Aluminum Producer Expands Operations in South Carolina

A manufacturer of flat-rolled aluminum products recently announced plans to expand its existing operations in Goose Creek, South Carolina, adding a new 220,000 square foot building and installing state-of-the-art equipment.

JW Aluminum expands operations at its Mount Holly location.

JW Aluminum launched the $255 million expansion of its Mount Holly plant in a project that it hopes will greatly enhance the company’s capabilities to serve its primary end markets, representing the most significant capital investment in domestic continuous cast technologies and capabilities since 2001. In addition to the Mount Holly location, JW Aluminum manufactures aluminum products for the automotive, aerospace and construction industries at three other mills around the country, including St. Louis, Missouri; Williamsport, Pennsylvania; and the latest addition to the JW Aluminum, a mill in Russellville, Arkansas.

“It’s an exciting new chapter in JW Aluminum’s story and a considerable progression in our strategic journey. As a domestic supplier, we’ve prevailed in an extremely challenging competitive environment. The outcome of this endeavor will empower us to produce superior product for our customers, provide increased value to our stakeholders and serve as a preferred supplier and employer for decades to come,” said Lee McCarter, CEO of JW Aluminum.

Hazelett Corporation also recently confirmed that the Hazelett® Twin-belt Continuous Casting Process will be utilized for the JW Aluminum expansion. The casting machine being supplied is capable of producing 2000 mm wide strip at approximately 50 metric tonnes per hour. Alloy capabilities include 1XXX, 3XXX, 5XXX, and 6XXX series.

“This new facility will be a model for the most cost-effective and energy-efficient sheet production in North America,” said David Hazelett, president. “And, it will significantly ease the projected shortage of aluminum coil in the United States.”

Hazelett Corporation designs, manufactures, installs, and services twin-belt continuous casting machines worldwide and is fully integrated with in-house engineering, manufacturing, R&D, and technical services.

Photo Credit: JW Aluminum

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Heat Treating Carbon Steel to Meet Air-Conditioning Demand

A global manufacturing company that provides innovation solutions to industrial, commercial and residential customers signed a contract for equipment supply and installation of a lamination annealing line that will heat treat low carbon and ultra-low carbon steel to soften and impart specific magnetic properties. 

Emerson Electric Co., based in St. Louis, Missouri, secured this agreement with Primetals Technologies for its plant in Russellville, Kentucky, in order to meet seasonal increased demand for air-conditioning units. The London-based Primetals Technologies, a leading engineering, plant-building, and lifecycle services partner for the metals industry, is responsible for the equipment installation, start-up, and commissioning services. Start-up is expected for Spring 2019.

Air-conditioning units that use small electric motors represent a significant portion of Emerson’s market. The market becomes active in late spring as consumers buy air conditioners in anticipation of warm summer days.

Initially, Emerson planned to have a longer lamination annealing line at its Reynosa, Mexico plant, but limited available space required extensive modifications to fit the new line. Instead, Emerson decided to install a new line at its existing Russellville plant. The Emerson and Primetals Technologies teams collaborated to find a cost-effective solution to shorten each section of the line to fit the Kentucky plant layout.

 

Photo Credit: Emerson Electric

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Expand Your Professional Network at ITPS/IFCS

ITPS/IFCS is designed to provide a place where industry executives can network and gain critical information for managing their manufacturing business. In addition to the exceptional presentation program, participants will have the opportunity network with other executives and Summit speakers during the Welcome Reception and a Taste of the South Dinner. These social events enable participants to exchange conversation, ideas, and knowledge with everyone in attendance within a casual setting.


Why I’m Attending:

“As an end-user, attending ITPS 2016 provided me with greater insight of the thermal processing industry and the challenges it faces. Furthermore, ITPS is a great opportunity to network and build relationships with key people within the industry. I have utilized those relationships several times over the past two years.”

Chad Spore, Staff Engineer

Enterprise Materials Engineering, John Deere

For complete Summit information, including hotel reservations and to register, visit ITPS/IFCS. To take advantage of our hotel group rate, book your room today!

