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Practical Approach to Determining Effective Case Depth of Gas Carburizing

BOTW-50w  Source:  Gear Technology

“Effective case depth is an important factor and goal in gas carburizing, involving complicated procedures in the furnace and requiring precise control of many thermal parameters. Based upon diffusion theory and years of carburizing experience, this paper calculates the effective case depth governed by carburizing temperature, time, carbon content of steel, and carbon potential of atmosphere. In light of this analysis, carburizing factors at various temperatures and carbon potentials for steels with different carbon content were calculated to determine the necessary carburizing cycle time. This methodology provides simple (without computer simulation) and practical guidance of optimized gas carburizing and has been applied to plant production. It shows that measured, effective case depth of gear parts covering most of the industrial application range (0.020 inch to over 0.250 inch) was in good agreement with the calculation.”

Read More:  Practical Approach to Determining Effective Case Depth of Gas Carburizing by March Li

March Li Metallurgist, Automotive Heat Treating, Practical Approach to Determining Effective Case Depth of Gas CarburizingAuthor March Li -Metallurgist

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TITAN® Vacuum Furnaces Take a Journey

Ipsen’s TITAN® product line has had quite the journey over the past few years. Found in facilities around the world, these vacuum furnaces can operate in most languages, feature several sizes and configurations and have a small footprint. Now, the PdMetrics® software platform for predictive maintenance also comes standard on TITAN heat-treating systems.

Most recently, Ipsen delivered two TITAN H2-size vacuum furnaces with 1.9-bar gas quenching and the PdMetrics platform to Japan. Shipped within three weeks of each other, these furnaces will be used by separate commercial heat treaters and feature 18” x 24” x 18” (455 mm x 610 mm x 455 mm) graphite hot zones with a 1,000-pound (450 kg) load capacity. They operate at temperatures up to 2,400 °F (1,320 °C) with ±10 °F (±6 °C) uniformity, and are capable of meeting applicable AMS 2750E and Nadcap requirements.

Through the PdMetrics platform – which securely connects to a network of integrated sensors on the furnace to gather and analyze data, run algorithms and provide real-time diagnostics – these TITAN furnaces provide sophisticated monitoring of critical systems and key parameters that improve the health and integrity of the equipment. Both companies also took a proactive approach to preventative maintenance by ordering one of Ipsen’s many spare parts kits. These kits consist of consumable and preventative maintenance items to help ensure equipment uptime and keep the furnace running smoothly.

Ipsen’s TITAN vacuum heat-treating systems provide an advanced solution in the form of speed, reliability and versatility of process capabilities. However, Ipsen is more than just an equipment manufacturer. They also offer expert-driven solutions for customers’ needs through all stages of the system’s life cycle, no matter the location – whether it is facilitating on-site installation, providing expert training and start-up assistance or delivering responsive field support and spare parts.

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GE to Purchase LM Windpower

LM Group Holding A/S announces today that Doughty Hanson, the European private equity firm, has agreed to sell its stakes in LM Wind Power Holding A/S to GE for an enterprise value of EUR 1.5 billion.  The transaction is expected to close in the first half of 2017, subject to regulatory approvals. The acquisition is valued at 8.3 times 2016 forecast EBITDA. LM Wind Power Holding A/S is the parent company of LM Group Holding A/S. The closing of the transaction will constitute a change of control under LM Group Holding A/S’s EUR 130 million fixed rate notes due 2019 and NOK 475 million floating rate notes due 2020.

Originally founded in 1940 as a furniture manufacturer, LM Wind Power has evolved to become one of the leading manufacturers of rotor blades for the wind industry. It has a global manufacturing footprint of 13 sites in eight countries across four continents and continues to expand.

For the first half of 2016, the company reported sales of EUR 491 million and EBITDA of EUR 87 million which represented year-on-year growth of 40% and 81% respectively.  In June of this year, LM Wind Power unveiled the world’s longest ever blade at 88.4 meters long, demonstrating the Company’s continued strength in technology and manufacturing.

