A new downstream aluminum fabrication facility is being planned in Inola, Oklahoma, to convert molten primary aluminum into value-added products. The project is intended to strengthen domestic aluminum supply chains and expand U.S. primary aluminum processing capacity by anchoring fabrication operations adjacent to a proposed new smelter.
Local firm U.S. Aluminum Company has signed an agreement with Emirates Global Aluminum (EGA) and Century Aluminum, the companies behind the planned primary aluminum production plant in Inola, Oklahoma, to explore the development of an aluminum fabrication plant near the smelter. The project, named Oklahoma Primary Aluminum, is expected to double U.S. primary aluminum production. U.S. Aluminum Company is the first downstream firm to formalize an agreement tied to the project.
Jesse Gary CEO Century Aluminum
U.S. Aluminum Company plans to build its facility near the smelter to process liquid aluminum into products for the electrical, defense, aerospace, automotive, and machinery industries. By locating next to the smelter, the company aims to strengthen the domestic supply chain and support growth of a broader downstream manufacturing ecosystem in the region.
“By establishing an aluminum hub in Oklahoma, we are strengthening and shortening the supply chain for a critical metal that supports American industries. Today’s announcement highlights the multiplier effect of revitalizing domestic production — attracting new infrastructure investment and creating jobs in adjacent industries,” said Jesse Gary, chief executive officer of Century Aluminum.
Founded by the Oklahoma City-based Plotkin family, owners of M-D Building Products, a long-standing aluminum fabrication company, U.S. Aluminum Company is focused on serving clients requiring domestically produced aluminum with high performance, traceability, and supply security.
Press release is available in its original form here.
A manufacturer specializing in advanced thermal management solutions has expanded its production capabilities with the delivery of a new continuous controlled atmosphere brazing (CAB) line. The system will support increased output of high-performance cooling components such as heat dissipation plates for data centers and cold plates for electric vehicles, while also serving demand across aviation, photovoltaics, and rail transport.
The company, a Chinese manufacturer focused on temperature control platforms and cooling systems, is investing in the continuous CAB line to strengthen production capacity and support growing demand for compact, high-efficiency thermal management technologies.
The CAB line, supplied by SECO/WARICK — a global thermal processing equipment manufacturer with operations in North America — features a 1,000mm (39.2 in) belt width and is designed to process multiple product types, including 3D vapor chambers and cold plates. The system includes a dry-off oven for part preparation, a radiation brazing furnace operating in a controlled atmosphere, a clean-out chamber to stabilize internal conditions, an air-jacketed cooling chamber, and a final cooling chamber. An integrated control system enables centralized operation and process management across all stages.
Piotr Skarbiński Vice President of Aluminum and CAB Products Segment SECO/WARWICK
“What makes this project unique is the ability to braze two distinct product groups — 3D-VC (3d vapor chambers) and cold plates — on a single line,” said Piotr Skarbiński, vice president of the Aluminum and CAB Products Segment at SECO/WARWICK. Through tailored throughput calculations and a customized cooling configuration, the system is engineered to deliver temperature uniformity and repeatable process control — factors essential to producing high-quality components for modern electronics and power systems, he adds.
As AI servers, EV systems, and advanced electronics generate increasing heat on compact surfaces, reliable aluminum brazing technologies remain essential to delivering performance, durability, and efficiency in next-generation thermal management systems.
Press release is available in its original form here.
Jupiter Aluminum Industries (JUPALCO), part of the Jupiter Group, has ordered two aluminum coil annealing furnaces to support production at its rolling mill operations, strengthening capacity and consistency for flat-rolled aluminum products serving automotive, construction, and packaging markets. The investment reflects continued global demand for advanced aluminum heat treating capacity.
The furnaces, slated for installation at JUPALCO’s rolling mill operations in India, are designed to handle large aluminum coils, with a maximum outside diameter of 2,600mm, widths up to 2,300mm, and a total gross load capacity of 93.6 metric tons. Multi-zone chamber configurations and advanced control systems are engineered to deliver precise temperature uniformity and repeatable annealing results across high-volume production runs.
