AUTOMOTIVE HEAT TREAT NEWS

Sapa Showcases Revolutionary Aluminium Brake Line for Cars

Sapa has developed the first-ever automotive aluminium brake line using a high-strength aluminium alloy.

“The entire industry is on a mission to reduce weight in cars as a key to lowering emissions. In Sapa, we are using our knowledge to identify new parts where we can use aluminium to make cars lighter, safer and more efficient. The brake line development is one such innovation that can reduce the weight with over 50 percent compared to steel,” says innovation and technology manager Jens Sandahl Sørensen. 

Fourteen meters of weight savings
The normal volume of a brake line in a light vehicle is around 12-14 meters. By replacing steel with aluminium in this component, car manufacturers can shed around 600 grams of the approximately 1 kilogram of weight.

“Aluminium is a material that gives enormous flexibility in both design and workability, and this opens up for new developments. The automotive market is one of Sapa’s main markets, and we are dedicated to investing in research and development to help car manufacturers develop lighter and safer cars,” says business development manager Klaus J. Sandfeld.

The full potential of extruded aluminium in cars and trucks is far from realized. Aluminium is often viewed only as an alternative material, but aluminium is not lightweight steel. “You can design components that simply cannot be manufactured in steel, with different properties and added functionality,” says Sandfeld.

Sapa supplies the automotive industry with a broad range of solutions based on aluminium profiles, from semi-finished to fully fabricated and value-adding components.

Facts about the brake line

– The high-strength alloy in combination with a proprietary designed production process and line-connection design brings optimized mechanical properties toward brake lines requirements.

– The new solution has passed tests toward OEM specifications, including vibration, burst, torque, leak, coating adhesion and corrosion.

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Prayon Purchases Gas-Fired Harper Rotary Kiln

Brian Fuller - Harper International, Heat Treat Industry Supplier News, Rotary Kiln Furnace
Brian Fuller – Sales Manager Harper International
Harper International, world leader in custom thermal processing solutions for advanced materials, has been awarded a contract for a high volume Rotary furnace system by Prayon, headquartered in Belgium.
The innovative reactor will be used for drying and calcining of Prayon’s advanced iron phosphate powder, a key component of lithium iron phosphate (LiFePO4) cathode materials used in rechargeable batteries for electric vehicles, and is a part of their recently announced new plant investment to supply the lithium ion battery market. The gas-fired Harper Rotary kiln will support their high volume operations with features to maximize Prayon’s production, including advanced tube features to provide enhanced reaction kinetics, gas-tight and dust-tight design, and internal heat recovery within the furnace chamber to improve energy efficiency. Prayon collaborated with Harper through their Ignite™ process during the development phase by supporting scale up planning and analysis. The Ignite™ program offers scale-up expertise and testing resources to help minimize risk and maximize efficiency for pilot and production level outputs. “Harper is focused on supporting the next generation of materials in advanced markets, and this project for the lithium iron phosphate market is a great representation of that”, commented Brian Fuller, Sales Manager for Harper International. “The material is an ideal solution for many of today’s most progressive technologies for electric power and storage battery systems, and we are proud to be a part of Prayon’s solution to supply this market.”

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Nippon Steel & Sumitomo Metal Make Titanium Fuel Tank for Honda CRF450R Motocrosser

BOTW-50w  Source:  Webike Moto News

This is the first time in the world that titanium sheet has been used as fuel tank material for a mass produced motorcycle.  Read more to find out the other features of the CRF450R.

Read More: Titanium Sheet Developed by Nippon Steel & Sumitomo Metal is Now Adopted to Fuel Tank on Honda DRF450R Motocrosser

Nippon Steel & Sumitomo Metal Make Titanium Fuel Tank for Honda CRF450R Motocrosser Read More »

Sapa’s New R&D Lab to Focus on Auto Extrusions

BOTW-50w  Source:  Light Metal Age

Sapa Extrusions opened a new R&D lab in Troy, MI, dedicated to the development of extruded aluminum solutions for the automotive industry. Read more to find out what key disciplines will be available at Sapa Technology Americas.