Commenting on the transaction, LM Wind Power CEO Marc de Jong, said:

“The offer from GE makes clear commercial sense for the growth of LM Wind Power and we are absolutely delighted with the prospects of having a world leader as our owner. It provides us with the necessary stability, visibility and strength to continue to realize the ambitious growth plans of the business and fully utilize our advanced design and technology, improve our manufacturing capabilities and reliability, expand our global footprint and reduce the Levelized Cost of Energy. It’s a great day for LM Wind Power and for the wind industry!”

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Heat Treat Basics: Bringing Nadcap to the Medical Industry

BOTW-50w  Source:  Power Transmission Engineering June 2016

“For suppliers, the other way to get involved is obviously through getting audited for accreditation. If you’re interested in an audit, the process is fairly straightforward. Once in contact with MedAccred, a supplier details their products and figures out what categories they should be applying for.”

Find out what medical options are available to the heat treating world by reading:  Bringing Nadcap to the Medical Industry

 

 

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Ampco-Pittsburgh Acquires ASW Steel Inc.

 

John Stanik CEO Ampco-Pittsburgh

John Stanik - CEO Ampco-Pittsburgh

Ampco-Pittsburgh said it would pay $3.5 million in cash and assume $9.6 million of the Welland, Ontario, company's liabilities. ASW will become a part of the Union Electric Steel Corp. division of Ampco-Pittsburgh. The manufacturing plant, with an electric arc furnace, is located close to the U.S.-Canadian border near Niagara Falls, N.Y., and Buffalo. It was founded in 1918 as the Dillon Crucible Steel Alloy Co. and was acquired by MMFX in 2010.

"This acquisition is a very important element in Ampco-Pittsburgh’s strategic diversification plan," said John Stanik, CEO of Ampco-Pittsburgh, in a statement. "ASW’s proven broad expertise in flexible steel refining methods will provide us with the capabilities to manufacture the additional chemistries needed to expand our reach in the open-die forging market. The transaction also enhances our ability to grow in markets in which we currently participate and to add new markets for customers in the oil and gas, power generation, aerospace, transportation, and construction industries.”

Ampco-Pittsburgh Acquires ASW Steel Inc. Read More »

Dana to Purchase Strategic Driveline Production Assets of SIFCO S.A.

Dana Incorporated announced a definitive agreement to purchase strategic assets of SIFCO S.A., a leading producer of forged and machined components located in Brazil.

Under the terms of the proposed purchase, Dana would acquire manufacturing and other assets of SIFCO. This acquisition will enable Dana to enhance its vertically integrated supply chain, which will further improve the company’s cost structure and customer satisfaction by leveraging SIFCO’s extensive experience and knowledge of sophisticated forged components.

“For nearly 70 years, Dana has operated in Brazil, which has long been one of the top ten economies in the world,” said James Kamsickas, president and chief executive officer of Dana. “This is an opportune time to invest in strategic and selective assets in Brazil that will further strengthen our position as one of the most trusted, top-tier suppliers to the mobility industry – thus positioning us for future profitable growth throughout the region.”

By expanding manufacturing capabilities in Brazil, the acquisition will also enable Dana to help vehicle manufacturers better accommodate local content requirements, which reduce import and other region-specific costs. It will also further strengthen Dana’s position as a central source for products that use forged and machined components throughout the region.

“Dana has worked with SIFCO for 40 years as a supplier of key components used in vehicle drivelines,” said Mark Wallace, president of Dana Commercial Vehicle Driveline Technologies. “This acquisition will add the talent and capabilities needed to help us meet the requirements of our commercial-vehicle customers and provide value for our light-vehicle and off-highway customers, as well.”

SIFCO has operated under judicial restructuring since 2014, and the transaction is subject to closing conditions, including bankruptcy court and regulatory approvals.  Final financial terms of the agreement are subject to the outcome of closing conditions. The transaction is expected to be completed by the end of 2016.

