DECALUB : Descaling, Lubrication, Drawing

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Innovators in Mechanical Descaling, Cleaning, Surface Preparation, Coating and Lubrication GREEN Technologies

Dies can have Infinite Life 
- see  Newsletter No.15 on  http://decalub.pagesperso-orange.fr/newsletter.htm
         
 Rod Dry Preparation                                    Wire Rod Lubrication                      Wire Cleaning
 
( with no speed limit )                                     ( for frictionless drawing )                  ( for plating finish ) 

 Decalub has introduced the New Way to draw steel wire in 
the 21st Century : The DCCD process


"  DCCD Process Revolutionizes Wire Drawing :
   Today, rod dry preparation cost 
   is 20 - 25 % of the cost of acid cleaned 
   and chemically coated rod ".

The DCCD ( Dry Cleaning, Coating and Drawing ) rod preparation and wire lubrication process 
combines the most innovative technologies , all dramatically simple to use , reflecting unprecedented 
PERFORMANCE and ECONOMIC EFFICIENCY .
DCCD process achieves the most unique scenario in modern wire drawing operations , in the most 
demanding H/C and L/C wire drawing applications , performing :

Rod In-line Preparation at Unlimited Speed , Scale and Rust Removal .... Totally Clean , GREEN and Dry Process .... 
Phosphate-Free Conversion Coating .... Immediate Cost Saving of 60 - 75 % and more .... 
-  Eliminating the Need for Phosphate, Borax and Wet Precoatings ....  Frictionless Drawing .... 
-  Output 2.2 - 4.9 Tonne / Hour ( from 5.5 - 13 mm, H/C Uncoated Rod ) .... Drawing at 18 m/s ( 3600 ft/min ) , H/C .... 
Dies Do Not Wear ( Unmeasurable Die Wear of 0.1 - 0.3 micron / tonne , H/C ) .... 
-  Operation at ZERO Energy Consumption, ZERO Maintenance Cost, ZERO Consumables Cost, .... 
-  Eliminating Lubricant Most Destructive Contaminants including Moisture ( enemy  No.1 for wire drawing process ) , Scale , Rust and Abrasive Fines .... etc.

For more information on DCCD process see :
-  Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm : " Wire Rod Acid-free Cleaning , Coating and Drawing - Clean, GREEN and Dry  , by DCCD process .
-  Newsletter No.16 on  http://decalub.pagesperso-orange.fr/newsletter.htm :
" Rod Rust and Scale Removal , Acid-Free Dry Preparation  , by SB system
-  Newsletter No.15 on  http://decalub.pagesperso-orange.fr/newsletter.htm : " Wire Rod Lubrication : Drawing Art of Steel Wire - Clean, GREEN and Dry , by PDH system .


Contact us
For any further information please contact us at : 
info@decalub.com

Industry News
:
For more information visit "What's new" pages.
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Rod Preparation : Drawing Art of Steel Wire - Clean , GREEN and Dry. 
DCCD rod preparation process is used in-line in the most demanding
H/C and L/C wire drawing applications , incorporating latest key technologies that enable rod mechanical scale and rust removal , surface specific dry preparation and phosphate-free conversion coating at no speed limit , allowing frictionless drawing in all drafts and virtually unmeasurable die wear. Rod moisture, the No.1 enemy for wire drawing , is completely eliminated. 
Applications enable output of  2.2 - 4.9 tonne / hour from 5.5 - 13 mm DCCD processed 0.83 - 0.90 %C mechanically descaled uncoated ( bare ) rod , operating at virtually ZERO energy consumption , ZERO maintenance cost and ZERO consumables cost , in a totally GREEN , clean and dry process , dramatically reducing cost per tonne of wire drawn , often reported to be 20 - 25 % of the cost of conventional process operating with aggressive chemicals ( acid , wet pre-coating , etc. ).  - DCCD system -
see  Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm
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  Wire Cleaning : From Drawn Dull to Wire Clean Glossy Plating Finish
PWC removes lubricant residue from drawn wire using plant normal cold water converted into a unique multi-way interaction cleaning medium, generating extreme pressure and hydrodynamic cavitations displace of contaminants, used to clean and polish drawn wire at high speed in a totally GREEN application, in-line with wire drawing machine, exiting the unit completely dry.  
Applications include wire direct brass coating, copper coating, galvanizing, plating, Al and Cu cladding, painting, plastic coating, wire cleaning prior to heat treatment and coating applications including patenting, annealing, etc.
PWC cleaning system can be used in production of bright wire with mirror reflective  finish for decorative applications. -  PWC system 
- see 
Newsletter No.17 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

