AUTOMOTIVE HEAT TREAT

Nippon Light Metal North America Inc. & ITOCHU Metals Corporation Launch Joint Venture in Georgia

 

Source: Light Metal Age

 

Nippon Light Metal North America Inc. and ITOCHU Metals Corporation have launched a joint venture to construct an aluminum forging plant in Adairsville, Georgia, for the manufacturing of aluminum automotive parts.

The two Japanese metals companies began construction on this new facility in an effort to meet the demand for lighter-weight vehicles.

An excerpt:

“As tighter environment[al] regulations are implemented around the world and the need for lighter-weight vehicles grows, it is expected that demand for aluminum products will also expand further in North America. In establishing a new facility in North America, Nippon Light Metal is aiming to strengthen its global supply structure by drawing on ITOCHU Metals’ business experience and network.”

 

Read more: “Nippon Light Metal Georgia to Build Automotive Aluminum Forging Plant”

 

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Cleveland-Cliffs Acquires AK Steel, Integrating Steel & Iron Ore Production

AK Steel, a leading producer of flat-rolled carbon, stainless, and electrical steel products was recently acquired by Cleveland-Cliffs Inc., an iron ore company, with a definitive merger agreement to position the new company to create a vertically integrated producer of value-added iron ore and steel products.

Lourenco Goncalves, chairman of the board, president, and CEO of Cleveland-Cliffs

Under the terms of the merger, Cleveland-Cliffs will acquire all of AK Steel’s common stock, and expand their capabilities across the entire manufacturing process, from mining to pelletizing to the development and production of finished high-value steel products, including next-generation advanced high strength steels for automotive and other industries.

“By combining the best-in-class quality of AK Steel’s assets and its enviable product mix with Cliffs’ debt profile and proven management team, we are creating a premier North American company, self-sufficient in iron ore pellets and geared toward high value-added steel products,” said Lourenco Goncalves, chairman of the board, president, and CEO of Cleveland-Cliffs, who will lead the expanded organization. He added that the new company “is well-positioned to serve both the blast furnace and electric arc furnace segments.”

Roger K. Newport, CEO of AK Steel

“The combination of Cliffs’ iron ore pellet capabilities and our innovative, high-quality steel product development and production is strategically compelling,” said Roger K. Newport, CEO of AK Steel. “Together, we expect to be able to take advantage of growth opportunities faster and more fully than either company could on its own. With AK Steel’s 120-year heritage, which began in Ohio, and expertise in steelmaking, AK Steel and Cliffs make an excellent combination, which we expect will facilitate a smooth integration process.”

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Carpenter Technology Corporation Opens Facility with Vacuum Heat Treating Capabilities

Carpenter Technology Corporation, a leader in high-performance specialty alloy-based materials and process solutions, recently announced the grand opening of its Emerging Technology Center (ETC) in Athens, Alabama, with capabilities for vacuum heat treating for multiple applications, including aerospace, automotive, energy, medical, defense, and other industries.

Carpenter Technology CEO Tony Thene

With a new, state-of-the-art quick cooling hot isostatic press (HIP) and vacuum heat treating system, Carpenter Technology’s 500,000-square-foot additive manufacturing (AM) facility provides the capability to atomize a range of specialty alloys into metal powder and manufacture the powder into finished parts using AM technology (3D metal printing).

"Our Emerging Technology Center is a critical component of Carpenter Technology’s future growth and development, and is aligned with our business strategy of evolving to an end-to-end solutions provider and influential leader in the AM area," said Carpenter Technology CEO Tony Thene. "We will also use it as a base to launch future investments as we expand our soft magnetics technology platform, scale up additional powder operations, and demonstrate a number of next-generation materials we have under development today."

The ETC investment complements Carpenter Technology’s 500,000-square-foot Alabama manufacturing facility, which began operations in 2014, and produces high-end specialty alloy products, primarily for the aerospace and energy markets.

"We have chosen to continue to invest in North Alabama because it offers three important advantages—a high-quality, tech-oriented workforce, a clear connection with the aerospace industry and a close working partnership with state and local government officials," said Thene.

"I have been looking forward to the opening of Carpenter Technology’s Emerging Technology Center since we joined with company leaders to announce plans for the facility at the Farnborough International Airshow in 2018," said Alabama Governor Kay Ivey. "I’m proud to see this world-class R&D center call Alabama home as we continue to strengthen the partnership with our friends at Carpenter Technology.

