AUTOMOTIVE HEAT TREAT NEWS

40-Ton Melting Furnace Heads to Mexico Aluminum Operation

/ ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT NEWS, BURNERS COMBUSTION SYSTEM NEWS

Neuman Aluminium is adding aluminum melting capacity at a new production operation in San Juan del Río, Mexico, where a 40-ton tiltable melting furnace will support on-site remelting of process scrap for automotive component production. The project integrates melting with aluminum forging operations as the manufacturer builds out its North American production capabilities.

Contract signing between Neuman Aluminium and Hirschvogel Group | Image Credit: Neuman Aluminium

The new operation is part of a partnership between Neuman Aluminium and Hirschvogel Group at Hirschvogel’s existing site in San Juan del Río. Neuman will produce directly at the site under a wall-to-wall manufacturing agreement, with a hall for input-material production expected to be ready for occupancy in July 2027.

Hirschvogel previously announced that construction had begun on two new production halls, each spanning approximately 7,500 square meters (80,730 square feet), following an automotive OEM contract for aluminum components to be produced in Europe and North America. The company said the Mexico operation would incorporate aluminum forging and integrated input-material production.

The new melting furnace will be supplied by Jasper GmbH and equipped with the company’s PulsReg pulsed regenerative burner technology. The system is designed for dusty furnace atmospheres and can operate using gas, oil, or coal dust. Jasper has identified the installation as its first major project in North America.

The integrated operation will allow process scrap generated during forming to be remelted directly on site and returned to the material cycle. Production at the expanded Mexico operation is scheduled to begin in early 2028.

Press release is available in its original form here.

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Annealing Line Modernization Supports Gen3 Steel Production

/ ANNEALING NEWS, AUTOMOTIVE HEAT TREAT NEWS

Hyundai Steel has completed a modernization of its continuous annealing and galvanizing line, integrating induction heating, rapid cooling, and thermal process controls to increase production of ultra-high-strength Gen3 steel for automotive applications.

The steelmaker contracted Fives, an international engineering group and thermal processing equipment supplier, to modernize the combined continuous annealing and galvanizing line (CVGL) at its No. 2 cold rolling mill in Dangjin, South Korea. The companies are also working together in North America, where Gives is supplying advanced coil finishing lines for Hundai-POSCO Louisiana Steel’s new 2.7-million-metric-ton-per-year automotive steel facility in Louisiana.

The Dangjin modernization focused on three areas: replacing the cooling section, integrating induction technology, and optimizing thermal control. The upgraded line incorporates Fives’ Dry FlashCooling technology operating with 75% hydrogen, including a recirculation system designed to reduce hydrogen and nitrogen consumption.

FlashCooling technology | Image Credit: Fives

A 4 MW CELES induction system was installed to provide rapid and uniform heating. The modernization also incorporated Fives’ Virtuo-L digital system for thermal process control tailored to Gen3 steel production.

The new cooling system provides temperature uniformity across the width of the steel strip within ±5°C (±9°F), including at high blowing speeds. The Virtuo-L system controls process parameters in both annealing and galvanizing modes.

After one year of operation, Fives reported 100% use of automatic speed control and 95% strip temperature accuracy. According to the supplier, heating control performance improved by 2% and cooling control performance by 1% compared iwth the previously installed system.

Press release is available in its original form here.

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Louisiana EAF Steel Mill Launches $5.8B Project

/ AUTOMOTIVE HEAT TREAT NEWS, FOUNDRY CASTING NEWS

A $5.8 billion electric arc furnace (EAF)-based integrated steel mill project has launched in Louisiana, establishing a new domestic source of automotive steel that will combine on-site direct reduced iron (DRI) production with EAF steelmaking. The facility is targeted to begin commercial production in 2029 with an annual capacity of 2.7 million metric tons of hot-rolled and cold-rolled steel sheet, primarily for automotive applications.

Hyundai Steel Company held a ceremonial event for the project at the RiverPlex MegaPark in Ascension Parish, Louisiana. The mill will be operated by HYUNDAI-POSCO Louisiana Steel LLC (HPLS), a joint venture between Hyundai Steel, POSCO, Hyundai Motor Company, and Kia Corporation. The investment establishes Hyundai Steel’s first North American steel production base.

