WCN Spring 2009

Onwards and upwards – innovations from Upcast ®

Several new and interesting developments have already been introduced into the Upcast system. These include: double- loop inductors; stepless power control for inductors; single- furnace line for 12,000tpa (an extension of the 10,000tpa, single-furnace line to 12,000tpa capacity); a double-furnace line for 40,000tpa; carrier-type cathode charging for double- furnace lines (an adaptation of the standard carrier-type cathode charging system); a “Universal” double coiler for rod diameters of 8mm–25mm and an automatic alloy feeder, designed to be used in double-furnace lines for the production of alloyed coppers such as silver bearing and phosphor deoxidised coppers. Operation of the alloy feeder is synchronised with the automatic

The Upward Continuous Casting method, better known as the Upcast® system, was innovated and developed by Outokumpu in the late 1960s for the production of copper and copper alloy wire rod. In 2006 Upcast celebrated the 35 th anniversary of the startup of the first production unit installed in Outokumpu’s Pori Foundry in Finland. Thankstoitsmodularconstruction each Upcast line is easy to upgrade and expand. This first production line has benefitted from several upgrades to keep it up-to-date and in continuous operation. To date, 170 Upcast casting lines have been delivered worldwide, the majority for oxygen-free copper but around 40 for copper alloys. To meet future challenges the Upcast legacy is carried forward under the banner of a recently formed (2006) company, Upcast Oy. Continuous development has been a characteristic feature of the Upcast technology throughout its history and now, under new ownership, the role of innovation will become even more marked. Descaling specialists USA‘s Wire Lab Company manufactures a comprehensive line of mechanical descaling machinery for steel wire producers. Awidevarietyofmodels allows customers to put in place the Wilco mechanical descaling system which most closely matches their wire drawing requirement, with consideration given to machinery investment, maintenance cost, cost for any consumable items and overall quality requirement of the finished wire product. Simple-to-use basic mechanical descaling systems (such as model 920 Air Jet and model 1030 Water Jet descalers) are well suited for producers of industrial quality wire products where emphasis is on maintaining the lowest possible overall production cost. More feature-rich Wilco descaling systems allow customers to use wire rods of various qualities with the objective being producing a consistently cleaned wire rod suitable for making into higher quality wire products. These Wilco descaling systems (model 1250 and model 1750 automatic wire brush descalers) incorporate the Wilco automatic rod-brushingmachine into the process. Eight circular wire brushes are

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Double-furnace continuous copper casting line

Upcast Oy – Finland Fax : +358 207 577 401 Email : info@upcast.com Website : www.upcast.com

melt transfer function and includes a feedback link, for accurate chemical analysis with minimal fluctuation.

positioned around the rod circumference to aggressively clean the rod surface of secondary scale and red rust – both detrimental to producing high quality wire products. More specialisedWilco descaling systems (model 1060 descaling system with lubri- cant precoating and model LRD scale breaker for large diameter rods) satisfy the needs of more specialised producers. The model 1060 as part of the mechanical descaling process applies lubricant precoating compound in the final stage of the mechanical descaling process. Manufacturers of high carbon wire and those working with very high finishing speeds benefit from the increased lubrication established by the precoating compound. The Wilco large rod scale breaker (model LRD) is designed for processing larger rods up to 19mm in diameter. Sheave offset is controlled by hydraulics, thereby allowing simple straight-through string up of the scale breaker. Many manufacturers rely on Wilco lubricant applicators and double die pressure die holders to maximize and maintain lubrication levels throughout the drawing operation. Wilco lubricant applicators are designed to simply “snap on” the rod or wire in the lubricant

section of the die box and then are covered with the dry lubricant. As the wiredrawing machine pulls the rod or wire, the rolls of the lubricant applicator compact the dry lubricant onto the rod or wire. Wilco pressure die holders are designed to force lubricant, under high pressure, onto the surface of the wire as it is being drawn. Installation of a Wilco pressure die holder in the first die box is essential for establishing a significant lubricant film while pressure die holders in the remaining die boxes will maintain such proper lubrication. Wire Lab Company – USA Fax : +1 216 433 0007

Email : e-mail@wirelab.com Website : www.wirelab.com

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WIRE & CABLE NEWS • Issue N° 40 • Spring 2009 • www.iwma.org