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Because of the frantic development pace of the Decalub's Dry Cleaning, Coating and Drawing (DCCD) process, latest performances (see Topics) will be presented on this page monthly to keep the readers up to date.


Topics / Performances ::

Previously presented Newsletters have described production parameters of the following topics.
Should you need further information on product specification and production variables, please contact us. 

1.  DCCD process & equipment with the new LVC (Lubricant Viscosity Control) technology permits obtaining performances which are greater than that being obtained with convential technique (using acid, borax, ...) :

- 5.5 mm (.218") H/C spring quality rod drawn to 1.3 mm (.051") at 18 m/s (3600 ft/min)
- 5.5 mm (.218") H/C rod drawn to 1.85 mm (.073") at 16 m/s (3200 ft/min)
- 5.5 mm (.218") 0.83/0.85 %C rod drawn to 2 mm (.079") at 12 m/s (2400 ft/min)
- 5.5 mm (.218") 0.72 %C rod drawn to 2.35 mm (.092") at 16 m/s (3200 ft/min)
- 5.5 mm (.218") 0.84 %C rod drawn to 3.25 mm (.128") at 8.3 m/s (1660 ft/min)

PC strand wire :
- 10.5 mm (.413") 0.85/0.88 %C rod drawn to 4.22 mm (.166") at 9 m/s (1800 ft/min)
-   8 mm (.315") 0.85/0.88 %C rod drawn to 3.10 mm (.122") at 10.5 m/s (2100 ft/min)
- 13 mm (.500") 0.85/0.88 %C rod drawn to 7 mm (.275") at 4.5 m/s (900 ft/min)

- L/C wire is drawn with no speed limitation (25 m/s, or 5000 ft/min, and more) dependent mainly on rod pay off and wire take up modes. 
DCCD process operates with "zero maintenance cost" ( there are no hot liquid tanks for rod pre-coating, no hot air blowers to dry wet rod ).

1.1.  DCCD processed 0.72 %C rod is currently drawn to 2.35 mm (.092") in 7 drafts at 16 m/s (3200 ft/min) with an exceptionally consistent wire colour (matt & dull) on all 7 blocks, with 15 C ( 60 F ) lower exiting wire temperature compared with acid cleaned and standard batch heavy borax coated rod drawn at the same speed.

2.  New Pressure Generator with LVC/PDH system performs an ultra-high pressure coating/lubrication of Zn coated H/C rod in the 1st draft and allows to draw the wire virtually without Zn loss on subsequent drafts.
 50 % greater residual Zn coating weight is obtained while drawing 0.80 %C galvanized rod from 5.5 to 9.5 mm (.218" to .375") down to finished sizes of 2.6 to 4.5 mm (.102" to .177") - high tensile rope wire quality. 
Galvanized H/C 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" ) 

3.  High-Performance steel rod dry coating/"plasticising" (LVC/PDH system), part of the DCCD process, allows H/C wire to be drawn directly from "green" rod at a high speed, without pre-coating.  
5.5 mm (.218") dia. H/C spring quality DCCD processed rod is drawn directly to 1.35 mm (.053") in 11 drafts at 18 m/s (3600 ft/min) with greatly improved wire ductility. At this speed, the wire color on all blocks maintains a dull and consistent matt appearance, the customer reports.  

4.  DCCD process cleans, prepares and coats H/C and L/C rod in-line without speed limitation, at  6 m/s (1200 ft/min) or more.  5.5 mm (.218") H/C or L/C rod can be processed at a rate of 4 tonnes/hour. 

5.  New Pressure Generator (LVC/PDH system) allows fully controlled high pressure coating/lubrication of Aluminium Clad steel wire in the 1st draft and dramatically reduces wire breaks. Aluminium/steel interface bonding conditions are maintained to the final size by a consistent "plasticised" exceptionally adherent lubricant residual. Aluminium Clad wire is now drawn at 50 % higher speed.

6.  Two PWC ( Pressure Wet Cleaning ) units in-line clean dry drawn CO2 welding wire from lubricant residual prior to Cu coating. The system is used for "plating" wire quality, "copperless" welding wire, ... 

