FEATURED NEWS

Japan-Based Foundry Builds First U.S. Manufacturing Facility

Global manufacturer of alloy castings for the automotive and industrial sectors, Kimura Foundry America, has announced plans to locate its first U.S.-based manufacturing facility in Shelbyville, Indiana. The 35,200-square-foot plant, built on 10 acres of property, will house 3D-printing equipment which will facilitate the production of complex castings and molds for its U.S. clients. Planning to break ground in October 2017, the subsidiary of Japan’s Kimura Group targets a December 2018 opening and plans to create 20 new jobs by 2020.

The company uses a proprietary process for casting molds using 3D printing technology, allowing it to manufacture products including stamping die castings and machine and industrial tool castings. These products are used in automotive engine parts, pumps, compressors and energy components. “Kimura has established a Development Department and is engaged in thoroughly researching improvements in quality and in developments of new products. This approach has enabled us to introduce positive techniques in the casting industry, which used to depend only on workers’ experience and good sense. The results of these research outcomes are fed back to our foundries,” reads the company’s website.

“When we were searching for our first U.S. manufacturing partner, Indiana offered exactly what we were seeking,” said Yoya Fukuda, Ph.D., president of Kimura Foundry America. “That is because Indiana is strategically located in the epicenter of the industries we serve. The state’s highly-developed transportation networks and its highly-skilled manufacturing workforce were an excellent match. Indiana has a long history of welcoming Japanese companies to the state, and we are looking forward to joining the many other Japanese companies in Shelby County.” Kimura Group employs more than 830 associates at its 10 facilities across three locations in Japan and at its North American sales office in Schaumburg, Illinois.

“Shelbyville is a great community in a prime location for industry growth with capable Hoosiers ready to get to work,” stated State Representative Sean Eberhart (R-Shelbyville). “Kimura Foundry America is a perfect fit as they join other global manufacturing companies that already call Shelbyville home.”

Kimura Group employs more than 830 associates at 10 facilities across three sites in Japan and at its North American sales office near Chicago. The company uses a proprietary process for casting molds using 3D-printing technology, allowing it to manufacture products including stamping die castings and machine and industrial tool castings used in automotive engine parts, pumps, compressors, and energy components.

Sources: Business Facilities, Foundry MagazineIndustrial Heating, Indiana House Republicans

 

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Veteran-Owned Heat Treat Supplier Commits 1% of Profits to Warrior 360

Global Furnace Materials, a heat treat industry supplier of refractory metals and carbon fibers based in Janesville, Wisconsin, recently announced the management decision to donate 1 percent of all profits to Warrior 360, a non-profit Veteran support program.

Nick Suchoski, the owner of GFM and a former soldier in the U.S. Army, was introduced to Warrior 360 by his former 1st Sergeant in the 82nd Airborne division. “I believe in giving back to those that made me who I am. My core values were developed through my time in the military, so I feel compelled to give back to the warrior community. My time in the military is the main reason for my successes, both personally and professionally, so this is my way to say thank you, by helping these warriors and their families soften some of the hardships that they have endured,” Suchoski said.

Warrior 360 is a non-profit organization that responds to the immediate needs of military veterans, including medical needs, home repair, and job-procuring skills. “This is just a snapshot of what GFM’s donations go towards,” added Suchoski.

Click here for more information about Warrior 360.

Click here for more information on Global Furnace Materials.

Photo credit: Global Furnace Materials

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Vacuum Furnace Hot Zone Improvement Patent Awarded for Streamlined Manufacture Configuration

An innovation in vacuum furnace hot zone design has landed a new U.S. Patent, No. 9,702,627, for a Souderton, Pennsylvania, vacuum heat treating and brazing furnaces supplier. This hot zone improvement centers on the configuration of heating element supports, providing for simpler, streamlined manufacture of the support assembly. The new design further provides for easy assembly and disassembly of heating elements, a significant improvement over prior designs.

