The Wire Association International, Inc.

The Wire Association International (WAI), Inc., founded in 1930, is a worldwide technical society for wire and cable industry professionals.
WAI HardWIRED

WAI HardWIRED

23 videos Last updated on November 20, 2019
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HardWIRED is WAI’s monthly e-mail newsletter which features a short, original video on an educational or training topic. The goal of these videos is to provide practical value that can translate directly to better performance on the shop floor.
1 S1.E0 Andy Talbot - Intro to WAI Hardwired 01:32

S1.E0 Andy Talbot - Intro to WAI Hardwired

Andy Talbot, President of the Wire Association International, introduces you to the new service WAI Hardwired. A monthly wire and cable video service.
2 S1.E1 Extruder Screw Cleaning 07:18

S1.E1 Extruder Screw Cleaning

Cleaning of an extruder screw at Nexans Energy in Chester, NY USA
3 S1.E2 Central Bursting 10:33

S1.E2 Central Bursting

This 10-minute video identifies the causes and corrections of central bursting defects, or cuppy wire. Presented by esteemed wire breaks expert Dr. Horace Pops, it includes detailed illustrations and an explanation of the stages of this type of break.
4 S1.E3 Wrap Testing & Torsion Twist Testing 08:56

S1.E3 Wrap Testing & Torsion Twist Testing

This video describes the setup and operation of a bench-top wrap tester for coil tempered spring wire and a torsion twist tester for brittleness, inclusions, and other flaws in ferrous and nonferrous materials. The processes are demonstrated on Sjogren Industries equipment.
5 S1.E4 Chatter 03:59

S1.E4 Chatter

This video (3:59) describes the natural vibration that causes chatter marks on wire between the die and draw block. Presented by respected machinery and drawing authority Don Young, it addresses remedies and key factors to ensure these fixes continue to work properly.
6 S1.E5 Measuring Dies 06:33

S1.E5 Measuring Dies

This video (6:33) explains how to perform some quick measurements to help determine if a die is within tolerance. Die Quip Corporation President Tom Maxwell outlines measurement of diameter, approach angle, and bearing length, as well as visual surface inspection.
7 S1.E6 Abrasion Damage 09:01

S1.E6 Abrasion Damage

This video (9:01) addresses surface abrasion to rod and wire products that can lead to breaks in drawing, rolling, or forming. Insteel metallurgist Chris Reeve details various potential causes of abrasions, and offers remedies to avoid these potentially damaging scenarios.
8 S1.E7 Cast and Helix 05:58

S1.E7 Cast and Helix

Don Young returns to WAI HardWired to explain how the measurements are taken and what adjustments can be made to the die box to change cast and helix on a standard draw block.
9 S1.E8 Hand Safety Pt I 08:26

S1.E8 Hand Safety Pt I

This video (8:12) details various methods and tools for mitigating hand injuries at General Cable Corporation’s plant in Williamsport, Pennsylvania. Part 1 describes precautions in areas that include reel changing, welding, sample cutting, and insulation stripping.
10 S1.E9 Die Angles 05:35

S1.E9 Die Angles

Esteemed industry experts Don Young and Tom Maxwell discuss the importance of having proper die angles in steep taper drafting. This video (5:47) offers some tips for finding the right contact points to prolong die life and maintain product quality.
11 S1.10 Plasma Surface Treatment 04:43

S1.10 Plasma Surface Treatment

In-line atmospheric plasma treatment cleans, etches, and functionalizes surfaces to improve wettability and bonding. In this video (4:43), Ryan Schuelke of Enercon Industries explains how plasma technology works, including tips for maximizing effectiveness.
12 S2.E1 Bull Block Calculations 07:44

S2.E1 Bull Block Calculations

Drawing expert Don Young explains how to determine what a bull block can actually pull. This video shows how to calculate not only what a given block is capable of, but also what die pull is needed to achieve a desired finish size.
13 S2.E2 Hand Safety Pt II 09:38