Piotr Skarbiński Vice President of Aluminum and CAB Products Segment SECO/WARWICK
The equipment will be supplied by SECO/WARWICK, a furnace supplier with North American locations, and incorporates the company’s Vortex 2.0 aluminum coil annealing technology, which uses high-velocity airflow to improve heat transfer, shorten cycle times, and reduce the risk of localized overheating. The design also supports energy-efficient operation while maintaining tight temperature tolerances throughout the annealing process.
According to Piotr Skarbiński, vice president of the CAB and Aluminum Products Segment at the SECO/WARWICK Group, the Vortex 2.0 is designed with a system of appropriately directed nozzles that support consistent aluminum processing while reducing cycle times and energy consumption.
The Indian market for flat-rolled aluminum products is growing rapidly, with its value expected to rise from USD 4.5 billion in 2025 to USD 12 billion by 2035. Investments by manufacturers like JUPALCO in new rolling mills highlight both the domestic growth potential and the wider demand for advanced annealing technologies in global markets.
Press release is available in its original form here.
Century Aluminum Company has emphasized that next-generation EX smelting technology will be critical to the development of its new primary aluminum smelter, one of the most advanced technologies deployed in the U.S. This platform is designed to improve productivity, reduce energy consumption per ton, and lower emissions, reinforcing both economic competitiveness and environmental performance in primary aluminum manufacturing.
Click on the image above to read more about Century Aluminum’s recent restart to boost U.S. production by 10%.
Planned for Inola, Oklahoma, at the Tulsa Port of Inola industrial park, the proposed facility is expected to produce up to 750,000 metric tons of primary aluminum annually, more than doubling current U.S. smelting capacity once fully operational. Century Aluminum will partner with Emirates Global Aluminum (EGA) on the project, with EGA contributing its proprietary EX smelting technology and holding a majority ownership stake, while Century Aluminum provides operational expertise and leadership in the U.S.-based aluminum production. The project aims to strengthen material availability for downstream manufacturers serving automotive, aerospace, energy, and defense markets.
Jesse Gary Chief Executive Officer Century Aluminum Company
“Our partner EGA brings world-class smelting technology and construction expertise that are fast-tracking our collective efforts to realize a new era of domestic primary aluminum production,” said Jesse Gary, chief executive officer of Century Aluminum Company. “This expanded production will benefit critical U.S. industries and create thousands of American manufacturing jobs, reinforcing the vital role of aluminum in national defense and economic vitality.”
EX technology is EGA’s next-generation smelting platform, featuring reduction cells that provide higher productivity per square meter than EGA’s previous DX+ Ultra technology. The cells are larger and have improved current efficiency, enabling greater aluminum production from each smelting cell. The technology supports more cost-effective aluminum production with lower emissions intensity, reinforcing the project’s operational and environmental goals.
For background on the initial announcement of this historic smelter project, click on the image above for our May coverage.
The use of EX technology also positions the project within the broader global landscape of aluminum smelting innovation, strengthening its appeal as an alternative source of advanced smelting capability at a time when governments and manufacturers are increasingly focused on supply chain resilience, domestic capacity, and technology diversification. EGA’s own communications highlight EX as a key step toward large-scale industrialization and a foundation for future growth as a smelting technology provider of choice in the global aluminum industry.
Construction is expected to begin as early as 2026, with commercial production anticipated before the end of the decade. Once completed, the facility is expected to support approximately 1,000 permanent direct jobs and support roughly 4,000 construction roles, while helping reduce reliance on imported aluminum and reinforcing domestic manufacturing capabilities. Industry leaders have described the project as a critical step toward rebuilding U.S. primary aluminum production and supporting long-term supply stability for North American manufacturers.
Press release is available in its original form here.Additional information comes from EGA’s June 2025 press release here.
Three aluminum melting furnaces at a Novelis site have been updated to achieve a more than 40% reduction in carbon footprint and significantly lower gas consumption. This project marks an important step forward in the decarbonization of industrial processes.
The upgrade includes Fives’ North American® regenerative technology. The North American TwinBed® II burners, manufactured by the supplier, are recognized for their energy efficiency and low emissions. From engineering and design to commissioning, the project was fully managed by Fives’ North American Combustion’s teams based in Bilbao, Spain.
Aluminum melting furnaces updated for environmental impact (Source: Novelis)Novelis and Fives upgrade three furnaces (Source: Novelis)Emilio Braghi, Executive Vice President and President Novelis Europe
Source: Novelis
This joint initiative in Voerde, Germany, by Novelis and Fives highlights the shared commitment to sustainability and innovation. The 40% reduction in carbon footprint is based on gas consumption compared to pre-upgrade levels measured in mid-2023 at the Voerde casthouse.