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Rod PDH Coating and Wire Lubrication Simplified and Improved : Unmeasurable Die Wear.
Wire rod in-line dry coating / lubrication by PDH phosphate free conversion coating creates a hard and ultra dense coat ( a thermally activated interfacial film ) that offers an extreme die wear performance, a virtually unmeasurable die wear rate, often reported to be  8 - 10 times lower than a conventional die wear. 
A typical die wear performance with mechanically descaled rod, H/C or L/C , drawn directly from uncoated bare rod ( without wet precoating chemicals ) :  PC strand wire,  0.89 %C, wire dia. 5.05 mm drawn at 6 - 7 m/sec, after 65 tons of wire drawn unmeasurable die wear in drafts No. 3 and 6.  Spring wire, frictionless drawing at 16 - 18 m/s, die wear rate =  0.1 - 0.3 micron per ton of wire drawn.
Now, the new coating and lubrication process eliminates the need for conventional rod and wire wet preparation ( including chemical cleaning / rinsing / wet pre-coating and drying ) ,  generating substantial saving ( + 55 % ) in the most demanding wire drawing applications, high carbon and low carbon.  -  PDH System. 
-  see 
Newsletter No.15 on  http://decalub.pagesperso-orange.fr/newsletter.htm   
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   Wire GREEN Cleaning Provides High-Glossy Finish , In-line, Exiting Totally Dry. 
Exceptional cleanliness obtained permits wire direct brass coating, copper coating, galvanizing and wire cleaning prior to heat treatment and coating applications including patenting, annealing, painting, plastic coating, etc.
PWC-S system performs drawn wire cleaning and polishing in-line with wire drawing machine at 6 to 12 m/s ( 1200 to 2400 ft/min ), providing extremely smooth corrosion resistant  wire in plating quality
The system incorporates new technology that enables normal plant water to be converted into a unique multi-action cleaner generating high pressure wetting / contaminants extreme pressure extrusion / hydrodynamic cavitations displace / and flush out , used to clean drawn wire at high-speed, providing wire glossy finish in plating quality exiting the unit totally dry.
 
-  PWC-S system - see Newsletter No.17 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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   Acid-free rod Dry Cleaning, Coating and Drawing ( DCCD ) process.
New substitute for acid in wire rod cleaning : the DCCD process is rapidly changing the current state of rod wet preparation and wire drawing , eliminating the need for acid cleaning / rinsing / wet pre-coating and drying , generating
substantial cost savings of 50 - 75 % in production of quality wires including spring wire, PC wire, plating wire, CO2 welding wire, etc .  DCCD process incorporates latest key technologies enabling rod mechanical scale removal, surface dry preparation at no speed limit and controlled pressure lubrication , allowing frictionless drawing in all drafts with die wear performance of 0.2 micron per ton of wire drawn , 18 m/s ( 3600 ft/min ) for spring wire, and in the most demanding applications with output of  2.2 - 3.6 tonne / hour from DCCD processed 0.73 - 0.87 %C mechanically descaled uncoated rod of 5.5 - 11 mm .  -  DCCD system  - see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm
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    Wire Dry Cleaned to White Metal at High Speed.  
BH-S system is an ultra-fine multi layer wire dry cleaning that provides a unique combination of wire cleanliness and surface finish at extreme speed, in-line, separating lubricant residue or other contaminants ( excess rust or scale ) from base material, displacing  contaminants by moving wire, exiting the unit super-clean of  white-metal appearance Applications include wire cleaning from lubricant residue prior to galvanizing, metallic coatings, Al or Cu cladding, heat treatment, etc., and rod cleaning prior to drawing.
Acid-free, caustic-free, without ultrasonic, without chemicals , this environmentally friendly system operates at virtually ZERO energy consumption providing significant process savings in production of clean H/C and L/C wires. In basic configuration, the BH-S units can be installed around the last drawing block, without modification of existing equipment, and can be operational within 1 hour -  BH-S system 
- see Products Page Item 5/ on  http://decalub.pagesperso-orange.fr/interest.htm 
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  Wire Cleaning for Plating Quality with Glossy Finish . 
PWC-S system performs drawn wire cleaning and polishing , in-line with wire drawing machine at 6 to 12 m/s ( 1200 to 2400 ft/min ). Exceptional cleanliness obtained permits wire direct brass coating, copper coating, galvanizing and wire cleaning prior to heat treatment and coating applications including patenting, annealing, painting, plastic coating, etc.
The system incorporates new technology which enables normal plant water to be converted into a unique multi-action high pressure wetting / hydrodynamic cavitations displace / flush cleaning liquid used to clean drawn wire at high-speed, providing wire glossy finish in plating quality exiting the unit completely dry
 
