ALUMINUM PROCESSING NEWS Archives

New Heat Treat System Ordered by Oregon Products

A new heat treat system that will help produce products for the logging industry has been ordered by Oregon Products.

Oregon Products, a brand of Blount International, Inc., will be adding a new continuous high capacity mesh belt austemper heat treatment system to its production facilities. A global manufacturer of saw chain and other replacement products for the forestry industry, Oregon plans to use the new equipment as part of a long-standing commitment to continuous quality improvement.

Kaitlyn McNaughton
Director of Engineering and R&D Labs
Blount International

“The primary business driver of this project is quality,” said Kaitlyn McNaughton, Director of Engineering and R&D Labs. “This new furnace is primarily targeted to raise the bar on quality for our harvester chain products, which perform under the highest loads and most extreme conditions.”

The austemper system, which CAN-ENG Furnaces International, Ltd. will design and commission, integrates a computerized loading system, pre-wash system, atmosphere-controlled mesh belt austenitizing furnace, molten salt quench conveyor system, post quench residual salt removal and recycling system, mesh belt parts drying oven, unloading system and CAN-ENG’s PET™ system which provides vital features such as individual lot/product traceability, detailed process data collection for continuous process improvements and comprehensive Industry 4.0 equipment diagnostics capability.

The system is scheduled for commissioning early 2020.

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Aluminum Giants Progress Toward Merger with EC Approval

October 2, 2019 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS

An industrial aluminum company headquartered in Atlanta, Georgia, recently received approval of its proposed acquisition of an Ohio-based aluminum rolled products producer, which would increase its capacity to provide lightweighting materials for the automotive market.

The European Commission announced approval for Novelis Inc. to acquire Aleris Corporation, conditioned upon the sale of Aleris’ plant in Duffel, Belgium, which produces aluminum for the automotive and specialties markets. Novelis is working expeditiously to market the plant to potential buyers, with the chosen counterparty and the definitive agreement for divestiture subject to European Commission approval.

With this conditional approval in the European Union, as well as a clear path forward for approval in the U.S., Novelis focuses on obtaining approval from the Chinese State Administration for Market Regulation (SAMR).

Steve Fisher, president and CEO, Novelis Inc

“Today’s announcement is another step forward in bringing Novelis and Aleris together, which will benefit our customers, employees, and the aluminum industry as a whole,” said Steve Fisher, president and CEO, Novelis Inc. “Overall, this transaction will strengthen our ability to compete against steel in the automotive market, meet growing customer demand for aluminum, achieve our recycling goals, and bolster our sustainability platform worldwide. In addition, it will further enhance our strategic position in Asia and diversify our overall product portfolio.”

The company expects to close the transaction by January 21, 2020, the outside date under the merger agreement.

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Aluminum Producer Announces $200M Investment in Rolling Plant

June 18, 2019 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS

A large aluminum producer recently announced a large investment in a new rolling plant in Ashland, Kentucky.

Braidy Industries, Inc. (Braidy) and Rusal jointly announced the approval by their respective Boards of Directors for Rusal to invest $200 million in Braidy Atlas mill. The companies estimate that it has been more than three decades since a greenfield aluminum rolling mill like Braidy was built in the U.S. The deal is expected to close in the second quarter of 2019.

“This is a sustainability match made in heaven for the global aluminum industry,” said Craig Bouchard, Braidy Industries Chairman and CEO.

Rusal intends to supply 200,000 tons of certified low-carbon prime aluminum ingot and slabs each year for a 10-year period, allowing Braidy to target lower carbon emissions.

Braidy is dependent on long-term supplies of high-quality, low-carbon aluminum, which is rarely supplied in the high quantity required for their production. If met, this order would be one of the world’s largest for one mill of high-quality, pre-alloyed and low-carbon primary aluminum slabs.

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Nitrocarburizing System Installed for Aluminum Extrusion Manufacturer

April 14, 2019 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, NITROCARBURIZING NEWS

A manufacturer of aluminum profiles and complex extrusion press products recently purchased a nitrocarburizing system for its new state-of-the-art manufacturing facility in northwestern Romania.

Quebec-based Nitrex delivered and installed the turnkey NX-815 nitrocarburizing system for Swiss corporation Alu Menziken Extrusion AG, incorporating the Nitreg®-C technology for treating aluminum extrusion dies at the greenfield site which produces a range of profile products for aerospace and automotive companies. The process technology adapts to the application requirements to deliver improved performance of extrusion dies.

