FOUNDRY CASTING NEWS

Heat Treat Tooling Manufacturer Adds Melting, Casting Capacity

A North American manufacturer of high-temperature heat treatment tooling and high-alloy components is adding melting, fabrication, and casting capacity through the acquisition of selected manufacturing assets from an Ohio-based supplier. The transaction will increase capacity for centrifugal and static cast products used across industrial applications.

WIRCO Inc. executed an asset purchase agreement with Cleveland, Ohio-based Alcon Industries Inc. on September 30. Under the agreement, WIRCO will acquire specifically identified manufacturing equipment, tooling, intellectual property, designs, drawings, and manufacturing processes from Alcon.

The acquired equipment includes melting furnaces, fabrication equipment, and casting machines that WIRCO expects to use to increase its fabrication, centrifugal casting, and static casting capabilities. The company said the additional capacity will provide greater manufacturing flexibility as client requirements grow.

The transaction also includes more than 1,000 active tools along with associated drawings, designs, process instructions, and other limited intellectual property. The assets could allow WIRCO to provide manufacturing solutions previously serviced by Alcon.

WIRCO manufactures high-temperature heat treatment tooling and high-alloy wear components for industries throughout North America. The company operates manufacturing facilities in Indiana, Wisconsin, and Illinois and sources its stainless steel requirements from U.S.-based manufacturing facilities.

WIRCO plans to implement the purchased assets at its operations to increase capacity, preserve tooling and manufacturing knowledge, and provide additional manufacturing capabilities to its clients. WIRCO remains a separate company from Alcon and is not assuming Alcon’s existing obligations or liabilities.

Press release is available in its original form here.

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New American Steel Complex Integrates DRI, EAF Production

Mesabi Metallics plans to invest $18 billion to integrate its Minnesota iron ore operations with a new Iowa steelmaking complex using hot direct-reduced iron (DRI) and electric arc furnace (EAF) technology. The integrated operation will establish a domestic supply chain for steel serving the automotive, defense, shipbuilding, energy, infrastructure, appliance, and other manufacturing sectors.

The company will invest $15 billion to build the Iowa complex, in addition to approximately $3 billion being spent to complete its iron ore mine and pellet operation in Nashwauk, Minnesota, which will supply iron ore and direct-reduction-grade pellets to the new steelmaking facility.

Mesabi Metallics’ Minnesota mine will produce Patriot Pellet, the company’s DR-grade iron ore pellet engineered for EAF steelmaking. More than 1,500 construction workers and over 200 full-time employees are currently working at the mine, with 350 full-time positions expected once the fully operational.

At the Iowa complex, DRI technology will remove oxygen from the Minnesota iron ore at temperatures below its melting point to create solid metallic iron. The DRI will then be fed into electric arc furnaces while still hot, reducing the energy required to melt the material and improving the efficiency and productivity of the steelmaking process.

The facility’s EAFs will use a mixture of hot iron produced by the plant’s DRI process and scrap steel. According to the company, the DRI-EAF configuration will reduce energy use and emissions compared with traditional blast furnace steelmaking.

Construction of the Iowa complex is expected to create more than 6,000 jobs. Once operational, the facility is expected to employ at least 1,750 full-time workers. Mesabi Metallics estimates the project will generate $95 billion in total economic output during construction and the first 10 years of full operations.

Press release is available in its original form here.

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Blast Furnace Reline Returns Furnace to Service

U.S. Steel has completed a $350 million blast furnace reline at its Gary Works operation in Indiana, returning more than 2 million tons of annual hot metal production capability to service. The project replaced the furnace’s refractory lining and restored critical systems supporting high-temperature ironmaking operations and long-term steel production.

Blast Furnace No. 14 has returned to service following completion of the reline project. The furnace is the largest at Gary Works and in U.S. Steel’s operating footprint.

