This page includes the following
Newsletters, see below :
- Newsletter No.18 :
" Rod Acid-free Cleaning , Coating and Drawing - Clean, GREEN and
Dry , by DCCD process : .. .... Rod Dry Preparation at ZERO Energy
Consumption .... Phosphate-Free Conversion Coating ........ "
- Newsletter No.17 :
" Wire Cleaning for Plating quality , by PWC system
: .....Glossy finish, Mirror Reflective Finish .... "
- Newsletter No.16 :
" Rod Rust and Scale Removal ,
Acid-Free Dry Preparation ,
by SB system : ....... Rod Dry Cleaning, Low Cost, Totally GREEN ...
- Newsletter No.15 :
" Wire Rod
Lubrication : Drawing Art of Steel Wire - Clean, GREEN and Dry , by
PDH system : ......... Rod Phosphate-Free Conversion
Coating / Lubrication, Replacing Phosphate, Borax and Wet Precoating, Output 2.2
- 4.9 Tonne/Hour ( 5.5 - 13 mm, 0.88 %C Rod ), Frictionless Drawing, ZERO Energy
Consumption, ZERO consumables cost, ......
- No.10 : ".... 300 tonnes per die ...."
- No.9 : ".... rod dry coating , ..... 125 % greater residual coat ,
.... frictionless drawing ...."
- No.8 : " .... galvanised H/C wire drawn virtually without Zn
loss on subsequent drafts .... "
Wire Rod Acid-free
Cleaning , Coating and Drawing -
Clean, GREEN and Dry -
( by DCCD process )
FIRST Rod Preparation and Coating
Process , Incorporating Abrasive
Particles ( Fines ) Capture , Is Changing the
World of Wire Drawing.
Rod In-line Preparation at Unlimited Speed , Scale
and Rust Removal .... Totally Green and Dry Process ....
Phosphate-Free Conversion Coating .... Immediate Cost Saving of 50
- 65 % 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 (
Moisture , Scale , Rust and Abrasive Fines ) ....
" DCCD Process Revolutionizes Wire Drawing :
Today, rod dry preparation cost
is 20 - 25 % of the cost of acid cleaned
and chemically coated rod "
and ECONOMIC EFFICIENCY vs. CONVENTIONAL MODE :
The Acid-free rod Dry Cleaning, Coating and Drawing ( DCCD ) process is
rapidly changing the current state of rod preparation and wire drawing,
enabling process users achieve dramatic cost saving (
in range of 60 - 75 % and more ) in production of drawn wire, including
Spring wire, Rope wire, PC strand wire, Plating wire, Cold-heading
wire, Galvanized wire, CO2 welding wire, AL clad wire, etc.
The DCCD utilises emerging technologies that achieve the most unique
scenario in modern wire drawing applications , making the process :
In-Line , Operating at ZERO Energy Consumption .
The DCCD process eliminates the need for conventional aggressive
cleaning chemicals and wet precoating chemicals , operating at virtually
triple ZERO in terms of Energy consumption , Consumables and
Maintenance cost, providing greater lubrication, hardly or no measurable
die-wear rate and improved performance. Thus dramatically
reducing cost per tonne of wire drawn , often reported to be 20
- 25 % of the cost of conventional process.
The DCCD process is reported to be of real simplicity, and
the most outstanding in rod preparation and wire lubrication. A number
of internationally recognized standard lubricants , dies and die stand
concepts are performing very well, benefiting from the DCCD unique
ability to control lubricant main features in terms of
viscosity, pressure and temperature, and thermal stability in all drafts.
Replacement of conventional rod wet
preparation, including acid cleaning / rinsing / wet pre-coating and
drying, by the new totally Dry Cleaning, Coating and Drawing ( DCCD
) process, generates the greatest amount of profit in
the most demanding wire drawing applications with high carbon and
low carbon wire, including 0.85 - 0.90 %C .
this photo shows Rod scale removal, surface preparation and drawing by DCCD process
For DCCD process performances see Topics Item 1 at http://pagesperso-orange.fr/decalub/photo.htm
1 / What is DCCD process ?
· DCCD ( Dry Cleaning, Coating and Drawing ) process is
used in all direct drawing applications from rod, including
0.85 - 0.90 %C mechanically descaled uncoated / bare rod drawn
without wet precoating chemicals.
· DCCD is used in the most demanding drawing
applications, allowing the highest drawing speeds, with all carbon
steel rods and wires, from mechanically descaled uncoated / bare rod,
including spring wire, rope wire, PC strand wirer, plating
wire, cold heading wire, CO2 welding wire, etc.
is a completely GREEN process
· DCCD is a revolutionary High-Performance steel
rod dry cleaning, coating and lubrication process, enabling
wire frictionless drawing at extreme speed.
is the first wire rod preparation and coating system with abrasive
particles ( fines ) capture and removal without interference
with die, achieving die wear of a unmeasurable
level ( about 0.2 micron per tonne ) , meaning the 3-body
abrasive wear is virtually eliminated.
· DCCD is a 100 % dry process,
incorporating latest key technologies where rod scale removal, surface
preparation and rod lubrication work in-line, eliminating the need for
phosphate and borax pre-coating chemicals and their wet substitutes, operating
at rod unlimited preparation speed.
· DCCD process operates at
"zero" maintenance cost as there are no acid, no hot liquid
tanks for rod pre-coating, no hot air blowers to dry wet rod, and the
process operates at virtually
"zero" energy consumption.
enables draw completely dry rod - this is an essential parameter in wire
2 / What does DCCD do
· DCCD achieves a high-performance wire rod dry coating /
lubrication with a completely fused liquefied lubricant deposited instantaneously
on rod uncoated surface.
· DCCD eliminates the most
destructive phenomenon in wire drawing process , namely :
- elimination of scale , rust
- elimination of moisture , the No.1
enemy for wire drawing
- elimination of two-body abrasive wear
· DCCD totally
eliminates rod moisture, the No.1 enemy
for wire drawing process, considered to be the second most
destructive lubricant contaminant - abrasive particles ( scale , rust ,
fines, etc. ) are considered to be the most destructive , also eliminated by
the DCCD process.
