FOUNDRY CASTING NEWS

Japan-Based Foundry Builds First U.S. Manufacturing Facility

Global manufacturer of alloy castings for the automotive and industrial sectors, Kimura Foundry America, has announced plans to locate its first U.S.-based manufacturing facility in Shelbyville, Indiana. The 35,200-square-foot plant, built on 10 acres of property, will house 3D-printing equipment which will facilitate the production of complex castings and molds for its U.S. clients. Planning to break ground in October 2017, the subsidiary of Japan’s Kimura Group targets a December 2018 opening and plans to create 20 new jobs by 2020.

The company uses a proprietary process for casting molds using 3D printing technology, allowing it to manufacture products including stamping die castings and machine and industrial tool castings. These products are used in automotive engine parts, pumps, compressors and energy components. “Kimura has established a Development Department and is engaged in thoroughly researching improvements in quality and in developments of new products. This approach has enabled us to introduce positive techniques in the casting industry, which used to depend only on workers’ experience and good sense. The results of these research outcomes are fed back to our foundries,” reads the company’s website.

“When we were searching for our first U.S. manufacturing partner, Indiana offered exactly what we were seeking,” said Yoya Fukuda, Ph.D., president of Kimura Foundry America. “That is because Indiana is strategically located in the epicenter of the industries we serve. The state’s highly-developed transportation networks and its highly-skilled manufacturing workforce were an excellent match. Indiana has a long history of welcoming Japanese companies to the state, and we are looking forward to joining the many other Japanese companies in Shelby County.” Kimura Group employs more than 830 associates at its 10 facilities across three locations in Japan and at its North American sales office in Schaumburg, Illinois.

“Shelbyville is a great community in a prime location for industry growth with capable Hoosiers ready to get to work,” stated State Representative Sean Eberhart (R-Shelbyville). “Kimura Foundry America is a perfect fit as they join other global manufacturing companies that already call Shelbyville home.”

Kimura Group employs more than 830 associates at 10 facilities across three sites in Japan and at its North American sales office near Chicago. The company uses a proprietary process for casting molds using 3D-printing technology, allowing it to manufacture products including stamping die castings and machine and industrial tool castings used in automotive engine parts, pumps, compressors, and energy components.

Sources: Business Facilities, Foundry MagazineIndustrial Heating, Indiana House Republicans

 

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EJ Americas Begins Construction on New Iron Foundry

 

EJ Americas, a global organization producing and distributing iron castings for municipal and infrastructure programs, broke ground in July for a greenfield foundry being built in Elmira, Michigan, 20 miles east of its current and original location in Warner Township. The new foundry is expected to be in operation by Fall 2018.

Founded in 1883 and previously known as East Jordan Iron Works and rebranded as EJ in 2011, the foundry has an operation that includes a cupola melting shop for ductile iron, three molding lines — automated green-sand molding, no-bake molding, and HWS molding for parts up to 76×60 in. EJ provides castings to the agricultural, forestry, marine and railroad industries, with a niche as a supplier of castings for water, sewer, and drainage systems and telecom and utility networks, and is best known for its production of manhole and utility covers, drainage grates, warning plates, tree grates, fire hydrants, grate valves and other specialized castings.

At the current location, the foundry has automated finish machining, coating, and assembly and testing for fire hydrants and valves. The new foundry in Michigan will expand casting capabilities, although specific details about the melting and casting operation have not been released. The company has a second U.S. plant in Ardmore, Oklahoma, and a network of foundries in Australia, Canada, France, and Ireland.  The corporate headquarters, pattern shop, product development group, water products, and regional sales office will remain in East Jordan.

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Melting Furnaces and Twin Chamber Furnace to be Installed

Significant milestones have been obtained with the construction and installation of two 70 mt melting furnaces and the installation of a 105 mt twin chamber furnace. Air pollution control equipment is currently being installed and the pit is being prepared to accept all of the casting equipment which will be installed in 2017. This is all part of GARMCO’s remelt expansion project.

GARMCO designed the plant to meet stringent Bahraini safety and environmental regulations. The new plant will provide GARMCO with the capability to cast an additional 120,000 tonnes of aluminium slab products. Once the slabs are rolled, the finished products will exceed customer quality requirements, improve operational safety, and reduce production costs. The plant is to be fully operational by December 2017.

