Rio Tinto

20 News Items to Keep You Current

/ HEAT TREAT NEWS

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry. Enjoy these 20 news items, including Solar Atmospheres’ addition of new vacuum heat treating and titanium processing capacity, Airtech Advanced Materials Group’s partnership with Evergreen Additive Manufacturing, Aalberts surface technologies’ Nadcap accreditation for coatings and thermal spray processes, and more!

Equipment

1. ITP Co. Ltd. has installed a new hot isostatic pressing (HIP) system supplied by Quintus Technologies to strengthen production capabilities for precious metal equipment used in glass manufacturing, supporting improved densification, product consistency, and manufacturing efficiency for precious metals.

2. New strip casting systems for rare-earth magnet manufacturing, supplied by Retech, are expected to support thermal processing operations tied to neodymium-iron-boron (NdFeB) magnet production in the U.S., serving industries including energy, electronics, automotive, and defense. The systems are designed for vacuum metallurgy applications involving high-temperature melting and casting processes used in advanced materials manufacturing.

3. Created by Metacarpal, the GEM prosthetic hand uses a fully mechanical design to deliver durability and functionality without batteries, sensors, or electronics. The device showcases how precision machining, Aluminum 7075, and surface engineering contribute to lightweight, wear-resistant systems, highlighting the rolse of materials and thermal processing technologies in advancing prosthetic performance while improving reliability for users in demanding environments.

4. IperionX has commissioned a 300-ton, six-axis SACMI powder metallurgy press to expand U.S. titanium component manufacturing capacity, supporting the production of near-net-shape parts for defense, aerospace, and industrial applications. The technology forms titanium preforms that can be sintered and forged into finished components, increasing production flexibility and supporting high-volume manufacturing pathways.

5. Solar Atmospheres has expanded its vacuum heat treating and titanium processing capabilities with the commissioning of a new vacuum furnace designed for hydriding and dehydriding (HDH) of titanium as well as a range of thermal processing applications. The addition is expected to increase capacity for titanium processing and vacuum heat treating operations, including annealing, stress relieving, solution treating, and aging.

6. Rio Tinto has begun commissioning a major expansion of its AP60 aluminum smelter technology in Quebec, increasing primary aluminum production capacity and supporting North American supply for transportation, construction, electrical, and consumer goods markets. The project centers on aluminum smelting, a high-temperature thermal processing operation that converts alumina into primary aluminum through electrolytic reduction.

7. Wall Colmonoy has expanded its vacuum brazing capacity with the addition of two new TITAN H6 vacuum furnace supplied by Ipsen to support the production of aerospace and defense components. The investment is expected to increase capacity for vacuum brazing and vacuum heat treating operations involving stainless steel and nickel-alloy heat exchanger cores and other high-temperature assemblies.

8. Isostatic Toll Services (ITS) has opened a new hot isostatic pressing (HIP) facility in Ohio, expanding certified thermal processing capacity for aerospace, defense, additive manufacturing, and advanced industrial applications. The new operation adds HIP systems, manufactured by American Isostatic Presses, Inc. (AIP), to the company’s global network, supporting clients with additional capacity, scheduling flexibility, and supply-chain resilience.

9. Steel Dynamics Inc. (SDI) has commissioned SMS group to modernize automation systems at its Butler, Indiana, hot strip mill through a controls upgrade that supports rolling operations and associated thermal processing functions within the facility. By updating the automation architecture that supports rolling and temperature-controlled manufacturing operations throughout the mill, the project is expected to help maintain stable production and support future operational requirements.

10. METEX Heat Treating Ltd. has expanded its ISO/IEC 17025:2017-accredited metallurgical laboratory capabilities by adding Tensile Testing (ASTM E8/E8M).

11. SSAB has awarded SMS group a contract to build a gas atomization plant at its Oxelösund, Sweden, site, enabling industrial-scale production of high-strength steel powders for additive manufacturing applications. The facility will use advanced melting, atomization, and powder-handling technologies to produce high-purity, spherical metal powders for 3D printing, helping meet growing demand across defense, industrial, and mobility sectors.

12. TZCO Chain Manufacturing has granted final acceptance to SMS group for a fully automatic MP 3150 closed-die forging press at its new facility in Jinzhong, China. It is designed to produce excavator track links at high volumes while reducing material waste, machining requirements, and production costs through advanced forging and automation technologies.