Click here to read more: Sapa’s New R&D Lab to Focus on Auto Extrusions:  Interview with Dave Lukasak, Sapa

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American Axle & Manufacturing Holdings, Inc. Announces Acquisition

David C. Dauch, Automotive Heat Treat

David C. Dauch – Chairman and CEO of AAM

American Axle & Manufacturing Holdings, Inc. and Metaldyne Performance Group Inc. announced that the companies have entered into a definitive merger agreement under which AAM will acquire MPG for approximately $1.6 billion in cash and stock, plus the assumption of $1.7 billion in net debt.  The combination brings together highly complementary businesses and forms a premier, global Tier 1 supplier with broad capabilities across powertrain, drivetrain and driveline product lines, as well as diversified customer base and end-markets.

Under the terms of the agreement, each share of MPG’s common stock will be converted into the right to receive $13.50 per share in cash and 0.5 share of AAM common stock. Upon closing of the transaction, AAM’s shareholders will own approximately 70% of the combined company and MPG’s shareholders will own approximately 30%.  The transaction has been unanimously approved by the boards of directors of both companies and is anticipated to close in the first half of 2017 subject to shareholder and regulatory approval and other customary closing conditions.

Concurrent with the signing of the merger agreement, AAM entered into a voting agreement with an affiliate of American Securities LLC, the controlling stockholder of MPG, pursuant to which American Securities LLC has agreed to vote in favor of and otherwise support the transaction, subject to the terms of the voting agreement. Following the transaction, an affiliate of American Securities LLC will own approximately 23% of the combined company.

“AAM’s transformational acquisition of MPG brings together two complementary Tier 1 organizations to create a company with greater scale and increased diversity across products, customers and end markets,” said David C. Dauch, AAM’s Chairman and Chief Executive Officer.  “MPG’s expertise in complex, highly-engineered powertrain components and its global footprint will be tremendous assets to AAM. We are excited about the powerful industrial logic in this combination that will allow us to create additional value for our customers and other key stakeholders.  Together, we are forming a company with increased earnings potential and enhanced cash flow generation that will allow us to rapidly reduce leverage while fueling growth and delivering value to our shareholders.”

George Thanopoulos, MPG’s Chief Executive Officer, added, “This compelling transaction offers MPG shareholders an immediate premium and significant participation in the growth potential of the combined organization and its talented associates.   MPG and AAM share a similar culture and value system, laser focused on quality, operational excellence and technology leadership, which creates a natural fit and clear path to value creation for stakeholders of both companies.”

Compelling Strategic Rationale            

  • Creates a global leader in powertrain, drivetrain and driveline: The combined company will have the power to deliver a wide range of quality, highly engineered components, modules and sub-systems across multiple engine, transmission and driveline applications.
  • Diversified global customer base and end markets:  Accelerates AAM’s profitable growth and diversification objectives, significantly reducing product, customer and end-market concentrations.
  • Complementary technologies focused on light-weighting, fuel efficiency, vehicle safety and performance solutions:  Expertise in complementary product, process and systems technology strongly position the company to address the global automotive mega trends for both mechanical and alternative propulsion systems.
  • Stronger financial profile through greater size, scale and enhanced cash flow generation: On a pro forma basis, the combined entity will represent nearly $7 billion of annual sales and have the potential to generate over $1.2 billion of EBITDA and $400 million of free cash flow after full integration.
  • Powerful industrial logic with significant synergies:  Estimated annual run rate of targeted cost synergies estimated to be between $100 and $120 million by 2018.About AAM
    AAM is a world leader in the manufacturing, engineering, design and validation of driveline and drivetrain systems and related components and modules, chassis systems, electric drive systems and metal-formed products for light trucks, sport utility vehicles, passenger cars, crossover vehicles and commercial vehicles.  In addition to locations in the United States (Michigan, Ohio, and Indiana), AAM also has offices or facilities in Brazil, China, Germany, India, Japan, Luxembourg, Mexico, Poland, Scotland, South Korea, Sweden and Thailand. AAM has approximately 13,000 employees globally.About MPG
    MPG is a leading provider of highly-engineered lightweight components for use in powertrain and suspension applications for the global light, commercial and industrial vehicle markets. MPG produces these components and modules using complex metal-forming manufacturing technologies and processes for a global customer base of vehicle OEMs and Tier I suppliers. MPG has a global footprint spanning more than 60 locations in 13 countries across North America, South America, Europe and Asia with approximately 12,000 employees.