-  PWC-S system - see Newsletter No.17 on  http://decalub.pagesperso-orange.fr/newsletter.htm  
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Wire Rod Dry Coating / Lubrication - Eliminating the Need for Conventional Wet Pre-coating Chemicals
PDH system die-stand incorporates the most unique coating technology which thermally activates and  liquefies a powder compound to instantaneously form a high performance hard coat over  uncoated rod or wire, in-line in a completely dry application, at ZERO energy  consumption, generating lubricant exceptional thermal stability in all drafts at  highest drawing speed , virtually eliminating friction and wear in the most demanding wire drawing and wire forming applications including  0.90 %C wire. Obtained extra high density layer acts as rust / corrosion / oxidation inhibitor 
-  PDH system -  see  Newsletter No.15 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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  Rod and Wire Green Cleaning for Plating and Galvanizing 
SB system incorporates advanced technology that benefits both rod and wire cleaning applications where the wire ductility and surface finish are of prime focus, particularly in production of Spring wire, Rope wire, Bead wire, PC strand wire, Plating wire, Cold-heading wire, CO2 welding wire and all other H/C and L/C wire qualities, including 0.88 - 0.90 %C mechanically descaled bare rod processed at unlimited entry speed providing
smooth ultra-fine brushing, effectively separating hard contaminants or lubricant residue from base material, evacuating dispersed contaminants by moving wire exiting the unit dry and very clean of white-metal appearance , providing a clean wire that is ideal for direct galvanizing and metallic and plastic coating, including Al and Cu cladding  -  SB system ( EuroWire, March 2014 ). - see Newsletter No.16 on  http://decalub.pagesperso-orange.fr/newsletter.ht
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  Rod Scale and Rust Removal , Dry Preparation and Drawing at Extreme Speed.  A totally GREEN process.
Acid-free rod Dry Cleaning, Coating and Drawing ( DCCD ) process incorporates advanced technology that benefits wire drawing applications where the wire ductility and surface finish are of prime focus, particularly in production of Spring wire, Rope wire, Bead wire, PC strand wire, Plating wire, Cold-heading wire, CO2 welding wire and all other H/C and L/C wire qualities, including 0.88 - 0.90 %C mechanically descaled uncoated ( bare ) rod. Rod moisture, the No.1 enemy for wire drawing , is completely eliminated. 
DCCD
features the unique coating technology that thermally activates standard lubricants which are converted from solid into liquefied state, in a perfectly fused solution , instantaneously deposited on uncoated rod to form a high-performance anti-friction coat at unlimited rod speed , in-line , at ZERO energy consumption , generating lubricant exceptional thermal stability in all drafts at extreme drawing speed and in high temperature applications  
-  DCCD system  - 
see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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Wire Cleaning and Polishing for Plating Quality. 
PWC system performs drawn wire cleaning and polishing , in-line with wire drawing machine at speeds up to 12 m/s ( 2400 ft/min ). Exceptional cleanliness obtained permits wire direct brass coating, copper coating, galvanizing and wire cleaning prior to heat treatment and coating applications including patenting, annealing, painting, plastic coating, etc.
PWC cleaning system can be used in production of bright wire with reflective  finish for decorative applications.

PWC system incorporates new technology which enables normal plant water to be converted into a unique multi-action cleaning medium that provides combination of high pressure wetting / hydrodynamic cavitations displace / flush cleaning and drying used to clean drawn wire at high-speed, providing wire smooth glossy finish in plating quality exiting the unit completely dry, in a totally GREEN process. 
  
