FOUNDRY CASTING NEWS

North American Heat Treater Welcomes New Ownership

Effective November 30, 2023, Joe A. Powell has sold his remaining shares in Akron Steel Treating Company, his family’s commercial heat treating business for over 80 years in Akron, Ohio, USA, to a fourth generation of new “family” ownership.

The team at AST will continue to deliver ISO and Nadcap aerospace heat treating and related metallurgical services to part making customers.

Joe A. Powell, AST’s Chairman of the Board, will remain active in the heat treating and metallurgical services community as president of Integrated Heat Treating Solutions, LLC. (IHTS). IHTS is a “heat transfer” consulting company for product development teams to enable more sustainable heat treating equipment and practices to be integrated into their new product designs. IHTS and its team of part making consultants enable their part making clients to deliver more “total added value” from heat treating and forging per BTU expended in making their products for their end users; including the design of the associated heating and quench cooling equipment for "leaner + greener, more sustainable, manufacturing" and for greater recyclability of metal alloys.

Pictured in the image above: AST’s new shareholder team, and Joe A. Powell, Chairman of the Board, are pictured from left to right: Matt Moldvay, President; Steve Powell, Vice President of Quality, Christina Powell Somogye, Vice President of Administration; Joe A. Powell, Chairman; and Joe N. Powell, Vice President of Sales. (Source: AST)

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Foundry Expands 3D Printing Capabilities

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A Louisiana-based foundry — a supplier of iron, stainless, and specialty alloy castings for paper/pulp, energy, mining, and petrochemical customers — is getting financial support for infrastructure investments from the state as part of a three-phase effort to expand its 3D printing operation for sand molds.

JB Shoaf
President
Howell Foundry

Howell Foundry plans to expand its 3D-printing capabilities following a $7.4 million update to its operation in St. Francisville, LA. This expansion is expected to create 26 new jobs and retain 22 current, according to an announcement by the Louisiana Economic Development agency. Work was scheduled to start in December for completion by the end of 2027, LED said.

The state will provide a $400,000 performance-based forgivable loan for infrastructure work, contingent upon Howell Foundry meeting investment and payroll targets. Also, the foundry is expected to participate in the state’s Quality Jobs and Industrial Tax Exemption programs.

The foundry emphasizes its ability to deliver complex parts with quick turnaround, using 3D-scanning to convert parts or patterns into reproducible programs, casting process simulation to plan and set-up production, and 3D-sand printing of molds and cores.

“Howell Foundry combines modern-day 3D innovations with proven craftsmanship in one of the oldest known trades to produce rapid and reliable solutions to its valued customers who are primarily located on the Gulf Coast,” stated company president JB Shoaf said. “We take great pride in being a local business that serves local businesses.”


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Fringe Friday: Desirability of the Deoxidation of Ductile Base Iron

What is deoxidation and how can it be useful for energy savings? In fact, can the process really save money and improve the quality of iron?

Sometimes our editors find items that are not exactly “heat treat” but do deal with interesting developments in one of our key markets: aerospace, automotive, medical, energy, or general manufacturing. To celebrate getting to the “fringe” of the weekend, Heat Treat Today presents today’s Heat Treat Fringe Friday article that answers these questions. Hint: Deoxidation is helpful, and the article points to how annealing heat treatment may not be necessary in order to meet the ferritic ductile iron elongation specification levels.

An excerpt:

Ductile iron producers typically add copper to the melt to enhance the material’s tensile strength. That becomes unnecessary when base iron is deoxidized prior to magnesium conversion treatment. The deoxidized iron’s strength rises to near 100,000 psi after deoxidation, without copper addition. Deoxidation removes the suspended MgO oxide particles that reduce strength and elongation in ductile iron.

Read more: “Deoxidation Saves Alloying Cost and Improves Iron Castability

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Fringe Friday: Nippon Steel Corporation To Acquire U. S. Steel

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Sometimes our editors find items that are not exactly “heat treat” but do deal with interesting developments in one of our key markets: aerospace, automotive, medical, energy, or general manufacturing.

