Automotive Heat Treating

Ohio Axle Production Facility to Support Light-Vehicle Programs

James Kamsickas, Dana president and CEO

A major engineering solutions group recently inaugurated a high-tech axle production facility in Toledo, Ohio, where the company will be able to provide support to automakers throughout the geographic region, but particularly those with light-vehicle programs, such as the Jeep Wrangler.

In addition to shoring up its passenger vehicle, commercial truck, and off-highway markets, Dana Incorporated expects the 300,000 sq. ft. facility to be supporting four vehicle programs and employing more than 350 people by 2020.

While the site of the new Dana facility was initially home to Willys-Overland Motors, which developed the original Jeep, the new Jeep Wrangler will be manufactured less than three miles away at FCA US LLC’s Toledo Assembly Complex.

“The investment in this new manufacturing facility supports Dana’s global growth and serves as the latest example of our commitment to the greater Toledo area, which has been our home for nearly 90 years,” said James Kamsickas, Dana president and CEO.  “It is an honor for Dana to return manufacturing to the same historic site where Toledo’s automotive industry began more than a century ago.”

Bob Pyle, president, Dana Light Vehicle Driveline Technologies

“Our new Toledo facility will integrate Dana’s best global manufacturing practices and advanced operating systems.  The plant’s products will feature Dana’s latest technologies, and the location – in close proximity to our customers and our World Headquarters and Maumee Technology Center – will benefit our customers, employees, and shareholders,” said Bob Pyle, president, Dana Light Vehicle Driveline Technologies.

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Aleris Opens Kentucky Plant, Includes Heat Treatment, Annealing Capabilities

Sean Stack , Aleris Chairman and CEO

Global aluminum producer Aleris recently announced the opening of its aluminum automotive body sheet production facility in Lewisport, Kentucky, which includes heat treatment and finishing capabilities, as well as a wide cold mill, and two continuous annealing lines. The company, which is headquartered in Cleveland, Ohio, launched the project in 2014 in response to the automotive industry’s demand for broader aluminum use in the production of lighter, more fuel-efficient vehicles. The Lewisport facility began shipping automotive products to customers in November.

Lewisport is Aleris’s first site in North America that is equipped with aluminum auto body sheet finishing capabilities and houses an automotive innovation center, which includes a state-of-the-art research and development center in Detroit.

“The opening of our new automotive facility in Kentucky marks the completion of a significant piece of our strategic realignment, which includes expanding our capacity and capabilities to serve the automotive industry and other high-value end uses,” said Aleris Chairman and CEO Sean Stack. “As an experienced supplier to automotive manufacturers in Europe, we look forward to partnering with customers more closely now in North America to bring them the most advanced auto body sheet products in the industry.”

 

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Honda Driveshaft Recall Due to Improper Heat Treating Process

Due to an improper heat treating process at a supplier, Honda is recalling 5,404 model-year 2017 Civic 2-door and 4-door vehicles equipped with 1.5-liter engines and automatic (CVT) transmissions in the United States to inspect, and, if needed, replace the right driveshaft, free of charge. Honda has received no customer reports related to this issue, which was discovered during routine quality checks at the factory.

Tthe right driveshafts in these vehicles may break if they are from affected production lots. If a driveshaft breaks, the vehicle will lose drive power when driving or may roll away when parked without the parking brake engaged, each increasing the risk of a crash. Dealers will inspect the driveshafts in the recalled vehicles to determine if they are from affected production lots, and, if so, replace them for free.

Honda is announcing this recall to encourage owners of affected vehicles to take them to an authorized dealer as soon as possible for inspection and potential repair. Mailed notification to owners of affected vehicles will occur in early-December 2017. Owners of 2017 Civics can also determine if their vehicles require repair now by visiting www.recalls.honda.com or by calling (888) 234-2138.

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Heat Treat Equipment Purchases — Recent Activity

Multiple transactions involving the contracting, purchasing, selling, shipment and delivery of heat treat systems, equipment, or services have taken place over the past several weeks; here are some we hope will be of interest to Heat Treat Today readers.

  1. (Automotive Heat Treat News) A Chinese steel manufacturer of parts for the automotive industry, Baosteel's Zhanjiang integrated steel production complex, opened with Fives' Stein Digiflex furnaces for a 700kt/yr continuous annealing line and a 270kt/yr galvanizing line for a 1,550mm wide cold rolling mill.
  2. (Manufacturing Heat Treat News) Spanish heavy industry manufacturer Forjas Iraeta Heavy Industry, S.L. (GRI Group), contracted a 30 ton/hour walking beam furnace to add to an existing flange production mill. German metals SMS Group launched the project, which is to install furnace technology for proper and optimal reheating of a wide range of products: the charge will include blooms from 200 to 500 millimeters square and round blooms from 300 to 700 millimeters in diameter, in lengths between three and five meters.