The facility will establish an integrated production system connecting on-site DRI production with EAF steelmaking and downstream production of automotive steel. A direct reduction plant will produce DRI on site and feed it directly into two EAFs through a continuous charging system. The configuration is designed to improve production efficiency and enable a higher share of DRI to be used in producing advanced steel grades.

Advanced refining and continuous casting facilities will be used to manage impurities such as nitrogen and sulfur to meet automotive steel quality requirements. The production route is expected to reduce carbon emissions from molten steel production by approximately 70% compared with the company’s conventional blast furnace process in Korea.

The facility will also incorporate carbon capture capabilities and is being designed to gradually replace the natural gas used in the direct reduction plant with hydrogen as infrastructure and availability develop.

With an annual steel production capacity of 2.7 million metric tons, the Louisiana mill will supply automotive steel to Hyundai Motor’s Alabama plant, Kia’s Georgia manufacturing facility, and Hyundai Motor Group Metaplant America, as well as other U.S. automakers. Producing automotive steel closer to clients is expected to strengthen supply stability, shorten delivery lead times, and enable faster technical and quality support.

Bo-Ryong Lee
President and CEO
Hyundai Steel Company

“Today, we are not simply announcing the construction of a new steel mill. We are standing at the starting point of a journey to shape the future of industry in Louisiana together,” said Bo-Ryong Lee, president and CEO of Hyundai Steel. “We aim to serve as a key supply chain partner to the North American automotive industry by providing a stable supply of high-quality automotive steel to [clients] in the United States and around the world.”

The project is part of Hyundai Motor Group’s $26 billion U.S. investment commitment through 2028. The Louisiana mill is expected to support 5,400 jobs, including 1,300 direct positions.

Press release is available in its original form here.

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Cleveland-Cliffs Invests $1B in Steelmaking Modernization

/ AUTOMOTIVE HEAT TREAT NEWS

Cleveland-Cliffs is investing $1 billion to modernize its Middletown Works steelmaking facility in Ohio, including upgrades and a planned rebuild of the site’s blast furnace as part of a broader project focused on production efficiency and emissions reduction.

The investment will be funded equally by Cleveland-Cliffs and a $500 million grant from the U.S. Department of Energy (DOE). The project is expected to extend the operating life of Middletown Works while maintaining its existing steelmaking capacity.

The modernization will include upgrades to the blast furnace, advanced material-handling infrastructure, and AI-enabled process controls. Cleveland-Cliffs also plans to construct a cogeneration facility that will capture blast furnace gas and use it to generate electricity and steam for the plant.

The company expects the cogeneration system to reduce Middletown Works’ reliance on purchased electricity and natural gas while lowering greenhouse gas emissions associated with the facility’s operations.

The project is expected to begin in 2026, with the blast furnace rebuild scheduled for completion in the first quarter of 2030. Cleveland-Cliffs anticipates that construction will support approximately 2,500 jobs while maintaining about 2,500 existing positions at Middletown Works.

Located in Middletown, Ohio, the integrated steelmaking facility produces approximately 3 million tons of raw steel annually. Its products primarily serve the automotive market, including applications requiring advanced high-strength steels.

Press release is available in its original form here.

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Major Steel Plant Shifts to Electric Steelmaking

/ AUTOMOTIVE HEAT TREAT NEWS

A major steel plant is replacing its existing blast furnace route with electric steelmaking as part of a transition to lower-emission steel production. The project will convert the facility into an electric arc furnace-based operation while supporting continued production of high-quality flat steel products, including grades used in the automotive industry.

Tenova, a global industrial furnace and metals technology supplier with North American operations, will supply the electric arc furnace for the transformation of Hüttenwerke Krupp Mannesmann (HKM) in Duisburg, Germany. The furnace, designed with a production capacity of 2.5 million tons per year, will be Germany’s largest electric arc furnace and will become the technological center of the plant’s transition under its new owner, Salzgitter AG.

The investment marks the beginning of a new phase for the Duisburg-Huckingen steelworks. By replacing the existing blast furnace route with electric steelmaking, HKM expects to reduce the carbon footprint of its operations while maintaining the plant’s competitiveness. The project reflects continued investment in electric steelmaking technologies as steel producers pursue lower-emission manufacturing.