 

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Practical Approach to Determining Effective Case Depth of Gas Carburizing

BOTW-50w  Source:  Gear Technology

“Effective case depth is an important factor and goal in gas carburizing, involving complicated procedures in the furnace and requiring precise control of many thermal parameters. Based upon diffusion theory and years of carburizing experience, this paper calculates the effective case depth governed by carburizing temperature, time, carbon content of steel, and carbon potential of atmosphere. In light of this analysis, carburizing factors at various temperatures and carbon potentials for steels with different carbon content were calculated to determine the necessary carburizing cycle time. This methodology provides simple (without computer simulation) and practical guidance of optimized gas carburizing and has been applied to plant production. It shows that measured, effective case depth of gear parts covering most of the industrial application range (0.020 inch to over 0.250 inch) was in good agreement with the calculation.”

Read More:  Practical Approach to Determining Effective Case Depth of Gas Carburizing by March Li

March Li Metallurgist, Automotive Heat Treating, Practical Approach to Determining Effective Case Depth of Gas CarburizingAuthor March Li -Metallurgist

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Dana to Purchase Strategic Driveline Production Assets of SIFCO S.A.

Dana Incorporated announced a definitive agreement to purchase strategic assets of SIFCO S.A., a leading producer of forged and machined components located in Brazil.

Under the terms of the proposed purchase, Dana would acquire manufacturing and other assets of SIFCO. This acquisition will enable Dana to enhance its vertically integrated supply chain, which will further improve the company’s cost structure and customer satisfaction by leveraging SIFCO’s extensive experience and knowledge of sophisticated forged components.

“For nearly 70 years, Dana has operated in Brazil, which has long been one of the top ten economies in the world,” said James Kamsickas, president and chief executive officer of Dana. “This is an opportune time to invest in strategic and selective assets in Brazil that will further strengthen our position as one of the most trusted, top-tier suppliers to the mobility industry – thus positioning us for future profitable growth throughout the region.”

By expanding manufacturing capabilities in Brazil, the acquisition will also enable Dana to help vehicle manufacturers better accommodate local content requirements, which reduce import and other region-specific costs. It will also further strengthen Dana’s position as a central source for products that use forged and machined components throughout the region.

“Dana has worked with SIFCO for 40 years as a supplier of key components used in vehicle drivelines,” said Mark Wallace, president of Dana Commercial Vehicle Driveline Technologies. “This acquisition will add the talent and capabilities needed to help us meet the requirements of our commercial-vehicle customers and provide value for our light-vehicle and off-highway customers, as well.”

SIFCO has operated under judicial restructuring since 2014, and the transaction is subject to closing conditions, including bankruptcy court and regulatory approvals.  Final financial terms of the agreement are subject to the outcome of closing conditions. The transaction is expected to be completed by the end of 2016.

Dana designs, manufactures, and distributes products in Brazil for virtually every major global producer of passenger vehicles, commercial trucks, and off-highway equipment.

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AMRICC to Use Field-Enhanced Sintering Pilot Plant

The Applied Materials Research, Innovation and Commercialisation Company (AMRICC) is a high-technology center where advanced materials and processes will be fast-tracked into commercial products rapidly and economically – and at the same time scientists of the future will be developed to create a ‘talent pipeline.’

Focused on putting Stoke-on-Trent and Staffordshire at the heart of the global advanced materials economy, AMRICC’s research laboratory, pilot plant and educational facility will be used to channel the expertise and heritage in steel and ceramics within the region for a new generation.

The launch event, which took place at the Moat House Hotel in Festival Park, followed the official opening of the Ceramic Valley Enterprise Zone, with which AMRICC will be closely associated.

