AUTOMOTIVE HEAT TREAT NEWS

Auto Parts Manufacturer to Increase Aluminum Production Capacity with Expansion, New Equipment

A global automotive parts manufacturer recently announced its plans to invest in the expansion of its Kentucky aluminum products plant.

Kobelco Aluminum Products & Extrusions Inc. (KPEX), the U.S. subsidiary of Kobe Steel, Ltd., based in Japan, expects the expansion to increase the production capacity of its plant in Bowling Green, Kentucky, in response to the growing demand for automotive extrusions and fabricated products in the United States.

Hiroaki Matsubara, Kobe Steel senior managing executive officer

Established in April 2016, KPEX manufactures aluminum extruded products for use as bumper materials and car frame materials. In November 2018, KPEX began integrated production, ranging from melting and casting to the final manufacturing process of fabrication. Plans call for new equipment for melting, extrusion, and fabrication to go into mass production in the first half of 2020. When the expansion is completed, KPEX will have two melting furnaces and two extrusion presses. Production capacity will increase to 1,000 tons per month, from the current 500 tons per month.

“Kobelco Aluminum Products & Extrusions Inc. was established in April 2016 using our technology from Japan, and with the cooperation of Kentucky officials, our customers, and all the employees working at Kobelco, we were able to successfully begin mass production here in the US,” said Hiroaki Matsubara, Kobe Steel senior managing executive officer. “And now, supported by even more robust demand for our products, we are proud to announce that we will be making our second major investment in our operations in less than two years. With that, our aim is to continue to make our contribution to the weight reduction of automobiles and to further develop our business footprint in the Bowling Green facility.”

Kobelco’s Bowling Green plant expansion (PC: Kobelco)

Main image PC: Forging Magazine

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EAF Mill Planned for Southwest U.S., Mexican Auto, Energy Markets

A U.S. steel producer recently announced plans to construct a state-of-the-art electric arc furnace (EAF) mill for flat roll steel in the U.S. southwest with an eye to serve the Mexican flat roll steel market.

Mark. D. Millett, Steel Dynamics President and Chief Executive Officer

Steel Dynamics, Inc. (SDI), based in Fort Wayne, Indiana, anticipates the facility to have an annual production capacity of approximately 3.0 million tons with the capability to produce the latest generation of Advanced High Strength Steel products.  The project will include a galvanizing line with an annual capacity of 450,000 tons with a product offering serving the energy, automotive, and equipment manufacturing industries.

SDI currently expects to locate the facility in the southwestern United States in order to reach the underserved Mexican flat roll steel market as well as the southern and southwestern states.  Determination of the final site location is subject to state and local government infrastructure and incentive support with an expectation of construction beginning in 2020, followed by the commencement of operations in the second half of 2021.

“We believe our unique operating culture, coupled with our considerable experience in successfully constructing and operating cost-effective and highly profitable steel mills, positions us well to execute this greenfield opportunity and to deliver strong long-term value creation,” said Mark. D. Millett, President and Chief Executive Officer. “We plan to utilize new technologies that will further reduce the gap between existing EAF and integrated steel mill production capabilities.”

 

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Heat Exchanger Supplier Purchases CAB Cooling System

An India-based independent heat exchanger manufacturer for the domestic automobile industry recently purchased a controlled atmosphere brazing system to reduce energy costs as well as improve production quality and operate within the latest environmental regulations.

NBR Cooling Systems commissioned the signature controlled atmosphere brazing (CAB) cooling system from SECO/WARWICK.

Liu Yedong, Managing Director, SECO/WARWICK RETECH

“We selected SECO/WARWICK because they provided a high-quality production assurance which we needed to keep our plant running efficiently along with low atmosphere consumption, minimum maintenance, and repeatable process results, all at a low capital cost investment,” said Aarif Hussain, NBR Cooling Systems managing director. “A SECO/WARWICK CAB system was definitely our first option – the company leverages many years of experience and guarantee continuous trouble-free operation at a high technological level and provides local contact, care and service.”

“We are pleased to support NBR Cooling Systems’ vision to become the leader in the national and international market for commercial heat exchangers and air conditioning systems for the automotive industry,” said Liu Yedong, Managing Director, SECO/WARWICK RETECH (China).