-  PWC system - see  Newsletter No.17 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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  Rod and Wire Lubrication Problems Eliminated.  
LVC/PDH ultra-high pressure rod dry coating / lubrication system provides an anti-friction full film coat  that maintains extreme thermal stability in all drafts at the highest wire drawing speed, in the most demanding drawing applications including high-tensile spring and plating wire, eliminating the need for phosphate, borax and their wet pre-coating substitutes. This is a GREEN and dry process operating at ZERO energy consumption and ZERO maintenance cost.
LVC/PDH system incorporates the latest key technologies automatically controlling all lubrication parameters, enabling the use of standard high melting  lubricants (
+ 240 C /  464 F ) which are converted from solid into liquefied state, in a perfectly fused solution , instantaneously deposited on uncoated rod to form a high-performance anti-friction coat at unlimited rod speed. 
System's typical applications : drawing speed of
18 m/s ( 3600 ft/min ) for spring wire, and the most demanding applications with output of  2.2 - 3.6 tonne / hour with 0.73 - 0.88 %C mechanically descaled uncoated rod of 5.5 - 11 mm.  -  LVC/PDH system - 
see  Newsletter No.15 on   http://decalub.pagesperso-orange.fr/newsletter.htm 
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   Extra Clean Wire at High-Speed.  
BHW system incorporates new brush cleaning technology which enables plant cold water to be converted into the most unique "micro-abrading liquid" agent providing hydro-dynamic cavitations at bristles / wire interface that smoothly impact drawn wire surface separating lubricant residue from base material, washing away dispersed contaminants by moving wire, exiting the unit super-clean of  white-metal appearance , enabling wire direct galvanizing and other metallic or plastic coatings.  
Acid-free, caustic-free, without ultrasonic, without chemicals , this environmentally friendly system operates at extreme speed and virtually zero energy consumption providing significant process savings in production of clean H/C and L/C wires. 
-  BHW system
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   Rod and Wire Dry Cleaning , In-line at High-Speed. 
SB ( Smooth-Brush ) system incorporates advanced technology that benefits both rod and wire cleaning applications where the wire ductility and surface finish are of prime focus, particularly in production of Spring wire, Rope wire, Bead wire, PC strand wire, Plating wire, Cold-heading wire, CO2 welding wire and all other H/C and L/C wire qualities, including 0.88 - 0.90 %C mechanically descaled bare rod processed at unlimited entry speed enabling output of 2.2 tonne/hour with 5.5 mm H/C rod.
SB system revolutionizes cleaning process by
smooth ultra-fine brushing, effectively separating hard contaminants or lubricant residue from base material, evacuating dispersed contaminants by moving wire exiting the unit dry and very clean of white-metal appearance , providing in a specific configuration a clean wire that is ideal for direct galvanizing and metallic and plastic coating, including Al and Cu cladding -  
SB system - see
Newsletter No.16 on  http://decalub.pagesperso-orange.fr/newsletter.htm
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Cleaning system provides Wire Glossy Finish
PWC-S system performs drawn wire cleaning and polishing , in-line with wire drawing machine at 6 to 12 m/s ( 1200 to 2400 ft/min ). Exceptional cleanliness obtained permits wire direct brass coating, copper coating, galvanizing and wire cleaning prior to heat treatment and coating applications including patenting, annealing, painting, plastic coating, etc.
The system incorporates new technology which enables normal plant water to be converted into a unique multi-action high pressure wetting / hydrodynamic cavitations displace / flush cleaning liquid used to clean drawn wire at high-speed, providing wire smooth glossy finish in plating quality exiting the unit completely dry .
 