· DCCD exhibits
high-performance wire rod Phosphate-Free Conversion Coating ,
enabling molten / liquefied lubricant to penetrate into
the surface and become chemically and mechanically interlocked
providing a hard high-density
strongly adherent full film Anti-friction coat,
weight adjustable, totally eliminating the need for conventional wet pre-coating
chemicals - see attached photo below for wire coating appearance ( 0.85 % C
. - this photo shows Anti-friction coat
( phosphate-free conversion coating ) on
0.85 %C mechanically descaled DCCD processed wire rod drawn directly
without wet pre-coating chemicals
· DCCD prevents metal-to-metal contact at
wire-die interface, enabling frictionless drawing of H/C high-tensile wire and
L/C wire including 0.83 - 0.88 %C.
· DCCD provides smooth drawing at low
temperature, superior surface finish and greatly improved wire
· DCCD delivers anti-wear coat highly regarded
for spring wire cold forming ( and similar applications ).
· DCCD creates cold-heading wire
anti-friction anti-wear coat, enabling cold-heading applications from
single blow up to 4 - 5 die blow progress ( replacing phosphate
and its wet substitutes in a number of applications ).
· DCCD performs cold-heading wire anti-moisture
/ anti-corrosive transparent full film coat, maintaining clean bright
wire appearance ( Decalub can advise lubricant quality ).
· DCCD provides wire high-density coat highly
regarded for its anti-friction and corrosion resistance.
· DCCD operates with all
solid lubricants, including low-melting sodium-wax based (
for cold-heading wire ) through high-melting calcium and sodium based
products, melting at high temperature range of 195 °C - 240 °C
/ 374 °F - 464 °F for all H/C rod coating
· DCCD guarantees lubricant anti-wear
anti-friction properties, lubricant film thermal
stability in all drafts, and corrosion resistance benefiting from
high density residual
full film coat.
· DCCD processed wire for galvanizing
applications features greatly improved physical
properties of the Zn / Fe layer ( intermetallic alloy zone
) benefiting from enhanced wire surface ductility highly
regarded in wire galvanizing process, enabling more demanding wire forming
applications and wire drawing with virtually no Zn loss in subsequent
· DCCD eliminates
· DCCD operates at
unlimited rod entry / preparation speed, limited mainly by rod
pay-off and wire take-up modes.
· DCCD features triple ZERO in terms of energy
consumption, consumables and
3 / How does DCCD work ?
· DCCD equipment is extremely compact, incorporating
three sections : rod 2-roll scale cracking by reverse bending at
controlled elongation, rod smooth brushing all around the rod circumference for
excess scale and rust removal and rod ultra-high pressure dry coating
· DCCD operates in the most unique multi-way interaction between lubricant
high-pressure ( up to 350 bars / 5000 psi, adjustable at will ),
lubricant temperature, lubricant viscosity and lubricant injection at wire
speed. All these variables are automatically controlled, all
"communicating together" in an extremely sensitive way
generating wear resistant high-density coat.
· DCCD thermally activates lubricant and die to provide a high
performance anti-friction anti-wear coat, at "zero" energy
· DCCD instantaneously converts solid lubricant into a molten
/ liquefied solution, making complete lubricant fusion in closed loop
circulation, which is instantaneously deposited on base material / uncoated
rod to form a full film high-performance coating at all speeds.
· DCCD controls lubricant film thermal
stability at all speeds.
· DCCD provides lubricant consistent coat by
strong bonding on rod surface thus completely eliminating the need for
conventional wet pre-coating chemicals.
4 / How does DCCD perform ?
DCCD process operates with all powder lubricants,
Ca and Na based, independently on lubricant melting point, including melting
temperature range of 195 °C - 240 °C / 374 °F - 464 °F
for H/C rod coating applications, enabling the highest output : 2.2
- 3.6 tonne / hour with 0.73 - 0.85 %C mechanically descaled uncoated
rod of 5.5 - 11 mm dia., making the process of Great
Potential for steel wire industry.
DCCD is highly regarded in high speed drawing
applications providing frictionless drawing
- 100 % higher speed with mechanically descaled uncoated rod, eliminating
the need for wet pre-coating chemicals.
DCCD operates at extreme speed
H/C wire is drawn at 18 m/s ( 3600 ft/min )
DCCD enables die life of 200 - 220 tonnes/die
1st draft, with 0.83 - 0.85 %C 5.5 mm (.218") mechanically
descaled uncoated / bare rod drawn directly without pre-coating
chemicals, and 60 - 80 tonnes/die in finishing draft.
More performances can be found in Topics Item 1
DCCD achieves unmeasurable die wear
50 - 60 tonne H/C runs. One of a remarkable applications includes mechanically
descaled uncoated PC strand wire rod, 0.89 %C, wire dia. 5.05 mm
drawn at 6 - 7 m/sec : after 60 tons of wire drawn unmeasurable die wear in
drafts No. 3 and 6.
DCCD performs in frictionless regime with die wear
rate of 0.10 to 0.30 micron / tonne of wire drawn
, 5 to
8 times longer die life with Spring wire, Rope wire, CO2 welding wire, etc.
DCCD greatly simplifies wire drawing process
by eliminating friction heat
exceptional full-film lubrication in all drafts, benefiting from the most
unique fully controlled 4-way interaction between the pressure, temperature,
lubricant viscosity and lubricant injection speed ( the LVC/PDH rod coating
· DCCD generates wire lower exiting temperature, decreased
by min. 21 °C ( 70 °F ) on top of drawing blocks, as a result of
· DCCD provides smooth drawing, superior wire surface
finish enabling in-line wire cleaning for plating quality and
cleaning for reflective wire finish for decorative
5 / Value of DCCD process
· DCCD revolutionizes wire drawing process -
customers target total saving of 60 - 75 % and more in production
cost of drawn wire .
· DCCD has an Enormous Potential in rod
preparation and wire lubrication, resulting in a lower product cost,
improved wire quality and environmental benefits, operating
worldwide in the most demanding applications among the largest wire
· DCCD eliminates wire lubrication problems.
