Closed-Loop Recycling • Mexican Aluminum Industry • Service Center Metals Ten Years & Growing Al Casting Conidence

Home , 1050 aluminium alloy, 5456 aluminium alloy, 7150 aluminium alloy, Alusil, Light Metal Age, Midas (comics)

• Closed-Loop Recycling • Mexican Aluminum Industry • Service Center Metals Ten Years & Growing Al Casting Conidence

Built on innovation and reined through experience, Wagstaff billet and ingot casting technologies are a gateway to proitability. Casthouses around the world rely on the history, experience, and service offered by Wagstaff to foster conidence within the casting operation. That conidence is valuable and necessary to safely cast aluminum and to ultimately maximize proits in the marketplace.

The leader in Direct Chill Casting Technology

› Casting Machines › Automation

› Rolling Ingot Casting Systems › Metal Level Control

› Billet Casting Systems › Worldwide Service and Support

To ind out how your operation can increase casting conidence Call +1 509 922 1404 | www.wagstaff.com

Directory of Secondary Aluminum Equipment Mfrs and Suppliers Index Page 71 Categories/Companies Page 72 Alphabetical Listing of Companies Page 76 DEPARTMENTS: Light Metal World ...... Page 80 New Equipment Spotlight ...... Page 84 Reg. U.S. Trademark Secondary News ...... Page 87 “The International Magazine of the Light Metal Industry” Extruder News ...... Page 88 Contracts & Expansions...... Page 90 July/August 2013 • Volume 71, No. 4 New Products/New Literature ...... Page 91 International Patent Calendar ...... Page 92 ARTICLES: Conference Calendar ...... Page 96 World Secondary Aluminum Industry Annual Review Classiieds ...... Page 97 By Rudolf P. Pawlek ...... Page 6 Personalities & Plants ...... Page 98 Service Center Metals: In a Land of Hope and Dreams By Joseph C. Benedyk ...... Page 18 COVER: This large, 6 x 7 inch aluminum extruded rectangular bar is one of Service Center Metals (SCM) 6061 Manifold Thunder Bar products. Aluminium Two Thousand Congress 2013 – Milan The Virginia extruder tailors its soft alloy extrusion products solely for Highlights of Extrusion Presentations service center customers. Premium bar products are designed for supe- By Joseph C. Benedyk ...... Page 24 rior machineability with elevated mechanical properties and commercial Second International Aluminum Recycling dimensional tolerances. At their ten year anniversary mark, SCM has Workshop, Trondheim, Norway also begun building a compact remelt plant. See story on page 18. By Anne Kvithyld and John Green ...... Page 30 Novelis Develops Sustainable Can Stock Copyright © 2013 by Fellom Publishing. All rights reserved. Interview with John Gardner, Novelis ...... Page 38 Articles may not be reproduced without written permission of the publisher. Grupo Cuprum: Mexico’s Largest Extrusion Company Publisher ...... ANN MARIE FELLOM By Andrea Svendsen...... Page 40 Associate Publisher ...... ERIC WESTLUND IMEDAL Congress Shows Robust Aluminum Industry Editor ...... Joseph C. Benedyk By Andrea Svendsen...... Page 44 Managing Editor ...... Andrea Svendsen Aluminum Recycling in the 21st Century: Circulation Manager ...... Claudia Compian Challenges and Opportunities Contributing Editor ...... Rudolf Pawlek By Marshall Jinlong Wang ...... Page 62 th LIGHT METAL AGE (ISSN 0024-3345) is published bi-monthly by Fellom Pub- 75 Anniversary for Gillespie & Powers lishing Co., 170 South Spruce Avenue, Suite 120, South San Francisco, CA Custom Designed Aluminum Melting ...... Page 66 94080-4519. SUBSCRIPTION RATES 2013, Hard Copy: 1 year U.S.— $52.00; 2 TMS Annual Meeting and Exhibition ...... Page 68 years— $66.00; 3 years— $80.00. Surface mail rates, 1 Year— $92.00; 2 years— $136.00; 3 years— $180.00. Airmail rates, 1 Year — $122.00; 2 years— $206.00; 3 Extrusion Industry News & Technology years— $290.00. Digital: 1 year— $35.00. Back issues $12.00 each plus postage. Special single copy prices for large directory issues— $15.00 plus postage. In- Flying Cut Puller Systems ...... Page 52 dex— $2.00 per year. Periodicals Postage Paid at South San Francisco, CA, and at The Beneits of Wet Blasting for Extrusion Die Shops ...... Page 54 additional mailing ofices. New Partnership Creates Tecalex USA ...... Page 56 POSTMASTER: Send address changes to LIGHT METAL AGE, 170 South th Spruce Avenue, Suite 120, South San Francisco, CA 94080-4519. Brightline Celebrates 60 ...... Page 58 Phone: (650) 588-8832 • FAX: (650) 588-0901 Turla Delivers Handling System for Automotive Line ...... Page 60 email: [email protected] • www.lightmetalage.com

4 LIGHT METAL AGE, AUGUST 2013

The Novelis Yeongju recycling and casting center that opened in October 2012 is the largest aluminum beverage can recycling facility in Asia. (Photo courtesy of Novelis Inc.) World Secondary Aluminum Industry Annual Review By Rudolf P. Pawlek, Contributing Editor

Editor’s Note: Companies covered in this review are those whose content is achieved, then one point is awarded.) Certain primary business is secondary aluminum production. However, limitations continue to prevent the aluminum industry this review is also comprised of companies with remelt facilities, from going to 100% recycled content including the avail- companies that process scrap from semifabricating processes (such ability and quality of recycled content sources, as well as as extrusion scrap, etc.), and companies that remelt aluminum the ability to maintain consistent inishes on products products (such as UBCs, automotive parts, etc.). with varying degrees of recycled materials versus those materials produced with higher concentrations of pri- This overview covers the period of June 2012 to June mary materials. 2013. In light of increasing energy and raw material pric- The demand for recycled aluminum for the automo- es for primary aluminum production, scrap is displac- tive market is also increasing, as auto manufacturers aim ing primary metal as feed for casthouses and foundries to not only decrease the weight in their vehicles, but also because it can cost 10-20% less. This has resulted in ris- to improve their carbon footprint across the entire value ing scrap prices and tight supply, which has caused some chain. smaller secondary smelters and recycling companies to close. Companies are looking more and more to increase Africa the worldwide amount of available scrap aluminum. Nigeria Novelis, Alcoa, and other organizations are investing in programs to increase the recycling rate of UBCs and In January 2013, the Federal Airports Authority of other scrap. Several companies are also starting to cre- Nigeria (FAAN) set up a special task force focused on ate closed-loop programs with their customers in order the disposal of abandoned aircraft in airports across the to ensure all scrap aluminum created during the manu- country. The aircraft, including models ranging from facturing process is sent back to the aluminum producer Fokker 28 and Embraer 100 to Boeing 727 and 737, will for recycling. be taken away, dismantled, and used as scrap aluminum Some companies have been making major capital infor recycling and conversion into corrugated aluminum vestments to expand their recycling capacities. Novelis, rooing sheet, sliding doors, windows, and other small- in particular, is in the process of doubling its worldwide scale industrial use. capacity through expansions at its facilities in Germany, Italy, South Korea, and Brazil. Both Alcoa and Aleris Re- South Africa cycling have invested in recycling expansions, as well, in the U.S. and Germany. In November 2012, Hulamin Limited entered into an Architects and the construction industry in general agreement with Bevcan, a division of Nampak Limited, continue to move towards a higher recycled content to supply aluminum sheet for the manufacture of alumi- product. Recycled content in aluminum-based products num bodied beverage cans. Deliveries to Bevcan are ex- is a valuable asset as it relates to LEED Certiication in pected to increase to 14,000 tons by 2015, in addition to buildings. The industry still operates under the LEED the can end and tab stock Hulamin already supplies. In 2009 edition, where recycled content materials can con- conjunction with this announcement, the company also tribute up to two points to a building’s total LEED points. reported that it is considering an appropriate investment (To achieve the two points the project must have at least in recycling infrastructure to reprocess UBCs back into 20% recycled content, based on cost of the total value can body sheet in a closed-loop recycling system. Bev- of the materials in the project. If at least 10% recycled erage cans in South Africa, other than for a small per-

6 LIGHT METAL AGE, AUGUST 2013 THORPE TECHNOLOGIES INC ENGINEERS · CONSTRUCTORS OF THERMAL PROCESSING EQUIPMENT INDUSTRIAL FURNACES · THERMAL OXIDIZERS · COMBUSTION SYSTEMS

EQUIPMENT FOR THE ALUMINUM INDUSTRY

QUALITY ENGINEERING AND CONSTRUCTION FOR PROVEN EQUIPMENT RELIABILITY AND PRODUCTIVITY THORPE TECHNOLOGIES INC ENGINEERS · CONSTRUCTORS OF THERMAL PROCESSING EQUIPMENT INDUSTRIAL FURNACES · THERMAL OXIDIZERS · COMBUSTION SYSTEMS 449 W Allen Ave · Suite 119 · San Dimas, CA · 91773 · Phone (562) 903-8230 · FAX (562) 903-8236 www.thorpetech.com - [email protected] centage of imported all-aluminum cans, have until now cycling joint venture, the undisputed leader in UBC recy- been made from steel tin-plate with an aluminum end. cling. The two companies previously were partners in the Currently, over 70% of the steel cans produced in South joint venture, which purchased more recycled cans than Africa are recovered for recycling and the recycling rate any other group, anywhere in the world. As a result of is expected to increase as a result of the higher intrinsic the new agreement, Alcoa took over full ownership and value of the aluminum in the new all-aluminum cans. operation of Evermore Recycling in August 2012, and made it part of Alcoa’s Global Packaging group. Alcoa’s Americas Evermore Recycling continues to be based in Nashville, Brazil TN. Employees of the joint venture were being given opportunities to join the respective companies. At the end of October 2012, Brazil led the world again In September, Alcoa, Alcoa Foundation, and Keep in aluminum can recycling, with 98.3% of cans recycled America Beautiful (KAB) announced a national com- by the industry in 2011. Brazil has been ranked number mitment to increase U.S. recycling rates at the Clinton one in aluminum can recycling since 2001, with 248,700 Global Initiative Annual Meeting. “ Action to Accelerate tonnes of aluminum cans recycled in 2011 out of 253,100 Recycling” will generate awareness, create incentives, tonnes consumed. Aluminum can consumption is ex- and provide recycling access and infrastructure so as to pected to show a 7% year-on-year increase in Brazil. Recy- increase U.S. recycling of aluminum, plastic, glass, and cling 248,700 tonnes of aluminum saves some 3,780 GWh paper. The commitment, which includes US$2m in fund- of electricity for the country, which is equivalent to the ing from Alcoa and Alcoa Foundation, is expected to domestic consumption of 6.5 million people in two mil- engage millions of Americans, and increase the current lion households. In May 2013, it was reported that Brazil U.S. recycling rate by 10%. Increasing the recycling rate recycles 21-23 billion aluminum cans. On average, each to 75% would generate close to 300 additional tonnes of citizen uses about 80 beverage cans per year in Brazil, recycled content, resulting in the avoidance of more than compared with 78 cans per year in Western Europe and 2,850 tons of greenhouse gas emissions. A recent report 32 cans per year in China. The U.S., at 350 cans per year, from the Blue-Green Alliance also found that a 75% reis the runaway leader in consumption. cycling rate for all municipal solid waste creates 1.5 mil- In August 2012, Novelis announced it was in the pro- lion jobs. “ Action to Accelerate Recycling” includes the cess of doubling its worldwide recycling capacity from 1.2 design and launch of seven innovative global recycling million to 2.1 million tonnes at its facilities in Germany, programs, such as Alcoa and Alcoa Foundation initiatives Italy, South Korea, and Brazil. Work at the company’s Bra- to increase awareness via a “ Pass the Can” Facebook app zilian subsidiary in Pindamonhangaba was ongoing, with (with donations to aid recycling programs), university US$35 million invested to double its recycling capacity to recycling challenges and youth led aluminum recycling 400,000 tpy. This will place the Brazilian branch ahead of drives, and programs to educate consumers about the re- its peers elsewhere in the world once it is completed in cyclability of pet food cans. Keep America Beautiful will 2014. Novelis operates ive can-collecting centers in the focus on initiatives to solicit the industry to pledge a 10% country, and also acquires scrap from other can collec- increase in the recycling of aluminum, paper, plastic, and tors and cooperatives. A smaller portion of scrap is im- glass in the workplace through a variety of programs, a ported from countries like the U.K., Saudi Arabia, Chile, multi-media campaign to reach 200 million people, and and Peru. Novelis recycles worldwide about 40 billion a program to provide recycling access and develop best UBCs per year. practices in 4-6 under served public venues (such as state fairs) with funding from Alcoa. U.S. In October, Alcoa Foundation and DoSomething.org announced “ 50 Cans,” the biggest youth-led aluminum In June 2012, the Aluminum Association testiied be- can recycling drive in the country, targeting high school fore the U.S. House of Representative’s Energy and Com- students. The goal of the drive was to activate a minimum merce Committee, Subcommittee on Environment and of 40,000 young people across the U.S. to participate in the Economy in regards to discussions on the draft bill, the campaign, which ran from October 24 through De- entitled “ The Increasing Manufacturing Competitiveness cember 18, 2012. “ 50 Cans” used an innovative model to through Improved Recycling Act of 2012.” Charles John- educate and encourage teens to recycle aluminum cans son, Association vice president for Environment, Health that otherwise would be thrown in the trash. Using the and Safety, noted, “ In 2010, Americans recycled US$1.6 Web, social media, and text messaging, teens who ran billion in aluminum cans. If the industry’s beverage can drives had the chance to win a US$5,000 scholarship, as recycling of 75% was achieved, the payback to Ameri- well as additional opportunities to win scholarships by can consumers would be US$2.1 billion.” He pointed sharing statistics about aluminum recycling via text mes- to aluminum as an industry that provides positive eco- sages. nomic impact, while mitigating negative environmental In October, Alcoa recognized its Top North American impacts, due in part to the fact that increasing aluminum Scrap Suppliers for 2012. This marks the eighth consecu- recycling increases energy eficiency. “The aluminum in - tive year that Alcoa’s Scrap purchasing group has hon- dustry’s position in favor of recycling is not green wash- ored the best suppliers in terms of safety, quality, volume, ing,” he said. “ It’s green business for us.” breadth of supply to multiple locations, and delivery per- In August 2012, the Aluminum Association, the Can formance. These suppliers are: American Iron and Metal Manufacturers Institute, and the Institute of Scrap Recy- LP (Montreal, Canada), Atlas Metal & Iron Corporation cling Industries reported that the U.S. recycling rate for (Denver, CO), Commercial Metals Company (Dallas, aluminum beverage containers jumped seven percentage TX), Jack Engle & Company (Los Angeles, CA), Louis points, from 58.1% to 65.1% for 2011. This means 61 bil- Padnos Iron and Metal Company (Holland, MI), Omni- lion cans were recycled in 2011, a milestone that marks source & Omnisource SE Corp. (Fort Wayne, SC), Ser- solid progress toward the industry’s goal of a 75% recycle vice Aluminum Corporation (Baltimore, MD), Schupan rate. & Sons Inc. (Kalamazoo, MI), State Metal Industries In July 2012, Alcoa reached an agreement with Novelis (Camden, NJ), and United Scrap Metal Inc. (Cicero, IL). whereby Alcoa assumed full control of the Evermore Re- In May, Alcoa announced that its US$21 million Alcoa

8 LIGHT METAL AGE, AUGUST 2013

Wheel and Transportation Products casthouse expansion other industry sources suggested that Coca-Cola could at its Barberton, OH, plant is expected to cut in half the coordinate their UBC-buying practices with tolling sup- total speciic energy used to recycle aluminum for forged pliers in a way that would mitigate any notable spot price wheels, reducing greenhouse gases, and increasing the increases. The irst trader also said Coca-Cola could use its overall eficiency and sustainability of the company’s push into UBC scrap purchasing as a bargaining tool in manufacturing process. One-hundred million pounds negotiating future can sheet supply contracts. Coca-Cola’s (43,500 tpy) of recycled scrap aluminum is enough to Bottlers’ Sales & Services (CCBSS) unit signed a multiyear make two million new Alcoa forged aluminum wheels. deal with Novelis covering the supply of can body, end, The casthouse takes chips and solids from an existing Al- and tab stock earlier in 2012. coa wheel machining plant in Barberton, as well as from In July 2012, Novelis announced its new organization Alcoa’s Cleveland, OH, forging plant, and recycles them to procure UBCs in North America, which would make into aluminum billets. The billets are then shipped to the company the largest UBC buyer in the region. The other wheel-processing facilities to forge into aluminum announcement followed the company’s decision to with- wheels. Locating the new facility on the same campus of draw from its Evermore joint venture with Alcoa. All of the an existing wheel production facility has led to an ap- UBCs procured directly through the new organization will proximately 90% cut in transportation-related energy be used for its recycling plants in Greensboro, GA; Berea, use. Construction of the 50,000 sq ft facility began in July KY; and Oswego, NY. Novelis worldwide currently buys the 2011. It is now up and running at full capacity and has equivalent of 40 billion cans a year, worth an estimated created more than 30 full-time jobs. US$1 billion. Novelis expects its global consumption of In June 2013, Alcoa and Boeing formed a closed-loop UBCs to grow to more than 60 billion cans by 2015. program to signiicantly increase the recycling of inter- In January 2013, Novelis announced it was looking to set nal aluminum aerospace alloys used during the produc- up closed-loop scrap supply chains with its North Ameri- tion of Boeing airplanes. The announcement was made can automotive aluminum customers, to meet an antici- at the Paris Air Show at Le Bourget, France. The pro- pated rapid growth in automotive sheet demand in 2013. gram will entail inter-modal transport of aluminum alloy The increase in auto demand will drive increased sales of scrap, including advanced alloys, from Boeing facilities lat-rolled sheet, but will also drive the generation of more in Auburn, WA, and Wichita, KS (as well as third-party scrap. Novelis is looking at setting up closed loops with processors in Auburn) to Alcoa’s Lafayette, IN, facility auto customers to obtain their scrap for converting it back for melting and recycling into new aerospace materials. to automotive sheet again. The company has a goal of in- The program calls for recycling of 2xxx and 7xxx alumi- creasing its use of non-can scrap from 1m tons in 2011 to num alloys used in the production of wing and fuselage 2m tons annually by 2015, and to 4m tons by 2020. This di- components of Boeing airplanes. The forms will include versiication into using more non-can scrap will help keep aluminum extrusions, sheet, and plate products. At the purchasing costs at a manageable level, and Novelis must outset, approximately 8 million lbs per year (3.630 tpy) of add scrap processing capacity in all of the regions in which aluminum is expected to be recycled. The new program it operates, including North America, to reach its goal of also lays the groundwork for expansion of the effort to 80% recycled content by 2020. capture scrap from Boeing sub-contractors, and to be ex- Also in January, Novelis talked about its global alumi- panded to include other aluminum scrap forms, includ- num situation. Record high aluminum premiums are a ing chips that remain after the machining of parts. function of the inancing deals locking up metal in warehouses. Novelis is moving from a dependence on primary aluminum by increasing scrap purchase. Aluminum can bodies typically have a low primary content, but value- added products in other sectors have a higher primary base. The company purchases about 3.5 million tpy of aluminum, equivalent to about 13,500 tons a day on a global basis, in the form of a mix of P1020 ingot, sheet from various primary producers, and scrap. It produces nearly 20% of the world’s lat-rolled aluminum products, and its customers include Coca-Cola Co. and automakers Ford, Audi, and BMW.

Asia China

The secondary aluminum industry in China has high Wing spar of a 777 under construction at the Boeing plant in Everette, capacity with a large number of producers; however, WA. The new closed-loop program with Alcoa will increase recycling industry-related statistics are incomplete. Based on data of internal aluminum aerospace alloys. from the China Nonferrous Metals Industry Association Recycling Metal Branch (CMRA), output of second- At the end of July 2012, Coca-Cola Recycling, Atlanta, ary aluminum hit 4.8 million tons in 2012, but Sunlight GA, announced it was seeking to boost its UBC scrap pur- Metal’s analytical and statistical model shows it ended up chasing by at least 50% in 2013, having contracted to pur- at 5.6 million tons, up 7.5% year-on-year. In 2012, China chase several hundred million pounds of UBC in 2012. consumed 5.13 million tons of secondary aluminum, up This led some traders to forecast further price increases 10.7%, and imported 2.593 million tons, down 3.5% and as competition for UBCs mounts, even as others expect shrinking for three years running. At present, import to see no change as a result, reported Metal Bulletin. UBC contributes to one-third of domestic output. Sunlight traders said that the company was probably looking at buy- Metal believes domestic scrap is ramping up with a coming tolling capacity at a major can sheet manufacturer, pound annual growth rate (CAGR) of 14% for the com- whereby they would simply pay a conversion cost to have ing three years, and that by year 2015 China will see 6.1 their purchased UBCs turned into can sheet. However, million tons of sorting scrap, equivalent to 5 million tons

10 LIGHT METAL AGE, AUGUST 2013 Aluminum Heat Processing Equipment

For over 50 years Consolidated Engineering Company has built a reputation as a leader in Aluminum quality heat processing equipment. With over 3,400 installations worldwide, a comprehensive background in innovative heat processing technologies and over 100 U.S. and foreign patents, CEC can help turn any heat processing challenge for extruders or rolling mills into a successful solution. Some of the equipment offered includes:

• Horizontal Heat Treat Systems • Atmosphere Coil Annealing Furnaces • Homogenizing Furnaces with CEC’s Variable Cool • Annealing Furnaces Fixed and Mobile • Delacquering Systems • Slab & Billet Preheaters • Nitriding Furnaces • Sow Preheating Furnaces • Aging Ovens • Forge Preheaters • Quick Quench Furnaces

To request a quote or for more information, please visit us at: WWW.CEC-INTL.COM

CONSOLIDATED ENGINEERING COMPANY Quality Heat Processing Technology U.S. HEADQUARTERS 1.866.486.6836 or 770.422.5100 of secondary aluminum, and output will hit 7.5 million In April 2013, Yechiu announced that its greenield proj- tons, but these also depend upon the size of import. ect to expand casting alloy production with 273,600 tpy of CMRA stated that rapid progress took place for the capacity would be completed between December 2015 and secondary aluminum industry in 2012, indicating sub- December 2016 and that its R&D center would be com- stantial energy eficiency and emission reduction. Energypleted between December 2013 and December 2014. This consumption averaged at 110 kg of standard coal per expansion was planned following the company’s listing in ton of secondary aluminum, down 30% from 2008. Data the Shanghai Stock Exchange on April 23, 2012 and raising from Sunlight Metal shows that more large-scale produc- 1,365 million yuan (US$222 million), but no rapid progress ers came on-stream, with ten new producers, each boast- was achieved until 2013, owing to insuficient space for the ing over 300,000 tons of capacity annually. project. Yechiu is the third largest producer of secondary Over capacity is the key challenge for the secondary aluminum in China. On April 12, 2013, the company invest- aluminum sector in China. According to CMRA, ca- ed 150 million yuan (US$24.4 million) on its wholly-owned pacity utilization rate in 2012 was only 70%, indicating Yechiu (Malaysia) project for the expansion of alloy ingot 2,000 kt plus of over capacity. Scrap prices averaged with 218,800 tpy of capacity. By late 2012, Yechiu owned 13,108 yuan/t (US$2,135/t) in 2012, down 4%, and 320,000 tpy of capacity, of which 269,000 tons was from its ADC12 alloy at 16,109 yuan/t (US$2,623/t), down 9%. Taicang facility in Jiangsu and 51,000 tpy from its Malaysian Unfair domestic competition and a chaotic market is operation. Upon the expansions in both China and Malay- driving the secondary aluminum industry into meager sia, its alloy capacity will hit 760,000 tpy by late 2016. proits and even tighter inancial straits. Despite this, In March 2013, Delta Aluminium Industry in Zhaoq- top producers in 2012 still expanded their capacity, ei- ing, Guangdong, a joint venture between Daiki Alumini- ther locally or elsewhere. They hoped to cut down op- um Industry and Mega Sunny, completed a technical up- erational cost and improve market share by expansion date of its third expansion project. Following the comple- or building greenield facilities located near automak- tion of its third expansion project with a new greenield ers and casthouses, aiming for direct supply of molten facility with 70,000 tpy of capacity in February 2012, the aluminum alloy to die casting lines. Greenield and ex- company’s capacity was brought to 220,000 tpy. At pres- pansion projects in 2012 included the following. ent, the company owns 300,000 tpy of alloy capacity. In March 2012, Longda Aluminum Industry (Yantai), the ifth plant of Lizhong Group, came on-stream with India 35,000 tpy of casting alloy in Yantai, Shandong. Now the group owns 600,000 tpy of capacity, related to function At the end of July 2012, Japan’s Nikkei MC Aluminium alloy, casting alloy, and wrought alloy. In the same month, Co. (NMA) and India’s Century Metals Recycling Private the group began construction on Changchun Longda Ltd. signed a joint venture agreement to build a 42,000-tpy Aluminum Industry, its sixth alloy plant scheduled to be secondary aluminum alloy plant in Haryana, India. Apart put into operation in 2013. from aluminum alloy ingots, it will also service nearby cus- In August 2012, following the construction and opera- tomers with over-the-road molten metal supplies. NMA’s tion of secondary aluminum facilities in Taiwan, Shang- aim in starting business in India is to keep pace with the hai, Fujian, and Chongqing, Sigma Group put on-stream country’s rapidly growing aluminum market due to in- a greenield facility in Rizhao, Shandong, with 100,000 creased auto production. The new company, named CMR tpy of capacity, mainly serving Hyundai Motor Group. Nikkei India Private Ltd. will have an annual production ca- Sigma Group is the largest producer of secondary alumi- pacity of 42,000 tons, and will start production in October num in China. With 800,000 tpy of capacity in operation, 2013. It will use imported aluminum scrap as raw material. the group is also constructing a sixth facility in Chang- chun, Jilin, dedicated to products for the FAW Group. By Saudi Arabia 2015, its total capacity will hit 1 million tpy. In June 2012, Gulf Extrusions was awarded a contract by an institution in Saudi Arabia to supply 800 tons of X-ECO recycled aluminum. The product contains 80% post-consumer recycled content. According to the company, it is the irst extrusion irm in the Gulf region to supply alloys from recycled aluminum.

South Korea

In October 2012, Novelis announced the opening of its aluminum recycling and casting center at its Yeongju facility, now the largest aluminum beverage can recycling center in Asia. The Yeongju recycling center is part of a multi-year, US$400 million expansion of Novelis’ operations in Korea. Asia is the world’s fastest growing market for rolled aluminum for beverage cans, cars, and consum- Sigma’s factory in Shanghai. er electronics. This project will have a capacity of 265,000 tpy, and will increase the company’s total consumption of In August 2012, Chongqing Soonbest Aluminum Alloy recycled aluminum to over 1.4 million tpy. Novelis expects moved to its new location in Hechuan District, Chong- to be a major buyer of aluminum scrap throughout Asia qing, with 66 acres of area and 300,000 tpy of capacity. The due to this investment. UBCs and other aluminum scrap company also began construction on a greenield facility will be processed by the new facility for remelting and cast- in Fuling, Chongqing with 100,000 tpy of capacity and an- ing into sheet ingot that will be rolled at the company’s other project with 100,000 tpy of capacity in Qingyuan, Yeongju and Ulsan plants. When running at full capacity, Guangdong. By late 2012, its integrated capacity totaled the new operation will add nearly 80 new positions to Nov- 500,000 tpy. elis’ 1,200 employee workforce in Korea.

