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.

1. Analyst-Investor Day
Tuesday, November 18, 2008
Fayetteville, TN
FUSHI COPPERWELD
Bimetallic
Products
Presented By
Dustin J. Fox
Global R&D Manager

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. Fushi Copperweld, Inc.
Manufacturing Locations
Telford, England
Dalian, China
Fayetteville, TN

4. Quality System
• Quality Management Systems
Certified to
ISO 9001
• Fully equipped metallurgical laboratory with SEM
(scanning electron microscope)

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. 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. 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. Bimetallic Wire
• Production Methods
– Solid Metal Cladding (Fushi Copperweld Process)
– Electroplating
– Liquid Metal Dipping
– Molten Welding – Billet Extrusion

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. 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. Bimetallic Wire Quality
COPPERWELD® Low Carbon 40% Poor Quality Producer Low Carbon 40%

12. Bimetallic Wire Quality
COPPERWELD® Low Carbon 40% Poor Quality Producer - Low Carbon 40%

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. 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. Copper-Clad Steel (CCS)
Applications – Con’t
CCS Tracer Wire
 Tracer Wire Plastic Pipe
 Automotive Wiring Harness
 Detonation Wire CCS
Wire

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. 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. 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. 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. 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. 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. 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