A Canadian manufacturer of extruded, fabricated, and anodized aluminum recently unveiled plans to expand to the US Midwest.
Extrusion (Source: Dajcor Aluminum)
Dajcor Aluminum announced a financial commitment to locate their first U.S. aluminum extrusion operation near Hazard, Kentucky, where they plan to hire 265 full-time employees.
Mike Kilby, President, Dajcor Aluminum (Source: Dajcor Aluminum)
Located within a 500 mile radius of several major U.S. markets, the Hazard facility will increase Dajcor’s potential to expand their extrusion supply capacity to a wide range of North American industries, including automotive, light rail transit, marine, construction, transportation, office furniture, lighting, military, and renewable energy.
With 300,000 square feet of manufacturing space at the eastern Kentucky operation, Dajcor intends to be in a position to supply extruded and fabricated aluminum components by the end of 2019.
“We are excited to get going on this expansion project for Dajcor,” said Mike Kilby, president and CEO of Dajcor. “This project will not only expand our capacity but also our geographic reach as our first manufacturing facility in the USA. Perry County, in Eastern Kentucky, offers a ready workforce as well as excellent state-of-the-art fabrication training facilities within the area. This fits well with our ‘All Under One Roof’ aluminum extrusion and fabrication business model” (Source: Hal Rogers).
A global metals manufacturer recently announced sale agreements of its divisions to two buyers: two non-core forging facilities to a middle-market private equity investment firm, and its Cast Products business to a manufacturing group.
Allegheny Technologies Incorporated (ATI) has agreed to sell the two non-core forging facilities to Wynnchurch Capital, LLC for $37 million in cash, and its Cast Products business to Consolidated Precision Products Corp. (CPP).
John Sims, Executive Vice President, HPMC segment
The forging facilities, located in Portland, Indiana, and Lebanon, Kentucky, are part of ATI’s High-Performance Materials & Components (HPMC) segment. They use primarily traditional forging methods to produce carbon steel forged products for use in the oil & gas, transportation, and construction & mining industries. They will be sold to Chicago, Illinois-based Wynnchurch Capital, LLC, a leading middle-market private equity investment firm. The transaction will close during the second quarter of 2019.
The ATI Cast Products business unit is part of the High-Performance Materials & Components (HPMC) segment. It produces titanium investment castings that are primarily used by aerospace & defense OEMs in the production of commercial jet airframes and engines. A post-casting machining facility in Salem, Oregon, will remain with ATI and provide services to CPP and others. CPP of Cleveland, Ohio, operates 16 global facilities manufacturing products primarily for the aerospace, defense, and industrial industries and is a portfolio company of Warburg Pincus, a leading global private equity firm. The transaction, subject to customary regulatory approvals, is expected to close in the early part of the third quarter of 2019.
Robert S. Wetherbee, President and Chief Executive Officer of ATI
“[The forging facilities] transaction is consistent with our ongoing efforts to actively evaluate our business portfolio to ensure we’re focused on key growth opportunities for HPMC in the aerospace & defense end-markets, specifically in nickel and titanium products as well as in advanced iso-thermal and hot-die forgings,” said John Sims, Executive Vice President, HPMC segment. “With the sale to Wynnchurch Capital, these solidly-performing, independent operations will become part of a company with a proven track record of investing in, growing and successfully operating industrial manufacturing businesses.”
“ATI’s HPMC segment is at its best when we couple our materials science expertise and extensive forging experience to produce critical jet engine components in our world-class production facilities,” added Sims. “ATI’s Cast Products business is a good fit for CPP’s aerospace and industrial focused business portfolio.”
“We continue to actively evaluate our business portfolio to ensure that we are focused on the businesses that offer ATI the best combination of growth, profitability, and corporate synergies,” said Robert S. Wetherbee, President and Chief Executive Officer of ATI.
A family-owned heat treatment company, situated in Lombardy, Italy, has expanded its surface treatment capabilities to include Nitreg® controlled nitriding, Nitreg®-C nitrocarburizing, and ONC® in-process oxidation treatments.
GalvanoTechnik invested in a compact Nitrex system, model NXK-609, configured to process 23.5” diameter by 35.5” high (600mm by 900mm) workloads that weigh up to 1300 lbs (600 kg). The system promises to comply with the temperature uniformity requirements of AMS 2750E, in addition to meeting specifications ASM 2759/10, which would make it possible to achieve required metallurgical and mechanical properties for controlled nitriding. NXK series is designed to leave a reduced footprint and combines three process technologies into one platform.