· DCCD eliminates wear by eliminating
· DCCD is
a 100 % dry process automatically controlled in operation, at all
speeds, without operator assistance.
· DCCD main items ( rod descaling, brushing and
pressure coating ) can be ordered separately.
· DCCD equipment is very compact, easy to
install in-line with existing wire drawing machine, and in its
basic configuration ( for 5.5 mm dia. rod ) it can be operational
within 1 hour.
Introduction of the DCCD process and equipment in its basic simple configuration can
be done from a maintenance budget without the need to get capital
approval. The major positive impact is immediate : elimination of acid,
phosphate and borax wet pre-coating, enabling drawing of dry rod
at extreme speed, longer die life, improved wire surface finish, etc.
IMPORTANT NOTE :
When we are asked to name essential , regarding mechanical descaling process,
where everything must be SMOOTH , we keep returning to the
Do NOT MUTILATE High Carbon rod, or Low Carbon rod , used for quality
products, by :
- excessive work hardening : two rod controlled reverse bends for rod
scale cracking are quite sufficient
- deep scratching : abrading / sanding belts and strong brush bristles may provide
high temperature and sparks that are often visible, ending by unavoidable formation of
martensite and product rapid fatigue failures ( as a consequence of residual stresses,
fines emmission, drop of ductility, etc ).
But scour boxes may also provide dramatic surface defects,
especially in high quality wire production where the surface finish is an
- intensive hammering : over-hardened surface by shot blasting,
extremely dangerous in multi draft applications with H/C wire .
- dipping descaled rod into water for dust removal or in-line wet
pre-coating without sufficient time for drying may have dramatic issues : rod moisture
is the No.1 enemy for wire drawing process
- Related information :
(1) - Wire Lubrication , High-melting Lubricants
A detailed list of lubricants is available for virtually every application.
The users are very impressed by the high performance of these products (
for Na based on H/C wire : melting point 240 °C / 464 °F,
high-performance EP additive 9 - 13 % , fatty acids 77 % , residual
moisture 1 - 2 % , etc. )
Please, contact Decalub for further information.
Wire Cleaning for Plating
PWC-S system )
From Drawn Dull to Wire Clean Glossy / Reflective Finish ,
Water Cleaned in a Totally GREEN Process
1/ What is PWC wire cleaning system ?
· PWC ( Pressure Wet
Cleaning ) system is used to clean drawn wire from lubricant
residual to obtain a bright and glossy finish in plating
incorporates new technology that enables normal plant water to
be converted into a unique cleaning medium generating high
pressure wetting / contaminants extreme pressure extrusion / hydrodynamic
cavitations displace / and contaminants flush out, used to clean drawn
wire at high-speed in a completely GREEN application.
· PWC simultaneously provides surface cleaning and
polishing, in-line, providing a high level of cleanliness of drawn
wire, without the need for acid, caustic and ultrasonic.
· PWC operates at all practical
speeds of wire drawing machine, exiting wire is perfectly dry.
· PWC system in a specific
configuration permits obtain drawn wire of a mirror reflective
photo shows the PWC-S wire cleaning unit in operation,
in a wire plating application
In a specific configuration the PWC system can be used in wire
cleaning for mirror reflective finish, recommended for
decorative wire applications, very resistant to corrosion.
photo shows the wire mirror reflective finish obtained
in a application drawn from mechanically descaled rod.
2/ What does PWC do ?
· PWC simultaneously performs wire
cleaning and polishing, in-line with wire drawing machine at 6 to
12 m/s ( 1200 to 2400 ft/min ).
· PWC generates extreme pressure all
around the wire circumference separating lubricant residue from base
material, washing away displaced contaminants by hydrodynamic
cavitations generated by the unit, enabling wire exit the unit very
clean in glossy finish of white-metal appearance
and totally dry.
· PWC's exceptional cleaning capability permits
wire direct brass coating, copper coating, and wire cleaning
prior to heat treatment and metallic coating applications
including patenting, annealing, zinc coating, painting, plastic
3/ How does PWC work ?
· PWC effectively loosens and removes lubricant
residue from the base material and is particularly recommended
for cleaning applications with wires drawn upon severe conditions,
resulting in increased heat and burned lubricant tightly bound to the
wire surface and embedded in micro cavities which are further flattened
leaving the wire surface perfectly smooth and polished to a gloss
· PWC washes away displaced contaminants from
cleaning chamber enabling moving wire to exit the unit completely
dry and very clean of white metal appearance.
· PWC can be used with a light emulsion including
a new corrosion preventive additive diluted at 3 - 5 % concentration,
recommended for wire decorative applications.
4/ How does PWC perform ?
· PWC is particularly
recommended for cleaning applications in which a conventional process
is inappropriate, especially with wires drawn upon severe conditions
resulting in increased heat and burned lubricant tightly bound to wire
surface and embedded in micro-cavities.
· PWC cleans drawn
wire from lubricant residue in applications prior to metallic and
· PWC is used in
cleaning applications including galvanizing, plating, annealing,
painting, welding ( chain, mesh, eliminating electric clamp
contact problems ), Al and Cu cladding, etc.
5/ PWC system performances / features :
- Environmentally friendly, clean and safe operation
- Cleaning medium : normal plant cold water, or very light
- In-line wire cleaning for plating quality
- Wire exits the unit perfectly dry,
- Wire smooth bright finish, can be obtained in reflective
appearance for decorative applications
- Mechanically descaled wire cleaned for plating quality
- CO2 dry drawn welding wire cleaned for plating finish prior to
in-line Cu coating
- CO2 welding wire cleaned for "copper-less" quality (
with rust preventive additives )
- Removal of lubricant residual embedded in micro cavities
- Intense cleaning energy generated by the PWC unit all around
- Fully automatic operation at pre-set flow and pressure
- Hermetically sealed "zero-emission"
system , no dust, no fume, no foam
- No air dryer required at unit exit, wire is perfectly
- Directly water cooled cleaning chamber enables
application with high tensile wire
- Unit installation on the last block of the wire drawing
machine enabling clean wire ( 100 % dry ) to be
- Simple to install and to use in-line with any wire drawing
6/ Value of PWC :
· PWC wire cleaning is a completely
· PWC is economical
and environmentally friendly.
