New strip casting systems for rare-earth magnet manufacturing are expected to support thermal processing operations tied to neodymium-iron-boron (NdFeB) magnet production in the U.S., serving industries including energy, electronics, automotive, and defense. The systems are designed for vacuum metallurgy applications involving high-temperature melting and casting processes used in advanced materials manufacturing.
Image Credit: SECO/WARWICK
Strip is a critical upstream step in the production of NdFeB magnets and other high-performance permanent magnets. The process rapidly solidifies molten alloy into thin strips, forming feedstock that is further processed into high-performance magnets used in electric motors, precision actuators, and other advanced technologies. The equipment, intended for strip casting operations used in the production of rare-earth magnetic materials, is being supplied by Retech, a division of SECO/WARWICK Group focused on vacuum metallurgy and metal processing technologies.
In high-performance magnet applications, precise system atmospheric control, casting cooling rate, and thermal control during solidification directly impact downstream magnetic properties. For this reason, Retech strip casters are designed to provide stable, repeating operating conditions over sustained production cycles.
Earl Good President Retech
“Advanced magnet manufacturing depends on precision at every stage of the process,” said Earl Good, president of Retech. “Our strip casting systems are built to provide the rapid cooling rates that achieve the grain structure necessary for producing magnets that maintain superior magnetic properties, even at high temperatures. These systems will support long-term domestic supply growth.”
Retech’s strip casting platforms can be integrated into larger melt and materials handling systems, supporting continuous industrial workflows rather than isolated batch processing. The equipment supplied in this case reflects ongoing investment in domestic magnet production capacity, as manufacturers work to strengthen U.S.-based supply chains for critical materials.
Press release is available in its original form here.
In today’s News from Abroadinstallment, we highlight several major global developments — from low-carbon steelmaking initiatives to meltshop modernization and new tube production capacity to the electrification of foundry operations — reflecting ongoing efforts to improve efficiency, reduce emissions, and modernize thermal processing worldwide.
Heat TreatTodaypartners with two international publications to deliver the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat. Furnaces International, a Quartz Business Media publication, primarily serves the English-speaking globe, and heat processing, a Vulkan-Verlag GmbH publication, serves mostly the European and Asian heat treat markets.
Low-Carbon Steel Project Builds on EAF Route
Marcegaglia and Danieli jointly announced the signing of an agreement related to the implementation of a major steelmaking and flat-rolling facility investment in Fos-sur-Mer, France. | Image Credit: Danieli
“Marcegaglia and Danieli have signed an agreement to implement a new steelmaking and flat-rolling facility in Fos-sur-Mer, France. The plant is set to produce over 2 Mtpy of liquid steel and up to 3 Mtpy of hot-rolled stainless and carbon steel coils, covering approximately 35% of Marcegaglia’s total coil and slab demand.”
“The plant will include a modern electric arc furnace, a single-strand continuous caster for thick slabs and a conventional hot-strip mill. Danieli highlighted that this configuration will ensure production efficiency, stable operations and product quality across a range of flat steel grades.”
Kardemir ordered a unified digital architecture from Primetals Technologies to optimize the processes of its entire meltshop. | Image Credit: Kardemir
“Steel producer Kardemir has awarded Primetals Technologies a contract to modernise the automation environment at its meltshop in Karabük, Türkiye. The project includes modernising the automation for three LD converters (BOFs) for single ladle furnaces (LFs), and one vacuum degasser (VD). Each converter is designed for 120-ton heats.”
“The Level 2 process optimisation system will integrate all BOF, LF, and VD units into a single digital architecture, connecting metallurgical, operational, and planning data in one environment. This ‘steelmaking backbone’ provides operators and metallurgists with a shared interface and standardised procedures, improving data consistency, process execution, and transparency across shifts.”
New tube plant in Altmünster has officially opened. | Image Credit: Wuppermann Metalltechnik GmbH
“Wuppermann Metalltechnik GmbH (WMT) has officially opened its new tube plant at the Altmünster site with a ceremonial event. More than 100 guests — including business partners and employees, as well as representatives from politics and industry — attended the event on April 24, 2026 and were given an exclusive insight into one of Europe’s most modern tube plants.”
“Through this investment, WMT is not only expanding its own production capacity but also significantly broadening its product range: the new state-of-the-art facility will manufacture, among other things, complex special profiles with wall thicknesses of up to 4 mm and an extended range of dimensions and strengths. Steel grades such as DP800, DP980 and 22MnB5, with tensile strengths of up to 1,000 MPa, will be processed.”
Phil Limbach (left), managing director of Beinbauer Group and Till Schreiter, CEO of ABP Induction Systems GmbH, at the contract signing. | Image Credit: ABP Induction Systems GmbH
“With the signing of the contract by Phil Limbach, member of the management of the Beinbauer Group, and ABP CEO Till Schreiter, as well as a joint site visit by the project teams of Beinbauer Casting and ABP Induction, the official starting signal was given for a groundbreaking major project.”
