ATMOSPHERE AIR FURNACES NEWS

İnsu Teknik Transforms Gas Spring Production

/ ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT NEWS, NITRIDING NEWS, NITROCARBURIZING NEWS

İnsu Teknik, a leader in the gas springs sector of the automotive industry, continues to pioneer innovation as a key supplier for after-market and OEMs, both in Turkey and internationally, having recently implemented a pit furnace with advanced technologies at its in-house heat treat facility in Bursa, Turkey.

İnsu Teknik and Nitrex team members with pit furnace installation
Source: Nitrex

As a first-time partner with Nitrex, İnsu Teknik has strategically invested in advanced heat treat technology, focusing on continuous improvement to enhance the quality of gas springs, operational efficiency, and environmental sustainability. Central to their decision was İnsu Teknik’s commitment to environmentally responsible manufacturing practices, which led them to seek a greener solution.

Commissioned in the last quarter of 2023, the system — featuring a large-capacity pit furnace — combines three key process technologies: Nitreg® controlled nitriding, Nitreg®-C controlled nitrocarburizing, and ONC® in-process post-oxidation. These technologies enhance the surface properties of gas spring rods, notably improving wear and corrosion resistance, and offering considerable operational advantages.

The system ensures uniform case depth and precisely managed nitride/nitrocarburizing layer formation, optimizing the mechanical properties of the gas spring rods. It minimizes part distortion — an advantage of operating at lower temperatures compared to salt bath nitrocarburizing — and eliminates the need for post-finishing operations due to the cleaner surface achieved through gas nitrocarburizing, thereby streamlining the manufacturing process.

A Tuff Sport brand gas spring by Insu Teknik. The rods undergo nitriding to enhance hardness and corrosion resistance, ultimately extending the lifecycle of the gas spring.
Source: Nitrex

Marcin Stoklosa, manager of Technical Sales — EMEA region at Nitrex, shared these insights, “The commissioning process was executed seamlessly, marking İnsu Teknik’s strategic shift towards greater control over their production processes. What sets this system apart is its versatility in meeting the specific requirements of various gas spring applications across various industries, including automotive, agriculture, machinery, marine, furniture, medical equipment, and more.”

The original press release from Nitrex is available here.

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Box Furnace Increases Tempering Capabilities for Castings Company

/ ATMOSPHERE AIR FURNACES NEWS, FEATURED NEWS, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS, TEMPERING NEWS
Tom Schulz Sales Manager L&L Special Furnace Source: L&L
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An investment castings manufacturer's heat treat department received a large floor-standing box furnace from a North American specialty furnace company. The furnace will be used as support in the client's tool and die production along with tempering of finished castings.

The L&L model XLE3436 box furnace from L&L Special Furnace has an effective work zone of 34” wide by 22” high by 32” deep. It is equipped with a direct-lift vertical door with a floor switch to activate. The cantilevered vertical door eliminates the need for the upright structure to reduce the overall height of the equipment.

Tom Schulz, sales manager at L&L, highlights the key role this will play for the heat treat department, saying that this type of furnace is the company's “workhorse when it comes to thermal processing.”

The inert blanketing gas enables the part to be heat-treated with minimal surface de-carb. A stack light indicates the furnace status via an audible and visual indicator light mounted on top of the control.

Additionally, the furnace is equipped with a pyrometry package that has reference control thermocouple ports along with corner locations to record the high and low points within the unit as indicated by the latest temperature uniformity survey.

The original press release from L&L Special Furnace is available upon request.

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Skuld Expanding by Opening New Foundry & Manufacturing Facility

/ ATMOSPHERE AIR FURNACES NEWS, FEATURED NEWS, FIXTURE REACKING SYSTEMS NEWS, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT, SINTERING POWDER METAL NEWS
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Skuld LLC announced that they had purchased the site belonging to the former Champion Foundry in Piqua, Ohio, a gray and iron foundry that had closed in March 2017. The company will continue to be focused on innovation in the metals industry, serving their clients through a number of innovations related to novel materials and manufacturing technologies.

The four buildings with nearly 32,000 square feet of space are being refurbished to be capable of casting a wide range of ferrous metals (gray, ductile iron, steels) and nonferrous metals (aluminum, brass, bronze, copper, nickel alloys). The plant will initially have 3,000 tons of capacity but plans are in place to expand to ten times that capacity in the next few years.

Skuld will be installing machining, foam blowing, a printer farm, and heat treating, adding to their current 5 small heat treat furnaces and adding to their operations, which primarily consist of lost foam casting. The new installations will aid the company as they serve the defense, tooling, and heavy equipment industries. They are also beginning to target production of heat treat fixtures and baskets.