12 LIGHT METAL AGE, AUGUST 2013 INDUSTRIAL FURNACES ENGINEERING REFRACTORY SERVICES

  E 

MASS FLOW DELAQUERING SYSTEMS

TYPICAL LAYOUT FOR SECONDARY ALUMINUM RECYCLING

SIDEWELL MELTING FURNACE AUTO TAPPER FOR SAFER TRANSFERS

GILLESPIE POWERS INC T D S L MO USA T F E V Taiwan are consumed outside the home, for example at the workplace or events and festivals. For this purpose, EAA has de- At the end of September 2012, Hydro entered into a veloped the “ Every Can Counts” concept, which originally binding agreement to sell its aluminum remelt plant in started in the U.K. and has meanwhile been introduced in Taiwan to Ting Sin Metal Co. Ltd. The transaction closed France, Austria, Romania, and Hungary, with Ireland to join in October. Ting Sin Metal, a company already in the Tai- soon. “ Every Can Counts” points out the importance of re- wanese aluminum remelt market, will take over the Hydro cycling each and every beverage can, regardless of where its Aluminium Taiwan operations, while Hydro will focus on contents are actually consumed. EAA continues to encour- supplying primary metal products to Taiwan. The remelter age the local authorities and waste management companies has a capacity of about 75,000 tpy of extrusion ingot, and is to improve existing collection and sorting facilities by us- mainly serving the Taiwanese market. ing the latest available sorting technologies, such as eddy currents and high-tech recognition systems, which quickly United Arab Emirates separate aluminum packaging items from other packaging. In this respect, EAA is happy with the recent European Par- In February 2013, the Emirates Environmental Group liament report on “Resource Eficiency,” which calls on the (EEG) reported that every year the United Arab Emir- member states to encourage the use of such technologies. ates (UAE) consumes more than 500 million aluminum Additionally, the European Parliament for the irst time rec- beverage cans and collects approximately 5% for recy- ognized materials, such as metals, as “ permanent materials.” cling, compared to the global average of 63%. In order Due to their characteristics, aluminum and other metals are to increase the number of aluminum cans collected for ininitely recyclable, and thus from an environmental point recycling, the organization has launched initiatives to of view are at an equal level with existing categories, such as encourage various segments of the community (institu- renewable and biodegradable materials. tions, government, and private entities) to participate in recycling. “ As one of the GCC’s largest beverage com- France panies, Aujan Coca Cola Beverages Company (ACCBC) and Rani Refreshments places great importance on the In March 2013, Constellium held a major ceremony to environmental sustainability of the business. It is, there- present to customers and partners its ground-breaking fore, important for us that the packaging is recovered casthouse in Issoire Puy-de-Dôme, France, dedicated to and reclaimed,” said Roland Ebelt, ceo of Rani Refresh- low density aluminum-lithium alloys. The event signals ments, one of the companies working with the EEG. The the industrialization of its Airware® alloy technology, organization managed to collect 6,533 kg of cans on Can which demonstrates a unique combination of strength, Collection Day, held February 28th, and aims to reach 25 lightness, resistance to fatigue, and recyclability. Airware tons before the end of 2013. has been selected for the Airbus A350 XWB (internal In April 2013, Cast Aluminium Industries (CAI), a mid- wing structures, fuselage), the Bombardier C-Series (fu- stream aluminum producer and recycler, signed a con- selage), and the SpaceX Falcon 9 rocket. Beyond product tract with Khalifa Industrial Zone Abu Dhabi (Kizad) for innovation, the company had to reinvent some manufac- the long term allocation of 33,000 sq m of land in close turing processes to industrialize this technology, adopt- proximity to Emirates Aluminium (EMAL). CAI special- ing a 360° approach to innovation and developing a new izes in aluminum dross recycling and will be the irst to process to make the recycling of Airware chips possible. represent “ horizontal integration” in Kizad’s aluminum A total amount of €52 million (US$68.6 million) was ded- cluster. By setting up a facility in Kizad, the company will icated to this project, which included a pilot phase that be able to serve its current client base, including EMAL, took place in its R&D center in Voreppe (Isère) three DUBAL, Alba, and Qatalum, as well as downstream Gulf years ago. industries. CAI expects to initially export 300 TEUs (con- The company is also engaged in working with aero- tainers) from the Khalifa Port when the new facility com- space industry partners to maximize recycling opportu- mences operations in the third quarter of 2014. nities and reduce environmental footprint, noting that 6,000 aircraft are scheduled for retirement by 2025. Europe Thus, Constellium is a collaborating industrial partner in the EU’s Process for Advanced Management of End-of- In July 2012, the European Aluminium Association Life Aircraft (PAMELA) project, which aims to recycle a (EAA) reported that two out of three aluminum bever- large part of these aircrafts’ aluminum structures. age cans are recycled in Europe. The overall recycling rate for aluminum beverage cans in the European Union (EU-27), including European Free Trade Association (EFTA) countries and Turkey, increased by 2.4% to 66.7% in 2010. After the dificult economic situation in the pre - vious years, the consumption of aluminum beverage cans increased by a further 2 billion units to a total of 36 billion cans in 2010. This means that at least 24 billion aluminum beverage cans were recycled, resulting in a total greenhouse gas saving of 2.5 million tonnes— the equivalent of taking 1 million passenger cars off the roads for a whole year. The EAA is conident that Europe should be able to recycle three out of four cans by around 2015 with further growth potential up to 2020. Several European countries are already close to or above this result, due to their highly eficient and well-established collection and sorting infrastructures. In order to capture the remaining cans, the aluminum Constellium held a ribbon cutting ceremony to present its new cast- industry and beverage can makers are focusing on cans that house in Issoire, dedicated to the production of Airware products.

14 LIGHT METAL AGE, AUGUST 2013 Germany

In July 2012, Aleris Recycling installed a new two-chamber preheat shaft furnace at its Deizisau Works in Ger- many. The installation will help the company return the broadest possible range of aluminum scrap to the production cycle using the smallest amount of energy possible. This is especially important for scrap grades that contain impurities, such as aluminum lids for yogurt containers, which are lacquered and require additional processing. The new Hertwich Ecomelt furnace, said the company, is well-suited to this kind of scrap. The furnace has increased the plant’s capacity by 20%. The liquid aluminum produced at Deizisau is used for the production of cylinder heads for an automotive manufacturer in the area. Novelis began expanding its Goettingen plant to meet growing de- In August 2012, Aleris acquired the casthouse of Vo- mand for recyclable automotive sheet. (Photo courtesy of Novelis Inc.) erde Aluminium (Voerdal) in Germany for an undis- closed fee, after Voerdal declared insolvency in May In May 2013, Novelis announced the expansion of 2012. The casthouse gives Aleris an additional casting its automotive sheet production capacity in Europe, by capacity of 115,000 tpy and increases Aleris’s manufac- adapting its Goettingen plant in Germany to help meet turing lexibility, as well as its inishing and recycling -ca growing demand for recyclable aluminum sheet for au- pacity. Voerdal is a long-time supplier of rolling ingot and tomobile manufacture. The plant will produce 20,000 billet to Aleris. The casthouse assures that Aleris will have tpy of automotive sheet, and a planned second phase an uninterrupted supply of product to meet increasing will double that capacity. Goettingen currently produces customer demand. high-quality sheet for the lithographic and packaging In September 2012, Norsk Hydro ASA announced that markets, as well as painted sheet for a variety of appli- it would replace the less cost-eficient remelting of cold cations. It also produces aluminum bottles, cartridges, metal with its in-house primary liquid metal sourcing for cans, and housings using the impact extrusion process. its Neuss and Grevenbroich rolling mills. In preparation for the ramp up of primary sourcing in Neuss, Hydro has Italy secured power contracts with Swedish energy group Vat- tenfall, totaling 2.2 TWh (250 MW) annually over ive In May 2013, Novelis announced the opening of the years. This switch to primary metal will allow the compa- €12-million (US$15.5 million) expanded aluminum re- ny to resume some of the curtailed production at Neuss, cycling and casting operation in Pieve Emanuele, includ- increasing production to around 150,000 tpy during the ing the installation of an Ecomelt scrap melting furnace irst half of 2013. of the PS-80 type with preheat shaft. The new furnace In November 2012, Novelis broke ground on a US$250 increases the recycling rate at the plant from 34% to 80% million aluminum recycling and casting center at its and is designed for processing 80 tons of metal per day. plant in Nachterstedt, Germany. Constructed adjacent to The Pieve plant is an integrated recycling, continuous the company’s existing aluminum rolling mill, the new casting, rolling, and inishing operation. The aluminum center will enable the company to produce 400,000 tpy of sheet and coil produced at the facility is sold to end users aluminum sheet ingot from recycled material and is pro- in a number of industrial and construction markets. The jected to be the world’s largest aluminum recycling cen- Pieve plant also supplies aluminum sheet to other Nov- ter. The center will process UBCs as well as other forms elis plants in Bresso, Italy and Germany, where it is proof aluminum scrap from across continental Europe. The cessed into pre-painted, textured, and bright inish mate- company expects the center to create 200 new jobs. In rial for use in transportation, construction, and industrial June 2013, the company celebrated a rooing ceremony applications, such as rooing, architectural cladding, and at the Nachterstedt plant, showing that the project is on domestic appliances. The expanded capacity in Italy also track for commissioning in mid-2014. frees up capacity elsewhere in the Novelis Europe system In April 2013, Novelis signed an agreement with that is needed for use in growth markets. Spanish energy solutions provider Abengoa, through its industrial waste recycling division Befesa, for the management of all of the aluminum dross produced by the company’s Nachterstedt recycling plant. Abengoa will build an aluminum recycling plant in the town of Bernburg, in the region of Saxony-Anhalt in the east of the country near to the Novelis plant, which will involve an investment of approximately €30 million (US$39 million). The new plant will produce 50,000 tpy of aluminum casting alloys in addition to its recovery of aluminum from dross produced at Novelis’s facility, which Befesa will then return to Novelis for reuse in a closed- loop arrangement. The plant will launch in 2014, and take the company’s total processing capacity at its nine European recycling plants to 1 million tpy of aluminum waste. With this new project, Abengoa will become the leading company in integrated aluminum waste recycling in Germany and will reinforce its position as the Ecomelt scrap melting furnace installed at the newly expanded recy- European leader in this sector. cling and casting plant at Pieve Emanuele.

LIGHT METAL AGE, AUGUST 2013 15 Norway (Aluminium, No. 1– 2, 2011) and will account for between 30% and 80% of all raw materials in the future in various In July 2012, Hydro recycled aluminum from a Ca- production programs. nadian Halifax plane that was shot down in Belgium in 1944 to create the sheet panels that form the roof of the U.K. recently inaugurated RAF Bomber Command Associa- tion Memorial in London. The company donated its ser- In October 2012, Bridgnorth Aluminium (Star Litho), vices, remelting the aluminum recovered from the WWII one of Europe’s leading producers of lithographic strip, bomber at its plant in Sunndal, Norway, and then turning ordered a complete brownield casthouse expansion it into coated metal plates at its Holmestrand rolling mill. from Mechatherm to produce slabs for its state-of-the-art In August 2012, Hydro announced plans to stop remelt rolling mill and stretch leveling line. Bridgnorth focuses operations at its Årdal plant. The two casthouses that pro- on maintaining a clean alloy system with a high purity duce sheet ingot and primary foundry alloys (PFA) were aluminum alloy product range and internal recycling of using remelting of cold metal to ill capacity, which was process scrap. Mechatherm will supply a 45 tonne top- found to be unproitable. Instead, the sheet ingot cast- loading tilting-melting furnace with Bloom twin head house will handle liquid metal from on-site primary pro- regenerative burners, rated for a melt rate of 12 tonnes duction and the PFA casting operations will no longer be per hour, which will operate with an Altek Sibre Force needed. under-hearth EMS. The melting furnace will feed a new 45 tonne holding furnace and new 45 tonne VDC slab Poland casting machine. The complete casting process will be fully automated, including all functions from the hold- In November 2012, Polish cast alloy producer Alumet- ing furnace through the metal treatment systems to the al announced it will increase its capacity to 180,000 tpy casting machine, including a mold metal level control of secondary aluminum by 2015. Bucking the trend for system. A SCADA system will be provided to monitor all production cutbacks among other European secondary equipment diagnostics. The project was delayed and irst producers, the company looks to take advantage of the metal is expected in 2014. growing demand for material in Poland and other east- In February 2013, billet producer Anglesey Aluminium ern European countries. Alumetal increased its capacity Metal (AAM) announced the closure of its 65,000 tpy from 90,000 tpy to 100,000 tpy in 2012, and its goal is remelt facility in Holyhead, Wales. Major losses due to to increase its market share from 4 to 6% by 2015. It greater competition in the market, material cost increas- will do this by building a new plant in Germany, due for es and a decline in demand for its products were the rea- completion by the end of 2014, with a capacity of 80,000 son for the closure. Since the smelter ceased its smelting tpy. The irst half of 2013 will be dificult, but during capacities in 2009, due to the company being unable to the second half, Alumetal expects some improvement. secure a commercially viable power contract, AAM has During this period the market should clear some of its been running remelt operations and producing billet for overcapacity, and some companies may even be forced the extrusion market. In the last three years, it produced into bankruptcy, which will leave room for the compa- nearly 250,000 tons of extrusion billets. The company, ny’s expansion. which is 51% owned by Rio Tinto, had been working to identify money saving and value-creation potential, along Russia with other options to ensure the site’s future viability and to offset the losses, but was ultimately unsuccessful. A In June 2013, UC Rusal and Israeli company Omen small team will continue working at the site to carry out High Pressure Die Casting, which specializes in the pro- the decommissioning process and to maintain the site duction of automotive components from non-ferrous until a buyer can be found. metals, announced the signing of a MOU outlining de- In March 2013, Jaguar Land Rover announced that it tails of the creation of a joint venture to produce automo- is developing a new alloy, called RivAlloy, which will have tive components for the promising domestic car market a higher recycled aluminum content. The chemistry of of Russia and CIS. The joint venture, which is to be held the alloy will allow it to tolerate higher levels of impuri- in equal share (50/50), will be based on a production ties from aluminum scrap castings that were previously site of the Volkhov aluminum smelter (VAZ). Rusal will discarded. The new alloy compliments the company’s on- provide the joint venture with a 10,000-15,000 sq m pro- going research into recycled aluminum through both its duction and operation space with a ready infrastructure REALCAR (REcycled ALuminum CAR) and REALCAR 2 and will supply non-alloyed secondary aluminum in 500 projects, which aim to establish closed-loop recycling for kg sows. The retroitting of the production site is made in aluminum and increase the use of recycled aluminum in line with the company’s complex capacity optimization program. Aluminum production at VAZ will be substitut- ed with the production of value-added products.

Slovenia

In November 2012, Impol from Slovenska Bistrica, placed an order with Hertwich Engineering, Austria, for the supply and erection of an Ecomelt scrap melting furnace of the PS-120 type with preheat shaft to be commissioned in July 2013. The production capacity of the furnace is 120 tonnes per day of predominantly proile scrap and sheet metal. In its 2012 Annual Report, Impol noted that the processing of secondary aluminum is becoming increasingly important. Globally, the estimated amount The 2013 Range Rover aluminum body-in-white (courtesy of Jaguar of secondary aluminum tops 20 million tonnes per year Land Rover).

16 LIGHT METAL AGE, AUGUST 2013 its cars in order to lower overall vehicle carbon footprint. ity under construction adjacent to the company’s Lafay- These projects are funded by the U.K. government’s Tech- ette, IN, plant that will provide an additional 20,000 tons nology Strategy Board with Novelis, STADCO, Norton Alu- of aluminum-lithium. The new facility will supply round minium, Brunel University, and Innoval as partners. and rectangular ingot for rolled, extruded, and forged In May 2013, Novelis completed a £1.7 million (US$2.6 applications, in sizes compatible with the largest alumi- million) upgrade program at its aluminum can recycling num aerospace components in service today. The Lafay- plant in Warrington, improving eficiency and doubling ette expansion is scheduled to be completed and online the capacity of its closed-loop recycling system. Mecha- by the end of 2014. These aluminum-lithium expansion therm supplied a 42 tonne melting furnace for the up- initiatives also provided Alcoa with the opportunity to in- grade, which also includes a new cleaning line for cans crease their aerospace recycling capabilities. that will boost the plant’s ability to remove deleterious materials, such as plastic, from bales of beverage cans be- Acknowledgement fore they are melted down. The Warrington plant melts aluminum beverage cans and other types of aluminum Dong Chunming, Sunlight Metal Consulting (Beijing) scrap into 27 tonne slabs, which are sent to its rolling Ltd., is gratefully acknowledged for compiling the sec- mills to make can sheet. About 8 billion beverage cans tion on China. He can be contacted at dong.chunming@ are illed in the U.K. every year, and 60% are recycled. yahoo.com. More information on the aluminum industry The plant also produces Novelis’ new high-recycled con- in China can be found at www.lightmetal.cn. tent evercan™ aluminum body sheet, which enables beverage companies to offer standard 12 oz. aluminum cans made from a minimum of 70% recycled content, includ- Rudolf P. Pawlek earned his de- ing 90% recycled aluminum in the cans’ body sheet. gree in extractive metallurgy at In June 2013, Alcoa completed the expansion of alumi- the Technical University of Ber- lin in 1967. After more than 20 num lithium capacity at its Kitts Green facility to serve the years with the primary aluminum growing demand for the company’s third generation of industry, he founded TS+C, Tech- aluminum-lithium alloys, which allow airframers to build nical Information Services and more fuel eficient and lower-cost airplanes versus com- Consulting, Sierre, Switzerland, posite alternatives. Alcoa projects its aluminum-lithium a service for the aluminum indus- revenues will quadruple over the next six years to nearly try. He is the author of Primary US$200 million. The Kitts Green expansion was the sec- Aluminium Smelters and Pro- ond phase of the three-part expansion program. This ducers of the World, published included the upgrade and expansion of casting capacity by Beuth Verlag GmbH (www. at the Kitts Green plant and also expanded capacity at beuth.de). For more information, contact Rudolf Pawlek at: its Technology Center in Alcoa Center, PA, by 30%. The [email protected]. third phase of the expansion is a new US$90 million facil-

LIGHT METAL AGE, AUGUST 2013 17 Service Center Metals: In a Land of Hope and Dreams A Decade of Dedication to Soft Alloy Extrusion and Still Growing By Joseph C. Benedyk, Editor

Figure 1. The interior view of Service Center Metals in Prince George, VA.

his year, Service Center Metals (SCM) of Prince the company boasts the second largest market share in George, VA, will be celebrating a decade of the industry and employs 122 people. In full operation manufacturing and supporting service centers sometime in 2014, the 24/7 compact remelt plant will throughout the U.S. by supplying them soft alloy eventually employ 16 people at ive per shift. extrudedT products tailored to their needs (Figure 1). An anniversary celebration in August also marks the build- Milestones, Operations, and Highlights ing of a new compact remelt plant adjacent to SCM’s extrusion plant. From an extrusion industry perspective, it is obvious The sharp focus by SCM on supplying distributors of that the consolidation in the aluminum industry shook metal products was there at the start, when this green- it up and in a way helped create SCM. When SCM irst ield extrusion plant broke ground in September 2002. started production many workers displaced as a result of Remarkably, this was the irst greenield extrusion plant Alcoa’s acquisition of Reynolds in 2000 provided an easily in the U.S. of the size for ten years (and there have been tapped workforce. Later the closure of some of Alumax’s only two more since). Production began in August 2003 extrusion plants also added to SCM’s experienced workon SCM’s irst press named “Elvis.” In 2006, they installed force. All of the company’s founders are former Reynolds a second press called the “ Boss,” which began production Metals company executives. The company was formed in April. After ten years of production, July 8, 2002 by Kelley, Dollins, and R. SCM has shipped over 650 million lbs Randolph “ Randy” Weis, vice presi- of extrusions to its service center cus- dent of sales and marketing. Extrusion tomers. production began in August 2003 on The “ rock and roll” theme that runs Elvis, a 2,800 tonne Presezzi/OMAV through SCM was inspired by R. Scott press of compact design with a shift- Kelley, its president and ceo, who is ing stem to reduce dead cycle time to a big fan of the genre. In describing under 20 seconds. A combination of the decade long growth of SCM, Kel- chest-type OMAV electric die heaters, ly says, “ Back in 2003, a lot of people single-cell Castool electric heaters, and thought we were crazy to start a green- Novatec infrared die ovens make pos- ield extrusion business. Well it’s been sible the routine 30 die changes per ten great years, we’re still crazy after day. This press line is equipped with a all these years, and we’re expanding 100 tonne stretcher to accommodate again.” Kelley and Lloyd S. “ Chip” the wide range of extrusion weights Dollins, vice president of operations, produced in 6063 and 6061 billet (0.5- have been working together (Figure 17 lbs/ft). In February 2005, SCM i- 2) for some time on the compact re- nanced, broke ground, and purchased melt plant expansion, a project that their second press equipped with a 350 oficially began this January. tonne stretcher. True to form, the new This project will fulill much of press, the Boss, started production Figure 2. Scott Kelley (left) and Chip Dol- SCM’s 6063 and 6061 billet needs in lins (right) looking over SCM’s plans for the in April 2006. It utilizes 14 inch 6063 the near future. It also caps a spectacu- compact remelt plant to supply ingot logs and 6061 billet to produce extrusions lar decade of growth for SCM. Today, for their extrusion operation. for the service center market, weigh-

18 LIGHT METAL AGE, AUGUST 2013 Packing lines and automation in the extrusion plant

Emmebi offers its customers a variety of packing and finishing plants, planned and built to size, that meet every industrial requirement, while guaranteeing a product which is 100% made in Italy. The Emmebi’s production line is also linked to the overall automation in the extrusion department, by offering innovative technical solutions aimed at improving safety, highly efficient plant performance and product quality, right up to the final customers. This was a rewarding choice, which allowed Emmebi to become the leader in the field of packing and automation.

Emmebi srl - Via della tecnologia 12 - 33050 Pavia di Udine (UD) Italy - tel. ++39.0432.675936 fax 685101 www.emmebi.net - [email protected] Emmebi North America - Mr. Carsten Dede - Division Manager - St. Augustine, FL 32080 USA Phone +1 (904) 806 8871 - [email protected] ing 1.5-60 lbs/ft. The OMAV stretchers on the two SCM hour based on performance. Reducing die change time presses are the largest in North America for the respec- is an important part of increasing extrusion produc- tive press sizes. tivity, and SCM has instituted a NASCAR inspired pit Presently, the two presses housed within the 156,000 stop challenge, whereby workers compete and are rated sq ft of the SCM plant have a capacity of over 105 million on minimum die change time. The overall indication lbs/yr and produce some 1,200 products for the service of productivity at SCM is equipment uptime. Both El- center market, all from 6063 or 6061 aluminum alloys vis and Boss average 85-90% uptime, with Elvis having (Figure 3). The Elvis and Boss presses are equipped with achieved a record milestone month in February 2012, programmable logic controls that manage and adjust 120 hitting 95.6%, and Boss having a record month in May press variables in order to achieve a run-to-recipe extru- 2012, hitting 92.7%. sion process for each shape (Figure 4). Employee safety at SCM, as part of their mission state- ment, has been benchmarked since production began in 2003. Dollins stressed how important this is to the company and was proud to relay the total case incident rate (TCIR) history since inception and how SCM has maintained a low TCIR and improved on it over the years (Figure 6).

Figure 3. Typical 6063 and 6061 extruded products.

Figure 6. Safety record of SCM from 2003 to 2012 of TCIR history.

In recognition of its business success, SCM has received many plaudits. In 2006, SCM was rated #10 on Entrepre- neur magazine’s “ Hot 100” list of faster growing small U.S. companies; three years later it was recognized as one of the fastest growing companies in America by Inc. magazine. In 2008, the Virginia Chamber of Commerce rated SCM as #4 (#1 in manufacturing) in its “ Fantastic 50” list of successful Virginia companies.

Serving Service Centers 100%

As its name suggests, the mission of SCM all along has Figure 4. (L-R) Josh Bland, Jamie Spencer, and Philip Moss in front of control panels for the Boss. been to dedicate 100% of their manufacturing and personnel resources to service center customers. Supplying Because the sizes distributors with standard shapes is in the genes of SCM’s produced by SCM’s El- three founders, who when they started the company in vis and Boss are often 2002 altogether had 48 years of extrusion business ex- massive, as required by perience, the majority of which involved serving the dis- their service center cus- tribution business. The market niche pursued by SCM is tomers, a robot called growing due to the increase in outsourcing of inventory “ Hal” (Figure 5) is used management and curtailing of supply chain costs by com- to assist the packing of panies using aluminum extrusions. SCM estimates that extrusions that are too service centers sell 16-18% of all soft alloy extrusions in heavy to handle manu- the U.S. depending on the state of the economy, and it ally. Hal packs the heavy intends to cater to the market needs of this extrusion extrusions into bundles, market segment. which are then aged be- As for product quality and operational eficiency, SCM fore packing and ship- has set its benchmark goals on customer service. Alto- ping. gether, their customer service department boasts a total Crewed for 24/6 of 110 years of experience. At the same time, the digital production and 24/7 age has made possible SCM’s “ Depot on Demand” prom- maintenance, SCM’s ise of ive day lead times on order entry to ship. This is 122 employees work enabled by SCM’s rapid turnover and product turns. Ac- on an incentive system cording to Kelley, “ People don’t want to keep stock on the that provides a boost to Figure 5. Hal the packing robot at shelves and, when they need it, they need it immediately. their wages, as much as work at SCM on extrusions too heavy With Depot on Demand, we promise to meet the needs a doubling of pay per to handle manually. of our service center customers in reducing their inven-

20 LIGHT METAL AGE, AUGUST 2013 OUR LIFE FOR PERFECT SHAPES

Thanks to the experience of our designers and the use of highly sophisticated WE PRODUCE programs, we provide reliable extrusion presses in order to optimise operating PERFECT MACHINES performances. We can offer various levels of control: For the Press only, TO REALIZE as well as the entire extrusion line. We can also perform complete mechanical, PERFECT SHAPES hydraulic, electrical revamping operations. Get in touch with us , we will be very proud to become your partner!

