AUTOMOTIVE HEAT TREAT NEWS Archives

Automotive Supplier in Alabama Purchases Heat Treatment System from Can -Eng Furnaces

CAN-ENG Furnaces International Limited has been contracted by a large Canadian-based Tier 1 Automotive Supplier located in Alabama to design, manufacture and commission an automated T-7 Heat Treatment System for the processing of high integrity aluminum automotive structural castings. CAN-ENG is a global expert in the design of thermal processing solutions for high pressure die castings (HPDC) and aluminum automotive structural components. CAN-ENG’s technology was chosen for this new light-weighting project because it offers inherent part handling features that reduce floor space requirements and energy consumption. The technology also provides predictable mechanical properties and maintains the dimensional stability of the casting.

The T-7 cell includes Robotic Handling, a Solution and Age Furnace with CAN-ENG’s Precision Air Quench (PAQ ™) technology, and controls integrated into a Level II SCADA system. CAN-ENG’s PAQ™ system offers a unique combination of recirculating air chambers, distribution nozzles, dampers and directional ductwork. Analysis of CFD modelling by CAN-ENG’s R and D Center ensures that the Precision Air Quench System (PAQ™) delivers controlled quench media to the casting, leading to repeatable and uniform mechanical properties and accurate dimensional results. CAN-ENG’s T-7 heat treatment system is integrated with up and down stream processing operations, reducing W.I.P inventories. It is scheduled to be commissioned in the summer of 2016 with a second phase to follow in 2017.

Automotive Supplier in Alabama Purchases Heat Treatment System from Can -Eng Furnaces Read More »

Automotive Engineers Look at Honing after Heat Treating

June 6, 2016 / AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS

Source: Manufacturing Engineering

“Another dramatic change in the process itself is the move away from first hobbing a gear, then shaving it and then heat treating it. Hobbing is a multipoint cutting process that rotates both tool and workpiece in precise relations to each other. It is used to rough cut multiple gear teeth at once. “Today, automakers are hobbing gears, heat treating them and then grinding them post-heat treat. This provides a harder, more robust gear. Post-heat treat finishing of these gears eliminates distortion or changes of geometry in that gear set. The tolerance requirement after grinding is pretty critical,” he said.”

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Magna Announces New Aluminum Casting Facility in the UK

June 3, 2016 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, FOUNDRY CASTING NEWS

Magna International Inc. today announced it will build a new world-class aluminum casting facility in Telford, United Kingdom, to support Jaguar Land Rover, the UK’s leading vehicle manufacturer.

The new facility is expected to be approximately 225,000 square feet and will create up to 295 jobs at full capacity. Working with the UK Trade & Investment and the Automotive Investment Organization, along with financial support from the UK Government’s Regional Growth Fund, helped to secure this project. Construction is expected to start in the autumn of 2016.

Once production begins in 2018, the facility will use Magna’s innovative high-pressure vacuum die casting process to produce a number of advanced lightweight aluminum castings– a key building block in the next generation all-aluminum and multi-material vehicle architectures. By using these types of castings, Magna helps automakers deliver maximum strength and stiffness and minimum weight, ultimately achieving better fuel economy, safety and handling.

“We are excited to work closely with Jaguar Land Rover in the development of this project which will bring the most advanced structural casting technologies to the UK,” said John Farrell, President of Cosma International, an operating unit of Magna International. “As lightweighting continues to be a key technology driver, we are uniquely positioned to help automakers achieve optimal weight savings throughout the vehicle architecture.”

Magna, through its Cosma International operating unit, is one of the world’s premier suppliers providing a comprehensive range of body, chassis and engineering solutions to automakers around the world.

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Automotive Aluminum Extrusion Market Grows

June 3, 2016 / ALUMINUM PROCESSING NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS

Source: Today’s Motor Vehicles – May/June 2016

Making Aluminum Extrusions

Dave Lukasak, director of metallurgy at Sapa Group, explains the process used to create extruded aluminum parts.

Cast logs – A furnace melts primary aluminum, aluminum scrap, and alloying elements to create the alloy. Workers then transfer the molten metal to a casting table where logs are cast in vertical, semi-continuous process. The end result are logs 200″ to 300″ in length.

