SECO/WARWICK

2 Al Billet Homogenizers & 2 Coolers Headed Coast to Coast

/ ANNEALING NEWS, COOLING SYSTEMS NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Two aluminum homogenizers and two coolers are set to enhance U.S. operations for an aluminum manufacturer with locations across America. One of each unit will be sent to locations on opposite sides of the U.S.

The supplier of these systems is SECO/WARWICK USA. Homogenizers are a type of annealing furnace used in the aluminum industry to prepare log billets for extrusion. They heat the aluminum alloy logs to near-melting temperatures, then allow them to cool slowly, leaving a uniform molecular structure free of stresses or irregularities that compromise extrusion quality.

While proper homogenization requires a slow cool-down period, the large loads at this manufacturer’s location in the western side of the U.S. would take far longer than necessary to cool passively. So, after homogenizing, the load is removed from the homogenizer and placed into a cooler unit. The cooling is accomplished using a bank of high-power fans to keep fresh air passing over the hot ingots but cooling aluminum alloy to room temperature from close to 1000°F is not as simple as just placing the load in front of the fans. Instead, the cooler has walls that contain the heated air so it can be safely ducted to the exterior.

Marcus Lord
Managing Director at SECO/WARWICK Corporation
Source: SECO/WARWICK

Headed to the eastern side of the U.S., the furnace and cooler are of a different style and customized to fit within the tighter footprint available in the facility. It is configured as a two-position traveling furnace with car-bottom loading, which means the furnace is mounted to roll on rails, with a door at both ends, so the load can be staged in open floor space, then the furnace rolls over the top of it. The cooler system is mounted on parallel rails, with an extendable roof and end walls, such that it can enclose the load, still stacked on the same furnace car-bottom. The furnace will replace the first traveling furnace that SECO/WARWICK ever fabricated, installed back in 1975, when the plant was under different ownership.

“We have provided this industry partner with equipment and support for decades and we share their commitment to a cleaner, greener future. These homogenizers and coolers will help them meet that commitment by increasing the energy efficiency of their aluminum production process,” commented Marcus Lord, the managing director at SECO/WARWICK USA.

The original press release can be accessed here.

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Vacuum Furnace for Nitriding Service Provider

/ MANUFACTURING HEAT TREAT, NITRIDING NEWS, VACUUM FURNACES NEWS

A nitriding service provider in Brazil will increase their production line with a single-chamber vacuum furnace from a manufacturer with North American locations.

Peter Lutz, president of Nitrion do Brasil says, “We were looking for a solution that would help not only increase our metal processing capabilities, but also efficiency and effectiveness.”

The SECO/WARWICK Vector vacuum furnace will operate in a new production hall and will handle Nitrion do Brasil’s increasing order volume. This order is a result of cooperation between SECO/WARWICK and their strategic partner in Brazil, Combustol.

Maciej Korecki
Vice President of Business of the Vacuum Furnace Segment
SECO/WARWICK

“Combustol supports SECO/WARWICK not only in sales but also in service activities and the supply of spare parts. Such a partner in such a remote location is a huge advantage,” commented Maciej Korecki, VP of the Vacuum Furnaces Segment in the SECO/WARWICK Group. He added, “[Nitrion do Brasil] bought a furnace that we could deliver quickly.”

The furnace on order will solve the commercial heat treater’s problem of hardening larger elements, because the furnace is equipped with a large working space. This will affect the process economics (energy savings and the graphite chamber’s increased efficiency) as well as the process cleanliness and speed. The furnace is equipped with convection heating – a system that improves the heat transfer efficiency when heating at lower temperatures, as well as directional cooling, which allows the system to efficiently cool parts with problematic shapes in various ways.

The original press release is available here.

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Titanium Production & Recycling To Increase for Aerospace Sector

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, TITANIUM PROCESSING, TITANIUM PROCESSING NEWS

EcoTitanium, a European plant for recycling and refining titanium alloys for critical applications, was opened in France in 2017. It was the first plant in Europe to melt titanium with a cold hearth furnace – a technology that allows users to recycle titanium reverts coming from forging and machining castings from the aerospace supply chain.

The SECO/WARWICK Group was chosen as the main supplier of advanced vacuum metallurgy technology for this strategic European project, securing the creation of an autonomous European titanium channel.

Sławomir Tomaszewski, director of the Vacuum Melting Furnaces Team in the SECO/WARWICK Group, comments, “The innovative VAR furnace will increase the Partner’s production capacity and can respond to the increased demand for titanium in Europe. EcoTitanium has created the first integrated titanium processing plants in Europe, which opens the door to European, ecological, and innovative solutions for the aerospace industry. We are glad that our Group is part of this strategic project and that Retech and SECO/WARWICK brand solutions constitute the core of the machine park.”

