wiredinUSA October 2015

INDEX

Cold formed fasteners

thread rolling, material hardness increases to 130,000 KSI from the original material tensile of 85,000 KSI, substantially improving integrity and durability, an important factor in mission critical applications such as aircraft and aerospace assemblies. Sussex Wire utilises cold forming and roll forming at room temperature to shape metal wire and alloys into highly engineered, precision, micro-miniature components. Superior Essex has launched its PowerWise™ category 5e cable, a 22-gauge communications data cable specifically designed for Internet connected devices that utilize power-over-Ethernet (PoE) and require higher levels of current. The PowerWise cat 5e cable provides 88 percent power efficiency for POE+and future 4PPoE applications over 100m distances. This improved power efficiency is due to 22 gauge copper wires being 59 percent larger than the 24-gauge copper wires typically used in category 5e cables. While some PoE devices require a cat 6A cable to support 10GB Ethernet, many devices will never need a data rate that exceeds the throughput capability of cat 5e. For devices such as LED lighting fixtures, the ongoing cost and the initial cost of the installation are the most important considerations for POE cable selection. PowerWise CAT 5e cable combines the power efficiency benefits of 22-gauge copper conductors with the design cost benefit of CAT 5e. Wise cable choice

S S A new threaded fastener designed to improve strength and economy

US aerospace supplier Sussex Wire has introduced a threaded fastener designed to improve strength and economy in critical applications. The CRES fastener has a threaded shank with an overall length of only 0.676", and a low-profile 0.25" diameter oval head. A reverse hex extrusion on the end of the shank opposite the head is created by cold forming and thread rolling. The economy of cold forming, coupled with the ability to create the hex socket without collapsing the reverse extrusion, was achieved through specialist tool design by the company’s in-house team. The component is said to incorporate all of the benefits of cold forming, including high part throughput rates, significant cost economy, and 100 percent net shape, resulting in zero scrap or material waste. In addition, the finished part is clean and burr-free after forming, eliminating expensive secondary operations. Sussex Wire says, however, that because of work hardening via cold forming and

wiredInUSA - October 2015

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