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Audi Extends Partnership for High-Tech Crash Absorption Alloy Components

The primary supplier of automotive body sheets for both closures and inner parts of the new Audi A6 model recently announced the extension of the partnership to provide a high-tech crash absorption alloy for the hood of this model.

Dieter Höll, Vice President of Global Automotive at Constellium

Constellium produces components, such as doors and trunks, for its partner Audi to achieve its lightweighting, design and safety targets, specifically Surfalex® with high surface quality and particular hemming and roping properties. This highly formable alloy has been designed to fulfill the most demanding pedestrian safety requirements.

 “Constellium is proud to extend its long-term partnership with Audi and to accompany them in their mission to build high-quality automobiles. To do so, Constellium supports Audi in solutions not only for closures but also for body-in-white parts requiring specific crash and mechanical performance such as the ones offered by Securalex®,” said Dieter Höll, Vice President of Global Automotive at Constellium.

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First Titanium Wheel Created with 3D Unveiled in California

The first titanium wheel created using EBM technology was recently unveiled during the official announcement of a partnership agreement between the two companies responsible for its design and manufacture.

HRE Wheels, headquartered in Vista, California, and GE Additive launched the new technology, which is a type of 3D printing to test the capabilities of additive manufacturing in a practical application and to create a highly-sophisticated wheel design with an elusive material like titanium. The new prototype wheel is known as “HRE3D+”.

With a traditional aluminum Monoblok wheel, 80% of material is removed from a 100-pound forged block of aluminum to create the final product. With additive manufacturing, only 5% of the material is removed and recycled, making the process far more efficient. Titanium also has a much higher specific strength than aluminum and is corrosion resistant, allowing it to be extremely lightweight and to be shown in its raw finish.

There was an intensive design collaboration between the Vista, California-based, team at HRE and the GE AddWorks team out of Ohio. Using design queues from two existing models of HRE wheels, the two companies worked together to create a stunning example of what is possible with additive manufacturing.

HRE President Alan Peltier

The wheel was produced on two Arcam EBM machines – Q20 and a Q10 in five separate sections, then combined using a custom center section and titanium fasteners.

“This is an incredibly exciting and important project for us as we get a glimpse into what the future of wheel design holds,” said HRE President Alan Peltier. “Working with GE Additive’s AddWorks team gave us access to the latest additive technology and an amazing team of engineers, allowing us to push the boundaries of wheel design beyond anything possible with current methods. To HRE, this partnership with GE Additive moves us into the future.”

Robert Hanet, senior design engineer, GE Additive AddWorks

“HRE prides itself on its commitment to excellence and superior quality in the marketplace. It was a natural fit for AddWorks to work on this project with them and really revolutionize the way wheels can be designed and manufactured,” said Robert Hanet, senior design engineer, GE Additive AddWorks.

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Neutron Researchers Looking for Ways to Improve Vehicle Safety and Fuel Efficiency

Source: Phys.org

 

Researchers working with a major U.S. steelmaker are responding to the increased demand for vehicles that are made safer and more fuel efficient by using neutrons “to better understand the properties of hydroformed advanced high-strength steel and how it responds to residual stress introduced during manufacturing,” according to Phys.org.

United States Steel Corporation (USS) industrial research engineers used neutrons at Oak Ridge National Laboratory’s Spallation Neutron Source to analyze materials exposed to different manufacturing processes.

“Because this is a new material containing retained austenite, we need to have a better understanding of its performance. A better understanding of how this material responds to different manufacturing processes like stamping or hydroforming will help us validate engineering models that will in turn make it easier to design and produce auto components that are lighter, stronger, and more durable.” ~ Lu Huang, USS industrial research engineer

 

Read more: “Neutrons Analyze Advanced High-Strength Steels To Improve Vehicle Safety and Efficiency”

 

Photo Credit: ORNL/Genevieve Martin. Photo caption: Lu Huang, USS industrial research engineer prepares a lightweighted advanced high strength steel component for neutron research at the Spallation Neutron Source’s VULCAN instrument. Data from this study may make it faster and easier for companies to design automotive components that are lighter, more durable, and safer. Credit: ORNL/Genevieve Martin

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CAB Technology Commissioned by Auto Parts Manufacturer

A manufacturer of automotive heat exchangers recently partnered with a leading heat treat furnace manufacturing company with a formidable U.S. presence to produce parts using a complete Controlled Atmosphere Brazing (CAB) line for its greenfield project in Gujrat, India.

