ALUMINUM PROCESSING NEWS

Heat Exchanger Manufacturer Anticipates New EV/CAB Line

/ ALUMINUM PROCESSING NEWS, ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS

An international manufacturer of heat exchangers is expecting a new EV/CAB line to support their production of components, subsystems, and system solutions for thermal management in cars. The company provides energy-saving and high-performance products for regular petroleum and diesel fueled cars, as well as solutions for new electric vehicles.

Piotr Skarbiński
Vice President of Aluminum and CAB Products Segment
SECOWARWICK
Source: LinkedIn

“The EV/CAB line on order is designed specifically for the production of “Snake” type battery coolers,” said Piotr Skarbiński, VP of the Aluminum Process and CAB Business Segment in SECO/WARWICK. He further commented that the heating and cooling design “contributes to the final product’s exceptional quality using our unique technology that achieves excellent temperature uniformity across the width of the belt, which is the key to successful production.”

The company will execute their first “Snake” battery coolers in SECO/WARWICK furnaces. This is the eighth CAB line which will operate in this automotive industry manufacturer’s plants and the second one with a width of 2,300 mm.

The controlled atmosphere brazing (CAB) line on order will include a convection preheating chamber, a radiation furnace and two cooling chambers. The entire system will be equipped with a dedicated control system.

“This cooperation opens new perspectives for the SECO/WARWICK Group development in our region. The excellent heating and cooling design contributes to perfect temperature uniformity across the 2300 mm belt width, which is the key to successful production. We have already sold over 20 such solutions in China, and the demand for them is constantly growing,” commented Liu Yedong, Managing Director of SECO/WARWICK China.

Around the world, the demand for battery coolers is increasing due to the increasing production of electric vehicles.

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Tool & Die Capabilities Increase with Heat Treat Box Furnace

/ ALUMINUM PROCESSING NEWS, FEATURED NEWS, HARDENING NEWS, MANUFACTURING HEAT TREAT, OVENS-HIGH-TEMPERATURE, TEMPERING NEWS

An electric box furnace, currently headed to a Midwest equipment provider, will ultimately be installed at a Snap-on production facility that services tool and die support within the company’s production line.

The model QDD29 economical dual-chamber heat treating and tempering oven from L&L Special Furnace has a compact over/under design that saves floor space and provides reliable heat treating in-house.

QDD29 economical dual-chamber furnace (Source: L&L Special Furnace)

The top chamber is primarily deployed for heat treating tool steels at temperatures up to 2200°F; the tempering chamber is suited to temperatures up to 1250°F and has a recirculation baffle that makes it suitable for small aluminum work as well. The hardening and tempering chambers have interior dimensions of 12” wide by 8” high by 24” deep, with total external dimensions of 55” wide by 70” tall by 56” deep.

The QDD29 is controlled with digital single setpoint controls along with overtemperature protection. Solid-state relays drive the heating elements in a control circuit.

This press release is available in its original form upon request.

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3 Heat Treat Furnaces for Annealing Aluminum

/ ALUMINUM PROCESSING NEWS, ANNEALING NEWS, FEATURED NEWS, MANUFACTURING HEAT TREAT

Jupiter Aluminum Industries (JUPALCO), a newly established aluminum factory which will be part of the Jupiter Group in India, has ordered three furnaces for annealing aluminum coils from a heat treat furnace manufacturer with North American locations.

The equipment ordered by the Jupiter Group from SECO/WARWICK includes three Vortex® 2.0 furnaces for aluminum annealing, two cooling chambers, and one loader. A system configured in this way will ensure the optimal production volume of the Indian rolling mill.  

The aim of JUPALCO’s new plant will be to achieve the highest level of domestic aluminum production in history and to create an ecosystem of comprehensive aluminum-based solutions. This is the first cooperation between SECO/WARWICK and the Jupiter Group.

The three Vortex furnaces are effective systems for annealing aluminum coils. In the Vortex 2.0 version, a system of straight nozzles has increased the heat transfer efficiency. The systems key feature is the increased heat transfer coefficient, achieved by directing high-velocity air to both sides of the coil. This allows air to flow over the coil edges, not just through its outer layer.