-  PWC-S system - see Newsletter No.17 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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    Acid-free rod Dry Cleaning, Coating and Drawing ( DCCD ) process.
New substitute for acid in wire rod cleaning : the DCCD process is rapidly changing the current state of rod wet preparation and wire drawing , eliminating the need for acid cleaning / rinsing / wet pre-coating and drying , generating
substantial cost savings of 50 - 64 % in production of quality wires including spring wire, PC wire, plating wire, CO2 welding wire, etc .  DCCD process incorporates latest key technologies enabling rod mechanical scale removal, surface dry preparation at no speed limit and controlled pressure lubrication , allowing frictionless drawing in all drafts with die wear performance of 0.2 micron per ton of wire drawn , 18 m/s ( 3600 ft/min ) for spring wire, and in the most demanding applications with output of  2.2 - 3.6 tonne / hour from DCCD processed 0.73 - 0.87 %C mechanically descaled uncoated rod of 5.5 - 11 mm .  -  DCCD system -
see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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   Lubricant Provides Rod Anti-friction Coat at All Speeds .  
LVC/PDH ultra-high pressure rod dry coating / lubrication system incorporates the latest key technologies automatically controlling all lubrication parameters, enabling the use of standard high melting  lubricants ( + 240 C /  464 F ) which are converted from solid into liquefied state and instantaneously deposited on uncoated rod to form a high-performance anti-friction coat at unlimited rod speed , providing exceptional thermal stability in all drafts at the highest wire drawing speed, eliminating the need for phosphate, borax and their wet pre-coating substitutes. 
System's typical applications : output of  2.2 - 3.6 tonne / hour with 0.73 - 0.85 %C mechanically descaled uncoated rod of 5.5 - 11 mm. 
-  LVC/PDH system  - see  Newsletter No.15 on  http://decalub.pagesperso-orange.fr/newsletter.htm
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Wire Cleaning for Galvanizing and Plating Quality
BHW cleaning system incorporates the new innovative technology which enables normal cold water to be converted into the most unique liquid agent, benefiting from water physical properties including micro-abrading, cooling, lubrication and polishing, used to clean drawn wire in-line with drawing machine at 6 to 12 m/s ( 1200 to 2400 ft/min ) , at virtually "zero energy consumption" , providing extra-clean wire of  white-metal appearance enabling wire direct galvanizing and other metallic or plastic coatings. 
At exit, the system can be fitted with the PWC wet cleaning unit providing wire polishing and complete ( 100 % ) removal of residual moisture.
Applications include cleaning and polishing of all wire qualities drawn from rod with calcium and sodium lubricants , providing very clean wire in
bright glossy finish for plating quality.   -  BHW/PWC system 
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  Rod Dry Cleaning by Micro-Abrading , In-line at High-Speed . 
SB ( Smooth-Brush ) system incorporates advanced technology which continuously uses liberated rod scale mixed with brush ultra-fine hard bristles converted into a unique micro-abrading rotating pads, pressure adjustable, that finely impact rod surface to effectively remove residual solid contaminants from base material, evacuating contaminants by moving rod exiting the unit very clean of white-metal appearance at 3.2 m/s ( 640 ft/min ) for 5.5 mm H/C rod ( output of 2.2 tonne/hour ). 
SB system is an excellent substitute to acid-cleaning , operating at virtually zero energy consumption
World's No.1 wire manufacturer uses more than 50 SB units for m
echanically descaled rod cleaning , in-line, for the most demanding wire direct drawing applications including spring wire, PC strand wire, high-tensile rope wire, plating wire, cold heading wire, etc.  - SB system
see  Newsletter No.16 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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     Rod Preparation : Dry vs. Wet . Anti-friction High-melting Lubricants Eliminate Wet Pre-coating .
DCCD process revolutionizes wire drawing by replacing conventional rod wet preparation including acid cleaning / rinsing / wet pre-coating chemicals and drying by a new totally ( 100 % ) dry process. Added benefit is LVC ( lubricant viscosity control ) that perfectly fuses high-melting ( + 240 C /  464 F ) lubricants generating a unique high-performance anti-friction full film coat that maintains an exceptional thermal stability in all drafts at extreme speed, recommended in high temperature wire drawing applications with 0.83 - 0.88 %C mechanically descaled uncoated rod  -  DCCD + LVC system
  see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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DECALUB at Wire major Exhibitions ( Dusseldorf , Atlanta , etc. ) .  Visitors to Decalub stand will be able to obtain information on : 
Top 10 Innovations from Decalub that are rapidly changing current state of wire drawing , with a prime focus on in-line rod dry preparation at no speed limit ,  high-performance lubricant used as rod dry coating medium, elimination of wet pre-coating chemicals,  wire frictionless drawing, wire and rod GREEN cleaning as well as themes " Die and lubricant communicate together " ,  " Thermally activated lubricant forming anti-friction coat " , " Drawing speed continues to rise ", " High-performance lime-based powder lubricant ",  " Dies can have infinite life ", " Where the heat has gone " and " Wire cleaning : From matte to mirror reflective finish "
- basic information can be found in Newsletter Pages on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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  Rod Dry Cleaning : Drawing Speed Continues To Rise
DCCD acid-free descalers incorporate rod dry coating stand that features unique technology which thermally activates a solid high-melting lubricant to instantaneously form a single or dual layer of an anti-wear and anti-friction coat on mechanically descaled uncoated rod
( including 0.85 - 0.90 %C ), in a completely dry application, in-line , at zero energy consumption, generating lubricant exceptional thermal stability in all drafts at extreme drawing speed in high temperature applications  -  DCCD system  - 
see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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Wire Cleaning : Drawn Wire in Plating Quality                             
PWC-S system incorporates new technology which enables normal plant water to be converted into a unique multi-action high pressure wetting / displace / flush cleaning liquid used to clean drawn wire at high-speed, providing a smooth and bright wire finish in plating quality. System simultaneously performs wire cleaning and polishing, in-line with wire drawing machine, at 6 to 12 m/s ( 1200 to 2400 ft/min ). Exceptional cleanliness obtained permits wire direct brass coating, copper coating, and wire cleaning prior to heat treatment and coating applications including annealing, painting, plastic coating, etc. 
-  PWC-S system  - 
see Newsletter No.17 on  http://decalub.pagesperso-orange.fr/newsletter.htm ____________________________

    Wire Cleaning , In-Line at High-Speed . Simplicity and Cost-Effectiveness 
BHW system incorporates new technology which enables normal plant water to be converted into the most unique "micro-abrading liquid" agent  that smoothly impact drawn wire surface separating lubricant residue from base material, washing away dispersed contaminants by moving wire, exiting the unit super-clean of  white-metal appearance , enabling direct galvanizing and other metallic or plastic coatings.  
Acid-free, caustic-free, without ultrasonic, without chemicals , this environmentally friendly system provides significant process savings in production of clean H/C and L/C wires.
  -  BHW system