PRESEZZI EXTRUSION North America HeadQuarters: PRESEZZI EXTRUSION S.p.A. Mr. Bruno Donada PRESEZZI EXTRUSION S.p.A. Sales Manager Via Rovereto 3/d Phone (0039) 039 635011 Chicago, IL -USA- Fax (0039) 039 63501220 Phone/Fax +1 (847) 676 2459 20871 Vimercate (MB) - ITALY [email protected] www.presezziextrusion.com [email protected] tories. The difference between larger extruders, who also have depot programs, and us is that they have inventory sitting on their loors that they sell from, while every inch of metal we extrude is already sold. That’s a signiicant difference.” SCM’s website (www.servicecentermetals.com) offers their 2012 catalog (The Orange Book) with some 1,200 products along with selected Depot on Demand products. SCM’s information technology manager, Bob Neale, is working on a new website that will have a customer portal that allows logging on securely to the website to receive information about their speciic products. This Figure 7. Lathe machining test being conducted at SCM on their portal will host not only an online catalog of products, but Lightning Rod Tite free machining rod. will also give customers an immediate dynamic inventory of their orders as soon as a new die is in the system, includ- extruded plate and square, hexagonal, and rectangular ing order status, certiication (tensile test results, chemis - bar. High mechanical strength and elongation are also try, etc.), and all information about delivery. It also pres- key properties in the wide range of structural extrusions ents customers with hot deals, special pricing for products offered in SCM’s catalogue. that they have ordered in the past, latest news from SCM, videos, and (as Neale deines) other cool stuff. Basics of Compact Remelt Plant Expansion the customer portal are ready to launch. The 81,000 sq ft building being built for SCM’s com- Tailoring Extrusion Technology to Service Center Needs pact remelt plant expansion (Figure 8) will help them close the loop on recycling scrap from their operation By concentrating its manufacturing skills on service supplemented by scrap from outside sources. The con- center needs, SCM has tailored its products and their cept involves a three-chamber melting furnace, state- properties accordingly. In its commitment to quality and of-the-art horizontal log casting equipment to produce eficiency to deliver superior product to its customers, in both 9 inch and 14 inch diameter logs (Figure 9), and May 2005, SCM’s Quality Management System received continuous homogenization equipment— all supplied by ISO 9001:2000 certiication. As an example of a quality Hertwich Engineering. Integrated environmental con- product tailored to service center needs, SCM boasts bet- trols will guarantee SCM will exceed EPA requirements. ter metallurgical properties, straightness, dimensional Although semi-continuous vertical DC casting is more tolerances, and surface quality relative to its competitors. common in the aluminum industry, the continuous hor- Six Sigma principles have been adopted as the basis of izontal DC casting process has been found to be more SCM’s continuous improvement program. Calvin Wiggins, the company’s director of quality and technical sales service, describes the superior features in SCM’s Lightning Rod Tite extruded rounds. He points out that these extruded rounds are mostly supplied in cold inished diameter tolerances, with a straightness tolerance of 0.003 inch/ft, and with surface roughness typically at 40-50 microinch rms or ra. Wiggins explains how this is done, “ It is a combination of special billet chemistry, new die rotation, careful die maintenance in terms of nitriding, and abrasive low surface treatment, process control, and inspection techniques.” Figure 8. New compact remelt plant in construction adjacent to the With regard to the importance of good machinabil- SCM plant (July 2013). ity in their products, Wiggins points to the

current trends in customer machining re- Log Conveyors/Buffers (2) quirements: unattended manufacturing, a 7 high degree of automation, tight OD toler- 8 Ultrasonic Log Testing Station 9 Continuous Log Homogenization Oven ances, chip breaking characteristics, and, 10 Log Cooling Station 8 to a lesser degree, surface inish. SCM’s 11 Semi-Automatic Log Banding Station 6061 products compete with 6262 alumi- 9 7 num alloy extrusions, the latter containing lead and bismuth additions to aid ma- 11 10 chinability. Although conventional 6061 rod extrusions do not normally meet the 6 Homogenizing & machinability standards of 6262 rod ex- Log Storage Bay 5 4 trusions, SCM has succeeded in achieving Melting & Casting Bay 3 good machinability in their 6061 Lightning Rod Tite products that competes favorably Scrap Bin Magazine with 6262 products (Figure 7). A major ad- 1 Automated Scrap Charging Machine vantage of SCM’s high machinability 6061 2 1 2 3 Three-Chamber Melting Furnace products is the absence of lead, which is Molten Metal Degassers & Filtration (2) requested by more and more customers. 4 Horizontal Casting Machines (2) Good machinability is a key property in 5 6 Log Saws (2) SCM’s line of lead-free 6061 products that includes not only Lightning Rod Tite, but also Manifold Thunder Bar and Velocity Figure 9. Schematic representation of the low chart of SCM’s future compact remelt Plate, as well as a wide range of sizes in plant.

22 LIGHT METAL AGE, AUGUST 2013 suitable for small volume billet log production at remelt Ten Year Anniversary and Groundbreaking Celebration plants such as this. It is also used widely for casting forging bars, small diameter billets, foundry ingots, and Kelley offered insight into the choice of Virginia’s busbars (see article by H. Zeillinger and A. Beevis, Light Gateway Region for his company’s location, pointing out Metal Age, June 1997). Hertwich Engineering has made all the logistical and inancial incentives that fostered the signiicant process improvements assuring that the qual- decision over a decade ago. The choice has been a good ity of horizontal continuous cast DC logs in the 9 inch one. In 2012, in a ield of 59 Virginia business contend- and 14 inch diameters used by SCM will be equivalent to ers, SCM was one of ive recipients of the Tayloe Murphy that usually obtained by vertical DC casting (Figure 10). Resilience Award for its entrepreneurial spirit from Uni- The expansion project, once completed, is expected to versity of Virginia – Darden School of Business. The ive add value to SCM’s manufacturing proile. As Dollins has winners represent some of the most resilient businesses said, “ Why add a compact remelt plant? It will strengthen in Virginia— those which display growth, a dogged en- our company and position us for future growth.” Some of trepreneurial spirit, and commitment to community in the advantages that Kelley and Dollins anticipate will be areas facing high unemployment, high poverty, and low continuous casting of logs in selected lengths for up to three entrepreneurial activity. days, integrated sawing of logs, and of course cost savings. With SCM’s anniversary celebration, Kelley shared The two casting lines, named “ Mick” and “ Keith” by Dollins, his thoughts on the past decade. To launch the com- will have a combined annual capacity of 75 million pounds. pany they began raising money a week before 9/11. At that point, the three founders were unsure about their futures, but they stuck it out and shipped their irst product in 2003. By 2006, after Boss started extruding product, SCM doubled its plant size and tripled capacity. And although the 2008 recession caused a rough patch for SCM, the company came out stronger than ever, with conidence shown by its employees, customers, and investors in its ability to grow the business. Kel- ley has always considered “ Land of Hope and Dreams” by Bruce Springsteen, the company’s theme song. “ It’s an epic song with train imagery, exploring big dreams, faith, and hard work. The song concludes by welcom- ing everybody who wants a new start and willing to pay the price to climb on board. I can tell you we have a Figure 10. Stack of 9 inch and 14 inch purchased 6063 and 6061 logs lot of amazing people on the SCM train. This is the at SCM will be replaced by logs made at their new compact remelt engine that has and will continue to power SCM into a plant. bright future.”

LIGHT METAL AGE, AUGUST 2013 23 Aluminium Two Thousand Congress 2013 – Milan Highlights of Extrusion Presentations By Joseph C. Benedyk, Editor

he 8th edi- ysis and Optimiza- tion of the tion) had instructors Aluminium from the University Two Thou- of Bologna, headed sandT Congress, held by professors Luca during May 14-18, Tomesani and Lo- 2013, in Milan, Italy, renzo Donati, both and organized by noted extrusion ex- Interall Srl, was a perts. An anodizing resounding success workshop (Techno- with 120 scientiic logical Review and and technical papers Updating) was led presented by inter- Figure 1. Delegates from around the world at the recent Aluminium Two Thousand by anodizing special- national experts de- Congress in Milan, Italy. ists from industry scribing the latest (Italtecno, MUNK, developments in aluminum markets, extrusion, anodiz- OMSG, PCS Sales, and Burlingham International) as well ing, die casting, rolling, coating, and advanced applica- as by consultants Jude Mary Runge, Anne Deacon Juhl, tions. At inal count, 392 participants from 50 countries and Massimo Masiero. Additionally the Aluminum Anod- attended the conference, and most attended the various izers Council (AAC) conducted a successful Anodizing technical sessions (Figure 1). Essentials workshop with 21 registrants. A coating work- The conference started on the morning of May 14th and shop (Technological Review and Updating in Aluminum dealt with various issues of “ Markets and Strategies,” direct- Pretreatment before Coating) was led by Fabio Vincenzi, ly relating to global extrusion markets, aluminum produc- Marcello Rossi, and Federico Vincenzi, all of Italtecno. tion in the Gulf, LME warehousing, and the new mission This article will review some of the extrusion articles of ESTAL (European Association for Surface Treatment and presentations at the congress to give our readers an on Aluminum). Topping off the morning was a special update on some of the latest technology and trends in focus session on “ Aluminum for Africa, Africa for Alumi- aluminum extrusion. num,” where presentations were made by political representatives of six African countries emphasizing business Review of Aluminum Extrusion Technology Presentations opportunities in the aluminum industry. These opportunities are emerging at a rapid rate, according to Saul K. A mainstay of all Aluminium Two Thousand conferenc- Molobi, consul general of South Africa. He has noted, for es, aluminum extrusion technology was a major feature example, that foreign trade agreements already in place at this world congress, with many of the 120 conference among African countries, which are part of the Southern papers devoted directly or indirectly to this ield. The African Development Community (SADC), represent a extrusion sessions reviewed here (Extrusion Dies; Extru- market of some 200 million customers; further integration sion Plant and Management; Extrusion Process; and Extrusion is expected in the future among SADC and two other ma- Products, Architectural Applications, and Special Uses/Tests) jor regional blocks, creating a potential future market of are indicative of the breadth of extrusion knowledge and some 700 million customers. developments presented at this latest congress. Afternoon technical sessions on the opening day and Extrusion Dies: The QForm-Extrusion software program those on the following two days consisted of four parallel developed by QuantorForm Ltd., Moscow, Russia, used in tracks that included: Extrusion Dies; Extrusion Process; many die making and extrusion companies, has been shown Extrusion Plant and Management; Extrusion Products, to accurately predict and control non-uniform metal low as Architectural Applications, and Special Uses/Tests; Anod- the extrusion leaves the die.1 The numerical model used in izing and Hard Anodizing; Measuring, Testing, Quality this program includes coupled simulation of material low Techniques, and Corrosion Protection; Metallurgy, Alloy and die deformation that can affect the bearing area during Billets, and Related Equipment; Casting and Die Casting; extrusion, thus affecting metal low. The model was success - Roll Technology; and Advanced Forming Processes. All pre- fully tested in practice to assess metal low and formation of sentations were made in English, and there was something the front tip of a studied proile (Figure 2). to learn no matter one’s special interest in this multifaceted aluminum industry. The last day of the conference sessions included a “ Russian Technical Day” in the Russian language tailored for Russian delegates with a dozen presentations on innovations in extrusion, anodizing, and powder coating. On May 17th, the day after the three-day congress, congress delegates had the chance to tour one of four Italian companies: extruders Bodega SPA or Proilati SPA, the anodizer and coating specialist Ponzio SRL, or extrusion press builder Presezzi Extrusion SPA. Also, on May 17th several congress delegates chose to register for what has become a mainstay of Aluminium Two Thousand Congress, workshops on extrusion, anod- Figure 2. Front tip of an extruded aluminum proile in coupled simula- izing, and coating. The extrusion workshop (Process Anal- tion (left) and in practice (right).

24 LIGHT METAL AGE, AUGUST 2013 Using a 3D CAD model, a fast inite element method (FEM) developed at ALKO Engineering, Netherlands, called VisualFade, predicts stresses and deformations in both lat and porthole extrusion dies for given extrusion die forces.2 Good results were obtained between simulation and experimental results on two separate dies. Simulation times were fast (2-3 min) although preparation time for the 3D CAD models was 10-15 min. Die wear in coated aluminum extrusion dies was investigated by means of a tribo-tension test developed in a collaboration between ETH Zürich (Insti- tute of Virtual Manufacturing), Switzerland, and WEFA Inotec, Germany.3 This test (Figure 3) enables the study of tribology in hot extrusion by accounting for temperature, velocity, and pressure. This test has been used to compare different WEFA CVD (chemical vapor deposition) coatings and aluminum alloys to study the effect of these extrusion parameters on friction moment and shear stress. In a parallel paper, Joachim Maier of WEFA Inotec presented more data obtained in the mentioned tribo-tension test showing the advantages of WE- FA’s CVD coatings over nitride coatings on extrusion dies.4 Market trends for coated aluminum extrusion dies are high-volume applications like multi- micro-port proiles, precision round tube proiles, and others, as well as dies for hard aluminum alloys. The tribo-torsion test makes it possible to investi- gate the friction and wear mechanisms between different coating layers and IRELESS aluminum alloys (Figure 4). Extrusion die life due to creep and fatigue during repeated cycles of extrusion has been analyzed by means of a comprehensive model developed TECHNOLOGY at the University of Bologna, Italy, for the prediction of deformation in ex- TURNING HEADS trusion dies in creep-fatigue regimes after multiple cycles of extrusion, and W this model was validated experimentally in a Gleeble simulator on a specimen that reproduced the mandrel on a porthole die (Figure 5).5 The validated model was applied to evaluating mandrel displacement as a function

Figure 3. Schematic drawing of tribo-torsion test specimen used in tests on a torsion machine at ETH and test data showing measured friction moment as a function of pressure (left), velocity (center), and temperature (right) in a study of the friction between 6082 aluminum alloy and a ceramic two-layer WEFA Inotec CVD coating.

wireless technology

Figure 4. Friction coeficients measured in the tribo-torsion test for three different aluminum +1-800-918-2600 alloys and various die coatings: double layer coatings BE5 (ceramic) and BE21 (boride based), a coating in development (CID), and conventional nitride. grancoclark.com [email protected] LIGHT METAL AGE, AUGUST 2013 25 U.A.E. (a two-cavity extrusion die with different proiles which resulted in accelerated delivery and cost-effective production of thermal break proiles).9 Extrusion Plant and Management: Among the seven presentations made in this session, three speciically dealt with extrusion process monitoring and control to manage key performance indicators (KPIs) by specially developed software modules tailored to the extrusion industry. The software module developed by the Manufacturing Establishment Group, Liechtenstein, is an electronically supported system that seeks to optimize overall press productivity by focusing on the KPIs of lost time, scrap, and ram speed.10 A new method for automatically setting extrusion process parameters, developed at the Univer- Figure 5. Displacement in creep-fatigue cycling of the University of sity of Kaiserlautern, Germany, is based on storing data Bologna specimen made of H11 steel heat treated to 44-48 HRC. of product features and corresponding optimal process parameters in a database and employing artiicial intel- of number of billets extruded in an industrial porthole ligence to estimate initial ram speed and exit tempera- die used to make tube extrusions based on an experi- ture settings.11 Finally, the goal of the jointly developed mental pressure-time diagram for a single cycle. software by Uno Informatica/Altair Engineering, Italy, is The effect of stress accelerated tempering, or how to go beyond the basic analysis of extrusion plant per- hardness of quenched and tempered hot work tool steels formance that normally utilizes generic KPIs, by allowing changes with stress at hot working or die casting tempera- managers to create more speciic KPIs that immediately tures, was reviewed by researchers at the Thermal Pro- identify lack of performance and related causes and pos- cessing Technology Center (TPTC) at the Illinois Insti- sible solutions.12 tute of Technology, U.S.6 Various types of thermal fatigue Hardware developments coupled with digital controls tests and hot tensile/creep tests conducted on tapered were described that improve extrusion productivity, en- specimens (Figure 6) have shown how stress affects hard- ergy conservation, and/or extrusion structural proper- ness and associated properties, including hot tensile, fa- ties. These included: die temperature controls by Castool tigue, and creep strength, as well as wear resistance of Tooling Systems, Canada,13 and an energy saving system these steels; thus, it ranks as one of the fundamental die (ESS) by Presezzi Extrusion, Italy, consisting of a new failure modes encountered in the extrusion and die cast- generation of drives and motors for the extrusion process ing industries. that allows for switching off the pumps when the press is Specialized extrusion die production techniques were idle during the extrusion cycle and selectively switching presented in papers from Neper Informatica, Italy (auto- off unused motors during extrusion (Figure 7).14 Auto- matic feature cognition and knowledge base machining mated warehousing, automated ground vehicles (AGVs), applied to automatic milling of extrusion dies),7 Micro and handling au- Technica Technologies, Germany (automatic abrasive tomation by Dima- low machining to improve die life, surface inish, andSimma, Italy, with throughput of extrusion dies),8 and Gulf Extrusions, special interest devoted to the latest innovations in automated warehousing at Sepalu- mic, Genlys, Dijon, France, where Di- maSimma’s automated warehouse handles up to 3,200 aluminum extrusion packets Figure 7. Schematic of the patented Presez- with containers in- zi Extrusion ESS that provides for 15-25% terfaced with the reduction in energy consumption during ex- coating line, ther- trusion operations. mal break line, and order commissioning were also presented.15 As part of this session, various innovative aluminum structures designed by G.C. Giuliani, consultant to Re- desco Progetti, Italy, were included.16 These exempliied how aluminum extrusions can improve structural eficiency in innovative connections composed of aluminum castings and extrusions, use of added extrusions for structural members, and long pre-stressed extruded beams. Applying these concepts to large-span trussed roof beams can lead to savings in material and labor. Extrusion Process: Researchers from the University of Bologna conducted experimental and numerical anal- Figure 6. Hardness (HRC converted from micro-hardness readings) yses, using DEFORM software, on the dynamic evolu- as a function of applied stress in hot tensile/creep testing at 1,050°F of tapered and heat treated H13 specimens. tion of grain shape in 6060 alloy during the extrusion process in direct extrusion of a rod and back extrusion

26 LIGHT METAL AGE, AUGUST 2013 of a cup shape, before and after static recrystallization of both shapes.17 This model, unlike previous ones, considered the entire evolution process, covered the full industrial range of process parameters, and was validated successfully in analysis of abnormal grain growth in extrusion. In a joint research program between extruder Alumat & Almax, Italy and the University of Bologna, several numerical simulations were performed using HyperXtrude® software in order to evaluate porthole die design practices on ram force, stress on mandrel legs, and extrudate temperatures in the extrusion of ZM21 magnesium alloy tubes.18 Several recommendations were made to reduce ram force, including use of chamfers on leg entrance in place of radii at corners, addition of an undercut at port exteriors, and relief on legs and central mandrel. In research conducted at TU Berlin, Germany, seamless 6060 alloy tubes with locally varied cross sections with outer diameter constant were extruded using a stepped mandrel that was axially moved during indirect extrusion experiments (Figure 8).19 Microstructures in regions with constant wall and transition zones were analyzed as a function of extrusion speed and ratio, while 3D FEM simulations of these tests were conducted to analyze material low in the process. Such tailored proiles with stronger cross sections in higher load regions are desired in order to save weight, especially in vehicles. OBUST

HEAVY DUTY BUILT TO LAST R

Figure 8. Graded transition of indirectly extruded tailored 6060 alloy seamless tubes made at TU Berlin: wall thickness t = 1.5 mm > t = 7.75 mm, extrusion direction ➞.

The joint article by Italian extruder Proilati, inert gas supplier Messer Italia, extrusion systems engineering irm Uno Informatica, and software irm Altair Engineering, Italy catalogued all of the productivity and quality improvements achieved by application of liquid nitrogen technology in the extrusion of a complex window proile from 6060 alloy on a 2,200 ton press.20 By using liquid nitrogen injection through the die (N5Nitrogen/Incal technology) various quality improvements were achieved compared with results from conventional extrusion dies: better heat removal from die bearings and proile sections resulting in a 20°C temperature reduction at an equivalent extrusion speed of 32 m/min, iner precipitation in the age hardened condition, and better surface inish. The latest technology in dummy block lubrication was described by James E. Dyla, president of Amcol, U.S.21 Electrostatically applied boron nitride ceramic powder and air atomized water based organic polymer solutions are designed to eliminate manual lubrication and fully automate the process of dummy block lubrication. Both technologies were compared and best practices in use explored. Extrusion Products, Architectural Applications, and Special Uses/Tests: Aluminum extrusions used in solar photovoltaic panel frames, racking systems, and para- bolic trough concentrated solar power frames as manufactured by Tekna, Italy, were described in this session.22 Details of thermal expansion guidelines to use in manufacturing aluminum space frames for the solar industry are important in designing for static and dynamic stresses resulting from thermal expansion. Larger Rollers Consultants from Redesco, Italy, described the specially designed aluminum extrusions and joining methods used in the new air trafic control tower at the Barcelona airport, which featured the self-supporting stair and lift core of the tower that was used as a template for the erection of precast concrete elements (Figure 9).23 The unique feature of the aluminum extrusions allowed for the design and construction of the 43.38 m high core. Standards in force in Italy for thermal break systems used in window and door frames, as well as curtain walls, were presented by representatives from Aital (Italian Association for the Surface Treatment of Aluminum), Italy, and Qualital, Italy, a European manufacturer of windows and doors.24 All the technical speciications required for aluminum thermal break proiles and recommendations for every processing step in applying thermal breaks to +1-800-918-2600 aluminum extrusion were listed in this paper. grancoclark.com [email protected] LIGHT METAL AGE, AUGUST 2013 27 Researchers from the Extrusion Die Design for Production of Complex Shape Fraunhofer Institute for Proiles,” Proc. of the 8th Aluminium Two Thousand World Mechanics of Materials, Congress, 2013. Germany, experimentally 2. Koopman, A.J., “ An Innovative and Accurate FEM characterized and mod- Method for the Prediction of Deformation and Stresses eled the anisotropic de- in Aluminum Extrusion Dies,” Op. cit. formation behavior of 3. Becker, C., P. Hora, and J. Maier, “An Optimized multi-hollow 6005A-T6 Tribo-testing Method for Coating Investigations for Alu- and 6008-T6 extrusions minum Extrusion Dies,” Op.cit. under crash relevant load- 4. Maier, J., “ Tribological Investigation on CVD Coated ing and compression.25 Extrusion Dies,” Op. cit. Uniaxial (Figure 10) and 5. Reggiani, B., L. Donati, and L. Tomesani, “A Com- biaxial tension, shear, parison between Different Approaches in the Evalua- and bending tests were tion of Extrusion Die Life: Static Strength, Fatigue, and performed along with Creep,” Op. cit. compression tests on full 6. Benedyk, J.C. and P. Nash, “Stress Accelerated Tem- size components. The ex- pering of Hot Work Steels as a Failure Mechanism in Alu- truded proiles exhibited minum Extrusion Tooling and Die Casting Dies,” Op. cit. pronounced anisotropic 7. Rocco, L., “ Easymill Automatic Cam for Aluminum deformation and damage Extrusion Dies,” Op. cit. behavior that was simu- 8. Stackhouse, J., “Beneits of Automating Your Die Pol- lated satisfactorily. ishing Using Advanced AFM Technology,” Op. cit. 9. Parida, S., “ Non-conventional Die for a Thermal Conclusion Break Proile,” Op. cit. 10. Dobler, M., “Aluminum Extrusion Press Down Time The referenced works Figure 9. Sequential erection of the Monitoring and Extrusion Process Monitoring,” Op. cit. presented here should give aluminum stair and lift core (top) 11. Pandit, M., “ Extruder Automation System with Self- readers an indication of the and the reinforced concrete hyper- setting Capability,” Op. Cit. boloid (bottom) for the Barcelona commitment to aluminum air trafic control tower. 12. Bertoletti, M., M. Bosisio, P. Longhi, and F. Gen- extrusion innovation and nari, “ Extrusion Intelligence: OEE Method in Extrusion practice that the Alumin- Sector,” Op. cit. ium Two Thousand con- 13. Robbins, P. and M. Rushton, “An Understanding of gresses have provided its Flow Stress is Fundamental to Increasing Productivity,” delegates. More papers on Op. cit. other links in the extrusion 14. Bonafacio, M., “ Energy Saving System: Reduction process chain, including of Energy Costs in Extrusion,” Op. cit. billet metallurgy and cast- 15. Trenti, D., “Integrated Logistics: Automatic Ware- ing, coatings, anodizing, houses, AGVs and Handling Automation from the Roll- quality control, measure- ing Mill up to the Extrusion Plant,” Op. cit. ment, etc., are part of the 16. Giuliani, G.C., “ Innovative Aluminum Structures,” congress proceedings. The Op .cit. oficial Aluminium Two 17. Segatori, A., B. Reggiani, L. Donati, and L. Tome- Thousand website (www. sani, “ Prediction of Grain Shape Evolution during Extru- aluminium2000.com) of- sion and Annealing of 6xxx Alloy,” Op. cit. fers extensive information 18. Pinter T. and B. Reggiani, “Quantitative Evaluation about this congress, while of Porthole Die Design Practices by Means of FE Analy- the numerous articles pub- ses,” Op. cit. lished in the proceedings of 19. Negendank, M., S. Müller, and W. Reimers, “ Extru- this congress are available sion of Tailored Aluminum Tubes,” Op. cit. from the secretariat at Inter- 20. Celani, P., M. Bertoletti, E. Mainetti, A. Ferrentino, all Srl (aluminium2000@ and C. Secli, “ Considerations about Heat Elimination interall.it). from Extrusion Dies by Using Liquid Nitrogen: Extrusion To be sure, Milan was an Speed Increase and Surface Defects Elimination, Metal- excellent choice of venue Figure 10. Extruded 6005-T6 pro- lurgical Structure Modiication, and Extrusion Process for this congress, and the ile and engineering stress-strain Simulation,” Op. cit. curves from different positions in Interall staff provided not the longitudinal direction. 21. Dyla, J.E., “ Billet and Block Lubrication Best Prac- only business opportuni- tices,” Op. cit. ties to delegates, but also a 22. Barbareschi, G., “ Fabrication of Extruded Alumi- very attractive social program that allowed participants to num Framing for the Solar Industry,” Op. cit. discover the beauty and history of Milan. The inal sight - 23. Giuliani, M.E. and G.C. Giuliani, “ The Self Sup- seeing tour for all participants on May 18th to the Bor- porting Aluminum Core for the Barcelona Airport Tow- romeo Islands in nearby Lake Maggiore was an enjoyable er,” Op. cit. conclusion to this congress. Details on the site selection 24. Barbarossa, G.P. and R. Boi, “Thermal Break Pro- for the 9th edition of this biannual conference to be held iles for Applications in Architecture: Reference Stan- in 2015 will be forthcoming from Interall. dards and Recommendations for Manufacturers,” Op. cit. References 25. Sun, D.Z., A. Ockewitz, G. Falkinger, and F. An- drieux, “ Characterization and Modeling of the Deforma- 1. Biba, N., S. Stebunov, and A. Lishny, “ Practical Im- tion and Damage Behavior of Thick-walled Aluminum plementation of Numerical Modeling to Optimization of Proiles,” Op. cit.

28 LIGHT METAL AGE, AUGUST 2013 Pictorial Highlights– Aluminium Two Thousand, Milan

At , our engineers are on the fore- front of developing industry leading technology. Dr. Walta Dalla Barba welcomes attendees. Keynote speakers at plenary session. Technology you can count on that’s built to last.

Exhibition area. Evening concert at Church of S. Christofora [email protected] NNOVATIVE al Naviglio. I

Arthur Brace (with wife, Marion) received an (L-R) Dr. Walter Dalla Barba and Patrizia award for 60 years of anodizing studies. Lancini, Italtecno, and Dino Costa, DEAR, Fives North American Combustion.