Piotr Skarbiński, Vice President of (Source: secowarwick.com)

With the use of patented air flow technology, the aluminum coil annealing systems operate with process cycles that are significantly shorter. This in turn ensures energy savings, increased efficiency, and improved surface quality of the finished coils.

“In the case of coil annealing,” commented Piotr Skarbiński, VP of the CAB and Aluminum Products Segment at the SECO/WARWICK Group, “the challenge is to optimize the process by reducing the cycle time as much as possible while maintaining the desired metallurgical properties throughout the entire load.”

The Jupiter Group plans to recycle over 50,000 tons of aluminum scrap every year once fully operational. This scrap will come from both in-house and customer scrap, purchased scrap, and recycled cans/foils etc. The new rolling mill in India will help the Group expand its footprint in the aluminum industry and produce Made in India products which will be known for its quality and reliable products and services. 

“Since the 1990’s,” says Mr. Sandeep Bajaj, CMD of Jupiter Aluminum Industries, JUPALCO, “the Jupiter Group processes aluminum as a partner of the converting and packaging industries. Ecology is an important value for us. It is included in our mission, just like our Partner’s. The rolling mill in India will be one of the most modern facilities of this type in this region, which is why we are equipping it with the best solutions available on the market.”

This press release is available in its original form here.

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Heat Treater Expands To Provide Nitriding Regional Services

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, ALUMINUM PROCESSING NEWS, ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FORGING, FORGING NEWS

Sudosilo S.A., a commercial heat treatment service provider in South America, is bringing premier nitriding to the Argentine industrial sector with the recent commissioning of turnkey heat treat installation. This newly operational nitriding system represents a significant milestone as the first of its kind in Argentina, offering third-party heat treatment services to the region.

Source: Nitrex

The integration of this system from NITREX — a global supplier of heat treat systems with North American locations — is set to establish a new benchmark for quality and precision in nitriding treatments. Particularly, it will help Sudosilo cater to various sectors, including aluminum injection, aluminum extrusion, forging, and oil applications.

Jerónimo Alberto Colazo
Production Manager
Sudosilo

Jerónimo Alberto Colazo, production manager at Sudosilo, highlighted, “The competitive edge of this installation lies in its meticulous control and automation capabilities, ensuring process stability and the ability to generate specialized processes and recipes tailored to unique requirements of each application. This high level of customization and precision guarantees superior quality, meeting the intricate demands of industries served by Sudosilo.”

This press release is available in its original form here.

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Aluminum Extrusion Operations Bring Nitriding In-House

/ ALUMINUM PROCESSING NEWS, ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT TECHNICAL CONTENT, FEATURED NEWS, MANUFACTURING HEAT TREAT NEWS, NITRIDING, NITRIDING NEWS

Extral SP. Z o.o., a Polish company specializing in aluminum extrusions, has bolstered its manufacturing capabilities to better serve the construction, automobile, and machinery industries. Alongside acquiring a new aluminum extrusion press, the company ordered a nitriding system to nitride H11 and H13 extrusion dies of various sizes.

Nitriding pit furnace from Nitrex

The Nitrex turnkey nitriding system includes an NX-1015 pit-type furnace with a 2-ton (4410-lb) load capacity and NITREG® technology, offering nitriding treatments that optimize die performance and throughput while concurrently reducing tooling costs.

This investment coincides with Extral’s expansion of its operational footprint in Poland, including the construction of a new building to house the extrusion press and furnace. This expansion enables the company to diversify its range of extruded products while maintaining a focus on sustainability and energy efficiency. The new nitriding installation will contribute to these objectives by providing more efficient use of process gases and electricity.

Marcin Stokłosa
Project Manager
Nitrex Poland
Source: LinkedIn.com

Previously, Extral outsourced its nitriding operations to a local heat treater, due to quality issues encountered with an underperforming in-house nitriding unit. However, this latest investment enables them to bring nitriding operations back in-house, ensuring better control over the quality and consistency of their nitrided dies while also benefiting from expedited turnaround times.