To celebrate getting to the “fringe” of the weekend, Heat Treat Today presents today’s Heat Treat Fringe Friday: the recent acquisition of U.S. Steel by Japan’s Nippon Steel Corporation and some coverage on what may derail the sale.


Nippon Steel Corporation (NSC), Japan’s largest steelmaker and one of the world’s leading steel manufacturers, and United States Steel Corporation (U. S. Steel), a leading steel producer with competitive advantages in low-cost iron ore, mini mill steelmaking, and best-in-class finishing capabilities, announced that they have entered into a definitive agreement pursuant to which NSC will acquire U. S. Steel for a total enterprise value of $14.9 billion. The transaction has been unanimously approved by the Board of Directors of both NSC and U. S. Steel.

NSC’s acquisition of U. S. Steel will enhance its world-leading manufacturing and technology capabilities and enable it to expand the geographic areas in which NSC can better serve all of its stakeholders. The transaction will further diversify NSC’s global footprint by significantly expanding its current production in the United States, adding to its primary geographies of Japan, ASEAN, and India. As a result of NSC’s acquisition of U. S. Steel, its expected total annual crude steel capacity will reach 86 million tonnes – accelerating progress towards NSC’s strategic goal of 100 million tonnes of global crude steel capacity annually.

NSC President Eiji Hashimoto said, “We are excited that this transaction brings together two companies with world-leading technologies and manufacturing capabilities, demonstrating our mission to serve customers worldwide, as well as our commitment to building a more environmentally friendly society through the decarbonization of steel.”

President and Chief Executive Officer of U. S. Steel, David B. Burritt, said, “For our U. S. Steel employees, who I continue to be thankful for, the transaction combines like-minded steel companies with an unwavering focus on safety, shared goals, values, and strategies underpinned by rich histories. For customers, U. S. Steel and NSC create a truly global steel company with combined capabilities and innovation capable of meeting our customers’ evolving needs. [December  18’s] announcement also benefits the United States – ensuring a competitive, domestic steel industry, while strengthening our presence globally. Our shared decarbonization focus is expected to enhance and accelerate our ability to provide customers with innovative steel solutions to meet sustainability goals.”

Read more about this press release here.

U.S. Response: Pushing Back

There has been some push-back from various effected entities. The United Steelworkers International Union has vocalized concerns for the deal, claiming that this acquisition would be bad for America and the steelworkers. David McCall, president of the United Steelworkers Union, has indicated that there may be legal reasons to make the deal void. U.S. President Joe Biden also has weighed in on the matter, believing that this deal requires scrutiny from a national security and supply chain perspective; comments on how the upcoming presidential election and the significance of Pennsylvania’s support have arisen.

But this pushback is not at all unexpected from a Japanese perspective. In the perspective of Kyodo News, the regulatory authorities in America and “strict antitrust laws” could continue to prove to be an impediment to the full acquisition.


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Jet Engine Manufacturer Modernizes with Updated Casting Furnace

Sławomir Tomaszewski
Vacuum Melting Team Director
SECO/WARWICK
Source: LinkedIn

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One of the world’s largest producers of jet engines has modernized their casting furnace, which was last updated two decades ago.

This company has two casting units supplied two decades ago by RETECH, a North America-based company belonging to the SECO/WARWICK Group. The modernization project was for the VIM EQ furnace - a system for the production of castings in equiaxed crystallization. It will involve replacing almost all the furnace components except the power supply, melting chambers and mold. The platforms will also remain unchanged. The remaining components will be replaced with more modern, ergonomic, and user-friendly parts and assemblies.

Says Sławomir Tomaszewski, vacuum melting team director at SECO/WARWICK, “This order includes the complete elimination of hydraulic components by replacing them with electrical components such as an elevator drive or crucible rotation drive. In addition, two old feeders: one for loading crucibles, the other for removing disposable crucibles, will be replaced with a modern system that can perform both activities."

He added, "An additional advantage of the operation will be the fact that the furnace operator will not have to come into physical contact with hot used crucibles, because they will be removed automatically without human intervention."