Fives, the turnkey construction contractor,achieved over 600,000 man hours without any lost time injuries. 2017 will be a challenging year for all personnel on this fast track project that commenced in March 2016 Commissioning of equipment is scheduled for April and the plant should be fully operational by December 2017.

 

 

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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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Brazilian Steel Producer Purchased Continuous Slab Caster

A two-strand continuous slab caster supplied by Primetals Technologies has gone on stream at Companhia Siderúrgica do Pecém (CSP), a Brazilian steel producer. The plant has a capacity of 3 million t of slabs per annum. The continuous slab caster is part of a new steel works in the Pecém Industrial and Port Complex in São Gonçalo do Amarante in the state of Ceará. Primetals received the order in 2012 from Posco E&C, a company based in South Korea.
The continuous slab caster has a machine radius of 9.5 m and a metallurgical length of 39.8 m. It produces slabs in thicknesses of 220, 250 and 300 mm, and in widths ranging from 1,100–2,300 mm. A wide range of steel grades are cast, from low-carbon structural steels to peritectic and micro-alloyed medium and high-carbon steels, such as ULC, LC, MC, HSLA and HC. The slabs are then rolled into plate and sheet metal for use in mechanical engineering, shipbuilding, boiler and pipeline construction. The maximum casting speed is 1.8 m/min. Primetals engineered the entire plant and supplied core components, the fluid systems, the basic and process automation, and technology packages. The project also included training the operator’s personnel, and supervising the construction and commissioning work.The scope of supply from Primetals included straight Smart Mold molds plus the DynaWidth technology package for dynamic width adjustment during casting. LevCon mold level control and an electromagnetic, multi-mode mold-stirring system were installed to ensure an optimum bath level in the mold. The DynaFlex mold oscillation provides flexible adaptation of the oscillation parameters. The caster’s strand-guide system has a remotely adjustable Smart Bender and Smart Segments which, together with DynaGap Soft Reduction 3D, means that slab thickness can be changed quickly and automatically. I-Star strand-guide rollers support the strand.The Dynacs 3D secondary cooling process model dynamically calculates a three-dimensional temperature profile along the whole length of the strand. This helps to determine precisely the working points of the secondary cooling and the final strand solidification in response to the casting speed, slab format and steel grade. The internal quality of the slabs is improved by using DynaGap Soft Reduction 3D. The roller gap is dynamically adjusted during final solidification based on the working points calculated by Dynacs 3D. DynaJet spray cooling with movable nozzles in the segments ensures uniform, optimum cooling of the slabs, and consequently a high quality surface.

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Foundry Sector’s Expectations

BOTW-50w  Source:  Foundry Gate

“India is the third largest manufacturer of metal castings globally, producing approx 10 million tonnes of castings in various metals.

The Institute of Indian Foundrymen (IIF) is the apex industry body promoting the competitiveness of India’s foundry industry. There are about 5,000 foundries in India largely in the MSME category.

The foundry or metal casting industry is a key component feeder for the various sectors such as auto, auto components, railways, agro, tractors, textile, cement making, electrical machinery, earthmoving machinery, power equipment, defence equipment, and aero and space industry its sustainable growth has become more important today than ever before given the emphasis of the government on “Make in India”.

Read More:  Foundry Sector’s Expectations

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Saudi Aramco Signs to Set Up High-End Forging & Casting Manufacturing Facility

Saudi Aramco has signed a Memorandum of Understanding (MoU) with GE (NYSE: GE) and Cividale SpA of Italy to build the Middle East and North Africa’s first-of-its-kind high-end forging & casting manufacturing facility that will serve the region’s maritime and energy industries.

Marking a joint investment of over US$400 million (SAR1.5 billion), the new facility, to be located in Ras Al-Khair under the Royal Commission of Jubail and Yanbu industrial area, aims to establish a high-value supply chain that boosts exports and economic competitiveness. Set to be operational in 2020, the plant will create 2,000 quality jobs in the Kingdom and catalyze the growth of Saudi small and medium enterprises (SMEs).

