FOUNDRY CASTING NEWS

Steel Industry Acquisitions: Updates Following US Election

/ FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS

As U.S. election results were announced last week, several steel industry players are in the midst of acquisitions that could mean changes for in-house heat treat operators in North America.

Cleveland-Cliffs Expands North American Presence

Lourenco Goncalves
Chairman, President, CEO
Cliffs
Source: Cliffs

Cleveland-Cliffs Inc. (“Cliffs”) today announced that it has successfully completed its acquisition of Stelco Holdings Inc. (“Stelco”). The addition of Stelco enhances Cliffs’ position as the largest flat-rolled steel producer in North America, diversifies Cliffs’ end-markets and expands its geographical presence in Canada. Stelco will continue operations as a wholly-owned subsidiary of Cliffs, preserving the name and iconic Canadian legacy of the business.

Lourenco Goncalves, chairman, president and CEO of Cliffs, stated: “Today marks a transformative step forward for Cleveland-Cliffs. By bringing Stelco into the Cliffs family, we are building on our commitment to integrated steelmaking and good paying union jobs in North America. This acquisition allows us to further diversify our customer base and lower our cost structure. We are excited about the opportunities this acquisition brings and appreciate the warm welcome we have received from all government officials in Canada. We take our permission to operate very seriously and aim to continue the Stelco legacy with dedication and purpose.”

Nothing New: Questions for Nippon-U. S. Steel Acquisition

Takahiro Mori
Vice Chairman and Executive Vice President
Nippon Steel
Source: Nippon Steel

This past April 2024, U. S. Steel was heralding the merger with Nippon Steel as advancing their sustainable steel goals. Still, outgoing President Joe Biden and Vice President Kamala Harris as well as President-Elect Donald Trump and Vice President-Elect JD Vance have all spoken out with concerns to preserve American ownership of U. S. Steel. “And I couldn’t agree more with President Biden,” commented Harris recently along the campaign trail in September, “US Steel should remain American owned and American operated.”

At this time, the U. S. Committee on Foreign Investment has the proposed acquisition under review until late December 2024.

If the deal is approved before the January 2025 inauguration, that does not guarantee that Trump would not overturn the results. However, “The previous Trump administration said it would attract foreign investment and create new jobs,” commented Nippon Steel Vice Chairman and Executive Vice President Takahiro Mori. “This (acquisition) is extremely in line with such a policy.” He still aims to see the deal close before the end of the calendar year.

The press release for the Cliff’s story is available in its original form here.

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Furniss & White Broadens Production at Heat Treat Facility With High-Performance Alloy Series

/ FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS

Furniss & White has partnered with a stainless steel technology company to produce its castings at its heat treatment facility using a new series of high-performance alloys. The foundry, which specializes in high-integrity stainless steel castings, fabrications, and precision machining, has signed a long-term agreement to manufacture its cast products using the high-performance alloys.

The castings are solution heat treated at approximately 1100°C (2012°F) and above and then water quenched by the company’s lift-off cover-type furnace with a load capacity of 5.3 tons (11,684.5 lbs). The N’GENIUS SeriesTM was developed by N’GENIUS Materials Technology and represents the total reinvention of conventional austenitic stainless steels, commonly known as the 300 Series.

Furniss & White will continue to produce its castings now using high-performance alloys under the N’GENIUS Series license for engineering products made using these advanced materials to its clients, serving the pump, valve, filter and engineering industries with castings from approximately 0.5kg to 2,600kg finished weight in a range of materials including carbon and low alloy steels, stainless steels, and nickel alloys. The firm manufactures an extensive selection of cast products for wide application in sectors including oil and gas, chemical, petrochemical, mining, marine, defense, and power generation.

Dr. Ces Roscoe
CEO of N’GENIUS Materials Technology
Source: LinkedIn

“For more than 44 years we have built a strong reputation as a high-quality British manufacturer of high integrity castings made in our modern foundry in the UK,” said Sam Scholes, managing director at Furniss & White. “Now, as an approved licensed N’GENIUS manufacturer, we are writing an exciting new chapter in our history and to be the first foundry in the world to have this capability makes us extremely proud. We expect these game-changing N’GENIUS materials will be extremely popular with our existing customers and help open up new opportunities in other markets including the U.S. and Canada and in clean energy industries such as hydrogen.”

“Furniss & White is a company that shares our own passion and drive for innovation, and we are absolutely delighted to be collaborating with them on what is destined to be an industry changing technology,” said Dr. Ces Roscoe, CEO of N’GENIUS Materials Technology and inventor of the N’GENIUS Series. “With a long history of steelmaking, Sheffield is widely regarded as the birthplace of stainless steel and it seems befitting that it will essentially be ‘reborn’ in the same city more than a century later.”