Marcin Stoklosa, project manager at Nitrex, said, “Working with Extral on this project has been a pleasure. . . . Seeing customers invest in their business and achieve their goals, especially when it aligns with our values of innovation and sustainability, is always rewarding.”

This press release is available in its original form here.

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Green Aluminum Aging Furnace for Aluminum Producer

/ ALUMINUM PROCESSING NEWS, ATMOSPHERE AIR FURNACES NEWS, MANUFACTURING HEAT TREAT

ALRO, one of the largest vertically integrated aluminum producers in Europe measured by production capacity, has purchased an aluminum aging furnace with electric heating. The project objective is to increase the output of high and very high added products.

The SECO/WARWICK furnace has been designed for aging type 2xxx, 6xxx and 7xxx aluminum plates with a length of up to 13,000 mm and a width of up to 2,200 mm. They can be arranged in one or two rows. The load will be placed horizontally on loading trays with the maximum capacity of 60 tons net. The furnace will be heated electrically, which will significantly reduce CO₂ gas emissions.

This electric furnace will replace three furnaces powered by natural gas with the aim of streamlining the heat treatment operations within the ALRO Processed Aluminum Division. The furnace represents an important step towards achieving the company's goal of becoming a greener producer.

Piotr Skarbiński, Vice President of the Aluminum Process and CAB Business Segments, SECO/WARWICK

Piotr Skarbiński, vice president of the Aluminum Process and CAB Business Segments at SECO/WARWICK, explains, “The challenge of reducing emissions is becoming an increasingly important purchasing impulse for customers. This applies in particular to European producers, because in this region of the world ecological regulations are currently the most restrictive. The aluminum aging furnace, powered by electric heaters, eliminates the emissions problem, hence the growing interest of aluminum producers in such solutions.”

 

Gheorghe Dobra, CEO, ALRO
(Source: Alro.ro)

Gheorghe Dobra, CEO at ALRO, commented, “The new equipment, provided by SECO/WARWICK, will support our program to maximize the value of the products we are manufacturing and will allow us to better serve our customer’s requirements. At the same time, the new technology will support our commitment to reduce our environmental footprint.”

 

"We have already completed several orders for new equipment for this customer," said Tomasz Kaczmarczyk, sales manager of the Aluminum Process and CAB Furnaces Teams at SECO/WARWICK, "including a gas aging furnace and ingot preheating furnace. We have also modernized furnaces for annealing aluminum sheet coils."

Tomasz Kaczmarczyk, Sales Manager of the Aluminum Process and CAB Furnaces Teams, SECO/WARWICK
(Source: SECOWARWICK.com)

Aging furnaces are designed to operate in the temperature range from 176ºF to 482ºF in accordance with the AMS2750G standard. The temperature uniformity guarantee throughout the entire load at the level of +/- 3ºC was achieved with the use of optimal heat flow inside the furnace using high-performance atmosphere mixers and a system of guides directing the air stream.

This press release is available in its original form here.

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2 VPA Furnaces Elevate Jet Manufacturer’s Heat Treat

/ AEROSPACE HEAT TREAT NEWS, ALUMINUM PROCESSING NEWS, ATMOSPHERE AIR FURNACES NEWS

In a move aimed at elevating its manufacturing capabilities, a leading jet engine manufacturer is gearing up to integrate two vapor phase aluminizing (VPA) coating furnaces during the first half of 2024.

These high-capacity, low-maintenance automated retort VPA furnaces from G-M Enterprises, a Nitrex company, are purposefully engineered with moving bases and a fixed heat chamber, enhancing operational efficiency. Each retort is sealed to the moving bases, allowing for concurrent handling of two loads, each containing three coating cans. The result is a streamlined process that runs two cycles back-to-back, completing the treatment in just over 24 hours. The automated furnace supports unattended start-ups, empowering operators to focus on preparing loads for the second system which facilitates concurrent operations for heightened productivity.

VPA furnace from G-M Enterprises, a Nitrex company
Source: Nitrex

Robert Huckins, national sales manager at G-M Enterprises, emphasized that the "VPA furnaces ensure seamless operations, providing our customer with a competitive edge in production capacity. This is crucial in meeting escalating demand while delivering high-performance and longer-lasting blades and vanes vital for high-temperature fired engines.”