GalvanoTechnik added nitriding and nitrocarburizing to its portfolio after engaging in deeper dialogue with its customers and identifying new needs. Six months after the installation and start-up of the Nitrex system, the company now supports customers in the defense and automotive industries to solve unique challenges related to wear and corrosion resistance as well as aesthetic surface finishes.
Applications range from firearms components, such as magazines and barrels, to automotive components. Working with GalvanoTechnik, the Nitrex Research & Technology team designed and tested process recipes to meet requirements for each part. All control recipes are stored to the Nitrex system process library; the operator simply selects the process for a specific application. The control system then takes over, automatically monitoring and adjusting parameters including time, temperature, atmosphere composition, and Kn nitriding potential.
Dr. Valery Rudnev, FASM, IFHTSE Fellow, was selected to be the Woodside lecturer at the most recent ASM Detroit Chapter meeting. The Woodside lecture took place on May 13, 2019, at Burton Manor in Livonia, Michigan. The title of the lecture was “Recent Theoretical and Practical Novelties in Induction Heat Treatment“.
Dr. Rudnev serves as Director of Science and Technology at Inductoheat, Inc. Known within the ASM Int’l and among induction heating professionals as “Professor Induction” for his 40+ years of experience in the heat treating industry, Dr. Rudnev centered his Woodside lecture on recent theoretical and practical novelties in induction heat treatment. He also unveiled common mispostulations associated with induction heating and frequently overlooked metallurgical subtleties.
Thermal processing by means of electromagnetic induction continues to grow at an accelerated rate, replacing alternative processes. Today’s metalworking and heat treating industry must quickly adjust to a rapidly changing business environment, maximizing cost effectiveness, process flexibility, and energy efficiency, yet satisfy continuously increasing demands for higher-quality products, equipment longevity, and environmental friendliness.
Induction heating is a multifaceted phenomenon comprising a complex interaction of electromagnetics, heat transfer, circuit analysis, power electronics and metallurgical phenomena that are tightly interrelated. Novel designs have appeared quite regularly.
The Woodside Lecture is named after William P. Woodside, who founded the American Society for Materials (ASM Int’l.) in Detroit in 1913. Each year, the chapter honors an outstanding member of
the ASM community by asking them to give the annual Woodside Lecture.
Dr. Rudnev holds more than 50 patents and inventions (U.S.and International) and has appeared in more than 250 engineering/scientific publications. He also frequently contributes content to Heat Treat Today. His most recent series, “Equipment Selection for Induction Hardening: Continuous and Progressive Hardening” can be found on Heat TreatToday’s website or in Heat Treat Today’s quarterly print editions.
Photo Caption: (from left-to-right) Dr. Robert C. McCune, FASM (Tech Chair of this event), Dr. James Boileau, ASM Detroit Chair 2018-19, and Dr. Valery Rudnev, FASM, IFHTSE Fellow (the Woodside Lecturer)
When heat treating complex parts, such as aerospace and defense components, businesses in the industry rely on an accreditation agency to enforce high standards to ensure safe, reliable products.
The Nadcap program:
Keeps aircraft in the sky, submarines underwater, satellites in orbit and weapons systems functioning as intended
Certifies heat treaters to conduct business in the aerospace and defense industries
Replaced the expensive and inefficient individual supplier audits aerospace and defense OEMs historically conducted on their own
Sets strict requirements regarding all aspects of heat treat operation.
“Nadcap requirements are quite prescriptive. Other industry standards programs give suppliers varying amounts of leeway en route to achieving the benchmarks they set. Nadcap features no such liberty. It’s their way or the highway.” – Paulo
These are professional-level spaces where heat treaters from industry sectors can discuss relevant issues and ideas, and Heat TreatTodaywill regularly provide content, keeping members current on the latest technologies, products, processes, and discussions. Be sure to check out Leaders in Automotive Heat Treat, in anticipation of our upcoming Automotive print edition. Join a group today!
A leading full metal shapes solutions provider has announced the opening of its new North American Powder Metallurgy Headquarters and Additive Manufacturing (AM) Customer Center. The 38,260 square foot facility, located in Auburn Hills, Michigan, expands the company’s global 3D printing network and extends its scope of in-house powder metallurgy capabilities.