The reline included replacement of the furnace’s refractory lining as well as restoration of critical systems designed to support safe, reliable operation and extend the furnace’s productive life. During the outage, teams also completed maintenance on supporting infrastructure, including the furnace gas, cooling water, hoisting, and stove systems.

The project required more than 1 million labor hours from employees and contractors, with a peak workforce of approximately 1,000 contractors on site per day.

David Burritt
President and CEO
U.S. Steel

“The return of Blast Furnace No. 14 is a great example of disciplined execution at U.S. Steel and is a testament to the skill, dedication, and unwavering focus on safety demonstrated by our employees, contractors, and partners,” said David B. Burritt, president and CEO of U.S. Steel. “This investment positions Gary Works to continue serving [clients], supporting American manufacturing, and creating value for years to come.”

Blast Furnace No. 14 is capable of producing more than 2 million tons of hot metal annually. The furnace incorporates large carbon block refractory produced by NDK, and it uses iron ore pellets sourced from U.S. Steel’s Minnesota Ore Operations as part of the company’s integrated steel supply chain.

The project comes as U.S. Steel continued hot strip mill and related steel shop upgrades at Gary Works intended to enhance capabilities, environmental performance, and operational reliability.

Press release is available in its original form here.

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Louisiana EAF Steel Mill Launches $5.8B Project

A $5.8 billion electric arc furnace (EAF)-based integrated steel mill project has launched in Louisiana, establishing a new domestic source of automotive steel that will combine on-site direct reduced iron (DRI) production with EAF steelmaking. The facility is targeted to begin commercial production in 2029 with an annual capacity of 2.7 million metric tons of hot-rolled and cold-rolled steel sheet, primarily for automotive applications.

Hyundai Steel Company held a ceremonial event for the project at the RiverPlex MegaPark in Ascension Parish, Louisiana. The mill will be operated by HYUNDAI-POSCO Louisiana Steel LLC (HPLS), a joint venture between Hyundai Steel, POSCO, Hyundai Motor Company, and Kia Corporation. The investment establishes Hyundai Steel’s first North American steel production base.

The facility will establish an integrated production system connecting on-site DRI production with EAF steelmaking and downstream production of automotive steel. A direct reduction plant will produce DRI on site and feed it directly into two EAFs through a continuous charging system. The configuration is designed to improve production efficiency and enable a higher share of DRI to be used in producing advanced steel grades.

Advanced refining and continuous casting facilities will be used to manage impurities such as nitrogen and sulfur to meet automotive steel quality requirements. The production route is expected to reduce carbon emissions from molten steel production by approximately 70% compared with the company’s conventional blast furnace process in Korea.

The facility will also incorporate carbon capture capabilities and is being designed to gradually replace the natural gas used in the direct reduction plant with hydrogen as infrastructure and availability develop.

With an annual steel production capacity of 2.7 million metric tons, the Louisiana mill will supply automotive steel to Hyundai Motor’s Alabama plant, Kia’s Georgia manufacturing facility, and Hyundai Motor Group Metaplant America, as well as other U.S. automakers. Producing automotive steel closer to clients is expected to strengthen supply stability, shorten delivery lead times, and enable faster technical and quality support.

Bo-Ryong Lee
President and CEO
Hyundai Steel Company

“Today, we are not simply announcing the construction of a new steel mill. We are standing at the starting point of a journey to shape the future of industry in Louisiana together,” said Bo-Ryong Lee, president and CEO of Hyundai Steel. “We aim to serve as a key supply chain partner to the North American automotive industry by providing a stable supply of high-quality automotive steel to [clients] in the United States and around the world.”

The project is part of Hyundai Motor Group’s $26 billion U.S. investment commitment through 2028. The Louisiana mill is expected to support 5,400 jobs, including 1,300 direct positions.

Press release is available in its original form here.

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Electric Arc Furnace Steelmaking Resumes After Power Outage

Electric arc furnace (EAF) steel production has resumed at Algoma Steel following a temporary suspension caused by an unplanned power generation outage. The restart restores steelmaking operations at a facility that transitioned fully to EAF production earlier this year.