Furniss & White has successfully completed a range of Manufacturing Procedure Qualification Tests at its facilities in various grades from the N’GENIUS Series.

Main image: Furniss & White casting an N’GENIUS grade alloy.

The press release is available in its original form here.

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$2.5B Acquisition Expands Steelmaker’s North American Reach

/ FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS

Cleveland-Cliffs Inc, a major supplier of steel to the automotive industry with heat treat capabilities, has announced its acquisition of Stelco Holdings Inc, an integrated steelmaker with two operational sites in the province of Ontario. The $2.5B (USD) transaction will bring 1,800 workers into the Cleveland-based steelmaker’s current workforce of 18,000 employed across its facilities in the United States and Canada.

Cleveland-Cliffs Inc. (Cliffs) recently released its definitive agreement to acquire Stelco Holdings Inc, increasing its steelmaking footprint and doubling the company’s exposure to the flat-rolled spot market, which includes raw materials, energy, and healthcare. Stelco adds capabilities that complement Cliffs’ existing operations, confirming the Cleveland-based steelmaker’s commitment and leadership in integrated steel production in North America.

Lourenco Goncalves
Chairman, President and CEO
Cleveland Cliffs

Stelco’s facilities consist of Lake Erie Works, a new integrated steelmaking facility in North America, and Hamilton Works, a downstream finishing and cokemaking facility, adding capabilities that complement Cliffs’ existing operations and product portfolio, while diversifying its market industries. Upon completion of the transaction, Cliffs shareholders will own approximately 95% and Stelco shareholders will own approximately 5% of the combined company, on a fully diluted basis.

“We did this deal the way it should be done, reaching a respectful agreement between the two parties that keeps national interests at the forefront and recognizes the importance of the workforce,” said Lourenco Goncalves, chairman, president and CEO of Cliffs. “The enterprise value of this transaction is significantly lower than the cost of building an equivalent replacement mill in the United States, and the cost structure is lower than what a new U.S. mill would provide us. Stelco is a company that respects the Union, treats their employees well, and leans into their cost advantages. With that, they are a perfect fit for Cleveland-Cliffs and our culture. We look forward to proving that our ownership of Stelco will be a net benefit for Canada, the province of Ontario, and the cities of Nanticoke and Hamilton.”

Alan Kestenbaum
Executive Chairman & CEO
Stelco Holdings

“I am proud of what we have accomplished over the past seven years, and the value we have generated,” said Alan Kestenbaum, executive chairman and CEO of Stelco. “Most importantly, we have revitalized Stelco and restored it to its iconic status in Canada. I know thac Cliffs will continue to build upon the excellent work and life environment we have created for all of our employees and continue to be a reliable supplier to our valued customers, while maintaining Stelco’s stature and reputation in Canada and maintaining our Canadian national interests. One of the important drivers for this transaction was receiving a meaningful portion of the consideration in Cliffs shares. I have strong belief and optimism in the North American steel market. I believe that Lourenco and his team have created a winning platform, and I intend to remain an investor in Cliffs for a long time to come as he and his team continue to build out their platform and business.”

Pictured in featured image: Lourenco Goncalves

The press release is available in its original form here.

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News From Abroad: Globally, Eyes Turn to the Future

/ FEATURED NEWS, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS

Today’s News from Abroad installment investigates the influence AI is bearing on the global field of heat treating, as well as a 2023 sustainability report and a future-looking question about the German foundry model amid transformations and a shortage of skilled workers. 

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

AI News No.1: Smart Manufacturing Proves Its Value

Viking Analytics and Bharat Forge sign a three-year contract

“A new agreement has been signed between Viking Analytics and Bharat Forge Kilsta (BFK) from Karlskoga. The agreement, which is for three years, provides BFK with the AI-based optimization tool ‘Smartforge’ after a 10-month implementation phase. Smartforge optimizes the forging process, primarily in the critical heat keeping process where the problems with scrap are greatest. The goal is to reduce discarded products by 50% and contribute to energy savings and a more environmentally friendly production.”

READ MORE: “AI-Driven ‘Smartforge’ To Enhance Forging Efficiency and Reduce Waste” – at heat-processing.com

AI News No. 2: Global Industry Goes “All In” With AI

Digital transformation and the concept of a sustainable economy go hand in hand with energy and environmental challenges.