Earl Good
Managing Director
Retech Systems, LLC
Source: Retech

“For EcoTitanium, we, as Retech and SECO/WARWICK, delivered two furnaces seven years ago: a plasma furnace (PAM) for consolidation and refining of titanium scrap using plasma torches operating in an inert gas atmosphere, and a VAR arc furnace for further refining of titanium ingots obtained from the PAM furnace. The current contract is a continuation of this project. We will deliver a second VAR furnace, which will significantly increase the Partner’s processing capabilities,” said Earl Good, managing director of Retech.

The new furnace’s advantage is its perfect fit into the customer’s existing infrastructure. For safe operation, VAR furnaces require complex construction work: a bunker, an explosive tunnel, as well as a dedicated control room located outside the furnace operating area.

This system is unique because current solutions in the field of furnace safety will be implemented at the design stage. These solutions result from both the experience gained by EcoTitanium and the SECO/WARWICK Group’s experience.

Source: SECO/WARWICK

“The delivery of this new VAR furnace will help us to secure our customer’s growing needs for producing titanium in the context of unprecedented production ramp-ups. We are pleased to open this new chapter of EcoTitanium’s history with our long-term partner SECO/WARWICK. SECO/WARWICK has indeed offered us best-in-class solutions in the field of vacuum metallurgy technology, in particular with its PAM systems from its Retech brand, which allows us to use around 75% of recycled materials and to divide by up to four the CO2 emissions created by titanium melting,” says Jean-François Juéry, president of EcoTitanium.

Titanium, a transition metal with unique properties, is valued for its strength-to-weight ratio. It has comparable durability to steel but is 50% lighter, making it an attractive choice for industries looking for strength without additional weight. The aerospace industry consumes over 30% of global demand, and the chemical sector another 40%. Additionally, titanium has found use in medicine, especially in joint replacement procedures, dental implants, and electronics.

This press release is available in its original form here.

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Heat Exchanger Manufacturer Anticipates New EV/CAB Line

/ ALUMINUM PROCESSING NEWS, ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS

An international manufacturer of heat exchangers is expecting a new EV/CAB line to support their production of components, subsystems, and system solutions for thermal management in cars. The company provides energy-saving and high-performance products for regular petroleum and diesel fueled cars, as well as solutions for new electric vehicles.

Piotr Skarbiński
Vice President of Aluminum and CAB Products Segment
SECOWARWICK
Source: LinkedIn

“The EV/CAB line on order is designed specifically for the production of “Snake” type battery coolers,” said Piotr Skarbiński, VP of the Aluminum Process and CAB Business Segment in SECO/WARWICK. He further commented that the heating and cooling design “contributes to the final product’s exceptional quality using our unique technology that achieves excellent temperature uniformity across the width of the belt, which is the key to successful production.”

The company will execute their first “Snake” battery coolers in SECO/WARWICK furnaces. This is the eighth CAB line which will operate in this automotive industry manufacturer’s plants and the second one with a width of 2,300 mm.

The controlled atmosphere brazing (CAB) line on order will include a convection preheating chamber, a radiation furnace and two cooling chambers. The entire system will be equipped with a dedicated control system.

“This cooperation opens new perspectives for the SECO/WARWICK Group development in our region. The excellent heating and cooling design contributes to perfect temperature uniformity across the 2300 mm belt width, which is the key to successful production. We have already sold over 20 such solutions in China, and the demand for them is constantly growing,” commented Liu Yedong, Managing Director of SECO/WARWICK China.

Around the world, the demand for battery coolers is increasing due to the increasing production of electric vehicles.

This press release is available in its original form here.

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Vacuum Induction Melting Solution from Upper NY

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, ENERGY HEAT TREAT, ENERGY HEAT TREAT NEWS, FOUNDRY CASTING, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

A custom-built vacuum induction melting (VIM) equipment is set to expand thermal processing for a manufacturer, whose operations already has two VIM solutions. 

The furnace will be fabricated at the Buffalo headquarters of Retech, a SECO/WARWICK Group subsidiary, to capitalize on available schedule improvements. As custom equipment, the subsidiary’s furnaces are not dependent on assembly-line style construction, so they can be fabricated and assembled just in either location.

While this client prefers not to divulge this VIM’s application, Retech’s solution can handle casting a wide range of materials used in applications from automotive and consumer products to critical, high-value equiaxed, directionally solidified, or single-crystal aerospace parts. Almost every furnace Retech makes is modified to meet the specifications and associated applications of its clients.