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Wire Lubrication : High-Melting Lubricants , Anti-Friction Coat, Corrosion Resistant. 
New high-melting lubricants are thermally activated to form anti-friction high-performance full-film lubricant coat , at no speed limit , at zero energy consumption. These new products enable demanding wire qualities to be drawn in much more economical way, replacing conventional rod wet preparation including chemical cleaning / rinsing / wet pre-coating and drying . When used with new totally dry DCCD process, high-melting lubricants generate the highest output : 2.2 - 3.6 tonne/hour with 0.83 - 0.85 %C uncoated / bare rod of 5.5 - 11 mm drawn in all applications up to 11 drafts.  -  Lubricants 

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  Rod Dry Preparation. High-Melting Lubricants for Frictionless Drawing :  Decalub's DCCD acid-free descalers incorporate rod dry coating system that operates with high-melting lubricants ( melting at temperature rage of 195 C - 240 C /  374 F - 464 F for H/C applications ) which are converted from solid into viscous liquid state to form a hard and  high-density anti-wear coat deposited on mechanically descaled DCCD processed bare rod , in-line, drawn directly at extreme speed , totally eliminating the need for wet pre-coating chemicals. This high-performance new coating , performed at zero energy consumption, maintains its thermal stability in all drafts enabling high-carbon wire rod ( including 0.85 - 0.90 %C ) to be drawn directly in 11 - 13 drafts at unlimited drawing speed , limited mainly by rod pay-off and wire take-up modes.  -   DCCD system Part 4  -  see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 
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Rod Preparation ( 100 % dry ) Eliminates Need for Wet Pre-coating Chemicals :  GP/PDH system incorporates unique technology which thermally activates a solid lubrication compound to instantaneously provide a single or 'dual' layer of anti-wear and extreme pressure protection that forms a solid coat on mechanically descaled bare rod, in-line, in a completely dry application, at zero energy consumption.
In H/C wire drawing applications ( including 0.83 - 0.88 %C bare rod ) , high melting lubricants ( 180 - 220 C / 356 - 428 F ) are converted from solid into molten / liquefied state, deposited in-line on mechanically descaled bare rod ( in 5 microseconds ) , eliminating conventional wet pre-coating chemicals , generating an exceptional thermal stability at the highest drawing speed , performing a high-density strongly adherent anti-wear multi-layer coat , automatically weight adjustable up to 10 g/m2.  -  PDH system - 
see  Newsletter No.15 on   http://decalub.pagesperso-orange.fr/newsletter.htm 
 
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Wire / Rod Dry Cleaning by Smooth-Brush ( SB ) system : Ultra-fine transversal brushing all around the wire circumference provides white-metal clean wire rod and guarantees unchanged wire rod surface physical properties, with no residual stress induced, no surface over hardening, no heat generation, enabling wire even plastic deformation and uniform metal flow within the die. 
Benefiting from its unique features, including polishing and adjustable 3 - 5 micron abrading, the SB system is used for in-line (a) :  Wire cleaning applications including metallic and plastic coatings, galvanizing ( with impressive Zn adherence ), welding ( chain, mesh ), annealing, painting, ... and (b) : Mechanically descaled rod cleaning in the most demanding wire direct drawing applications including spring wire, PC strand wire, high-tensile rope wire, plating wire, cold heading wire, etc.
   SB
system -
see  Newsletter No.16 on  http://decalub.pagesperso-orange.fr/newsletter.htm  

Wire Lubrication Eliminates Friction and Wear.  PDH system uses a unique combination of lubricant injection speed, pressure, temperature and viscosity to instantaneously convert solid lubricant into liquefied high-performance hard coat, at zero energy consumption, and maintain its thermal stability at a temperature of 195 C - 220 C ( 374 F - 428 F ) enabling high-carbon wire rod ( 0.85 - 0.90 %C ) to be drawn directly at extreme speed without phosphate and borax wet pre-coating chemicals. 
Typical applications, non-coated rod :  0.72 %C wire drawn to 2.35 mm ( .092") at 16 m/s ( 3200 ft/min ), PC strand wire drawn to 5.05 mm ( .199" ) at 6 - 7 m/s ( 1200 - 1400 ft/min ) with no measurable die wear after 60 tons of wire drawn ( wear rate = 0.1 - 0.3 micron/ton )
PDH system ,  Part 2
- see Newsletter No.15 on   http://decalub.pagesperso-orange.fr/newsletter.htm 