Professor Lorenzo Donato and Jude Mary Gala Dinner. Runge. Log Washer

+1-800-918-2600 Final sight seeing tour at Lago Maggiore. Spectacular display to end of memorable grancoclark.com days in Milan at Isola Bella. [email protected] LIGHT METAL AGE, AUGUST 2013 29 Figure 1: Participants at the aluminum recycling workshop held in Trondheim. Second International Aluminum Recycling Workshop, Trondheim, Norway By Anne Kvithyld, SINTEF, and John Green, JASG Consulting

n June 9-11, 2013, some 33 representatives changes that have taken place in the industry recently. from aluminum companies, research insti- One key change is the rapid emergence of China in the tutions, universities, and other associations production of aluminum (annual global production is es- from eight countries assembled in Trond- timated at ~60 million tonnes)— they now operate more heim,O Norway, for the Second International Aluminum than 50% of the world’s 231 primary smelters and also Recycling Workshop. This meeting was a follow-up to a produce ~85% of the world’s supply of magnesium, an similar meeting held in 2010. In addition to Norway, the important alloying element for aluminum. He went on to countries represented were Australia, Canada, Germany, note that North America and Europe have become more France, Turkey, Sweden, and the U.S. The majority of dominant in recycling, having 316 and 273 remelting fa- workshop attendees are shown in Figure 1. cilities, respectively, as compared to China with 71 plants, The workshop was organized by SINTEF, the Research according to the International Aluminium Institute. This Council of Norway, and the Norwegian University of Sci- appears to be part of the evolution of the industry as en- ence and Technology and was chaired by Anne Kvithyld ergy costs increase in more developed economies. of SINTEF. In addition, Alcoa, Hydro, and SAPA spon- Green noted that aluminum use in transportation is sored the event. expected to accelerate not only for reasons of fuel -efi After the irst meeting three years ago, an Aluminum ciency, performance and safety, but also because of the Recycling Roadmap was prepared1 with the object of fo- new CAFÉ regulations mandating 54.5 miles per gallon cusing the interests of all key stakeholders, especially in- by 2025 (currently the value is 27.5 mpg). This large industrial and academic researchers, on the current status crease can only be met with signiicant additional down- and technology needs of the recycling of aluminum. The weighting of vehicles through the use of lightweight alu- Roadmap dealt with the topics of the collection and sort- minum. According to Dick Schultz, Ducker Worldwide, ing of aluminum scrap, decoating and melting, treatment in 2012 the average U.S. vehicle was estimated to contain of dross and salt cake, and the reining of melted recy - 343 lbs of aluminum, of which 81% was castings and 19% cled aluminum. A similar suite of topics was addressed in was wrought material, so this number would clearly con- this second meeting with a focus on discussions in small tinue to increase. groups, following brief presentations by experts in spe- In his presentation, Ray Peterson, Aleris International, ciic topics, and frequent update summaries to the wider explored the changes since the last meeting from the audience. industrial perspective. He noted there was a greater de- Kvithyld established four speciic goals for the meet- mand for scrap by all major aluminum companies, driven ing— set priorities for the existing roadmap on alumi- by sustainability programs. For instance, he noted that num recycling, disseminate information on aluminum Novelis has set a goal of 80% scrap content in its products recycling and encourage development of collaborative by the year 2020. The demand for scrap has been accen- R&D projects, encourage dissemination of best practices tuated by China paying high prices for “ good scrap” and in all aspects of aluminum recycling, and enhance alumi- causing a tight market. As a result, producers in Europe num recycling on a global basis. and North America have been forced to process more heavily contaminated scrap, with a detrimental impact on Plenary Session cost and the environment. Unfortunately, the export of scrap not only results in the loss of the metal, but also of In opening the Plenary Session, John Green, JASG Con- the embedded energy within it. As a result of the tight sulting, emphasized the important facts that recycling of market, many large companies are pulling more process- aluminum saves energy, reduces emissions, lowers capi- ing in-house, presumably to better control the scrap. tal costs, and reduces the balance of payments— critical Peterson noted that more pre-processing is occurring to the U.S. at present. He went on to note some of the in U.S. plants and scrap yards. This includes eddy current

30 LIGHT METAL AGE, AUGUST 2013 Novelis PAE Expert in Casthouse Equipment

Using our technical expertise and experience, we engineer, build and commission complete CC and DC aluminium casting lines.

Continuous strip roll casters JUMBO 3C - 3CM DC slab and billet casters, AUTOPAK automation system In-furnace metal treatment system IRMA In-line metal treatment units ALPUR, JETCLEANER, PDBF, CFF After-sales services novelis.com/PAE

Novelis PAE Tel +33 4 76 57 87 00 Certiied by Bureau Centr’Alp • BP 24 Fax +33 4 76 56 65 39 Veritas Certiication 38341 Voreppe cedex [email protected] ISO 9001 • ISO 14001 France www.novelis.com/PAE OHSAS 18001 machines to remove organic contamination, more use of Discussion Sessions XRF hand-held analyzers to assist with alloy identiica- tion, and even use of rare earth magnets to remove para- After the Plenary Session, the agenda moved to the magnetic materials, such as stainless steels. He also noted heart of the meeting, namely the extensive discussion ses- that rotary furnaces are becoming larger and more auto- sions on collection and sorting of aluminum scrap, melt- mated, and some are able to handle organic compounds ing and reining, treatment of dross and salt cake, and through additions of air or oxygen, which also improves the use of aluminum scrap and its properties and alloy energy eficiency. Regarding the treatment of dross and development. salt, he noted that the U.S. is still committed to rotary These sessions were structured to enable many peo- salt processing due to available and inexpensive landills ple to participate. For example, in each of the four and no environmental restrictions. Lastly, he mentioned topic areas, there were two speakers, or advocates, that the concept of an alloy designed for recycling holds who briely laid out the key issues on each topic to little appeal for manufacturers— in each case they simply the whole conference group. After hearing the key is- want the most appropriate alloy for the application at the sues, the meeting split up into four smaller groups (6-8 best price. people). These smaller groups worked to develop solu- Mark Schlesinger, Missouri University of Science and tions, suggestions, or concepts to approach the issues Technology, explored the changes from the academic laid out by the area experts or advocates. The smaller viewpoint and had a great perspective due to the sabbati- groups also selected a spokesperson whose job was to cal year he had spent at SINTEF, where his main accom- report back to the whole group when it reassembled. plishment had been to complete a new edition of his ex- In this manner, many individuals had an active role in cellent book, Aluminum Recycling. He discussed several pro- the development of key suggestions or concepts to ad- cess options for improving aluminum production. As one dress speciic issues. example, he cited the work of Matsuzaki, et al.,2 where the These issues were tabulated and considered by the simple act of stirring the aluminum melt provided more whole group. Eventually, each person was given three heat uniformity, such that less input energy was needed, points (votes) to indicate their considered view of what and less dross was created (Figure 2). were the best and most important suggestions or concepts to address the speciic issues in each area. In the tables that follow it may be seen that there was some di- Figure 2. versity of opinion, but in most cases it was evident which were the signiicant issues, and which areas warranted additional work and research. To improve the clarity and readability of the tables, when a proposed sugges- tion did not receive any points (votes), it was generally deleted. Collection and Sorting: The two expert advocates in this area were John Bufington of MillerCoors Brewing Company/KTH and Adam Gesing of Gesing Consul- tants. In his talk, Bufington mentioned that recycling is the crux for the sustainability of aluminum. He also mentioned the need to consider the different streams of metal and the need to keep them separate. For ex- Figure 2. Difference of temperature from the upper to the bottom in the ample, the alloys used in aerospace are much different furnace with and without stirring (Matsuzaki, et al., 2011).2 than those used for containers and packaging. Bufing- ton also pinpointed several basic issues about recycling. He also discussed the pros and cons of methods for im- For example, some cultures are more effective in recy- purity control in molten aluminum and noted the wide cling than others, e.g. Brazil, where there are special range of alloying additions in some alloys. Regarding conditions to encourage recycling. He also noted that Fe content, which is frequently cited as a problem ele- mandates work to enhance the collection process, but ment, he noted the use of sodium borate as a means of tend to come with a political cost. He ended by propos- controlling Fe levels. The Fe content can be reduced by ing a smart vending machine that would encourage the ~50%, but the disadvantage is that some sodium is intro- process and provide an incentive to reward the recycler. duced into the metal, see Chen, et al.3 This observation Gesing noted that the main issue in collection is with prompted several discussions, and eventually a consensus old scrap; new scrap generated in a production process was reached that as long as aluminum use continues to from side and edge trim, for example, is all collected and expand, the simplest and most economical method to promptly recycled. He reviewed the sources of the vari- control metal impurities, such as Fe, Si, etc., is by dilu- ous types of scrap and concluded that the main issue is tion with virgin aluminum. with the 11 million tons per year of post-consumer mate- Stian Nygaard, SINTEF, discussed the many opportu- rial. He also compared the numerous sorting technolo- nities for international cooperation that are presently gies now available, as well as the cleaning technologies available in the European Union (EU) for R&D in the and made the point that cleaner scrap provides greater aluminum area. He noted the program Sustainable Pro- yields in recycling. cess Industry through Resource and Energy Eficiency Here, an extensive discussion centered on the recycling (SPIRE) in the EU and suggested the SPIRE technology of automotive hulks. The issue was whether it is better roadmap as a place to learn more about their projects.4 to shred the auto hulk completely (taking ~40 seconds) There is a call for aluminum projects in the future, and then use capital intensive automated sorting technol- many of which require a foreign partner with shared ogy, as is practiced in North America, or whether there efforts and funding. He noted that there were already should be some speciic, labor-intensive dismantling of many aluminum oriented programs by the Research aluminum-rich components, such as the powertrain. Council of Norway and the Centres for Research-based The latter approach was generally favored by Europeans, Innovation. because of the relatively lower salary structure and capi-

32 LIGHT METAL AGE, AUGUST 2013

Grp # Suggestions Points Rank Grp # Suggestions Points Rank For old scrap, determine whether it is better to upgrade An option: decoating before melting at the same plant the scrap or route it into existing secondary alloys, which 2 can control emissions and recover energy, but at a can be batched from mixed scrap. cost of additional investment and more complicated 2 1 Cleaning is an important step to reduce melt losses and logistics. Decoating results in fewer inclusions. UBC maintain product purity when going from collection to recycling provides a reference standard for an efficient 12 1 sorting. Few participants in the recycling process chain 1 decoating and melting method. want to consider this step. It is better to remove iron from scrap before melting, Recycling works better in EU than in US. Need to than refining it from the molten metal. Any proposed change attitudes in US, to set up some system to reward 3 process for Fe and Si removal from the melt (e.g. 84 behavior. fractional solidification), needs to compete There are challenges with a number of different alloys, economically with dilution by prime. 2 but there will always be sufficient primary metal that can 1 Need a de-magging process that removes and be used for dilution. recovers Mg; options are vapor and electrorefining 13 1 Need more knowledge concerning recycling in India and 6 processes. Problem with de-magging of high-Mg Asia. 2 alloys is dross generation and high metal loss. No action required for new scrap. 1 Silicon removal, why should we? Can we? 4 For old scrap, there is a need to get the public more Can we change furnace design for Al? For instance, 6 4 involved in pre-sorting in-house waste. high productivity, low melt loss furnace designs. Consider increased dismantling of End Of Life vehicles 5 for better recycling efficiency. Safety is first, accidents affect all of us. Air bags are Define sorting and process lines of different products, becoming an issue, but some are surviving the recycling 2 3 such as dross, collected scrap. Technologies are there, process and exploding in the melting furnaces. we just need to convince industry that there is a return 93 Melting coated scrap and using organics as a fuel on investment. Maybe this is a role for the Aluminum source. Need better models on how to use that. Need 93 3 Association. to better understand organic contaminants. Involve scrap dealers in considering improved Inclusion removal is an issue for any secondary 84 6 technologies for scrap sorting. material. Biggest bottleneck for old scrap is collection. We need Real time chemical analysis inside a furnace during 84 more knowledge of old scrap sources by market and 12 1 melting. also of metal losses. Off-gas treatment: any technological change for Need to understand different country and cultural issues. 4 1 remelters must meet regulations for emissions and Plans for one country may not work in another. 2 Plenty of primary aluminum is available, so maybe it is 4 safety, and must keep up with changing regulations. not necessary to concentrate so much on sorting – 1 Can industry affect these regulations? dilution is easier. There is scope for improvement in optimizing salt flux. 10 2 Table I. Issues and suggestions for the collection and sorting of alu- Table II. Issues and suggestions for the melting and reining of alumi- minum scrap. num scrap.

tal costs and the current high unemployment situation and control NOx emissions, and provided a schematic there. This is a good example of different approaches be- for the wet scrubbing of furnace off-gas. Again, extensive ing preferred in different parts of the world, depending discussions occurred and the key points are tabulated in on local economics. Table II. After these introductions, the four groups discussed Treatment of Dross and Salt Cake: The second day of dis- the issues further and all suggestions for the collection cussions followed a similar format with the advocates be- and sorting of aluminum scrap were tabulated by group, ing Ralf Urbach, Ingenieurberatung für Metallurgie und together with points accumulated and the resulting rank- Rohstoffe, and Anne Pichat, Constellium. Urbach started ing in Table I. off by deining dross and describing its generation. He Melting and Reining: A similar discussion process estimated that dross represents about 2% of yearly ingot was adopted in the case of the melting and reiningproduction of or, assuming that dross contains ~60% Al, aluminum scrap. In this case the advocates were John around 3.2 million tons of dross. He noted that the ob- Grandield of Grandield Technology and Christoph ject is to minimize dross formation for the minimum cost Schmitz of ALCUTEC Engineering. Grandield, a con- and metal loss. He also mentioned that dross formation sultant from Australia, started by pointing out all the can range from 1-6% depending on process variables, ways a consultant can interact in a project and illustrat- such as temperature, stirring, and alloy additions, Mg- ed this by an example of recent work in tracking the containing alloys being especially prone. In the furnace, increase in Ni and V impurities in aluminum alloys. He the use of fused salts can have markedly beneicial effects noted that in luxing there are many different systems in reducing the entrapment of liquid metal. A big differ- of delivering essentially the same technology and the ence is in the regulations regarding the disposal of salt consultant can help in assessing the relative merits of slag. In Europe, this material is considered hazardous each. He then went on to compare the merits of the and, accordingly, is extensively treated, while in the U.S. new Advanced Compacted Filtration process for mol- it is not considered hazardous and can be landilled. This ten metal and showed it was superior to other iltra- arbitrary distinction drives a lot of the technology differ- tion schemes.5 Lastly, he discussed the potential for a ences. de-magging process and indicated the potential beneit Pichat presented a series of low diagrams for dross for- of such a process to both aluminum and magnesium in- mation and factors which impact the process. She also dustries if it could be invented. examined slag formation in the same manner. From the Schmitz discussed the issues from the perspective of environmental perspective, it is important to try to mini- melting, furnace control and design, and waste gas clean- mize salt use, as this in turn lowers fume and dust collec- ing. He pointed out the importance of melt stirring in en- tion requirements. In terms of processing, it is critical to ergy reduction and also the use of organic contamination reduce the cooling time for dross as this minimizes subse- in providing additional energy to the melter. He cited the quent oxidation of the metal. After these introductions, advantages of automated furnace controls and pointed discussions took place and the suggestions are tabulated

out how burner controls can minimize CO2 formation in Table III.

34 LIGHT METAL AGE, AUGUST 2013

Grp # Suggestions Points Rank Grp # Suggestions Points Rank Reduce the amount of oxidation occuring outside the furnace Recycling-friendly alloys? Manufacturers want best 2 5 and recover as much Al as possible. material for application. Study the effectiveness and safe handling of reactive salts Need to take common alloy scrap materials and learn to containing nitrates and sulfates on their ability to separate the 6 4 1 move it to a higher value material; use different process molten Al from dross. 2 Maximize dross/Al recovery with a dedicated furnace; skim such a powder production. Should be working with OEMs to influence alloy dross and put it directly in dedicated furnace containing a 1 1 metal vortex. Dross won’t be cooled. Low metal content salt- 4 development and selection. oxide balls would form in vortex. Would need multiple Need a standard method to calculate percent of recycled 12 2 furnaces for non-compatible alloys. metal. Study possibility of estimating metal content of dross in 6 4 Pressure from market for recycled materials in products is furnace: Thermography? System to measure weight gain? not as high as anticipated — still not mandated by 1 Landfilling of salt cake; why hazardous in EU and not in U.S.? 2 regulations. Economics of salt-free melting vs salt/ processing/ recycling. 1 Availability of post-consumer scrap is not high, but is 3 How to reduce dross, make melting process as efficient and 2 increasing. environmentally friendly as possible: strike balance between Focus on recycling into lower grade materials as well as 12 1 1 dross generation and general energy efficiency. Seek to products higher in the value chain. maintain high productivity and reduce dross. 2 Work on alloy development on how to use recycled metal Fundamental research to establish best melting practice to 2 in extrusion and rolling lines. minimize oxidation, as well as skimming practice, burner 2 Work to ensure that low CO is credited properly with operation, surface area/size of parts/slabs/ingots, influence of 2 2 atmosphere. products containing recycled Al. Study the impact of furnace design, surface area, and Study chemistry and properties in alloy development, 9 3 temperature on dross formation. tolerance testing, and mechanical corrosion resistance — 1 Re-evaluate fluxing practices/combinations for releasing the adjust compositions while maintaining properties. Al, i.e. impact of fluorides and chlorides on skin and of various 1 For now, better to dismantle cars, especially for items like inert atmospheres on oxide strength and thickening. 7 4 3 3 engine blocks. Consider automated skimming. 4 Restructure mechanics of scrap system; educate scrap Why still using salt? Create guidelines of when and where to 1 2 supplier for properties. use salt and, if so, what kinds of salt. Review regulations and barriers for upgrading of recycled Study the interaction of refractories, liquid metals, and salts. 2 1 material, e.g. into aerospace applications. Pros and cons of salt vs salt-free treatment, including economics and process analysis (centrifuge vs paddle). With Define alloys which are more or less sensitive to 12 1 1 trends for less landfills, need salt-free processing with high recycling, both cast and wrought. recovery. Is this possible? Specification of a recycling-friendly alloy. Need new 4 Develop efficient, manageable quick quenching of salt slag alloys? 1 4 4 dross. Need better understanding of effect of all contaminants on 16 1 Immediate skim-metal separation, e.g. reactive salts sidewell. 1 alloy properties. Electrolysis of dross? Done in Australia for a non-Mg alloy. Find efficient, low cost refining technologies. 8 3 Rather than using a salt-free process, put back in cell, melt 3 scrap in salt bath, then use electrolysis to clean oxides out of Table IV. Issues and suggestions for the use of aluminum scrap and salt—no dross is generated. its properties and alloy development. Table III. Issues and suggestions for the treatment of dross and salt cake from aluminum recycling. ees and are listed in order of decreasing points (votes) received (note that the votes received should only be Use of Aluminum Scrap, Properties and Alloy Development: considered as a qualitative measure): In this last discussion series, Snorre Fjeldbo of Hydro • There is a need for better understanding of the and Ola Jensrud of SINTEF were the advocates. Fjeld- effect of all contaminants from major and minor ele- bo, following up on suggestions from Das published in ments on alloy properties. (16 votes) Light Metal Age, 2006,6 explored the concept of recycling • There is a need for a de-magging process that re- friendly alloys. He contrasted several possible alloy com- moves and recovers magnesium— the problem with de- positions for the major alloy series, concluding by advo- magging of high-Mg containing alloys is dross genera- cating an AA6060 alloy for extruded proiles. He indicat- tion and high metal loss. (13 votes) ed this alloy should have the required strength, surface • Cleaning is an important step to reduce melt loss quality, and corrosion resistance, as well as the mechani- and maintain product purity when going from collec- cal properties and chemistry to gain acceptance in the tion to sorting; unfortunately few participants in the marketplace. recycling chain want to consider this step. (12 votes) Jensrud detailed all the manufacturing steps and com- • The biggest bottleneck for old scrap is collection; plexities involved with specifying and manufacturing an more knowledge is needed of old scrap sources by mar- automotive component to be produced on three differ- ket and also of metal losses. (12 votes) ent continents. As an example, Jensrud cited a AA6082 • How do we reduce dross formation while making the chassis component, a front lower control arm in forged melting process as eficient and environmentally friendly aluminum, which was planned to contain up to 75% old as possible? What is the correct balance between dross aluminum scrap. Different possible processing routes generation and energy eficiency? (12 votes) were also explored. Finally Jensrud reviewed some of the • There is a need for the pros and cons of salt versus lessons learned from the EU Superlight Car project that salt-free treatment, including economic and process was fabricated using a multi-materials approach and con- analysis (centrifuge vs paddle) with trends to minimize tained some 53% Al, 36% steel, and 7% Mg. Again the landills. There is also a need for salt-free processing suggestions, needs, and concepts generated during the with high recovery rates— is this possible? (12 votes) discussion are shown in Table IV. • A standard method to calculate the percentage of recycled metal is needed. (12 votes) Summary • There is scope for improvement in the salt-lux process. (10 votes) The following needs, suggestions, or statements re- • Better models are needed on melting coated scrap ceived a broad measure of support from the attend- and taking advantage of the coatings as a fuel source,

36 LIGHT METAL AGE, AUGUST 2013 as well as a better understanding of the organic contaminants. (9 votes) • Study of the impact of furnace design, surface area, and temperature on dross formation is needed. (9 votes) • Deine the sorting and processing lines for different products; technologies are available, but industry needs conviction that ROI is suitable. (9 votes)

Acknowledgements

The authors greatly appreciate the inancial support of the event sponsors. John Green would also like to ac- knowledge the great hospitality of the conference orga- nizers. All attendees must have fond memories of histori- cal walks in beautiful Trondheim (Figure 3), of aquavit tastings, and especially of great restaurants!

References

1. “ Roadmap – From Europe and North America: Workshop on Aluminium Recycling,” SINTEF, June 13- 15, 2010, www.sintef.no/upload/Materialer_kjemi/do Figure 3. View from workshop dinner, where the Munkholmen medi- kumenter/roadmap-aluminium-recycling-web.pdf. eval fortress can be seen in the middle of the Trondheim fjord. 2. Matsuzaki, Kunio, Toru Shimizu, Yoichi Murakoshi, and Kenzo Takahashi, “Evaluation of Effects of Stirring search Area, July 2012, www.spire2030.eu/uploads/Mod in a Melting Furnace for Aluminum,” Light Metals 2011, ules/Documents/spire-roadmap_broch_july2013_pbp. TMS, 2011, pp. 1,199- 1,203. pdf. 3. Chen, Chong, Jun Wang, Da Shu, Jing Xue, Bao-de 5. Breton, Francis, Peter Waite, and Patrice Robichaud, sun, Yong-sheng Xue, and Qing-min Yan, “ Iron reduction “Advanced Compact Filtration (ACF): An eficient and in aluminum by electroslag reining,” Transactions of Non- lexible iltration process,” Light Metals 2013, TMS, 2013, ferrous Metal Society of China, Vol. 22, Issue 4, 2012, pp. pp. 967- 972. 964−969. 6. Das, Subodh K., “ Designing Aluminum Alloys for a 4. “ Sustainable Process Industry through Resource Recycle-Friendly World,” Light Metal Age, Vol, 64, No. 3, and Energy Eficiency – SPIRE Roadmap,” European- Re2006, pp. 26-32.

State of the art extrusion presses from 660MT-12,500MT Extrusion presses and related equipment.

China office: Archie Rodriguez Tom Nentwick Susi Xu +86-139 2820 4445 Tel: 954-224-1267 Tel: 330-506-9291 [email protected] [email protected] [email protected]

MSGC GROUP CO.,LTD Visit: www.extrusionsupplies.com

LIGHT METAL AGE, AUGUST 2013 37 Novelis Develops Sustainable Can Stock Interview with John Gardner, Chief Sustainability Oficer at Novelis

ince the beginning of 2011, tent can sheet to customers. We are also putting sys- John Gardner has served as tems in place to manage globally integrated recycling Novelis’ irst chief sustain- infrastructure, including the kinds of supply chain ability oficer. He has been tools necessary to be able to trace high-recycled con- withS Novelis for more than 28 years, tent as part of a standard certiication process through spending much of his time in Eu- our system. rope in a variety of roles, including positions within sales and market- Tell us a bit about the certiication process for evercan. Why ing, operations, human resources, was this important? recycling, and corporate affairs. As Our entire supply chain was reviewed, audited, and chief sustainability oficer, he is re- certiied by SCS Global Services, the top provider of sponsible for leading the develop- John Gardner. environmental and sustainability certiications and cre- ment of a globally integrated sus- ator of the Forest Stewardship Council certiication for tainability strategy that relects the company’s commit- responsible forestry management. This process begins ment to delivering sustainable solutions in its processes from the point of sourcing UBCs and continues through and products. This commitment has led the company to the preparation and remelting process in our recycling pursue the development of new high-recycled content centers. Each ingot and coil is followed through the products, such as the evercan™ , as well as expand its re- processing in our plants, and shipping to canmakers cycling operations around the world. and ultimately to brand holders for illing. We have the ability to trace the full chain from end to end to ensure Novelis recently introduced its evercan aluminum can body that consumers can be certain the aluminum cans they sheet with high recycled content. Please tell us more about this are purchasing contain high-recycled content. We will new can sheet. What alloy is it made from? also be regularly audited by SCS to review documen- The Novelis evercan beverage can sheet is can body tation and traceability to ensure we continue to meet stock that is made from 90% recycled content. It’s the these rigorous standards. industry’s irst independently certiied, high-recycled content aluminum designed speciically for the beverage Will all of Novelis’ operations be manufacturing the evercan can market. When this new can body is combined with material, or only select facilities? the can end, the resulting beverage can contains a signii- Novelis’ evercan will be globally available by the end cantly higher percentage of recycled content than exists of the year. As of today, three of Novelis’ recycling fa- in today’s aluminum beverage cans. It is the same alloy cilities— Berea, KY, and Greensboro, GA, in the U.S. as standard can body stock, but certiied to contain high- and Latchford in the U.K.—have been certiied by SCS recycled content. Global Services. By the end of 2013, the company plans to have its recycling centers in Pindamonhangaba, Brazil; How long has the evercan solution been in development? What Yeongju, South Korea; and Oswego, NY, also certiied to prompted its development? produce evercan. We began work on the program more than a year ago; however, we What are the beneits of the evercan prod- began the certiication process for uct? What impact will it have on the alumi- this irst phase offering of the % 90 num recycling and can industries? recycled content can body stock early The high-recycled content in ever- this year. This program is part of our can showcases the great sustainable commitment to sustainable aluminum qualities of the aluminum can. It’s a product innovation and our goal to perfect example of a circular economy reach 80% recycled content in our where we can realize greater beneit by products by 2020. closing the loop and recovering more In addition, consumers in many post-consumer UBCs and making new parts of the world are increasingly ones that contain the highest levels of making purchase decisions based recycled content— it is environmental- upon the sustainability characteristics ly and economically optimal. Purchas- of the product they’re buying. A can ing beverages in an evercan will enable with high-recycled content will allow environmentally conscious consumers those consumers to do their part to to enjoy sustainable products and raise help reduce the impact to our envi- the visibility of recycling as a consumer ronment and encourage more end-of- initiative. life recycling. Have any companies signed contracts as What technical challenges were faced in of yet to use the material in their cans? developing a high-recycled content alloy for We are very encouraged by the in- can body sheet? How were these overcome? terest we have received from custom- We have been investing heavily ers on evercan. Now that we have an- in our recycling infrastructure and nounced our certiication program, technology around the world, so that we are engaged in discussions with nu- we now have the volume and scale merous customers regarding potential globally to offer high-recycled con- evercan agreements.

