FOUNDRY CASTING NEWS

6 Heat Treat Events From Around the Globe

/ FEATURED NEWS, FOUNDRY CASTING NEWS, MANUFACTURING HEAT TREAT

Today, we look to our European information partner, heatprocessing, to explore what international tradeshows you can look forward to, such as Thermprocess 2023 next June!

The Trade Fair Quartet: GIFA / METEC / THERMPROCESS / NEWCAST

"The international trade fair quartet GIFA, METEC, THERMPROCESS and NEWCAST is THE platform for meetings and business. International buyers, users, experts and decision makers from the metallurgy, heat technology and foundry industries meet here at four events, at the same time and at the same place." (Website)

When: June 12-16, 2023 (all-day)

Where: Düsseldorf, Germany

Read More: "GIFA / METEC / THERMPROCESS / NEWCAST"

 

EUROGUSS - International Trade Fair for Die Casting

"The international die casting industry meets at the biggest trade fair for die casting for the 14th time. The product range shows innovative solutions for die casting processes like aluminium die casting, magnesium die casting or zinc die casting. The event also focuses on topics like rapid prototyping, die casting machinery and material testing." (Website)

When: January 18-20, 2022 (all-day)

Where: Nuremberg, Germany

Read More: "Euroguss"

 

HANNOVER MESSE

"HANNOVER MESSE is the most important international platform and hot spot for industrial transformation - with excellent innovations or unusual products. Here you will find all the facts that make one thing even clearer: participation is an absolute 'must'!" (Website)

When: April 25-29, 2022 (all-day)

Where: Hannover, Germany

Read More: "Hannover Messe"

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Aerospace Castings Manufacturer Orders Large Capacity Casting Furnace

/ AEROSPACE HEAT TREAT, FEATURED NEWS, FOUNDRY CASTING NEWS, VACUUM FURNACES NEWS

Michael Lister
Director of Sales - North America
Consarc Corporation

HTD Size-PR LogoThe Doncasters Group recently ordered a vacuum furnace for their Doncasters Southern Tool facility in Oxford, Alabama. The order includes startup and installation with delivery scheduled before the end of 2021.

The new 300-pound Consarc vacuum precision investment casting (VPIC) furnace is equipped with high vacuum capabilities, controls, and increased automation with Teach Pour and other features that will give this furnace exceptionally high productivity for Doncasters Group.

The company is an international manufacturer of high-precision engineering components, designed to operate in the most demanding conditions. They serve the world’s leading OEMs in the aerospace, industrial gas turbine, and specialist automotive markets.

This order represents the 16th VPIC ordered from Consarc for delivery in North America in the last 24 months. Globally, the supplier has received 30 orders for this type of equipment in the same time frame.

"The recent strength in obtaining new orders for this product line is a testament to a customer centric philosophy we have at Consarc," said Michael Lister, director of Sales – North America at Consarc Corporation. "Our clients are sophisticated process owners who are well versed in the equipment and have demanding specifications placed on them by their own customers. Our collaborative approach in design, both before and after the order, is why customers trust [us] with these high value projects. We are able to understand their current problems and engineer long term solutions to mitigate those issues."

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Smart Materials, Magnesium Alloys Manufacturer Breaks Ground on Expanded Foundry

/ ENERGY HEAT TREAT, FOUNDRY CASTING NEWS

A manufacturer of smart materials for the oil and gas industry and advanced magnesium alloys for lightweighting recently broke ground on its expanded magnesium foundry for manufacturing dissolvable metals.

Andrew Sherman, CEO of Terves

Terves Inc launched the 12,000 sq. ft. expansion to its Magnesium Foundry, an H3-classified magnesium metal processing facility expansion which enables the company to further expand its metal processing, heat treatment, machining, and storage capabilities.  The expansion plans include additional permanent mold and materials handling and storage space, and the addition of sand casting, squeeze casting, and diecasting capabilities for custom magnesium and magnesium alloys and composites, in addition to further expansion of build-to-print component CNC machining services. These additions enable the company to support aerospace and defense magnesium applications in addition to Terves’ leading position in the dissolvable oilfield tool market.

