ALUMINUM PROCESSING NEWS

Green Aluminum Aging Furnace for Aluminum Producer

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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2 VPA Furnaces Elevate Jet Manufacturer’s Heat Treat

In a move aimed at elevating its manufacturing capabilities, a leading jet engine manufacturer is gearing up to integrate two vapor phase aluminizing (VPA) coating furnaces during the first half of 2024.

These high-capacity, low-maintenance automated retort VPA furnaces from G-M Enterprises, a Nitrex company, are purposefully engineered with moving bases and a fixed heat chamber, enhancing operational efficiency. Each retort is sealed to the moving bases, allowing for concurrent handling of two loads, each containing three coating cans. The result is a streamlined process that runs two cycles back-to-back, completing the treatment in just over 24 hours. The automated furnace supports unattended start-ups, empowering operators to focus on preparing loads for the second system which facilitates concurrent operations for heightened productivity.

VPA furnace from G-M Enterprises, a Nitrex company
Source: Nitrex

Robert Huckins, national sales manager at G-M Enterprises, emphasized that the "VPA furnaces ensure seamless operations, providing our customer with a competitive edge in production capacity. This is crucial in meeting escalating demand while delivering high-performance and longer-lasting blades and vanes vital for high-temperature fired engines.”

A feature of the VPA design is the raised fixed heat chamber, effectively shielding operators and the furnace room against potential heat exposure. This innovation eliminates the need for cumbersome protective heat suits. The hot retort remains securely housed within the insulated furnace, prioritizing operator well-being. Furthermore, this safety measure confines the load base and retort/coating load within the SAR/VPA furnace housing until the retort temperature drops below 150°C (300°F).

This strategic investment not only underscores the manufacturer’s commitment to staying at the forefront of technological advancements but also solidifies a lasting partnership.

This press release is available in its original form here.


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News From Abroad: A Glimpse Into the International Market

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

In this installment, explore important company partnerships with wide-spread industry effects as well as innovative new technologies from abroad.


TECHMO CAR Welcomes Anthony Tropeano as New Senior Advisor

Founded in 1961, TECHMO CAR drives innovation in the engineering and manufacturing of mobile and stationary equipment for the aluminum and metal production sector. (Source: Furnaces International)

"Anthony Tropeano of TT CONSULTING INC. has joined TECHMO CAR as a Senior Advisor for the US and Mexico market. Mr. Tropeano has spent over 40 years in the primary, secondary and downstream aluminum and metals worldwide market.”

Read more: “Anthony Tropeano has joined TECHMO CAR” at Furnaces International

New Tin Plate Complex from Partnership Between Danieli and Habaş Group

Caption: Situated in Aliağa near Izmir, the new facility will serve the needs of the packaging industry and the increasing need for cold-rolled and annealed thin sheets. (Source: heat processing)

"The facility, with a capacity of 900,000 tons per year, will produce a diverse range of steel grades, including T1 to T4 and DR7 to DR10. Among its offerings are 250,000 tons of tinplate, 150,000 tons of thin, continuous annealed cold-rolled coil, and 500,000 tons of semi-finished products. The complex comprises four crucial process areas: electrolytic cleaning, cold rolling and tempering, electrolytic tinning, and continuous annealing.”

Read more: “Danieli and Habaş Group Forge Future with New Tin-Plate Complex” at heat processing.com

SMS Group Partners with Turkish Plant Operator Kardemir to Digitize Blast Furnace 5

Using BFXpert solution from Paul Wurth, SMS Group has digitized a blast furnace belonging to Kardemir, Türkiye’s oldest blast furnace operator. (Source: Furnaces International)

"The Paul Wurth BFXpert system is a comprehensive package of systems for the chemical and thermal control of blast furnaces. It is an integrated level-2 process control and operator guidance system for superior blast furnace operation, utilizing the benefits of artificial intelligence to take process optimization to the next level and towards a fully autonomous blast furnace."

Read more: "SMS group successfully digitalizes Kardemir’s blast furnace 5 with BFXpert solution from Paul Wurth” at Furnaces International

Karlsruhe Institute of Technology (KIT) Develops New Process for Sustainable Pig Iron Production

“By integrating the blast furnace and coking plant as well as the consistent recycling of process gases and heat, CO₂ emissions in steel production can be reduced.” (Source: heat processing.com)

"Around eight percent of global CO₂ emissions are caused by the steel industry. Professor Olaf Deutschmann from the Institute for Technical Chemistry and Polymer Chemistry (ITCP) at KIT is of the opinion that this must change quickly. In the long term, thanks to new hydrogen technologies, there is a climate-neutral perspective, but it will still be a few years before sufficient green hydrogen is available worldwide and newly built plants go into operation.”