38 LIGHT METAL AGE, AUGUST 2013 Last summer, Novelis announced that it was working to de- recycling investments strengthen our ability to process velop a unialloy solution for aluminum cans with the ultimate recycled materials in all four regions where we operate, aim of bringing recycled content in cans up to 100%. How is taking into account scrap availability in the region and Novelis progressing toward this goal? Does the company have a our rolled product demand. completion date by which they hope to accomplish this? We recently commissioned an aluminum recycling and For the past 18 months, the Research & Technology casting center at our Yeongju, South Korea, facility. The team has been working on alloy chemistry and the tech- new operation is the largest aluminum beverage can recy- nology around can forming and continues to explore fur- cling center in Asia. The Yeongju recycling center is part ther development. The 90% recycled content can body of a multi-year, $400 million expansion of Novelis’ opera- sheet is the irst step towards our ultimate vision of a can tions in Korea. Asia is the world’s fastest growing market made from up to 100% recycled material. This is a long- for rolled aluminum used to create beverage cans, cars, term development project. It’s premature to speculate on and consumer electronics. any speciic timelines. We also have a $32 million recycling investment under way at our plant in Pindamonhangaba, Brazil. The ex- Novelis has a goal to achieve 80% recycled content in its products pansion includes a state-of-the-art recycling line that will by 2020. How well is the company progressing toward that goal? nearly double the plant’s capacity to recycle UBCs and We are making meaningful progress against our goals other aluminum scrap from 200,000 tonnes per year to and are starting to see some real beneits from our global 390,000 tonnes per year. recycling strategy. We began this journey when we were at Work progresses on our 400 kilotonne recycling and 33% recycled content globally. In just two short years, we casting facility in Nachterstedt, Germany, that will ulti- have increased this to 43%. Our mid-decade goal of 50% mately be the world’s largest and most high-tech scrap is well within reach. recycling center. Slated to open in July 2014, the center will process UBCs as well as numerous other forms of alu- Novelis has been working to expand its recycling operations minum scrap from across continental Europe. across the world, including the Pieve Emanuele facility in Mi- We also recently commissioned a new aluminum recy- lan, Italy, its facility in Nachterstedt, Germany, its center in cling and continuous casting line at our Pieve Emanuele Yeongju, South Korea, and the plant in Pindamonhangaba, facility in Milan. The $15 million expansion brings ad- Brazil. Please tell us more about these efforts. vanced technology that will enable the company to recy- We have a number of important recycling projects un- cle aluminum scrap into high quality aluminum sheet for der way that support our 80% recycled content target. further processing at operations in Italy and Germany. Over the past two years, Novelis has launched nearly $450 At Novelis, these aggressive investments in recycling million in projects designed to increase Novelis’ recy- projects are making our closed-loop business model cling and casting capacity to 2.1 million tonnes by 2015. more eficient, while also providing a secure, predictable We conduct strategic reviews of our business to deter- supply of recycled input material for our plants and the mine where and when to fund capital investments. Our global customers we serve.

LIGHT METAL AGE, AUGUST 2013 39 Grupo Cuprum: Mexico’s Largest Extrusion Company Leading Producer of Windows, Ladders, and Fabricated Products By Andrea Svendsen, Managing Editor

hrough various acquisitions and moderniza- sell architectural proiles, glass, and hardware directly tions, Grupo Cuprum has grown over its 65 to small manufacturers of custom made windows). The years to become the largest aluminum extrusion group also has a contract with Home Depot for the sale company in Mexico. The privately owned com- of standard sized windows. panyT incorporates vertical integration and value-added Ladders represent a signiicant part of the group’s production to set themselves apart from other produc- overall business (21%). Located close to the extrusion ers. Not only does the company cast its own billet, but it plant in Monterrey, the facility manufactures ladders out also provides fabrication services and maintains its own of aluminum, iberglass, wood, and steel and ships them fabricated windows shop and ladder manufacturing. Dur- to their distribution centers throughout Canada and the ing a recent visit to Mexico City, Light Metal Age was in- U.S. Ladder brands in which Grupo Cuprum aluminum vited to visit the company’s extrusion plant, which houses can be found include Louisville (100% owned by Cu- a complete production chain, from billet production to prum), Davidson, DeWalt, and Black & Decker. extrusion to powder coating and anodizing. The tour was In the architectural arena, the group sells aluminum hosted by Jorge Salazar, plant manager, who presented proiles for curtain wall projects around the world, - in information about the overall company, as well as the cluding the Austonian Tower in Austin, TX; the Chicago Mexico City plant and its capabilities. Children’s Hospital in Chicago, IL; Terminal One at the JFK Airport in New York, NY; and the roof of the Cape Group History and Overview Town Stadium built for the 2010 World Cup in South Af- rica, as well as numerous buildings throughout Mexico. Cuprum was founded in 1948 in the city of Monter- Grupo Cuprum is the leading producer of aluminum rey with one 170 tonne press for the extrusion of cop- windows and doors in Mexico, where there are few stan- per (“ cuprum” is Latin for “ copper” ), and ten years later dard window sizes, though standard windows are starting switched its production over to the manufacturing of to be used in high volume construction. While building aluminum extrusions (Figure 1). In 1989, the company a new structure, construction companies in Mexico will was acquired by Grupo Imsa, which maintained owner- leave an opening, which will later be measured and it- ship of the company until 2010, when the two owning ted with a custom window. Cuprum provides stock sized families divided ownership, with one moving away from proiles, which aluminum distributors sell on the local the aluminum extrusion business and one continuing to market. operate what is now known as Grupo Cuprum. The company has certiications from PPG Industries for Duranar polymer coatings and Valspar for Fluropon coatings, as well as from the Procuraduría Federal de Pro- tección al Ambiente – PROFEPA (Federal Attorney for Environmental Protection) with a Clean Industry Certii- cation, which is awarded to companies that meet the standards of air emissions, wastewater discharge, and waste management, among other requirements.

The Mexico City Extrusion Facility

Located in Tlalnepantla just outside the city, the Mex- ico City plant is housed on a 90,000 sq meter site. When Cuprum purchased the Alcomex S.A. de C.V. site in 1998, Figure 1. Industrial proiles extruded by Grupo Cuprum. it was outitted with ive presses. Three of the presses were removed, and two small indirect presses were kept In addition to the Monterrey facility, Grupo Cuprum for start up of the Mexico City site. Shortly thereafter, Cu- operates two other extrusion plants, in Mexico City and prum moved two more presses to the site from another Guadalajara. The Mexico City site was purchased in 1998 recently acquired plant, also in Tlalnepantla. Since then, and the Guadalajara plant was acquired in 2011. A sec- the company has purchased two additional presses, bring- ond press was brought over from a former Nacobre plant ing the total number of presses at Mexico City to six. In in Puebla and installed at the Guadalajara facility. Across addition to its extrusion facilities, the plant has a foundry, all three plants the company has a total of 15 presses. inishing capabilities (including powder coating and a Grupo Cuprum produces 80,000 tons per year of alu- new anodizing line installed in March 2013), a fabrication minum extrusions, which are used in a variety of indus- shop for local customers, and a die shop. The die shop tries, including windows and doors, curtain wall ladders, produces around 22 dies per day and provides dies to all automotive (such as sunroof installations for Volkswa- of Grupo Cuprum’s facilities (Figure 2). gen, as well as other components for General Motors, The onsite foundry has three furnaces. The three tilt- Ford, and Chrysler), manufacturing, healthcare, and ing rotary furnaces with regenerative burners (30, 26, agriculture, as well as standard shapes (bars, rods, tees, and 24 tons) melt both in-house scrap and scrap collect- etc.). In addition, the company has a lat products busi- ed and purchased from outside sources. A mix of primary ness (for distribution of aluminum sheet and foil), a aluminum in the form of T-ingots is also used. The tilting site for fabrication of windows in Monterrey, a ladders furnaces feed into a Wagstaff vertical DC caster, which plant, an industrial business with die casting and a fab- produces 125-130 logs per day. The plant also has a ho- rication shop, and 73 construction stores (where they mogenizing oven.

40 LIGHT METAL AGE, AUGUST 2013 We’re Growing.

More plants. More capability. More service. More ETS quality dies.

At ETS, we are building the largest, most advanced It all adds up to more capability to deliver what die production capability in the industry so we can you need in easy pushing, longer-lasting dies save our customers time and money. wherever extrusions are made. Multi-core, We can design and produce more than 5000 high quality multi-cavity, domed dies, shut-off, you name it. dies each month in 145,000 sq ft of manufacturing space Nobody does it like we do. in North and South America, including a new plant in Faster service, better answers. Wylie, TX, plus our new location in Medellin, Colombia. Adding to that in 2013, we will have an all-new 35,000 sq ft plant coming online in Sorocaba, Brazil.

Exco Tooling Solutions Michigan 1-866-749-3437 Texas 1-972-442-2312 Canada 1-800-461-6298 Colombia (57) 4-562-8755 www.etsdies.com

ETS Sorocaba, Brazil ISO9001:2008 Certiﬁ ed Figure 2. Final shaping of a die being done by hand. Figure 4. Powder coating line with Class I and Class II inishes.

Figure 3. Extrusion area in building two. Figure 5. Tanks of the newly installed anodizing line.

The extrusion area is split between two buildings built and installed by the skilled workforce at Cuprum. which house three presses each (Figure 3). These The line is able to produce a full range of color options presses range from a 5 inch Lombard (900 tons) to an (from champagne to black), including colors produced 11 inch SMS Meer (3,400 tons). Each of the presses by optical interference anodizing, such as grey, blue, and is supported by a combination of OMAV, Turla, and green, which are not common on the Mexican market. Granco Clark automated handling equipment, includ- Anodizing chemicals are provided by Alsan and the line ing runout tables, pullers, and stretchers. Quenching has a capacity of around 450 tons per month. is done either by air or water, depending on the de- All of the proiles at the plant are manually packed sired temper of the proile. Accurate control of the into bundles, which is more cost-effective and allows extrusion process is maintained through PLC moni- the personnel to perform a inal quality check before toring, which controls the pressure, extrusion speed, shipping. The organized shipping area has a scan- temperature both inside and outside of the press, and ning and barcode system that provides 99% assurance other variables. An average of 2,300 tons of extrusions of where a customer’s order is at any given time. The are manufactured per month in 6000 series alloys and warehouse has a capacity to hold 3,000 tons of extru- some in the 1000 series. sions and implements a vertical storage system to opti- The Gema powder coating line was installed in 2005 mize space. with a simple layout with a capacity of around 750 tons The facility also implements environmental measures, per month (Figure 4). Proiles are loaded on a track, such as the new rainwater collection system, which was then carried through a series of three cleanings, and installed in May 2013. This system helps the plant re- three rinses before being soaked with a binding agent duce 15% of its consumption of city water. In environ- to ensure the quality of the inish, followed by 15 min- mental work outside the plant, Cuprum employees took utes of drying in an oven. The track then carries the part in a reforestation campaign with the government proiles past two powder coating heads, the irst coats of Mexico and planted 200 new trees at Sierra de Gua- the front, the second coats the back. The inal step is dalupe, a mountain near the Mexico City site. processing through the curing oven, after which the The Mexico City facility employs 1,000 people, in- proiles are stacked and packaged by hand. Every hour, cluding a dedicated maintenance team. From extrusion a quality check is performed to ensure there are no operators to the administration personnel, the people scratches or other defects and that the proiles con- at Cuprum have pride in their work. Salazar, who has form to international norms, AAMA and Qualicoat. been working for Cuprum for over six years, said, “ This The anodizing line (Figure 5), which took ten months is the irst Mexican-owned company I’ve worked for, to build, started operation in March 2013 and produces and I’m proud to work here. I think Cuprum is able proiles with AAMA Class I and Class II inishes. It has 32 to be competitive because of its good quality products tanks, some of which were brought over from the former and because we give value and good service to our cus- Nacobre plant in Puebla and upgraded; the rest were tomers— that’s the vision of Cuprum.”

42 LIGHT METAL AGE, AUGUST 2013 The Automatic Die Cleaning System from Belco adapts through a full diagnostic system and optimization tools that allow you to continuously improve its process.

The system greatly reduces operational hazards by Belco Industries Incorporated automating many aspects of the die cleaning process 9138 W. Belding Road, Belding, MI 48809 which may otherwise be done manually with ventilation 616.794.0410 • www.belcoind.com and protective equipment. Intelligent controls allow for job completion without re-cleaning or other hassle.

Trust your die cleaning needs to Belco’s Automatic Die Cleaning System. Easy installation, reliable operation, and a safer atmosphere for your operators make the system a wise choice. IMEDAL Congress Shows Robust Aluminum Industry Automotive Market Fueling Growth in Mexico By Andrea Svendsen, Managing Editor

he ifth International Aluminum Congress and Mexichem. Both afirmed that Exhibition, held July 17-20, took on special sig- the Mexican aluminum indus- niicance as it marked the 40th anniversary cel- try is growing, with new manu- ebration of its host, the Instituto del Aluminio facturing investments that will T(IMEDAL). The congress was situated in Mexico City’s rank the country as the fourth centro historico, a region richly layered with history, from or ifth largest producer of the Aztec ruins sprouting out of the Zócalo (main plaza) automobiles in the world, in and the ornate marble beauty of the Palacio de Bellas which aluminum will play an Artes to modern architecture, such as the Museo Souma- essential role. “ This is a great ya, which features a seemingly impossible curved alumi- moment for Mexico, and this num façade (Figure 1). is a great moment for alumi- Congress sessions featured presentations from various num,” said Arellano. sectors of the aluminum industry, covering topics such Following the opening Figure 2. Ramón Arellano. as industry trends and trade practices, melting furnace speeches, Edgar A. Rangel eficiency, anodic hard coatings, extrusion management (Figure 3), commercial di- practices, rheocasting, refractory materials, coatings for rector of industrial proiles aluminum proiles, aluminum composites, and more. Inand fabrication for Grupo addition to the congress, the event included an exhibi- Cuprum, was sworn in as the tion area, working table sessions, and a tour of Grupo Cu- new chairman of IMEDAL. prum’s Mexico City extrusion plant. Social events includ- While the Mexican industry ed a gala dinner featuring soaring operatic music, a golf has reached exceptional levels tournament, and a nighttime bus tour of the city center. of growth and offers excellent opportunities, he said, “ We Day One have before us many challenges and we need to be prepared Delegates were welcomed to the congress by Ramón to meet these challenges.” He Arellano (Figure 2), past-chairman of IMEDAL, and pointed out that the Mexican Figure 3. Edgar A. Rangel. Ricardo Muñóz, director of the executive committee at aluminum industry should work cooperatively with international industries, such as the U.S., rather than ight them, provided those countries follow the rules of fair trade. The irst presentation, given by Heidi Biggs Brock (Figure 4), president of the Aluminum Association, looked at aluminum industry trends in the U.S. Demand and consumption of aluminum is trending toward pre-recession levels and indicators show that growth should continue, but despite positive indicators, the industry is still digging out of a hole, said Brock. In the U.S., Figure 4. Heidi Biggs Brock. consumption totaled 9 million tonnes in 2012, a 27% increase from 2009, with one-third of this supply from secondary production. The building and construction and automotive industries are showing growth, but the container industry is down. The transportation market is fueling aluminum’s growth, she said, noting the CAFE and other international regulations driving vehicle lightweighting, as well as proposed standards from President Obama for environmental improvements in trucking leets. She added that sustainability is a factor that differentiates aluminum from other industries. Since 1991, energy demand for primary aluminum is down 17% with GHG emissions down by 42%. For secondary production, energy demand is down by 58% and emissions by 65%. She closed by listing the Association’s Figure 1. The Museo Soumaya in Mexico City has a façade covered initiatives to advance aluminum, including work by the with 16,000 aluminum hexagons. Aluminum Transportation Group; the development of

44 LIGHT METAL AGE, AUGUST 2013 Extrusion and Forging Upgrades

Butech Bliss continues to be one of the industry’s leaders in extrusion and forging press upgrades and recently completed an order for replacement platen on a 4,800 ton press.

We Build Things. Better. Always have, always will. At Butech Bliss, we’ve been building things better for a long time. For 125 years, industries have counted on us to deliver the design, engineering and technological advantages necessary to help them succeed. Let us prove it to you.

To learn more about our world-renowned manufacturing and technology center, call +1 (330) 337-0000, visit ButechBliss.com or email [email protected].

Extrusion/Forging Presses & Stretcher Products & Services l Main Cylinders l Butt Shears l Main Rams l Tie Rods l Platens l Billet Loaders l Crossheads l Die Shuttle Systems l Containers l Engineering Studies l Container Housings l FEA Analysis

Scan with your Smartphone to learn how Butech Bliss We Build Things. Better. can help you build a better business. 550 South Ellsworth Avenue, Salem, OH 44460 an Aluminum Caucus, a bi-partisan group on Capitol the molten aluminum solidiies and will penetrate the Hill in support of the aluminum industry; an updated lining no further. He said pumps increase circulation in economic impact study in Fall 2013; and other efforts. the melt, improving melt rate (eficiency) and providing Rafael Delgado of Delgado, Izquierdo & Associates more uniform alloying and temperature, with the disad- looked at issues of foreign trade, export, and import in vantages of high maintenance, fragile components, and 2013. He explained that auto manufacturers are moving being unsuitable for batch operation. Charging the fur- production into Mexico for two reasons; it has the ad- nace is another point where eficiency can be improved, vantage of being close to the U.S., the biggest car market taking into consideration the charge mix (ingots, butts in the world, and it has access to quality aluminum pro- and cropped ends, small extrusion pieces, etc.) and the duction. He then provided an overview of Mexico’s tariff speed of the charge. Top charging furnaces provide the policies and trade regulations and how they are likely to greatest eficiency in this regard. Other issues to consider change and affect the industry. Delgado presented infor- are combustion control (air/fuel ratio), pressure control mation on free trade agreements, which eliminate tariffs, (damper on chimney), and waste heat recovery (for ex- import quotas, and preferences on most goods and ser- ample, heat from the lue can be used to preheat com- vices traded between participating countries. One of the bustion air). most important and ambitious of these is the Trans-Pacif- ic Partnership (TPP), a free trade mega-zone agreement between ten countries, including the U.S., Australia, Bru- nei, Chili, Japan, Malasia, New Zealand, Peru, Singapore, and Vietnam. With TPP, the U.S. will have 40-50% of its trade under one agreement. As of June 2012, Canada and Mexico are in negotiations to join TPP and these negotiations will be ongoing through 2014. It is vital that Mexico participate in this agreement, explained Del- gado, outlining the beneits this would provide for the country. China meanwhile is watching the TPP carefully and is in the process of forming its own free trade agreements in order to compete. Currently, China has 30-40% of its commerce under the China-Peru Free Trade Agree- ment. Delgado closed by looking at the U.S.’s review of imported aluminum and products from China and its imposed tariffs and noted that Mexico needs to take similar Figure 5. Diagram showing heat low in a melt furnace. action to hinder unfair trade practices in the aluminum industry. Anodic hard coatings were looked at by Bladamiro Jesús Villegas, Harbor Intelligence, presented on the Moreno of Electroacabados S.A., who presented an trends and relevant factors of the aluminum market. overview of the anodizing process and its properties, In regards to growth rates in primary production, he including increased corrosion resistance and improved pointed to the Middle East and India as being the ma- aesthetic qualities. He said that many industries require jor players with signiicant expansions. China, though a hard coatings (between 400-500 HB), which have greater large market, will only play by itself and therefore will not resistance to abrasion and longer lasting colors. Abrasion contribute to the worldwide industry. He said that prices resistance is important for the car market, where hard are the lowest in history, but that they can’t stay that way anodic coatings are being used for pistons, as well as avia- and will likely begin to improve in November of this year, tion (landing gear and transmissions) and ships (masts). though they will still remain low. The issue, he explained, Other markets include heat sinks (for aesthetic appeal), is not with demand (which is growing), but with over sup- industrial lamps (protection against corrosive gases), and ply, which will likely remain. In regards to demand, he architecture (for both aesthetics and use in regions with said Mexico is probably the most attractive market in Lat- saline environments and acid rain). He said the industry in America with growth of 10% per year projected for the is working toward more standardized proiles with less next ive years. This is a better situation than even Brazil, water marks and a more homogeneous surface. and primary aluminum producers in all regions will be recognizing Mexico as an attractive market. Day Two For secondary aluminum, Villegas said that just like primary aluminum, the industry has had its worst year in The second day of the congress began with a presen- history. In the secondary industry, a company’s worth is tation by Stephen Jackson, Bloom Engineering, on re- determined by their scrap supply. Scrap availability is not generative combustion for aluminum melt furnaces and likely to improve, because demand will be greater than the company’s LumiFlame technology. Regenerative the available aluminum scrap. Though he expects that burners, typically functioning in pairs, are designed to margins will improve. improve eficiency (to around 60%), reduce the heat -go In addressing warehousing issues, Villegas said a new ing out the chimneystack, and put it back into the load. proposal by the London Metal Exchange (LME) will go Jackson explained that regenerative burners not only into effect in 2014, which will regulate warehouses, short- provide fuel savings, but can also increase production be- ening lead times and reducing prime rates, though the cause the greater heat allows for more metal input. NOx

effect will be varied. Eventually, he said, aluminum will and CO2 emissions are also reduced, as about 80% of the have higher LME prices, but a lower premium. gases that normally go up the lue are put back through Al Kennedy, Kennedy Eurotech, presented the prin- the burner head; this also allows for a smaller lue design ciples of fuel economy for aluminum melt furnaces. on the furnace, as well as reduced bag house and dust Looking at the heat balance in the furnace, he showed collection requirements. He also said that regenerative that most of the heat in a furnace goes up the lue (up burners allow less oxygen into the melt, reducing dross. to 62.5%), resulting in ineficiency (Figure 5). Another Carlos Castañeda, Henkel Mexicana, gave a presenta- important point of heat loss is the freeze plane, where tion on improving eficiency and minimizing the environ-

46 LIGHT METAL AGE, AUGUST 2013 THERMIKA INFRA-RED DIE HEATING SYSTEM

1. Energy Savings of 50% 2. Economic Payback within 12 Months 3. Improved Recovery 4. Reduced “Die Pulls” or “Die Failure” 5. Reduction in Die Breakage 6. Reduced Scrap 7. High Quality Surface Finish

Thermika Systems is the industry leader in high eficiency heating technology. As a result, the Thermika Systems infra-red die oven is now the most advanced and eficient die heating system in the world. It saves MONEY, ENERGY, IMPROVES PRODUCTION THERMIKA DIE OVENS EFFICIENCY and PRODUCES A SUPERIOR PRODUCT. ARE THE ABSOLUTE STATE-OF-THE-ART Thermika Systems will design a custom solution designed to maximize your bottom line. IN IR DIE HEATING.

ECO FOR INDUSTRY

For more information about our products, contact:

THERMIKA SYSTEMS INC. NORTH AMERICAN SALES 2-169 Golden Drive www.extrusionsupplies.com Coquitlam, British Columbia, Phone: +1 (330) 506-9291 Canada V3K 6T1 [email protected]

Toll-Free: +1 (800) 585-8650 Phone: +1 (604) 357-4780 Fax: +1 (604) 357-4782 [email protected] www.thermikasystems.com mental impact of lubricants, or die casting release agents. He said a lubricant needs to provide good wetting, good release without deformation, clean castings without stain- ing, avoid welding of the aluminum to the mold, lower die temperature to reduce wear, resist bacterial infection (which causes strange smells and ineficient lubrication), and provide protection to extend the life of the die, among other concerns. He then presented the types of lubricants Figure 6. Placement of the FSW spindle showing penetration (left) and available and gave an overview of best practices for the different types. To improve eficiency, operators need to exit (right). check dilution and the spray systems for blockage; must Figure 6 maintain the integrity of the lubricant, ensuring it is well net shape processes. RHC is a semi-solid manufacturing mixed; need a spray system that covers all surfaces of the process that involves stirring molten metal as it is slowly die with a homogeneous ilm; and must perform regular cooled until it begins to solidify, at which point it is inject- maintenance, especially for nozzles, tubing, and pipes. He ed into a die or forged. Due to the thixotropic behavior ended by explaining that good lubrication can increase in the semi-solid state, the injection process requires less production and decrease costs. power and materials, reduces damage to tools, provides A method for developing and implementing an effec- better control of solidiication, and fewer shrinkage de- tive preventative maintenance program was presented by fects. Honda in the Accord is using this process to pro- Carlos Linares, SMS Meer Service Inc., who pointed to a duce engine blocks, wheels, and other products. Chavez lack of planning as the root cause of most maintenance is- and a team designed and assembled a prototype RHC sues. He suggested that extruders take the following steps system to produce Al-7%Si alloy, though results were not to develop a plan of action: identify potential problems discussed at this time. He noted the biggest challenge to with Failure Mode Effect & Analysis (FMEA), specify and the RHC process is knowing when to ill the cast. target maintenance tasks, and form a plan and execute James Parkes of Mechatherm announced that the it. FMEA is performed by identifying a component of company formed a new collaboration with Nutec Bick- assembly, brainstorming potential failure modes, listing ley in 2013 that would allow it to deliver furnaces and potential effects of the failure modes, assigning severity equipment to the Mexican and U.S. markets while taking rankings (based on severity of the consequences of fail- advantage of Nutec’s local services. Parkes said that Me- ure), assign occurrence rankings (how frequently failure chatherm has seen a decline in orders from the primary is likely to occur), assign detection rankings (likelihood aluminum casthouse market, but a dramatic increase in problem will be detected before failure), calculate risk orders from secondary industry. He then presented an priority number (RPN = Severity x Occurrence x Detec- overview of furnace selection criteria based on the kinds tion), develop an action plan, take action, and inally re- of scrap being melted (from heavy clean scrap to con- calculate the RPN after improvements have been made. taminated UBC scrap to furnace dross), before turning Linares explained that a proper maintenance schedule, his attention to a case study about the installation of a combined with proper training and an inventory of spare complete melting and casting line for China Steel Alu- parts, directly relates to dramatically lowering costs over minium Corp. (CSA) in Taiwan (Figure 7). In September many years. 2011, CSA ordered an 80 tonne static furnace and a 60 Alejandro Manzano, Cinvestav, spoke about the devel- tonne twin chamber furnace, as well as auxiliary equip- opment of modular tools for friction stir welding (FSW) ment and casting machines, for the melting and process- of aluminum alloys. He explained that FSW is a solid- ing of heavy clean scrap, primary ingot, extrusion scrap, state process for welding two aluminum panels together, light swarf pucks, and light scrap coils and edge trim. as well as aluminum to other materials such as titanium John Horno, Insertec Hornos y Refractarios, presented and Kevlar. This process is especially beneicial for the an overview of refractory materials for the aluminum in- aerospace industry, he said, noting the forthcoming de- dustry. Descriptions of refractory classiications and char- velopment of a global jet with a fuselage made of alumi- acteristics were given, including chemical composition num and titanium. In a previous study, Manzano and a (acid, base, or neutral), form, and density, as well as insu- team of researchers looked at FSW spindles (tips) made lation needs, thermal conductivity, melting points, com- with H13 steel to determine which shape (square, round, pression resistance, porosity (varies between 12-30%), triangle, and others) provides the best performance over density, corrosion resistance, bonding, and other factors. multiple repetitions, with a square shaped spindle show- Issues with the proper manufacture and installation of ing the best results. Once this was determined, the team refractory products were also covered. began to develop a modular system for the tool, allowing the spindles to be changed quickly without replacing the entire tool head. This would lower maintenance costs and would allow different shaped spindles to be interchanged depending on welding needs. Tests were performed with the modular tooling to determine the optimal welding velocity (Figure 6), in addition to stress and hardness tests, and it was found that the modular tool design was able to generate similar mechanical properties to FSW welds obtained with one piece tools. J. Federico Chavez of the Instituto Politécnico Nacio- nal presented the development of Al-Si alloys by a simpli- ied rheocasting (RHC) process. Al-Si alloys are often fabricated by the high pressure die casting (HPDC) process due to the eficiency of production and low cost. RHC was presented as a new trend in manufacturing with great potential and with several advantages over other near Figure 7. Scrap charging machine supplied to CSA.