The MoU follows a preliminary partnership between Saudi Aramco and Cividale, a leading European producer in the steel and cast iron sector, to conduct feasibility studies for forging and casting manufacturing services in the Kingdom. GE has come on board to extend its expertise and investment in developing the world-class manufacturing plant through a joint venture between the three entities.

The Forging & Casting Manufacturing Facility complements plans by Saudi Aramco to develop several industrial projects in the Kingdom including a maritime project focused on building, maintenance, repair and overhaul (MRO) of offshore platforms, jack-ups, offshore service vessels and commercial tankers.

Saudi Aramco is also working with its partners to develop an onshore rig manufacturing facility for providing new build and MRO services to onshore rigs and systems; an engine manufacturing project for the manufacturing, maintenance and repair of diesel engines, manufacturing and repair of marine pumps; and an Energy Industrial City to accelerate manufacturing industries in the oil and gas sector.

The Forging & Casting Manufacturing Facility will serve all these projects in addition to providing the best-in-class services and technologies to downstream & other industries across the region and global markets. It will also support the ongoing emphasis of the government, under Saudi Vision 2030, to develop the mining sector of the Kingdom by creating a domestic source-market for various raw materials & supplies that go into the production line.

Abdallah I. Al-Saadan, Senior Vice President, Finance, Strategy & Development, Saudi Aramco, said: “The MoU reflects our ambition to create a robust supply chain that builds positive synergies in the oil and gas manufacturing sector. This builds on our deep commitment to support the goals of Saudi Vision 2030 to promote economic and industrial diversification in the Kingdom and boost localized manufacturing.”

Rami Qasem, President & CEO, GE Oil & Gas, Middle East, North Africa & Turkey said: “For the Forging & Casting Manufacturing Facility, we will leverage our already strong expertise in ‘Made in Saudi’ manufacturing. Together with our partners, we will actively engage Saudi SMEs to support the plant’s operations, and train & hire Saudi professionals, adding further value to the economy. By building a domestic forging and casting production unit, Saudi and regional customers can achieve greater operational efficiencies in product procurement, repair and service support.”

Antonio Valduga, President of Cividale, added: “The feasibility assessment study underlines the strong potential for a world-class manufacturing facility for forging and casting services in the Kingdom. Developing a full-fledged facility through the joint partnership will position Saudi Arabia as a technology and services hub for specialized equipment and services.”

The collaboration is a strong example of the public-private partnerships that the government fosters under Saudi Vision 2030 to develop local manufacturing capabilities that add significant value to the economy.

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Magna Announces New Aluminum Casting Facility in the UK

Magna International Inc. today announced it will build a new world-class aluminum casting facility in Telford, United Kingdom, to support Jaguar Land Rover, the UK’s leading vehicle manufacturer.

The new facility is expected to be approximately 225,000 square feet and will create up to 295 jobs at full capacity. Working with the UK Trade & Investment and the Automotive Investment Organization, along with financial support from the UK Government’s Regional Growth Fund, helped to secure this project. Construction is expected to start in the autumn of 2016.

Once production begins in 2018, the facility will use Magna’s innovative high-pressure vacuum die casting process to produce a number of advanced lightweight aluminum castings– a key building block in the next generation all-aluminum and multi-material vehicle architectures.  By using these types of castings, Magna helps automakers deliver maximum strength and stiffness and minimum weight, ultimately achieving better fuel economy, safety and handling.

“We are excited to work closely with Jaguar Land Rover in the development of this project which will bring the most advanced structural casting technologies to the UK,” said John Farrell, President of Cosma International, an operating unit of Magna International.   “As lightweighting continues to be a key technology driver, we are uniquely positioned to help automakers achieve optimal weight savings throughout the vehicle architecture.”

Magna, through its Cosma International operating unit, is one of the world’s premier suppliers providing a comprehensive range of body, chassis and engineering solutions to automakers around the world.