Tenova’s scope of supply includes a 285-ton Consteel® EAF, complete with auxiliary plants on a turnkey basis. The furnace will incorporate Tenova’s Consteel® continuous scrap charging technology and an Electro Magnetic Stirring (EMS) System developed in partnership with ABB. It is designed to deliver a continuous production rate of 380 tons per hour to the existing secondary metallurgy line and slab caster, enabling production of high-quality flat steel products, including grades that meet automotive industry standards. The new facility will be installed in a dedicated building within the HKM production site.

Paolo Stagnoli
Sales and Marketing Director for EAF & LF
Tenova

According to Paolo Stagnoli, sales and marketing director for EAF & LF at Tenova, the project followed an extensive period of collaboration between HKM and Tenova to develop a solution tailored to the operational requirements of the Duisburg steelworks. “It took almost two years of joint studies and intensive discussion between HKM and Tenova to define this ambitious project and fine-tune the technological solution to the unique constraints and needs of the productive site,” he said.

The project expands Tenova’s portfolio of electric arc furnace installations and reflects continued adoption of electric steelmaking technologies designed to improve process efficiency, reduce energy consumption, minimize environmental impact, and support lower-carbon steel production.

Press release is available in its original form here.

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AI Inspection for Forging Quality Control

/ AUTOMOTIVE HEAT TREAT NEWS, FORGING NEWS

Hirschvogel is implementing automated inspection of closed-die forgings to replace manual visual checks, enabling faster detection of surface defects and dimensional deviations in automotive components. The approach supports more consistent quality outcomes in forged parts while reducing error rates and scrap in high-volume production environments.

Working in partnership with SMS group, a global supplier of materials industry technology with North American headquarters in Pittsburgh, Pennsylvania, Hirschvogel, a global automotive supplier specializing in solid metal forming, has deployed an automated final inspection system for closed-die-forged components at its Denklingen, Germany, facility. The system replaces an existing manual testing station with a fully digital process designed to evaluate each component in seconds.

3D rendering of the test station: Visualization of the automated final inspection for closed-die-forged automotive components. | Image Credit: SMS group
The automated final inspection allows various types of closed-die forging defects to be identified and categorized (example shown). | Image Credit: SMS group

The inspection solution integrates automated handling and high-resolution imaging to assess surface conditions and geometry. A robot moves forgings directly from transport containers, while camera sensors capture images that are analyzed in fractions of a second. Detected defects are classified against a digital catalog, reducing the likelihoos of misclassification and minimizing pseudo-scrap, or the disposal of acceptable parts.

The system was developed in cooperation with image processing specialist Sightwise as well. As part of SMS group’s iForge digitalization platform, the inspection is designed to integrate into forging production lines and support automated quality assurance workflows.

Axel Rossbach
Forging Technology Expert
SMS group

A key feature of the system is its use of synthetic training data to develop inspection models. Instead of relying on physical samples of defective parts, the system uses CAD and 3D model data to simulate material properties, surface textures, and defect types. This allows analysis models to be prepared within hours rather than weeks.

“The new system enables us to speed up the final inspection significantly and ensure maximum process stability in the line itself,” said Axel Rossbach, forging technology expert at SMS group. The scalable system can also be adapted to new product variants, supporting production flexibility in automotive forging operations.

Press release is available in its original form here.

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GM Invests in Casting Capacity Expansion

/ AUTOMOTIVE HEAT TREAT NEWS, FOUNDRY CASTING NEWS

General Motors announced plans to invest more than $150 million in its Saginaw Metal Casting Operations facility in Michigan to support production of V8 engine blocks and cylinder heads used in full-size trucks and SUVs. The project includes new and upgraded equipment for casting and machining operations, enabling the facility to increase production capacity and maintain output for current engine programs. The Saginaw site has supplied engine components for multiple generations of GM vehicles.

This new commitment builds on the approximately $5.5 billion in investments GM made in 2025, underscoring GM’s support for U.S. manufacturing, while securing the future of this facility and its employees.

“By enabling the production of next-generation engine blocks and cylinder heads for full-size trucks, the plant is well-positioned for the future. This not only secures existing jobs but also strengthens the local economy, and ensures the plant continues to be an integral part of the automotive supply chain,” said John Lancaster, plant director.

Press release is available in its original form here, where readers can also watch an embedded video providing additional context on the investment.