VIM from the Retech Buffalo, NY location. Source: SECO/WARWICK

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2 CAB Lines for American Auto Part Manufacturer

/ ATMOSPHERE AIR FURNACES NEWS, AUTOMOTIVE HEAT TREAT, BRAZING NEWS, FEATURED NEWS

A heat treat furnace manufacturer with North American locations will provide an American partner with two identical continuous CAB lines for brazing aluminum heat exchangers, specifically battery coolers. The furnaces will be used in Mexico and Spain.

The SECO CAB lines will be used for protective atmosphere brazing aluminum of heat exchangers. Such solutions are used by leading automotive parts manufacturers and are used for mass production of battery coolers among other types of heat exchangers. This purchase was preceded by tests in the R&D laboratory.

Piotr Skarbiński, Vice President of Aluminum and CAB Product Segments, SECO/WARWICK Group (photo source: secowarwick.com)

“The purchased CAB lines,” explained Piotr Skarbiński, VP of Aluminum and CAB Product Segments, SECO/WARWICK Group, “will be the first solutions of this type in the customer’s factories.”

This press release is available in its original form here.

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3 Heat Treat Furnaces for Annealing Aluminum

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

Jupiter Aluminum Industries (JUPALCO), a newly established aluminum factory which will be part of the Jupiter Group in India, has ordered three furnaces for annealing aluminum coils from a heat treat furnace manufacturer with North American locations.

The equipment ordered by the Jupiter Group from SECO/WARWICK includes three Vortex® 2.0 furnaces for aluminum annealing, two cooling chambers, and one loader. A system configured in this way will ensure the optimal production volume of the Indian rolling mill.  

The aim of JUPALCO’s new plant will be to achieve the highest level of domestic aluminum production in history and to create an ecosystem of comprehensive aluminum-based solutions. This is the first cooperation between SECO/WARWICK and the Jupiter Group.

The three Vortex furnaces are effective systems for annealing aluminum coils. In the Vortex 2.0 version, a system of straight nozzles has increased the heat transfer efficiency. The systems key feature is the increased heat transfer coefficient, achieved by directing high-velocity air to both sides of the coil. This allows air to flow over the coil edges, not just through its outer layer.

Piotr Skarbiński, Vice President of (Source: secowarwick.com)

With the use of patented air flow technology, the aluminum coil annealing systems operate with process cycles that are significantly shorter. This in turn ensures energy savings, increased efficiency, and improved surface quality of the finished coils.

“In the case of coil annealing,” commented Piotr Skarbiński, VP of the CAB and Aluminum Products Segment at the SECO/WARWICK Group, “the challenge is to optimize the process by reducing the cycle time as much as possible while maintaining the desired metallurgical properties throughout the entire load.”

The Jupiter Group plans to recycle over 50,000 tons of aluminum scrap every year once fully operational. This scrap will come from both in-house and customer scrap, purchased scrap, and recycled cans/foils etc. The new rolling mill in India will help the Group expand its footprint in the aluminum industry and produce Made in India products which will be known for its quality and reliable products and services. 

“Since the 1990’s,” says Mr. Sandeep Bajaj, CMD of Jupiter Aluminum Industries, JUPALCO, “the Jupiter Group processes aluminum as a partner of the converting and packaging industries. Ecology is an important value for us. It is included in our mission, just like our Partner’s. The rolling mill in India will be one of the most modern facilities of this type in this region, which is why we are equipping it with the best solutions available on the market.”

This press release is available in its original form here.

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Manufacturer To Receive EB Furnace for Large-Ingot Casting

/ FOUNDRY CASTING, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

A North America-based company is set to receive a four-gun electron beam hearth melting furnace from their industry partner of 3 years.

Retech, a division of SECO/WARWICK Group, received this third contract in as many years from the returning partner after the successful planning, installation, commissioning, and subsequent operation and progress of the last two EB hearth melters. Along with that, repeat orders from a known partner reduce uncertainty and risk for the company. Put more simply, practice makes perfect.  

Source: SECO/WARWICK
Source: SECO/WARWICK

These EB furnaces have a throughput that is suitable for large-ingot casting of reactive/refractory metals when alloying with metals having similar vaporization temperatures, whereas plasma arc melting, although slower, would be the more suitable choice for dissimilar vaporization temperatures.

Earl Good
Managing Director at Retech Systems, LLC
Source: Retech

“We are thrilled to be an ongoing partner in this customer’s growth,” said Earl Good, managing director of Retech Systems. “We know they have multiple competitive options for their vacuum metallurgy equipment, so we take nothing for granted, and work hard to earn their business every step of the way. Ongoing awards like this suggest we’re doing a lot of things right.”  

Retech produces and assembles vacuum melting equipment entirely in North America. Their integrated R&D, manufacturing, and assembly facility in Buffalo allows them to do that. The North American supplier also has exclusive use of electron beam guns from Von Ardenne, industry pioneers of electron beam technology.  

This press release is available in its original form here.

