Automotive Heat Treating

Callies Precision Engine Components Improves Process

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

Callies Precision Engine Components of Fostoria, OH has installed an automated nitriding process control system from Super Systems Inc (SSi).  Callies, a leading supplier to the high performance engine market for 28 years, is always looking at opportunities to invest in technologies that improve quality, reduce cost and collapse delivery time to the customer – and the SSI Nitriding system was a perfect fit.  “Our goal has been to outfit all equipment with the latest technological controls to assure complete accountability with our in-house operations.  This was the main reason we teamed up with Super Systems.”

The engineered control system from SSi provides Callies with the ability to perform tight nitriding process control using an easy-to-use recipe system that maintains tight tolerances on temperature(s), gas flows and nitriding potential.  The relatively shallow nitride case delivers a tremendous improvement to fatigue life of every Callies crankshaft.  The extremely hard nitrided surface also gives the crankshaft excellent wear resistance.   The SSi control system provides the latest in sensor and flow technology for measuring the nitrding atmosphere and an operator-friendly interface to provide complete traceability to the process and load data.

The SSi control panel was retrofitted on an existing a Lindberg pit furnace previously used for nitriding.  Delivering proper surface and case properties requires in-situ control of the nitriding potential (Kn) and control of the ammonia, dissociated ammonia and nitrogen gases.  The system delivered by SSi also included the control of the Dissociated Ammonia (DA) generator.  The controls for the DA generator provided gas flow monitoring and temperature control to ensure the ammonia is fully cracked prior to being used as process gas in the furnace.

Callies takes their heat treating seriously as illustrated by their investment in SSi which is just part of the million dollar plus investment in the department.  Carefully controlled heat treating can be found throughout their manufacturing process which includes induction, neutral hardening, and carburizing.

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Metal Magnesium Ingots Produced in Quebec

/ AUTOMOTIVE HEAT TREAT, FEATURED NEWS

The  first metal magnesium ingots have been produced at the Danville demonstration plant in Quebec by Alliance Magnesium Inc. . This achievement comes after four years of technological development, design and construction of a pilot plant.The ingots, which are now produced on a regular basis, are used to validate the manufacturing process developed by AMI and to collect the technical and economic information necessary for the subsequent phases of magnesium production.

“This is a crucial step in the development of AMI that has just been completed. It depends on the hard work of all our staff, as well as our financial, technical and government partners who share our ambition to become the greenest magnesium producer on the planet. “Said Dr. Joël Fournier, Chief Executive Officer of AMI.

AMI is also announcing a $ 4.1 million loan from the Fonds de diversification économique de la MRC des Sources, a fund created by the Government of Québec. The proceeds of this funding will go toward the operations of its pilot plant and the preparation of its $ 100 million commercial demonstration plant, which will take shape during the year and create more than 70 jobs.

“We are delighted to count the Regional Fund as one of our strategic partners in the evolution of our company,” said Dr. Fournier. “This financial contribution demonstrates the recognition of AMI’s business model as a key driver of the region’s economic recovery and its positive impact on the community. ” he added.

AMI has invested more than $ 12 million in the region over the past three years and directly and subcontracts more than 20 professionals and operators.

About Alliance Magnesium Inc.

Alliance Magnesium is a privately-owned Canadian company engaged in the production of magnesium metal and other valuable minerals from serpentine. AMI has developed an innovative technology and process that gives it a cleaner and less expensive approach than those currently used worldwide by magnesium producers. The new AMI process is an alternative to the thermal process, which is one of the most important sources of CO2 emissions in the world. AMI has developed a three-stage development program that will lead to an annual production of 50,000 tons in 2019 and the creation of more than 350 jobs.

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Melting Line, Casting Line and Two Forging Presses to be Installed

/ AUTOMOTIVE HEAT TREAT, FEATURED NEWS, FORGING NEWS

Production of aluminum forged suspension products will be expanded by Kobe Aluminum Automotive Products, LLC, to meet the rising demand in North America.

Based in Bowling Green, Kentucky, KAAP decided in November 2015 to install a melting and casting line and two forging presses. Mass production is scheduled to begin in summer 2017. When this capital investment is completed, KAAP will have three melting and casting lines and eight forging presses. Production capacity will increase from the current 540,000 pieces per month to 750,000 pieces per month.