· PWC offers significant downstream benefits and immediate
cost-savings in production of clean wire.
· PWC unit is compact and can be easily
installed on the finishing / last block of a wire dry drawing
· PWC system provides the ultimate combination of
simplicity and effectiveness : acid-free, caustic-free, without
ultrasonic, without chemicals, using normal plant cold water, or
very light emulsion.
and Scale Removal ,
Acid-Fee Dry Preparation -
( by SB
From Scale and Rust to White Metal Clean
Finish .... Output 2.2 - 4.9 Tonne / Hour ( from 5.5 - 13 mm
H/C Rod ....
In-Line .... Totally Clean, GREEN and Dry Process .... Using Scale
To Remove Rust at ZERO Consumables Cost ....
Cleaning Cost : 0.20 - 0.50 Euro per tonne .... Fully Automatic Brush
( Abrasive Pad ) Wear and Load Control , Adjustable at Will
Smooth Cleaning, Providing Satin Finish .... Direct Conversion
Coating .... No Moisture .... etc.
" SB System
Revolutionises Rod Cleaning :
Integrating over 95 % of liberated mill scale
converted into compact abrasive pads removing rust
providing high quality clean rod surface at
and maintenance cost ( at 0.20 - 0.50
Euro per tonne ).
WIRE ROD RUST : The Most
Destructive Natural Disaster in the History of Modern Wire Drawing
since the introduction of Decalub GREEN
Dry Cleaning Technologies, including SB System.
1/ What is SB (
Smooth-Brash ) system ?
· SB ( Smooth Brush ) system is the most
innovative mill rod dry cleaning method that removes excess of
rod scale and rust, converting over 95 % of rod coarse scale
into micro-abrasive medium ( compacted scale sharp particles ),
providing extreme efficiency and simplicity in rod dry cleaning
applications, H/C and L/C, including 0.98 %C.
· SB cleaned rod is used for the most demanding wire
drawing applications, including Spring wire, Plating wire,
Galvanised wire, PC strand wire, Al clad wire, Cold-heading wire,
CO2 welding wire, etc.
· SB is a high-performance multi-layer micro-abrading
cleaning process that provides smooth white metal clean
wire rod in satin finish.
· SB cleaning efficiency :
- This photo shows 3 rod samples commented as follows
- Sample A : Mill rod, originally manufactured for the
application, is descaled by simple riverse bending ( scale cracking
) and stored outside in rod-yard for a period of 6 - 8 weeks prior
to SB brushing by a single or double SB unit as per
samples B and C below. This rod shows a thin rust layer
covering almost 90 % of rod surface.
- Sample B : Excess of scale and rust removed by one (1) SB unit at
0.6 - 0.8 m/s ( up to 160 ft/min )
- Sample C : Excess of scale and rust removed by two (2) SB
units at 1.5 to 2 m/s ( up to 400 ft/min )
Remark : the two rods B and C have
the same surface finish.
SB is a totally GREEN cleaning process of great
potential for in-line rod dry cleaning
prior to drawing, highly regarded by the largest wire
· SB cleaned rod can
be drawn directly without conventional wet
pre-coating chemicals, benefiting from micron size rod
surface texture, adjustable ( 5 to 8 micron
surface profile ) , that consistently carries on the
lubricant into drawing die where it promotes a strong
· SB rod cleaning
and surface preparation completely eliminates rod
moisture, the enemy No.1 for wire
drawing process. Absence of moisture in rod preperation creates
huge potential for significant cost savings and
efficiency in wire drawing.
· SB is very compact and can be incorporated
in any existing operation to remove surface
contaminants and to promote consistent adhesion of subsequently
UNEQUALED RELIABILITY AND EFFICIENCY :
" SB system dry
cleans and prepares rod surface by creating extremely receptive
about 5-micron size bonding sites
of an homogenous and very compact organization ,
similar to phosphate crystalline morphology ,
greatly enhancing lubricant pick up ,
anchor effect and adherence. This in drawing process forms
a high performance
full film anti-friction lubricant
conversion coating that is found to
perform comparable to
than zinc phosphate, or any other in-line wet
pre-coating chemical .
Such a surface morphology is highly regarded in severe
applications, including H/C
drawing using Low borax or ZERO borax powders ".
· SB is an effective method to remove excess
of rod scale and rust.
· SB is used in-line with a simple 2-roll
reverse bending rod scale breaker / descaler that delivers
SB cleaned rod to wire drawing machine.
· SB uses liberated rod mill scale to remove
· SB is an excellent substitute for rod acid
cleaning , and for other wet cleaning chemicals.
· SB is used in-line with a simple 2-roll
reverse bending rod scale breaker / descaler that delivers
SB cleaned rod to wire drawing machine.
· SB is an excellent substitute for acid
cleaning , and for other wet chemicals, in
applications including both rod and wire cleaning.
· SB is an acid-free wire rod dry
cleaning process that operates in-line with drawing machine
providing lower operating costs by significant energy and
maintenance time savings, providing complete environmentally
friendly wire rod cleaning process.
· SB is an ultra-fine
multi-layer dry cleaning by transversal brushing / scale
abrasion all around the wire rod circumference, at high speed,
that provides a unique combination of wire rod
cleanliness and surface smooth finish.
This photo shows a double SB rod brushing unit in
2/ What does SB do ?
SB captures the rod scale converting it to
micro-abrading pads that remove excess of scale and
rust leaving the rod surface
clean of white metal appearance.
· SB revolutionizes
wire drawing process by eliminating the need for acid cleaning
and other aggressive wet cleaning chemicals.
· SB is rapidly changing the current state of
wire rod preparation, replacing conventional wet preparation by
the new totally dry GREEN technology.
SB continuously creates and maintains a high-performance
ultra-fine long life abrasive pad of extreme hardness ( mill coarse
scale particles ) , said to approach diamond hardness,
applied all around the rod circumference ,
operating at automatically controlled pressure.