Dana designs, manufactures, and distributes products in Brazil for virtually every major global producer of passenger vehicles, commercial trucks, and off-highway equipment.

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AMRICC to Use Field-Enhanced Sintering Pilot Plant

The Applied Materials Research, Innovation and Commercialisation Company (AMRICC) is a high-technology center where advanced materials and processes will be fast-tracked into commercial products rapidly and economically – and at the same time scientists of the future will be developed to create a ‘talent pipeline.’

Focused on putting Stoke-on-Trent and Staffordshire at the heart of the global advanced materials economy, AMRICC’s research laboratory, pilot plant and educational facility will be used to channel the expertise and heritage in steel and ceramics within the region for a new generation.

The launch event, which took place at the Moat House Hotel in Festival Park, followed the official opening of the Ceramic Valley Enterprise Zone, with which AMRICC will be closely associated.

Dr Cathryn Hickey, AMRICC chief executive, said: “AMRICC offers the UK – and Stoke-on-Trent and Staffordshire in particular – a unique opportunity to become the world leader in the commercialisation of materials and materials process development.”

Traditionally, once a new material or process is discovered, bringing it to commercial use in the marketplace has taken up to 20 years or more.

This is quite an unbelievable time lag which can result in a host of missed opportunities for all involved.

In some cases the flow of innovation to fully commercialised products never happens and it’s this ‘valley of death’ which AMRICC will address.

AMRICC’s unique collaboration between academia and industry partners will help companies drive innovation to develop, manufacture and deploy advanced materials much faster and at a fraction of the cost.

This will enable new business models and approaches to collaboration to be achieved, and these will extend beyond the current open innovation concept.

Fully integrated solutions involving material innovation, as well as new process technology will enable unmet customer needs and new market challenges to be addressed.

With its state-of-the-art facilities, AMRICC will not only deliver commercialisation expertise, it will also be a centre of excellence for a number of exciting new disruptive technologies, which are on their way to market and are set to shake up current ways of working.

These areas include the development of unique encapsulation materials for drug abuse deterrent formulations, which are in significant market demand in the US.

And with the world’s first field-enhanced sintering pilot plant, which is a unique way of reaching extremely high temperatures very rapidly, AMRICC will be developing, with partners, a number of beneficial applications to bring to market.

These include thermal barrier coatings for the aerospace and automotive sectors as well as sensor technologies for the electronics industry.

But it’s not just about developing materials and technologies – at AMRICC we’re also proud to be developing people.

Working with some of the world’s leading universities, AMRICC will be delivering Master’s Degrees and PhDs to develop the ‘commercial technocrats’ of the future – materials scientists with both business acumen and a wide range of commercial and industrial experience.

AMRICC is being set up with the support of the international materials technology company Lucideon as well as Stoke-on-Trent City Council and the Stoke–on-Trent and Staffordshire Local Enterprise Partnership.

It will be initially based alongside Lucideon’s headquarters in Penkhull and, in future, is set to establish within the Ceramic Valley Enterprise Zone – to be developed on along the A500 corridor in Stoke-on-Trent and Newcastle under Lyme.

Dr Hickey added: “The launch of the Ceramic Valley Enterprise Zone and AMRICC today marks a significant and exciting day for the region.

In the future, we plan for AMRICC to be positioned within the Ceramic Valley Enterprise Zone where it will help to attract companies to the area, so it’s quite fitting that the company is launched today alongside the Enterprise Zone.

We look forward to working with our colleagues in the Ceramic Valley to drive the reputation of Stoke and Staffordshire in manufacturing and materials processing.