 

Main graphic photo credits: Carpenter Technology

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Who’s Winning the Steel v. Aluminum Battle? Both, in the Form of Mixed Materials, per Auto Industry Watchers

 

Source: SME Media

 

It wasn’t long ago that auto industry watchers were casting votes for either steel or aluminum in what was to be a big competition in what metals would be used in automotive lightweighting.

Would it be the heavy-weight champion steel which was ramping up its development of high-strength, lower-weight steels? Or would the new contender on the block, aluminum, gather more adherents to lightweighting in the wake of Ford Motor Company choosing aluminum for its F-150 and Super Duty pickup bodies?

An excerpt:

“A consensus has emerged. The future for the industry is a mix of materials, a mix that will vary from vehicle to vehicle. It’s also likely to be a more complex future, with composite materials making inroads in the long run.”

Jay Baron, retired president of the Center for Automotive Research (CAR), Ann Arbor, Michigan

“You have to take into account all sorts of factors,” said Jay Baron, retired president of the Center for Automotive Research (CAR), Ann Arbor, Michigan. Vibration and stiffness figure into the equation, he said. And there’s cost. “It’s much more than weight and strength.”

Designing and building vehicles with a patchwork quilt approach to materials is how some brands are tackling the lightweighting challenge. Most are also exploring advanced technological processes such as a combination of 3D printing and artificial intelligence, friction welding technology, and rethinking other automotive systems, e.g., braking.

Read more: “Lightweighting’s New Phase

 

Main image credit / caption: Manufacturing Technology Inc. (MTI) / The MTI-built LF35-75 at Lightweight Innovations for Tomorrow is ideal for unique part geometries, near-net shapes and full-size part development for all industries, according to MTI. 

 

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Aluminum Provider Completes Expansion of Extrusion Operation

 

Source: Light Metal Age

 

A Pennsylvania company that provides aluminum fabrication, extrusion, and casting products across a variety of industries recently celebrated the completion of the expansion of its facility in Leetonia, Ohio, where new equipment was installed aimed at increasing the company’s capabilities.

Pennex Aluminum, which was also marking the 40th anniversary of Pennex being purchased by the Metal Exchange Corporation, specializes in aluminum extrusions and fabricated components for the automotive, construction, HVAC, landscaping, and off-road vehicle markets at the Leetonia facility.

 

Read more: “Pennex Aluminum Completes Expansion of its Extrusion Operation in Ohio”

Main image credit / caption: Pennex  / opening of Pennex’s new extrusion press line at Leetonia in 2015.

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Steelmaker Orders Key Furnace Equipment to Produce Advanced High Strength Steels for Auto Industry

A U.S. steel producer recently purchased key process equipment for the existing continuous galvanizing line (CGL) at its Columbus, Mississippi, plant.

Steel Dynamics Inc., based in Fort Wayne, Indiana, plans to modify its current CGL#1 to produce advanced high strength steels (AHSS) for the automotive industry.

ANDRITZ, an international technology group providing plants, systems, equipment, and services for various industries, will supply engineering and delivery of a new direct-fired furnace (DFF), new differential rapid jet cooling (DRJC), and after pot coolers (APC). The project will be implemented during the fourth quarter of 2020.

The ANDRITZ delivery also includes the supply of model-predictive advanced furnace control (AFC) for the complete furnace sections as well as automation and electrical equipment and supervision of erection and commissioning.

 

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Nucor Contracts Quenching Unit, Caster for Kentucky Plate Mill Facility

A company that provides construction and mechanical engineering for the steel and nonferrous metals industry was recently selected for the supply of new equipment for a new plate mill facility, including a quenching unit, a single-strand caster, and other key elements of the production chain.

Nucor Corporation selected The SMS Group to design and produce the single-strand caster for ultra-wide and thick slabs for an annual capacity of 1.45 million tons (1.6 million short tons) at Nucor’s new plate mill facility in Brandenburg, Kentucky. The new casting machine is expected to be one of the largest casters worldwide.

Johnny Jacobs, vice president and general manager of Nucor Brandenburg

“SMS group and Nucor make a good team, and the caster will be essential to the success of our new plate mill facility,” said Johnny Jacobs, vice president and general manager of Nucor Brandenburg.

Incorporated in the project are several special technological features, including robotic applications on the casting platform and an HD mold with fiber optics and electromagnetic stirring, as well as a customized roller apron, a quenching unit, and a second cutting line.