A feature of the VPA design is the raised fixed heat chamber, effectively shielding operators and the furnace room against potential heat exposure. This innovation eliminates the need for cumbersome protective heat suits. The hot retort remains securely housed within the insulated furnace, prioritizing operator well-being. Furthermore, this safety measure confines the load base and retort/coating load within the SAR/VPA furnace housing until the retort temperature drops below 150°C (300°F).

This strategic investment not only underscores the manufacturer’s commitment to staying at the forefront of technological advancements but also solidifies a lasting partnership.

This press release is available in its original form here.

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News From Abroad: A Glimpse Into the International Market

/ ALUMINUM PROCESSING NEWS, ANNEALING NEWS, ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, MANUFACTURING HEAT TREAT NEWS / Leave a Comment
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Heat Treat Today is partnering with two international publications: heat processing, a Vulkan-Verlag GmbH publication that serves mostly the European and Asian heat treat markets, and Furnaces International, a Quartz Business Media publication that primarily serves the English-speaking globe. Through these partnerships, we are sharing the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat.

In this installment, explore important company partnerships with wide-spread industry effects as well as innovative new technologies from abroad.

TECHMO CAR Welcomes Anthony Tropeano as New Senior Advisor

Founded in 1961, TECHMO CAR drives innovation in the engineering and manufacturing of mobile and stationary equipment for the aluminum and metal production sector. (Source: Furnaces International)

"Anthony Tropeano of TT CONSULTING INC. has joined TECHMO CAR as a Senior Advisor for the US and Mexico market. Mr. Tropeano has spent over 40 years in the primary, secondary and downstream aluminum and metals worldwide market.”

Read more: “Anthony Tropeano has joined TECHMO CAR” at Furnaces International

New Tin Plate Complex from Partnership Between Danieli and Habaş Group

Caption: Situated in Aliağa near Izmir, the new facility will serve the needs of the packaging industry and the increasing need for cold-rolled and annealed thin sheets. (Source: heat processing)

"The facility, with a capacity of 900,000 tons per year, will produce a diverse range of steel grades, including T1 to T4 and DR7 to DR10. Among its offerings are 250,000 tons of tinplate, 150,000 tons of thin, continuous annealed cold-rolled coil, and 500,000 tons of semi-finished products. The complex comprises four crucial process areas: electrolytic cleaning, cold rolling and tempering, electrolytic tinning, and continuous annealing.”

Read more: “Danieli and Habaş Group Forge Future with New Tin-Plate Complex” at heat processing.com

SMS Group Partners with Turkish Plant Operator Kardemir to Digitize Blast Furnace 5

Using BFXpert solution from Paul Wurth, SMS Group has digitized a blast furnace belonging to Kardemir, Türkiye’s oldest blast furnace operator. (Source: Furnaces International)

"The Paul Wurth BFXpert system is a comprehensive package of systems for the chemical and thermal control of blast furnaces. It is an integrated level-2 process control and operator guidance system for superior blast furnace operation, utilizing the benefits of artificial intelligence to take process optimization to the next level and towards a fully autonomous blast furnace."

Read more: "SMS group successfully digitalizes Kardemir’s blast furnace 5 with BFXpert solution from Paul Wurth” at Furnaces International

Karlsruhe Institute of Technology (KIT) Develops New Process for Sustainable Pig Iron Production

“By integrating the blast furnace and coking plant as well as the consistent recycling of process gases and heat, CO₂ emissions in steel production can be reduced.” (Source: heat processing.com)

"Around eight percent of global CO₂ emissions are caused by the steel industry. Professor Olaf Deutschmann from the Institute for Technical Chemistry and Polymer Chemistry (ITCP) at KIT is of the opinion that this must change quickly. In the long term, thanks to new hydrogen technologies, there is a climate-neutral perspective, but it will still be a few years before sufficient green hydrogen is available worldwide and newly built plants go into operation.”