Solar Manufacturing, Inc., recognizes inventors Robert Wilson, Solar Manufacturing’s VP of Engineering, and Mark Hughes, Senior Design Engineer.

Copies of U.S. Patent No. 9,702,627 B2 may be obtained by visiting www.uspto.gov or click here for a pdf of the patent.

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Voestalpine Expands 3D Metal Printing Activities to Asia and North America

In April 2017, a new research center for 3D printing of highly complex metal components launched operations in Singapore, as part of an expansion project that will include two more production plants in Taiwan and Canada in August and the fall. At the same time, voestalpine, a global technology and capital goods group, is expanding metal powder production for additive manufacturing at its subsidiaries Böhler Edelstahl GmbH & Co KG, Austria, and Uddeholms AB, Sweden. These operations follow the successful start of the voestalpine Additive Manufacturing Center in Düsseldorf, Germany, in 2016.

In metal additive manufacturing—also known as 3D printing—digital design data is used to add material layer by layer in order to create highly complex parts with completely new forms and functionalities without any material loss. The base material is different types of processed metal powder. Metal-based additive manufacturing is expanding in sectors such as the aerospace, automotive, tool making, and medical industries that require very sophisticated custom products.

voestalpine Technology Institute Asia, set to open in August 2017 in Taiwan, is the Group’s third research center for metal additive manufacturing. In addition, capacity for high-tech printing for both research and commercial purposes is being built up in Toronto, the first voestalpine site for this manufacturing process in the NAFTA region.

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EJ Americas Begins Construction on New Iron Foundry

 

EJ Americas, a global organization producing and distributing iron castings for municipal and infrastructure programs, broke ground in July for a greenfield foundry being built in Elmira, Michigan, 20 miles east of its current and original location in Warner Township. The new foundry is expected to be in operation by Fall 2018.

Founded in 1883 and previously known as East Jordan Iron Works and rebranded as EJ in 2011, the foundry has an operation that includes a cupola melting shop for ductile iron, three molding lines — automated green-sand molding, no-bake molding, and HWS molding for parts up to 76×60 in. EJ provides castings to the agricultural, forestry, marine and railroad industries, with a niche as a supplier of castings for water, sewer, and drainage systems and telecom and utility networks, and is best known for its production of manhole and utility covers, drainage grates, warning plates, tree grates, fire hydrants, grate valves and other specialized castings.

At the current location, the foundry has automated finish machining, coating, and assembly and testing for fire hydrants and valves. The new foundry in Michigan will expand casting capabilities, although specific details about the melting and casting operation have not been released. The company has a second U.S. plant in Ardmore, Oklahoma, and a network of foundries in Australia, Canada, France, and Ireland.  The corporate headquarters, pattern shop, product development group, water products, and regional sales office will remain in East Jordan.

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Tracked Vehicle Rollers Get Controlled Heat Treatment Using Movicon SCADA

Source: Process and Control Today

 

The accuracy and energy efficiency of the heat treatment for rollers used in heavy duty tracked vehicles such as earth moving equipment, construction, and mining equipment, diesel and natural gas engines, and industrial gas turbines have been improved by the use of a control system based on Movicon SCADA.

The automated production line is part of a large factory in Bologna, Italy, and comes complete with a tempering process involving various heat treatment furnaces, one for annealing,  one for austenitizing, one for the tempering process used for the final heat treatment and three baths for the in‐between quenching process of the austenitized pieces. This is followed by the final stage where a programmed controlled robot is used for the palletization stage to unload, and store finished pieces transported through on the conveyor. The first step is the austenitizing process involving an annealing furnace which heats the metal to obtain a uniform solid structure with complete solubilization of the Cementite (iron carbide) to improve and reinforce both steel roller resistance and endurance. This is followed by the quenching process where three banks have been provided to shunt through more pieces quicker into the first available bath to increase the plant’s productive capacity and protect their quality which may diminish if exposed too long in open air. The baths carry out a repeated process of cooling and tempering by reheating the pieces at specific temperature ranges until the metal reaches the perfect hardness suited for the rollers’ purpose. Once this process is completed, the pieces continue on to the tempering furnace for the final process where they are reheated to a temperature lower than the one used in the quenching stage. Once this temperature has been reached the pieces are then slowly cooled down with temperatures gradually lowered until completely cooled to ensure that tension is reduced within the metal without altering its hardness. When finished the pieces are then ready for palletization by being stacked onto pallets and stored appropriately and ready for the next procedures.