 

“Dissolvable Metals are the New Composites as far as oilfield tools are concerned,” said Andrew Sherman, CEO of Terves. “Oilfield tools made from composite materials were adopted in the industry about two decades ago and today occupy a sizable market share. We are seeing a major adoption and growth trajectory for oilfield tools made from dissolvable magnesium materials. At the end of 2017, roughly 2% of all frac plugs deployed in the field were being made using dissolvable metals and the market is expected to grow to 5% of all frac plugs deployed in the field by the end of 2018 – a 250% growth in one year, with adoption and use increasing through 2025. We are seeing tremendous innovation as the industry gains extensive field experience with these new Engineered Response multifunctional materials, including several new staging and completion tools engineered using dissolvable materials. Given the massive value-add of dissolvable tools, primarily eliminating post-completion drill-outs coupled with the ability to do longer laterals, we expect that dissolvable tools would replace over 30% of drillable tools used in well completion over the next 3-5 years. Terves is investing in a further doubling of production capacity for cast and wrought magnesium products, and the expansion frees up space in existing facilities for initial production of new Engineered Response products, including revolutionary expandable structural materials and gas-generating reactive materials.”

 

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Metals Manufacturer Announces Sale of Heat Treating Facilities, Casting Business

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

A global metals manufacturer recently announced sale agreements of its divisions to two buyers: two non-core forging facilities to a middle-market private equity investment firm, and its Cast Products business to a manufacturing group.

Allegheny Technologies Incorporated (ATI) has agreed to sell the two non-core forging facilities to Wynnchurch Capital, LLC for $37 million in cash, and its Cast Products business to Consolidated Precision Products Corp. (CPP).

John Sims, Executive Vice President, HPMC segment

The forging facilities, located in Portland, Indiana, and Lebanon, Kentucky, are part of ATI’s High-Performance Materials & Components (HPMC) segment. They use primarily traditional forging methods to produce carbon steel forged products for use in the oil & gas, transportation, and construction & mining industries. They will be sold to Chicago, Illinois-based Wynnchurch Capital, LLC, a leading middle-market private equity investment firm. The transaction will close during the second quarter of 2019.

The ATI Cast Products business unit is part of the High-Performance Materials & Components (HPMC) segment. It produces titanium investment castings that are primarily used by aerospace & defense OEMs in the production of commercial jet airframes and engines. A post-casting machining facility in Salem, Oregon, will remain with ATI and provide services to CPP and others. CPP of Cleveland, Ohio, operates 16 global facilities manufacturing products primarily for the aerospace, defense, and industrial industries and is a portfolio company of Warburg Pincus, a leading global private equity firm. The transaction, subject to customary regulatory approvals, is expected to close in the early part of the third quarter of 2019.

Robert S. Wetherbee, President and Chief Executive Officer of ATI

“[The forging facilities] transaction is consistent with our ongoing efforts to actively evaluate our business portfolio to ensure we’re focused on key growth opportunities for HPMC in the aerospace & defense end-markets, specifically in nickel and titanium products as well as in advanced iso-thermal and hot-die forgings,” said John Sims, Executive Vice President, HPMC segment. “With the sale to Wynnchurch Capital, these solidly-performing, independent operations will become part of a company with a proven track record of investing in, growing and successfully operating industrial manufacturing businesses.”

“ATI’s HPMC segment is at its best when we couple our materials science expertise and extensive forging experience to produce critical jet engine components in our world-class production facilities,” added Sims. “ATI’s Cast Products business is a good fit for CPP’s aerospace and industrial focused business portfolio.”

“We continue to actively evaluate our business portfolio to ensure that we are focused on the businesses that offer ATI the best combination of growth, profitability, and corporate synergies,” said Robert S. Wetherbee, President and Chief Executive Officer of ATI.

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Major U.S. Steelmaker to Invest in Endless Casting & Rolling Technology

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

A U.S. integrated steel producer headquartered in Pittsburgh, Pennsylvania, recently announced that it will invest more than $1 billion to construct new facilities in Pennsylvania, including a sustainable endless casting and rolling facility at its Edgar Thomson Plant in Braddock, Pennsylvania.

David B. Burritt, president and CEO of U.S. Steel

United States Steel Corporation (U.S. Steel) announcement highlights] the company’s continued commitment to steelmaking in Pennsylvania. In addition to the endless casting and rolling facility, the company plans to build a cogeneration facility at its Clairton Plant in Clairton, Pennsylvania. Both are part of the U.S. Steel’s Mon Valley Works.