Homogenize – Ingot casting is a non-equilibrium process, so solidification results in a non-uniform structure that could lead to micro-scale, non-uniform properties in the final product. To counter this, the cast logs are heated to approximately 570°C, depending on the alloy. The resultant metal has a more uniform structure better suited for extrusion and creation of the final product. After homogenization the logs are cooled quickly to lock the uniform structure in place.

Extrusion – Billets and the tool-steel die are heated to between 490°C and 520°C. An extrusion press then forces the billet through the small opening in the die using about 90,000psi. Temperature control is critical as deformation from squeezing material through the die opening increases the temperature of the aluminum significantly. If the temperature of the ingot is too hot, the heat of deformation can take the aluminum to a temperature where tearing occurs as the profile emerges from the die. If the temperature is too low, the physical strength of the final extrusion can be compromised. Employees use two-dimensional dies to create flat profiles or three-dimensional ones to create more complex shapes such as boxed beams. Cathleen Rutsey, an automotive applications engineer at Sapa, says she keeps an old Play-Doh press in her office to demonstrate the basics of controlling extrusion shapes.

Quench – Parts are air-cooled or water-cooled, upon exiting the press, depending on the shape, alloy, and intended use. Quenching locks elements in solid solution critical for developing the final strength of those extrusions that are heat treatable, such as 6000 series alloys.

Age – Finished parts are heated from 175°C to 230°C for up to 12 hours. Following aging, material strength will continue to increase for about a week, so Lukasak says it’s important to use a first-in-first-out (FIFO) inventory management system.

Precipitation aging – Heat-treatable aluminum alloys require artificial aging to achieve the required mechanical properties for the intended application. For 6000 series alloys, extrusions are heated to approximately 175°C to for up to eight hours – specific practices are alloy dependent. If a customer needs to form extrusions, doing so in the precipitation-aged condition can result in cracking, so some customers purchase unaged extrusions to have softer material that has better forming properties. Lukasak adds that even at room temperature, heat-treatable extrusion alloys continue to gain strength through what is termed natural aging. The initial increase is rapid with a 25% to 30% increase in strength in 2 to 10 days, so first-in-first-out inventory management helps create a more consistent forming operation.

Automotive Aluminum Extrusion Market Grows Read More »

Schuler Acquires Leading Die Manufacturer AWEBA

June 1, 2016 / AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, FIXTURE REACKING SYSTEMS NEWS, FOUNDRY CASTING NEWS

Schuler AG, the market leader in forming equipment, is to take over the die construction specialist AWEBA and thus greatly expand its activities in this business field. Based in Aue, Germany, the AWEBA Group is one of the world’s leading full-service providers of dies and fixtures. Under the terms of the purchase agreement, Schuler will acquire a 100 percent stake in AWEBA Werkzeugbau GmbH Aue.

The transaction is still subject to the approval of the relevant anti-trust authorities. AWEBA Werkzeugbau GmbH was previously held by private and institutional investors. The parties have agreed not to disclose any details about the purchase agreement.

AWEBA was founded in 1882 as “Bernhard Hiltmann Spezialfabrik für Schnitt und Stanzwerkzeug”. The company today supplies international customers in the automotive and electrical industries, as well as machine and plant manufacturers. The product portfolio includes forming, cutting, hydroforming, and die-casting dies, as well as fixtures and a comprehensive range of services.
In fiscal year 2015, the AWEBA Group generated sales revenue of around € 60 million.

Schuler CEO Stefan Klebert commented: “We are delighted to add a successfully managed company like AWEBA to our Group. With its high level of expertise in research and development and excellent engineering know-how, the company is a perfect fit for Schuler. The acquisition is part of our growth strategy. AWEBA complements our product portfolio in forming technology in line with market requirements and will expand and strengthen our existing activities in die construction.”

The AWEBA Group employs around 600 people, including almost 200 highly skilled engineers and toolmakers. The company owns 40 valuable patents in the field of die manufacturing.

AWEBA CEO Udo Binder stated: “Becoming a member of the Schuler Group opens up tremendous opportunities for the further expansion of AWEBA. Schuler’s global market standing will enable us to quickly grow our international presence and enhance our profile as a global system supplier. This gives AWEBA growth opportunities which would not have been achievable without Schuler.”

The AWEBA takeover is Schuler’s second major acquisition in the last twelve months. Last year, the company acquired a majority stake in the Chinese press manufacturer Yadon with annual sales of around € 110 million.