“Sustainability is at the core of Novelis’ business model,” said Emilio Braghi, executive vice president and president of Novelis Europe. “With our company vision, Novelis 3×30, we’ve set ambitious goals to advance circularity and decarbonization by 2030. The upgrade of our three melting furnaces represents a practical advancement in reducing our environmental footprint and improving operational efficiency.”
“This project represents a new milestone in our long-standing collaboration with Novelis, which began nearly two decades ago,” added Pablo Arribalzaga, managing director for Europe at Fives North American Combustion. “We are proud to support Novelis’ sustainability journey with high-performance, low-emission combustion solutions tailored to their operations.”
Press release is available in its original form here.
A U.S. Air Forcecontract has been awarded for 38 advanced aerospace heat treating furnaces. The furnaces will enhance mission-critical aircraft maintenance capabilities at bases across the United States and overseas.
Phillips Corporation Federal Division and DELTA H® Technologies will provide the furnaces. Of the 38 are 13 Model DCAHT®-181248-1200/500-MIL units and 25 Defender Series Model DEF-DC-RH-242436/1200-CH-242436/1200 units. Deliveries are scheduled over the next year to provide the USAF with heat treating capacity for aviation-grade metals to meet AMS2750H compliance and NAVAIR TO 1-1A-9 standards.
“Phillips Federal is honored to support the U.S. Air Force through this partnership,” said Kelley Padham, president of Phillips Corporation, Federal Division. “Our collaboration with DELTA H Technologies continues to expand the boundaries of advanced manufacturing for the Department of Defense — empowering readiness, resilience, and rapid innovation wherever our warfighters serve.”
Service member team working with new Delta H furnace Source: Delta H Technologies
Richard Conway, director and CTO of DELTA H Technologies and a U.S. Air Force veteran, added: “Ten years ago, the Air Force asked us to help solve a problem. As an engineer and veteran, it became a personal mission to provide the best heat treating solutions possible. Today, knowing the USAF relies on DELTA H and Phillips Federal for this critical technology is deeply humbling.”
The DCAHT® Model has dual convection-heated chambers with certified TUS work volume at 18” W × 12” H × 48” L. The lower chamber operates to 1200°F for aluminum solution heat treating with a roll-away quench tank, and an upper chamber which operates up to 500°F for aluminum aging.
The Defender Series Model has dual TUS-certified work volumes at 24” W × 24” H × 36” L. The convection chamber operates between 200°F–1200°F with rapid cooling from 1000°F to <200°F in under 30 minutes, enabling complete solution heat treating, annealing, and aging (T6). The radiant chamber operates between 1000°F–2000°F, with inert gas atmosphere capability.
Press release is available in its original form here.
In today’s News from Abroad installment, we highlight one steel mill‘s environmental improvement efforts, an Indian aluminum plant expansion, and a self-learning furnace system for aluminum processing.
Heat TreatTodaypartners with two international publications to deliver the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat. Furnaces International, a Quartz Business Media publication, primarily serves the English-speaking globe, and heat processing, a Vulkan-Verlag GmbH publication, serves mostly the European and Asian heat treat markets.
Tata Steel Praised for Low CO2
Tata Steel plant Source: Furnaces International
“Jonathan Brearley, chief executive of Ofgem, has praised Tata Steel UK’s move to low-CO₂ at its Port Talbot site. The comments were made during a visit to the site in Wales, with Brearley partaking in a tour around the premises. Brearley said: ‘Back in 2016 and 2023, most of the conversation was about electricity and gas prices and the pressure they put on the steel business. What’s inspiring today is seeing Tata Steel moving towards electric arc furnace-based steelmaking and helping to deliver a green future.’ He further highlighted Great Britain’s energy regulator’s role in enabling investment by ensuring industrial customers, like Tata, have the right conditions to transition, including fair energy pricing and strong grid connections.”