Read more: “KIT: New process for sustainable pig iron production” at heat processing.com


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Jet Engine Manufacturer Modernizes with Updated Casting Furnace

Sławomir Tomaszewski
Vacuum Melting Team Director
SECO/WARWICK
Source: LinkedIn

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One of the world’s largest producers of jet engines has modernized their casting furnace, which was last updated two decades ago.

This company has two casting units supplied two decades ago by RETECH, a North America-based company belonging to the SECO/WARWICK Group. The modernization project was for the VIM EQ furnace - a system for the production of castings in equiaxed crystallization. It will involve replacing almost all the furnace components except the power supply, melting chambers and mold. The platforms will also remain unchanged. The remaining components will be replaced with more modern, ergonomic, and user-friendly parts and assemblies.

Says Sławomir Tomaszewski, vacuum melting team director at SECO/WARWICK, “This order includes the complete elimination of hydraulic components by replacing them with electrical components such as an elevator drive or crucible rotation drive. In addition, two old feeders: one for loading crucibles, the other for removing disposable crucibles, will be replaced with a modern system that can perform both activities."

He added, "An additional advantage of the operation will be the fact that the furnace operator will not have to come into physical contact with hot used crucibles, because they will be removed automatically without human intervention."

 

 


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3 Aluminum Heat Treat Systems Delivered for USAF

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Richard B. Conway
Founder/Director/ CTO
DELTA H® Technologies, LLC
Source: DELTA H

Three heat treat systems have recently been delivered and commissioned to joint base San Antonio-Randolph for maintaining the T-38 Talon Trainer aircraft.

These systems are a dual chamber model DCAHT®-181248-1200/500-MIL, a DCAHT®-241672-1200/500-MIL, and a large single chamber SCAHT®-303048-1200-MIL.

USAF depot level heat treating requires full compliance to AMS2750G.  The heat treating systems provided by DELTA H were for replacing existing systems which were too troublesome or costly to try to qualify and were never designed for modern pyrometry standards. The furnace systems were placed into production service the week following qualifying and training.

JBSA-Randolph – SCAHT®-303048-1200-MIL & DCAHT®-241672-1200/500-MIL Includes Power Driven Quench Tank
Source: DELTA H

Richard Conway, director and CTO of DELTA H, states, "We are grateful and humbled to be recognized among the mission critical technology partners supporting this very important project, and pleased to play a part in extending the service life of the valuable T-38 airframe."

JBSA-Randolph, TX – DCAHT®-181248-1200/500-MIL Heat Treat Computer Work Station
Source: DELTA H

Third party compliance and initial qualifying certification of all 5 chambers were provided by Conrad Kacsik Instrument Systems of Solon, Ohio.

Jake Kacsik, president of Conrad Kacsik Instrument Systems, shares, “The results are always impressive when testing DELTA H furnaces. By far the most reliable and consistent systems for maintaining the strict standards of aerospace pyrometry. Richard and I not only have a career-long professional relationship, but also, we both served in the USAF.”

DELTA H is exclusively represented worldwide by PHILLIPS FEDERAL Division for all military and government sales.

JBSA-Randolph, TX – SCAHT®-303048-1200-MIL & DCAHT®-181248-1200/500-MIL
Source: DELTA H

John Murray, retired SMSgt of USAF and product manager of Phillips Corporation, Federal Division added, “DELTA H compliments our product offerings to Metals Tech facilities. Regardless of traditional machining or additive manufacturing, Phillips Corporation – Federal Division strives to meet the needs of the USAF Fabrication Flight Warfighter, providing the best solutions for their support of US power projection and strategic deterrence. Phillips Corporation – Federal Division stands beside USAF Fabrication Flights around the globe ready to cut, fabricate, manufacture, and metallurgically process any part-anytime-anywhere."


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Aluminum Rolling Company Expands Operations with Heat Treat Software

The aluminum rolling division of ElvalHalcor S.A., Elval, has placed an order for a sustainability suite with a heat treat supplier with North American locations. This technology will be used for Elval’s flat-rolled aluminum manufacturing plant based in Oinofyta, Greece.

Drakotos Athanasios
Electrical & Electronic Maintenance Deputy Director
Elval
Source: LinkedIn

The Viridis Energy & Sustainability Suite from SMS group will contribute to Elval’s goal to reduce carbon emissions and optimize overall production processes. With the installation of two modules of the Suite, Viridis Performance and Viridis Grids, Elval will be equipped to meet the ever-increasing demands for responsible and energy-efficient management in the aluminum industry.

The automated machine learning (Auto ML) resources of Viridis Performance calculate targets automatically, maintaining relevance in changing production conditions. It will comprise over 70 equipment assets, such as melting furnaces, preheating furnaces, hot and cold rolling mills, among others. Viridis Grids will support Elval to precisely and autonomously calculate energy consumption forecast based on the production plan via automated machine learning resources.