Dr Cathryn Hickey, AMRICC chief executive, said: “AMRICC offers the UK – and Stoke-on-Trent and Staffordshire in particular – a unique opportunity to become the world leader in the commercialisation of materials and materials process development.”

Traditionally, once a new material or process is discovered, bringing it to commercial use in the marketplace has taken up to 20 years or more.

This is quite an unbelievable time lag which can result in a host of missed opportunities for all involved.

In some cases the flow of innovation to fully commercialised products never happens and it’s this ‘valley of death’ which AMRICC will address.

AMRICC’s unique collaboration between academia and industry partners will help companies drive innovation to develop, manufacture and deploy advanced materials much faster and at a fraction of the cost.

This will enable new business models and approaches to collaboration to be achieved, and these will extend beyond the current open innovation concept.

Fully integrated solutions involving material innovation, as well as new process technology will enable unmet customer needs and new market challenges to be addressed.

With its state-of-the-art facilities, AMRICC will not only deliver commercialisation expertise, it will also be a centre of excellence for a number of exciting new disruptive technologies, which are on their way to market and are set to shake up current ways of working.

These areas include the development of unique encapsulation materials for drug abuse deterrent formulations, which are in significant market demand in the US.

And with the world’s first field-enhanced sintering pilot plant, which is a unique way of reaching extremely high temperatures very rapidly, AMRICC will be developing, with partners, a number of beneficial applications to bring to market.

These include thermal barrier coatings for the aerospace and automotive sectors as well as sensor technologies for the electronics industry.

But it’s not just about developing materials and technologies – at AMRICC we’re also proud to be developing people.

Working with some of the world’s leading universities, AMRICC will be delivering Master’s Degrees and PhDs to develop the ‘commercial technocrats’ of the future – materials scientists with both business acumen and a wide range of commercial and industrial experience.

AMRICC is being set up with the support of the international materials technology company Lucideon as well as Stoke-on-Trent City Council and the Stoke–on-Trent and Staffordshire Local Enterprise Partnership.

It will be initially based alongside Lucideon’s headquarters in Penkhull and, in future, is set to establish within the Ceramic Valley Enterprise Zone – to be developed on along the A500 corridor in Stoke-on-Trent and Newcastle under Lyme.

Dr Hickey added: “The launch of the Ceramic Valley Enterprise Zone and AMRICC today marks a significant and exciting day for the region.

In the future, we plan for AMRICC to be positioned within the Ceramic Valley Enterprise Zone where it will help to attract companies to the area, so it’s quite fitting that the company is launched today alongside the Enterprise Zone.

We look forward to working with our colleagues in the Ceramic Valley to drive the reputation of Stoke and Staffordshire in manufacturing and materials processing.

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Vacuum Assisted High Pressure Die Casting Technology Used in Manufacturing

BOTW-50w  Source: La Metallurgia Italiana –

Primary aluminum-silicon-magnesium alloys are by far the most widely used type in the manufacturing of safety parts for the automotive industry, such as suspension components and wheels, due to their excellent castability and good mechanical properties which can be further improved by heat treatment: solution, followed by water quenching and artificial aging T6 or T7. The recent structural castings, being extremely thin walled (of the order of 2.5 mm) and of rather great dimensions usually require the
use of High Pressure Die Casting. These parts must be defect free and heat treatable to attain the requested properties, ductility and weldability being the most difficult to achieve. Vacuum must be applied as well as a combination of precautions relative to the die design, die lubrication, melt quality and shot profile have to be taken.

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Novelis China Supplying Sheet for Aluminum-Intensive Jaguar XFL

BOTW-50w  Source:  Light Metal Age –

Novelis China is supplying aluminum solutions for the all-new, aluminum-intensive Jaguar XFL, the first Jaguar model from Chery Jaguar Land Rover Automotive Co., Ltd. Chery Jaguar Land Rover started up production at its Changzhu Plant – China’s first purpose-built aluminum body shop, where the Jaguar XFL will be assembled. Most of the aluminum alloys for the Changzhu body shop will be supplied by the Novelis sheet finishing and heat-treatment plant located in Changzhu, China.

Read more:

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