The cutting-edge endless casting and rolling technology combines thin slab casting and hot rolled band production into one continuous process and, according to U.S. Steel, will make Mon Valley Works the first facility of this type in the United States, and one of only a handful in the world, replacing the existing traditional slab caster and hot strip mill facilities at the Mon Valley location.

“This is a truly transformational investment for U. S. Steel,” said David B. Burritt, president and CEO of U.S. Steel. “We are combining our integrated steelmaking process with industry-leading endless casting and rolling to reinvest in steelmaking and secure the future for a new generation of steelworkers in Western Pennsylvania and the Mon Valley. U. S. Steel’s investment in leading technology and advanced manufacturing aligns with our vision to be the industry leader in delivering high-quality, value-added products and innovative solutions that address our customers’ most challenging steel needs for the future. We believe that adding sustainable steel technology to our footprint will create long-term value for our employees, our region, our customers and our investors.”

With this investment, Mon Valley Works will become the principal source of substrate for the production of
the company’s industry-leading XG3™ Advanced High Strength Steel (AHSS) that assists automotive customers in
meeting fuel efficiency standards. This project, in addition to producing sustainable AHSS, will improve
environmental performance, energy conservation and reduce our carbon footprint associated with Mon Valley Works. First coil production is expected in 2022, contingent upon permitting and construction.

 

Photo credit: Image still from video, U.S. Steel Youtube page

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Heat Treat Line Expanded at Aerospace Aluminum Castings Facility

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

A New Hampshire-based manufacturer of sophisticated aluminum investment castings for predominantly aerospace applications recently expanded its capabilities with two electric drop bottom ovens.

Uni-Cast purchased the two furnaces for installation at its factory located in Londonderry, NH, from Pyradia Belfab, based in Saint-Hubert, Quebec. Pyradia designs and manufactures custom industrial equipment for aluminum heat treating, web converting, and dust collecting applications.

“After reviewing many quotes, we thought they were the best value out there. They make quality ovens at a competitive price. They have reasonable lead times and good engineering. I highly recommend them,” said Henri Fine, owner of Uni-Cast, which incorporates heat treating and precipitation hardening in the casting process in order to provide dimensional stability, strength, and hardness.

 

Main photo: Still image captured from video at Pyradia’s website.

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Iron Foundry Expanding into Aluminum at Ohio Facility

/ AEROSPACE HEAT TREAT, AEROSPACE HEAT TREAT NEWS, FOUNDRY CASTING NEWS

 

Source: Business Journal Daily

 

An iron casting foundry located in Hubbard, Ohio, is expanding into aluminum casting with an aluminum slab and billet plant at its current site.

Ellwood Engineered Castings is investing $60 million to house its new Ellwood Aluminum division to serve customers in the aerospace and other industries.

 

Read more: “Ellwood Group Diversifies with $60M Aluminum Plant”

 

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Aluminum Casting Facility Opens To Supply Jaguar Land Rover

/ AUTOMOTIVE HEAT TREAT, AUTOMOTIVE HEAT TREAT NEWS, FOUNDRY CASTING NEWS

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.”

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Four Vacuum Heat Treat Systems Shipped to Casting Company

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

Four vacuum furnaces were recently shipped to a major casting company in Arizona, three with a free work area of 54″ W x 41″ H x 72″ L and one with a free work area of 24″ W x 24″ H x 36″ L.

The supplier, G-M Enterprises, based in Corona, California, announced that all four are 2-bar furnaces with innovative hot zone design and construction. A 1200 gpm water cooling system was included in the installation.

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Automotive Supplier Expands in Alabama with Aluminum Casting Facility

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

A global automotive supplier recently announced an expansion of its operations at its Kamtek facility in Birmingham, Alabama.

Magna International reported that its new facility will feature a manufacturing process–high-pressure aluminum casting–that further enables the supplier to provide vehicle lightweighting and part-reduction solutions for customers. The new capabilities improve upon traditional steel multi-piece welded assemblies, which can take upwards of 12 stampings to produce one structural component. High-pressure aluminum casting allows production of full structures in one piece, reducing vehicle mass without compromising performance, structural integrity or safety.

Magna invested approximately $60 million to add the 150,000-square-foot facility. The Kamtek facility employs approximately 850 people and produces structural components for various customers including Mercedes-Benz, Volkswagen and Nissan. The new facility will initially produce lightweight aluminum front shock towers for a major global automaker, with additional customers and programs expected in the future. At full capacity, the expansion has the potential to generate more than 100 jobs.

 

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