Wire / Rod Lubrication for Frictionless Drawing . Process enables fully automatic control of crucial lubrication parameters performing a high-density strongly adherent anti-wear coat for low through high carbon wire ( including mechanically descaled 0.88 - 0.90 %C bare rod ) instantaneously deposited , eliminating the need for conventional wet pre-coating chemicals. This prevents metal-to-metal contact at wire-die interface ( by a complete physical separation ), allowing frictionless drawing with die wear performance of 0.2 micron per ton of wire drawn.  100 % dry application operating at zero energy consumption and with no speed limit  -  PDH system ,  Part 1see Newsletter No.15 on   http://decalub.pagesperso-orange.fr/newsletter.htm 

Cleaning system provides wire glossy finish : Installed in last draft of a drawing machine to clean drawn wire from lubricant contaminants and obtain wire with a glossy finish . Operating with semi-solid high-viscosity products , containing anti-corrosion additives , isimultaneously performs surface cleaning and polishing, providing a high level of cleanliness of dry drawn wires, drawn with calcium or sodium lubricants - GP/PDH-CL system -


Cleaning and Lubrication of Wire .  Benefiting from its highly regarded and unique ability to control lubricant injection speed in a continuous "IN and OUT" closed or open circuit motion, the system performs :
(a)  Wire dry coating with a ultra strongly adherent anti-wear hard coat for spring wire, cold-heading wire ( coating weight of 10 g/m2 replacing phosphate coating ), benefiting from a completely fused and liquefied lubrication solution  deposited in 5 - 10 microseconds time, enabling frictionless drawing , through an ultra thin coat for plating wire.
(b)  In-line wire cleaning in last draft, operating with semi-solid lubricants providing
wire clean bright finish at 12 m/sec ( 2400 ft/min )  -  GPS/PDH system  -
Newsletter No.15 on   http://decalub.pagesperso-orange.fr/newsletter.htm 

High-Performance Rod Dry Coating for mechanically descaled H/C and L/C rods enables automatic control of lubricant thermal stability, at all rod speeds, operating at zero energy consumption, performing : 
(a) a high density strongly adherent anti-wear dual-layer coat for H/C wire, benefiting from high-melting solid lubricants forming a hard 8 - 12 g/m2 adjustable coat , and 
(b) a nano-layer coat for plating wire, and reflective wire cleaned in-line with semi-solid high viscosity products with anti-corrosion additives  -  DCCD system ,  Part 3
see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

Rod Preparation with No Speed Limit enables Frictionless Drawing : Dry process ( 100 % ) incorporates latest key technologies where rod scale removal, surface preparation and lubrication work in-line. Crucial lubrication parameters ( pressure / temperature / viscosity ) communicate all together in a sensitive multi-way interaction, forming an ultra-performant full-film solid lubricant coat ( 7 g/m2 for 0.88 %C rod ), eliminating wet pre-coating ( phosphate / borax / substitutes ), enabling high-speed drawing. Spring wire drawn at 18 m/s ( 3600 ft/min ) ;  5.5 mm 0.72 %C rod drawn to 2.35 mm at 16 m/s (3200 ft/min) ;  5.5 mm 0.84 %C rod drawn to 3.25 mm at 8.3 m/s (1660 ft/min)  -  DCCD system ,  Part 2 -
see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

Rod Dry Cleaning and Preparation Have Enormous Potential : Replacement of wet chemicals ( acid cleaning / rinsing / phosphate coating / borax coating / drying ) , by mechanical descaling and dry coating, revolutionizes wire drawing process. Solid drawing lubricant, converted into liquid layer, forms a strongly adherent full-film hard coat, adjustable ( 4 to 10 g/m2 ), permitting extreme drawing conditions : (a) new process eliminates pre-coating, enables frictionless drawing at high-speed with die wear of  0.10 - 0.30 micron per ton of wire drawn ; (b) achieves output of 2.2 tonne/hour with 5.5 mm mechanically descaled 0.83/0.88 %C bare rod, in a 100 % dry process - DCCD system , Part 1

Wire Lubrication Problems are Eliminated : Introduction of 'New-Coat' coating system boosts wire lubrication, achieving residual coat increased by 55 % to 60 % with H/C wire ( including 0.88 %C ) benefiting from 3-way interactions between lubricant pressure, viscosity and temperature, automatically controlled, completely eliminating pre-coating chemicals, creating ideal frictionless drawing conditions at highest speed. As a result of extremely smooth wire surface obtained, the same system can be used for wire cleaning providing glossy finish when used in final draft with soluble oil or paste  - GPS/PDH system 

Plating Wire : Wire drawn with 'New-Coat' and cleaned in-line in bright finish for plating quality, benefiting from the new automatically controlled frictionless nano-film lubrication / wire polishing  - PWC system  -  see Newsletter No.17 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