 

Main photo caption: (L-R) Keith Watson, SMS Group vice president; Burkhard Dahmen, SMS Group GmbH president and CEO; John Ferriola, Nucor chairman and CEO; Leon Topalian, Nucor president and COO

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Alfa Romeo Racing Invests in High-Pressure Heat Treatment

A Swiss company that operates Alfa Romeo Racing recently partnered with a global leader in high-pressure heat treatment (HPHT) technology for processing high-performance materials.

Christoph Hansen, head of technical development at Sauber Engineering AG

Sauber Motorsport AG, a part of the Sauber Group of Companies, launched a long-term partnership with Title Sponsor Alfa Romeo in 2018 and have now chosen Quintus Technologies to supply their hot isostatic pressing (HIP) equipment.

"The partnership with Quintus is an important milestone on Sauber Engineering’s Additive Manufacturing journey" said Christoph Hansen, head of technical development at Sauber Engineering AG. "The implementation of the hot isostatic pressing process adds massive value in bringing performance to our car as well as for the demanding needs of our customers. By using Quintus’s HIP technology, the Sauber Group will be able to push the boundaries of what we do even further and bring the materials we produce to an outstanding level."

Jan Söderström, CEO of Quintus Technologies

With the QIH 21 M URQ®, Alfa Romeo Racing has access to Quintus’s proprietary URQ® technology, which allows heat treatment and cooling to be combined in a single process, known as high-pressure heat treatment. The QIH 21 M URQ® has an operating temperature of 2,552°F (1,400°C).

"We are excited to be partnering with one of the most iconic Formula One teams—Alfa Romeo Racing," said Jan Söderström, CEO of Quintus Technologies. “This collaboration brings together two organizations at the forefront of advanced development and product innovation in the AM field. Working with Alfa Romeo Racing also gives us at Quintus a unique opportunity to show a large audience how well the modern HIP technology optimizes material properties."

Main photo credit: Speedcafe

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Ohio Steel Producer Advances Expansion with Order of Tunnel, Shuttle Furnaces

Dual-line tunnel furnace © ANDRITZ

A leading Ohio steel producer recently advanced an expansion project by ordering heat treating equipment to increase its supply of hot-rolled coils for end-use in the automotive sector, as well as construction, agriculture, and general manufacturing applications.

North Star Bluescope Steel Limited, based in Delta, Ohio, recently placed an order with international technology group ANDRITZ for a tunnel furnace along with two shuttle furnaces to convey slabs from casters to the company’s two-stand roughing mill.

Besides the furnace equipment, ANDRITZ will supply Level 1 and Level 2 automation systems. The shuttle furnaces will be installed during the fourth quarter of 2020. The tunnel furnace is scheduled to start production by the end of 2021.

North Star BlueScope also plans on adding a third electric arc furnace and a second continuous caster. The expansion will increase the annual capacity by 800,000 to 900,000 metric tons.

 

Main photo credit: North Star Bluescope Steel 

 

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Global Heat Treater Opens New Facility in Prague

The world’s largest heat treat provider recently marked the opening of its new heat treatment plant in the Czech Republic.

Roman Poslusny welcomes guests to the official opening ceremony.

Bodycote held an official opening ceremony at the new facility in central Prague which has expanded space for broader heat treatment capabilities for the automotive and general manufacturing industries.

“Bodycote is proud to be opening our newest facility in Prague, where we can be close to our customers and grow to meet their future demand,” said Paul Clough, president of Bodycote’s classical heat treatment division for Northern Europe & Asia.

“The Czech Republic is an excellent place for Bodycote to invest in order to support our customers’ supply chains locally,” said Roman Poslusny, vice president of operations of Central Eastern Europe for Bodycote’s classical heat treatment division. “This expansion helps to demonstrate our commitment to our Eastern European customers by providing the best possible service.”

The VIP ceremony was attended by the local mayor of Hostivice (Prague-West district), arch. Klára Čápová, and the British ambassador to the Czech Republic, Nick Archer.

 

Main image credit/caption: Bodycote / Left to right: Paul Clough, President of Northern & Eastern Europe (Bodycote); Klara Capova, Mayor of Hostivice; Nick Archer, British Ambassador; Baris Telseren, Senior Vice President Eastern Europe (Bodycote); Roman Poslusny, Vice President Central Eastern Europe (Bodycote).

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