Read more: “KIT: New process for sustainable pig iron production” at heat processing.com

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Jet Engine Manufacturer Modernizes with Updated Casting Furnace

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, ALUMINUM PROCESSING NEWS, FEATURED NEWS, FOUNDRY CASTING, FOUNDRY CASTING NEWS / Leave a Comment

Sławomir Tomaszewski
Vacuum Melting Team Director
SECO/WARWICK
Source: LinkedIn

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One of the world’s largest producers of jet engines has modernized their casting furnace, which was last updated two decades ago.

This company has two casting units supplied two decades ago by RETECH, a North America-based company belonging to the SECO/WARWICK Group. The modernization project was for the VIM EQ furnace - a system for the production of castings in equiaxed crystallization. It will involve replacing almost all the furnace components except the power supply, melting chambers and mold. The platforms will also remain unchanged. The remaining components will be replaced with more modern, ergonomic, and user-friendly parts and assemblies.

Says Sławomir Tomaszewski, vacuum melting team director at SECO/WARWICK, “This order includes the complete elimination of hydraulic components by replacing them with electrical components such as an elevator drive or crucible rotation drive. In addition, two old feeders: one for loading crucibles, the other for removing disposable crucibles, will be replaced with a modern system that can perform both activities."

He added, "An additional advantage of the operation will be the fact that the furnace operator will not have to come into physical contact with hot used crucibles, because they will be removed automatically without human intervention."

 

 

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3 Aluminum Heat Treat Systems Delivered for USAF

/ AEROSPACE HEAT TREAT NEWS, ALUMINUM PROCESSING NEWS, ATMOSPHERE AIR FURNACES NEWS / Leave a Comment
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Richard B. Conway
Founder/Director/ CTO
DELTA H® Technologies, LLC
Source: DELTA H

Three heat treat systems have recently been delivered and commissioned to joint base San Antonio-Randolph for maintaining the T-38 Talon Trainer aircraft.

These systems are a dual chamber model DCAHT®-181248-1200/500-MIL, a DCAHT®-241672-1200/500-MIL, and a large single chamber SCAHT®-303048-1200-MIL.

USAF depot level heat treating requires full compliance to AMS2750G.  The heat treating systems provided by DELTA H were for replacing existing systems which were too troublesome or costly to try to qualify and were never designed for modern pyrometry standards. The furnace systems were placed into production service the week following qualifying and training.

JBSA-Randolph – SCAHT®-303048-1200-MIL & DCAHT®-241672-1200/500-MIL Includes Power Driven Quench Tank
Source: DELTA H

Richard Conway, director and CTO of DELTA H, states, "We are grateful and humbled to be recognized among the mission critical technology partners supporting this very important project, and pleased to play a part in extending the service life of the valuable T-38 airframe."

JBSA-Randolph, TX – DCAHT®-181248-1200/500-MIL Heat Treat Computer Work Station
Source: DELTA H

Third party compliance and initial qualifying certification of all 5 chambers were provided by Conrad Kacsik Instrument Systems of Solon, Ohio.

Jake Kacsik, president of Conrad Kacsik Instrument Systems, shares, “The results are always impressive when testing DELTA H furnaces. By far the most reliable and consistent systems for maintaining the strict standards of aerospace pyrometry. Richard and I not only have a career-long professional relationship, but also, we both served in the USAF.”

DELTA H is exclusively represented worldwide by PHILLIPS FEDERAL Division for all military and government sales.

JBSA-Randolph, TX – SCAHT®-303048-1200-MIL & DCAHT®-181248-1200/500-MIL
Source: DELTA H

John Murray, retired SMSgt of USAF and product manager of Phillips Corporation, Federal Division added, “DELTA H compliments our product offerings to Metals Tech facilities. Regardless of traditional machining or additive manufacturing, Phillips Corporation – Federal Division strives to meet the needs of the USAF Fabrication Flight Warfighter, providing the best solutions for their support of US power projection and strategic deterrence. Phillips Corporation – Federal Division stands beside USAF Fabrication Flights around the globe ready to cut, fabricate, manufacture, and metallurgically process any part-anytime-anywhere."

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