“According to a report by the Boston Consulting Group (BCG), nearly 80 percent of companies around the world consider innovation to be one of their three main priorities this year, and 66% of them plan to increase spending for this purpose, of which 42% are ready to invest up to 10% more than before. Innovation is one of the SECO/WARWICK Group’s values, embedded in its DNA. Industry 4.0 is the guiding principle in the Group’s mentality and strategic direction, which identifies AI, automation and digitization as a priority.”

READ MORE: “SECO/WARWICK Bets On Artificial Intelligence (AI)” at heat-processing.com

A Sustainability Commitment to a Greener, Equal Future Shows Results

Tenova’s 2023 Sustainability Report illustrates the company’s ESG-guided sustainability framework, including energy efficiency initiatives, circular economy solutions, and sustainable innovation.

“Tenova has announced the launch of its new Sustainability Report, which tracks the progress the company has made against its sustainability agenda over the past year. The Report illustrates the company’s ESG-guided sustainability framework, including energy efficiency initiatives, circular economy solutions, and sustainable innovation. . . . Tenova’s flagship technologies–Direct Reduction Iron (DRI), Electric Arc Furnaces (EAFs), and the Silicon Steel ones–are essential in driving the decarbonization of both the metals industry and the planet. This is demonstrated by its major international projects, which are set to make a substantial impact on sustainability in Europe, China, and other parts of the world.”

READ MORE: “The 2023 Tenova Sustainability Report Reconfirms the Company’s Commitment to a Greener and Equal Future” at furnaces-international.com. 

German foundry Industry Navigating a Path Forward

At its third “Zukunftstag“ (Future Day), the German Foundry Association (BDG) discussed: Do we still need casting from Germany? And why is the industry currently facing such difficulties?

“At its third ‘Zukunftstag’ (Future Day), the German Foundry Association (BDG) posed a rhetorical question to stakeholders and the industry: Do we still need casting from Germany? And why is the industry currently facing such difficulties? The Federal Association of the German Foundry Industry launched the ‘Future Day’ format in 2020 in order to visualize and establish generally applicable topics from corporate management and framework conditions in open discourse with experts from outside the industry, in addition to the industry’s technically focused conferences. In addition to economic policy framework conditions, the program revolved around skilled workers in the afternoon. The German foundry industry, part of the energy-intensive SME sector, is struggling amid transformations and a shortage of skilled workers.”

READ MORE: “Energy-Intensive and Medium-Sized: Is German Foundry a Discontinued Model?” at heat-processing.com. 

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overhead view of Pittsburgh point with US Steel and Nippon Steel logos

U. S. Steel-Nippon Steel Merger Will Expand Pittsburgh Steelmaker’s Technical Base

/ FEATURED NEWS, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS
David Burritt
president and CEO
U.S. Steel
Source: U.S. Steel

Access to technology and expertise in integrated mills are among the advantages that will accompany the U. S. Steel–Nippon Steel merger, according to David Burritt, U. S. Steel’s CEO. Heat treatment processes are an element in integrated mill operations within both companies’ profiles.

On December 18, 2023, it was announced that Japanese steelmaker Nippon Steel (NSC) would acquire Pittsburgh–based U. S. Steel. Under the deal, Nippon Steel would acquire the company for $14.1 billion, which totals to $14.9 billion when including the assumption of U.S. Steel’s debt. As part of the deal, Nippon Steel will invest $1.4 billion in U. S. Steel’s assets and will share technical knowledge, stated Burritt during his keynote address to the 2024 Global Steel Dynamics Forum.

“They’re experts in integrated mills, and they want to invest here,” he said.

In April, Nippon Steel released a statement that the merger will include U. S. Steel having access to Nippon’s technologies and R&D advancements, “help[ing] U. S. Steel produce more advanced and environmentally sustainable steel for domestic customers.”

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News from Abroad: Casting Metal and Forging a Venture

/ FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS

Today’s News from Abroad installment brings us news of casting equipment supplied in China, heat treat supplier joint venture forged in Austria, and big standardization plans in Germany — where doing LESS is more.

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

High-Performance Continuous Caster on Order 

Representatives from Primetals Technologies and Wuyang Iron and Steel at the signing ceremony
Source: Primetals Technologies

“Wuyang Iron and Steel has awarded Primetals Technologies an order for a 1-strand continuous caster with several record-breaking features. The continuous casting plant will be put into operation at the Wuyang plant in Wugang, Henan Province, and is expected to be the most powerful of its kind in the world. It will also produce the thickest slabs in the world, up to 460 millimeters thick. Thanks to the new facilities, Wuyang will be able to produce sheet metal for heavy-duty applications such as shipbuilding and the wind power sector. The annual capacity will be one million tonnes of high-quality slabs.”