Registration discounts are available for IHEA, CCAI, MTI, CECOF, JIFMA, VDMA, Electrocoat Association, and WiM members.

[button link=”www.itps-ifcs.com” size=”default” icon=”Select a Icon” side=”right” target=”blank” color=”b70900″ textcolor=”ffffff”]Register Now[/button] Save 25% with promo code ED25C.

Heat Treat Today is proud to be a co-sponsor of this event.

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Canadian Centers of Excellence Established for Helicopter Airframe, Engine MRO Services

An independent provider of engine and airframe services recently announced a 12-18 month company restructuring of its primary Canadian MRO facilities to create three different Centers of Excellence (COEs) specifically for supporting Helicopter Airframe/Component MRO services, Helicopter Engine MRO services and Turboprop Engine MRO services at facilities located in Langley, British Columbia; Winnipeg, Manitoba; and Summerside, Prince Edward Island.

Russell Ford, CEO of StandardAero

In addition, StandardAero intends to wind down its operations at its Richmond, B.C. facility by June of 2019 as part of the restructuring plans. Helicopter engine MRO services currently performed at Richmond will be relocated to StandardAero’s Winnipeg facility, including all Safran Arriel 1&2, Rolls-Royce M250, GE T700 and Pratt & Whitney Canada (P&WC) PT6T helicopter engine MRO services. Winnipeg will serve as the company’s COE for all Helicopter Engine MRO services. Helicopter dynamic components, currently located in Richmond, will be relocated to the company’s Langley facility which will serve as the COE for Helicopter Airframes/Component MRO services moving forward.

In order to accommodate all of the helicopter engine MRO capabilities in Winnipeg, StandardAero is moving its Winnipeg P&WC PW100 MRO engine services and as well as the existing P&WC PT6A work to its facility in Summerside – which will become the company’s COE for Turboprop Engine MRO.

“Over the past several months, our team has been working carefully to drive integration activities and program management to combine our legacy StandardAero and Vector Aerospace facilities,” said Russell Ford, CEO of StandardAero. “A big part of our overall acquisition strategy is to ensure we establish these Centers of Excellence (COEs) and combine or consolidate relevant engine platforms to eliminate duplicate operations, while also freeing up capacity to accommodate our growth programs.”

StandardAero services include engine and airframe maintenance, repair and overhaul, engine component repair, engineering services, interior completions and paint applications to a diverse array of customers in business and general aviation, airline, military, helicopter, components, and energy markets.

 

Photo credit: StandardAero

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Clarity and Accuracy in Heat Treat Specifications Ensures Quality Processing

 

Source: Paulo Learning Center

 

Heat treaters strive to deliver parts that meet industry and manufacturers’ specifications with precision, but too often the information they get from customers is inadequate, unclear or incorrect. This article from Paulo’s Learning Center provides 7 points of data that will help a metallurgist treat parts to stand up to the manufacturer’s intended application, including:

  • making sure materials are clearly identified
  • specifying the process required
  • noting prescribed hardness tolerance
  • identifying case depth tolerance
  • sharing the right amount of information
  • providing correct hardness scales
  • identifying inspection points

 

Read more: “Understanding Heat Treatment Specifications”

 

Photo credit: Paulo Learning Center

 

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Induction Heating Manufacturer Doubles Facility Space to Meet Demand

Tony Mazzullo, president of Ambrell

An induction heating manufacturer has moved its operations to a facility twice the size of the previous location to accommodate increased demands for its products and industry solutions.

Ambrell Corporation, the thermal segment subsidiary of inTEST Corporation, which designs and manufactures thermal management products, recently broke ground on the new 80,000 sq ft facility in Rochester, New York. The $2.1 million project, which started in September 2017, included a complete company relocation from its previous manufacturing facility in Scottsville, New York.

“This is an exciting time for Ambrell and marks a huge milestone for the company, its employees, and customers who will all benefit from the opportunities this expansion presents,” said Tony Mazzullo, president of Ambrell, at the previous ribbon-cutting ceremony. “This new facility adds floor space to our Applications Laboratory to provide our customers with access to all of Ambrell’s products when they visit The Lab at Ambrell. The addition of floor space and equipment will also enable us to manufacture more products to meet the growing demands of our customers. In addition, our highly efficient manufacturing floor will enable us to maximize throughput while continuing to manufacture solutions that are innovative, of very high quality, and reliable.”