7.  It has been reported that results obtained with DCCD processed fresh rod are better - the rod is cleaner -  than the results obtained with acid cleaned and precoated rod. This is attributed to unavoidable "wrap contact areas" (adjacent rod rings) in acid cleaning process, resulting in inconsistent scale removal.   
Plain carbon rods with light scale of 0.5 kg/tonne (1 lb/ton) - for instance for CO2 welding quality - or heavy scale of 5 kg/tonne (10 lb/ton) are DCCD processed at unlimited rod inlet speed, and are obtained exceptionally clean with no difference. 

7.1.  A unique 2-roll 360-degree wrap angle rod descaling concept (180 + 180), with 100 % controlled rod elongation in 2 planes, and in-line rod smooth surface preparation & coating prior to drawing (SB/LVC system), dramatically reduces wire residual stresses in production of high tensile H/C quality wire, resulting in greatly increased wire ductility.

Essential remark
: Any additional (absolutely unnecessary ) rod bend by a scale cracking roll will induce metal work hardening which may be detrimental in further processing, especially with  fine wire sizes, L/C or H/C.
A larger number of scale cracking rolls may double the pulling through force which in turn dramatically increases the quantity of embedded scale particles into the rod surface, unavoidably resulting in highly increased friction, die overheating and lubricant film deterioration. 
 
7.2. Decalub descaling system operates with 50 % lower pulling through force which in turn eliminates subsurface scale entrapped on rod surface by scale cracking rolls.
 No weld break is reported with all rod qualities processed, including 0.88 %C rod. 

8.  More than 90 % of standard dry lubricants perform very well in the most severe drawing applications, at all speeds. When their viscosity is controlled in "closed loop" lubrication with the LVC/PDH pressure dry coating system in the 1st draft, these products coat / "plasticise" and lubricate the bare rod in a one-step operation and create an exceptionally adherent and consistent full film anti-wear residual coat which allows high speed drawing of the high tensile wire with a zero lubricant consumption waste, benefiting from a completely fused not flaking coat. Remaining drafts are lubricated with lubricant in normal die-boxes. 
The system users worldwide, report the most of lubricants now dramatically gain in quality when used in conjunction with the LVC/PDH system enabling the bare rod up to 0.88 %C content to be dry coated/lubricated and drawn at a rod entry speed of 3.6 m/s (720 ft/min) in-line with a drawing machine, completely eliminating the need for conventional wet pre-coatings chemicals ( phosphate, borax, etc. ).
Laboratory reports, operating parameters and photos showing wire appearance on blocks are available and can be e-mailed upon request. 

8.1. Rod dry coating and wire lubrication today are performed in a new way ( 100 % dry ), in a one-step operation, very easy to apply, enabling high performances in terms of drawing speed and wire quality.
Powder particles size in the soap box  has no influence so that thin or coarse grain products perform with no difference at all speeds and with dies traditional geometry. There is no risk of tunneling nor pressure fluctuation at die entrance allowing the lubricants to perform a consistent residual film, adjustable at will on finished products : up to 2.60 g/m2 on H/C wire and up to 6 g/m2 on L/C wire ( LVC/PDH system ).
These unique features permit direct drawing of H/C wire from mechanically descaled bare rod ( DCCD process ), without pre-coating, at the high speeds, and enable to produce the wires in bright finish with a thin lubricant film obtained with sodium lubricants which are easy to remove by washing.     

8.2.  LVC/PDH ( = GP/PDH ) wire rod dry coating and lubrication system is a specific Pressure Die Holder ( PDH ), activated by passing wire ( pulled by wire drawing  machine ), controlling lubrication process variables communicating all together in an extremely sensitive multi-way interaction ,  potentially consisting of a :
- directly water cooled lubricant compression chamber used for Lubricant Viscosity Control ( LVC ) ,
- step-less lubricant pressure adjustment used for lubricant coating weight control, 
- drawing die stand , and
- multi-roll anti-slipping pressure generator that greatly improves lubricant particles adhesion , completely eliminating problems with lubricant powder flow. 
These unique features permit a complete fusion of lubricant powder, eliminating friction heat and thermal build up , as a result of automatically controlled lubricant viscosity and lubricant temperature, achieving : 
- hard anti-friction coat , weight adjustable , for Spring wire, Rope wire, PC wire, Cold-Heading wire, L/C wire, etc,  and
- light film coat , water soluble, for Plating wire, and other wire cleaning applications.
At wire-die interface , a high-performance full film coat provides physical separation of metal-to-metal contact enabling frictionless drawing . 
Die wear rate : 0.30 micron / tonne of wire drawn directly from 0.88 %C mechanically descaled bare uncoated rod, without wet pre-coating chemicals. 