The QIH 286 URC® press for ITP
Strip casting system supplied by Retech, a division of SECO/WARWICK Group
A fully mechanical GEM prosthetic hand from Metacarpal
SACMI powder press at IperionX’s titanium manufacturing campus in Virginia
Solar Atmospheres’ 12-foot furnace
Rio Tinto’s AP60 smelter in Saguenay — Lac-Saint-Jean, Quebec Canada
TITAN vacuum furnace at Wall Colmonoy
The shop floor at the ITS-Ohio facility in Mount Vernon, Ohio
The first coil production with the modernized process automation scheduled for late 2026
Tensile testing at METEX
The forthcoming gas atomization plant at SSAB’s Sweden site
The new fully automatic MP 3150 eccentric closed-die forging press at TZCO’s new forging shop in Jinzhong, China

Company & Personnel

13. Airtech Advanced Materials Group and Evergreen Additive Manufacturing have entered into an exclusive partnership to expand large-format additive manufacturing solutions for maritime applications. By combining Airtech’s advanced materials portfolio with Evergreen’s manufacturing expertise, the collaboration aims to accelerate the adoption of large-scale 3D-printed tooling and components, supporting more efficient and flexible production across the maritime industry.

14. Solar Atmospheres of Western PA marked a major milestone with a 25th anniversary event that brought together employees, clients, partners, and community members for a day of reflection, connection, and looking ahead.

15. Ipsen announced the launch of its newest regional service hub, strategically located to support clients throughout Alabama and Georgia. Officially launched in June 2026, the new hub provides regional clients with a single point of contact for routine maintenance, preventative service, and technical support.

16. SECO/WARWICK marked its 35th anniversary, highlighting the company’s evolution from a Polish-American partnership founded in 1991 into a global supplier of heat treatment and vacuum metallurgy technologies.

17. Hubbard-Hall has appointed Stephen Boyd as Chief Financial Officer (CFO), bringing extensive financial and manufacturing experience to the company’s executive team.

Airtech and Evergreen maritime AM partnership
Solar Atmospheres’s 25th anniversary celebration
Local support for clients throughout Alabama and Georgia
SECO/WARWICK’s 35th anniversary
Stephen Boyd, the newly appointed CFO at Hubbard-Hall

Kudos

18. Aalberts surface technologies has achieved Nadcap accreditation for coatings and thermal spray processes at its Kalisz, Poland, facility. The milestone strengthens the company’s position in aerospace surface engineering and supports manufacturers that rely on high-performance thermal spray coatings and heat treatment technologies for critical components.

19. Norsk Titanium’s Plattsburgh, New York facility has earned Nadcap accreditation for additive manufacturing.

20. Aalberts surface technologies’ Wadsworth team continued their 24-month merit on the Nadcap certificate, achieving zero findings on both the heat treating and quality management system audit.

Nadcap accredited Kalisz facility
Wadsworth team continuing their 24-month Nadcap merit

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AP60 Upgrade Increases Aluminum Smelting Capacity

/ ALUMINUM PROCESSING NEWS, MANUFACTURING HEAT TREAT NEWS

Rio Tinto has begun commissioning a major expansion of its AP60 aluminum smelter technology in Quebec, increasing primary aluminum production capacity and supporting North American supply for transportation, construction, electrical, and consumer goods markets. The project centers on aluminum smelting, a high-temperature thermal processing operation that converts alumina into primary aluminum through electrolytic reduction.

The USD$1.5 billion expansion at the Complexe Arvida facility adds 96 new AP60 smelting pots and is expected to be fully operational by the end of 2026. Once complete, the project will increase production capacity by approximately 160,00 metric tons annually, bringing total AP60 output to 220,000 metric tons of primary aluminum per year. The startup process began in March.

The AP60 technology was developed by the company’s research and development teams and, when combined with hydropower used at its Canadian operations, generates one-sixth of the greenhouse gas emissions per ton of aluminum compared with the industry average. The expansion also supports the transition to carbon-free aluminum electrolysis technology being developed through the ELYSIS partnership.

Jérôme Pécresse
Chief Executive
Rio Tinto Aluminium & Lithium

“For 100 years, Quebec has been at the heart of the aluminum industry, and with AP60, Rio Tinto is now strongly positioned for decades to come,” said Jérôme Pécresse, chief executive of Rio Tinto Aluminium & Lithium. He added that the expanded smelter is expected to reduce carbon emissions by up to 90% in fine particulate matter compared with the older Arvida smelter.