The company resumed electric arc furnace (EAF) steel production at its Sault Ste. Marie, Ontario, facility on August 29 after working with the Independent Electricity System Operator (IESO) to establish interim operating arrangements. Algoma Steel reported that it is sustaining production and shipping steel under those arrangements while an affected turbine at its Lake Superior Power (LSP) generating facility remains unavailable.

The outage was first reported on August 17. Because LSP supplies electricity to Algoma’s steelmaking operations, the company temporarily suspended EAF production while downstream finishing and shipping activities continued. Algoma had initially estimated that the EAF outage would last no more than 21 days while it pursued options for restoring power.

Algoma is pursuing multiple options to restore full generating capacity at LSP, including repairing and returning the affected turbine to service or securing a replacement turbine. The steelmaker is working with GE and other parties to advance the alternatives in parallel and determine the most effective and timely path to restoring full generating capacity.

The EAF restart is significant for Algoma following its transition away from traditional integrated steelmaking. The company permanently ceased production at its blast furnace and associated coke batteries in January 2026, making its EAF facility the sole source of liquid steel for its plate and hot-rolled coil operations.

Construction of a second EAF unit is nearing completion, with first steel production expected in the third quarter of 2026. Once the EAF transformation is complete, the facility is expected to have approximately 3.7 million tons of annual raw steel production capacity.

Press release is available in its original form here. Additional information is from Algoma Steel’s August 17, 2026 original outage announcement, the company’s May 12 Q1 results, as well as the July 29 Q2 release.

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New Aluminum Remelting Facility Begins Billet Production

RevoCast Aluminum Billets Ltd., a manufacturer of recycled aluminum billets, has begun production at a new aluminum remelting facility in British Columbia, adding more than 80,000 tons of annual billet capacity to serve the North American extrusion market.

The company has successfully cast its first aluminum billet at its new remelting facility in Langley, British Columbia, marking the start of operations at the Canadian plant.

The first billet was cast on August 1, 2026, following the completion of the new facility. RevoCast said the milestone resulted from planning and collaboration among its employees, partners, and suppliers, including Wagstaff, Inc., a manufacturer of aluminum direct-chill casting equipment, and HERTWICH Engineering GmbH, a supplier of aluminum casthouse equipment and technology.

The aluminum remelting facility has an annual production capacity of more than 80,000 tons (176.4 million pounds) of aluminum billets and is designed to serve extrusion markets on the West Coast and in the Pacific Northwest.

RevoCast produces remelt billets in the 6xxx aluminum alloy series. The billets are available in diameters of 178 mm (7 in) and 203 mm (8 in), with maximum sellable lengths of 7.3 m (288 in). The facility incorporates energy-efficient equipment and is designed to use high levels of recycled content while reducing carbon emissions associated with billet production.

The company aims to deliver high-quality aluminum billets while strengthening the North American aluminum supply chain.

Press release is available in its original form here. Additional information provided by RevoCast on their website.

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New DRI Plant Planned for US Pig Iron Production

NEMO Industries is planning a new direct reduction iron (DRI) plant in Louisiana to strengthen domestic pig iron production by supplying high-carbon DRI for electric smelting. The project will support both U.S. and international markets while incorporating technologies designed to improve process efficiency and provide flexibility for future lower-carbon ironmaking.

NEMO Industries has selected Tenova, a global metals technology company with North American operations, to provide the ENERGIRON direct reduction technology for its proposed Ironworks I facility. Located in Louisiana, the plant will produce up to 2.5 million metric tons per year of hot and cold DRI. Tenova will begin front-end engineering design (FEED) as the project advances toward a final investment decision, currently expected in December 2027.