    The SMS-Shougang Jingtang United Iron & Steel Co Ltd project team at the contract signing ceremony for the new galvanizing line.
  3. (Manufacturing Heat Treat News) In addition, SMS Group recently received a contract for a continuous hot-dip galvanizing line for high-strength steel grades to be supplied to Shougang Jingtang United Iron & Steel Co., Ltd., China. This is the sixth strip processing line to be installed in this works on Caofeidian Island, a man-made island offshore the Chinese province of Hebei. The line will produce 360,000 tons of hot-dip galvanized steel strip, including high-strength grades with tensile strengths of up to 1,350 MPa.
  4. (Manufacturing Heat Treat News) Two electrically heated Pacemaker integral quench furnaces have been shipped by Lindberg/MPH, based in Riverside, Michigan, to be used for carburizing and hardening applications.
  5. (Manufacturing Heat Treat News) Lindberg/MPH has also shipped to an electronic components manufacturer a 1200°F single-zone tube furnace to be used for annealing, ashing, carbon firing, ceramic firing, hardening, sintering, solution treating, stress relieving, and other heat treating applications.
  6. (Aerospace Heat Treat News) Lindberg/MPH announced the shipment of an electrically heated gas nitriding pit furnace for a leading aerospace supplier. The pit furnace system performs a two-stage nitriding process to achieve high surface hardness on A11 and H13 steel parts.
  7. (Manufacturing Heat Treat News) An electrically heated, steam atmosphere, pit furnace has been shipped by Lindberg/MPH to an engineered components manufacturer. The equipment will be used with a steam generator for steam treating tools steels.
  8. (Automotive Heat Treat News) An automotive supplier is the recipient of a fourth Lindberg/MPH transaction, a multi-chamber, electrically heated hot stamping furnace to be used to preheat steel blanks for hot stamping structural automotive components. 
  9. (Automotive Heat Treat News) Can-Eng Furnaces recently completed commissioning an electrically heated furnace line addition to a leading bearing manufacturer’s existing production line. Responsible for producing planet shafts and pump vane products, the line now features a compact 1,000 lb/hr atmosphere temper and soluble oil system for rust prevention.
  10. (Automotive Heat Treat News) A Montreal-based manufacturer of advanced plasma processes received an order for the sale of a second DROSRITE™ Furnace System to a North American automobile parts manufacturer. PyroGenesis Canada Inc. developed the patented salt-free, cost-effective, sustainable process for maximizing metal recovery from dross, a waste generated in the metallurgical industry.

Heat Treat Today finds the robust activity of heat treatment equipment sales and acquisitions an exciting topic to report on and would be interested in your supplier news tips. Please send any information you feel may be of interest to readers of Heat Treat Today to the editor at editor@heattreattoday.com.

 

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Wooster, OH, Auto Supplier Facility Celebrates 40th with E-Mobility Expansion

Marc McGrath, President of Automotive Americas, Schaeffler

A global automotive and industrial supplier recently launched the company’s latest expansion, its U.S. center for advanced e-mobility development located at its existing Wooster, Ohio, facility.

Schaeffler Group USA Inc., which delivers high-precision components and systems in engine, transmission, and chassis applications, as well as rolling and plain bearing solutions for a large number of industrial applications, commemorated the facility’s 40th anniversary with a grand opening celebration and unveiling of the $60 million capital investment.

Already established as the center for Schaeffler’s torque converter product line, the newly renovated Wooster campus will equip employees with the capacity for the production of hybrid modules, the first of the electrification projects, which combines the electric motor with a hydrodynamic converter to yield a P2 hybrid solution. Beginning in 2018, the facility will produce the module for a major U.S. automotive manufacturer. The team is also engaged in pure electric vehicle technology development, including the production of Schaeffler’s e-axles.

“From 2007 to 2016, our automotive business has outpaced market growth by nearly double and we have expanded our manufacturing capacity in Wooster to keep pace with growth in our automotive transmission business, ” said Marc McGrath, president Automotive Americas, Schaeffler. “This latest investment, which builds upon our recent $36.5 million expansion of our Fort Mill, S.C. facility, prepares us for the production of future transmission technologies and further optimizes the facility’s vertical integration.”

Opening ceremony for the expansion of the Wooster plant. Among the guests were (from left) Patrick Lindemann, Vice President Transmission Systems; Bruce G. Warmbold, Regional CEO Americas; Bob Breneman, Mayor of Wooster; Klaus Rosenfeld, CEO of Schaeffler AG; Mary Taylor, Lieutenant Governor of Ohio; Georg F. W. Schaeffler, Chairman of the Supervisory Board of Schaeffler; Matthias Zink, CEO Automotive; Oliver Jung, Chief Operating Officer; Shelly Flint, Director Human Resources Transmission Systems and Automotive; and Marc McGrath, President of Automotive Americas. Photo credit: Schaeffler

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Hyundai Recall Traced to Heat Treatment Induction Coil

 

Source: RecallMasters.com

Stock Photo

More than 400 Hyundai vehicles have been recalled due to concerns about defective crankshaft assemblies, according to information released by the National Transportation Safety Administration. In May 2017, Hyundai Motor America (HMA) received a report from a customer about a knocking sound during operation of his 2017 Santa Fe sport utility vehicle and initiated an investigation. An inspection of recovered engine assemblies revealed that engine bearings had seized due to improperly produced crankshaft pin surfaces, a condition traced back to a crankshaft heat treatment coil that was improperly positioned during production in January 2017.

