ALUMINUM PROCESSING NEWS

Who’s Winning the Steel v. Aluminum Battle? Both, in the Form of Mixed Materials, per Auto Industry Watchers

 

Source: SME Media

 

It wasn’t long ago that auto industry watchers were casting votes for either steel or aluminum in what was to be a big competition in what metals would be used in automotive lightweighting.

Would it be the heavy-weight champion steel which was ramping up its development of high-strength, lower-weight steels? Or would the new contender on the block, aluminum, gather more adherents to lightweighting in the wake of Ford Motor Company choosing aluminum for its F-150 and Super Duty pickup bodies?

An excerpt:

“A consensus has emerged. The future for the industry is a mix of materials, a mix that will vary from vehicle to vehicle. It’s also likely to be a more complex future, with composite materials making inroads in the long run.”

Jay Baron, retired president of the Center for Automotive Research (CAR), Ann Arbor, Michigan

“You have to take into account all sorts of factors,” said Jay Baron, retired president of the Center for Automotive Research (CAR), Ann Arbor, Michigan. Vibration and stiffness figure into the equation, he said. And there’s cost. “It’s much more than weight and strength.”

Designing and building vehicles with a patchwork quilt approach to materials is how some brands are tackling the lightweighting challenge. Most are also exploring advanced technological processes such as a combination of 3D printing and artificial intelligence, friction welding technology, and rethinking other automotive systems, e.g., braking.

Read more: “Lightweighting’s New Phase

 

Main image credit / caption: Manufacturing Technology Inc. (MTI) / The MTI-built LF35-75 at Lightweight Innovations for Tomorrow is ideal for unique part geometries, near-net shapes and full-size part development for all industries, according to MTI. 

 

Who’s Winning the Steel v. Aluminum Battle? Both, in the Form of Mixed Materials, per Auto Industry Watchers Read More »

Aluminum Provider Completes Expansion of Extrusion Operation

 

Source: Light Metal Age

 

A Pennsylvania company that provides aluminum fabrication, extrusion, and casting products across a variety of industries recently celebrated the completion of the expansion of its facility in Leetonia, Ohio, where new equipment was installed aimed at increasing the company’s capabilities.

Pennex Aluminum, which was also marking the 40th anniversary of Pennex being purchased by the Metal Exchange Corporation, specializes in aluminum extrusions and fabricated components for the automotive, construction, HVAC, landscaping, and off-road vehicle markets at the Leetonia facility.

 

Read more: “Pennex Aluminum Completes Expansion of its Extrusion Operation in Ohio”

Main image credit / caption: Pennex  / opening of Pennex’s new extrusion press line at Leetonia in 2015.

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Aluminum Producer Awarded Department of Defense Grant to Optimize Armor Plate Production

A global aluminum manufacturer of products for multiple applications, including aerospace, automotive and packaging, recently announced that its Ravenwood, West Virginia, facility has been selected by the U.S. Department of Defense for a nearly $9.5 million grant to increase throughput, quality, and performance of cold-rolled aluminum.

Constellium will perform electrical, mechanical, and hydraulic system upgrades to Ravenswood’s 144" cold rolling mill, which is critically important for the manufacture of high-performance aluminum plate for ballistic and blast protection of military vehicles.

The funding was awarded to Constellium SE by the U.S. Department of Defense’s Cornerstone OTA and will be managed by the Army Research Laboratory (ARL) at Aberdeen Proving Ground, Maryland. Constellium will use the funds to perform electrical, mechanical, and hydraulic system upgrades to Ravenswood’s 144" cold rolling mill and add state of the art automation and process controls. The mill is critically important for the manufacture of high-performance aluminum plate for ballistic and blast protection of military vehicles. Army and Marine Corps modernization programs will require an increased capacity of the U.S. industrial base to produce cold rolled plate over the next decade. In coordination with Cornerstone and ARL, Constellium will also invest in developing manufacturing processes and armor plate that will optimize the additional capacity and process controls of the upgraded mill.

Buddy Stemple, CEO of Constellium Rolled Products Ravenswood

"This investment by the Department of Defense will enable us to meet the increased demand for cold-rolled plate over the next 5 to 10 years and also significantly improve the performance of armor against constantly evolving threats," commented Buddy Stemple, CEO of Constellium Rolled Products Ravenswood. "We are very excited to have this opportunity to help protect our troops."