In the latest expansion plan announced today, KAAP plans to invest approximately US$53 million (about 5.8 billion yen) to install an additional melting and casting line and two forging presses. Startup is to begin in stages starting from autumn 2018, with completion slated for early 2019. KAAP anticipates hiring 100 more people.

When the latest capital investment is completed, KAAP will have a total of four melting and casting lines and 10 forging presses. Production capacity will increase to 970,000 pieces per month, and employees are anticipated to total 600 people.

KAAP was established in 2003 as a joint venture by Kobe Steel, Mitsui & Co., Ltd. and Toyota Tsusho Corporation to produce aluminum forged suspension products in the United States. Ever since it began production in 2005, KAAP has maintained the top share of the North American market for aluminum forged suspension products.

The United States is the world’s second-largest automobile market, and car production is anticipated to continue growing. Production of approximately 17.5 million cars in 2016 is projected to increase to 19 million cars in 2020.

Owing to their light weight, aluminum forged suspensions contribute to improving the fuel economy of cars. Demand has been rising due to the increasing need to reduce the weight of car bodies in response to environmental regulations.

KAAP began by supplying mainly Japanese automakers in the United States. It now supplies U.S. automakers, too. KAAP anticipates that in the future automakers will use aluminum forged suspension products in a wider range of vehicles.

This latest expansion will further contribute to solidifying KAAP’s position in the North American market for aluminum forged suspension products.

Outline of Seventh Expansion

Extension of building:  About 13,000 sq m (140,000 sq ft)

Equipment:  1 melting and casting line, 2 forging presses, auxiliary equipment

Investment amount:  About $53 million

No. of employees to be hired:  About 100 (when in full operation)

Start-up of equipment:  To be in stages from autumn 2018

 

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Dana Breaks Ground on New Gear Manufacturing Facility in Europe

/ AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS

Dana Incorporated broke ground on a state-of-the-art gear manufacturing facility in Europe to support new business in the region.  The 140,000 square-foot (13,000 square-meter) facility in Győr, Hungary will provide customers in the region with access to Dana’s advanced design, engineering, and manufacturing expertise to support their sourcing initiatives and technology strategies.

The company is investing approximately €46 million in the new facility, which will begin production in early 2018 employing approximately 200 highly qualified associates when full production is reached in 2020.

The facility will produce Spicer® AdvanTEK® hypoid or spiral bevel ring and pinion gear sets.  Dana manufactures gears for traditional banjo and beam axles, as well as all-wheel-drive systems.  Full axle assembly on the site is possible in the future.

The company’s AdvanTEK line of gears offers best-in-class noise, vibration, and harshness (NVH) performance, as well as greater power density in a compact package.  When integrated into an axle, these gear sets are responsible for transmitting driving torque to the wheels – delivering improved fuel efficiency, enhanced vehicle performance, and maximum durability for the complete spectrum of light and commercial vehicles.

The new plant will serve as the company’s fourth operation in Hungary.  The decision to develop another plant within the country was made possible by the Hungarian Investment Promotion Agency (HIPA), which awarded Dana development grants and tax incentives.

“We are excited to be building this new gear-manufacturing facility to support new business growth in Europe,” said Bob Pyle, president of Dana Light Vehicle Driveline Technologies.  “This plant is strategically positioned in close proximity to our existing Győr operations and will enable us to deliver technologies to our European customers more quickly and cost effectively.

“We are grateful for the strong support that HIPA and the Hungarian government have provided as we expand our gear-manufacturing capacity in the region.  Dana has operated in Győr for more than 10 years, and we know from experience that we can find exceptional employees there,” Pyle added.

 

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Premier Global Tier One Auto Supplier Formed by Union

/ AUTOMOTIVE HEAT TREAT, FEATURED NEWS

Metaldyne Performance Group Inc. has been acquired by American Axle & Manufacturing Holdings, Inc. . The transaction was unanimously approved by the boards of directors of both companies and recently approved by stockholders of AAM and MPG.