Sarah Jordan, CEO, Skuld LLC

Production at the new site is scheduled to begin in April 2024. Sarah Jordan, CEO of Skuld LLC, commented, "Skuld is looking forward to getting our induction melting furnaces installed so that we can produce higher temperature iron, steel, and nickel alloy castings." She continued, "many [heat treaters] have custom furnace components and fixtures that require high temperature metals. These parts can have extremely long lead times, sometimes over a year, which is a problem if they are stocked out." By using their new tooling free processes, Jordan says that they can help clients drive lead times down to less than a month, if not a day for emergency spares.

Skuld is a company founded by two metallurgical engineers, Mark DeBruin and Sarah Jordan, with ties to the heat treat industry. DeBruin is the former CTO of Thermal Process Holdings. Jordan formerly worked in heat treating at Timken and Commercial Metals and was a staff engineer for Nadcap heat treat.

The full press release from Skuld LLC is available upon request.

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ECOACERO Expands Rebar Potential with New Mill

/ ATMOSPHERE AIR FURNACES NEWS, ATMOSPHERE/AIR FURNACES 2, FEATURED NEWS, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS
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ECOACERO, an ESTRELLA Group company, has placed an order for a new rebar mill with a heat treater with North American locations. It will be located nearby Santo Domingo, in Dominican Republic, for serving the growing local and regional construction industry.

The upcoming ECOACERO facility with a rebar mill from SMS group will introduce a versatile range of rebar to the market, tailored to meet the demands of different construction industry segments, manufactured with state-of-the-art technology from SMS, and adhering to rigorous international quality standards.

The complete project, conceptualized with a sustainability philosophy, consists of two phases, with the forthcoming integration of a steel production, involving a melt shop with a continuous casting machine, from the scrap processing.

The scope of delivery of the SMS includes a reheating furnace for billets, feeding a continuous single-strand rolling mill. Products are finished on a MEERdrive® finishing block, a machine that reduces CO₂ emissions and boots plant efficiency. Water boxes in the production process enable steel with improved mechanical properties through quenching and self-tempering of the bars, minimizing the use of expensive alloying elements in the melt shop.

From left to right: Pedro Estrella, Director of ECOACERO; Giuseppe Maniscalco, CEO of industrial division Grupo Estrella; Filippo Verlezza, SMS group and Nicola Redolfi, SMS group (Source: SMS group)

The second phase involves a modern electric arc furnace (EAF), high electrical efficient and designed with burner and oxygen injector technology to reduce CO₂ emissions and operating costs.

The scrap charging-based electric arc furnace will be equipped with the latest SMS technologies for safe and automatic operation aimed at reducing the carbon footprint. The entire melting-refining-casting process line is monitored by X-Pact® Level 2 system.

The plant commissioning is scheduled for the beginning of 2025, pointing to ECOACERO as the one of the largest and modern steel companies in the Caribbean and Central America.

This SMS group press release can be found 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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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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News from Abroad: Furnace Updates and Lowered Emissions

/ ATMOSPHERE AIR FURNACES NEWS, ATMOSPHERE/AIR FURNACES 2, FOUNDRY CASTING, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS / Leave a Comment

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 article, international companies scale up their equipment and scale down their carbon emission. 

German Steelmaker Dillinger Completes Slab Pusher Furnace in Rolling Mill

"The stock corporation of Dillinger Hüttenwerke (Dillinger) has successfully converted its slab pusher furnace 2 in the rolling mill." (Source: Furnaces International)

"For the customer, this means that the availability of large, heavy sheets increases. With these, weld seams can be saved and, thanks to more efficient production, more offshore foundations can ultimately be produced and installed. The modernization of the slab impact furnace, as well as the new edge milling machine for the delivery of “fabricated” offshore wind sheets, is one of a number of investments in the offshore wind market that are currently being planned and implemented at Dillinger."

 

Read More: “Dillinger: Investment in slab pusher furnace successfully completed" at heat processing

 

 

Global Steel Producers Partner To Cut Carbon Emissions

Heat transfer supplier Alfa Laval has created a partnership with Finnish steelmaker Outokumpu to cut carbon emissions. (Source: Furnaces International)

“Most of the Alfa Laval steel purchased from Outokumpu, a global steel manufacturer, will now be the low carbon stainless steel variety. This change applies to heat exchangers used in the energy transition towards a more sustainable energy supply, including energy efficiency, waste heat recovery, and heat pumps. These heat exchangers are currently produced in large quantities with the potential for future growth, says Alfa Laval.”