The company is exploring different energy options to meet the smelter’s power requirements. Source: Furnaces International
“Indian aluminium producer Nalco is continuing with its plant to expand its smelter in Angul. It will add approximately 0.5 million tonnes of capacity at the facility, with technology for the project being finalised it said. In its annual report for the year, the company said a project report with technology from the Technology Licensor is being prepared. ‘Pre-project activities have been initiated. The acquisition of requisite land through IDCO, Govt. of Odisha is underway and environmental clearance for the project is under progress.’ The company is exploring different energy options to meet the smelter’s power requirements.”
The BatchPilot has transformed casthouse operations by increasing “right first time” batching. Source: Furnaces International
“A furnace weighing system from Aluminium Casthouse Technologies (ACT) is now ‘self-learning’ to achieve higher production levels in casthouses. Knowing the correct weight of metal in the furnace is crucial to ensure slabs are consistently cast to the precise length ordered by the customer and the BatchPilot is used in casthouses worldwide to accurately measure furnace liquid metal weight. Determining exactly what is wanted aluminium and what is unwanted dross, it means casthouses don’t have to rely on visual estimates of furnace heel weight, which are unreliable. This often leads to short casts, overfilling of the furnace or potentially restricting the number of slabs cast, all hugely wasteful.”
Arconic Corporation (“Arconic” or the “Company”) will boost high purity aluminum (HPA) capacity for aerospace and defense applications at its Davenport Works plant, a facility with in-house heat treatment. The $57.5 million project has effectively doubled domestic production of high purity aluminum, a critical material to aerospace and defense applications.
Diana Perreiah Executive Vice President of Rolled Products North America Arconic Source: Arconic
The expansion is being carried out at the Davenport Works plant in Iowa and was commissioned on September 25. The project was supported by an award of $45.5 million from the U.S. Department of War in 2023, utilizing Defense Production Act (DPA) Title III authorities. The Defense Production Act Title III program supports domestic industrial capabilities essential to national security.
Diana Perreiah, executive vice president of Rolled Products North America for Arconic, said, “Arconic is honored to support American leadership in advanced manufacturing by expanding domestic production of high purity aluminum for next-generation aerospace and defense applications. This project strengthens critical supply chains and supports national defense priorities, while reinforcing our role as a trusted partner in delivering materials essential to U.S. security and competitiveness.”
With the design and installation of two new furnaces and advanced control and automation systems, the project provides the United States surge capacity for HPA production and mitigates potential risks to national security in the event of an industrial mobilization. Among the defense applications that require HPA are the bulkheads for the F-35 and advanced armor plate for the Joint Light Tactical Vehicle.
At a ribbon-cutting ceremony on September 25, distinguished guests included Iowa Governor Kim Reynolds, Lieutenant Governor Chris Cournoyer, U.S. Senator Joni Ernst, U.S. Representative Mariannette Miller-Meeks, State Representative Gary Mohr, Riverdale Mayor Anthony Heddlesten, Iowa Association of Business and Industry President Nicole Crain, and Quad Cities Chamber of Commerce president and CEO Peter Tokar III to mark the milestone of commissioning the facility.
Arconic Corporation, headquartered in Pittsburgh, Pennsylvania, is a leading provider of aluminum sheet, plate and extrusions, as well as innovative architectural products, that advance the ground transportation, aerospace, building and construction, industrial and packaging end markets. For more information, visit www.arconic.com.
Press release is available in its original form here.
Century Aluminum Company has announced plans to restart over 50,000 mt of idled production at its Mt. Holly, SC smelter. Part of a $50 million investment, the effort will create over 100 jobs and boost U.S. domestic aluminum production by almost 10%.
Jesse Gary CEO Century Aluminum
The restart will enable the plant to achieve full production (up from current 75%) by June 30, 2026. The restart follows President Donald’s Trump’s tariffs for primary aluminum, most recently increasing the tariffs to 50% on aluminum imports without exceptions or exemptions.
“Our team stands ready to continue leading the resurgence of domestic primary aluminum, starting with bringing our Mt. Holly smelter back to full production.” said CEO of Century Aluminum Company, Jesse Gary.
The restart was made possible with the help of South Carolina Public Service Authority (Santee Cooper), Mt. Holly’s power supplier. The parties extended the current contract through 2031 to purchase the additional power necessary for the restart. The final details of the restart will be subject to a definitive agreement with Santee Cooper, along with confirmation of economic incentives provided by Berkeley County and the state of South Carolina.