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Heat Treat Capacity Expands in Northern Mexico

/ AUTOMOTIVE HEAT TREAT NEWS, HARDENING NEWS, MEDICAL HEAT TREAT NEWS, NITRIDING NEWS

Bodycote announced plans to open a new heat treatment facility in Apodaca, Mexico, expanding regional capacity for case hardening and nitriding processes used in automotive, industrial, and medical components. The additional capacity is expected to support growing manufacturing activity by improving supply chain responsiveness and access to localized thermal processing services.

Extending its network to better support clients across Mexico and the southern United States, the site is intended to reduce logistical complexity and strengthen supply chain resilience while supporting ongoing near-shoring efforts. The new facility will complement existing operations in Silao, San Luis Potosí, and Guaymas, providing additional flexibility for clients requiring regional heat treating services. Scheduled to open in 2026, the site will support both new and existing programs as demand grows across key manufacturing sectors.

Operations at the facility will include a range of precision heat treatment capabilities, including carburizing, carbonitriding, and nitrocarburizing. These processes are used to improve surface hardness, wear resistance, and fatigue performance while maintaining core strength in critical components.

Bodycote is engaging with clients early to support future capacity planning and qualification activities, with site tours planned for Q2 2026. The facility is expected to ramp up operations in phases as demand increases.

Press release is available in its original form here.

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Linamar Boosts Gear, Forging Capabilities with Acquisition

/ AUTOMOTIVE HEAT TREAT NEWS, FORGING NEWS

Linamar Corporation, a North American manufacturer with in-house heat treating capabilities, has acquired select assets of Winning BLW, strengthening its capabilities in warm forging and precision gear manufacturing for automotive and industrial applications. The acquisition supports production of bevel and helical gears, components that typically require controlled heat treating to achieve the hardness, wear resistance, and fatigue strength needed for drivetrain systems.

The facilities included in the transaction are located in Remscheid and Penzberg, Germany, bringing established expertise in forging and gear production into Linamar’s global manufacturing network. The Remscheid facility handles mass production of high-performance precision bevel and intermediate gears for light vehicle market, while the Penzberg facility specializes in helical gears and high-precision components serving the commercial and off-highway sectors. Through these acquisitions, Linamar expands its offering of precision bevel and helical gears, as well as small- to medium-sized drivetrain and transmission components.

Jim Jarrell
CEO and President
Linamar Corporation

“These acquisitions are a great strategic fit for Linamar. They strengthen our technology and manufacturing capabilities in products where we are already strong, deepen relationships with key global [clients], and position us for continued growth by increasing our content per vehicle across multiple markets,” said Jim Jarrell, CEO and president of Linamar.

The additions strengthen Linamar’s position in designed and machined gears, deepen its forging capabilities, and support its vertically integrated manufacturing approach.

Press release is available in its original form here.

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Global Automotive Supplier Acquisition Expands Operations

/ AUTOMOTIVE HEAT TREAT NEWS, SINTERING POWDER METAL NEWS

Dauch Corporation has completed its acquisition of Dowlais Group plc, combining two global automotive manufacturers in a move that expands driveline, metal forming, and powder metallurgy operations worldwide. The transaction broadens manufacturing capabilities and strengthens support for internal combustion, hybrid, and electric vehicle platforms across global markets.

David C. Dauch
Chairman and CEO
Dauch Corporation
Image Credit: Detroit Regional Chamber

Dauch Corporation finalized its previously announce acquisition of Dowlais Group plc, including subsidiaries GKN Automotive and GKN Powder Metallurgy. David C. Dauch, chairman and chief executive officer, said the closing marks an important step in bringing together complementary engineering and manufacturing capabilities under one organization.

The combined business will operate under the Dauch Corporation name and remain headquartered in Detroit. The board of directors will expand to include Simon Mackenzie Smith and Fiona MacAulay as independent directors, effective February 5, 2026.

The leadership structure includes Michael J. Lynch as president of driveline and Markus Bannert as president of metal forming, along with executives overseeing finance, strategy, human resources, communications, and legal functions. Business unit leadership includes Tolga Oal as president of axle systems; Mark Gabriel as president of sideshafts, propshafts, and ePowertrain; Jake Stiteler leading forging operations; and Jean-Marc Durbuis leading powder metallurgy operations.

Dauch Corporation supplies driveline and metal forming products to the global automotive industry and reports operations in 24 countries with more than 175 locations worldwide.

Press release is available in its original form here.

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