FOUNDRY CASTING NEWS

Iron Foundry Expanding into Aluminum at Ohio Facility

 

Source: Business Journal Daily

 

An iron casting foundry located in Hubbard, Ohio, is expanding into aluminum casting with an aluminum slab and billet plant at its current site.

Ellwood Engineered Castings is investing $60 million to house its new Ellwood Aluminum division to serve customers in the aerospace and other industries.

 

Read more: “Ellwood Group Diversifies with $60M Aluminum Plant”

 

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Aluminum Casting Facility Opens To Supply Jaguar Land Rover

An international automotive technology supplier headquartered in Canada recently opened a 225,000-square foot aluminum casting facility in Telford, England, which will supply structural castings to Jaguar Land Rover, a leading vehicle manufacturer in the U.K.

Ben Goater, general manager of Cosma Castings U.K.

Magna’s new operations will see use of its patented vacuum die-casting process in which advanced lightweight aluminum castings help maximize strength and stiffness and minimize weight, improving fuel economy, safety, and handling. As electrified and hybrid powertrains become more common in the automotive industry, high-pressure aluminum castings can be a key factor in reducing overall vehicle weight.

“With this new aluminum casting facility, we have established a world-class center of excellence to bring the most advanced structural casting technologies to the U.K.,” said John Farrell, president of Cosma International, which is the operating unit of Magna and supplies a comprehensive range of body, chassis and engineering solutions to automakers around the world. Magna now has nine manufacturing facilities with more than 2,200 employees throughout the U.K.

“The manufacture of aluminum castings is an important building block for the next generation of all-aluminum and multi-material vehicle architectures,” said Ben Goater, general manager of Cosma Castings U.K.

Photo credit: Magna and caption: “Magna officials were joined by Ian Harnett from Jaguar Land Rover (center) and members of local government to celebrate the grand opening of Magna’s new aluminum casting facility in Telford, England.”

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Four Vacuum Heat Treat Systems Shipped to Casting Company

Four vacuum furnaces were recently shipped to a major casting company in Arizona, three with a free work area of 54″ W x 41″ H x 72″ L and one with a free work area of 24″ W x 24″ H x 36″ L.

The supplier, G-M Enterprises, based in Corona, California, announced that all four are 2-bar furnaces with innovative hot zone design and construction. A 1200 gpm water cooling system was included in the installation.

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Automotive Supplier Expands in Alabama with Aluminum Casting Facility

A global automotive supplier recently announced an expansion of its operations at its Kamtek facility in Birmingham, Alabama.

Magna International reported that its new facility will feature a manufacturing process–high-pressure aluminum casting–that further enables the supplier to provide vehicle lightweighting and part-reduction solutions for customers. The new capabilities improve upon traditional steel multi-piece welded assemblies, which can take upwards of 12 stampings to produce one structural component. High-pressure aluminum casting allows production of full structures in one piece, reducing vehicle mass without compromising performance, structural integrity or safety.

Magna invested approximately $60 million to add the 150,000-square-foot facility. The Kamtek facility employs approximately 850 people and produces structural components for various customers including Mercedes-Benz, Volkswagen and Nissan. The new facility will initially produce lightweight aluminum front shock towers for a major global automaker, with additional customers and programs expected in the future. At full capacity, the expansion has the potential to generate more than 100 jobs.

 

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

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

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

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

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

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

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

 

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EJ Americas Begins Construction on New Iron Foundry

 

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

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

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

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Melting Furnaces and Twin Chamber Furnace to be Installed

Significant milestones have been obtained with the construction and installation of two 70 mt melting furnaces and the installation of a 105 mt twin chamber furnace. Air pollution control equipment is currently being installed and the pit is being prepared to accept all of the casting equipment which will be installed in 2017. This is all part of GARMCO’s remelt expansion project.

GARMCO designed the plant to meet stringent Bahraini safety and environmental regulations. The new plant will provide GARMCO with the capability to cast an additional 120,000 tonnes of aluminium slab products. Once the slabs are rolled, the finished products will exceed customer quality requirements, improve operational safety, and reduce production costs. The plant is to be fully operational by December 2017.

Fives, the turnkey construction contractor,achieved over 600,000 man hours without any lost time injuries. 2017 will be a challenging year for all personnel on this fast track project that commenced in March 2016 Commissioning of equipment is scheduled for April and the plant should be fully operational by December 2017.

 

 

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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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Brazilian Steel Producer Purchased Continuous Slab Caster

A two-strand continuous slab caster supplied by Primetals Technologies has gone on stream at Companhia Siderúrgica do Pecém (CSP), a Brazilian steel producer. The plant has a capacity of 3 million t of slabs per annum. The continuous slab caster is part of a new steel works in the Pecém Industrial and Port Complex in São Gonçalo do Amarante in the state of Ceará. Primetals received the order in 2012 from Posco E&C, a company based in South Korea.
The continuous slab caster has a machine radius of 9.5 m and a metallurgical length of 39.8 m. It produces slabs in thicknesses of 220, 250 and 300 mm, and in widths ranging from 1,100–2,300 mm. A wide range of steel grades are cast, from low-carbon structural steels to peritectic and micro-alloyed medium and high-carbon steels, such as ULC, LC, MC, HSLA and HC. The slabs are then rolled into plate and sheet metal for use in mechanical engineering, shipbuilding, boiler and pipeline construction. The maximum casting speed is 1.8 m/min. Primetals engineered the entire plant and supplied core components, the fluid systems, the basic and process automation, and technology packages. The project also included training the operator’s personnel, and supervising the construction and commissioning work.The scope of supply from Primetals included straight Smart Mold molds plus the DynaWidth technology package for dynamic width adjustment during casting. LevCon mold level control and an electromagnetic, multi-mode mold-stirring system were installed to ensure an optimum bath level in the mold. The DynaFlex mold oscillation provides flexible adaptation of the oscillation parameters. The caster’s strand-guide system has a remotely adjustable Smart Bender and Smart Segments which, together with DynaGap Soft Reduction 3D, means that slab thickness can be changed quickly and automatically. I-Star strand-guide rollers support the strand.The Dynacs 3D secondary cooling process model dynamically calculates a three-dimensional temperature profile along the whole length of the strand. This helps to determine precisely the working points of the secondary cooling and the final strand solidification in response to the casting speed, slab format and steel grade. The internal quality of the slabs is improved by using DynaGap Soft Reduction 3D. The roller gap is dynamically adjusted during final solidification based on the working points calculated by Dynacs 3D. DynaJet spray cooling with movable nozzles in the segments ensures uniform, optimum cooling of the slabs, and consequently a high quality surface.

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Foundry Sector’s Expectations

BOTW-50w  Source:  Foundry Gate

“India is the third largest manufacturer of metal castings globally, producing approx 10 million tonnes of castings in various metals.

The Institute of Indian Foundrymen (IIF) is the apex industry body promoting the competitiveness of India’s foundry industry. There are about 5,000 foundries in India largely in the MSME category.

The foundry or metal casting industry is a key component feeder for the various sectors such as auto, auto components, railways, agro, tractors, textile, cement making, electrical machinery, earthmoving machinery, power equipment, defence equipment, and aero and space industry its sustainable growth has become more important today than ever before given the emphasis of the government on “Make in India”.

Read More:  Foundry Sector’s Expectations

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