Bimetallic

Products

FUSHI COPPERWELD

Presented By

Dustin J. Fox

Global R&D Manager

Analyst-Investor Day

Tuesday, November 18, 2008

Fayetteville, TN

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

Fushi Copperweld, Inc.

Manufacturing Locations

Telford, England

Dalian, China

Fayetteville, TN

Quality System

• Quality Management Systems

Certified to

ISO 9001• Fully equipped metallurgical laboratory with SEM

(scanning electron microscope)

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

one when processing (drawing)

– Ratio of metal thickness

remains constant while drawing

– Metallurgical bond at interface

1.02mm CCS 40% 75X

5.83mm CCS 40% 14X

Metallurgical Bond

STEM-HAADF-XEDS

As tested by University of Alabama

Tuscaloosa, Alabama

0

20

40

60

80

100

0 100 200 300 400 500 600 700 800

Cu

Fe

Com

post

ion

, w

t%

Distance, nm

Interdiffusion zone spans ~ 80 nm

Copper-Clad Steel (CCS)

0

20

40

60

80

100

0 50 100 150 200

CuAl

Co

mp

os

tio

n, w

t%Distance, nm

Interdiffusion zone spans ~ 50 nm

Copper-Clad Aluminum (CCA)

Product Features

Bimetallic wires combine the features of dissimilar metals to achieve a cost and/or a performance advantage

Copper-Clad Aluminum

- Conductivity of copper

(high frequency applications) - Low weight of aluminum - Substantial weight savings versus copper - Low scrap value (theft resistance)

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)

Relative length of identical weights

of CCA and Copper wire

CCA Copper

Bimetallic Wire

• Production Methods

– Solid Metal Cladding (Fushi Copperweld Process)

– Electroplating

– Liquid Metal Dipping

– Molten Welding – Billet Extrusion

Solid Metal Cladding

Copper-Clad Steel (CCS) Process

Cooling

Take-up

Carbon steel rod

Two strips of high purity copper

Pressure & heat

Metallurgical Bond

Bimetallic Wire Quality

COPPERWELD (copper-clad steel) Low Carbon 21%

Poor Quality Producer (copper-plated steel) Low Carbon 21%

100X of Steel Core

100X of Steel Core

1500X of copper cladding on steel core

1500X of copper plating on steel core

Voids between copper

plating and steel core

Bimetallic Wire Quality

Poor Quality Producer Low Carbon 40%COPPERWELD® Low Carbon 40%

Bimetallic Wire Quality

COPPERWELD® Low Carbon 40% Poor Quality Producer - Low Carbon 40%

Copper-Clad Steel (CCS)

Applications

Telephone and CATV drop wire

Catenary wire for electrified railroads

Electronic lead wire

CCS

CCS Cable

CCS Catenary

CCS Lead Wires

Copper-Clad Steel (CCS)

Applications – Con’t

Grounding wire for electric power systems

Buried Counterpoise WireBuilding Ground

Lightning

Protection

Substation Grounding

Grid Wire

Fence Ground

Pole

Ground

Wire

Transformer

Ground

Transmission System

Distribution System

Copper-Clad Steel (CCS)

Applications – Con’t

Tracer Wire

Automotive Wiring Harness

Detonation Wire

Plastic Pipe

CCS

Wire

CCS Tracer Wire

Solid Metal Cladding

Copper-Clad Aluminum (CCA) Process

CleaningDrawing

Copper-Clad

Aluminum RodTube Forming

Tube Seam

Welding

DrawingPressure

Bonding

Die

Aluminum Rod

Copper Strip

Take-up

High Purity Aluminum rod

One Strip High Purity Copper

Extreme Pressure & Cleanliness

Metallurgical Bond

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

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

Copper CladdingSteel or Aluminum Core

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)

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

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

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