Rio Tinto said the AP60 expansion, together with a planned aluminum recycling center at Arvida, will more than offset production losses associated with the closure of older potrooms at the site. The project supported more than 1,500 jobs during peak construction and is expected to directly support approximately 100 permanent positions.

Press release is available in its original form here.
Main image shows Rio Tinto’s AP60 smelter in Saguenay — Lac-Saint-Jean, Quebec Canada. Image Credit: Rio Tinto

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News from Abroad: Energy, Automation, and Emerging Manufacturing Technologies

/ HEAT TREAT NEWS

In today’s News from Abroadinstallment, we highlight several major global developments — from furnace installations to energy agreements to automation upgrades and additive manufacturing advances — underscoring continued investment in reliability, material innovation, and production efficiency across the global metals processing landscape.

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

Annealing Systems Back Expansion of High-Grade Steel

This contract demonstrates the advanced technologies supplied by Fives, which are essential for steelmakers to produce high-value steels for the automotive industry.

“Fives has signed a major contract with Yongfeng Group for three annealing furnaces of new strip processing lines. Yongfeng Group is building a new facility in Linyi, Shandong province of China to produce a wide variety of high-grade steel products, including exposed and non-exposed automotive sheets and advanced high-strength steels.”

“The new vertical annealing furnaces will be equipped with the latest generation of the AdvanTek combustion system, characterized by energy efficiency, fuel flexibility, and low emissions, as well as a FlashCooling rapid cooling system. The FlashCooling system is a unique cooling technology capable of using high hydrogen gas, offering operational flexibility in cooling rate control, temperature cycle control, and uniformity of cooling.”

Read more: “Fives delivers annealing furnaces for high-end steel lines” at furnaces-international.com.

Power Deal Secures Long-Term Future of Aluminum Smelter

Operating since 1982, the Boyne smelter is the second-largest aluminium smelter in Australia.

“The future of the Boyne aluminium smelter in Gladstone, Australia, has been secured until at least 2040. Rio Tinto, the Queensland Government, and the Commonwealth Government have struck a partnership to secure a long-term future for the smelter and ensure it remains internationally cost-competitive beyond its current power contract.”

“Rio Tinto Aluminium & Lithium Chief Executive Jérôme Pécresse said: ‘As fossil fuels become increasingly expensive, this investment, combined with the power purchase agreements we have already signed, positions Boyne to be among the world’s first aluminium smelters underpinned by solar and wind power. It also ensures heavy manufacturing like aluminium smelting can continue in Gladstone for the long term and preserves one of the few fully integrated aluminium value chains in the world — from bauxite mining to alumina refining to aluminium smelting all in Queensland — as demand for aluminium continues to grow with the energy transition.’”

Read more: “Boyne aluminium smelter secures power contract” at furnaces-international.com.

Updated Control Systems Boost Reliability at Hot Strip Mill

Primetals Technologies upgrades automation systems at hot-strip mill. | Image Credit: Primetals Technologies

“Primetals Technologies has received the final acceptance certificate (FAC) from a Turkish steel producer after successfully completing a phased upgrade of its hot-strip mill.”

“Phase 1 focused on upgrading the process automation system, while Phase 2 included modernizing the basic automation system and implementing advanced profile and flatness control. Primetals Technologies also installed the ALEX condition monitoring system. The hot-strip mill was restarted as scheduled following installation and commissioning.”

Read more: “Primetals Technologies’ Modernization of Automation Systems Boosts Reliability at Hot-Strip Mill” at heat processing.

New Metal Powder Supports Additive Manufacturing for Aerospace Components

This is a heat exchanger prototype for aerospace applications. Outokumpu’s metal powder grades support precise 3D printing for complex geometries. | Image Credit: Outokumpu

“Outokumpu, a supplier of sustainable stainless steels, has achieved significant progress in additive metal powder manufacturing in collaboration with MT Aerospace. As a result of the partnership, a modified 316L stainless steel powder was developed, specifically designed for aerospace applications.”

“The product development project, “Modified 316L powder for aerospace [1157],” was carried out at Outokumpu’s Metal Powder Research Center in Krefeld, Germany. The focus was on precise chemical adjustments within the ASTM F3184 standard and optimization of process parameters during powder production. The result is a modified version of the 316L powder, which allows MT Aerospace to achieve the desired mechanical properties in components using the powder bed laser melting process and meets the precision and performance requirements of the aerospace industry.”

Read more: “Outokumpu and MT Aerospace are advancing additive manufacturing for aerospace applications” at heat processing.