 

Read More: “"Outokumpu and Alfa Laval partner to cut emissions"  at furnaces-international.com

 

Japanese Steelmaker JFE Steel Plans To Build New EAF To Replace Blast Furnace

JFE's plans for an electric arc furnace will be used for the automotive industry and will reduce carbon emissions. (Source: heat processing)

“The steelmaker is considering building an EAF that can produce 2Mt of high-grade steel when the No.2 unit is due for refurbishment, JFE president Yoshihisa Kitano said. He added that the EAF would reduce CO2 emissions by 2.6Mt/yr from current levels emitted by the blast furnace."

 

Read More: "JFE mulls building 'one of the world's largest' EAFs" at furnaces-international.com

 

 

Indian Manufacturer Refratechnik Group Opens New Factory for Metals Industry  

"The Refratechnik Group opens its new factory in India." (Source: heat processing)

"The state-of-the-art greenfield factory was built to produce MgO-C refractory products, high-alumina bricks, as well as monolithic products for the steel, cement and non-ferrous metal industries. The plant will employ more than 300 people in the short term and more than 400 people in the long term."

 

Read More: "The Refratechnik Group opens a modern factory in India" at heat-processing.com

 

 

 

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Aluminum Rolling Company Expands Operations with Heat Treat Software

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

The aluminum rolling division of ElvalHalcor S.A., Elval, has placed an order for a sustainability suite with a heat treat supplier with North American locations. This technology will be used for Elval’s flat-rolled aluminum manufacturing plant based in Oinofyta, Greece.

Drakotos Athanasios
Electrical & Electronic Maintenance Deputy Director
Elval
Source: LinkedIn

The Viridis Energy & Sustainability Suite from SMS group will contribute to Elval’s goal to reduce carbon emissions and optimize overall production processes. With the installation of two modules of the Suite, Viridis Performance and Viridis Grids, Elval will be equipped to meet the ever-increasing demands for responsible and energy-efficient management in the aluminum industry.

The automated machine learning (Auto ML) resources of Viridis Performance calculate targets automatically, maintaining relevance in changing production conditions. It will comprise over 70 equipment assets, such as melting furnaces, preheating furnaces, hot and cold rolling mills, among others. Viridis Grids will support Elval to precisely and autonomously calculate energy consumption forecast based on the production plan via automated machine learning resources.

Stated Drakotos Athanasios, the electrical & electronic maintenance deputy director at Elval, “Our partnership with SMS group represents a significant step in our sustainability journey. The Viridis Energy & Sustainability Suite aligns perfectly with our commitment to sustainable aluminum production and reducing our energy and environmental footprint. We are confident that this investment will have a positive impact on our operations and support our carbon footprint reduction pathway”.

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Automotive Parts Manufacturer Increases Production Capacity with Nitriding System

/ ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT, FEATURED NEWS, NITRIDING NEWS

Nikola Dzepina
Nitrex Regional Manager – Asia
Source: NITREX

An automotive parts manufacturer, Baida Electronic Equipment Co. Ltd., has recently increased its production capacity with the acquisition of nitriding system from a heat treat supplier with North American locations.

The newly integrated large pit-type nitriding system, model NX-1630 from Nitrex, will play a pivotal role in supporting Baida’s production targets, with a load capacity of 15,400 lb. (7000 kg) and load size of 61″ (1550 mm) in diameter by 118″ (3000 mm) in height.

Says Nikola Dzepina, account executive at Nitrex, “Baida and Nitrex have fostered a strong and enduring partnership over the years. Nitrex engineering and aftersales teams consistently provide essential support and expertise to ensure optimal furnace and application performance. This subsequent order not only strengthens Baida’s manufacturing capabilities but also reaffirms Nitrex’s standing as the preferred partner for companies seeking advanced nitriding solutions.”

 

 

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HVAC Manufacturer To Increase CAB Capabilities

/ ATMOSPHERE AIR FURNACES NEWS, FEATURED NEWS, MANUFACTURING HEAT TREAT, NITRIDING

An HVAC manufacturer contracted a new controlled atmosphere brazing furnace. With this system, the company anticipates gains in both productivity and energy efficiency and reduction in their plant’s overall carbon footprint.

The contract for the system was awarded to SECO/WARWICK’s American subsidiary.

“Their manufacturing line is not a smooth, even flow of identical parts," remarked Marcus Lord, managing director at SECO/WARWICK USA, "Instead, part flow is intermittent and variable sizes. It is why we made the Active Only® CAB Furnace, to meet just such a demand.”

The operating sequence of the Active Only® CAB furnace is divided into stages, including: loading, drying in the dryer, nitrogen purging in the purging chamber, heating and brazing in a proprietary convection chamber, pre-cooling in the cooling chamber with an air-jacket, and the final direct air cooling in the final cooling chamber.

This semi-continuous furnace system will operate on a part-time basis; it will also allow for variable heating and cooling rates, depending on indexing times. Additionally, the furnace can braze the widest variety of heat exchangers when lower total production requirements are needed.

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