“In the coming months, the Schwerte foundry will undergo a fundamental technological transformation. The existing cupola furnace will be replaced by a modern, electrically powered induction melting furnace. For Beinbauer Casting, this project represents more than just a technological upgrade…The new electric arc furnace enables more sustainable production, the fulfillment of new [client] requirements, and long-term growth at the German site.”
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.
Two vacuum induction melting (VIM) casting systems are being deployed to support the production of components used in power generation turbine manufacturing. The systems are designed to produce advanced alloys with controlled microstructures for components operating under demanding thermal and mechanical conditions.
The equipment, engineered to support both equiaxed (EQ) and directionally solidified (DS) casting processes, will be used in the production of high-performance, nickel-based alloy turbine components. These casting technologies are critical for achieving the structural integrity, thermal resistance, and performance consistency required in modern power generation turbines operating under extreme conditions.
Earl Good President Retech
Retech, a U.S.-based company and part of the SECO/WARWICK Group, supplied the two VIM systems. “These systems were designed to build on prior installations while incorporating specific changes requested by the [client] to support their current and future production goals,” said Earl Good, president of Retech. The systems are based on Retech’s core designs but incorporate client-specific modifications, tailoring feeder configurations to align with the client’s established production practices. This enables repeatable casting while maintaining precise thermal and atmospheric control throughout the process.
The order continues a relationship between Retech and the client that dates back to the 1980s, with several legacy systems still in operation at the facility. The client has indicated plans to expand capacity in the coming years, including potential additional system purchases and replacement of older equipment.
Press release is available in its original form here.
A new production facility for lightweight refractory materials has opened in Missouri, increasing supply for furnace-lined industrial processes that operate at elevated temperatures. The materials support thermal insulation and durability in equipment used across sectors such as petrochemicals, aluminum, and power generation, where reliable furnace performance is essential to high-temperature manufacturing and other heat-intensive processing operations.
The new lightweight monolithics production facility in Fulton | Image Credit: HWI
HWI, a member of Calderys, has opened a lightweight monolithics production facility in Fulton, Missouri. Built on existing HWI property at the company’s Rotary Kiln complex, the greenfield investment increases production capacity for lightweight refractory materials used to line heaters, reformers, boilers, crackers, and furnaces in a range of industrial applications.
The facility has direct access to local clay reserves, enabling vertical integration intended to support raw material consistency and supply reliability. Operational features include a furnace system used to produce GREENLITE® aggregate, along with robotic automation for packaging and material handling, as well as updated packaging capabilities.
Michel Cornelissen President and CEO Calderys Group
The added capacity is expected to shorten lead times, support make-to-stock inventory, and allow the company to pursue larger projects that were previously limited by supply constraints. Premium GREENLITE® products, including the GREENLITE®-45-L family of monolithics and GREENLITE® 115 AR brick, are now shipping through the company’s distribution network.
“Demand for these high-performance, energy-saving lightweight refractories continues to grow rapidly while global supply chains remain under pressure,” said Michel Cornelissen, president and CEO of Calderys Group.
Monolithic refractories provide insulation and structural stability for equipment operating in high-temperature environments. HWI’s GREENLITE® lightweight monolithics provide insulation with optimized strength-to-density ratios that help minimize heat loss, reduce fuel consumption and CO2 emissions, extend campaign life, and enable longer service intervals. These, in turn, help clients lower operating costs and improve energy efficiency while maintaining productivity and reliability.
Press release is available in its original form here. Main image shows the ribbon cutting with local officials at the Fulton plant. Image Credit: HWI
JISCO Carbon Steel, a global steel producer serving international markets including North America, has commissioned a new integrated CSP®-HSM line at its Jiayuguan facility following an upgrade and expansion project. The new production line combines Compact Strip Production (CSP®) with a hot strip mill (HSM) into a fully integrated system with complete automation. The move increases annual production capacity from 2 million to 4.5 million tons and enhances operational flexibility and stable production performance.
The newly commissioned line integrates CSP® casting and rolling with a newly installed hot strip mill, creating a continuous production route that allows rapid switching between production modes. According to the company, the system enables fast ramp-up and stable rolling performance while maintaining controllable quality from the start of operations. Importantly, the expansion was executed without interrupting ongoing CSP® production.
The upgrade includes the installation of new mechanical equipment and a complete automation package designed to coordinate casting and rolling operations. The automation system supports process control, operational stability, and consistent production results across product grades.
Technology and automation systems for the integrated CSP®-HSM line were supplied by SMS Group, which provided engineering, mechanical equipment, and its X-Pact® automation platform, including models and visualization systems for coordinated line control.