 

 


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News from Abroad: Furnace Updates and Lowered Emissions

Heat Treat Today is partnering with two international publications: heat processing, a Vulkan-Verlag GmbH publication that serves mostly the European and Asian heat treat markets, and Furnaces International, a Quartz Business Media publication that primarily serves the English-speaking globe. Through these partnerships, we are sharing the latest news, tech tips, and cutting-edge articles that will serve our audience — manufacturers with in-house heat treat.

In this article, international companies scale up their equipment and scale down their carbon emission. 


German Steelmaker Dillinger Completes Slab Pusher Furnace in Rolling Mill

"The stock corporation of Dillinger Hüttenwerke (Dillinger) has successfully converted its slab pusher furnace 2 in the rolling mill." (Source: Furnaces International)

"For the customer, this means that the availability of large, heavy sheets increases. With these, weld seams can be saved and, thanks to more efficient production, more offshore foundations can ultimately be produced and installed. The modernization of the slab impact furnace, as well as the new edge milling machine for the delivery of “fabricated” offshore wind sheets, is one of a number of investments in the offshore wind market that are currently being planned and implemented at Dillinger."

 

Read More: “Dillinger: Investment in slab pusher furnace successfully completed" at heat processing

 

 

Global Steel Producers Partner To Cut Carbon Emissions

Heat transfer supplier Alfa Laval has created a partnership with Finnish steelmaker Outokumpu to cut carbon emissions. (Source: Furnaces International)

“Most of the Alfa Laval steel purchased from Outokumpu, a global steel manufacturer, will now be the low carbon stainless steel variety. This change applies to heat exchangers used in the energy transition towards a more sustainable energy supply, including energy efficiency, waste heat recovery, and heat pumps. These heat exchangers are currently produced in large quantities with the potential for future growth, says Alfa Laval.”

 

Read More: “"Outokumpu and Alfa Laval partner to cut emissions"  at furnaces-international.com

 

Japanese Steelmaker JFE Steel Plans To Build New EAF To Replace Blast Furnace

JFE's plans for an electric arc furnace will be used for the automotive industry and will reduce carbon emissions. (Source: heat processing)

“The steelmaker is considering building an EAF that can produce 2Mt of high-grade steel when the No.2 unit is due for refurbishment, JFE president Yoshihisa Kitano said. He added that the EAF would reduce CO2 emissions by 2.6Mt/yr from current levels emitted by the blast furnace."

 

Read More: "JFE mulls building 'one of the world's largest' EAFs" at furnaces-international.com

 

 

Indian Manufacturer Refratechnik Group Opens New Factory for Metals Industry  

"The Refratechnik Group opens its new factory in India." (Source: heat processing)

"The state-of-the-art greenfield factory was built to produce MgO-C refractory products, high-alumina bricks, as well as monolithic products for the steel, cement and non-ferrous metal industries. The plant will employ more than 300 people in the short term and more than 400 people in the long term."

 

Read More: "The Refratechnik Group opens a modern factory in India" at heat-processing.com

 

 

 


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Double Reduction Mill Offers Sustainable Solutions for Tinplate Company

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A tinplate company will receive a new order for a tinplate coating line (TCL) and tinplate double reduction mill (TDRM) from a company with North American locations specialized in sustainable thermal processing solutions for the metals and mining industries.

Giuseppe Zanzi
Chief Representative Officer of South East Asia and Oceania
Tenova
Source: Tenova

These orders from Tenova are for the Tinplate Company of India Ltd., a subsidiary of Tata Steel, for its new Tinplate Complex at the Jamshedpur plant in Jharkhand, India.

The TCL includes an independent pre-tinning section with sulfuric acid for iron control in the electrolyte solution and an advance tinplate coating control close loop to achieve the best strip coating quality and stability. The IGBT AFE rectifier technology allows for efficiency in tinplate coating which moreover allows for low electrical consumption.

The TDRM plays a key role in obtaining a combination of ultra-light strip gauge and required hardness. This mill is equipped with automatic gauge control (AGC) cylinders, an automatic flatness control (AFC) system, a roughness control system, and a dedicated reduction control for double reduced (DR) tin plate.