Century Aluminum is an integrated producer of bauxite, alumina, and primary aluminum products. At full capacity, Mt. Holly smelter has an economic impact of over $890 million annually in the state of South Carolina. Century is the largest producer of primary aluminum in the United States, and operates production facilities in Iceland, the Netherlands, and Jamaica.
Press release is available in its original form here.
A company in advanced metal casting technologies has shipped its first commercial additive manufacturing evaporative casting (AMEC) machine to the University of Tennessee, Knoxville (UTK). The system will be installed at UTK’s manufacturing research facility, where it will support continuing education, casting research, and workforce development in next-generation manufacturing.
Lightning Metal LM-16 is Skuld LLC‘s flagship machine for additive manufacturing evaporative casting (AMEC). The machine is a tool-less, net-shape casting process capable of producing aerospace grade aluminum and other high-performance alloys with minimal post-processing. The system enables rapid prototyping, reduced lead times, and flexible alloy compatibility, making it ideal for both industrial and academic environments.
The Lightning Metal LM-16 AMEC machine by Skuld Source: Skuld LLCSarah Jordan Founder & CEO Skuld, LLC Source: Author
“This milestone represents…a signal that advanced casting is entering a new era,” said Sarah Jordan, co-founder and chief executive officer at Skuld. “The University of Tennessee is a national leader in manufacturing innovation, and we’re proud to support their mission with a system that bridges research and real-world application.”
Adam Penna Director, Sales and Marketing Skuld Source: Linkedin
UTK will use Lightning Metal LM-16 platform to expand its materials science curriculum, conduct applied research in casting and alloy development, and provide hands-on training for students and professionals entering the manufacturing workforce.
“This is exactly the kind of partnership we envisioned when we launched the Lightning Metal platform,” said Adam J. Penna, director of sales and marketing at Skuld. “It’s a platform that empowers innovation in evaporative casting utilizing 3D printing for improved features like edges and surfaces while also reducing the need for tooling cost…whether you’re solving supply chain challenges or training the next generation of engineers.”
The Technology
Skuld’s AMEC technology merges lost foam with polymer 3D-printing. Heating up to around 2000°F, the machine operates as an automated micro-foundry. The Lightning Metal LM-16 removes the safety issues of handling molten metal and is perfect for small, custom, one-off aluminum parts fasteners. It makes products in a 7″ cube, melting approximately 16lbs of aluminum, and can also process brass or bronze.
The machine is sized to be able to move through standard doorways and utilizes single-phase power, like a dryer plug.
The casting works by utilizing a hollow polymer shape in place of lost foam, where the molten metal vaporizes the polymer. This is a subset of the casting field called lost foam, which is a variation on lost wax investment casting, and eliminates around 90% of process steps, making for fewer costs and a faster process. The mold is insulated with a thin ceramic shell, ceramic beads, a metal container called a flask, and unbonded beads.
Gear produced by Lightning Metal LM-16 Source: Skuld LLCProduct of Lightning Metal LM-16 Source: Skuld LLCProduct of Lightning Metal LM-16 Source: Skuld LLC Source: Skuld LLC
Heat Treat Today asked what difficulties Skuld faced in developing this technology. The development process faced several unique hurdles, such as heat retention due its small size (compared with a large furnace), as well as crafting the machine’s automation while not allowing it to be hackable.
Applications
SBIR awarded to Skuld LLC Source: Skuld LLC
The Lightning Metal LM-16 is for those without an in-house foundry. It works well for replacement parts for in-house heat treatment, for example: hooks, baskets, or rollers. The machine can also produce spare parts or be utilized for prototyping pieces that can be used by higher volume machines. The Lightning Metal LM-16 operates well at around one hundred pieces per year.
The AMEC technology eliminates machining (which reducing costs for clean machining), and drives down the cost substantially associated with cooling for lost foam. The process also avoids HIPing, reducing the need for powder bed fusion parts.
The system enables reverse-engineering for discontinued items, and could be particularly applicable for heavy equipment, agriculture, compressors, and railroads.
The Lightning Metal LM-16 deployment marks a major step in Skuld’s commercialization strategy, following over $9 million in Department of Defense contracts and successful pilot programs with the U.S. Air ForceandDefense Logistics Agency. The company was recently awarded an SBIR for additive manufacturing.
For more information on this technological innovation, please contact Adam Penna at apenna@skuldllc.com.