Commissioning ceremony on February 2, 2026, at JISCO’s site. | Image Credit: SMS Group
“Bringing the world’s first integrated CSP®-HSM line into production is a strategic leap for JISCO Carbon Steel. We now have the flexibility to align products and processes with customer needs in real time, backed by stable, repeatable quality from day one,” said Mr. Qiao Degao, CEO of JISCO Hongyu New Materials Co., Ltd. “SMS group’s automation technology and disciplined project execution were essential to meeting our schedule and performance targets.”
With the line now in operation, JISCO expands its production capacity and strengthens process integration between casting and hot rolling, positioning the Jiayuguan facility for increased throughput and operational flexibility in the flat steel market.
Press release is available in its original form here. Main image shows the SMS Group team at JISCO after the successful first coil. Image Credit: SMS Group
PSW Group announced the launch of its High Integrity Diecasting Center (HIDC) at the Magretech plant in Bellevue, Ohio, a new semi-solid casting center that enables clients to trial and optimize aluminum and magnesium castings with improved quality and structural integrity. The facility uses semi-solid and high-pressure die-casting technologies to support prototyping, process development, new product introduction, and pilot-to-production scaling for clients evaluating liquid and semi-solid casting processes. The investment places semi-solid casting R&D and engineering at the core of PSW’s strategy to accelerate low-carbon, high-integrity light metal innovation.
The new center features semi-solid casting technologies, including Comptech and Rheo-Structural Systems (RSS) for aluminum and Thixotropic Piston Injection (TPI) for magnesium. Notably, HIDC is one of the few semi-solid casting centers in North America offering both aluminum and magnesium semi-solid casting alongside conventional and structural high-pressure die-casting (HPDC).
Dr. Tao Wang Global Head of Products and Sustainability PSW Group
“As clients demand lighter, stronger, and lower-carbon components, HIDC’s semi-solid platform unlocks quality, efficiency, and speed to market,” said Dr. Tao Wang, global head of Products and Sustainability at PSW Group. “By integrating advanced semi-solid technologies with our global R&D, we accelerate alloy development while reducing production emissions.” The HIDC gives original equipment manufacturers (OEMs), Tier 1 suppliers, and die casters the ability to trial, develop, test, and optimize new aluminum and magnesium alloys and evaluate casting technologies to determine the best combination for their specific products and applications.
“The HIDC enhances our U.S. manufacturing footprint and shortens time-to-market for next-generation components,” added Dr. Wang. It’s a pivotal step in our roadmap to low-carbon, high-integrity light metal systems.”
Press release is available in its original form here.
Century Aluminum Company has emphasized that next-generation EX smelting technology will be critical to the development of its new primary aluminum smelter, one of the most advanced technologies deployed in the U.S. This platform is designed to improve productivity, reduce energy consumption per ton, and lower emissions, reinforcing both economic competitiveness and environmental performance in primary aluminum manufacturing.
Click on the image above to read more about Century Aluminum’s recent restart to boost U.S. production by 10%.
Planned for Inola, Oklahoma, at the Tulsa Port of Inola industrial park, the proposed facility is expected to produce up to 750,000 metric tons of primary aluminum annually, more than doubling current U.S. smelting capacity once fully operational. Century Aluminum will partner with Emirates Global Aluminum (EGA) on the project, with EGA contributing its proprietary EX smelting technology and holding a majority ownership stake, while Century Aluminum provides operational expertise and leadership in the U.S.-based aluminum production. The project aims to strengthen material availability for downstream manufacturers serving automotive, aerospace, energy, and defense markets.
Jesse Gary Chief Executive Officer Century Aluminum Company
“Our partner EGA brings world-class smelting technology and construction expertise that are fast-tracking our collective efforts to realize a new era of domestic primary aluminum production,” said Jesse Gary, chief executive officer of Century Aluminum Company. “This expanded production will benefit critical U.S. industries and create thousands of American manufacturing jobs, reinforcing the vital role of aluminum in national defense and economic vitality.”
EX technology is EGA’s next-generation smelting platform, featuring reduction cells that provide higher productivity per square meter than EGA’s previous DX+ Ultra technology. The cells are larger and have improved current efficiency, enabling greater aluminum production from each smelting cell. The technology supports more cost-effective aluminum production with lower emissions intensity, reinforcing the project’s operational and environmental goals.
For background on the initial announcement of this historic smelter project, click on the image above for our May coverage.
The use of EX technology also positions the project within the broader global landscape of aluminum smelting innovation, strengthening its appeal as an alternative source of advanced smelting capability at a time when governments and manufacturers are increasingly focused on supply chain resilience, domestic capacity, and technology diversification. EGA’s own communications highlight EX as a key step toward large-scale industrialization and a foundation for future growth as a smelting technology provider of choice in the global aluminum industry.