Read more: “Tracked Vehicle Rollers Get Controlled Heat Treatment Using Movicon SCADA”

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IQF Furnace Line Expands Services for Oil-Field Industry Client

An oil-field related industry company recently ordered a complete (IQF) furnace line from Premier Furnace Specialists/BeaverMatic, consisting of a new internal quench furnace, temper furnace, spray/dunk washer, low-temperature industrial oven, 1,500 CFH endothermic generator, and manual load cart. All new equipment is designed to match existing equipment with 30″ x 48″x 26″ loads weighing 1,500 pounds while using standard “Beaver” baskets.

The control system is configured to allow for automated and manual sequencing, recipe management, and digital data collection. Current design meets AMS 2750 E, NEC, and current NFPA guidelines. This design allows for updates to existing equipment for installation of the future SCADA system. Construction will be complete in August 2017.

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15 Atmosphere and Vacuum Furnaces Shipped to Aerospace, Commercial, MIM Industry Customers

Fifteen atmosphere and vacuum furnaces were shipped to customers in aerospace, commercial heat treating and MIM industries around the world during the second quarter of 2017, including China, Hong Kong, India, Japan, Saudi Arabia, and the United States.

The shipments included:

*   Two large, vertical (bottom-loading) MetalMaster® vacuum furnaces, each with a 120″ (3 m) diameter work zone and 10,000-pound (4,500 kg) load capacity
*   Five standard TITAN® vacuum furnaces complete with PdMetrics®
*   Debind and sinter vacuum furnaces for the MIM industry
*   ATLAS integral quench atmosphere furnace, which was delivered six weeks after order placement

In addition to these transactions, Ipsen USA of Cherry Valley, Illinois, delivered several custom-built vacuum furnaces that will process parts for the aerospace industry.

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Hauck Heat Treatment Dzierżoniów Installs New EMO Washing Machine

Hauck Heat Treatment Dzierżoniów recently installed at its facility in Poland a new EMO Oberflächentechnik cleaning and degreasing machine (model VAIOCS S) with a batch size of 1220mm x 910mm x 760mm.

The EMO degreaser can use organic solvents such as hydrocarbons (AIII), modified alcohols and chlorinated hydrocarbons to allow perfectly tailored cleaning, ensuring all surfaces are free of dirt and residues. The parts are fully and efficiently dried due to the integrated vacuum drying system. Thanks to the patented design of the machine, it can clean and dry parts with even the most complex geometry – even those which are difficult for other cleaning and degreasing machines. The technology used in the EMO degreaser is state-of-the-art and allows environmentally friendly processes and a reduced energy consumption.

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TMK IPSCO restarts operations at Tulsa Port of Catoosa

Source:  Tulsa World

Keith Marquart leads a tour of the control room of the TMK IPSCO facility at the Tulsa Port of Catoosa. Photo Credit: Cory Young/Tulsa World

When the price of oil nosedived, one of this area’s casualties was TMK IPSCO, which idled its plant in September 2015.

“There was really no business for us,” said Joel Mastervich, vice president and chief operating officer of the company, which does welding, heat-treating, and threading on pipes used in drilling operations. “We had to make tough decisions back then. So we did.”

TMK IPSCO celebrated the restart of operations—and the creation of 168 jobs by year’s end—at a news conference August 8, 2017, at the Tulsa Port of Catoosa.

Read more: “Manufacturer restarts operations at Tulsa Port of Catoosa

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