· SB provides rod surface selective
low Ra texture ( about 5-micron size , adjustable )
that effectively vehicles lubricant powder from soap
box into the drawing die where it is chemically
and mechanically interlocked with the rod surface,
forming a hard and consistent anti-wear and anti-friction conversion
coating that is found to perform comparable to or better
than zinc phosphate in many demanding applications.
· SB achieves in-line direct drawing
from mechanically descaled uncoated bare rod , at
virtually ZERO energy consumption, ZERO consumables cost and ZERO
maintenance cost. Thus dramatically lowering production cost.
· SB is a very popular rod
cleaning system, acclaimed world wire among the largest
· SB provides white-metal clean rod
· SB keeps rod totally dry.
· SB cleaned rod allows for improved
wire ductility benefiting from total elimination of
hydrogen embrittlement and rod "wraps contact" areas
problems both encountered in conventional acid cleaning process.
· SB operates at ZERO maintenance cost.
· SB 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 during drawing for the most
demanding drawing applications including 0.98 %C mechanically
· SB provides high-performance wire rod
surface morphology, with selective texture adjustable
at will that is ideal for in-line rod dry coating
and drawing , replacing conventional phosphate and borax
pre-coatings chemicals and their wet substitutes.
· SB can be
supplied in triple unit configuration, highly regarded for
removing rod corrosion at extreme speed
applications, including 0.90 %C rod.
3/ How does SB work ?
· SB system incorporates revolutionary new
technology that continuously uses liberated rod
coarse scale, converted into micro-abrading cleaning pads
to effectively remove residual excess of rust
and scale from base material.
· SB incorporates high density ultra-fine
brush bristles that trap, retain and compact rod mill
scale creating high-performance abrading pads, continuously
renewed by the new scale that finely impact wire rod
surface separating rust and scale residue
from base material.
· SB operates in a multi-layer
cleaning mode that smoothly removes residual rust
without causing any damage to the rod surface.
· SB evacuates away dispersed contaminants by
moving rod, exiting the SB unit clean of
· SB utilizes liberated mill scale and
its extremely abrasive properties, ideal for the
application, delivering outstanding rod GREEN
cleaning process resulting in a dramatically low
maintenance cost and an exceptionally long brushes life time.
· SB is fitted with fully automatic
control of brush pressure and brush wear
compensation - no operator assistance is required.
· SB enables produce clean rod at a significantly
· SB operates at virtually triple
ZERO in terms of energy, maintenance and consumables cost.
4/ How does SB perform ?
· SB is used in rod
and wire cleaning applications including metallic
coatings, galvanizing ( with impressive Zn adherence ), plating
wire , cold heading, welding ( chain, mesh ), annealing,
patenting, painting, cleaning prior to induction heat treatment of PC
wire stabilizing, Al and Cu clad wire, etc.
· SB is used in mechanically descaled rod
cleaning applications for the most demanding wire
qualities, drawn directly without pre-coating wet
chemicals , including H/C wire ( 0.85 - 0.90 %C )
where the surface finish and wire ductility are of the
greatest importance, particularly in production of Spring
wire, PC Strand wire, high-tensile Rope wire, Bead wire, etc.
· SB provides rod adjustable 5 - 8
micron ultra-fine abrading and exceptional cleanliness with
surface morphology that is of great potential for wire
smooth drawing and in-line wire cleaning and polishing. The
surface texture obtained is highly regarded as it greatly
improves lubricant adherence and eliminates the need for wet
· SB effectively cleans descaled rod at
virtually ZERO consumables cost ( one set of
brushes cleans 100 - 120 tonnes of rod ), at high speed, enabling
remove rust and scale in wide range
of rod qualities, from fresh to older rod with rust
coverage up to 60 % and pit depth up
to 16 microns.
· SB removes rod rust and scale at Cost of 0.20 - 0.50 Euro per tonne , at no
speed limitation, using liberated mill scale compacted in
brush bristles forming a unique low cost high-performance abrading
/ cleaning pads that never clogs, continuously renewed by liberated
· SB cleaning system is used in
single, double or eventually triple unit configuration for
extreme operating conditions. However, the SB
in single unit configuration is highly regarded
for a number of standard applications.
· SB unit is very compact and can be easily
incorporated into existing operation.
· SB is maintenance free, enabling brushes
replacement in less than 1 min. without need for tools.
: Drawn Wire Cleaning , using the same SB system in a
specific operational mode ( use of brush bristles only ) ,
· SB system can also be used for drawn
wire cleaning, removing dry lubricant residue, or
other contaminants, prior
to direct galvanizing, be-metallic coating ( Al cladding ,
Cu cladding ), plastic coating, PC wire cleaning prior to heat
treatment, cleaning of annealed
wire, cleaning of patented wire, chain wire cleaning prior welding, mesh wire
cleaning prior to welding, etc., and in all wire cleaning
applications where the surface finish and wire ductility are of the
· SB system is used for in-line wire polishing in
cold-heading applications ,
· SB is also used in drawn wire cleaning
applications, in single or in
multi-brush configuration, providing
an extra-clean wire of white-metal appearance,
at high-speed, enabling wire direct galvanizing, promoting exceptional
Zn adherence and improved zinc-iron interface
properties, enabling galvanized H/C and L/C wires to be
drawn virtually without Zn loss in subsequent
5/ Value of SB
· SB revolutionises wire rod drawing
process.by eliminating the need for acid cleaning and other
aggressive wet cleaning chemicals.
· SB system has many advantages -
several hundreds units are in operation worldwide in the most
· SB is a totally GREEN dry
· SB is Effective Simplicity in
removing rust by liberated rod mill scale.
· SB operates at virtually triple ZERO
in terms of energy, maintenance and consumables cost.
· SB removes rod rust and scale at
Cost of 0.20 - 0.50 Euro per tonne
· SB cleaning system offers remarkable wire
mechanical properties and consistency, operating in-line
with wire drawing machine at no speed limitation.