James Pelrin, inTEST president and CEO

“The new facility is designed to meet the demands of Ambrell’s growing business, increasing current capabilities for both product design and manufacturing,” commented James Pelrin, inTEST president and CEO. “To accommodate this rapid company growth, we are expanding from approximately 40,000 square feet at the previous facility to 80,000 square feet at the new location.”

inTEST designs and manufactures induction heating products for joining and forming metals for use in a variety of industrial markets, including automotive, aerospace &defense, machinery, wire & fasteners, medical, and semiconductor.

 

 

Photo caption and credit: Ribbon-cutting ceremony with Ambrell and inTEST representatives and local and state officials; Twitter

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Heat Treatment to Strengthen Stents

 

Source: Buehler.com

 

Manufactured from titanium, 316L steel, cobalt chromium alloys, platinum chromium, titanium (Ti6Al4VELI) and nitinol alloys, medical stents are a critical component in treatments that require mesh scaffolding to open blocked vessels or ducts. In order to validate the thickness of the walls or strengthen the stent where modifications have taken place, manufacturers utilize laser machining, which can result in microstructural changes to the alloy. Heat treatment enters as a vital process to relieve internal stresses and improve fatigue properties.

“Nitinol stents which are generally self-expanding utilize the elastic properties of the alloy and require a shape-setting process to fix the final shape of the stent,” write Dr. E. Mogire and D. Crozet in a paper recently published by Buehler.

 

Read more: “Metallographic Preparation of Medical Implants – Stents, Orthopaedics…”

 

 

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Growth for Iowa Heat Treater Means New Addition, New Equipment

An Iowa-based heat treat company providing thermal processing and metallurgical solutions for multiple industries, including aerospace, energy, and automotive, recently announced breaking ground on a 15,000 sq ft new addition, which will include two new heat treating equipment installations.

This is the first expansion at the corporate headquarters at Advanced Heat Treat Corp. (AHT) since 1998. The new addition will allow AHT to segregate its trademark processes, UltraGlow® (ion nitriding/nitrocarburizing) and UltraOx® (gaseous ferritic nitriding/nitrocarburizing and oxidation treatments) and maintain its state of the art manufacturing feel and presence.

The new expansion will bring with it two new gaseous ferritic nitriding/nitrocarburzing units w/sizes up to 13’ tall and 5’ wide. The new additions will be twofold:

  • the larger unit (13’ x 5’) will allow AHT to grow its longer-like product line, for processing long plastic injection screws for the plastics industry, hydraulic cylinder rods for the agriculture and/or construction industry lines and various pump, motor, shaft components for the oil and energy industries, and
  • the smaller unit (4’ x 5’) will be designed to capture more of the aerospace product line market; this unit will be targeted to be Nadcap approved by late 2018 to early 2019. By doing so, AHT will then have two Nadcap-approved processes inside its walls: Ion Nitriding and Gaseous Nitriding.

“This expansion will allow us better control of product flow, inventory control and process capacity,” said William Cowell, vice president of Ion Nitriding and plant manager. “We’ll be nearly doubling our gaseous nitriding capacity  with these additional units, and with the floor space, we’ll be able to better accommodate our customer demands.”

Mikel Woods, president of AHT

AHT currently has 55 ion/gaseous nitriding units across its four locations in Waterloo, Iowa; Monroe, Michigan; and Cullman, Alabama.

“I’m excited on many counts. One, we’re adding capacity/backup to an already growing agriculture/construction market. Two, we’re targeting to add a new Nadcap process in order to expand further into the aerospace market and meet more of our aerospace customer demands and requests. And three, we’re gearing up to go even bigger in 2019: with the expansion, we’ve planned to build/design a gaseous unit that will process parts up to twenty feet. This unit will allow us to enter various markets for growth,” said Mikel Woods, president of AHT.