AMRICC to Use Field-Enhanced Sintering Pilot Plant Read More »

Vacuum Assisted High Pressure Die Casting Technology Used in Manufacturing

BOTW-50w  Source: La Metallurgia Italiana –

Primary aluminum-silicon-magnesium alloys are by far the most widely used type in the manufacturing of safety parts for the automotive industry, such as suspension components and wheels, due to their excellent castability and good mechanical properties which can be further improved by heat treatment: solution, followed by water quenching and artificial aging T6 or T7. The recent structural castings, being extremely thin walled (of the order of 2.5 mm) and of rather great dimensions usually require the
use of High Pressure Die Casting. These parts must be defect free and heat treatable to attain the requested properties, ductility and weldability being the most difficult to achieve. Vacuum must be applied as well as a combination of precautions relative to the die design, die lubrication, melt quality and shot profile have to be taken.

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RHI, Magnesita Combine Creating a Leading Refractory Company

RHI and the controlling shareholders of Magnesita, GP and Rhône (“Magnesita’s Controlling Shareholders”), have reached an agreement to combine the operations of RHI and Magnesita to create a leading refractory company. The combined company, to be named RHI Magnesita, will be established in the Netherlands and listed in London.

Accordingly, RHI’s Management Board has agreed to sign a share purchase agreement with Magnesita’s Controlling Shareholders regarding the acquisition of a controlling stake of at least 46%, but no more than 50% plus one share of the entire share capital in Magnesita, pending RHI’s Supervisory Board approval.

The consideration for the 46% stake will consist of cash amounting to € 118 million and 4.6 million new shares to be issued by RHI Magnesita.

A subsequent mandatory tender offer will be launched as a result of which a maximum number of 5.4 million RHI Magnesita shares will be issued, bringing the total number of newly issued RHI Magnesita shares to up to 10.0 million. The offer will also include a cash-only alternative amounting to € 8.19 per Magnesita share.

As a result of the transaction, GP, Magnesita’s largest shareholder, will become a relevant shareholder of RHI Magnesita and will be represented on its board of directors.

Following registration of the corporate restructurings, RHI’s shares will cease to be listed on the Vienna Stock Exchange. RHI’s migration from Austria and listing in London are subject to approval by RHI’s shareholders’ meeting. The transaction is also subject to approvals by relevant competition authorities. The place of effective management will be Austria.

The transaction is expected to complete in 2017. Both companies will remain completely separate and independent until then RHI Magnesita will be a leading refractory company with an enhanced growth profile due to improved regional presence and complementary asset portfolios. RHI, based in Austria, is a global supplier of high-grade refractory products, with 2015 revenues of € 1,753 million Brazil-based Magnesita is a global provider of integrated refractory solutions, services and industrial minerals, with revenues of US$ 1,013 million (€ 914 million) in 2015

Transaction Overview
RHI AG (“RHI”) and the controlling shareholders of Magnesita Refratários S.A. (“Magnesita”), investment vehicles affiliated with GP Investments (“GP”) and Rhône Capital (“Rhône”, and together with GP, “Magnesita’s Controlling Shareholders”), announce that they have reached an agreement to combine the operations of RHI and Magnesita to create a leading refractory company to be named RHI Magnesita.

Accordingly, RHI’s Management Board has agreed to sign a share purchase agreement (“SPA”) with Magnesita’s Controlling Shareholders regarding the acquisition of a controlling stake of at least 46%, but no more than 50% plus one share of the total share capital in Magnesita (the “Transaction”), pending RHI’s Supervisory Board approval. The purchase price for the 46% stake will be paid in cash amounting to € 118 million and 4.6 million new shares to be issued by RHI Magnesita, a new RHI entity to be established in the Netherlands and listed in London. Based on RHI’s six-month volume-weighted average price (“VWAP”) of € 19.52, the implied value of the 46% stake amounts to € 208 million.

As a result of the transaction, GP will become a relevant shareholder of RHI Magnesita. The combined company’s corporate governance will be constituted on a one-tier board structure while GP will be represented on the board of directors. All RHI Magnesita shares issued as a result of the Transaction and subsequent mandatory tender offer will be subject to a minimum 12-month lock-up period.