GKN PM Powder Metal Compaction Press (Source: GKN Powder Metallurgy)
Housing over 80 employees from the three GKN Powder Metallurgy’s businesses, Hoeganaes, GKN Sinter Metals and GKN Additive, the space is designed to inspire teamwork and enhance exceptional customer experiences. The building includes 20,700 square feet of collaborative working areas and 17,700 square feet of shop floor space to complete the cohesive working environment.
“We are excited to start a new journey in Auburn Hills with a space that is dedicated to our team, our community and the advanced technology we create for our customers,” said Reid Southby, President, GKN Sinter Metals Large Segment. “This building reinforces our commitment to the North American market and continued global growth.”
The building includes a 3,200 square foot AM Customer Center, equipped with two EOS M290 Direct
GKN Powder Metallurgy celebrated the opening of its North American PM Headquarter and AM Customer Center with an internal celebration on April 8.
Metal Laser Sinter (DMLS) printers. The DMLS machines incorporate powder bed fusion technology, creating functional prototypes within a two-week lead time and allowing customers to test factors such as usability, ergonomics, manufacturability and materials in the early stages of the development process.
“GKN Powder Metallurgy is at an exhilarating point in its journey of growth and innovation,” Southby added. “We now have the opportunity to provide our customers and strategic partners with local and exceptional support on all fronts of our business.
A large North American supplier of refractory products and services is responding to domestic steelmakers’ increased capacity and solving their refractory challenges through several new initiatives.
Mirroring its steel customers’ investments to boost production capabilities and upgrade facilities, HarbisonWalker International (HWI) is investing to increase capacity by 25 percent in 2019 at key steel refractory facilities. In fact, approximately one-half of HWI’s capital investment dollars will have a direct positive impact on its steel industry customers. Much of the investment will be at its White Cloud, Michigan facility, which manufactures refractory products primarily for steelmakers.
HWI Announces Investments and Digital Refractory Transformation at AISTech 2019
This is the latest in a series of capital investments that HWI has made at White Cloud over the past three years. In 2018, HWI integrated new equipment and technologies to modernize the facility.
The 2019 investment includes expansion to accommodate new warehouse and shipping space, which is being constructed with American-made steel. Additional manufacturing space will house new production technologies, including a new brick press and packaging line, manufacturing technologies that improve production efficiency and worker safety.
“The improvements will further optimize production, product quality, and delivery efficiencies for our steel customers,” said Carol R. Jackson, Chairman and CEO, HarbisonWalker International. “The new press and warehouse increase our capacity to supply our industry-leading products including mag carbon brick for steel ladles, electric arc furnaces (EAF), and basic oxygen furnaces (BOF). The new packaging line allows for increased handling safety and provides quality control benefits associated with our product.”
One year after announcing its plan to significantly invest in monolithic refractories manufacturing, HWI built and opened a new, state-of-the-art facility in South Point, Ohio in 2018. It is North America’s most technologically advanced refractories plant and one of the top globally. Featuring state-of-the-art processes and technology, the South Point plant is now fully operational and supplying steel industry products.
In addition to physical expansion and technology integration in its plants, HWI is evolving the refractory industry for the 21st century by taking a holistic approach to advancing its use of data. HWI is aggressively initiating programs to help customers transition numerous decision-making processes from experienced-based to data-based, through use of various sensor and data acquisition systems, for instance.
Through the expertise of its team and strategic partnerships with industry leaders, HWI is employing sensor technologies, such as infrared cameras, and also utilizing three-dimensional laser measurement to make digital twins of physical assets. These technologies, along with ‘edge’ software that can access datasets from various plant level sources, are helping HWI develop tools to increase product campaign life and improve worker safety. Performance data will also benefit future generations of HWI products.
The outcomes for steelmakers include closer collaboration for customized products and continuous improvement, optimizing throughput and analytical insights to find even more significant cost savings.
“HWI is working to transform data into process improvements and business intelligence that help steel industry customers work safer and smarter, with even better tools for knowledge sharing,” noted Jackson. “Combining our digital transformation with HWI’s proven products and the industry-leading expertise of our field services team, we’re effectively positioned to deliver for our steel customers today and in the future as our industries evolve together.”