· SB generates wire rod selective
surface texture that greatly improves
adherence of coatings ( dry lubricants, Zn coating, Al and Cu cladding,
· SB has a very
short pay-back period
· SB is incorporated in Decalub DCCD
( Dry Cleaning, Coating and Drawing ) process that eliminates
the most costly parameters in wire drawing process ,
including elimination of acid and wet pre-coating
chemicals, providing significant cost savings, environmental
benefits and productivity improvements.
Wire Rod Lubrication : Drawing Art
of Steel Wire - Clean, GREEN and Dry -
( by PDH system
Can Have Infinite Life.
It Is ALL
About Lubricant Film Configuration.
Green and Dry Process .... Phosphate-Free Conversion
Coating .... Immediate
Cost Saving of 50 - 65
% and more ....
Eliminating the Need for Phosphate, Borax
and Wet Precoatings .... Frictionless Drawing From
Uncoated Rod / Wire ....
Output 2.2 - 4.9 Tonne / Hour ( from 5.5 - 13 mm, H/C
Uncoated Rod ) .... Drawing at 18 m/s ( 3600 ft/min ),
Dies Do Not Wear ( Unmeasurable Die Wear of
0.1 - 0.3 micron / tonne, H/C ) .... Operation at ZERO
ZERO Maintenance Cost, ZERO Consumables Cost .... Eliminating
Lubricant Most Destructive Contaminants including
Moisture , Scale , Rust and Abrasive Fines ....
Wire Drawing :
Today, rod dry preparation cost
is 20 - 25 % of the cost of acid
and chemically coated rod "
PERFORMANCE and ECONOMIC
EFFICIENCY vs. CONVENTIONAL
of conventional wire rod wet preparation by the PDH system Phosphate-Free
changes rapidly the current state of wire drawing. The
major positive impact is immediate. Replacement of phosphate,
borax and their wet substitutes makes the PDH dry coating
process one of the most outstanding ever obtained in wire
- This photo shows the PDH unit installation on
the 1st block in rod dry coating / lubrication
1/ What is PDH system ?
PDH is a Clean, GREEN and Dry high-performance
steel rod and wire coating & lubrication process
that revolutionizes present state of wire drawing, enabling
wire frictionless drawing
( dies virtually do
not wear ) at extreme speed
0.88 - 0.90 %C
is the FIRST wire rod coating and lubrication system
with abrasive particles ( fines ) capture and
removal without interference with die, achieving
die wear of a unmeasurable
level ( about 0.2 micron per tonne ) , meaning
the 3-body abrasive wear is eliminated.
PDH dies can have Infinite Life. Benefiting
from the most unique
multi-way interaction between lubricant pressure,
viscosity , and in operation with a next
" white graphite " powder
, the PDH system creates a full film
phosphate free conversion coating highly
regarded in the
L/C and H/C applications"
· PDH is used in-line in the most
demanding drawing applications with all carbon steel rods and
wires, mechanically descaled or acid cleaned, uncoated or
pre-coated, in applications including Spring Wire, Rope
Wire, PC Strand Wire, Plating Wire, Cold Heading Wire, Galvanized
Wire, CO2 Welding Wire, AL Clad Wire, etc.
· PDH provides the next generation Phosphate-Free
Conversion Coating, making the process :
at ZERO Energy Consumption - that
eliminates the need for conventional wet precoating
chemicals, resulting in dramatic cost savings.
· PDH technology is reported to be the most
outstanding ever obtained in rod and wire lubrication,
generating a cost saving of 60 - 75 % and more in
production of drawn wire.
This photo shows the PDH unit in basic configuration
PDH wire rod coating / lubrication process
operates at ZERO maintenance cost
there is no wet pre-coating chemicals, no hot liquid
tanks for wire rod pre-coating, no hot air blowers to
dry wet rod.
PDH operates at ZERO energy consumption,
it is a unique energy saver
. PDH unit
recovers drawing heat energy and thermally activates powder
lubricant converting it into a molten / liquefied state
forming a high-performance dry carrier coat
exceptional adherence on wire surface.
PDH is an ultra-high pressure dry coating /
lubrication technology that thermally activates solid
lubricant to provide a high performance anti-friction
PDH is a GREEN and 100 % dry process, eliminating
the need for phosphate and borax pre-coating
and their wet substitutes, operating at
unlimited rod entry speed.
PDH is a totally GREEN and Dry
operating at triple ZERO
in terms of energy
consumption, maintenance cost and consumables cost ( no
additional coating compound is required ) , making the
PDH lubrication process one of the most
ever obtained in rod dry preparation
and wire lubrication.
PDH dramatically lowers operating costs.
2/ What does PDH do ?
· PDH achieves a high-performance wire
rod dry coating / lubrication, in one-step operation, with
completely fused liquefied drawing lubricant.
· PDH converts solid lubricant
into a molten / liquefied solution,
thermally activated, instantaneously deposited
on rod or wire, forming a high
Conversion Coating , a dry carrier coat that
offers an extreme die wear performance in all drafts.
enables molten / liquefied lubricant to
penetrate into the surface porosity and become chemically
and mechanically interlocked providing a hard high-density
strongly adherent full film anti-friction coat,
weight adjustable, that is found to perform comparable
to or better than zinc phosphate in the
most sever H/C applications, totally
eliminating the need for conventional wet pre-coating
chemicals - see attached photo below for wire coating
- This photo shows the Anti-friction
Coat on 0.85 %C mechanically descaled PDH processed wire drawn
directly without pre-coating chemicals
· PDH dry coats the rod in-line, totally
eliminating rod moisture the No.1 enemy for wire
· PDH prevents metal-to-metal contact at wire-die
interface, forming a physical separation at wire-die
interface, enabling frictionless drawing of H/C
high-tensile wire and L/C wire, including 0.83 - 0.88
· PDH provides smooth drawing, superior
surface finish and improved wire ductility.
· PDH delivers anti-wear coat highly regarded
for spring wire cold forming ( and similar applications
· PDH creates cold-heading wire
anti-friction high-density coat, enabling cold-heading applications
from single blow up to 4 - 5 die blow progress (
replacing phosphate and its wet substitutes ).