“With a focus on the environment, Alu Menziken also sought to introduce eco-friendly technologies for all equipment at its greenfield facility. Not only is there a benefit of reduced process gas use with the Nitrex system, the integral high-efficiency neutralizer also helps comply with environmental regulations,” said Marcin Stoklosa, Nitrex European Project Manager.

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Aluminum Extrusion Expansion in Pennsylvania Supports Auto Markets

November 2, 2018 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS

A supplier of infinite aluminum recently announced it plans to invest in two new aluminum extrusion presses to support the growing automotive, architectural and transportation markets in North America.

Hydro plans to install a 4,500-ton 10” aluminum press line at its Cressona, Pennsylvania, location to serve the traditional automotive and distribution segments and also installing a 7,000-ton dual container 12”/14” press line in the West region to serve the electric vehicle, transportation, and commercial building and construction segments.

“We are very excited about Hydro’s continued investments in North America,” said Jack Pell, Vice President of Automotive Business Development for Hydro Extrusion North America. “This new equipment merges state-of-the-art billet heating and quench capabilities with larger billet diameters and enables us to produce larger extruded aluminum shapes with thinner walls from stronger alloys – the ‘holy grail’ for our automotive customers.”

Hydro expects these presses to be operational by 2020.

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Major Aluminum Acquisition to Broaden Aero, Auto Products

August 3, 2018 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS

An Atlanta-based provider of aluminum rolling and recycling recently announced the company has signed a definitive agreement to acquire Aleris Corp., Cleveland, a global supplier of rolled aluminum products supplier based in Cleveland, Ohio.

Novelis Inc. will acquire Aleris Corp’s 13 manufacturing facilities across North America, Asia, and Europe, including new automotive finishing lines in Lewisport, Kentucky, and significant auto capacity in Duffel, Belgium, providing a more diverse product portfolio, including aerospace, automotive, building and construction, commercial transportation and specialty products.

“Acquiring Aleris is the right opportunity at the right time as they are set for transformational growth,” said Steve Fisher, President and CEO, Novelis Inc. “The significant investments they’ve made in the high-demand, high-value aerospace and automotive segments have resulted in favorable long-term, global contracts. These investments, coupled with a diverse and talented workforce, will add tremendous value to our organization and allow us to deliver the highest quality innovative aluminum solutions to our customers.”

As part of the acquisition, Novelis will acquire Aleris’ 13 manufacturing facilities across North America, Asia and Europe. Aleris’ new automotive finishing lines in Lewisport, Kentucky, of which a significant amount of its capacity is already under contract, along with auto capacity in Duffel, Belgium, will allow Novelis to further diversify its global footprint and customer base.

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Aluminum Producer to Double Capacity in China

July 6, 2018 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS

Kumar Mangalam Birla, chairman of the board of directors of Novelis Inc. and chairman of the board of directors of Hindalco Industries Limited

A global aluminum producer announced recently that an investment in a continuous annealing solution heat (CASH) treatment line will contribute to doubling its automotive aluminum body sheet capacity at its Changzhou facility in China.

Novelis Inc states that the approximately $180 million investment, which will also include a high-speed slitter as well as a fully automated packaging line, will add approximately 100 kilotonnes (over 220 million pounds) of capacity. This will enhance Novelis’ ability to supply innovative aluminum solutions to its global automotive customer base as well as Chinese domestic producers. Novelis expects to begin expanding its existing facility in 2018 in order to be operational by 2020.

“By adding another strategic asset to expand its operations in China, Novelis continues to leverage the strength of the Aditya Birla Group as the global leader in aluminum rolling,” said Kumar Mangalam Birla, chairman of the board of directors of Novelis Inc. and chairman of the board of directors of Hindalco Industries Limited. “Investing ahead of projected customer demand enables Novelis to offer premium products and a reliable supply chain to automakers as they continue to adopt more automotive aluminum.”

“As our customers continue to see aluminum as the material of choice to meet their lightweighting and performance goals, Novelis is strengthening its leadership position in the world’s largest automotive market place,” said Steve Fisher, President and CEO, Novelis Inc. “We believe China’s commitment to fuel efficiency and reducing emissions represent a large and favorable opportunity that will require greater adoption of aluminium, particularly in the rapidly growing electric vehicle market.”

This is Novelis’ second automotive investment this year, having recently announced a $300 million greenfield manufacturing facility in Guthrie, Kentucky, USA.

