ALUMINUM PROCESSING NEWS

Major Aluminum Acquisition to Broaden Aero, Auto Products

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.

Steve Fisher, President and CEO, Novelis Inc

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 AmericaAsia 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

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.”

Steve Fisher, President and CEO, Novelis Inc

“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

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.

Tom Christie, president of ATEK Metal Technologies

“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

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.

Rio Tinto chief executive J-S Jacques

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

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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Orders for North American Steel, Aluminum on Rise

 

Source: ThomasNet.com

 

Orders for North American steel and aluminum have been on the rise since speculative talk about restrictions on the import of metals began last year, according to Tony Uphoff at Thomasnet.com, and the recent recommendation from U.S. Commerce Department Secretary Wilbur Ross to impose steep tariffs on foreign steel and aluminum seems to support the motivation behind the trend. Alcoa, Arconic, AK Steel, U.S. Steel, and Nucor were among the U.S. steel and aluminum manufacturers which saw increased activity prior to the announcement.

Read more here about the specific percentages proposed and the U.S. output goal: “Proposed Steel & Aluminum Tariffs Bolster Domestic Metals Sourcing”.

 

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Heat-Treatable Alloy Arrives for N. American Automakers

A world leader in aluminum rolled products recently announced the North American availability of a heat-treatable alloy, its latest addition to a series designed to provide greater flexibility for automakers and other industries.

Novelis Inc. unveiled the Advanz™ 6HF – e/s200, a high-formable aluminum alloy that is distinctive for its superior formability, strength performance, and weight savings for outer and inner applications. The material has sustained successful application in Europe.

The 6xxx-series alloy enables new opportunities to use aluminum for body sides, door inners, decklid outers and inners, and other closure panels. The alloy can also be used in designs and applications that required bending without the risk of cracking. In addition, Advanz™ 6HF – e/s200 creates a weight savings of nearly one-third over steel in inner door applications, benefitting vehicles that need to achieve weight reduction per customer specifications.

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Rolled Aluminum for Auto Body Production Included in Logan Expansion

A flat-rolled aluminum sheet manufacturer recently broke ground on Phase II of its expansion project in Logan County, Kentucky, where the company’s Phase I facility opened late last month, an investment of $240 million expanding recycling/new ingot casting capabilities to 600 million pounds of cast ingot annually, increasing the capacities of rolling mills, scalping, and pre-heat operations, and creating approximately 190 employment opportunities.
Logan Aluminum Inc.’s new project includes a planned mill that will strengthen cold rolling production and boost capacity for heavier gauge rolled sheet manufactured into automotive body and structural panels. When completed, the $125 million project is expected to provide 60 jobs for the area.
“Almost two years ago to the day, we held our groundbreaking for the new DC4 Recycle Facility, and now we are here today for the ceremonial ribbon cutting of DC4, and for the groundbreaking of Logan’s new Cold Mill – CM4,” said Ken Perdue, Logan Aluminum Plant Manager. “It’s an exciting time for aluminum and it’s a really exciting time for aluminum in Kentucky.”
Logan Aluminum Inc. was established in 1983 and is a joint venture between Tri-Arrows Aluminum Inc., headquartered in Louisville, Kentucky, and Novelis Inc., based in Atlanta, Georgia.
 Photo by Karen Logan Logan County Chamber of Commerce

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Swedish Aluminum Supplier Gränges Increasing Tennessee Presence

A Swedish supplier of rolled aluminum products that has operations in Sweden, China, and the U.S. recently announced an expansion project that will incorporate investment in heat treat equipment, including annealing furnaces.

Johan Menckel, Gränges CEO

Gränges of Stockholm, Sweden, will invest $110 million (U.S.) to increase the capacity of its aluminum rolling operation in Huntingdon, Tennessee, from 160K tons to  nearly 200K tons per year, creating 85 permanent full-time jobs and servicing its North American market with light gauge foil, automotive heat exchanger materials, and heating, ventilation, and air conditioning (HVAC) applications. This is the company’s second major investment in Huntingdon since 2000.

“The expansion in Huntingdon marks the next step in our strategic growth plan for the North American market. Gränges has built a strong reputation in the aluminum rolling industry, and this expansion allows us to further support our customers’ growth”, says Gränges CEO Johan Menckel. Other expansion projects will include buildings, casters, cold rolling mills, and
slitters.

Patrick Lawlor, Gränges Americas President

“The investment represents a long-term commitment to our customers, employees, and shareholders as we grow in support of our strategic markets”, says Gränges Americas President, Patrick Lawlor.

The expansion was supported by Tennessee (TN) Governor Bill Haslam, the TN Department of Economic and Community Development, Tennessee Valley Authority, and local Huntingdon Officials.

“In TN, we take pride in the fact that our hardworking residents still make things,” said Tennessee Governor Bill Haslam. “The Gränges facility is a vital part of the Carroll County community and I’d like to thank Gränges for committing to create new jobs in Huntingdon and bringing us closer to making TN the No. 1 location in the Southeast for high-quality jobs.”

 

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U.S.-Produced Aluminum Cladding Adorns Façade of South African Mall

 

Source: AlCircle

 

To achieve a distinctive look that can be seen from a distance, a shopping mall in the economically developing township of Waterfall City, located between Johannesburg and Pretoria in South Africa, has turned to a U.S. manufacturer of flat-rolled aluminum products to cover the cladding of its parking garage with a façade made of sheets of aluminum measuring 1,437 x 3,880 mm (4.7 x 12.7 ft.), each treated with weather-resistant coating and classified for fire protection. The unique wave-look of the façade was achieved by laying aluminum plates horizontally.

Read more: “Novelis Does Cladding for South Africa Mall with Its ff2 Pre-Painted Aluminum Facade”

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