48 LIGHT METAL AGE, AUGUST 2013

Working Tables: Following the inal presentation of the day, delegates representing various companies in the Mexican aluminum industry gathered together for working table discussions to determine if it can prepare for the future projected growth of the aluminum industry. It was determined that Mexican companies need to imple- ment new processes for improved eficiency, quality, and environmental standards, and they need to be active participants in developing innovative and patented technologies. Furthermore, alliances need to be made with scrap suppliers to ensure the supply of metal for companies in the country and scrap collection needs to be elevated. Enhanced cooperation with U.S. industry was also determined to be a priority. Figure 8. Comparison of Florida resistance levels for Interpon coatings, as well as PVDF liquid coating. Day Three to report every accident and near miss no matter how mi- Salvador Tovar of Servicios Comerciales Metalúrgicos nor, so it can be investigated and action taken to prevent SC began the third day with a presentation on how to it. “ You can’t avoid large accidents without preventing the save money with eficient furnace operation and pro- small ones,” said Kennedy. He then gave an overview of vided basic everyday concepts for lowering energy use. potential hazards to look out for in the extrusion plant, He said that rather than using fans to keep the foundry including concerns with tooling (cold or room tempera- area cool enough for operators (loss of a BTU per sq ft), ture tools, improperly supported dies, etc.), heat (alumi- it’s better to use proper ventilation and insulation of the num can appear cool, as can equipment), ire (caused by furnaces to reduce energy costs. Also, to optimize energy oils, hydraulic luids, etc.), improper lifting techniques, use in the furnace, run the furnace at full capacity and material handling (crane and forklift accidents), and the ensure that the load is at one-fourth melting capacity per extrusion equipment itself. hour, adjust combustion ratio for optimal air/gas mix Kennedy then gave special attention to molten metal (long lames function ineficiently), and add a circulat- safety, noting that explosions can be caused by chemical ing pump, which can increase eficiency up to 72-73%.reactions or water within the metal. Water explosions, He emphasized the importance of cleaning and remov- which are more common, are caused by molten metal ing residue from the furnace to ensure optimal perfor- falling on a damp surface or by water trapped inside the mance, as well as checking and changing the air ilters ingot prior to melting. Explosions can be prevented by regularly. Slag should be removed from the bath often, drying all surfaces with torches or compressed air, avoid- so that the heat can properly penetrate to the metal; if ing the use of lat surfaces, keeping a volume of 2-3 m of the furnace creates more than a half inch of slag per half water at the bottom of the casting pit, having an air drop hour, he recommended further investigation into why to atomize falling metal, and preheating of ingots to re- the furnace is a slag producer. He concluded that doing move any moisture. Plants should also have escape routes an audit of the foundry is the best place to start in order as part of their layout, and employees should wear proper to determine where energy waste is occurring in the op- protective gear at all times. eration. Alejandro Omar Ruiz Alva, Alchem, gave a presentation Looking at high durability inishes for aluminum pro- about identifying and preventing defects on lacquered iles, Eduardo Faz of Akzo Nobel asked, what’s the use aluminum for the architectural industry. He discussed of architects spending hours choosing paint colors, if the kinds of defects— such as craters, pores and bubbles, the color fades in just a few years? He then listed three needle points, blisters, stains, internal corrosion, yellow- main types of coatings— Interpon Series D1000 (AAMA ing, and peeling— and their causes (such as improper 2603, Qualicoat 1), Series D2000 (AAMA 2604, Qualicoat cleaning or pretreatment or problems with the metal sur- 2), and Series D3000 (AAMA 2605, Qualicoat 3)— and face) and offered possible solutions for their prevention. gave examples of each. Durability is discussed in terms These kinds of defects can be minimized by establishing of years it would last in Florida, a standard/test devel- precise working conditions, properly training workers to oped by AAMA due to Florida’s particularly aggressive identify defects and recognize causes, and establishing a sun and its high saline, marine environment (Figure 8). system for monitoring quality of production. Interpon D1036 is a polyester-based coating, used mainly Alejandro Garcia Hinojosa, Universidad Nacional for residential construction (interior and some exterior), Autónoma de México (UNAM), looked at the develop- which has a Florida resistance rating of one year. Inter- ment of components made of cast aluminum metal ma- pon D2525 is an ultradurable, polyester-based coating, trix composites. He said composite materials, which are often used for large projects with a resistance against al- a mix of two or more materials, can provide high me- kalis and a Florida rating of three years. In general these chanical properties, increased strength and ductility, and paints will have the same color and shine for 15 years, prevent fatigue, creep, thermal shock, and thermal elon- which keeps the architect happy, he said. Interpon D3000 gation. He gave an overview of aluminum composites Fluoromax is a luorocarbon-based coating with a Florida (speciically those infused with ceramic particles) and rating of ten years and a guarantee of the color lasting looked at the casting processes used to make them and for over 20 years, though Faz suggested that this level of their microstructure. In addition to manufacturing an durability is unnecessary for most projects. entire component out of a composite material, selective Kennedy returned to the podium to provide a review of reinforcement can be used. While the cost of composites extrusion plant safety techniques. He said many managers is still high, it is getting more competitive, he said. Audi focus on plant conditions, but that safety experts say acci- already uses aluminum composites for their brake discs dents are most often caused by unsafe acts performed by and Toyota for their piston rings, and it’s likely the mate- personnel, rather than by unsafe conditions. Therefore, rial’s use will increase in aerospace, automotive, military, workers must be kept alert, properly trained, and taught and sporting equipment.

50 LIGHT METAL AGE, AUGUST 2013 Investment banking services provided by HL Capital, Inc.; investment advisory services provided by HL Financial Advisors, Inc. In the European Economic Area and Hong Kong services provided by HL (Europe) Limited and HL (China) Limited, respectively. It is not known whether the listed clients approve or disapprove of Houlihan Lokey or the advisory services provided. Tombstones represent selected transactions completed from 2006 forward. Source: Thomson Reuters. 0713 METALS INDUSTRY EXPERTISE INDUSTRYMETALS No. 1M&AAdvisorforAllU.S.IndustrialTransactions No. 1M&AAdvisorforU.S.Transactions Under$3Billion Selected Transactions comprehensive recapitalization has completeda Wise MetalsGroupLLC has beenacquiredby FINANCIA RESTRUCTURING FINANCIAL MA CAPITAL MERGERS &ACQUISITIONS HL .com L ADVISORY RKETS Company Advisor Sellside Advisor S ERVICES has beenacquiredby court restructuring has confirmedanout-of- En+ GroupLimited Company Advisor Sellside Advisor Bill Peluchiwski 312.456.4705 •[email protected] Mike Jenny 312.456.4714 •[email protected] INDUSTRIALS GROUPCONTACTS has beenacquiredby a divisionof company’s commonstock new notes, cashandthe the exchangeofnotesfor transaction, including of-court restructuring has completedanout- • Senior VicePresident,NonferrousMetals • Senior ManagingDirector, Co-Headofthe IndustrialsGroup Company Advisor Sellside Advisor conversion agreementwith has enteredintoalong-term has beenacquiredby a portfoliocompanyof Financial Advisor Sellside Advisor Extrusion Industry News & Technology Flying Cut Puller Systems By Jeffrey Ferman, Granco Clark

number of lying cut puller designs exist on the market today for aluminum extruders. Granco Clark believes there are misconceptions, misun- derstandings, and in some cases mistruths sur- roundingA this subject. Choice of type can vary based upon a number of factors. Performance and design speciica - tions are a simple way to look at puller systems (Figure 1) but this article seeks to provide a deeper understanding of the mechanics involved. By clarifying some deinitions, providing a way to measure reliability, and offering guidelines for achieving maximum reliability, smoothness, and responsiveness, it is hoped that the extruder can save repairs and costly production losses by considering the best system for their needs. Critical speciications include: maximum extrusion speed, maximum lying cut speed, leadout length requirement, downtime prevention pro- visions, maintenance schedules, ease of repair, and percentage of chip collection.

Figure 2. Puller mounted lying saw.

from the die. Top suppliers design the leadout equipment to ensure this handoff takes place without causing a die mark. Among the features integrated into the best offerings should be: (1) an adjustable roller table at the press exit to isolate the proile from any downstream proile movement as it exits the die and (2) individual lowering rollers in the leadout to allow the heads to operate below system height thus enabling the lying cut to be performed without any lifting of the proile. A two-device (Figure 3), single rail lying cut puller has Figure 1. Granco Clark’s double puller features two puller heads on the a secondary handoff downstream. This handoff occurs same track, allowing it to see the mark/weld and cut proiles on the ly. far downstream, typically 100 ft (30m) or more from the die. This distance isolates the die bearing surface from motion resulting in a die mark free handoff. Individual Handoff lowering rollers also eliminates any lifting of the proile during this handoff event. The irst issue is to deine the term “handoff” and how it relates to lying cut puller systems (Figure 2). A handoff is the transfer of material from one device to another device. These devices may be called a “ puller” , “ puller head”, “hot saw”, or “lying saw”, depending on the -de vice and the supplier. The necessary actions are match speed of the two devices and transfer the pulling torque (tension) from one device to another device. Surpris- ingly, there is a belief that a three-device lying cut puller system does not perform a handoff. Every lying cut puller system has a handoff by deini- tion: at the beginning of the live cycle the proile is controlled by one device. After the proile is cut on-the-ly, the remaining (short) proile is controlled by a different device. In order for this to occur there must be a speed matching event and a torque transfer event. For any company to claim their offering does not perform a handoff requires a redeinition of “handoff “ to something other than speed matching and torque transfer. The cut-on-the-ly handoff is the critical event because it occurs in the leadout area, typically less than 30 ft (9m) Figure 3. 3-D model of double puller.

52 LIGHT METAL AGE, AUGUST 2013 Reliability • Minimize wiring – any wires that are lexed in a cy- clical manner become a regular failure point, reducing Another implication in the market is that a three-de- MTBF. Wiring failures can be dificult to troubleshoot, vice puller design is more reliable than a two-device pull- increasing MTTR. er design. Reliability consists of two factors: how often • Simplify component replacement – this will reduce does a piece of equipment fail and how long will it take to MTTR. restore that equipment to operation. These factors have formal names and deinitions. How often an item fails is Smoothness/Responsiveness called Mean Time Between Failure (MTBF). How long to restore the item to operation is called Mean Time To Smoothness of operation is the observed result of a Repair (MTTR). Any study of reliability can ultimately be low-backlash system. If a system has little backlash then reduced to these two factors. Reliability is improved by acceleration, deceleration, and direction change will ap- increasing MTBF and decreasing MTTR. pear smooth to the observer. The MTBF of a system is deined as the combination All mechanical systems require a method for backlash of the MTBF of the various components of the system, a adjustment as components wear. A gear driven system textbook example for a generic system with three com- requires some form of tooth mesh adjustment. A chain ponents follows: driven system requires a chain tensioning system. If these

For components c1 through cx, where MTBF(c) is the systems are manually adjusted, then there is a very real MTBF of each component potential adjustment will be overlooked and the system will not operate smoothly. Top suppliers provide precise,

1/(1/MTBF(c1) + 1/MTBF(c2) +… + 1/MTBF(cx)) = automatic adjustments, so there is no requirement to System MTBF monitor or adjust the system. This is true whether the drive is chain, belt, or gear rack and pinion. Example 1: Responsiveness is all about mass and drag (friction). System with (3) components Larger, heavier devices cannot respond as quickly as a

c1 = 3,000 hour MTBF lighter device. While production equipment needs to be c2 = 2,000 hour MTBF robust to handle the imposed loads, care must be given c3 = 4,000 hour MTBF that the structures are not “ overbuilt” , that is to say, they 1/(1/3,000 + 1/2,000 + 1/4,000) = 923 hr MTBF should never have unnecessary material included. Top suppliers will minimize the mass of the pulling heads For the second example an extremely reliable 4th com- by reducing unnecessary on-board components like air ponent is added: compressors, gear boxes, drive components, conductor Example 2: carriers, etc. It is also important that a supplier utilize

c1 = 3,000 hour MTBF modern materials to minimize mass. This can be as sim- c2 = 2,000 hour MTBF ple as using steel tube instead of bar or plate. A tube c3 = 4,000 hour MTBF provides excellent load carrying with light weight. It can c4 = 48,000 hour MTBF be more expensive to fabricate heads in this manner, 1/(1/3,000 + 1/2,000 + 1/4,000+1/48,000) = 905 hr MTBF but the result is a strong and more responsive puller head. Please remember that modern presses are being Note that the MTBF is still reduced, even though the tasked with wide ranges of proile weights from order new component is an order of magnitude more reliable to order and the puller heads themselves can damage than the irst three components. Adding equipment will lighter shapes if they are unnecessarily heavy simply due always reduce the reliability of a system. So designing in to momentum. additional equipment (heads) decreases system reliabil- Friction is not as visible. The system friction includes ity as the trade-off for providing “ limp-along” functional- not only the carriage rail, bearings, and the drive system ity after failure. It should be noted that properly engi- but also parasitic losses such as power-track drag. How neered pullers will allow for a means of extruding with a can an extruder determine the actual system losses that puller in the event of failure, whether there be two heads are affecting responsiveness? One way is to compare drive or three including the saw, rather than abandoning the system horsepower (KW) for the same speciication of maxi- pullers altogether until repairs can be made. Suggesting mum pulling tension and maximum extrusion speed. this is not possible with a two head design is completely You can’t circumvent physics. If a supplier requires a 30% incorrect if designed properly. or 50% larger motor to achieve the same performance, The second issue in reliability is MTTR, which mea- then they are accelerating a larger mass and/or ighting sures the time required to return the equipment to ser- higher system friction. Be diligent to monitor the per- vice after a failure. We can illustrate MTTR by observing formance promises as they relate to speeds and pulling the difference in downtime required to replace a puller tensions. drive chain and replace a continuous gear rack running the length of a puller system. The chain can be replaced Summary in a couple of hours while a gear rack replacement could require 60-80 hours to replace. Serviceability is a major The bottom line when considering a new puller sys- design consideration for MTTR. tem for an extrusion line, is to be careful not to assign To achieve maximum reliability, here are some general unjustiied value to proposed features and beneits that guidelines for designing: do nothing to enhance the extrusion line throughput • Simplify the design – reducing complexity will in- and recovery performance. Be sure the choice of puller crease MTBF. system offers a solution that meets needs while main- • Minimize the number of motions – this will also in- taining some semblance of simplicity for sustainability. crease MTBF due to fewer bearings, cylinders, solenoids For more information, go to www.grancoclark.com. and so on.

LIGHT METAL AGE, AUGUST 2013 53 Extrusion Industry News & Technology The Beneits of Wet Blasting for Extrusion Die Shops By Craig Johnson, CJi Systems

s part of the extrusion process, there is a vital re- The Wet Blasting Process: Originally pioneered by Nor- quirement for ongoing cleaning and polishing man Ashworth in the 1940s, wet or vapor blasting has of dies. This is a critical operation for continual grown to it a wide range of applications with its main production within an extrusion plant, but one purpose to provide a highly precise surface inish. (The Athat is often considered time consuming and full of te- Ashworth family founded the Vapormatt Company in dious processes. 1978.) However, without proper care and attention given to Wet blasting uses water and an abrasive medium to form the preparation of dies, extruders risk high extrusion slurry in the sump tank of the installed system. As the slur- scrap rates and low die success rates. During the 1990s, ry is pumped through the system towards the gun heads, many extruders attempted to tackle this problem by compressed air is introduced; by allowing the slurry and adopting a dry blasting system; these bulky and typically air to synthesize within the mixing chamber of the gun dusty machines utilize steel shot to reduce the amount of a highly powerful blast stream is created, which in turn manual iling involved at the die correction stage, but are accelerates through the boron carbide nozzles. Having im- often cumbersome to use and hard to maintain. As tech- pacted upon the bearing surfaces, the slurry is then recir- nologies and processes have improved, there is a need culated through the same system for continuous use. for die shop managers to assess new alternatives, processes that are showing strong signs of being extremely Vent viable in that they are both time saving and cost-effective. Gas In Enclosure This article looks to explain the beneits of adopting a Slurry In Abrasive In wet blast technology for use in extrusion die shops. Gas In Liquid In Gas Application Advantages: With wet blast technology, ex- Acceleration Zone Blast Gun

truders are able to achieve a quicker, more effective and Additive In Mixing Chamber consistent polishing action that can improve the die suc- Stirrer cess rate when compared with conventional systems. Wet Slurry Acceleration Zone Abrasive Pump Gun Movement Velocity blasting is able to remove deep-seated contamination Nozzle Geometry Mixing Chamber without impinging on or damaging the underlying sub- Blast Angle Controllable Factors strate. The process also removes the time consuming dry- Blast Distance Gas - Type, Pressure, Flow Speed and Temperature ing stage, prior to polishing, that is often required after Slurry - Solid/Liquid Ratio Liquid - Type, Pressure, Flow Speed and Temperature caustic cleaning. Solid - Type, Size, Hardness and Shape The primary beneits gained from using a wet blast Gun/part kinematics - Velocity, Distance and Angle system are that dies are polished to a much higher standard and the wet blast process can save extruders several minutes of manual polishing per die. With an industry Similar to dry blasting, it is the abrasive content that average of 100-150 dies cleaned per day, one extruder ex- plays an essential role in achieving the desired surface perienced a payback on their system within six months. and this is very controllable as the form, hardness, and Being far more intensive than dry blasting, wet blasting mesh size of abrasive particles can be changed to suit the allows particles to low across the surface, leading to in- application. The recommended abrasive used for the die creased contact with the surface and therefore a higher cleaning application is a pre-mixed compound of both rate of polishing. aluminum oxide and glass beads and this mix yields two The improved die success rate is also a major advantage key beneits. The abrasive action of the aluminum oxide of the wet blast process, which also beneits the complete particles easily removes all traces of surface contami- operation. The ability of the wet blast process to provide nants on the bearing surfaces and die faces, while the uniform polishing means the die proiles can be precisely glass bead particles work to polish and peen the die face maintained. This is a technological advantage for extrud- and bearing surfaces to remove traces of carbonization. ers as the dry blast process has been known to abrade This intensive process ensures that the nascent surfaces critical surfaces at different rates due to the low, or lackare left extremely clean when compared with the alterna- of, in the particles. The intensity of some dry blasting ma- tives, making a wet blasted die very easy to nitride. Having chines can damage a die causing the extruded proiles been wet blasted, nitrogen can easily diffuse into the die to perform poorly; with wet blasting, this is not an issue. due to the reactivity of the bearing surfaces. The ability to constantly achieve consistent and uniform As mentioned, the luid dynamics involved with the polishes allows extruders to improve their die success process allow particles to be buffered by lubricating them rate. From working with various extruders, who use wet in water and this creates a far less aggressive action than blasting, it has been found that die success rates can be dry blasting. The water allows the abrasive media to low increased by as much as 4%. consistently over the bearing surfaces, so the die proiles Wet blasting can also provide a better working environ- can remain unchanged in their geometries. It is the low ment. By adding water to the process, there is an elimi- of water that gives wet blasting a distinct advantage over nation of all airborne particles and a reduction in the traditional means, as the slurry can easily navigate and amount of abrasive surrounding the machines that can permeate the often tortuous paths found in intricate die cause loors to become slippery. These higher levels of designs while achieving a uniform polish. industrial hygiene mean there is less of a requirement for Suitable Systems: The range of wet blasting solutions any housekeeping within the die shop. Wet blasting also available to die shops is wide and allows great lexibility has the advantage of eliminating the drying stage that is with regard to production output. The main constraints often required after the caustic rinse. on system capacity are the size of the loading area and

54 LIGHT METAL AGE, AUGUST 2013 the speed at which a cycle can be completed. All systems maintain. Plants with larger outputs can use a fully auto- are designed to be completely closed loop, which means matic system. The largest of these systems can be installed any water loss is through evaporation only, and this en- to fulill a large part of the die polishing operation. Not ables extensive periods of use. Systems are also itted with only do 12 gun systems effectively clean dies from both a powerful pump to aid the process. The pump is itted to sides, but a rinse and powerful drying stage means that maintain the continuous blasting cycle by supplying the over one cycle, dies can go straight from their caustic blast guns with a constant low of the slurry. This is also bath to the inspection area. connected to a iltration system, which quickly removes The automatic systems are also controllable, with PLC co- any efluent that could contaminate or affect the abra- ordinating activities to ensure smooth running while moni- sive low. Consequently, iltration is key for preserving the toring for any faults. Programmable variables can include quality of the slurry. cycle speed, blasting intensity, and rinsing quality. Automatic In larger systems, there is an option to have secondary abrasive dosing can be included to maintain concentration pumps installed and this provides yet more power for an levels of the abrasive. All of the data from the PLC is then even better blasting process. The continuous pumping linked to a HMI on the operator panel, so pre-programmed cycle is an essential action, as the density of the abrasive sequences can be selected and progress monitored. means it will sink to the bottom of the sump when the Due to the size of the dies, wet blasting machines are machine is not in use. Through continual agitation of the built to be structurally secure both in durability and overall sump water, the blasting cycle can offer highly consistent strength. With wet blasting, it is important to use a suit- results on the desired surface. able material that can stand up to wet conditions, while Newly cleaned dies are left with extremely reactive sur- offering the rigidity that is required for a stable processing faces, enabling easier nitriding should the dies require environment. Most cabinets are made from iberglass as it. As a response to the reactivity of the newly cleaned this material is not only water proof but also very quiet and dies, additives, such as rust inhibitors, can be mixed into capable of holding loads of up to 3,300 lbs (1,500 kgs). the sump tank to help preserve the nascent surface. With the movement of wet blast systems into the extru- Larger systems can also be designed to include drying sion die industry, extruders have gained access to a tech- systems, removing yet another process that will save ex- nology that is not only far more effective than traditional truders more time. methods, but also has the ability to yield great savings in Manual or automatic systems can be used, as deter- both the polishing operations and the extrusion depart- mined by the number of dies cleaned per day. Manual ment as a whole. Wet blasting offers lexible solutions for systems tend to comprise a small cabinet that an operator extruders of all sizes and all production requirements to uses to control one blast nozzle. This system, particularly harness the potential of this process, and this is apparent for smaller plants as their price makes them an afford- from the range of both automatic and manual systems able investment, will quickly pay itself back and is easy to that are available.

The only die cleaning and polishing system you’ll need.

Increase your die success rate today

State of the art wet blasting Our machines save time, in fully automated or manual streamline production Call 509-926-4800 machine configurations and enhance quality or email [email protected]

North American agent: CJi Systems Inc.

LIGHT METAL AGE, AUGUST 2013 55 Extrusion Industry News & Technology

The Tecalex front loading tandem cylinder extrusion press is now being offered in North America. New Partnership Creates Tecalex USA

n early 2013, negotiations were inalized for the and reverse engineering capabilities, newly formed partnership of Pittsburgh based Cun- along with a seasoned resume of retro- ningham Machine Design (CMD) and Tecalex Spain it and replacement components on to create the new entity Tecalex USA. Started as an existing presses, Cunningham knew Iextrusion die manufacturer in Barcelona, Spain in 1965, that partnering with a company like Tecalex has been building their unique front loading de- Tecalex would create a truly unique signed press since 1984 and offering associated extrusion full service supplier of new and used equipment for handling, heating, and tooling, since be- extrusion equipment for the U.S. coming incorporated in 1989. Currently they have over market. Tecalex USA has many of the 77 complete extrusion press lines installed worldwide. engineering personnel that worked Jim Cunningham. CMD and Tecalex met and were drawn to each other with Cunningham at Pollock Engi- at the ET ’12 show in Miami, FL, in May 2012. Together neering. “ Pollock was one of the best they saw they could offer a complementary full range of run, customer oriented companies I equipment and services and they recognized an equal have ever been a part of,” Cunning- commitment to a high level of excellence in extrusion ham stated. “ I’ve worked hard to keep equipment manufacture and service. Tecalex realized that core together at CMD to provide that to be successful in the U.S. market you need to sup- that same level of service and profes- port it within the U.S., not remotely from Europe. The sionalism. It dovetails nicely with how best way to achieve that goal was to partner with an ex- Tecalex Spain approaches their core isting company that had the experi- business model.” Another member James Bunting. ence with the domestic press market of the team that some in the North and also had the same dedication to American market may recognize is James Bunting, the new customer service that the Spanish sales manager for Tecalex USA, who formerly worked with company has achieved in the global Castool. Additionally, Tecalex Spain will have engineering market. “It took a long time to ind support live in Pittsburgh, PA, to provide the quick and the right partner, one that possesses dedicated extrusion response times required. the same principles that have made us a leader in the European and Press and Handling Asian markets,” stated Josep Barcelo, Josep Barcelo. general manager of Tecalex Spain. Tecalex knew from its very irst press in 1984 that a Jim Cunningham, owner of CMD, previously worked for front loading press was a superior design. While widely Pollock Engineering and SMS Sutton and has successfully accepted today, this was a radical design back in 1984. run CMD since 2006. With a complete array of custom The press also features a patented tandem cylinder de-

56 LIGHT METAL AGE, AUGUST 2013 www.tecalexusa.com

8510 Perry Highway O ce Phone: 412-635-0609 Pittsburgh, PA15237 O ce Fax: 412-635-0631 Extrusion Industry News & Technology

sign. From the beginning, Tecalex felt that current press designs with a large main cylinder and two pull back cylinders could be improved upon. By using a main tandem cylinder, with two pistons on the same axis, they eliminated the crosshead and the side pull back cylinders. This also enabled a reduction in the main cylinder diameter, a decrease of the front plate dimensions, and shrinking of the overall distance between the tie rods. All of these things create a compact and more rigid design with less delection of the front plate. This new company is uniquely positioned, as it is able to provide a full suite of cutting-edge aluminum extrusion press and handling equipment, while also providing retroit, maintenance, and tooling services. Equipment beyond the press include: log/billet loaders and furnaces, shears and hot saws, billet loaders, quenchers, pullers, runout tables (Figure 5), stretchers, stacker/destackers, Figure 5. Example of a standard runout table layout. and aging and die ovens. They also offer custom and reverse engineering services and replacements and retroits. LLC in Texas for a complete extrusion line that includes: Tecalex primarily uses Allen-Bradley or Siemens drives a new 30 MN front loading extrusion press, log loading and electrics with Rexroth pumps, but are able to meet table, hot shear, billet loader, quenching table, double whatever speciications the customer requires. “At Tecalex puller with lying saw, one man stretcher, inishing saw, USA, we are committed to providing multiple solutions and related auxiliary equipment. Jamie Rentfrow, ceo for all extrusion equipment requirements. Since we offer of Ascend traveled to Spain to see the Tecalex press. He new equipment as well as retroit and upgrade services, chose the front load short stroke press for its compact we can accommodate our customers’ needs with cost ef- size and short dead cycle time. According to Rentfrow, fective solutions to meet their equipment and inancial “ The double puller was smooth on the handoff helping needs,” said Cunningham. “ Our customers are the most prevent snap marks that are often associated with other important part of Tecalex USA. We strive to achieve rela- types of pullers. We also bought a second double puller tionships with our customers rather than simply supplying and a new log furnace for our 7 inch press. We were also components or services.” impressed that they will have a presence in the U.S. for Quickly out of the gate, Tecalex USA was delighted any technical help that may be required going forward.” to secure a deal in May with Ascend Custom Extrusions The press is expected to be delivered February 2014. Briteline Celebrates 60th Anniversary riteline Extrusions, Inc. in Summerville, SC, kicks the company also enlarged a powder coat oven in 2003, off its 60th anniversary in September. According to expanded brushing operations in 2005, installed a billet Bthe company’s founder and president, Ken Kabine, oven in 2008, and in 2010, introduced acid etch anod- “ We are one of the few full service extruders left.” Brite- izing at the same time they started exporting to Canada. line Moulding began as a fabricator of extrusions in 1953 In 2011 another building was added for a new anodizing with 15 employees. They moved to their present location line installed in 2012. Briteline is a three-generation fam- in 1960 and installed their irst 750 ton press in 1965. ily concern, which includes daughter, Diane Bagwell and Today they have two 6-inch circle size extrusion presses, grandsons Bo Bagwell and Chris Kabine. The company specializing in small extrusions, with both powder coating footprint has grown from two buildings in 1953 to 22 and brite dip anodizing, as well as fabrication capabilities. buildings today, all overseen by Kabine who with Brite- Kabine worked for both the William L. Bonnell Com- line has capitalized on supplying markets that require pany and Benada Aluminum before buying into a part- careful handling and ine inishing techniques. nership in the Southeast. Kabine was known for his ex- It’s clear the company won’t be celebrating their 60th pertise in inishing. Starting with supplying trim, it was anniversary by sitting still. With a year of running their the shower door market, which solidiied the company’s new 20 ft anodizing line (pictured) under their belt, con- prospects. Together with his son, Ed, he continued to struction is under way for increasing bufing capacity and grow the company: installing a new anodizing line in modernizing and expanding the company’s billet man- 1968, adding a new anodizing building in 1982, install- agement system. A third heat treat oven is in the works ing a powder coat system in 1986, and a new powder coat to support Briteline’s growing export market. They are building with automated powder coat also in the process of evaluating both line in 1992. Though the company ex- hard coat and boric sulfuric anodiz- perienced a ire in 1993 that destroyed ing. At 86, Kabine continues to have 75% of the plant, they have continued the vision and passion for growing the to expand their capacity and capabili- company. He said, “ Our small presses ties. and brite dip anodizing capabilities de- Kabine bought out his partner and ine who we are. Our employees know gave employees 49% of the company how to handle the extrusions from the in 1995, the same year they began ex- press to packing. They are our best as- ports to the U.K. In 2001, Briteline set.” Kabine is at work every day, walk- added a new CNC machining center. Briteline’s newest 20 ft anodizing line in- ing the plant loor, inish samples in his While adding and upgrading presses stalled in 2012. pocket.