READ MORE: “Primetals Technologies: Chinese steel producer orders high-performance continuous caster” at heat-processing.com

Aichelin in Austria

Left to right, 1. row: Christian Grosspointner, CEO Aichelin Group; Mehmet Özdeşlik, CEO Sistem Teknik; 2. row: Wolfgang Brosche, Erwin Strauszberger, Beril Özdeşlik, Beste Özdeşlik, Gökhan Lale, Levent Sindel.
Source: Aichelin

“The Aichelin Group and Sistem Teknik have signed an agreement to establish a joint venture in Austria. This joint venture will produce and distribute industrial vacuum heat treatment technologies and services in Europe. The Aichelin Group is thus adding a promising segment to its existing product portfolio.”

READ MORE: “Aichelin expands portfolio” at heat-processing.com

Germany Decides To Do LESS

Two steelmaker groups, GMH (Georgsmarienhütte) Gruppe and Swiss Steel, have issued notes of approval for the proposal from German steel federation for a standard for low-emission steel (LESS).
Source: worldsteel

Dec“Two steelmaker groups, GMH (Georgsmarienhütte) Gruppe and Swiss Steel, have issued notes of approval for the proposal from German steel federation for a standard for low-emission steel (LESS). Both mills happen to be makers of special bar qualities, and the word of Swiss Steel may have some international weight, given it has melt shops in Germany, Switzerland and France. WV Stahl announced on Monday that it has set a cornerstone for prime markets for climate-friendly streel with a standard its members developed together with the German economy and climate protection ministry. The Low Emission Steel Standard (LESS), as it is called, is the first standard that makes the main customary production routes, blast furnace and EAF, comparable in terms of their efforts to decarbonise. Its centrepiece is a labelling system for the classification of low-CO2 steels.”

READ MORE: “Mills Welcome German Federation’s Low-Emission Standard LESS” at heat-processing.com

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News from Abroad: Safer Technologies and Carbon Cutting

/ BURNERS & COMBUSTION SYSTEMS, BURNERS COMBUSTION SYSTEM NEWS, FOUNDRY CASTING, FOUNDRY CASTING NEWS, HEAT TREAT NEWS, HEAT TREAT NEWS INDUSTRIES, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

Today’s News from Abroad installment highlights more carbon-cutting trends from the steel industry, ranging from robots in the cast house to recycling best practices.  

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

Robots Bring Safety to Casting 

Primetals Technologies’ new customized LiquiRob robotics system in operation at Siam Yamato Steel’s Map Ta Phut plant Source: Primetals Technologies

“Thai steel producer Siam Yamato Steel has implemented a new robot concept from Primetals Technologies, including LiquiRob, at its steelworks in Map Ta Phut . . .. Thanks to the robotics solution, safety and occupational health in the steelworks have significantly improved. Previously, workers who manually operated the shadow tube had to stand directly next to the distributor and the stream of steel flowing out of the ladle. In the case of a so-called ‘frozen pan.’” 

READ MORE: “Primetals Technologies: New robotics concept for safer casting processes” at heat-processing.com

Carbon Cut with Induction Solution at High Heats

CELES EcoTransFlux™ brings green high heating abilities to the induction heating technology. Source: Furnaces International

“Nippon Steel Stainless Steel Corporation and Sojitz Group met with our induction team at Fives headquarters in Paris for a detailed design review of the transverse flux induction heating system. CELES EcoTransFlux™ is an induction heating technology with very high heating rates at extremely high temperatures, and a compact footprint. It also has a minimal environmental footprint, making it beneficial for steelmakers to improve their carbon, stainless or electrical steel production.” 

READ MORE: “Breakthrough technology for steelmakers” at furnaces-international.com

Standards To Maximize Can Recyclability

EAGP members signed an agreement to engage in a standardisation project for beverage cans. Source: Anrita1705/Pixabay

“Four leading flat-rolled aluminium manufacturers and members of the European Aluminium Packaging Group (EAPG), Constellium, Elval, Novelis and Speira, have signed an agreement to engage in a standardisation project to maximise the recycled content levels of the beverage can and thus substantially lower carbon emissions, focused on increased recyclability of the can end.” 

