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This page includes the following Newsletters :

- Newsletter No.18 :  " Wire 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 .... "
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NEWSLETTER No.18            

Wire Rod Acid-free Cleaning , Coating and Drawing - Clean, GREEN and Dry  -  ( by DCCD process ) 

FIRST Rod Preparation and Coating Process With Abrasive Particles ( Fines ) Capture Is Changing Wire Drawing World.

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 ) .... etc.


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

PERFORMANCE 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 :
Green ,
Clean ,
Instantaneous ,
Controllable ,
Repeatable ,
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  
For photos of equipment see : http://www.wirefirst.com/newsdetail.php?ID=3845  


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.
 DCCD 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.
 DCCD 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. 
 DCCD enables draw completely dry rod - this is an essential parameter in wire drawing.


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 and fines
-  elimination of moisture , the No.1 enemy for wire drawing process

-  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 a 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 ductility.
 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 applications.
 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 drafts. 
DCCD eliminates lubrication problems.
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 maintenance cost.

 
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 / lubrication. 
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 consumption.
 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 at 35 - 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 in 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 at  http://decalub.pagesperso-orange.fr/photo.htm

DCCD achieves unmeasurable die wear in 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 thus providing 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 technology ).
DCCD generates wire lower exiting temperature, decreased by min. 21 C ( 70 F ) on top of drawing blocks, as a result of frictionless drawing.
DCCD provides smooth drawing, superior wire surface finish enabling in-line wire cleaning for plating quality and cleaning for reflective wire finish for decorative applications.  


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 corporations.
DCCD eliminates wire lubrication problems.
DCCD eliminates wear by eliminating friction.
 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.

6 /   IMPORTANT NOTE :  

When we are asked to name essential , regarding mechanical descaling process, where everything must be SMOOTH , we keep returning to the same : 

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 important parameter.  
- 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  -  http://www.wirefirst.com/newsdetail.php?ID=3079
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.
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NEWSLETTER No.17

Wire Cleaning for Plating Quality  ( by PWC-S  system ) - ttp://www.wirefirst.com/newsdetail.php?ID=3765
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 quality .
PWC 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 appearance.

   - this 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.

  - This 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 coating, etc.


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 finish.
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 plastic coatings.
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 emulsion
- In-line wire cleaning for plating quality
- Wire exits the unit perfectly dry, in bright glossy finish
- 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 wire circumference
- 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 dry
- 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 spooled directly
- Simple to install and to use in-line with any wire drawing machine
 

6/  Value of PWC :

PWC wire cleaning is a completely GREEN process.
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 machine. 
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.
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NEWSLETTER No.16

Rod Rust and Scale Removal , Acid-Fee  Dry Preparation  -  ( by SB system ) http://www.wirefirst.com/newsdetail.php?ID=3550


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 and
    providing high quality clean rod surface at ZERO consumables
    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 Industry is
No
Longer an Alarming Phenomenon, 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 corporations worldwide.
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 adhesive bond.
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 consistant adhesion of subsequently applied coating.
SB cleans and prepares rod surface by promoting micron size bonding sites that formes highly desired anchor effect for subsequent coating , including direct lubrication , pre-coating , etc. 
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 rust.
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 operation 


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 sharp long lasting abrasive pad , of extreme hardness ( mill coarse scale particles ) said to approach diamond hardness, applied all around the rod circumference, operating at automatically adjustable 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 wire producers.

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 descaled rod. 
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 white-metal appearance
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 reduced cost,
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, 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 pre-coating chemicals.
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 new scale.
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.

4.1/  Alternative : Drawn Wire Cleaning , using the same SB system in a specific operational mode ( use of brush bristles only ) , in-line.
 
SB system can also be used for drawn wire cleaning, removing dry lubricant residue prior to direct galvanizing, be-metallic coating ( Al cladding , Cu cladding ), plastic coating, PC wire cleaning prior to heat treatment, chain wire cleaning prior welding, mesh wire cleaning prior to welding, etc. 
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 drafts.


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 demanding applications.
SB is a totally GREEN dry cleaning process.
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, etc. ).
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.
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NEWSLETTER No.15

Wire Rod Lubrication : Drawing Art of Steel Wire - Clean, GREEN and Dry
 
 -  ( by PDH system ) - see  http://www.wirefirst.com/newsdetail.php?ID=3421

It Is ALL About Lubricant Film Configuration.

Totally Green and Dry Process .... Phosphate-Free Conversion Coating .... Immediate Cost Saving of 50 - 6
5 % 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 ), 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 , Scale , Rust and Abrasive Fines .... etc. 

PDH System
Revolutionizes Wire Drawing :
   Today, rod dry preparation cost 
   is 20 - 25 % of the cost of acid cleaned 
   and chemically coated rod "
________________________________

PERFORMANCE and ECONOMIC EFFICIENCY vs. CONVENTIONAL
MODE :  
Today, replacement of conventional wire rod wet preparation by the PDH system Phosphate-Free Conversion Coating 
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 rod lubrication.

   -
This photo shows the PDH unit installation on the 1st block in rod dry coating / lubrication application


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, including 0.88 - 0.90 %C
 PDH 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 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 :  
Clean , 
Instantaneous , 
Controllable , 
Repeatable , 
In-Line , 
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 as 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 with an 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 anti-wear coat.
PDH is a GREEN and 100 % dry process, eliminating the need for phosphate and borax pre-coating chemicals and their wet substitutes, operating at unlimited rod entry speed.
PDH is a totally GREEN and Dry process, 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 outstanding 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 a 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 performance dry carrier coat that offers an extreme die wear performance in all drafts.
 PDH performs a 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.
 PDH performs a 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.

   - 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 drawing.
 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 %C.
 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 resistance.

PDH operates with all powder lubricants, including low-melting sodium-wax based and high-melting ( 240 C / 464 F ) sodium calcium based products.
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 drawing 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 , H/C 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 times. 
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 friction heat, benefiting from fully controlled lubricant viscosity and temperature, enabling an automatically controlled fusion of standard dry lubricants.
PDH generates wire lower exit temperature.
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 plating quality , 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 eliminating friction.
 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 separately .  
 PDH can be install into an existing soap box of a wire drawing machine, and it can be moved from draft to draft where required.
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.

__________________________________________
__________________________________________

 

NEWSLETTER No.10

300 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.

Laboratory reports :
- 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 20C (68F) 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 "intermediate" coating


Remark : It has been reported,  420 tonnes/die in the 1st draft in a L/C application from 5.5 mm (.218") dia. rod. 
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NEWSLETTER No.9

LVC/PDH system performs rod/wire lubrication for frictionless drawing  

The automatic 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 to
- 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, ...). 

Laboratory reports :
- 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. 
_______________________________________


NEWSLETTER No.8 :

LVC/PDH system enables galvanized H/C wire to be drawn virtually without Zn loss in subsequent drafts - another application in - frictionless drawing  

- 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 production )
- 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 100%
- 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 % lower. "   
_____________________________________

Contact :
 E-mail :
info@decalub.com
 Fax : 33 1 60 20 20 21


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