58 LIGHT METAL AGE, AUGUST 2013

Extrusion Industry News & Technology Turla Delivers High Tech Handling System for Bonnell’s Dedicated Automotive Line

n February 2013, Bonnell Aluminum in Newnan, GA, awarded Turla Srl with the contract for the supply of a complete extrusion handling system to be integrated with a new Presezzi 33 MN press. This $17 millionI expansion project will provide the company with a new state-of-the-art extrusion line, dedicated to serving the growing demand for aluminum extrusion from automotive and light truck manufacturers. Bonnell set out very clear technical requirements for its new handling system in terms of performance, including solid delivery of uniformly heated billets to the extrusion press; powerful and lexible quenching suitable for a broad range of aluminum alloys, including air and water cooling quench modes; smooth and defect-free management of proiles on the runout and the cooling table; and precise and clean operations at the inishing saw. On the basis of existing handling systems observed at operations Figure 2. STeP5 log heater. in Europe, Bonnell concluded that Turla’s equipment met all of its expectations in terms of performance and approximately 380 tonnes, equal to the emission of 150 ability to properly produce the desired range of alumi- medium size cars. num extrusion products. In addition to the environmental beneits, a reduction of gas consumption represents a huge reduction of produc- Extrusion Handling System tion costs. Cost of gas varies country by country, but on average the annual savings can be measured in several tens of This new handling sys- thousands of dollars, which can be a vital issue in the pay- tem represents Turla’s back analysis of a machine that can normally last for more comeback to the U.S. than 20 years. One of the features, not often found in any extrusion market, after other log heater, is the ability to control gas consumption in having installed previ- each heating zone of the heater. A PLC controller calculates ous systems in the U.S. the quantity of gas used at any moment, providing opera- and Canada between the tors with the amount of money spent for gas. This lets the 1990s and early 2000s. company calculate the portion of costs for gas in real time This order is the natural per each pound of proiles produced and to immediately evolution of the impor- analyze critical consumption points, rather than waiting for tant projects carried out Figure 1. DPC model double puller. the gas bill at the end of the month and trying to under- by Turla for customers stand where losses and ineficiencies occurred. involved in the automotive market in Europe, such as In terms of comparing production beneits, given the Constellium, Hydro, Sapa, and other major players in the same level of throughput of a traditional log heater, the extrusion ield. The scope of Turla’s supply to Bonnell STeP5 throughput is 30-40% shorter. Given the same includes a DPC model double puller (Figure 1), full cool- amount of space, it provides some 50% higher through- ing table, stretcher, and gauge table, as well as a STeP5 log put (ton/hr), an important aspect in plants where lack of heater and a QAH quenching system. space is a problem. Log Heater: The STeP5 log heater provides low cost op- The high eficiency also provides excellent heating uni- eration with minimal emissions (Figure 2). Produced by formity. The log heater has the optimal amount of insula- Turla in 2008, this log heater represents a turning point tion and the proper form of indirect heating to achieve in aluminum log heating technology. Most of the log/bil- target temperature in order to provide the best possible let heaters available on the market are uniform in design homogenization of the billet. This will result in better ex- with an average fuel eficiency of approximately 55%, trusion with any kind of die, even with harder alloys. occasionally 60%. These log heaters normally generate One of the most appreciated features of the STeP5 is the signiicant amounts of pollution, both in terms of com- minimized maintenance costs. The high quality rollers bustion residuals and hot gases. and other parts have shown such optimal results during The name, STeP5, stands for Super Thermal eficiency the log heater’s years of service that Turla is able to offer aimed for Production, with the “+5” standing for its ive a seven year warranty. This extended warranty on rollers energy recuperation steps. It also stands for “ Save The and other parts in the combustion chamber represents a Planet,” since a clever use of the energy permits a drastic huge improvement in maintenance practices that results reduction of pollution, thus a great beneit to the world. in less labor cost, less money spent on rollers, no produc- The fuel consumption eficiency (thermal eficiency) of tion stops for replacement of rollers, and above all no the log heater is measurable at 81%. According to Turla, more unexpected stops due to sudden roller failure. This this is approximately 1.5 times more eficient than any log heater has also been recently purchased by Gutmann other log heater on the market. Assuming 12,000 tpy of Group (one of the largest extrusion groups in Germany gross production on a single extrusion line, this trans- with three production sites) to produce high accuracy pro- lates to a yearly reduction of carbon dioxide emission of iles and to dramatically reduce pollution impact.

60 LIGHT METAL AGE, AUGUST 2013 Quench System: The QAH quenching system (Figure 3) was speciically developed for extrusion companies active in the automotive industry. Turla’s goal has been “ no compromise” in providing the maximum cooling power under various conditions using either air or water. Most quenching systems on the market are good at doing one thing, either air quenching or water quenching. The QAH system is fully adaptable and able to use either water or air modes, since these independent systems can be individually selected when a given alloy is produced. Therefore, when a 6082 alloy needs to be quenched, the water mode is used, while the air mode can be used for when a 6060 alloy must be produced. The water spray mode has independent nozzle rows placed 360° around the extrusion center line in order to cover 100% of the extrusion surface area. These nozzle rows can be electronically set to provide from Figure 3. QAH quenching system. 0-100% of its maximum water low delivery with constant pressure. Such values settings are then stored in a group (Constellium Burg and Constellium France). proile recipe, so that when a given proile is produced, Hydro Aluminium Nenzing (Austria) and Sapa Proiles the water delivery values will be automatically recalled (Hungary) also ordered QAH this year. and precisely set. The air mode of the quenching system includes dif- Conclusion ferent air blowing fans, each independently controlled. Because Turla is the only Italian producer ISO9001:2008- The system to be installed in Bonnell’s Newnan facil- certiied for aluminum extrusion handling systems, all its ity at the end of 2013 will take advantage of all the best systems are always engineered and veriied by means of a technology developed by Turla in its decades of experi- FEM tool before being sent into service. ence and cooperation with the most advanced European Since the QAH quench was developed for the auto- extrusion groups. The new extrusion line, supported by motive industry, companies such as Constellium Singen Turla handling systems, will permit Bonnell to work in (perhaps the largest aluminum plant in Germany active the best conditions to produce the highest quality pro- in automotive) have purchased three of these quenching iles with the shortest return on investment once the -ex systems in 2012, as well as two other plants of the same pansion is started up in early 2014.

extrude . anodize . powder coat . fabricate

BRITELINE EXTRUSIONS, INC. 575 Beech Hill Road Summerville, SC 29485 Phone: 843.873.4410 FAX: 843-873-8129 www.briteline.net

LIGHT METAL AGE, AUGUST 2013 61 Aluminum Recycling in the 21st Century: Challenges and Opportunities By Marshall Jinlong Wang, The Aluminum Association

luminum recycling is a process of new metal pendent on the service time of the products in various production by using consumer and industrial market sectors, as well as society’s ability to eficiently and “ wastes,” aluminum scrap metal, as raw mate- effectively collect these products. Most of these products rial resources. Scrap is melted, reined, and -ad serve a very long time during their use phase— usually de- Ajusted into desirable alloys for subsequent use in making cades and sometimes up to a century. Because aluminum consumer or industrial products. There is no functional is a relatively “ young” material, most product retirement difference between products made with primary alumi- did not happen until the late 20th century. num versus recycled aluminum. Today, more and more retired aluminum products be- Aluminum recycling began almost concurrently with come available as a scrap source in North America. The the irst commercial production of primary aluminum transportation and building and construction sectors are in the U.S.1 Over the decades, along with the increased the most rapidly growing sources of old aluminum scrap. availability of scrap, recycled aluminum makes up a great- This is due to the fact that some of the early mass-scale er and greater percentage of the overall metal shipment applications in these sectors are gradually reaching their to end-use markets. Aluminum recycling is becoming an designated service life and therefore become available indispensable strategic part of the aluminum industry. As for recovery. The increased resource availability is a ma- shown in Figure 1, the U.S. recycled 6.4 million tons of jor driving factor for the growing secondary aluminum aluminum scrap in 2012, of which 4.4 million tons was industry in the region. consumed in the domestic market, more than one-third of the total domestic metal supply. In fact, in recent years, Demand & Trends the U.S. has been producing more secondary than primary aluminum. Market demand is certainly another determining fac- The ever increasing recycling of the metal is a result of tor for the growth of the industry. During the past two de- many concurrent factors, such as increasing scrap avail- cades, apparent consumption of aluminum in the world ability, increasing market demand for recycled alumi- has increased almost three times, from a little under 20 num, rising energy prices, and improved recycling tech- million tons in 1989 to an estimated 56 million tons in nology. 2012.2 Most forecasts suggest that this trend will continue during the next two decades.3 The signiicant increase in market demand has led to not only rapid growth in primary metal production, but also to a signiicant increase in secondary aluminum supply. For instance, the global supply of secondary aluminum in 1989 was estimated to be only 5 million tons, but by 2012, the amount had grown to about 14 million tons. Meanwhile, consumer awareness in green products has helped accelerate the use of recycled aluminum. Recycling aluminum demands as little as 5% of the energy as producing primary aluminum. At the same time, it also helps eliminate the need for mining and saves many other critical natural resources. In addition, it signiicantly Figure 1. U.S. domestic scrap consumption and exports. (Data source: The Aluminum reduces the emissions and waste associated Association.) with primary production. Recycling a ton of aluminum saves the equivalent energy of up to 24 barrels of oil. Due to these environmental beneits Scrap Sources associated with recycled products, some market sectors have set up incentive mechanisms to encourage recy- New Scrap: The raw material of aluminum recycling cling. For instance, the Leadership in Energy and Envi- scrap, which comes from two possible sources: the indus- ronmental Design (LEED) system developed by the U.S. trial manufacturing processes where aluminum is fab- Green Building Council (USGBC) has set up criteria and ricated into products, and the retirement of aluminum incentives to encourage both recycling and the use of re- products from their service to consumers. Scrap from cycled materials in building products. industrial manufacturing is often called new scrap. It is a Finally, rising energy prices and technological prog- result of fabrication activities where pieces of aluminum ress have helped further drive the demand of recycled are sheared off to make new shapes. The quantity of such aluminum. A less energy-intensive product, like recycled scrap generation is generally ixed and proportional to aluminum, will always be more competitive in times when the total shipments of aluminum products to consumers energy prices are high, as long as the products have the and end-users. same function and performance. Technological progress Old Scrap: Scrap from retired aluminum products is during the past three decades has made it possible for the often called old scrap and the quantity is completely de- recycling of aluminum to be an increasingly closed-loop

62 LIGHT METAL AGE, AUGUST 2013 Trust...

Solid competence for the aluminum industry

Being able to trust in the expertise and performance of Whether in new plant construction or revamp projects, our every team member, is the foundation for success. To our solid process know-how encompasses the complete produc- customers around the world this means being able to count tion cycle, including the integration of the latest electrical on a comprehensive offering in the area of aluminum produc- engineering and automation solutions. tion. From thermal pre-treatment to shaping and reﬁ ning, we always meet the constantly rising challenges of the market. Conﬁ dence through performance – SMS Siemag.

SMS SIEMAG AG Eduard-Schloemann-Strasse 4 Phone: +49 211 881-0 E-mail: [email protected] 40237 Düsseldorf, Germany Fax: +49 211 881-4902 Internet: www.sms-siemag.com system, meaning alloys are recycled into the same alloys. done to get the precious material back at the end-of-life Previously, aluminum was more frequently “ downcycled,” and keep it for future generations. This is both a dificult a phenomenon that is caused through the contamina- challenge and a great opportunity. Only through better tion of unwanted agents during the recycling process, so societal coordination can the aluminum recycling indus- that the recycled metal has to be used for making high try achieve better service to the people in a more sustain- alloying-content alloys that are more “ tolerable” to exotic able way. elements. For instance, recycled aluminum was tradition- Another challenge is technological progress. Mate- ally mostly used for casting products, such as automobile rial recycling has traditionally been considered a low- parts, appliances, tools, and engineering equipment. tech practice and has therefore long been neglected by During the past two decades, however, the use of recycled the research and innovation community. This situation metal has been extended to almost all alloy forms, prod- needs to change in the 21st century given the natural uct categories, and market sectors. A recent life cycle as- resource challenges we all face. The development of the sessment (LCA) survey conducted by the Aluminum As- aluminum recycling industry has proven that technol- sociation shows that the majority of semi-fabricated prod- ogy can always drive better, more eficient, and more ucts contain over 50% of recycled metal. complete recycling. There are great opportunities for technology progress in almost all stages of the alumi- Challenges & Opportunities num recycling value chain. For instance, the dazzling development of sensoring, With a bright future ahead for the aluminum recycling positioning, and tracking technologies in the consumer industry, challenges remain. One such challenge is the electronics world has opened numerous possibilities for sourcing of raw materials— scrap. As mentioned previ- future aluminum scrap collection and sorting. Already ously, the increase of raw material availability will come there are technologies used in the industry for such pur- mainly from retired products and such availability is fore- poses. One such example is the near-infrared or X-ray seen. However, the actual recovery— the collection of system that is designed to identify and remove contami- such scrap— is another matter. Aluminum is one of the nants from aluminum scrap. Another example is a hand- most recycled common materials. But too much of the held X-ray luorescence device that can help determine metal is still lost in landills each year and recovering thisalloy grade and chemical compositions of aluminum material is virtually impossible. scrap.5 But the potential for even greater technological The problem for the loss of the material exists in the enhancements exists. For instance, future aluminum disconnect between parties in the recycling value chain. products could be made with “ IDs,” so that they will be The recycling value chain, or the material low chain, in- able to be tracked all the way throughout their in-use volves three distinct parties: the scrap generators, the col- lifetime until they get recycled. Such a system could dra- lectors and processors, and the recyclers (the new mate- matically help the aluminum recycling industry precisely rial makers). Among the three parties, only the recyclers “ mine” its raw materials and recycle them in a closed- are considered to be part of the aluminum industry. But loop fashion— same alloys to same alloys. the most critical party to ensure that recycling actually Another area for technological development is design occurs are the scrap generators. The scrap generators for recycling. This includes developing more recycling often have the “ right” and control to decide where the “ friendly” alloys and designing products so that they can scrap goes—including to landills. The scrap collectors be more easily dissembled and recycled. and processors, on the other hand, can affect the quality A third area for technological opportunities is in fur- of scrap— whether it is well-sorted and clean. The recy- nace technologies. Great progress has been achieved in clers are responsible for turning scrap into new materials the past three decades and today’s furnaces are much and products serving exactly the same function in an ef- more eficient and cleaner than those in the past. Future icient, effective, and environmentally friendly manner. attention should be paid to the treatment and removal The most disconnected among the key parties is often of unwanted contaminants and chemicals in furnaces, so the scrap generator. In the industrial and commercial the recycled metal can have precisely desired speciica- part of society, such as transportation, building and con- tions and that the drawback of mixed source scrap can be struction, utility and infrastructure, and manufacturing, maximally reduced. most of the scrap generated ends up being recycled. In Looking to the later part of the 21st century, the impor- the individual consumer part of society, however, things tance of aluminum recycling will only grow and oppor- get much more complex due to the involvement of hun- tunities for the aluminum industry to improve practices dreds of millions of individual stakeholders. In many af- will expand. Challenges will always accompany societal luent societies like ours, there is not enough inancial development. But let me leave you with a Chinese saying: incentive for individual consumers to recycle their used Opportunities co-exist with challenges. Whoever faces products, particularly when that product is small items the challenges and seizes the opportunities wins the busi- like packaging, portable electronics, toys, and batteries. ness. The lack of legal and regulatory measures makes things worse. The clearest example of this may be in aluminum References can recycling, where the consumer recycling rate of cans in the U.S. hovers around 60%. As a consequence, a large 1. Aluminum Recycling Casebook, The Aluminum Associa- amount of aluminum, worth more than one billion dol- tion, 1998. lars, is estimated to be lost in North America each year 2. Annual Statistical Review, The Aluminum Association, and a large proportion of such loss could be prevented Multiple Years. with appropriate regulatory or market incentives.4 3. CRU Group and Harbor Aluminum Intelligence, Facing the material loss challenge, the aluminum in- Various Meeting Presentations, Multiple Years. dustry has made signiicant efforts to promote recycling. 4. “ Aluminum: The Element of Sustainability – A North Measures include advocacy campaigns, consumer educa- American Aluminum Industry Sustainability Report,” tion and promotion, research and study on individual The Aluminum Association, 2011. behaviors, and outreach and coordination with policy- 5. Kuhn, Mareike, “ Aluminum: No Future without Re- makers, regulators, and NGOs. Much more needs to be cycling,” Recycling International, March 2013, No. 2.

64 LIGHT METAL AGE, AUGUST 2013 THE PROPERZI EVOLUTION FOR MODERN INGOT PRODUCTION

www.properzi.com · [email protected]

HEADQUARTERS FRANC E D IVIS ION USA BRANCH Continuus-Properzi S.p.A. Properzi France Properzi International, Inc. Via Emilia Km 310 Parc d’activité du Vert Galant 909 Ridgebrook Road 26858 – Sordio – LO – Italy 78 Avenue du Château Suite # 102 Phone: +39. 02. 988 49 21 BP 27745 Saint Ouen l’Aumône Sparks, Maryland 21152 – USA Fax: +39. 02. 981 03 58 Phone: +33. 1. 34 32 34 80 Phone: +1. 443. 212. 4320 [email protected] Fax: +33. 1. 34 32 34 89 Fax: +1. 866. 905. 4320 [email protected] [email protected] 75th Anniversary for Gillespie & Powers Custom Designed Aluminum Melting

ith a deep rooted background in manufactur- Charles K. Gillespie (Figure ing and installing refractories and furnaces 4), son of the founder, came in the aluminum industry, many of Gillespie on board as a partner with & Powers (G&P) technical developments John R. From that time until Whave laid the groundwork for improved metal recovery John R.’s death in 2006, they industry-wide. The company’s accumulated experience guided G&P through stages in refractory and furnace design has played a signiicantof systematic growth and pros- role in advancing the knowledge in this ield. G&P hasperity. “ It was through their built upon its 75 years of experience to become a niche vision and leadership that the supplier of high temperature furnaces. company integrated into the aluminum industry, beginning History with refractory rebuilding services and now culminating in Charles A. Gillespie (Figure the complete design and fur- Figure 3. John R. Gillespie. 1) irst formed Gillespie Com- nace building activities that pany as a proprietorship in the company is engaged in,” 1931. Later in February 1938, said Jon Gillespie (Figure 5), Charles formed a partnership John R.’s son. Following the with Frank X. Powers to create step down of Charles K. in No- Gillespie & Powers. In 1950, vember 2007, Jon was named two years after the death of president of the company. Powers, the partnership was (Jon’s son, John B. Gillespie converted to the present corpo- graduated from Rolla in 2011 ration. From its inception the and is currently involved in company operated on a region- project management for the al basis involved with masonry company.) Figure 1. Charles A. Gil- installation services, primarily lespie. From the St. Louis point of in heating systems and electric operation, G&P continues to Figure 4. Charles K. Gil- generator stations. Around the time of the formation maintain its refractory masonry lespie. of the partnership, the city of St. Louis, MO, passed a construction activities, as well rigid smoke abatement law that thrust the company into as the aluminum industry seg- a great deal of research into the installation of new coal- ment, including the design burning equipment in many existing boilers. Following and installation of melting and this, the company was heavily involved with the conver- scrap preparation equipment. sion of much of the hand-ired equipment to stokers, In addition, the company has and inally converted much of this equipment to iring refractory masonry construc- oil and gas. tion ield ofices in Iowa,- Ken From its initial home and storefront operations, the tucky, and northern Missouri, company moved into its irst corporate ofices in August as well as their corporate head- 1961 in midtown St. Louis. It was in the early 1960s that, quarters in St. Louis, which as a result of providing refractory repair services to a house the engineering ofices number of aluminum clients, the company expanded and a mobilization center for into the aluminum industry providing complete design their activities in North and Figure 5. Jon R. Gillespie. and installation of aluminum melting furnaces (Figure South America and Asia. Ap- 2), especially in larger stationary type of equipment proximately 65 people make up the core staff and ield up to 150 tons in capacity. Operations at the St. Louis supervisors, whose efforts are ever changing in expand- site were expanded under the direction of John R. Gil- ing supplemental craft involvement on speciic projects lespie (Figure 3), nephew of the founder. John R. was during the course of their ield construction activities. named president of the company in 1966 and in 1968 “ We believe that much of our success in the aluminum industry has been derived from our application of the knowledge that we have learned from supplying maintenance and operations assistance to people in the industry on a routine basis as a part of our ongoing refractory masonry and construction services,” said Jon. “ Improve- ments learned from these experiences have been crafted into our new equipment models to the satisfaction of our customers.”

Technical Advancement

Through its active involvement with customers, G&P has developed new technologies in order to improve melt rate and eficiency of its equipment for the process- Figure 2. Sidewell melting furnace. ing and melting of aluminum. The company was granted

66 LIGHT METAL AGE, AUGUST 2013 al client,” said Jon. “ We also have a keen appreciation of the requirement for maintaining a construction schedule and delivering the equipment on time and ready to perform. These qualities, coupled together with our continued accumulation of knowledge as it relates to the func- tionality of these devices for continued improvement has contributed to our longevity.”

Moving Forward

G&P is currently in various stages of progress on ive melting furnace projects across the U.S., including stationary melters with regenerative iring and tilting capabilities. The company is also in the process of con- tainerizing and shipping equipment for several major Figure 6. Mass low decoating system. South American aluminum remelt plant expansions, in- volving delacquering and melting equipment, and has its irst U.S. patent in 1989 for an apparatus designed to recently completed the installation of two high capacity generate a vortex in the melt. John R. was the primary au- delacquering machines and three melting furnaces for thor of this and ive other U.S. patents, all of which relate a client in the Asian market. Jon also noted that the re- to equipment and devices for the improvement of pre- fractory maintenance segment of the business remains paring and processing scrap aluminum, for improving strong, with ongoing maintenance and repair activity of the eficiency of the melting of aluminum, and featuresfurnace equipment for a variety of metal melting cus- related to the construction of furnaces. “ This continued tomers. technical development has been the special strength of The company is in the process of developing low con- our company for decades,” said Jon. trol for transferring and casting and is expanding recy- The company also currently has six other U.S. patents cling capabilities in order to move beyond decoating pending in this same area of research, including a re- and melting to include scrap receiving and preparation mote thermocouple sensing and control system for metal equipment, encompassing a turnkey responsibility for kilns, a regenerative melting and holding furnace with scrap recycling plants. In the refractory repair and main- an improved media box, a regen system media bed loattenance segment, G&P is adding to its project manage- sled, an auto tapper low control system, reversible jamb ment team and expanding its mobilization centers to im- blocks and an associated method for using them, and a prove the supply of services to key customers on a timely temperature control system and method for metal kilns. basis, as well as to reinforce its commitment to “ what they “ One very impor- do best”—the problem solving of refractory modiica - tant technical achieve- tions and relining, which has served the company well ment,” added Jon, “ was for the past 75 years. the precise true-scale “ We certainly believe the future in the aluminum mar- water models of our ketplace is going to be enhanced with the recent increase open sidewell melting in the natural gas production. This will have a long term furnace system, which impact on the expansion of the infrastructure in the alu- have provided valu- minum industry, which G&P hopes to be a part of,” said able information for Jon. “ In the refractory and maintenance sector, we con- designing the most ef- tinue to seek opportunities to expand to provide mobili- fective arrangement zation centers for the supply of the services to key custom- of connecting features ers on a timely basis. We also continue to move forward to between the wells and diversify geographically and take advantage of building the main hearth of fur- relationships with competent suppliers offshore.” naces.” Other develop- Having built on its initial strengths in the refractory in- ments by the company dustry, G&P has drawn together a team of experienced are a reverse low melt- individuals, who have worked to make the company rec- ing concept that can ognized in the worldwide aluminum industry (Figure 8). be applied when large quantities of heavy Figure 7. A vortex system for rapidly scrap are to be pre- submerging lightweight scrap in a melt- heated and melted; a ing operation. mass low delacquering system for the continuous removal of contamination from UBCs and other lightweight scrap prior to melting (Figure 6); a vortex submerging system for the rapid submerging of lightweight scrap in a continuous sidewell melting operation (Figure 7); an auto tapper that attach- es to the side of the furnace and acts as safety device, providing continuous automatic tapping of molten metal, and that can be combined with a low control system; and a twin-head regenerative burner arrangement that can it burners on an existing melter when the geometry of the furnace is an issue. “ Most of our new aluminum industry sales are custom designed to it the special requirements of each individu- Figure 8. The current Gillespie & Powers team.