“Today is an historic day where we combine the strengths of both AAM and MPG into a premier, global Tier 1 automotive supplier with broader capabilities across multiple product lines,” said David C. Dauch, AAM Chairman and Chief Executive Officer. “This transformational acquisition will allow us to maximize stakeholder value by creating a company with greater size, scale and increased business diversification that delivers efficient, powerful and innovative solutions for our customers.”

 

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Heat Treatment Process Helps Develop Stronger Titanium Alloy

/ AUTOMOTIVE HEAT TREAT, FEATURED NEWS, TITANIUM PROCESSING TECHNICAL CONTENT

  Source:  Engineering 360

Researchers at the Department of Energy’s Pacific Northwest National Laboratory found a way to double the strength of steel by using a heat treatment process.  Read more to get the details of the process….

Read more: Researchers Develop Stronger Titanium Alloy by the Engineering 360 Newsdesk

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Automotive Industry to Benefit from New SBQ Steel Mill

/ AUTOMOTIVE HEAT TREAT, ENERGY HEAT TREAT, FEATURED NEWS
Charter Steel today announced plans to build a new Special Bar Quality (SBQ) bar
mill adjacent to its existing coil mill and steelmaking operations in Cuyahoga Heights, Ohio. The highly automated rolling mill will utilize precision sizing to produce diameters from .750 to 3.250 inches (19 to 83mm) in bar lengths from 12 to 50 feet (3.7 to 15.3m). Company leaders said the project, which will not interrupt existing steel coil operations, will support Charter Steel’s desire to serve new markets, and will add production flexibility for the benefit of its existing and prospective new customers.
The new mill represents an investment of $150 million and is expected to be online in the second half of 2018, said John W. Mellowes, CEO of parent company Charter Manufacturing Company, Inc. The project will create about 25 jobs and represents the largest single investment in the family owned company’s 81 year history.
“Growth and continuous improvement are in Charter’s DNA,” Mellowes said. “We see an
opportunity here to grow by leveraging a very successful high service model, coupled with advanced steelmaking, to serve both existing and prospective new customers with an engineered, cut length bar.
“That said,” Mellowes continued, “we will be forever fastened to our loyal coiled rod and coiled bar customers. In fact, as part of this project, we will also be adding new coil finishing assets that will enhance our coil package, our surface quality and the flexibility to roll more sizes more often coiled or straight.”
Charter Steel has produced SBQ coiled rod and coiled bar products in Cuyahoga Heights since 2002. Since 2006, the company has invested more than $250 million to bring new steelmaking assets and technology to the site that includes an electric arc furnace, ladle metallurgical refinement, deep vacuum tank degassing and an advanced billet caster producing a 7×7 inch (180x180mm) semi finished product. Today, Charter Steel is producing highly engineered steels for sophisticated applications in the Aerospace, Bearing, Cold Heading, Free Machining and High Quality Spring markets. A melt capacity increase from a series of recent investments and productivity gains from continuous improvement projects will provide the additional steel for the new bar mill. Construction of the new mill is expected to begin this spring.

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Arconic Announces Multi-Year Deal with Toyota

/ AUTOMOTIVE HEAT TREAT, FEATURED NEWS

Global technology, engineering and advanced manufacturing leader Arconic announced a multi-year supply deal with Toyota North America. Arconic is supplying aluminum to Toyota for its all-new Lexus RX. The vehicle debuted last year and became Toyota’s first vehicle in North America to prominently feature aluminum exterior panels.

“Automakers worldwide are turning to aluminum for the stronger, tougher, higher performing vehicles that consumers demand,” said Mark Vrablec, President of Arconic’s Aerospace & Automotive Products business. “Many bestselling vehicles in America have already converted to aluminum for improved performance, including better fuel efficiency, more towing and payload capacity, and improved vehicle safety scores. This trend will continue. We are proud to expand our relationship with Toyota.”

This makes Arconic the sole aluminum sheet supplier to Toyota for the Lexus RX, named by Consumer Reports as the Best Luxury SUV of 2016.

The Arconic and Toyota deal draws on the strong automotive expertise and manufacturing capability of Arconic’s Global Rolled Products business. Arconic will supply Toyota from its plants in Davenport, Iowa, and Danville, Illinois.

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