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Meet Rio Tinto’s Revolutionary New Alloy

/ ALLOY FABRICATIONS NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FEATURED NEWS

Global mining and metals specialist Rio Tinto is taking orders for its new aluminum wheel alloy known as Revolution-Al™. Researchers at its Arvida Research and Development Centre in Quebec, Canada, have spent more than five years developing a stronger car wheel alloy that would help cut fuel consumption and improve both safety and handling. The London-based firm says it received its first order for the new Revolution-Al™ alloy in September 2019 and that it designed the alloy to be easy to recycle.

Jerome Fourmann,
Technical Director,
Rio Tinto

“We wanted to offer automakers a new, innovative alloy that allowed them, through styling and design, to reduce the weight of the wheels, which is very important to improving fuel efficiency – because, in the end, people want to drive not just the safest but also the greenest and most innovative cars,” states Jerome Fourmann, a technical director at Rio Tinto.

According to Rio Tinto, Revolution-Al™ is 15 to 20 percent stronger than the current predominant wheel alloy, A356.2. They claim this translates to a 7 percent weight reduction and improved fuel efficiency or battery range. Additionally, Rio Tinto claims, Revolution-Al™ can be cast in existing facilities and requires less time to produce a wheel, thereby reducing the cost and increasing the rate of production.

The improved alloy features numerous claims; for instance, it is said to be 15 to 20% stronger than the traditional A356.2 alloy, has a seamless transition with existing casting processes, and requires a 2-hour shorter ageing cycle for heat treatment than the A356.2 alloy.

Jean-Francois Laplante,
Industrial Product and Investment Director,
Rio Tinto

It is worth noting that industrial trials of the new alloy, along with an official OEM test program, featured an optimized automotive wheel design, and Revolution-Al™ passed all OEM trials. What’s more, the alloy can be recycled onto itself, eliminating the need for selling the scrap at a discount.

“The current wheel alloy has been around for a long time and now we’re coming to the market with a new way of doing things,” says Rio Tinto Industrial Product and Investment Director Jean-Francois Laplante. “We were super excited when we saw the result.”

Photo Credit: Light Metal Age

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World’s First Carbon-free Aluminum Smelting Process Developed in Joint Venture

/ ALUMINUM PROCESSING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

An Australian-British metals and mining corporation based in London in conjunction with a Pittsburgh-based aluminum producer recently announced an innovative process to make aluminum that produces oxygen and eliminates all direct greenhouse gas emissions from the traditional smelting process.

The new venture between Rio Tinto and Alcoa Corporation, known as Elysis, to develop the process and license the technology so that it can be used to retrofit existing smelters or build new facilities. Elysis will be headquartered in Montreal with a research facility in Quebec’s Saguenay–Lac-Saint-Jean region.

Rio Tinto chief executive J-S Jacques

When fully developed and implemented, it will eliminate direct greenhouse gas emissions from the smelting process and strengthen the closely integrated Canada-United States aluminum and manufacturing industry. The patent-protected technology, developed by Alcoa, is currently producing metal at the Alcoa Technical Center, near Pittsburgh, Pennsylvania, where the process has been operating at different scales since 2009.

“This is a revolutionary smelting process that can deliver a significant reduction in carbon emissions. It builds on the key role aluminum has to play in driving human progress, by making products infinitely recyclable, stronger, lighter and more fuel efficient,” said Rio Tinto chief executive J-S Jacques.

Vincent Christ, who brings more than 30 years’ experience at Rio Tinto Aluminium, has been named Chief Executive Officer of Elysis.

 

Photo credit and caption: Rio Tinto; employee at the Saguenay–Lac-Saint-Jean works

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A Dozen Quick Heat Treat News Items to Keep You Current

/ FEATURED NEWS, HEAT TREAT NEWS INDUSTRIES

A Dozen Quick Heat Treat News Items to Keep You Current

Heat Treat Today offers News Chatter, a feature highlighting representative moves, transactions, and kudos from around the industry.