High Speed Dry Cleaning for Rod and Wire : Inline smooth ultra-fine brushing at no speed limitation provides extra-clean wire / rod of white-metal appearance , performing (a) : Rod surface specific morphology by micro-abrasion ( adjustable at will , 5 - 15 microns ) for inline dry coating / lubrication and direct drawing of mechanically descaled H/C rod ( including 0.90 %C ), and (b) : Drawn wire cleaning / polishing for metallic and plastic coating applications - SB system 
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Lubricant Viscosity Control ( LVC ) Revolutionizes Wire Drawing : Development of fully controlled ultra-high pressure rod dry coating / lubrication process eliminates frictional heating , enabling the highest drawing speed and a  low die wear rate of 0.30 micron / tone in manufacture of H/C ( 0.83-0.85 %C ) high-strength wire, drawn directly from mechanically descaled bare rod without wet pre-coating chemicals. In LVC/PDH version , the system offers unique high-performances in terms of speed , wire quality and cost efficiency, operating at Zero energy consumption  - LVC/PDH system - see Newsletter No.15 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

In-line Acid-Free rod cleaning and preparation system permits frictionless drawing of H/C wire, including 0.88 %C content : 100  % dry process incorporates new coating technique ( GP/PDH ) achieving 50-57 % thicker lubricant film, extremely adherent, enabling drawing ' at machine maximum speed (spring wire at 18 m/sec = 3600 ft/min ) with greatly improved wire fatigue properties - DCCD system -
see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

New Wire Cleaning system resulting from high speed rotary multi-head micro-brushing providing extra-clean wire, eliminating the most costly parameters in drawn wire cleaning process. Applications including wire plating, patenting, galvanising, wire "polishing" ( cold heading, chain welding ), plastic coating, AL cladding, etc.  -  SB ( Smooth Brush ) system - see  Newsletter No.16 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

Rod Dry Cleaning : Rod micro-roughing ( 10 to 20 microns, adjustable ) and new lubricant viscosity control 'eliminate pre-coating' chemicals enabling 'frictionless' drawing of H/C wire at 18 m/s ( 3600 ft/min ) directly from mechanically descaled bare rod ; also permitting wire 'bright' finishes in all L/C drawing applications  - DCCD system -  see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

One of the Greatest Performances in H/C steel wire drawing ever made : New dry process eliminates pre-coating chemicals, enabling frictionless drawing at high-speed with die wear of  0.30 micron per ton of wire drawn.  Output of 2.2 tonne/hour from 5.5  mm mechanically descaled 0.83/0.88 %C bare rod - for performances visit  http://pagesperso-orange.fr/decalub/photo.htm  

Wire Cleaning : Drawn wire in smooth bright finish for 'plating' quality, in-line, at 12 m/s ( 2400 ft/min ). Hermetically sealed 'zero emission' system, operating with a wide variety of environmentally friendly cleaning mediums containing the new rust preventive additives, supplies clean and polished wire of reflective appearance  - PWC system - see Newsletter No.17 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

Lubricant Viscosity Control ( LVC ) revolutionizes wire lubrication and drawing with virtually no speed limitation.  LVC is a unique dry coating process performing a hard lubricant coat for H/C spring wire and a light water soluble coat for plating wire, enabling 'frictionless' drawing with die wear of 0.20 micron / tonne of wire drawn. Pre-coating chemicals are eliminated for all H/C and L/C applications including 0.88 %C mechanically descaled bare rod  -  LVC/PDH system  - see Newsletter No.15 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

Acid-free Rod Cleaning, in-line dry preparation and wire full film lubrication ( physical separation at wire/die interface ), offer a total saving of 50-64 % in production of High-Carbon wire, enabling 5.5 mm dia. 0.83 - 0.88 %C bare rod to be drawn directly with an output of 2.2 tonne/hour  - DCCD system 
- see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm 

High-performance dry re-coating of drawn High-Carbon wire increases lubricant coat weight by 57 % in intermediate drafts with
sodium lubricants , without speed limitation, insures full film lubrication and smooth 'frictionless' drawing ; the same unit can be used for in-line wire cleaning applications ( plating wire, bright reflective wire, etc. )  - GPS/PDH system



 Newsletter pages : 
Each Newsletter describes a unique performance. 

Previous : Newsletter No.18 : " Integration of DCCD processed rod and molten/liquefied lubrication compound ( LVC system ) provides exceptionally adherent "plasticised" residual coating that generates 50 % lower exiting wire temperature, resulting in higher drawing speed and dramatically improved ductility with H/C high tensile wire"

Next to appear : " DCCD process eliminates traditional pre-coatings and enables direct drawing from 0.83 % C rod with virtually no friction in subsequent drafts, exiting wire temperature not exceeding 38C ( 100F ) at 13.5 m/s ( 2700 ft/min ). "
 
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Last modified :  18-02-2019.