 

Photo credit/captions: Image 1: Wikipedia / Bradley Fighting Vehicle; Image 2: Constellium 

 

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New Heat Treat System Ordered by Oregon Products

A new heat treat system that will help produce products for the logging industry has been ordered by Oregon Products.

Oregon Products, a brand of Blount International, Inc., will be adding a new continuous high capacity mesh belt austemper heat treatment system to its production facilities. A global manufacturer of saw chain and other replacement products for the forestry industry, Oregon plans to use the new equipment as part of a long-standing commitment to continuous quality improvement.

Kaitlyn McNaughton
Director of Engineering and R&D Labs
Blount International

“The primary business driver of this project is quality,” said Kaitlyn McNaughton, Director of Engineering and R&D Labs. “This new furnace is primarily targeted to raise the bar on quality for our harvester chain products, which perform under the highest loads and most extreme conditions.”

The austemper system, which  CAN-ENG Furnaces International, Ltd. will design and commission, integrates a computerized loading system, pre-wash system, atmosphere-controlled mesh belt austenitizing furnace, molten salt quench conveyor system, post quench residual salt removal and recycling system, mesh belt parts drying oven, unloading system and CAN-ENG’s PET™ system which provides vital features such as individual lot/product traceability, detailed process data collection for continuous process improvements and comprehensive Industry 4.0 equipment diagnostics capability.

The system is scheduled for commissioning early 2020.

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Aluminum Giants Progress Toward Merger with EC Approval

An industrial aluminum company headquartered in Atlanta, Georgia, recently received approval of its proposed acquisition of an Ohio-based aluminum rolled products producer, which would increase its capacity to provide lightweighting materials for the automotive market.

The European Commission announced approval for Novelis Inc. to acquire Aleris Corporation, conditioned upon the sale of Aleris’ plant in Duffel, Belgium, which produces aluminum for the automotive and specialties markets. Novelis is working expeditiously to market the plant to potential buyers, with the chosen counterparty and the definitive agreement for divestiture subject to European Commission approval.

With this conditional approval in the European Union, as well as a clear path forward for approval in the U.S., Novelis focuses on obtaining approval from the Chinese State Administration for Market Regulation (SAMR).

Steve Fisher, president and CEO, Novelis Inc

“Today’s announcement is another step forward in bringing Novelis and Aleris together, which will benefit our customers, employees, and the aluminum industry as a whole,” said Steve Fisher, president and CEO, Novelis Inc. “Overall, this transaction will strengthen our ability to compete against steel in the automotive market, meet growing customer demand for aluminum, achieve our recycling goals, and bolster our sustainability platform worldwide. In addition, it will further enhance our strategic position in Asia and diversify our overall product portfolio.”

The company expects to close the transaction by January 21, 2020, the outside date under the merger agreement.

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Aluminum Producer Announces $200M Investment in Rolling Plant

A large aluminum producer recently announced a large investment in a new rolling plant in Ashland, Kentucky.

Braidy Industries, Inc. (Braidy) and Rusal jointly announced the approval by their respective Boards of Directors for Rusal to invest $200 million in Braidy Atlas mill. The companies estimate that it has been more than three decades since a greenfield aluminum rolling mill like Braidy was built in the U.S. The deal is expected to close in the second quarter of 2019.

Craig Bouchard, Braidy Industries Chairman and CEO

“This is a sustainability match made in heaven for the global aluminum industry,” said Craig Bouchard, Braidy Industries Chairman and CEO.

Rusal intends to supply 200,000 tons of certified low-carbon prime aluminum ingot and slabs each year for a 10-year period, allowing Braidy to target lower carbon emissions.

Braidy is dependent on long-term supplies of high-quality, low-carbon aluminum, which is rarely supplied in the high quantity required for their production. If met, this order would be one of the world’s largest for one mill of high-quality, pre-alloyed and low-carbon primary aluminum slabs.

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Nitrocarburizing System Installed for Aluminum Extrusion Manufacturer

A manufacturer of aluminum profiles and complex extrusion press products recently purchased a nitrocarburizing system for its new state-of-the-art manufacturing facility in northwestern Romania.

Quebec-based Nitrex delivered and installed the turnkey NX-815 nitrocarburizing system for Swiss corporation Alu Menziken Extrusion AG, incorporating the Nitreg®-C technology for treating aluminum extrusion dies at the greenfield site which produces a range of profile products for aerospace and automotive companies. The process technology adapts to the application requirements to deliver improved performance of extrusion dies.