Personnel and Company Chatter

  • Lars Jonsson has been appointed new employee representative to the Bulten AB board for a term of office of three years. Lars has been employed at Bulten’s plant in Hallstahammar since 1984 where he has worked as a machine operator until two years ago when he switched to tool maker. Bulten is a supplier of fasteners to the international automotive industry.
  • Paulo’s Cleveland division is expanding to add 50,000 sq ft, allow for the installation of more vacuum heat treatment furnaces, and provide optimized flow of work through the facility. The Cleveland plant primarily serves the aerospace, power generation, and agriculture industries and specializes in precise high-temperature vacuum heat treatment and brazing of nickel-based superalloys.
  • James R. Darsey, executive vice president of raw materials for Nucor Corporation announced his upcoming retirement after more than 39 years of service with Nucor.  Effective June 10, 2018, Craig A. Feldman will be promoted to the role of executive vice president of raw materials.  Mr. Feldman began his career with the David J. Joseph Company (DJJ) in 1986 and stayed with the company, becoming president of DJJ in 2013. When DJJ was acquired by Nucor in 2008, Feldman became a vice president and general manager of Nucor Corporation.  Upon his promotion to EVP, Mr. Feldman will retain his role as president of DJJ.
  • Dr. Steve Offley recently joined Phoenix Temperature Measurement as Product Marketing Manager, bringing over 21 years of experience in the industrial process temperature monitoring industry. Besides promoting and marketing PhoenixTM’s temperature monitoring productions, Dr. Offley will focus on development of new and innovative processes temperature-monitoring solutions.
  • Solar Atmospheres of Western PA recently installed a second machining center to support its newest service for customers – tensile testing. By adding a brand new fully programmable 8100 RPM Haas VF2 milling center, Solar is now able to support the machining of flat tensile specimens. This machining ability fully complements the function of the 10,000 PSI hydraulic jaw that is an integral component of the Tinius Olsen 300SL tensile machine. These massive hydraulic jaws can grip either threaded round or flat specimens.

Equipment Chatter

  • A 750°F (399°C), gas-fired cabinet oven was recently supplied by Grieve Corporation to be used for baking radiator cores at the customer’s facility. The workspace dimensions of this oven, the No. 1046, measure 80″ W x 88″ D x 18″ H, with a 76″ wide x 76″ long, 750 lb. capacity pneumatic operated rollout shelf with an insulated plug to seal doorway opening.
  • An intermediate-sized front-loading box furnace was recently delivered to the Canadian Government Forestry Division. L&L Special Furnace Co., Inc., equipped the furnace, which meets Canadian electrical standards, with an atmosphere-sealed case for use with inert gas to displace oxygen and minimize surface de-carb. It is purged with inert gas prior to loading and the parts are then heated under a controlled atmosphere. There is a 1″ NPT survey port located on the right side of the furnace employed for calibration and uniformity surveys.
  • An aerospace and defense company recently purchased a rotary hearth furnace to heat treat state-of-the-art equipment, specifically to process specialized gears for helicopters. Ipsen plans to deliver the rotary hearth furnace early next year.

Kudos Chatter

  • Advanced Heat Treat Corp. recently reported that its Iowa (MidPort-Corporate Office and Burton Ave, Waterloo) and Michigan locations have successfully transitioned from ISO/TS 16949:2009 to ISO 9001:2015 / IATF 16949:2016.
  • Stock Drive Products/Sterling Instrument (SDP/SI) has also announced that it meets all certification requirements of the new ISO 9001:2015 + AS9100D standard, maintaining processes that provide superior components and assemblies with detailed quality reporting.
  • Harbison Walker International (HWI), based in western Pennsylvania, adds its announcement to the mix, reporting that its Thomasville, Georgia, monolithic/precast facility recently became the first of the company’s North American locations to earn ISO 9001:2015 certification, followed by HWI’s South Shore, Kentucky, plant becoming the first refractory brick manufacturing plant in North America to achieve the same status. Both plants achieved this quality system recognition based on the recommendation of SRI Quality System Registrar.
  • Rio Tinto celebrates the distinction of being the first company in the world to receive certification under the Aluminium Stewardship Initiative (ASI), the highest internationally recognized standard for robust environmental, social and governance practices across the aluminum lifecycle of production, use, and recycling. The certification follows an independent third party audit and covers a range of operations, from bauxite mining to alumina refining, aluminum smelting, the creation of value-added products, transformation and recycling, and associated activities. Rio Tinto’s five aluminum smelters, the Vaudreuil refinery, casting and spent potlining treatment centers, and associated infrastructure such as power, port and railway facilities in Quebec, Canada, have been certified, along with the Gove bauxite mine in Australia.

Heat Treat Today is pleased to join in the announcements of growth and achievement throughout the industry by highlighting them here on our News Chatter page. Please send any information you feel may be of interest to manufacturers with in-house heat treat departments especially in the aerospace, automotive, medical, and energy sectors to the editor at editor@heattreattoday.com.

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