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
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 those
obtained with conventional technique .
For more information on DCCD process see Newsletter No.18 on http://decalub.pagesperso-orange.fr/newsletter.htm :
" Wire Rod Acid-free Cleaning , Coating and Drawing - Clean,
GREEN and Dry , by DCCD process .
- 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
- 5.5 mm (.218") 0.83/0.85 %C rod drawn to 2 mm (.079") at 12 m/s
- 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
- 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
- L/C wire is drawn without speed limitation (25
m/s, or 5000 ft/min, and more) dependent mainly on rod pay off and wire take up
DCCD process operates at "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
4. DCCD process cleans, prepares and coats H/C and L/C rod in-line without speed
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
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
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 at zero
lubricant consumption waste, benefiting from a completely fused not
flaking coat. Remaining drafts are lubricated with lubricant in normal
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 ),
a one-step operation, very easy to apply, enabling high performances in terms of drawing speed and
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
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
- drawing die stand , and
- multi-roll anti-slipping pressure generator that greatly improves lubricant
particles adhesion , completely eliminating problems with lubricant powder
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
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 virtually without speed limitation,
benefiting even plastic deformation and uniform metal flow within
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 at "zero energy
consumption" and at "zero consumables cost", at a
production rate of 2.2 tonne/hour and at 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
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
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
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 45°C = 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
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
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)
drawn wire from lubricant residual in-line, prior to induction heat treatment,
with virtually "zero energy consumption" and "zero consumables cost" - PC
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
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 : firstname.lastname@example.org
Fax : 33 1 60 20 20 21