S2.E2 Hand Safety Pt II

The second part of a two-part series, this video explores more ways to mitigate hand injuries at General Cable Corporation’s plant in Williamsport, Pennsylvania. Part 2 describes safe approaches to shipping and packaging, cable cutting, and coil and reel handling.
14 S2.E3 Lubrication Maintenance, Part 1: Dry Powder for Ferrous Wiredrawing 08:08

S2.E3 Lubrication Maintenance, Part 1: Dry Powder for Ferrous Wiredrawing

David Gzesh of Blachford Corporation offers tips for monitoring and maintenance of dry powder lubricant for ferrous applications. In this video, he addresses factors that change the lube composition in the soap box along with issues affecting lubricant flow.
15 S2.E4 Annealing of Electrical Conductors, Part 1 11:30

S2.E4 Annealing of Electrical Conductors, Part 1

This annealing video addresses principles that apply to both ferrous and nonferrous materials, with an emphasis on copper conductors. Dr. Horace Pops discusses property changes during annealing, impurities, and the issues that chemical analysis can often overlook.
16 S2.E5 Lubrication Maintenance, Part 2: Wet Lubricants for Fine Ferrous, Copper, and Aluminum Wiredrawing 10:14

S2.E5 Lubrication Maintenance, Part 2: Wet Lubricants for Fine Ferrous, Copper, and Aluminum Wiredrawing

Part 2 of this two-part series on maintenance of lubricants focuses on lube controls in wet drawing applications. David Gzesh of Blachford Corporation returns with advice on tests for concentration, pH, conductivity, and microbes.
17 S2.E6 Annealing of Electrical Conductors, Part 2 08:35

S2.E6 Annealing of Electrical Conductors, Part 2

The second part of a two-part series, this video discusses continuous online strand annealing. Dr. Horace Pops returns to examine the effects of time and temperature on final properties.
18 S2.E7: The Competitive Advantage of Digital Manufacturing, Part 1 11:35

S2.E7: The Competitive Advantage of Digital Manufacturing, Part 1

In this first of two videos, Willem Sundblad of Oden Technologies details the stages for building intelligence into a system, and describes the potential for Industry 4.0 to improve production, increase efficiency, and eliminate waste.
19 S2:E8: The History of Wire Drawing 11:27

S2:E8: The History of Wire Drawing

This video examines the rich history of copper and wiredrawing, tracing developments and techniques through the ages. Dr. Horace Pops leads the discussion, which also includes some details on the development of continuous casting.
20 S2:E9:The Competitive Advantage of Digital Manufacturing, Part 2 09:51

S2:E9:The Competitive Advantage of Digital Manufacturing, Part 2

Willem Sundblad of Oden Technologies returns in this second of two videos on Industry 4.0. In this installment, he outlines the financial and practical benefits of using the cloud in automated data collection.
21 S2:E10 - Top 10 Most Frequently Cited OSHA Violations: Part 1 22:12

S2:E10 - Top 10 Most Frequently Cited OSHA Violations: Part 1

This first part of two videos examines five of the top ten violations most frequently cited by OSHA in spring and wire product manufacturing. OSHA safety consultant Greg Sipos breaks down topics like guarding and lockout/tagout to explain how each can be corrected.
22 S2:E11 - Top 10 Most Frequently Cited OSHA Violations: Part 2 10:23

S2:E11 - Top 10 Most Frequently Cited OSHA Violations: Part 2

This second (10:23) of two videos looks at more of the violations most often cited by OSHA in spring and wire product manufacturing. OSHA safety consultant Greg Sipos offers more advice on correcting issues that include personal and respiratory protection as well as lift trucks.
23 S2:E12 - Optimizing performance and life of wire die and other plant lubricants 14:54

S2:E12 - Optimizing performance and life of wire die and other plant lubricants

Richard Janosky from MRG Laboratories discusses the focus on optimizing performance and life of the wire die and other plant lubricants with periodic sampling and analysis. Including a case study at IWM International LLC for further explanation on best practices.