A Korean automotive parts maker recently broke ground on a manufacturing facility in Murray, Kentucky, that will house forging, heat treating, and machining gears and drivetrain parts, as well as administrative and design departments.
DAE-IL Corp. (DIC), headquartered in Ulsan, South Korea, will manufacture automotive transmission gears at the 295,000-square-foot plant being built in the Murray-West Industrial Park in Calloway County. The company expects to produce gears of the powertrain for internal combustion engine vehicles as well as gearboxes and differential assemblies for new cars.
“DIC is the best-specialized gear manufacturer in Korea,” said Johnny Kim, DIC president. “As global demand for our product is growing rapidly, [we]want to have this new facility here in the United States to satisfy our U.S. customers. I heard that Kentucky is at the heart of automotive and aerospace industries and has contributed growth to the national economy. With the highly skilled workers of this community, we will continue this trend for sure.”
“DIC will be at the forefront of the advancement of electric vehicles,” Kim added.
An Arkansas-based steel producer for automotive and electrical markets recently announced the expansion of its LEED-certified facility, doubling its hot-rolled steel production capacity to 3.3 million tons annually.
Dave Stickler, CEO of Big River Steel
In addition, the expansion at Big River Steel’s Flex Mill™, which began operations in early 2017, will facilitate the company’s ability to produce even higher grades of electrical steel, demand for which is expected to increase with continued focus on energy efficiency and the increase in hybrid and electric vehicle sales.
“Our $1.2 billion expansion will further cement Big River Steel’s position as a global leader in terms of advanced manufacturing and environmental stewardship,” said Dave Stickler, Big River Steel’s chief executive officer. “Announcing this investment less than 18 months after beginning operations is a testament to the hard work and great success of the men and women on our team.”
Engineering efforts are already underway with SMS group GmbH, the primary technology provider, and major construction activity will begin later this year and continue for approximately 24 months. In addition to doubling its hot-rolled steel production and enhancing its electrical steel capability, Big River is also contemplating the installation of a next-generation coating line focused on automotive applications.
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 America, Asia 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.
A startup aluminum anodizing company has announced plans to build its premier location in Fort Wayne, Indiana, to serve the automotive, construction, boating, and industrial markets in the Midwest region. The facility will house 32 ft tanks to accommodate aluminum parts up to 30 ft in length.
Northern Indiana Anodize will invest nearly $7 million to build the facility with construction beginning on the 47,000-square-foot facility in August and be complete in March 2019.
“With the economy growing, we’re seeing companies changing from steel parts to aluminum for weight and performance purposes,” said Bruce Fogler, chief financial officer at NIA. “We know there’s a high demand for anodizing providers and a shortage of large-tank anodizing facilities, so we’re starting this company to provide high-quality services in a growing industry.”
A leader in high pressure technology headquartered in Västerås, Sweden, recently commissioned hot isostatic presses for development and production of high-performance AM components in high-performance car and aviation applications as well as demanding applications within the aerospace, automotive, and energy sectors.
Stefan Seidel, CTO of Pankl Racing Systems
Quintus Technologies, which specializes in the design, manufacture, installation, and support of high pressure systems for sheet metal forming and densification of advanced materials and critical industrial components, supplied a Quintus HIP to Pankl Racing Systems in their new Pankl Additive Manufacturing Competence Center (PAMCC) in Kapfenberg, Austria.
The QIH48 will complement Pankl’s heat treatment facilities for HIP post-treatment. The PAMCC is an initiative of Pankl Racing Systems in collaboration with Voestalpine/Böhler Edelstahl, EOS and Quintus Technologies.
“As market leaders in our industry, we need the best equipment and best partners for our advanced AM production,” said Stefan Seidel, CTO of Pankl Racing Systems.
Jan Söderström, CEO of Quintus Technologies
“High-speed, high-tech, high-quality–we are impressed with this commitment of Pankl to their customers and their own objectives and happy to become part of their effort to broaden the application fields for AM in the racing car industry,” said Jan Söderström, CEO of Quintus Technologies.
“Quintus’ capability to deliver an easy-to-install, compact HIP system in a very fast time is very important for rolling out our AM strategy and business plan. We are looking forward to adding the Quintus HIP to our production portfolio,” said Wolfgang Plasser, CEO of Pankl Racing Systems.
Wolfgang Plasser, CEO of Pankl Racing Systems
Pankl Racing Systems specializes in developing and manufacturing engine and drivetrain components for racing cars, high-performance vehicles, and the aerospace industry.
In addition, the Center for Engineering and Industrial Development (CIDESI) in Querétaro, Mexico, has purchased and installed a HIP system from Quintus Technologies®, the QIH-15L. CIDESI is one of Mexico’s top research and innovation organizations, playing a key role in helping the country’s industry generate technological breakthroughs as well as educate the next generation of engineers for future challenges. The Quintus HIP system installed at CIDESI features a work zone of 7.32 inches (186 mm) in diameter and 19.69 inches (500 mm) in height; an operating temperature of 2552° F (1400° C); and pressure of 207 MPa (30,000 psi).
“Quintus Technologies has for several years worked with universities and research institutes in the development of education in many research areas, in North America and globally. We are honored to have been selected by CIDESI to deliver this HIP system. It proves our commitment to deliver reliable HIP systems to this educational and specialized technological sector,” said Söderström.