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Heat Treat Today’s Induction Expert Dr. Valery Rudnev Recognized at TPiM 2018

Dr. Valery Rudnev, who writes Heat Treat Today‘s column, “Dr Valery Rudnev On . . . “, was recognized during the opening ceremony of the American Society for Materials (ASM International) Thermal Processing in Motion 2018 (TPiM 2018) conference held this month in Spartanburg, South Carolina, and received two prestigious awards for his contributions in the field of induction heating and heat-treating.

Dr. Rudnev, Director of Science and Technology at Inductoheat Inc., an Inductotherm Group Company, was elected as a Fellow to the International Federation for Heat Treatment and Surface Engineering (IFHTSE) “[f]or his preeminence in induction heat treating and modeling of the induction heat treating process” (IFTSE, 2018). As a Fellow of ASM International with more than 30 years of experience, he is considered by many to be one of the leading global figures in the induction heating and is known among induction heating professionals as “Professor Induction.” His credits include a great deal of “know-how”, more than 50 patents and inventions (U.S. and International), and more than 250 engineering/scientific publications.

Dr. Richard D. Sisson Jr., George F. Fuller Professor, Director of Manufacturing and Materials Engineering and the Director of the Center for Heat Treating Excellence at Worcester Polytechnic Institute, and Professor Rafael Colás, Professor and Metallurgist Engineer, Universidad Autónoma de Nuevo León, were awarded fellowships with IFHTSE.

Dr. Rudnev was also presented with the ASM International “Best-Paper in Heat Treating” award for co-authoring an article entitled “Revolution – Not Evolution – Necessary to Advance Induction Heat Treating.” The article was published in the September 2017 issue of Advanced Materials & Processes Magazine (HTPro quarterly newsletter) and co-authored with Gary Doyon, Collin Russell, and John Maher. The ASM International Heat Treating Society, Research and Development Committee, established this award to recognize the best papers in the heat treat industry each year.

IFHTSE is a nonprofit group of scientific/technological societies and associations, groups and companies and individuals whose primary interest is heat treatment and surface engineering.

We at Heat Treat Today congratulate Dr. Valery Rudnev on these accomplishments!

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Galvanizing Line Plans Approved at Arkansas Sheet Mill

A North Carolina-based steel producer with operations primarily in the U.S. and Canada recently announced plans to expand heat treating capabilities at its Arkansas facility with a galvanizing line to support the company’s strategy to grow its automotive market share.

John Ferriola, chairman, CEO and president of Nucor

Nucor Corporation’s Board of Directors approved the construction plans at the sheet mill in Hickman of a galvanizing line at the company’s sheet mill with a target date for operations to begin in the first half of 20121. The $240 million investment with an annual capacity of approximately 500,000 tons complements the company’s $230 million investment currently underway to construct a specialty cold mill complex at Nucor Steel Arkansas.

“At Nucor Steel Arkansas, we are building one of the most modern and efficient steel mills in the world,” said John Ferriola, chairman, CEO and president of Nucor. “This new galvanizing line, coupled with our new specialty cold mill complex, will allow us to efficiently produce products beyond the capability of any North American mill, and to have the flexibility to meet current and future demand for advanced high-strength steel products.”

The company is also evaluating building additional galvanizing lines at its other sheet mills as part of Nucor’s initiative to further expand its sheet business.

MaryEmily Slate, vice president and general manager, Nucor Steel Arkansas

“Building this galvanizing line will diversify the product mix at Nucor Steel Arkansas and allow us to better serve our automotive and value-added customers,” said MaryEmily Slate, vice president and general manager, Nucor Steel Arkansas. “We are positioning ourselves to become a major supplier to the growing galvanized market in the U.S.”

Nucor and its affiliates are manufacturers of steel products, with operating facilities primarily in the U.S. and Canada.  Products produced include: carbon and alloy steel — in bars, beams, sheet and plate; hollow structural section tubing; electrical conduit; steel piling; steel joists and joist girders; steel deck; fabricated concrete reinforcing steel; cold finished steel; steel fasteners; metal building systems; steel grating; and wire and wire mesh.

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