FSIN Analyst Day 2008 - Bimetallic Products

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Presentation given by Dustin J. Fox, Global R&D Manager, at Fushi Copperweld's 2008 Analyst Day held at Copperweld Bimetallics headquarters on Novemeber 18, 2008.

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FSIN Analyst Day 2008 - Bimetallic Products

  1. 1. Analyst-Investor Day Tuesday, November 18, 2008 Fayetteville, TN FUSHI COPPERWELD Bimetallic Products Presented By Dustin J. Fox Global R&D Manager
  2. 2. History of Copperweld • Rankin, PA. (1915) • Glassport, PA. (1927) (Molten welding of copper to steel was the early process) • Fayetteville, Tennessee – 1975 “green field facility” - CCA only – 1979 Solid Cladding CCS Clad lines installed • Fushi International acquires Copperweld, October 2007
  3. 3. Fushi Copperweld, Inc. Manufacturing Locations Telford, England Dalian, China Fayetteville, TN
  4. 4. Quality System • Quality Management Systems Certified to ISO 9001 • Fully equipped metallurgical laboratory with SEM (scanning electron microscope)
  5. 5. Bimetallic Wire • What is Bimetallic Wire? – A Substitute for a single metal – Outer metal is different from inner metal – Bond allows metals to act as 1.02mm CCS 40% 75X one when processing (drawing) – Ratio of metal thickness remains constant while drawing – Metallurgical bond at interface 5.83mm CCS 40% 14X
  6. 6. Metallurgical Bond Copper-Clad Steel (CCS) Copper-Clad Aluminum (CCA) Interdiffusion zone spans ~ 80 nm Interdiffusion zone spans ~ 50 nm 100 100 80 80 Compostion, wt% Compostion, wt% 60 Cu 60 Cu Fe Al 40 40 20 20 0 0 0 100 200 300 400 500 600 700 800 0 50 100 150 200 Distance, nm Distance, nm STEM-HAADF-XEDS As tested by University of Alabama Tuscaloosa, Alabama
  7. 7. Product Features  Bimetallic wires combine the features of dissimilar metals to achieve a cost and/or a performance advantage  Copper-Clad Aluminum CCA Copper - Conductivity of copper  (high frequency applications) - Low weight of aluminum - Substantial weight savings versus copper - Low scrap value (theft resistance) Relative length of identical weights of CCA and Copper wire  Copper-Clad Steel (Copperweld® Wire) - Conductivity of copper  (high frequency applications) - Strength of steel - Corrosion resistance - Fusing current similar to copper - Durability - Low scrap value (excellent theft resistance)
  8. 8. Bimetallic Wire • Production Methods – Solid Metal Cladding (Fushi Copperweld Process) – Electroplating – Liquid Metal Dipping – Molten Welding – Billet Extrusion
  9. 9. Solid Metal Cladding Copper-Clad Steel (CCS) Process Carbon steel rod Two strips of high purity copper Pressure & heat Metallurgical Bond Take-up Cooling
  10. 10. Bimetallic Wire Quality COPPERWELD (copper-clad steel) Low Carbon 21% 1500X of copper cladding on steel core 100X of Steel Core Poor Quality Producer (copper-plated steel) Low Carbon 21% Voids between copper plating and steel core 1500X of copper plating on steel core 100X of Steel Core
  11. 11. Bimetallic Wire Quality COPPERWELD® Low Carbon 40% Poor Quality Producer Low Carbon 40%
  12. 12. Bimetallic Wire Quality COPPERWELD® Low Carbon 40% Poor Quality Producer - Low Carbon 40%
  13. 13. Copper-Clad Steel (CCS) Applications  Telephone and CATV drop wire CCS CCS Cable  Catenary wire for electrified railroads CCS Catenary  Electronic lead wire CCS Lead Wires
  14. 14. Copper-Clad Steel (CCS) Applications – Con’t Grounding wire for electric power systems Lightning Protection Transmission System Building Ground Substation Grounding Buried Counterpoise Wire Grid Wire Distribution System Transformer Ground Pole Ground Wire Fence Ground
  15. 15. Copper-Clad Steel (CCS) Applications – Con’t CCS Tracer Wire  Tracer Wire Plastic Pipe  Automotive Wiring Harness  Detonation Wire CCS Wire
  16. 16. Solid Metal Cladding Copper-Clad Aluminum (CCA) Process High Purity Aluminum rod One Strip High Purity Copper Extreme Pressure & Cleanliness Metallurgical Bond Tube Seam Welding Pressure Take-up Aluminum Rod Bonding Drawing Die Drawing Cleaning Copper-Clad Tube Forming Aluminum Rod Copper Strip
  17. 17. Copper-Clad Aluminum (CCA) Applications – Coaxial Distribution Cable – Building Wire – Power Cables – RF Cables – Cellular Towers – Braid Wire – Data (LAN) Cables – Wiring Harness (power leads) – Magnet Wire – Automotive Battery Cables – Jumper/Booster Cables
  18. 18. High Frequency Signals • Signal only travels on outer surface of center conductor (skin effect) • Copper Clad Aluminum & Copper Clad Steel exceeds the minimum copper thickness for high frequency signals High Frequency Signal Steel or Aluminum Core Copper Cladding
  19. 19. Bimetallic Research and Development • University of Alabama’s Materials Metrology Research Program – One-Year Agreement with Provisions for Extension – Access to specialized materials experts and state-of-the-art research technology through UA’s Central Analytical Facility (CAF) • Copper-Clad Stainless Steel – Applications in highly corrosive environments with sensitive equipment – Non-magnetic, high strength characteristics • Copper-Clad Aluminum Tape (CCAT) • CCA Bus Bar • Copper-Clad Aluminum Magnesium Alloy (CCAM - Wire)
  20. 20. Copper-Clad Aluminum Tape (CCAT)  Solid Metal Cladding  One strip of high purity Aluminum  One strip of high purity Copper  Extreme Pressure and Cleanliness  Metallurgical Bond  RF Cables – Cellular Towers
  21. 21. CCA Bus Bar • Electrical Power Distribution Systems • 15%-20% Copper by Volume • Patented Method - Lower Cost vs. Molten Extrusion Method • AC Skin Effect – Direct Substitution of Copper • Typical Sizes (mm) – 30X3 – 40X4 – 50X5 – 80X8 – 100X10 – 120X10
  22. 22. Copper-Clad Aluminum Magnesium Alloy Wire (CCAM) • High Tensile Strength CCA – 30-40% higher than Standard CCA – New standards under development – 15% Copper by Volume • Use as Braid/Shielding Wire • Other applications and markets being developed

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