he worked in various capacities for O.M. Lesmo in Europe. Tom Maxwell Jr., Die Quip Corp. The die is the most important part of the drawing process and without it the best drawing machines, lubricant, and treatment systems cannot reduce the wire diameter. However, with a die, vice pliers, and a hammer, wire can be drawn, albeit slowly, as it has been for over 2,000 years. The intention of this course is to provide an understanding of what makes a die work, how it is designed, causes of failure, and problems with drawing larger sizes. Tom Maxwell Jr. is president of Die Quip Corp., Bethel Park, Pennsylvania, USA. He holds a bachelor’s degree in industrial technology-management from California University of Pennsylvania and an associate’s degree in tool and die design from Alliance College. He is a member of WAI’s board of directors, member relations committee, exhibition planning committee, and conference programming committee; past chairman of the exhibition planning committee; and past president of the Ohio Valley Chapter. Robert Shemenski, RMS Consulting Inc. This course discusses tensile, bend, torsion, fatigue, and hardness testing procedures. It illustrates interpretation of test results in terms of sample properties. It also presents practical exercises of data analysis. Robert Shemenski is president of RMS Consulting, Inc., North Canton, Ohio, USA, a provider of metallurgical and corrosion engineering services. He has taught corrosion science and engineering as an adjunct professor at the University of Akron, USA. He has long been active in several professional societies, including the WAI, where he served as president in 1999 and 2000. Dieter Brandstätter, Ebner Industrieofenbau GmbH The course focuses on heat treatment of steel. It includes principles, basic methods of various heat treatments (stress relieving, annealing, normalizing, various hardening, and tempering procedures) and cold treatment. It also provides an overview of heat treating equipment, use of special atmosphere, and furnace safety. Case studies include annealing of copper base alloy wire and cold heading quality wire rod in high convection hydrogen bell annealing furnaces. Dieter Brandstätter is vice president – technology at Ebner Industrieofenbau GmbH, Leonding, Austria. He is responsible for process and equipment development for the company’s steel division. He has been with the company since 1985. His previous positions included process management in R&D and senior manager, process development. He previously worked in the Melbourne, Australia, research center of Comalco and in the heat treatment management shop for Magna International in Newmarket, Ontario, Canada. He holds a master’s degree in metallurgy and a degree in mechanical engineering from the University of Leoben, Austria. He has published several articles in international magazines and holds several patents in heat treatmnt technology. Peter Blokker, Esco Engineering This course is a review of the practices of rod and wire coil cleaning and coating with some discussion of strand pickling. The main type of cleaning discussed is based on pickling with a brief discussion of mechanical descaling. The pickling section covers removal of oil and dirt, types of acids used, proper rinsing, environmental concerns, fume control, and waste treatment. The coating section looks at phosphate and lube, lime, polymer, and disposal. Peter Blokker is a professional engineer with ESCO Engineering in Kingsville, Ontario, Canada. He has worked for the company as a consulting engineer since 1994. His duties have been in the evaluation of existing pickling and fume control and the design of new pickling lines and fume control system. He has a degree in mechanical engineering from the University of Windsor, Canada, and a diploma for chemical technology from St. Clair College in Windsor. ESCO is a consulting engineering firm specializing in metal pickling, fume and pollution control, and chemical process layout. Stainless Steel Wire Processing Rick Gordon, Gerdau Ameristeel “What makes steel stainless”? This course covers general characteristics and metallurgy of stainless steels and alloy application examples. It includes basic alloy selection criteria, industry specifications, and mechanical properties of stainless alloys (annealed / drawn). The manufacture of stainless steel rods is reviewed. At the stainless steel wire mill, the course examines inspection, rod and process wire cleaning, heat treating, and wiredrawing. Examples are given for easy-to-draw alloys and difficult-to-draw alloys. C. Richard Gordon is technical service metallurgist at Gerdau Ameristeel. He has over 30 years’ experience in the steel and wire industries. He previously worked with the National Standard Company managing groups working in the areas of R&D, quality, and process technology for carbon steel and stainless steel wire products. He is a graduate of the Illinois Institute of Technology with master’s and BS degrees in metallurgical and materials engineering. He serves on the Board of Directors for the ASM International’s Notre Dame Chapter and is also a member of ASTM, TMS, and WAI. Current Stranding Processes of Cable and Conductors Sean Harrington, Ceeco Bartell Stranding or twisting of conductors and cables can be constructed on a wide range of equipment. The type of machine depends on whether it is used for insulated or non-insulated wire, the number of wires, the type and size of wires, as well as the particular cable standard being used. This course discusses the different types of equipment and products that can be used in stranding, highlighting the benefits and negatives of each type. It also highlights some of the latest developments in the stranding processes. Sean Harrington is sales and marketing manager for Ceeco Bartell Products, Bartell Machinery Systems LLC, Woodbridge, Ontario, Canada. He spent the majority of his career in the design and manufacture of machines for the wire and cable industry at a variety of companies both in the UK and Canada. He holds an honors degree in mechanical engineering. Horace Pops, Horace Pops Consulting Inc. This presentation reviews several continuous in-line processes, including melting, casting, solidification, hot rolling, and cleaning of nonferrous rod. Important manufacturing parameters and problems are addressed in order to achieve wire that is free from surface and internal defects such as macroporosity. Different commercial continuous systems are discussed. Several other processes are covered, including shaped wire rolling, armor cable manufacture, transfer of molten metal, and plastic extrusion. Horace Pops is president of Horace Pops Consulting, Inc., Ft. Wayne, Indiana, USA. He previously was director, metals laboratory at Superior Essex in Ft. Wayne. He joined Superior Essex in 1972. He founded the company’s corporate metals laboratory. He holds an Sc.D. degree from the University of Pittsburgh and M.Met.E. degree from Lehigh University, and a B.Met.E. degree from Rensselaer Polytechnic Institute. He was president of the Wire Association International from 1992-93. He is the sole or co-holder of 10 patents. Many of his papers have been published in leading technical journals. |
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