Karnavati Car Air Conditioners Pvt. Ltd, Ahmedabad, (KCPL), which produces a wide variety of high-quality radiators, condensers, cooling coils, and fan assemblies, will utilize SECO/WARWICK’s CAB line and related equipment in the manufacturing process, including thermal degreaser, fluxer, dry-off oven, air quality and cleaning. The system will be utilized for aluminum heat exchangers of all types for the automotive market.

“KCPL is one of the fastest growing companies in India,” said Kartik Jethwa – Chief Engineer, KCPL, “dealing in automotive radiators, condensers, cooling coils and fan assemblies. We have selected the complete SECO/WARWICK’s CAB brazing line because the system versatility will enable our company to produce a wide variety of high-quality products with the lowest possible cost – our goal is to continue our rapid pace of growth and improve profitability by modernizing our brazing operation.”

“We are proud technology partners with KCPL and look forward to their continued success. Since 1984, SECO/WARWICK has been the leader in the evolution and innovations in CAB technologies ensuring our customers that they will receive the finest system value and professional technical services to keep their equipment online and operating efficiently for many years in the future,” said Piotr Skarbinski, VP, Aluminum Process and CAB Technology, SECO/WARWICK.

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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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Steelmaker Commissions for Modernization of Annealing Line

A global steelmaker based in Sweden has turned to a French industrial engineering group to modernize the thermal part of its continuous annealing line at its Borlänge plant.

Fives will update the SSAB facility with the goal to increase the efficiency and capacity of the existing CAL in order to produce advanced high-strength steel (AHSS) with a view to meeting increasing demand from the automotive industry. Once complete, the line will have the capacity to produce 650 000 tons per year, up from the current production rate of 500 000 tons per year.

Fives was contracted to modernize the thermal part of the CAL by replacing the jet preheating furnace and installing inductors in cascade to increase efficiency. Fives will install a new Stein jet preheating furnace to recover the heat from the radiant tube furnace and four CELES MP inductors.

The optimized design of the preheating furnace blowing boxes and tightness of the new seal is expected to result in the recovery of more power will be recovered, allowing the strip to be preheated to higher temperatures. CELES MP inductors, a proven technology, will then increase the strip temperature before the strip entries into the radiant tube furnace.

In total, 16 MW of power will be installed as part of this project. The modernization of the thermal part will be implemented very quickly and will be completed by November 2019.

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European Steel Acquisitions Set To Double Metals Production Capacity

A British-owned international metals and industrial group, specializing in commodities, metals recycling, manufacture of steel, aluminum and engineering products recently announced a conditional agreement to purchase four European steel plants.

The Liberty Group, which is part of the GFG Alliance will acquire ArcelorMittal’s major integrated works at Galati in Romania and Ostrava in the Czech Republic, along with rolling mills at Skopje in Macedonia and Piombino in Italy.

Jay Hambro, chief investment officer of the GFG Alliance

Adding these major steel hubs more than doubles Liberty’s global metal manufacturing capacity in the U.K. as a steel and aluminum supplier to the automotive, aviation and specialist engineering sectors and in Australia supplying steel for building and infrastructure. The Group also makes steel in the USA for the automotive and other sectors.

The four sites in the package have a combined rolling capacity of around 8m tonnes a year and would give Liberty the ability to supply a full range of finished steels, including plate, hot rolled coil, cold rolled coil, galvanized sheet, tin plate, bar, wire rod, and rail. The plants serve domestic and wider European markets, including automotive, construction, industrial machinery, and oil and gas sectors.

“Following relevant approvals for this transaction, the GFG Alliance will have a number of new global hubs in Europe,” said Jay Hambro, chief investment officer of the GFG Alliance. “These steel operations are high-performing, profitable assets with modern equipment, excellent transport connections to key markets and high-skilled workforces. There is huge potential for expansion, further modernization and the application of GFG’s GREENSTEEL strategy.

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