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Aluminum Caster Expands Facility, Technology Capabilities, Including Heat Treatment

June 13, 2018 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS

An aluminum casting producer in New Hampton, Iowa, announced ongoing plans to expand its plant and technical capabilities, including space to house expanded heat treatment operations, to keep up with growing demand. ATEK Metal Technologies ships thousands of aluminum castings each day and has recently completed a significant expansion of its metal casting, heat treatment and finished machining capabilities. The major building expansion is expected to be completed in December of 2018.

“We need additional plant space to support growth,” said Tom Christie, president of ATEK Metal Technologies. “The new building will allow us to consolidate our warehousing and shipping areas and make room on the plant floor for ongoing expansion of operations.”

On the technical side, the new robotic de-gating and deburring of castings operations will be operational in July 2018.

“We added 40 percent to our low-pressure permanent mold casting capacity to keep up with our accelerating growth,” said Christie. “We also have added state-of-the-art precision machining capabilities to be able to provide our customers with cast and machined finished components.”

ATEK Metal Technologies supplies aluminum castings that meet specifications for motorsports, recreation, transportation and industrial markets industries. The entire plant expansion is scheduled to be complete by the end of 2018.

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World’s First Carbon-free Aluminum Smelting Process Developed in Joint Venture

May 17, 2018 / ALUMINUM PROCESSING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

An Australian-British metals and mining corporation based in London in conjunction with a Pittsburgh-based aluminum producer recently announced an innovative process to make aluminum that produces oxygen and eliminates all direct greenhouse gas emissions from the traditional smelting process.

The new venture between Rio Tinto and Alcoa Corporation, known as Elysis, to develop the process and license the technology so that it can be used to retrofit existing smelters or build new facilities. Elysis will be headquartered in Montreal with a research facility in Quebec’s Saguenay–Lac-Saint-Jean region.

When fully developed and implemented, it will eliminate direct greenhouse gas emissions from the smelting process and strengthen the closely integrated Canada-United States aluminum and manufacturing industry. The patent-protected technology, developed by Alcoa, is currently producing metal at the Alcoa Technical Center, near Pittsburgh, Pennsylvania, where the process has been operating at different scales since 2009.

“This is a revolutionary smelting process that can deliver a significant reduction in carbon emissions. It builds on the key role aluminum has to play in driving human progress, by making products infinitely recyclable, stronger, lighter and more fuel efficient,” said Rio Tinto chief executive J-S Jacques.

Vincent Christ, who brings more than 30 years’ experience at Rio Tinto Aluminium, has been named Chief Executive Officer of Elysis.

Photo credit and caption: Rio Tinto; employee at the Saguenay–Lac-Saint-Jean works

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Aluminum Extrusion Producer Increases No. American Coverage with Acquisition, New Facilities

April 12, 2018 / ALUMINUM PROCESSING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

A North American extrusion and forging grade billet producer recently announced plans to proceed with new aluminum remelt facilities for billet and slab ingot casting and related processes and services. This will involve new facilities, increasing the company’s existing 1 billion pounds per year capacity by 75%.

With this approval from the Giampaolo Group Management Board, Matalco increases capacity by 350 million pounds in Lordstown, Ohio, 180 million pounds in Canton, Ohio, 225
million pounds in Bluffton, Indiana (previously Alexin LLC), and 250 million pounds in Brampton, Ontario.

Tom Horter, president of Matalco USA Operations Photo credit: Light Metal Age

Earlier in the year, Matalco acquired Alexin LLC.

The catalyst for these investments is in response to the needs voiced by customers in under-served market geographies, their requirements for increased product breadth, and processing services for the vast and growing automotive fflat-rolled aluminum product supply chain and the product feature needs of specialty alloy aluminum billet markets.

“We are an established leader in the remelt aluminum business. Matalco’s four existing aluminum plants have the broadest product offering and flexibility for providing closed loop, scrap-based billet, and slab ingot products,” said Tom Horter, president of Matalco USA Operations noted. “The proven capabilities of our people, assets, and technologies provide the nucleus and granularity for understanding market challenges and generating the solutions to meet the
future supply chain requirements of our customers.”

Horter added, “The recent integration of Alexin into Matalco has provided the right base for new employee training and innovative product and process development enabling speed to
market in these growing niche areas, bringing to life the exciting business possibilities to attain the Giampaolo Group’s medium and long-term objectives for our businesses.”

Matalco has not announced the number of plants that have been approved, nor their exact locations.

“Our team has been working with state and local economic representatives in the Upper Midwest states of Michigan, Illinois, Wisconsin, and Minnesota, and the southern states of Alabama, Tennessee, and Kentucky,” said Frank Mastrandrea, from the Giampaolo Group Management Board.

Photo credit: Vecohio

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