LVC/PDH is an integral part of the " Acid-free Rod Dry Cleaning , Coating and Drawing " by DCCD process. For further information please see Newsletter No.18 on  http://decalub.pagesperso-orange.fr/newsletter.htm

8.2.1.  GP/PDH  wire intermediate dry re-coating / lubrication system increases lubricant coat weight by + 57 % in one intermediate draft with H/C or L/C wire drawn with sodium lubricants, enabling full film lubrication ( physical separation of metal-to-metal contact at wire-die interface ) and frictionless smooth drawing with no speed limitation, benefiting even plastic deformation and uniform metal flow within the die.
Full film lubrication eliminates hardened layer ( 20 - 50 microns ) on wire generated by friction, eliminating wire residual stresses.

8.3.   5.5 mm (.218")  0.78-0.84 %C green rod is dry cleaned & surface prepared in the 1st draft, in-line with a drawing machine, with a molten/"liquefied" lubricant with "zero energy consumption" and with "zero consumables cost", at a production rate of 2.2 tonne/hour and with the rod entry speed of 3.3 m/s (660 ft/min) -  DCCD + LVC/PDH process.
In this application, during 4 days (3-shift/day) no wire break, no weld has occurred. 
The 5th day, in the 1st draft the same die was still in operation. The customer reports this is "another unique performance" achieved with the DCCD technology.

9.  DCCD processed ( mechanically descaled ) CO2 welding quality rod of 5.5 mm (.218") dia. is drawn directly, in-line, without pre-coating chemicals, to a wire range of 1.8 to 2.1 mm (.070 to .083") at 18 m/s (3600 ft/min), in a 100 % dry process. Rod coating adjustable in weight up to 10 -16 g/m2 (0.051 oz/sq.ft.), extremely adherent and hard full-film coat greatly benefiting wire lubrication in the next wire wet drawing process.
Automatic control of lubricant viscosity ( LVC/PDH system ) by a 2-way interaction between lubricant pressure and temperature, continuously controlled within the PDH lubricant compression chamber, performs an anti-wear lubricant coat of 4 - 6 g/m2 (0.020 oz/sq.ft) on the finished dry drawn wire , essential for further wet drawing operation.  Exceptional wire high-density hard dry coat  wire permits 35 - 40 % higher output in wet drawing operation and allows for 0.8 mm (.031") to be drawn smoothly with a superior surface finish and better wire quality vs. a conventional method. Smoothly drawn wire is not difficult to clean in-line prior to copper coating.
A unique combination of essential process features permits production of CO2 welding wire that complies with the most demanding International standards.

9.1. Same consideration as mentioned above :  The 5.5 mm CO2 welding quality rod is drawn directly from mechanically descaled and DCCD processed rod , without wet  pre-coating chemicals, to 2.2 - 2.45 mm at 16 m/s ( 3200 ft/min ) , with an output of 2.2 tonne / hour.
Residual hard high-performance coat on 2.2 - 2.45 mm wire : about 4.5 g/m2, adjustable, allows for wire direct wet drawing down to 0.80 - 1.3 mm dia. at 12 m/s ( 2400 ft/min ). Greatly increased die life, enabling high-speed drawing and wire excellent finish. This wire is cleaned in-line with wire wet drawing machine prior to copper coating. 

10.  DCCD processed H/C rod is drawn at a temperature of 42 C ( 108 F), whereas the acid cleaned and borax coated rod is drawn with the same conditions at 65 C ( 150 F) - both wire temperatures are measured on spooler. 