Construction is expected to begin as early as 2026, with commercial production anticipated before the end of the decade. Once completed, the facility is expected to support approximately 1,000 permanent direct jobs and support roughly 4,000 construction roles, while helping reduce reliance on imported aluminum and reinforcing domestic manufacturing capabilities. Industry leaders have described the project as a critical step toward rebuilding U.S. primary aluminum production and supporting long-term supply stability for North American manufacturers.
Press release is available in its original form here.Additional information comes from EGA’s June 2025 press release here.
IperionX continues to advance domestic titanium manufacturing and thermal processing capabilities in a recent commitment to reduce long lead times for critical pump components used for naval shipbuilding. This addresses supply chain constraints that have slowed ship construction and maintenance. By shortening production timelines, the initiative supports improved fleet readiness while reinforcing domestic manufacturing capacity for mission-critical naval systems.
The effort is being demonstrated through a project with Carver Pump Company, a U.S.-based manufacturer of mission-critical pumps for naval applications. Carver Pump has placed an initial purchase order with IperionX for prototype titanium components. Leveraging domestically produced titanium metal powder and integrated in-house manufacturing, the project will focus on producing and testing cost-competitive replacements for traditionally cast pump components.
Titanium components are essential in naval pump systems due to their high strength-to-weight ratio, corrosion resistance, and ability to withstand extreme marine environments. However, traditionally cast titanium parts often face supply chain bottlenecks, with lead times exceeding 12 months, contributing to equipment and vessel downtime.
Anastasios (Taso) Arima CEO IperionX Source: IperionX
IperionX’s approach is designed to deliver step-change improvements in production efficiency. Each titanium component is expected to be produced in less than one week using the company’s low-cost domestically produced titanium metal powder and advanced manufacturing capabilities, significantly reducing reliance on conventional casting routes.
“Transitioning from lead times measured in years to timelines measured in days allows us to better support on-time naval shipbuilding and sustainment, directly enhancing fleet readiness,” said Anastasios (Taso) Arima, CEO of IperionX.
The purchase order covers the development of four prototype pump impellers, with manufacturing anticipated to be complete in May 2026. Successful completion of the prototyping and testing phase could lead to larger-scale production agreements supporting additional naval components.
Press release is available in its original form here.
Kaiser Aluminum Corp., a producer of heat treated, flat-rolled aluminum products, has completed a $25 million expansion of its Trentwood rolling mill in Spokane Valley. This marks the latest phase of the company’s long-term strategy to increase heat treatment throughput for aerospace, automotive, and general engineering markets.
The original source was published in Spokane Journal of Business, and the following content has been adapted for our Heat TreatToday audience.
The project, which is part of more than $415 million invested in the facility over the past 20 years, extends one of the mill’s major heat treat furnaces, increasing plate-processing output by approximately 5 percent. For in-house heat treaters, the upgrade reflects a continued industrywide push toward higher-capacity, efficiency-driven thermal operations as demand for tight chemistry and reliable mechanical properties climbs.
Kaiser Aluminum has completed a $25 million project at its Spokane Valley plant that includes an expansion of its horizontal heat treat furnace. Source: Kaiser Aluminum Corp.
According to Kevin Barron, vice president of manufacturing, the expansion enhances the mill’s ability to heat treat and stretch large-format aluminum plate products without altering staffing levels at the 1,000-employee site. The project was completed within the plant’s existing footprint with support from regional contractors and furnace supplier Otto Junker USA.
The Trentwood mill, one of only three U.S. sites capable of producing heat treated aerospace-grade plate, has undergone seven phases of reinvestment since 2005. Recent work builds on earlier additions to the facility’s furnace lineup, along with upgrades to hot rolling, homogenizing, and casting capacity — areas closely linked to the performance and consistency of downstream heat treating.
Kaiser paused expansion activities during the pandemic, storing some equipment purchased pre-COVID. With the current project complete, the company has reestablished its pattern of continuous, phased improvements intended to keep pace with global aerospace and defense demand.
For manufacturers with in-house heat treat operations, Kaiser’s latest phase underscores a broader trend: large producers are expanding thermal processing capability not only to increase volume but to ensure uniformity, cleanliness, and repeatability at scale. As aerospace OEMs tighten specifications, upstream suppliers are reinforcing their heat treatment infrastructure to meet rising expectations for precision and throughput.
Kaiser Aluminum, headquartered in Franklin, Tennessee, operates 13 facilities across the U.S. and Canada. The Trentwood site remains a key supplier to Boeing and other aerospace manufacturers, continuing a relationship that dates back to World War II.
Press release is available in its original form here.