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Bodycote To Open New Heat Treatment Facility in Mexico

May 24, 2016 / AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, HEAT TREAT NEWS

Bodycote, the world’s largest thermal processing services provider, today announces the company will open a new, state-of-the-art heat treatment plant in San Luis Potosi, Mexico.

Mexico is one of the largest automotive manufacturing countries in the western hemisphere, with many of the world’s leading car manufacturers investing in manufacturing and assembly plants.

Bodycote’s latest investment, a 100,0002ft facility, established to serve the country’s extensive and growing automotive supply chain, will be capable of supporting large automotive projects and providing the necessary heat treatment services for technologically advanced components, such as complicated transmissions.

The plant, which will be TS 16949 certified as well as holding all required OEM quality approvals, will offer a wide range of heat treatment processes, including low pressure carburizing, ferritic nitrocarburizing, and Bodycote’s proprietary Corr-I-Dur® process.

In addition to the existing Silao and Empalme plants, the San Luis Potosi facility will be Bodycote’s third plant in Mexico and will be able to provide customers with complementary services and qualified backup to the existing sites, if needed. It is scheduled to be fully operational by fourth quarter.

Bodycote To Open New Heat Treatment Facility in Mexico Read More »

GM Dumps Korea as Source for 2017 Holden Commodore

May 23, 2016 / AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS

Source: Wheels

“The same factor that pushed General Motors to quit building the Holden Commodore in Australia – the high cost of labour – appears to have led it to dump a decision to build the first-ever fully imported Holden Commodore in Korea.”

GM Dumps Korea as Source for 2017 Holden Commodore Read More »

Alcoa Unveils Four New Specialty Alloys

April 28, 2016 / ALLOY FABRICATIONS NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, HEAT TREATING ACCESSORIES

Source: Alcoa

“Lightweight, high-performance metals leader Alcoa (NYSE:AA) today launched a family of innovative foundry alloys designed to meet the growing need for both part performance and lightweighting in the automotive industry and beyond.”

Alcoa Unveils Four New Specialty Alloys Read More »

In-House Heat Treatment Process Works Too Well

March 31, 2016 / AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, HEAT TREAT NEWS

Source: Today’s Motor Vehicles

“We developed our own hot-stamping process to be cost competitive,” says Elie Mordovanaki, general manager of operations and engineering for Merit Technologies Worldwide, GNS America’s hot-stamping division. “However, mechanical trimming is not optimal after the heat treating process takes place.”

In-House Heat Treatment Process Works Too Well Read More »

Industrial Batch Ovens to Automotive Supplier

March 15, 2016 / AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS, HEAT TREATING EQUIPMENT, OVENS-HIGH-TEMPERATURE

Wisconsin Oven Corporation announced the shipment of two (2) direct gas fired batch ovens to a leading automotive supplier for tempering tire molds. The tempering process of the molds results in a longer mold life. This industrial oven was designed with the load capacity of 6,000 pounds and provides easy access of loading and unloading of tire molds by fork truck.

Each tempering batch oven has a maximum operating temperature rating of 800°F, work chamber dimensions of 5’0”W x 5’0”L x 8’0”H, and a 6” reinforced insulated floor. The recirculation system utilizes combination airflow which provides both horizontal and vertical upward airflow to maximize heating rates and temperature uniformity of the product. The batch oven is equipped with a 10,850 CFM @ 15 HP belt-driven blower. Supply air is delivered through fully adjustable boxed ducts and side-mounted along the length on each side of the work chambers. The heating system features an industrial air heat burner rated at 850,000 BTU per hour.

“Designing a solution for our customers that improves their production process is always a top priority. Improved work flow and ease of loading/unloading was a focus for this project to increase production efficiencies.” Tom Trueman, Senior Application Engineer, Wisconsin Oven Corporation

Unique features of these tempering batch ovens include:

Load capacity to 6,000 pounds
575-volt electrical capacity
Operating temperatures to 800° F
3/16” plate construction for durability
High volume of air flow; 10,850 CFM
Motorized dampers for quick cool down
Natural gas fired
Programmable controller
Meets all Canadian requirements – CUL, CSA TSSA
Field inspection provided by a trained factory technician
Temperature triggered door locks with safety pull cord

Industrial Batch Ovens to Automotive Supplier Read More »

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