The resulting combination will be a leading refractory company. Refractories are materials that retain their strength at high temperatures and are used in various industrial processes in the steel, cement, nonferrous metals, glass and chemicals industries. The combination will bring under one roof two complementary businesses, both in terms of products and geographical footprint. RHI, based in Austria, is a global supplier of high-grade refractory products, with 2015 revenues of € 1,753 million and adjusted EBITDA of € 198 million. Brazil-based Magnesita is a global provider of integrated refractory solutions, services and industrial minerals, with revenues of US$ 1,013 million (€ 914 million) and adjusted EBITDA of US$ 145 million (€ 131 million) in 2015.1

The completion of the transaction is amongst others subject to

(i) approvals by the relevant competition authorities,

(ii) the migration of RHI to the Netherlands,

(iii) the listing of RHI Magnesita’s shares in the premium segment of the Official List on the Main Market of the London Stock Exchange and

(iv) RHI’s shareholders not having exceeded statutory withdrawal rights in an amount of more than € 70 million in connection with organizational changes preceding RHI’s migration from Austria.

The migration and the preceding organizational changes in Austria require qualified approval by RHI’s shareholders’ meeting. If the transaction is terminated for reasons not under the control of Magnesita’s Controlling Shareholders, an aggregate break fee of up to € 20 million is payable by RHI to Magnesita’s Controlling Shareholders.

The migration of RHI to the Netherlands and the subsequent listing on the London Stock Exchange have the objective of reinforcing and underlining the truly international scope of the enlarged combined company, enhancing its capital markets presence and maximizing value potential for the company’s shareholders. The migration of RHI will be effected by RHI Magnesita becoming the ultimate holding company of RHI Group and the shareholders of RHI will cease to hold shares in RHI and instead hold RHI Magnesita shares. Following registration of the corporate restructurings, RHI’s shares cease to be listed on the Vienna Stock Exchange. The place of effective management of RHI Magnesita will be Austria.

The transaction is expected to complete in 2017. Until then, the two companies will remain completely separate and independent. Therefore customers, suppliers, employees and other stakeholders should expect no change in management teams, commercial relationships, supply chains and product offerings during this period.

Mandatory Tender Offer
Following completion of the transaction, a mandatory tender offer will be launched by RHI Magnesita or one of its affiliates (“Offer”) for the remaining shares in Magnesita. As part of the Offer, a maximum number of 5.4 million RHI Magnesita shares will be issued, resulting in an aggregate number of no more than 10.0 million newly issued shares to finance the acquisition. The Offer will include the option to sell shares on the same payment terms as the transaction as well as a cash-only alternative amounting to € 8.19 per Magnesita share (subject to certain adjustments according to the SPA). If some or all of Magnesita’s other shareholders elect not to receive RHI Magnesita shares in the Offer, Magnesita’s Controlling Shareholders have committed to purchase additionally at least 1.9 million and at most 3.4 million of the remaining new RHI Magnesita shares, thereby increasing their total number of RHI Magnesita shares to a maximum of 8.0 million. RHI may decide to combine the Offer with a delisting offer and/or a voluntary offer to exit Magnesita from the “Novo Mercado” listing segment. The Offer will follow applicable Brazilian laws and regulations. Any RHI Magnesita shares that are not taken up in the Offer by Magnesita’s shareholders may be either placed into the market or with institutional investors.

Financial Terms of the Transaction
Based on RHI’s six-month VWAP of € 19.52, the implied value for the entire share capital of Magnesita will be € 451 million, 45% above Magnesita’s market capitalization as of October 4, 2016.2 The transaction will be financed by additional debt and the issuance of 4.6 million RHI Magnesita shares to Magnesita’s Controlling Shareholders. The transaction will increase RHI’s current financial leverage, measured as net debt to EBITDA, to 4.0x at closing of the transaction when assuming an acquisition of Magnesita’s entire share capital. RHI expects, however, that leverage will decline to below 2.0x by 2020 as a result of the strong cash generation profile of the newly combined company. Magnesita will continue to finance itself on a standalone basis without credit support from RHI Group. Before or at completion of the transaction, Magnesita is expected to adopt RHI’s accounting practices, which, according to RHI, could lead to significant, however substantially non-cash adjustments in Magnesita’s book equity value.