HWI has also recently innovated and patented new functional product solutions that are helping steel customers further reduce downtime and increase performance. These solutions allow for faster, easier installation with improved ergonomics.
In addition to its products, HWI also provides around-the-clock support from the most extensive service team in the U.S. and offers dedicated iron and steel application specialists who provide highly customized solutions.
Earlier this spring, a heat treat equipment organization appointed several professionals to new leadership roles.
Established in 1929 to meet the need for effective group action in promoting the interests of industrial furnace manufacturers, The Industrial Heating Equipment Association (IHEA) has expanded and currently includes designers and manufacturers of all types of industrial heat processing equipment used for the melting, refining and heat processing of ferrous and nonferrous metals and certain nonmetallic materials and heat-treatment of products made from them.
IHEA announced its 2019 – 2020 Board of Directors and Executive Officers. IHEA’s President is Michael Stowe of Advanced Energy; Scott Bishop of Alabama Power Company assumes the role of Vice-President; and Jeff Valuck of Surface Combustion was elected Treasurer. Serving as Past President is Daniel Llaguno of Nutec Bickley.
IHEA also welcomed three new board members: Gary Berwick of Dry Coolers, Bob Fincken of Super Systems, Inc., and Doug Glenn of Heat Treat Today. IHEA President Michael Stowe comments, “At our recent annual meeting in Sarasota, FL, we were very excited to officially appoint three new board members. They will each serve a three-year term, with service through the 2022 annual meeting. These folks represent dozens of years of process heating experience across several different markets. IHEA is very fortunate to have them serving on our board.”
Gary Berwick is a veteran in the heat-treating industry with over 30 years’ experience. He has been involved with IHEA since the early 1990s and stays active through his engineered sales role with Dry Coolers. Berwick is also a member of the Metal Treating Institute and the American Society of Manufacturing. IHEA is fortunate to have Gary’s valuable contributions on the Education committee as well.
IHEA gains a respected industry professional in Bob Fincken of Super Systems Inc. Fincken is their national sales manager for all of North America with 30 years of experience in controls and sensors. He is a great asset on IHEA’s Safety Standards and Codes committee and provides input for IHEA’s educational tools to support the association’s knowledge base.
Publisher of Heat Treat Today, Doug Glenn returns to the IHEA Board of Directors. His support of the association spans 25 years and includes everything from promotion, sponsorships, speaking engagements, and serving as a committee chair. Doug has an extensive background in publishing, marketing and association business. IHEA is pleased to have Doug’s dedication and commitment.
To complete the Board of Directors for 2019 – 2020, IHEA is proud to name those continuing their service:
B.J. Bernard, Surface Combustion, Inc.; Brian Kelly, Honeywell Thermal Solutions; Francis Liebens, SOLO Swiss Group, John Podach, Fostoria Process Equipment, a div. of TPI Corp., Jason Safarz, Selas Heat Technology Co. LLC; and John Stanley, Karl Dungs, Inc.
The parent company of a western Pennsylvania-base heat treat furnace manufacturer recently announced a partnership with a Serbian defense materials manufacturer to supply new heat processing equipment.
Zastava Arms, which manufactures firearms and artillery, based in Kragujevac, Serbia, replaced dated equipment with a new SECO/WARWICK high-temperature box furnace. The new equipment includes tighter temperature uniformity and fully automated temperature controls.
“We chose the SECO/WARWICK technology based on our previous experience and because it fits perfectly with our current Quality Management System by providing real-time controls that ensure a high-quality product and profitable operation,” said Vladan Živković, Manager of Department of Technology with Zastava Arms. “Zastava Arms has been a supplier to the defense industry for many decades and will stay among top defense suppliers thanks to investments in high-quality technology.”
Jarosław Talerzak, Vice President of Thermal Segment at SECO/WARWICK
According to DefenseWeb, the defense industry of Serbia is the largest in the Western Balkans and manufacturers must implement strict standards in order to meet the criteria to get a permit for manufacturing.
“We have enjoyed a long partnership with Zastava Arms and are pleased to continue supplying advanced technology solutions for every heat treatment application,” said Jarosław Talerzak, Vice President of Thermal Segment at SECO/WARWICK. “As a technology partner, we are positioned to support our customer’s growth by offering a wide range of service and equipment options especially for the very demanding industries represented by our partner.”
Main photo credit/caption: MilMag Facebook/Serbian Zastava Arms assault rifle