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Schuler Acquires Leading Die Manufacturer AWEBA

Schuler AG, the market leader in forming equipment, is to take over the die construction specialist AWEBA and thus greatly expand its activities in this business field. Based in Aue, Germany, the AWEBA Group is one of the world’s leading full-service providers of dies and fixtures. Under the terms of the purchase agreement, Schuler will acquire a 100 percent stake in AWEBA Werkzeugbau GmbH Aue.

The transaction is still subject to the approval of the relevant anti-trust authorities. AWEBA Werkzeugbau GmbH was previously held by private and institutional investors. The parties have agreed not to disclose any details about the purchase agreement.

AWEBA was founded in 1882 as “Bernhard Hiltmann Spezialfabrik für Schnitt und Stanzwerkzeug”. The company today supplies international customers in the automotive and electrical industries, as well as machine and plant manufacturers. The product portfolio includes forming, cutting, hydroforming, and die-casting dies, as well as fixtures and a comprehensive range of services.
In fiscal year 2015, the AWEBA Group generated sales revenue of around € 60 million.

Schuler CEO Stefan Klebert commented: “We are delighted to add a successfully managed company like AWEBA to our Group. With its high level of expertise in research and development and excellent engineering know-how, the company is a perfect fit for Schuler. The acquisition is part of our growth strategy. AWEBA complements our product portfolio in forming technology in line with market requirements and will expand and strengthen our existing activities in die construction.”

The AWEBA Group employs around 600 people, including almost 200 highly skilled engineers and toolmakers. The company owns 40 valuable patents in the field of die manufacturing.

AWEBA CEO Udo Binder stated: “Becoming a member of the Schuler Group opens up tremendous opportunities for the further expansion of AWEBA. Schuler’s global market standing will enable us to quickly grow our international presence and enhance our profile as a global system supplier. This gives AWEBA growth opportunities which would not have been achievable without Schuler.”

The AWEBA takeover is Schuler’s second major acquisition in the last twelve months. Last year, the company acquired a majority stake in the Chinese press manufacturer Yadon with annual sales of around € 110 million.

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Hitachi Metals Automotive Components to Be Division of Waupaca Foundry

Waupaca Foundry Inc., Waupaca, Wisconsin, announced it will merge with Hitachi Metals Automotive Components USA LLC (HMAC). The merger is part of a larger reorganization within Hitachi Metals Foundry America designed to position the integrated organization for growth and meet customer demand.

According to a news release, Waupaca Foundry will assume the assets and liabilities of HMAC. Both companies are currently subsidiaries of Hitachi Metals Foundry America (HMFA). After the merger, HMAC will become a division of Waupaca Foundry, but will continue to operate under the HMAC name.

Subject to customary conditions, the merger is expected to be complete on April 1.

Daily operations at Waupaca will not be impacted, and the merger is part of the firms’ strategic alignment.

“The merger with HMAC allows us to further integrate castings and value added services for our customers in diverse markets,” said Gary Gigante, CEO, Waupaca Foundry. “We are committed to being the world’s leading casting solutions provider, and this is a critical step in achieving that goal.”

In 2014, Hitachi Metals Ltd. purchased Waupaca Foundry from KPS Capital Partners LP, a New York-based private equity firm.

Waupaca Foundry produces gray iron, ductile iron and austempered ductile iron castings and employs more than 3,900 people at six manufacturing facilities, including three in Waupaca and others in Marinette, Wisconsin; Tell City, Indiana; and Etowah, Tennessee.

HMAC produces cast, machined and assembled ductile iron suspension and exhaust components for global automotive OEMs. It currently operates a machine and assembly plant in Effingham, Illinois, as well as a ductile iron casting facility in Lawrenceville, Pennsylvania.

The company employs 485 people across all locations.

“This reorganization further unites Hitachi Metals’ product design engineering expertise and materials development with Waupaca Foundry’s manufacturing excellence,” said Eddie Nakano, president and CEO, HMFA. “The merger will unite an experienced leadership team that is focused on delivering the most innovative products and technology to a growing base of global customers.”

HMAC CEO Mike Nikolai said the merger is a response to increased customer demand.

“Centralizing machine and assembly operations allows us to be more flexible in meeting the evolving demands of our customers,” Nikolai said. “We’ve already increased overall operational capacity and are positioning our organizations for long-term, sustainable growth.”

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