· PDH performs cold-heading wire
anti-moisture / anti-corrosive transparent full film coat,
maintaining clean bright wire appearance (
Decalub can advise lubricant quality / reference ).
· PDH provides wire rod high-density
coat, highly regarded for its anti-friction and corrosion
· PDH operates with all powder lubricants,
including low-melting sodium-wax based and high-melting
( 240 °C / 464 °F ) sodium calcium based
· PDH guarantees lubricant anti-wear
anti-friction properties, lubricant film thermal
stability in all drafts, and corrosion resistance
benefiting from high density residual coat.
· PDH operates at unlimited drawing speed,
limited mainly by rod pay-off and wire take-up mode.
PDH is supplied in 2 versions : (a) version GP/PDH for
1.6 - 8 mm wire rod dia. , and (b) version LVC/PDH for 5.5
- 13 mm wire rod dia.
3/ How does PDH work ?
· PDH operates in the most
unique multi-way interaction between lubricant
high-pressure ( up to 350 bars / 5000 psi,
adjustable at will ), lubricant temperature,
lubricant viscosity and lubricant injection at wire
speed without pressure fluctuation. All these variables
are automatically controlled, all "communicating
together" in an extremely sensitive way
generating a wear resistant high-density coat ,
consistent and weight adjustable at all speeds.
· PDH performs Lubricant
Viscosity Control ( LVC ), the MUST for modern
wire drawing operations. The LVC process is an
integral part of Decalub DCCD acid-free rod dry
preparation and in-line drawing at extreme speed, and at
unlimited rod inlet speed.
· PDH converts solid lubricant
into a molten / liquefied solution , making
complete lubricant fusion in closed loop circulation,
instantaneously deposited on rod or
wire - this generates a hard and
ultra dense thermally activated coating that
offers an extreme die wear performance.
· PDH controls lubricant
film thermal stability at all speeds, adjustable
even during drawing operation..
· PDH provides lubricant
consistent coat by strong bonding on wire rod surface
thus totally eliminating the need for conventional
wet pre-coating chemicals.
4/ How does PDH perform ?
PDH provides SMOOTH frictionless
and 35 - 100 % higher speed,
eliminating the need for wet pre-coating chemicals,
whatever the rod preparation mechanically descaled or acid
cleaned, bare uncoated or pre-coated.
PDH operates at extreme speed ,
wire drawn at 18 m/s ( 3600 ft/min )
PDH enables die life of +
200 - 220 tonne / die
in 1st draft with 0.83
- 0.85 %C 5.5 mm (.218") mechanically descaled
bare uncoated rod drawn directly without wet pre-coating
chemicals, and 60 - 80 tonne /
die in finishing draft. In the 1st draft,
die life of 500 tonne / die has been reported several
More performances can be found in Topics Item
1 on http://decalub.pagesperso-orange.fr/photo.htm
· PDH achieves unmeasurable die
wear in 50 - 60 tonne H/C runs. One of a
remarkable applications include mechanically descaled
uncoated PC strand wire, 0.89 %C, wire dia.
5.05 mm drawn at 6 - 7 m/sec : after 60 tons of wire drawn
unmeasurable die wear in drafts No. 3 - 4 - 5 and 6.
PDH performs in frictionless
regime with die wear rate of 0.1 to 0.3
micron / tonne of wire drawn
, 5 to 10
times longer die life in applications including
Spring wire, Rope wire , PC wire, CO2
welding wire, etc.
PDH increases wire quality ( surface
finish, ductility, etc. ) by eliminating
, benefiting from fully controlled
lubricant viscosity and temperature, enabling an automatically
controlled fusion of standard dry lubricants.
PDH generates wire lower exit
PDH creates a light ( nano-film
) water soluble coat, a must for wire cleaning
applications, providing an extremely smooth drawing
and a superior wire finish that boosts in-line cleaning for
, or wire
cleaning of mirror reflective finish
for decorative applications, both qualities
obtained by cold water used as cleaning medium.
PDH boosts an older machine
perform almost as a new one resulting in higher
reductions ( 41 % stainless steel , 30 % high
carbon steel ), higher speed, reduced number of
drawing blocks, drawing of cooler wire, etc.
5/ Value of PDH
PDH revolutionizes wire drawing
process. Customers report substantial saving in
production cost of drawn wire.
PDH has a Great Potential for
wire rod coating and lubrication, resulting in a lower
product cost, improved wire quality and environmental
benefits - several hundreds PDH units are in
operation worldwide in the most demanding applications.
PDH eliminates wire lubrication
problems, lowering drawing machine downtime by at
least 50 % .
PDH eliminates wear by
PDH performs at ZERO energy
consumption, at ZERO consumables cost and at
ZERO maintenance cost - it is a
GREEN 100 % dry process, automatically controlled in
operation at all speeds without operator assistance.
PDH is compact, easy to
install onto existing wire drawing machine and it
can be operational within 15 min.
PDH can be ordered
PDH can be install into
an existing soap box of a wire drawing machine,
and it can be moved from draft to draft
PDH is the Most Innovative Coating
/ Lubrication Process of the High Potential for
steel wire industry, reported by all users worldwide - it
is one of the most outstanding ever obtained in rod preparation
and wire lubrication.
tonnes/die ! One die produced 296 tonnes of wire drawn with
the PDH system in LVC version installed in drafts No.1 and No.5 of
an 8-block 900 mm dia. machine drawing traditionally cleaned and
surface prepared 0.80/0.83 %C rod from 12 to 5 mm (.472 to
.197") at 7 m/s (1400 ft/min) - P.C. strand wire quality.