Giuseppe Zanzi, chief representative officer of South East Asia and Oceania at Tenova, commented, “We are very proud to have been selected as the main technological partner for Tata Group tinplate expansion. Thanks to our solutions, Tata will be able to achieve a sustainable production based on low electrical consumption and very large production capacity.”


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Charlotte Pipe and Foundry Opens New Site in North Carolina

A 122-year-old cast-iron pipe maker started operating its $460-million ferrous foundry in North Carolina, and celebrated its role in “revitalizing manufacturing in the U.S.”

Charlotte Pipe and Foundry Company, a maker of cast iron and plastic pipe and fittings for plumbing applications, held its grand opening of a new $460 million foundry in Oakboro, North Carolina. Charlotte Pipe’s new foundry is situated on 700 acres in Stanly County, about 35 miles east of the cast iron foundry it operated in Uptown Charlotte for more than 100 years.

“The move to Oakboro will spur growth of other businesses, including vendors who supply and support the plant, opening a new window of economic growth for Stanly County,” said Hooper Hardison, CEO of Charlotte Pipe. “Even better, the region is already home to many of the Company’s associates who will benefit from reduced commute times and increased amenities within their work environment.”

Charlotte Pipe’s Oakboro Foundry, which became fully operational on September 5, 2023, employs more than 530 associates, and according to Hardison, up to another 500 construction workers were on the Oakboro jobsite each day over three years, working more than 1.2 million hours to open the new plant. All construction materials and supplies for the new foundry were 100% Made in the USA, as are all Charlotte Pipe products.

In addition, Charlotte Pipe added a rail spur to connect the new plant to the Aberdeen Carolina & Western Railway, a short-line railroad that crosses central North Carolina. The Aberdeen line connects to the Norfolk Southern Railway, giving the Oakboro Foundry rail access to move recycled materials to and from the Eastern Seaboard and the Midwest.


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GKN Aerospace Expands with 2 New AM Systems

GKN Aerospace has expanded its capabilities with additive manufacturing (AM) machines, accelerating its industrialization of sustainable aero engine solutions. This new technology will offer more reliable and sustainable alternatives to traditional castings and forgings.

The supplier of these machines is Nikon SLM Solutions, whose NXG XII 600's printing area and 12 lasers align with GKN Aerospace's vision to produce large parts with high productivity. Two systems have been ordered, one to be used with In718 and another for Ti64.

In the words of Martin Thordén, VP of Permanova, the newly formed business unit for material solutions within GKN Aerospace, "Partnering with Nikon SLM Solutions is a key milestone in our journey to create better, more sustainable aerospace products. . . . This collaboration provides us access to cutting-edge additive manufacturing capabilities necessary to propel us towards our net zero ambition."

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Al Reverb Furnace Fabrication Begins at Al Extrusion Plant

A multinational aluminum producer ordered a new 100,000 lb. capacity tilt melting aluminum furnace for one of their regional aluminum extrusion plants. Fabricated in PA, the furnace will incorporate several features to meet the manufacturer’s efficiency, production, and capacity requirements, as well as options to accelerate melting and transfer flow.

SECO/WARWICK USA will fabricate this aluminum reverb furnace. “Most of the damage to a furnace like this is from loading it with a forklift,” comments Marcus Lord, managing director at SECO/WARWICK USA. “Either bumping into the refractory around the door or being a bit clumsy with large awkward chunks of aluminum. It means the door is open a lot, and when it is closed, it might not have the best seal because the sills, jams and lentils are all beaten up. This furnace has a separate loading mechanism, so the door doesn’t need to open nearly as often. It really extends the life of the refractory, but it’s a huge efficiency boost too.”

This furnace will be fabricated with additional features, including capabilities to allow for a magnetic stirrer (supplied by the client) to be mounted under the furnace, saving more energy by increasing the melt rate by up to 10%. It will be capable of completely one full batch cycle in under 6 hours, for four batches a day, yielding a total of 340,000 to 400,000 lbs. per day. These combined factors will result in a fuel economy when the burners are firing in the regenerative mode of less than 1200 BTU per pound during the melt cycle.


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