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New Furnace Line for Railroad Component Manufacturer

/ ATMOSPHERE GENERATORS NEWS, FEATURED NEWS, MANUFACTURING HEAT TREAT, PARTS CLEANING NEWS, TEMPERING NEWS, VACUUM FURNACES NEWS

A supplier to the railway industry has ordered a technological line consisting of two vacuum furnaces, three tempering furnaces, and two washers. The line will be utilized for hardening processes of steel parts used in railway rolling stock.

The SECO/WARWICK line for voestalpine Fastening Systems consists of an electric chamber furnace, a washer, a cooling station, and an endothermic atmosphere generator. The hardening process will be carried out in a controlled atmosphere with temperatures up to 1742°F.

Additionally, the technological line includes an electric chamber furnace designed for the heat treatment of steel parts in a protective nitrogen atmosphere at temperatures up to 1292°F, along with a washer, cooling station and endothermic generator. The line will include a loader operating in automatic mode, a set of roller tables and a closed loop water system. The number of the supplied technological line units is selected to ensure the quality of manufactured components.

Mariusz Raszewski, Deputy Director of the Aluminum Process and CAB Furnaces Team, SECO/WARWICK (Source: SECO/WARWICK)

Mariusz Raszewski, deputy director of the Aluminum Process and CAB Furnaces Team at SECO/WARWICK said, “The line is configured in such a way that if the volume of the company products decreases, the customer can also offer commercial processing due to the wide technological spectrum of this main furnace unit.”

The whole solution will be supervised by a master system, which is used for the continuous monitoring of the heat treatment equipment operation and provides advanced data analysis for the production processes.

Mariusz Fogtman, COO, voestalpine Fastening Systems (Source: voestalpine Fastening Systems)

“The universal furnace solution will allow [us] to process details in various configurations,” Mariusz Fogtman, COO of voestalpine Fastening Systems commented. “Apart from technological parameters, it is important for us to limit the processed details’ deformations, which is possible in the ordered solution. SECO/WARWICK presented a partnership and flexible approach to the challenge of this order”

This press release is available in its original form here.

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Green Aluminum Aging Furnace for Aluminum Producer

/ ALUMINUM PROCESSING NEWS, ATMOSPHERE AIR FURNACES NEWS, MANUFACTURING HEAT TREAT

ALRO, one of the largest vertically integrated aluminum producers in Europe measured by production capacity, has purchased an aluminum aging furnace with electric heating. The project objective is to increase the output of high and very high added products.

The SECO/WARWICK furnace has been designed for aging type 2xxx, 6xxx and 7xxx aluminum plates with a length of up to 13,000 mm and a width of up to 2,200 mm. They can be arranged in one or two rows. The load will be placed horizontally on loading trays with the maximum capacity of 60 tons net. The furnace will be heated electrically, which will significantly reduce CO₂ gas emissions.

This electric furnace will replace three furnaces powered by natural gas with the aim of streamlining the heat treatment operations within the ALRO Processed Aluminum Division. The furnace represents an important step towards achieving the company's goal of becoming a greener producer.

Piotr Skarbiński, Vice President of the Aluminum Process and CAB Business Segments, SECO/WARWICK

Piotr Skarbiński, vice president of the Aluminum Process and CAB Business Segments at SECO/WARWICK, explains, “The challenge of reducing emissions is becoming an increasingly important purchasing impulse for customers. This applies in particular to European producers, because in this region of the world ecological regulations are currently the most restrictive. The aluminum aging furnace, powered by electric heaters, eliminates the emissions problem, hence the growing interest of aluminum producers in such solutions.”

 

Gheorghe Dobra, CEO, ALRO
(Source: Alro.ro)

Gheorghe Dobra, CEO at ALRO, commented, “The new equipment, provided by SECO/WARWICK, will support our program to maximize the value of the products we are manufacturing and will allow us to better serve our customer’s requirements. At the same time, the new technology will support our commitment to reduce our environmental footprint.”

 

"We have already completed several orders for new equipment for this customer," said Tomasz Kaczmarczyk, sales manager of the Aluminum Process and CAB Furnaces Teams at SECO/WARWICK, "including a gas aging furnace and ingot preheating furnace. We have also modernized furnaces for annealing aluminum sheet coils."

Tomasz Kaczmarczyk, Sales Manager of the Aluminum Process and CAB Furnaces Teams, SECO/WARWICK
(Source: SECOWARWICK.com)

Aging furnaces are designed to operate in the temperature range from 176ºF to 482ºF in accordance with the AMS2750G standard. The temperature uniformity guarantee throughout the entire load at the level of +/- 3ºC was achieved with the use of optimal heat flow inside the furnace using high-performance atmosphere mixers and a system of guides directing the air stream.

This press release is available in its original form here.

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