A total of four reports of 2017 Santa Fe vehicles exhibiting abnormal engine noise were received by the company. In addition, one of these reports indicated the vehicle had stalled due to eventual failure of the engine. Although Hyundai is not aware of any accidents, injuries, or customer complaints related to this condition, HMA decided to conduct a voluntary safety recall and notified dealers in September. Owners were informed via first class mail in October. It is estimated that no more than 25 percent of the vehicles affected by the recall actually contain the defective parts.

To view the Safety Recall Report posted by the National Highway Traffic Safety Administration or to learn what to do if you own a 2017 Hyundai Santa Fe, click here: Part 573 Safety Recall Report.

Read more: “Hyundai Recalls Vehicles with Defective Crankshafts”

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Heat-Treatable Alloy Arrives for N. American Automakers

A world leader in aluminum rolled products recently announced the North American availability of a heat-treatable alloy, its latest addition to a series designed to provide greater flexibility for automakers and other industries.

Novelis Inc. unveiled the Advanz™ 6HF – e/s200, a high-formable aluminum alloy that is distinctive for its superior formability, strength performance, and weight savings for outer and inner applications. The material has sustained successful application in Europe.

The 6xxx-series alloy enables new opportunities to use aluminum for body sides, door inners, decklid outers and inners, and other closure panels. The alloy can also be used in designs and applications that required bending without the risk of cracking. In addition, Advanz™ 6HF – e/s200 creates a weight savings of nearly one-third over steel in inner door applications, benefitting vehicles that need to achieve weight reduction per customer specifications.

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Rolled Aluminum for Auto Body Production Included in Logan Expansion

A flat-rolled aluminum sheet manufacturer recently broke ground on Phase II of its expansion project in Logan County, Kentucky, where the company’s Phase I facility opened late last month, an investment of $240 million expanding recycling/new ingot casting capabilities to 600 million pounds of cast ingot annually, increasing the capacities of rolling mills, scalping, and pre-heat operations, and creating approximately 190 employment opportunities.
Logan Aluminum Inc.’s new project includes a planned mill that will strengthen cold rolling production and boost capacity for heavier gauge rolled sheet manufactured into automotive body and structural panels. When completed, the $125 million project is expected to provide 60 jobs for the area.
“Almost two years ago to the day, we held our groundbreaking for the new DC4 Recycle Facility, and now we are here today for the ceremonial ribbon cutting of DC4, and for the groundbreaking of Logan’s new Cold Mill – CM4,” said Ken Perdue, Logan Aluminum Plant Manager. “It’s an exciting time for aluminum and it’s a really exciting time for aluminum in Kentucky.”
Logan Aluminum Inc. was established in 1983 and is a joint venture between Tri-Arrows Aluminum Inc., headquartered in Louisville, Kentucky, and Novelis Inc., based in Atlanta, Georgia.
 Photo by Karen Logan Logan County Chamber of Commerce

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Auto, Aerospace Demand for Aluminum Favors Hindalco Bid

 

Source: Moneycontrol.com

 

Aluminum manufacturer Hindalco Industries Ltd is considering a bid to acquire a U.S. maker of aluminum rolled products as a move to advance the India-based company’s efforts to expand its reach into the automotive and aerospace sectors.

The private equity owners of Aleris Corporation, located in Cleveland, Ohio, ended talks with China Zhongwang Holdings last month due to heightened U.S. national security concerns and now find the company courted by Hindalco, through its U.S.-based subsidiary Novelis, as well as several other firms, including Norsk Hydro of Norway, Japan’s UACJ Corp., and Arconic (formerly Alcoa). Aleris Corporation is valued at approximately $2.5B, although a bidding war could escalate that figure to greater than $3B.

Read more: “Hindalco Eyes Aleris Corp. to Tap Growing Aluminium Demand”

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Austenitizing, Salt Quenching Processes Enhance Auto Supplier’s Heat Treating Capabilities

A Mexico-based automotive supplier recently awarded a contract for the design and manufacture of a 1,500 lb/hr mesh belt furnace system for the austenitizing and molten salt quenching of unique components used in the manufacture of its drivetrain systems.

This contract was awarded to Can-Eng Furnaces International Ltd, which has scheduled the project to be commissioned early 2018 in Mexico’s centralized automotive manufacturing corridor. Incorporating several technological advancements for continuous atmosphere processing of products requiring carbon diffusion and quenching via a molten salt system, known as austempering, the new system includes: automated bin-dumping loading, mesh belt atmosphere hardening furnace, salt quench, post-quench wash and rinse system, mesh belt temper oven, and endothermic gas generator.

 

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