11.  High tensile steel wire of 2100 MPa ( 298,800 psi) is drawn directly from DCCD processed "green" rod without pre-coating.  Die life, for H/C 5.5 mm (.218") rod : 180-200 tonnes/die, 50-80 tonnes produced with last die, depending on application.
 
12.  DCCD process dramatically reduces residual stresses as a result of drawing with virtually no friction (wire/die interface) and a low wire temperature (38 to 45C = 100 to113 F ), witnessed by a very consistent and remarkable wire ductility (39 to 41 torsions on 50 samples tested, 0.70 %C , 2.1 mm  = .082" dia.).     

13.  New and the most powerful rod dry coating technology (LVC/PDH system) operates automatically, at unlimited rod entry speed, and allows high speed drawing practice without the need for understanding of multi-way interaction between rod carbon content, rod inlet speed, rod surface roughness, lubrication pressure, die geometry and heat distribution. Main production variables are self adjusted.  

Remark
: For a new equipment, in a 0.81/0.83 %C application with the DCCD process & equipment in the most sophisticated configuration, the machine  Start Up time was only 25 min., including the time for rod welding.   

13.1.  Sensitive and fully automatic Lubricant Viscosity Control (LVC) system in the 1st draft performs an exceptionally adherent "plasticised" and consistent (not flaking) residual coating weight, adjustable at will up to 16 g/m2 (.051 oz/sq.ft.). Residual lubricant film on finished wire is adjustable up to 40 % of that value for applications in 7 to 9 drafts.  

13.2.  Residual coating weight obtained with LVC/PDH system on H/C wire is greater and more consistent than that obtained with conventional technology on acid cleaned and borax coated rod. 
Laboratory reports : H/C wire drawn from DCCD processed rod in 11 drafts, finished wire tensile 2150 MPa (306,000 psi), residual coating weight 2.60 g/m2 (.009 oz/sq.ft) - remarkable (!)- exceptionally regular die wear (concentric), no scouring present, excellent wire ductility.

Remark : Wire color on all blocks maintained a dull and consistent matt appearance - wire samples, or photos, may be obtained upon request

14.  DCCD processed 0.81/0.85 %C bare rod is drawn directly in-line, without pre-coating, from 5.5 mm (.218") to 1.85 to 2.05 mm (.073" to .080") at 12 to 14 m/s (2400 to 2800 ft/min) with virtually no friction, with wire exiting temperature of 38 C (100 F). The performance is reported : "exceptional, no more acid, no more borax, ... remarkable wire ductility and excellent surface conditions".

15. S-B (Smooth-Brush) system
(acid-free, 100 % dry) cleans drawn wire from lubricant residual in-line, prior to induction heat treatment, with virtually "zero energy consumption" and "zero consumables cost" - PC wire stabilizing.
Lubricant residual is reduced by 85/90 %, practically no fume is coming out from the heating tube. The system dramatically reduces time-consuming cleaning requirements on induction heating furnace and water cooling tank. Furnace cleaning interval is now five (5) times that required by conventional technique.


16. S-B system effectively cleans drawn wires from lubricant residual, in-line, in chain welding process. Acid cleaning is no longer required.

17.  300 tonnes/die produced in the 1st draft with the PDH system in LVC version (pressurised and liquefied coating), in application from 12 mm (.472") traditionally prepared 0.80/0.83 %C rod drawn in 8 drafts at 7 m/s (1400 ft/min) - PC strand wire quality.  

18. LVC/PDH system eliminates conventional pre-coatings and enables 0.85 - 0.88 %C mechanically descaled and DCCD processed bare rod to be dry coated/"plasticised" in-line with a 125 % greater lubricant residual, at rod entry speed of 3.3 m/s (660 ft/min), with "zero energy consumption", with die life exceeding 150 tonnes of rod processed.     

19. PWC (Pressure Wet Cleaning ) system cleans dry drawn wire from lubricant residual, in-line with wire drawing machine, at 6 to 12 m/s ( 1200 to 2400 ft/min ) dependent on wire size. Exceptional cleanliness obtained in smooth and glossy finish in "plating" quality permits wire direct Brass coating, Zinc coating, Copper coating, .... and wire cleaning prior to heat treatment applications.      


For further detailed information on production parameters, please contact us at :

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

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DECALUB, 2000