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.
A steel manufacturer and a corporation that provides automation and robotics technologies, both from Japan, recently announced that automakers are the target users for a jointly developed experimental robotic welding system that will join dissimilar metals — such as aluminum and high strength steel — with the goal of bypassing traditional methods of assembly, including rivets, fasteners, and adhesive bonding.
Kobe Steel developed the EASW process (element arc spot welding) and FANUC Corporation adapted it to high-speed application in assembly-based manufacturing.
“Specifically, the system performs a series of actions at high speeds, including position detection, smooth and accurate movement of the robot, pressurization, feed and engagement of the rivets, and arc welding.” — Light Metal Age
A Detroit-based manufacturer of automobile driveline and drivetrain components and systems, which includes heat treating under its metal forming division, recently announced expansions of its operations in China and Spain.
David C. Dauch, AAM Chairman & Chief Executive Officer
American Axle & Manufacturing (AAM) and Liuzhou Wuling Automobile Industry Co. Ltd. entered into a joint venture agreement to manufacture driveline systems, beginning production later this year in a state-of-the-art manufacturing facility located in the state-level economic development zone of East Liuzhou, in the Guangxi Province. Independent rear axles and driveheads will be manufactured at Liuzhou AAM.
“Liuzhou AAM will also continue to enhance our ability to provide both conventional and electric drive axles in the world’s largest automotive market,” said David C. Dauch, AAM Chairman and Chief Executive Officer.
Liuzhou AAM will produce driveline technology for SAIC-GM-Wuling’s SUV and MPV models. SAIC-GM-Wuling is a joint venture between General Motors and SAIC and is the largest manufacturer of rear-wheel-drive light vehicles in China.
In addition, AAM will open a new facility in Barcelona, Spain, in January 2019, producing powertrain components for Europe’s leading automakers including Renault, BMW, Daimler, Porsche, Audi, and Ford.
“The new facility will help AAM meet customer demand for products that help reduce noise and vibrations from downsized engines,” said Dauch.
Photo caption: Donald Joseph, president of AAM Asia and Weimin Li, Deputy General Manager, Guangxi Automobile Group at the Liuzhou AAM Automotive Driveline System Co., Ltd. signing ceremony.
An international automotive technology supplier headquartered in Canada recently opened a 225,000-square foot aluminum casting facility in Telford, England, which will supply structural castings to Jaguar Land Rover, a leading vehicle manufacturer in the U.K.
Ben Goater, general manager of Cosma Castings U.K.
Magna’s new operations will see use of its patented vacuum die-casting process in which advanced lightweight aluminum castings help maximize strength and stiffness and minimize weight, improving fuel economy, safety, and handling. As electrified and hybrid powertrains become more common in the automotive industry, high-pressure aluminum castings can be a key factor in reducing overall vehicle weight.
“With this new aluminum casting facility, we have established a world-class center of excellence to bring the most advanced structural casting technologies to the U.K.,” said John Farrell, president of Cosma International, which is the operating unit of Magna and supplies a comprehensive range of body, chassis and engineering solutions to automakers around the world. Magna now has nine manufacturing facilities with more than 2,200 employees throughout the U.K.
“The manufacture of aluminum castings is an important building block for the next generation of all-aluminum and multi-material vehicle architectures,” said Ben Goater, general manager of Cosma Castings U.K.
Photo credit: Magna and caption: “Magna officials were joined by Ian Harnett from Jaguar Land Rover (center) and members of local government to celebrate the grand opening of Magna’s new aluminum casting facility in Telford, England.”
A manufacturer of flat-rolled aluminum products recently announced plans to expand its existing operations in Goose Creek, South Carolina, adding a new 220,000 square foot building and installing state-of-the-art equipment.
JW Aluminum expands operations at its Mount Holly location.
JW Aluminum launched the $255 million expansion of its Mount Holly plant in a project that it hopes will greatly enhance the company’s capabilities to serve its primary end markets, representing the most significant capital investment in domestic continuous cast technologies and capabilities since 2001. In addition to the Mount Holly location, JW Aluminum manufactures aluminum products for the automotive, aerospace and construction industries at three other mills around the country, including St. Louis, Missouri; Williamsport, Pennsylvania; and the latest addition to the JW Aluminum, a mill in Russellville, Arkansas.
“It’s an exciting new chapter in JW Aluminum’s story and a considerable progression in our strategic journey. As a domestic supplier, we’ve prevailed in an extremely challenging competitive environment. The outcome of this endeavor will empower us to produce superior product for our customers, provide increased value to our stakeholders and serve as a preferred supplier and employer for decades to come,” said Lee McCarter, CEO of JW Aluminum.
Hazelett Corporation also recently confirmed that the Hazelett® Twin-belt Continuous Casting Process will be utilized for the JW Aluminum expansion. The casting machine being supplied is capable of producing 2000 mm wide strip at approximately 50 metric tonnes per hour. Alloy capabilities include 1XXX, 3XXX, 5XXX, and 6XXX series.
“This new facility will be a model for the most cost-effective and energy-efficient sheet production in North America,” said David Hazelett, president. “And, it will significantly ease the projected shortage of aluminum coil in the United States.”
Hazelett Corporation designs, manufactures, installs, and services twin-belt continuous casting machines worldwide and is fully integrated with in-house engineering, manufacturing, R&D, and technical services.