READ MORE: “European Aluminium Producers Agree on Standardisation Project for Cans” at heat-processing.com

Mini-Mill Investment Transforms Future for Swedish Metal Manufacturer

Fossil-free mini-mill Source: Furnaces International

“SSAB’s Board of Directors have taken the decision to proceed with the next step in SSABs transition, building a state-of-the-art fossil-free mini-mill in Luleå, Sweden. When completed SSAB will close the current blast furnace-based production system. This will reduce Sweden’s CO2 emissions with 7% in addition to the 3% from the Oxelösund mill conversion.” 

READ MORE: SSAB continues the transformation with a fossil-free mini-mill in Luleå, Sweden” at furnaces-international.com

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Vacuum Induction Melting Solution from Upper NY

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, ENERGY HEAT TREAT, ENERGY HEAT TREAT NEWS, FOUNDRY CASTING, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

A custom-built vacuum induction melting (VIM) equipment is set to expand thermal processing for a manufacturer, whose operations already has two VIM solutions. 

The furnace will be fabricated at the Buffalo headquarters of Retech, a SECO/WARWICK Group subsidiary, to capitalize on available schedule improvements. As custom equipment, the subsidiary’s furnaces are not dependent on assembly-line style construction, so they can be fabricated and assembled just in either location.

While this client prefers not to divulge this VIM’s application, Retech’s solution can handle casting a wide range of materials used in applications from automotive and consumer products to critical, high-value equiaxed, directionally solidified, or single-crystal aerospace parts. Almost every furnace Retech makes is modified to meet the specifications and associated applications of its clients.

VIM from the Retech Buffalo, NY location. Source: SECO/WARWICK

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Manufacturer To Receive EB Furnace for Large-Ingot Casting

/ FOUNDRY CASTING, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT, MANUFACTURING HEAT TREAT NEWS

A North America-based company is set to receive a four-gun electron beam hearth melting furnace from their industry partner of 3 years.

Retech, a division of SECO/WARWICK Group, received this third contract in as many years from the returning partner after the successful planning, installation, commissioning, and subsequent operation and progress of the last two EB hearth melters. Along with that, repeat orders from a known partner reduce uncertainty and risk for the company. Put more simply, practice makes perfect.  

Source: SECO/WARWICK
Source: SECO/WARWICK

These EB furnaces have a throughput that is suitable for large-ingot casting of reactive/refractory metals when alloying with metals having similar vaporization temperatures, whereas plasma arc melting, although slower, would be the more suitable choice for dissimilar vaporization temperatures.

Earl Good
Managing Director at Retech Systems, LLC
Source: Retech

“We are thrilled to be an ongoing partner in this customer’s growth,” said Earl Good, managing director of Retech Systems. “We know they have multiple competitive options for their vacuum metallurgy equipment, so we take nothing for granted, and work hard to earn their business every step of the way. Ongoing awards like this suggest we’re doing a lot of things right.”  

Retech produces and assembles vacuum melting equipment entirely in North America. Their integrated R&D, manufacturing, and assembly facility in Buffalo allows them to do that. The North American supplier also has exclusive use of electron beam guns from Von Ardenne, industry pioneers of electron beam technology.  

This press release is available in its original form here.

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US Army Enlists Metallus for Munitions Expansion

/ FEATURED NEWS, FORGING NEWS, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT NEWS

Metallus, formerly known as TimkenSteel and a leader in high-quality specialty metals, manufactured components, and supply chain solutions, announced that the company has entered an agreement for up to $99 million in funding from the United States Army.

Half of the funding is currently obligated, with the balance subject to mutual agreement during subsequent phases after the final project details are presented to the Army. This funding will support a project aimed at bolstering the Army’s mission of ramping up artillery shell production in the coming years.

Mike Williams
President and CEO
Metallus
Source: Metallus

Specifically, this project will enable the development of additional capacity to help fulfill increased global demand for artillery shells. The new capability is expected to increase throughput of high-quality bar-based products used in artillery applications and support approximately $60 million of incremental base sales annually, demand dependent. The company is targeting late 2025 for this new capability to be operational with funding to be provided throughout the procurement and installation process.

“Metallus is honored to expand our commitment to the defense sector, reliably providing high-quality specialty metals for critical applications. With this funding, we intend to further optimize our assets to meet the Department of Defense’s heightened demand while reducing our carbon footprint,” affirmed Mike Williams, president and CEO.

The 2022 National Defense Strategy outlines the Department of Defense’s commitment to establishing a modernized and coordinated defense industrial network. This initiative aims to develop a reliable and resilient supply chain of industrial partners over the next several years that will significantly enhance the nation’s defense capabilities for the long-term.

This press release is available in its original form here.

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