- acid cleaned and phosphate coated rod
- concentric and regular die wear, with no scouring present
- original die dia. increased by 50 microns (.002")
- die wear rate : 0.09 micron/1 km of wire drawn (.000056 in./mile)
- dies in drafts No.3 and 4, with conventional die lubrication,
produced 250 tonnes each
- decreased wire temperature by 20°C (68°F) on top of block
- greatly improved wire ductility
- PDH/LVC unit in draft No.1 is operating with liquified and highly
pressurized coating/lubrication compound
- second PDH unit in standard version in draft No.5 is used for
Remark : It has been
reported, 420 tonnes/die in the 1st draft in a L/C
application from 5.5 mm (.218") dia. rod.
system performs rod/wire lubrication for frictionless drawing
Lubricant Viscosity Control (LVC) and the Ultra-High Pressure
Coating/Lubrication (PDH), applied in the 1st draft of a wire
drawing machine, offer a 'New way to draw steel wire in the 21st
century'. One of the unique features of the system is that it offers
a high-performance rod/wire coating in-line, with "zero energy
consumption", with no limitation of rod entry speed.
The LVC/PDH system "plasticises" the rod by a
pressurized hot liquefied lubricant and permits drawing with
virtually "zero friction" in subsequent drafts, with
just normal die-stands, resulting in a consistent and improved
wire ductility, higher drawing speed and longer die life.
The system is applicable on all steel rods and alloys :
mechanically descaled or acid cleaned, bare or precoated, bright or
galvanized (practically no Zn loss even with high tensile wire).
In production of high tensile H/C wire, including spring wire, bead
wire, ... , residual stresses are greatly decreased thus providing a
good fatigue property (no martensite, no strain aging ).
In virtually all current applications, traditional in-line precoatings,
including borax coating, are no longer required.
The LVC operates in closed circuit lubrication and features
"zero lubricant consumption/waste".
The sensitive control of lubricant viscosity (LVC/PDH) in the 1st draft
"plasticises" the rod/wire and allows an exceptionally
adherent, consistent and adjustable residual coating weight , up
- 16 g/m2 (.051 oz/sq.ft) in 1st draft on L/C wire
- 12 g/m2 (.038 oz/sq.ft) in 1st draft on H/C wire
The weight of residual lubricant film on finished wire is adjustable
up to 45 % of these values for applications in 6 to 8 drafts, up to 38 %
for applications in 7 to 9 drafts, etc ...
Specific requirements can be obtained easily (lighter coatings for
bright or plating quality wire, ...).
- 0.83 %C rod drawn from 9.5 mm (.375") to 3.5 mm (.138").
Ultra-high pressure coating/lubrication with one LVC/PDH unit in 1st
draft. Residual coating weight is 7.2 g/m2 (.023 oz/sq.ft) while with
traditional means coating weight is 3.2 g/m2 (.010 oz/sq.ft). This is
125 % greater residual coating on rod.
Residual coating on drawn finished wire is 3.02 g/m2 (.0096 oz/sq.ft),
versus coating weight of 1.71 (.0055 oz/sq.ft) obtained with traditional
means. This is 77 % greater residual coating on finished wire -
this wire is coiled on a former (stem) by a rotodie with no lubrication
in last draft, samples are cut from every coil produced.
- NiCr alloy (extremely abrasive product).
Laboratory inspection report : "No measurable increase of die size
after 11 km (6.82 mile) of 3.76 mm (.148") wire drawn reduced by 36
% in one draft.
In the same application, with traditional means, die size increases by
0.0127 mm (.0005"). This is a very severe die wear, corresponding
to a rate of 1.23 micron/km (.0008 in/mile) of wire drawn.
- 5.5 mm (.218") 0.78/0.84 %C DCCD processed
"green" rod is dry cleaned & surface prepared in-line at
"zero energy consumption" at production rates of 1.95 to 2.2
tonnes/hour, with the rod entry speed approaching 3 m/s (600 ft/min). In
this application, during 4 days (2-shift/day) no one break, no one weld
has occurred. The 5th day, in the 1st draft (LVC/PDH coating system) the
same die was still in operation - more than 180 tonnes per die.
The customer reports "this is another unique performance".
DCCD processed 0.72 %C rod is currently drawn to 2.35 mm in 7 drafts at
16 m/s (3200 ft/min) with an exceptionally consistent wire colour (matt
& dull) on all 7 blocks with 10 - 15 °C (50 - 59 °F) lower
temperature, compared with the standard acid cleaned and heavy borax
coated rod drawn at the same speed.
These unique performances are attributed to the new ultra-high pressure
coating by LVC/PDH system in the 1st draft in conjunction with
multi-melting lubrication products (standard Ca/Na based).
A remarkable residual coating weight on finished wire is obtained
in average of 2.60 g/m2 (.009 oz/sq.ft.) with a minimum of 2.48
g/m2 and a maximum of 2.75 g/m2.
Remark : The residual coating weight obtained with LVC/PDH system in
both applications is greater and more consistent than that
obtained with the traditionally acid cleaned and borax coated rod.
enables galvanized H/C wire to be drawn virtually without Zn loss
in subsequent drafts - another application in - frictionless
- 5.5 mm ( .218" )
galvanised 0.70 - 0.90 %C rod
- LVC/PDH unit in 1st draft,
reduction 23 - 26 % followed by taper drafting designed for equal
heat generation over the machine
- Finished wire : 1.64 mm (
.064" ) drawn at 12 m/s ( 2400 ft/min ), max. 2.5 mm (
.094" ) speed not reported
- Wire tensile : 1860 - 1960 MPa
( 264,770 - 279,000 psi )
- Galvanised 5.5 mm ( .218"
) rod drawn to 1.32 mm ( .052" ) at 15 m/s ( 3000 ft/min ),
minimum wire size drawn from rod 1.1 mm ( .043" ).
Reported advantages with the LVC/PDH
dry coating system :
- Zinc-iron interface properties are dramatically improved ( the same
phenomenon has been often reported in production of H/C cladded wire
- No more Zinc in the 1st soap box - Zinc is not
"caking" back, it perfectly follows the rod through the die
- Zinc loss on finished wire : 5
%, practically "zero"
- Die life : increased by 60 to
- Virtually "frictionless" drawing
Next Newsletter to appear : " DCCD processed 0.83/0.85 %C
rod is drawn directly, without precoating, at speeds that are higher
than speeds obtained with acid cleaned and traditionally coated rod.
Exiting wire temperature of wire drawn with the new process is 50 %
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