The facility will use the ENERGIRON Zero Reformer configuration, a direct reduction technology jointly developed by Tenova and Danieli. The plant will also incorporate the HYTEMP hot DRI transport system and be designed to accommodate future carbon caption integration. In addition, the facility includes provisions for future hydrogen use as Gulf Coast hydrogen infrastructure develops, providing flexibility for evolving feedstock and decarbonization strategies.

Michael DuBose
Co-Founder and President
NEMO Industries
Stefano Maggiolino
President and CEO
Tenova HYL

Michael DuBose, co-founder and president of NEMO Industries said recent market disruptions have underscored the need for a more resilient domestic pig iron supply chain. “Recent market disruptions including war, tariffs, and weather have reinforced the national security case for a resilient American pig iron supply,” DuBose said. “ENERGIRON DRI technology positions us to develop a pig iron facility that will strengthen the American steel supply chain and reduce our reliance on imported steel inputs.”

Stefano Maggiolino, president and CEO of Tenova HYL, said the project highlights how direct reduction technology can help manufacturers balance operational efficiency and sustainability goals. “It gives NEMO Industries the technical foundation in terms of capital and operating expenditures, carbon content, and sustainability to prove its DRI-based pig iron model,” he said.

Press release is available in its original form here.

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Steelmaker to Double Rebar Production Capacity

Hybar LLC has secured financing to support construction of a second electric rebar mini mill, a project that will expand domestic steelmaking capacity through electric arc furnace technology. The additional mill will increase reinforcing steel production for the U.S. construction sector.

The company announced it has secured approximately $1.1 billion in financing to support the expansion, which will be built adjacent to the company’s existing facility in Osceola, Arkansas. Upon completion, the second mill is expected to double the company’s annual reinforcing steel production capacity to approximately 1.3 million tons.

SMS group supplied the company’s electric arc furnace, continuous caster, and rolling mill for the existing facility. Now, SMS group has been commissioned to supply the technology and equipment for the expansion mill. Construction is expected to be completed in about 24 months.

Hybar’s rebar is being used in data center projects, medical campus expansions, the energy infrastructure buildout, and the continued repair and upgrading of roads, bridges, and tunnels. Hybar plans to continue penetrating these markets with the expansion mill.

Press release is available in its original form here.

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Vacuum Arc Remelting Supports Aerospace Casting

A titanium casting manufacturer is expanding its vacuum melting capacity with the installation of a vacuum arc remelting consumable casting furnace, increasing capacity for near-net-shape titanium components serving the aerospace industry. The investment is intended to improve production lead times while supporting growing demand for titanium castings used in high-performance applications.

Castings Technology chooses Retech VAR. | Image Credit: SECO/WARWICK Group

Castings Technology, the United Kingdom’s only commercial titanium casting specialist, selected a VAR Consumable Caster (VAR-CC) furnace from Retech, a global vacuum metallurgy company within the SECO/WARWICK Group based in North America. The furnace will be installed at the company’s new 18,000-square-meter facility, where it will be used to cast titanium ingots into ceramic molds.

Richard Cook
Managing Director
Castings Technology

“The delivery of the new VAR furnace will help us fulfill the growing needs of our exacting client base,” said Richard Cook, managing director of Castings Technology. “Due to dynamic growth and significant constraints within our current facility, we are in the process of relocating to a new site of about 18,000 square meter just a short distance away. The relocation is on plan, with a period of parallel operation continuing throughout 2026 to fully mitigate any risk to our clients’ programs.”

The new furnace is expected to support increased demand for titanium, especially from the aerospace sector, where backlogs have now surpassed pre-pandemic levels. Titanium’s high strength-to-weight ratio and corrosion resistance have made it a widely used material across many sectors, including aerospace, motorsport, medical prosthetics, restorative dentistry, and high-duty rotating equipment. Near-net-shape titanium casting also provides mechanical properties comparable to forged or wrought material while increasing fatigue resistance.

Press release is available in its original form here.

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Strip Casting Systems Support Magnet Production

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.

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