“With a focus on the environment, Alu Menziken also sought to introduce eco-friendly technologies for all equipment at its greenfield facility. Not only is there a benefit of reduced process gas use with the Nitrex system, the integral high-efficiency neutralizer also helps comply with environmental regulations,” said Marcin Stoklosa, Nitrex European Project Manager.

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Aluminum Extrusion Expansion in Pennsylvania Supports Auto Markets

A supplier of infinite aluminum recently announced it plans to invest in two new aluminum extrusion presses to support the growing automotive, architectural and transportation markets in North America.

Hydro plans to install a 4,500-ton 10” aluminum press line at its Cressona, Pennsylvania, location to serve the traditional automotive and distribution segments and also installing a 7,000-ton dual container 12”/14” press line in the West region to serve the electric vehicle, transportation, and commercial building and construction segments.

“We are very excited about Hydro’s continued investments in North America,” said Jack Pell, Vice President of Automotive Business Development for Hydro Extrusion North America. “This new equipment merges state-of-the-art billet heating and quench capabilities with larger billet diameters and enables us to produce larger extruded aluminum shapes with thinner walls from stronger alloys – the ‘holy grail’ for our automotive customers.”

Hydro expects these presses to be operational by 2020.

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Major Aluminum Acquisition to Broaden Aero, Auto Products

An Atlanta-based provider of aluminum rolling and recycling recently announced the company has signed a definitive agreement to acquire Aleris Corp., Cleveland, a global supplier of rolled aluminum products supplier based in Cleveland, Ohio.

Steve Fisher, President and CEO, Novelis Inc

Novelis Inc. will acquire Aleris Corp’s 13 manufacturing facilities across North America, Asia, and Europe, including new automotive finishing lines in Lewisport, Kentucky, and significant auto capacity in Duffel, Belgium, providing a more diverse product portfolio, including aerospace, automotive, building and construction, commercial transportation and specialty products.

“Acquiring Aleris is the right opportunity at the right time as they are set for transformational growth,” said Steve Fisher, President and CEO, Novelis Inc. “The significant investments they’ve made in the high-demand, high-value aerospace and automotive segments have resulted in favorable long-term, global contracts. These investments, coupled with a diverse and talented workforce, will add tremendous value to our organization and allow us to deliver the highest quality innovative aluminum solutions to our customers.”

As part of the acquisition, Novelis will acquire Aleris’ 13 manufacturing facilities across North AmericaAsia and Europe. Aleris’ new automotive finishing lines in Lewisport, Kentucky, of which a significant amount of its capacity is already under contract, along with auto capacity in Duffel, Belgium, will allow Novelis to further diversify its global footprint and customer base.

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Aluminum Producer to Double Capacity in China

Kumar Mangalam Birla, chairman of the board of directors of Novelis Inc. and chairman of the board of directors of Hindalco Industries Limited

A global aluminum producer announced recently that an investment in a continuous annealing solution heat (CASH) treatment line will contribute to doubling its automotive aluminum body sheet capacity at its Changzhou facility in China.

Novelis Inc states that the approximately $180 million investment, which will also include a high-speed slitter as well as a fully automated packaging line, will add approximately 100 kilotonnes (over 220 million pounds) of capacity. This will enhance Novelis’ ability to supply innovative aluminum solutions to its global automotive customer base as well as Chinese domestic producers. Novelis expects to begin expanding its existing facility in 2018 in order to be operational by 2020.

“By adding another strategic asset to expand its operations in China, Novelis continues to leverage the strength of the Aditya Birla Group as the global leader in aluminum rolling,” said Kumar Mangalam Birla, chairman of the board of directors of Novelis Inc. and chairman of the board of directors of Hindalco Industries Limited. “Investing ahead of projected customer demand enables Novelis to offer premium products and a reliable supply chain to automakers as they continue to adopt more automotive aluminum.”

Steve Fisher, President and CEO, Novelis Inc

“As our customers continue to see aluminum as the material of choice to meet their lightweighting and performance goals, Novelis is strengthening its leadership position in the world’s largest automotive market place,” said Steve Fisher, President and CEO, Novelis Inc. “We believe China’s commitment to fuel efficiency and reducing emissions represent a large and favorable opportunity that will require greater adoption of aluminium, particularly in the rapidly growing electric vehicle market.”

This is Novelis’ second automotive investment this year, having recently announced a $300 million greenfield manufacturing facility in Guthrie, Kentucky, USA.

 

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