Stated Drakotos Athanasios, the electrical & electronic maintenance deputy director at Elval, “Our partnership with SMS group represents a significant step in our sustainability journey. The Viridis Energy & Sustainability Suite aligns perfectly with our commitment to sustainable aluminum production and reducing our energy and environmental footprint. We are confident that this investment will have a positive impact on our operations and support our carbon footprint reduction pathway”.

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Exothermic Atmosphere Generator Supplied to Skana Aluminum

Skana Aluminum Company in Manitowoc, Wisconsin, has recently been supplied with an Exogas™ exothermic atmosphere generator.

The atmosphere generator from SECO/WARWICK USA, an American SECO/WARWICK Group subsidiary, provides an indirect-chilled exothermic atmosphere for annealing, brazing, normalizing, drawing, and tempering.

Says Marcus Lord, managing director of SECO/WARWICK USA, “At 30,000 CFH, it is one of the largest atmosphere generator units we’ve made to date. It should be plenty large enough to meet the exothermic atmosphere needs of the multiple processes within the Skana plant.”

Skana has also placed an order with the furnace supplier for a smaller atmospheric gas drier for use elsewhere in the plant.


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Fringe Friday: Airbus Expands Capabilities with AM and 3D Printing

Sometimes our editors find items that are not exactly “heat treat” but do deal with interesting developments in one of our key markets: aerospace, automotive, medical, energy, or general manufacturing.

To celebrate getting to the “fringe” of the weekend, Heat Treat Today presents today’s Heat Treat Fringe Friday: an exciting development in Additive Manufacturing with Airbus Helicopters using 3D printing.


Helmut Fárber
Site Manager
Airbus Helicopters in Donauwöth

Airbus Helicopters is to use 3D printing technology to produce components for its helicopter vehicles and the aircraft of parent company Airbus.

Airbus Helicopters will use TRUMPF‘s 3D printing technology to produce components for its electric-powered City Airbus experimental high-speed Racer helicopter, as well as the Airbus A350 and A320 passenger aircraft, with structural components made of titanium and high-strength aluminum believed to be the focus. The company is investing heavily in additive manufacturing technology because of its ability to reduce weight and, in turn, bring down fuel consumption and costs. It is said to be exploring the part consolidation of some systems, again to save weight, and values the capacity to reuse powder.

“With innovative manufacturing processes, we are working on the helicopters of the future in Donauwörth,” commented Helmut Fárber, site manager at Airbus Helicopters in Donauwöth. “Among other things, 3D printing helps reduce the weight of components.”

Said Richard Bannmueller, CEO of TRUMPF Laser and System Technology, “Additive manufacturing saves expensive raw material and can lower production costs in the aviation industry. 3D printers only use the material that designers actually need for their components and that ends up taking off in the aircraft.”

Airbus, like many other aerospace manufacturers, has had a keen interest in additive manufacturing technology for several years, with the company recently signing a 3.8 million EUR contract with Oerlikon for the additive manufacture of satellite antenna clusters.


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C/A Design Adds Horizontal Spray Quench Furnace

A horizontal spray quench furnace has been completed for C/A Design’s heat treat facility in Exeter, NH. The system will help treat components for the aerospace and defense industry.

The furnace, from Wisconsin Oven, will be used for the solution treatment of aluminum. The system is designed to soak the product load at temperature in the furnace and then a pusher mechanism rapidly moves the load into the spray quench. The spray quench offers reduced distortion in comparison to submersion quenching.

The maximum temperature for this system is 1150°F and it has the capacity to heat a 200 pound aluminum load plus the work grid and product fixture. C/A Design’s new furnace has the capability to meet AMS 2750G, Class 2 furnace and Instrumentation Type D requirements.


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Aluminum Industry Sees Expansion in Canada

Aluminerie Alouette, based in Sept-Îles, Quebec, Canada, announced several investments in its aluminum smelting operations. These include upgrades to anode baking furnaces as well as a planned installation of new potline technologies that will address waste streams at the site. The Canadian aluminum producer’s new technologies will increase operations and address environmental issues.

Alouette restarted the first firing ramps of its No. 1 (ABF-1) anode baking furnace after a refractory relining project, which was completed with EPCM support from Hatch. With furnace No. 1 restarted, the companies are now beginning work on the restart of a second furnace reline (ABF-2), which is expected to be completed in 2024.

Additionally, Alouette signed two contracts totaling $2.7 million with PyroGenesis Canada Inc. The first contract will address the treatment of spent pot lining (SPL) waste. The technology proposed will use plasma arc thermal treatment to transform the carbonaceous and refractory materials contained in SPL into synthesis gas and aluminum fluoride. The objective of the second contract is to process excess electrolytic bath in a plasma arc thermal treatment plant with the goal of producing aluminum fluoride.


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