Enhanced Growth Profile and Global Footprint
The combination of RHI and Magnesita represents a unique opportunity to accelerate growth in certain regions, resulting from the high complementary of the businesses both in terms of geographic footprint and products.

Magnesita’s presence in South America and the United States fits well with RHI’s presence in Europe and Asia. It results in strengthened geographic clusters of the combined company by adding production facilities in several markets in which RHI and Magnesita are lacking capacity on their own. This combination will also strengthen the competitive position against the Chinese refractory industry, which is expected to consolidate in the coming years as announced by the Chinese government. Moreover, Magnesita’s position in dolomite-based products is highly complementary to RHI’s asset portfolio, which traditionally has a strong focus and an excellent market reputation for high-quality magnesite products.

The combination of RHI and Magnesita will enable the combined company to offer its customers an even broader product and service portfolio thereby delivering enhanced value-add. Additional potential for value creation will be realized through synergies and the implementation of common proven standards of operational and commercial excellence.

Significant Value Creation and Synergy Potential
The Transaction will result in meaningful synergies in the following key areas, amongst others:

(i)      a highly complementary offering of value-added products and services as a result of the combination of both product portfolios;

(ii)     a more efficient cost structure, benefitting from economies of scale in important operational areas such as raw materials supply, freight, marketing and administration, as well as an optimized operational set-up leading to enhanced flexibility in production and an improved cost basis;

(iii)    an optimized working capital structure, especially given Magnesita’s presence in the Americas, by means of improved inventory management and related costs, resulting from the complementary regional footprint of RHI and Magnesita’s operations and customer base; and

(iv)   a relevant reduction in capital expenditure requirements and maintenance costs.

As a result of the transaction, RHI expects minimum net run-rate synergies on EBIT level of approx. € 36 million by 2020. However, RHI is optimistic that as a result of the Offer, RHI Magnesita’s stake in Magnesita will significantly exceed 46%. In this case, RHI expects substantially higher synergies of approx. € 72 million, especially in the areas of enhanced production efficiency and cost benefits in research and development, marketing and administrative functions. In addition, capital expenditure synergies are expected to amount to between € 2 million and € 7 million annually, while aggregate working capital savings of € 40 million are expected in the coming years.

Cash integration costs as a result of the transaction are expected by RHI to be of the magnitude of € 50 million to € 90 million, while non-cash integration costs, effectively write-offs, should vary between € 20 million and € 35 million, depending on the amount of Magnesita shares acquired pursuant to the Transaction and subsequent Offer. Both cash and non-cash integration costs will mainly crystallize in 2017 and 2018.

Increased Financial Targets
As a result of the transaction, RHI’s mid-term financial targets will surpass RHI’s current targets. RHI expects the combined company to generate fully consolidated revenues of € 2.6 billion to € 2.8 billion (previously € 2.0 to € 2.2 billion) with an operating EBIT margin of more than 12% (previously more than 10%) by 2020. It projects a cumulative operating cash flow of approx. € 1.1 billion for the period from 2017 to 2020 for the combined business, assuming an acquisition of Magnesita’s entire share capital.

RHI expects RHI Magnesita to pay stable dividends in 2017 and 2018, in line with RHI’s previous years’ payment levels. In the mid- to long-term, however, RHI Magnesita aims to increase its dividend payments, as a result of stronger cash flow generation resulting from synergies, organic growth and de-leveraging of the company’s capital structure.

RHI, Magnesita Combine Creating a Leading Refractory Company Read More »