LIGHT METAL AGE, AUGUST 2013 67 San Antonio, TX TMS 2013 Annual Meeting and Exhibition

he TMS 2013 Annual Meet- of the Norwegian University of Sci- ing and Exhibition, held ence and Technology for his service in San Antonio, TX, from to the technical community and to March 3-7, hosted more aluminum reduction technology. thanT 4,000 materials scientists and The Light Metals Award was given engineers, of which more than 1,000 to Vladislav Gorbunov and Gennady were students. The event featured Podgorodetsky, National University the presentation of nearly 3,000 tech- of Science and Technology, and Gen- nical papers and an exhibition with nadiy Klimetenok and Andrey Panov, nearly 100 exhibitors (some of whose UC Rusal Engineering and Technolo- pictures follow on page 69, L-R). gy Center, for their paper “Directions for Large Scale Utilization of Bauxite Honors & Awards Residue.” Four Light Metals Subject Awards At the TMS-AIME Honors and were also given, including the Alumi- Awards Banquet, 2012 TMS presi- num Reduction Technology Award dent Wolfgang Schneider, Hydro Alu- to Ingo Eick of Hydro Aluminium minium, welcomed Elizabeth Holm Deutschland and Kristian Etienne (pictured), who was installed as the Elizabeth Holm, TMS president. Einarsrud and Stein Tore Johansen of 57th president of TMS. A professor of SINTEF Materials and Chemistry; the materials science and engineering at his service in expanding TMS’ reach Electrode Technology for Aluminum Carnegie Mellon University in Pitts- through cooperation with other or- Production Award to Barry Sadler of burgh, PA, Holm was serving as the ganizations and organization of ma- Net Carbon Consulting Pty; the Re- society’s vice president and has been terials conferences. A Brimacombe cycling Award to Tracey Brommer a member for 20 years. In her open- Medal was awarded to Alan Luo, of PA Consulting, Britt Elin Gihleen- ing comments, she noted that TMS General Motors Co., for his contribu- gen of Scandpower, and Randolph was in great shape to respond to the tions to the research of lightweight Kirchain and Elsa Olivetti of Mas- trends in its profession and the needs aluminum and magnesium alloys, sachusetts Institute of Technology; of its members. “ My goal is to refocus from computational alloy design to and the Warren Peterson Cast Shop on sustaining members and activities automotive applications, as well as for for Aluminum Production Award to to ensure that the professional soci- his service to the society via work in Malcom Couper and Mark Easton of ety that has served them so well since technical committees, the Light Met- Monash University, Nick Parson of 1871 remains their destination of als Division (LMD), and program- Rio Tinto Alcan, Lisa Sweet of CAST choice for the next 142 years,” said ming and publication committees. Crc, and John Taylor of University of Holm. She added that she hopes to In addition, the AIME Champion H. Queensland. emphasize the development of pro- Mathewson Award was given to Paul grams to support young- and mid- Krajewski, General Motors Co., and Aluminum Session career professional members and to Eric M. Taleff, University of Texas, for focus on issues of geographic and de- their paper, “Effect of Microstructure While each of the seven present- mographic diversity. on Cavitation during Hot Deforma- ers during the Aluminum Keynote Following presentations by TMS tion of Fine-Grained Aluminum-Mag- Session focused on different issues, leaders, the society presented honors nesium Alloy as Revealed through approaches, and technologies, the and awards of excellence in multiple Three-Dimensional Characteriza- impact of impurities across the en- divisions. Ray Peterson, Aleris In- tion.” tire aluminum supply chain was a ternational, received the Alexander The LMD Distinguished Service consistent theme that underscored Scott Distinguished Service Award for Award was given to Jomar Thonstad each presentation. Session chair, Les

Wolfgang Schneider presented Schneider awarded Alan Luo a George Luxbacher presented an John Hryn presented the LMD the Alexander Scott Distinguished Brimacombe Medal. AIME Champion H. Mathewson Distinguished Service Award to Service Award to Ray Peterson Award to Paul Krajewski (far right) Jomar Thonstad (right). (right). and Eric M. Taleff.

68 LIGHT METAL AGE, AUGUST 2013 San Antonio, TX TMS 2013

Edwards, vp, Technical Services, Rain CII Carbon, said, “ The primary goal is to bring people together from the bauxite/alumina, reduction, electrode, and casthouse areas… we need to think about impurities holistically rather than something that affects each area separately.” Stephen Lindsay, Alcoa, in his talk on Raw Material Impurities and the Challenge Ahead, noted that as the demand on existing resources for raw materials increases, raw material purity will likely decline over time. In turn, impurities and changes in impurities will take on greater meaning for process control, equipment design and selection, metal products, Aluminum keynote speakers (L-R): John Grandield, Andrea Weber, Muhammad Rhamdhani, and environmental, health, and safe- James Metson, Karl Bartholomew, Stephen Lindsay, Stewart Hamilton, and Les Edwards. ty considerations. “ Impurities have the potential to reshape certain as- quence, although the U.S. is produc- room to the casthouse. Muhammad pects of the design and operation of ing a better quality crude, the “ quality Rhamdhani, Swinburne University smelters, electrode plants, cast shops, of pet coke has gotten worse.” of Technology, offered an in-depth and reineries,” Lindsay said. “Many Andrea Weber, Rio Tinto Alcan overview of current and emerging of the potential outcomes of higher (RTA) Sebree, provided an overview technologies for impurities removal. impurities may not require new tech- of an effective technical improvement While these techniques work well for nology, but different applications of plan in Impact of Higher Vanadium Lev- selected elements, he concluded that existing technologies.” els on Smelter Operations. Sebree made the boron treatment process for con- In Impacts of Impurities Introduced into a choice to accept increased impuri- trolling vanadium is not optimized the Aluminium Reduction Cell, James ties in one of the primary cokes used and no existing technique effective- Metson, University of Auckland, in the coke blend supplied to the ly controls nickel in the casthouse. looked beyond metal quality, noting, smelter, in return for a signiicant cost“ Strategies through the whole process “ It is also necessary to consider those discount. Faced with a negative im- chain may need to be considered,” he impurities which don’t report to the pact on anode consumption, current said. “ And some fundamental studies metal.” While the industry is getting eficiency, power consumption, and need to be carried out.” better at some aspects of managing other metrics, RTA developed a work In the inal presentation, John impurities, Metson said, “ The ne- quality management system to ensure Grandield, Grandield Technology glected part is the electrochemistry that all potline operators, regardless Pty Ltd., examined the potential im- and the impacts on the process are of experience level, were well trained pact of impurities on the end prod- considerable. This is driving down in basic practices. The project started uct. In An Initial Assessment of the Effects our ability to dissolve alumina and with a focused analysis of practices in of Increased Ni and V Content in AA6063 tightening the production window. In a 42-pot test section, where the most and A356 Alloys, he shared an investi- some parts of the world, we are well critical 20% of these procedures were gation conducted for two commonly out of our comfort zone in terms of then identiied. These procedures used alloys, AA6060/6063 and A356, our understanding of this chemistry, were made the subject of an intensive in which castings were produced with decreasing our ability to dissolve alu- training session for all operators and low typical levels of NiV and with high mina at the rate we need.” allowed for the implementation of a NiV levels approaching the maximum In Changes in Global Reining and Its system to monitor individual perfor- P1020 speciication of 300 ppm each. Impact on Anode Quality Petroleum Coke, mance. Microstructural changes, tensile Karl Bartholomew, KBC Advanced Stewart Hamilton, New Zealand Al- properties, and corrosion resistance Technologies, Inc., outlined the eco- uminium Smelters Ltd, also touched were measured, with small changes nomic drivers that have profoundly on the human factor necessary for in corrosion performance and tensile affected the quality and quantity of success in Impact on Smelter Operations properties detected in some instanc- calcinable anode grade petroleum of Operating High Purity Reduction Cells. es. While the exact effects depend on coke. Of particular signiicance hasPresented as a case study, Hamilton the alloy system, Grandield noted been the rapid emergence of shale oil noted that “ everyone must be en- that “ vanadium and nickel may have production in the U.S. “ Since 2009, gaged in the mindset,” because of the effects even at dilute levels on some the U.S. has gone from almost no expense and complexity of high puri- properties. We need to start to coor- production of shale oil to over a mil- ty production. “ The good thing about dinate with customers, so that they do lion barrels a day,” said Bartholomew. a high purity focus is that it rubs off not suddenly ind that the properties However, in the prevailing business into other areas,” he said. “ The more of their products have changed.” model, a very small percentage of we focus on purity, the more we un- All of the technical papers pre- this high quality crude is sent to cok- derstand and improve other param- sented in the keynote session are ing rooms. Comparatively, more than eters of smelter operations.” published in the Light Metals 2013 30% of certain types of poor quality Management of Impurities in Cast proceedings, which are available crude from outside of the U.S. is used House with Particular Reference to Ni and in the TMS Knowledge Center: to make petroleum coke. As a conse- V moved the discussion from the pot http://knowledge.tms.org.

LIGHT METAL AGE, AUGUST 2013 69 San Antonio, TX TMS 2013

Stephen Jackson and Jim Checkeye, Bloom Pierre Farge, Fives Cinetic Group, and Dominique Privé and Dror Shaked, Brochot Engineering Fabienne Virieux, Pierre Mahieu, and Xavier Genin, Fives Solios

Frank Beck and Werner Nowitzki, Glama François Mousseau, Jean-Pierre Gagné, and Karl St-Laurent and Kevin Williams, Machinenbau Marc-André Thibault, STAS Advanced Dynamics

Rainer Ehmann, Gautschi John Trimbur, John Allen, Robert Jenkins, Mohammed Yahya, DUBAL, and Abdul and David Burrow, Thorpe Technologies Raheem Al Hashemi, EMAL

Ian Marsh, Jon Gillespie, Rob Nash, and Steve Iijima and Eishin Takahashi, Zmag David Edgerton, Nederman LLC, and Scott Dan Corley, Gillespie + Powers America Gongaware, MikroPul

Elwin Roetman and Steven van der Bent, Berthold Hohl and Stefan Vucic, Eirich David Wilburn, Ellen Wilburn, Domenico Hencon Di Lisa, Anke Di Lisa, Detlef Maiwald, and Sigrid Maiwald, innovatherm

70 LIGHT METAL AGE, AUGUST 2013 Index to Directory of Secondary Aluminum* Equipment Manufacturers & Suppliers

Alloying Elements ...... 72 Launders, Troughs, Crucibles ...... 74 Automation/Control Systems ...... 72 Lubrication/Coatings ...... 74 Briquetting ...... 72 Material Handling Equipment/Vehicles ...... 74 Casting Equipment - Billet/Slab/Ingot/Strip ...... 72 Metallographic Services ...... 74 Chip Handling ...... 72 Metal Measurement/Testing ...... 74 Chip Melter ...... 72 Molds ...... 74 Combustion Equipment ...... 72 Molten Level Control ...... 74 Compactors ...... 72 Molten Metal Analysis ...... 74 Consulting Engineers (Primary Business) ...... 72 Molten Metal Filtration ...... 74 Conveyors ...... 72 Molten Metal Pumps ...... 74 Degassing ...... 72 Molten Metal Transfer Trucks ...... 74 Delacquering/Decoating Equipment ...... 72 Pollution Control Equipment ...... 74 Dross Cooling Equipment ...... 72 Quality Control ...... 74 Dross Handling Equipment ...... 72 Refractory Supply/Maintenance ...... 74 Electromagnetic Stirring Equipment ...... 72 Rotary Gas/Flux Injectors ...... 74 Furnace Charging Machines ...... 72 Rotary Kilns/Dryers ...... 74 Furnace Tending Machines ...... 72 Sawing Systems/Equipment ...... 74 Furnaces – Holding ...... 73 Scrap Submergence Systems ...... 75 Furnaces – Homogenizing ...... 73 Separation Systems ...... 75 Furnaces – Melting ...... 73 Shredders ...... 75 Furnaces – Preheat ...... 73 Sow Casting/Handling Equipment ...... 75 Furnaces – Rotary ...... 73 Stirring/Vortexing Equipment ...... 75 Grain Reining Rod Dispensers ...... 73 Strapping/Packaging ...... 75 Hydraulic Drive Systems ...... 73 Temperature Measurement/Control Equipment ...... 75 Hydrogen Analyzers ...... 73 Ultrasonic Testing ...... 75 Inclusion Measurement ...... 73 Used Equipment / Equipment Agents Industrial Gases ...... 73 (Primary Business) ...... 75 Ingot Stacking/Handling Equipment ...... 73 Vibratory Feeders ...... 75 Ladle Equipment ...... 74 Weighing Equipment ...... 75 *Secondary aluminum producers are deined as secondary smelters and remelters of aluminum. Secondary smelters process different types of scrap, while remelters process billets or pure scrap of one or more alloy.

Molten Metal Level Control

Our PLPR Non Contact Probe for The ProH Digital Camera Sensor robot automation allows exact positioning combines high performance triangulation for the ladle to operate correctly. technology with all the control functions It replaces the previously used you need to maintain an accurate contact electrodes. molten metal level.

The Precimeter Group develops produces and sells solutions for molten metal level control. We offer a wide range of equipment in this industry. Please visit our homepage for more info: www.precimeter.com

Eastern and Central Europe, Die Casting and EM Pumps Western Europe, Middle East, Africa, Asia and Australia North, Central and South America Carli Precimeter GmbH Precimeter Control AB Sentech Precimeter Inc. Kirberg 5/ 51674 Wiehl/ Germany Östra Hamnen 7/ SE-475 42 Hönö/ SE 2215 S. 48th Str. #C / Tempe, AZ 85282/ U.S.A Phone: +49-2262-701624 Fax: +49-2262-701625 Phone: +46-31-764 55 20 Fax: +46-31-764 55 29 Phone: +1 (480) 829-1923 Fax: +1 (480) 894-5546 www.precimeter.com/dc www.precimeter.com www.precimeter.com [email protected] [email protected] [email protected]

LIGHT METAL AGE, AUGUST 2013 71 Directory of Secondary Aluminum Equipment Manufacturers & Suppliers Categories/Companies

ALLOYING ELEMENTS Sistem Teknik Ltd. STI DELACQUERING/ DECOATING AMG Aluminum Zmag America, Ltd. EQUIPMENT A. Cesana Srl Apogee Technology, Inc. Excellent Foundry Fluxes Company COMBUSTION EQUIPMENT Chinook Sciences, LLC Pyrotek Inc. Air Liquide Industrial U.S. LP Consolidated Engineering Company Scottish Chemical Industries Air Products and Chemicals, Inc. Gillespie & Powers, Inc. Surface Combustion, Inc. Bloom Engineering Major Furnace Australia Pty Ltd. Fives North American Combustion Mechatherm International Ltd. AUTOMATION/ CONTROL Furnace Engineering Pty. Ltd. Sistem Teknik Ltd. STI SYSTEMS Gillespie & Powers, Inc. Thorpe Technologies Inc. ABB Inc. Hauck Manufacturing Co. Advanced Dynamics HCT Ltd. DROSS COOLING EQUIPMENT Almex USA Inc. Innovatherm ALTEK-MDY, LLC Butech Bliss Linde, Inc. Mansell & Associates Innovatherm Major Furnace Australia Pty Ltd. mfs engineering ltd. Linde, Inc. Mechatherm International Ltd. Outotec (Canada) Ltd. Mechatherm International Ltd. Metal 7 Inc. Pyrotek Inc. Metal 7 Inc. mfs engineering ltd. STAS Novelis PAE North American Combustion Outotec (Canada) Ltd. Services, Ltd. DROSS HANDLING PMC Systems, Inc. Remelt Technologies, Inc. EQUIPMENT Precimeter Control AB Sistem Teknik Ltd. STI Advanced Dynamics Sistem Teknik Ltd. STI Surface Combustion, Inc. ALTEK-MDY, LLC Surface Combustion, Inc. Thorpe Technologies Inc. Major Furnace Australia Pty Ltd. Wagstaff, Inc. VHE ehf Mansell & Associates Mechatherm International Ltd. BRIQUETTING COMPACTORS mfs engineering ltd. Hertwich Engineering JMC Recycling Systems Ltd. STAS mfs engineering ltd. SSI Shredding Systems, Inc. ELECTROMAGNETIC STIRRING CASTING EQUIPMENT – CONSULTING ENGINEERS EQUIPMENT BILLET/ SLAB/ INGOT/ STRIP (PRIMARY BUSINESS) ABB Inc. Almex USA Inc. B.S. Metallurgy ALTEK-MDY, LLC Bosch Rexroth Corporation Hatch Furnace Engineering Pty. Ltd. Castal Engineering Penta Engineering P.A. Gillespie & Powers, Inc. A. Cesana Srl Quality Consultants BV Hertwich Engineering Consolidated Ceramic Products Inc. Inductotherm Corp. Continuus Properzi S.P.A. CONVEYORS Mechatherm International Ltd. Gautschi Engineering GmbH ACI-Canefco Solios Thermal Hertwich Engineering Advanced Dynamics HPI GmbH Bosch Rexroth Corporation FURNACE CHARGING JMC Recycling Systems Ltd. Consolidated Engineering Company MACHINES LOI Thermprocess GmbH GLAMA Maschinenbau GmbH ACI-Canefco Mansell & Associates Infa S.A. Advanced Dynamics Mechatherm International Ltd. Mansell & Associates Consolidated Engineering Company mfs engineering ltd. Metal 7 Inc. Furnace Engineering Pty. Ltd. Novelis PAE GHI Hornos Industriales, S.L. o.d.t. Engineering Pty Ltd. DEGASSING GLAMA Maschinenbau GmbH Outotec (Canada) Ltd. Almex USA Inc. GNA alutech inc. Permatech Inc. Apogee Technology, Inc. Hencon B.V. Properzi International, Inc. A. Cesana Srl Hertwich Engineering Pyrotek Inc. Continuus Properzi S.P.A. HPI GmbH Quality Consultants BV Excellent Foundry Fluxes Company Inductotherm Corp. Remelt Technologies, Inc. Furnace Engineering Pty. Ltd. Otto Junker GmbH Sistem Teknik Ltd. STI Gautschi Engineering GmbH Major Furnace Australia Pty Ltd. Wagstaff, Inc. Mechatherm International Ltd. Mansell & Associates Mersen USA Greenville-MI Corp. Mechatherm International Ltd. CHIP HANDLING Molten Metal Equipment Innovations mfs engineering ltd. ACI-Canefco Novelis PAE Outotec (Canada) Ltd. Advanced Dynamics Permatech Inc. Pyrotek Inc. B&O Saws, Inc. Properzi International, Inc. Remelt Technologies, Inc. Hencon B.V. Pyrotek Inc. Sistem Teknik Ltd. STI Mechatherm International Ltd. Refraco Inc. Surface Combustion, Inc. Sistem Teknik Ltd. STI Scottish Chemical Industries Thorpe Technologies Inc. Sistem Teknik Ltd. STI CHIP MELTER STAS FURNACE TENDING MACHINES Gillespie & Powers, Inc. Advanced Dynamics GNA alutech inc. ALTEK-MDY, LLC

72 LIGHT METAL AGE, AUGUST 2013 Directory of Secondary Aluminum Equipment Manufacturers & Suppliers Categories/Companies

GHI Hornos Industriales, S.L. FURNACES – MELTING Major Furnace Australia Pty Ltd. GLAMA Maschinenbau GmbH ACI-Canefco Mansell & Associates Hencon B.V. Air Liquide Industrial U.S. LP Mechatherm International Ltd. Hertwich Engineering Almex USA Inc. Refraco Inc. Mechatherm International Ltd. Apogee Technology, Inc. SECO/Warwick mfs engineering ltd. Castal Engineering Sistem Teknik Ltd. STI A. Cesana Srl Surface Combustion, Inc. FURNACES – HOLDING Continuus Properzi S.P.A. Thermserve Limited ACI-Canefco EFR Thorpe Technologies Inc. Apogee Technology, Inc. Furnace Engineering Pty. Ltd. Castal Engineering Gautschi Engineering GmbH GRAIN REFINING ROD A. Cesana Srl GHI Hornos Industriales, S.L. DISPENSERS Continuus Properzi S.P.A. Gillespie & Powers, Inc. Acme Machine Works, Inc. EFR GNA alutech inc. Almex USA Inc. Furnace Engineering Pty. Ltd. Hertwich Engineering AMG Aluminum Gautschi Engineering GmbH Inductotherm Corp. Apogee Technology, Inc. GHI Hornos Industriales, S.L. Otto Junker GmbH A. Cesana Srl Gillespie & Powers, Inc. LOI Thermprocess GmbH Infa S.A. GNA alutech inc. Major Furnace Australia Pty Ltd. Mechatherm International Ltd. Hertwich Engineering Mansell & Associates Novelis PAE Inductotherm Corp. Mechatherm International Ltd. o.d.t. Engineering Pty Ltd. Infa S.A. mfs engineering ltd. Otto Junker GmbH North American Combustion HYDRAULIC DRIVE SYSTEMS LOI Thermprocess GmbH Services, Ltd. Apogee Technology, Inc. Major Furnace Australia Pty Ltd. Permatech Inc. Bosch Rexroth Corporation Mansell & Associates Properzi International, Inc. Major Furnace Australia Pty Ltd. Mechatherm International Ltd. Refraco Inc. VHE ehf mfs engineering ltd. The Schaefer Group, Inc. North American Combustion SECO/Warwick HYDROGEN ANALYZERS Services, Ltd. Sistem Teknik Ltd. STI ABB Analytical Measurement Permatech Inc. Solios Thermal Air Liquide Industrial U.S. LP Properzi International, Inc. Thermserve Limited Almex USA Inc. Pyrotek Inc. Thorpe Technologies Inc. A. Cesana Srl Refraco Inc. Pyrotek Inc. The Schaefer Group, Inc. FURNACES – PREHEAT Scottish Chemical Industries SECO/Warwick ACI-Canefco Sistem Teknik Ltd. STI Can-Eng Furnaces International INCLUSION MEASUREMENT Solios Thermal Consolidated Engineering Company ABB Analytical Measurement Surface Combustion, Inc. EFR Almex USA Inc. Thermserve Limited Furnace Engineering Pty. Ltd. Pyrotek Inc. Thorpe Technologies Inc. GHI Hornos Industriales, S.L. Scottish Chemical Industries Gillespie & Powers, Inc. FURNACES – HOMOGENIZING GNA alutech inc. INDUSTRIAL GASES ACI-Canefco Otto Junker GmbH Air Liquide Industrial U.S. LP Apogee Technology, Inc. LOI Thermprocess GmbH Air Products and Chemicals, Inc. Can-Eng Furnaces International Major Furnace Australia Pty Ltd. Linde, Inc. Consolidated Engineering Company Mechatherm International Ltd. EFR mfs engineering ltd. INGOT STACKING/ HANDLING Furnace Engineering Pty. Ltd. North American Combustion EQUIPMENT Gautschi Engineering GmbH Services, Ltd. ACI-Canefco GHI Hornos Industriales, S.L. Permatech Inc. Acme Machine Works, Inc. GNA alutech inc. Refraco Inc. Advanced Dynamics Hertwich Engineering SECO/Warwick B&O Saws, Inc. HPI GmbH Sistem Teknik Ltd. STI Bradley Lifting Corp. Otto Junker GmbH Solios Thermal Continuus Properzi S.P.A. LOI Thermprocess GmbH Surface Combustion, Inc. Gautschi Engineering GmbH Mechatherm International Ltd. Thermserve Limited Hertwich Engineering mfs engineering ltd. Thorpe Technologies Inc. JMC Recycling Systems Ltd. North American Combustion VHE ehf Mansell & Associates Services, Ltd. Zircar Refractory Composites, Inc. Metal 7 Inc. Refraco Inc. mfs engineering ltd. Remelt Technologies, Inc. FURNACES – ROTARY o.d.t. Engineering Pty Ltd. SECO/Warwick ALTEK-MDY, LLC Outotec (Canada) Ltd. Sistem Teknik Ltd. STI Can-Eng Furnaces International Permatech Inc. Solios Thermal Furnace Engineering Pty. Ltd. Properzi International, Inc. Tellkamp Systems, Inc. GHI Hornos Industriales, S.L. Thermserve Limited Hertwich Engineering Thorpe Technologies Inc. LOI Thermprocess GmbH

LIGHT METAL AGE, AUGUST 2013 73 Directory of Secondary Aluminum Equipment Manufacturers & Suppliers Categories/Companies

LADLE EQUIPMENT METALLOGRAPHIC SERVICES MOLTEN METAL TRANSFER Bosch Rexroth Corporation ABB Analytical Measurement TRUCKS Furnace Engineering Pty. Ltd. Almex USA Inc. GLAMA Maschinenbau GmbH Gillespie & Powers, Inc. Pyrotek Inc. Hencon B.V. GLAMA Maschinenbau GmbH SELEE Corporation Hencon B.V. POLLUTION CONTROL Linde, Inc. METAL MEASUREMENT/ EQUIPMENT Mansell & Associates TESTING Chinook Sciences, LLC Metal 7 Inc. ABB Analytical Measurement Gillespie & Powers, Inc. North American Combustion Almex USA Inc. Innovatherm Services, Ltd. Wagstaff, Inc. Mansell & Associates Outotec (Canada) Ltd. Nederman Permatech Inc. MOLDS Surface Combustion, Inc. Pyrotek Inc. Gautschi Engineering GmbH Tellkamp Systems, Inc. Refraco Inc. GES, Inc. The Schaefer Group, Inc. Mersen USA Greenville-MI Corp. QUALITY CONTROL STAS Novelis PAE ABB Analytical Measurement o.d.t. Engineering Pty Ltd. Almex USA Inc. LAUNDERS, TROUGHS, Wagstaff, Inc. Apogee Technology, Inc. CRUCIBLES Permatech Inc. ACI-Canefco MOLTEN LEVEL CONTROL Pyrotek Inc. Apogee Technology, Inc. Almex USA Inc. A. Cesana Srl Apogee Technology, Inc. REFRACTORY SUPPLY/ Furnace Engineering Pty. Ltd. Consolidated Ceramic Products Inc. MAINTENANCE GES, Inc. Furnace Engineering Pty. Ltd. Apogee Technology, Inc. Hencon B.V. Gautschi Engineering GmbH Gillespie & Powers, Inc. Infa S.A. Gillespie & Powers, Inc. Infa S.A. Mansell & Associates Infa S.A. Mechatherm International Ltd. mfs engineering ltd. Mechatherm International Ltd. North American Combustion Molten Metal Equipment Innovations Molten Metal Equipment Innovations Services, Ltd. North American Combustion Novelis PAE Novelis PAE Services, Ltd. Outotec (Canada) Ltd. Permatech Inc. Outotec (Canada) Ltd. Precimeter Control AB Pyrotek Inc. Permatech Inc. Sentech Precimeter Inc. Refraco Inc. Pyrotek Inc. VHE ehf The Schaefer Group, Inc. Refraco Inc. Wagstaff, Inc. Scottish Chemical Industries The Schaefer Group, Inc. Surface Combustion, Inc. Scottish Chemical Industries MOLTEN METAL ANALYSIS Wahl Refactory Solutions SELEE Corporation ABB Analytical Measurement ZIRCAR Ceramics, Inc. Solios Thermal Almex USA Inc. Zircar Refractory Composites, Inc. Thorpe Technologies Inc. Wagstaff, Inc. MOLTEN METAL FILTRATION ROTARY GAS/ FLUX Wahl Refactory Solutions ACI-Canefco INJECTORS Almex USA Inc. Apogee Technology, Inc. LUBRICATION/ COATINGS Apogee Technology, Inc. Excellent Foundry Fluxes Company Apogee Technology, Inc. Gautschi Engineering GmbH GES, Inc. A. Cesana Srl Infa S.A. Molten Metal Equipment Innovations DryLube Mechatherm International Ltd. Scottish Chemical Industries Metal 7 Inc. Novelis PAE STAS Novelis PAE Permatech Inc. Permatech Inc. Properzi International, Inc. ROTARY KILNS/ DRYERS Pyrotek Inc. The Schaefer Group, Inc. Gillespie & Powers, Inc. Scottish Chemical Industries Scottish Chemical Industries Major Furnace Australia Pty Ltd. SELEE Corporation Sistem Teknik Ltd. STI MATERIAL HANDLING STAS Surface Combustion, Inc. EQUIPMENT/ VEHICLES Urja Products Pvt. Ltd. Thorpe Technologies Inc. Bosch Rexroth Corporation Zircar Refractory Composites, Inc. Butech Bliss SAWING SYSTEMS/ Can-Eng Furnaces International MOLTEN METAL PUMPS EQUIPMENT Consolidated Engineering Company Apogee Technology, Inc. ACI-Canefco GLAMA Maschinenbau GmbH GES, Inc. Acme Machine Works, Inc. Hencon B.V. Gillespie & Powers, Inc. Advanced Dynamics Permatech Inc. Mechatherm International Ltd. B&O Saws, Inc. Pyrotek Inc. Molten Metal Equipment Innovations Bosch Rexroth Corporation Solios Thermal Permatech Inc. DryLube Surface Combustion, Inc. Precimeter Control AB Hertwich Engineering Zmag America, Ltd. HPI GmbH MetlSaw Systems Inc.

74 LIGHT METAL AGE, AUGUST 2013 Directory of Secondary Aluminum Equipment Manufacturers & Suppliers Categories/Companies mfs engineering ltd. Mansell & Associates VHE ehf August Mössner GmbH + Co. KG Mechatherm International Ltd. Williamson Corp. Outotec (Canada) Ltd. o.d.t. Engineering Pty Ltd. REISCH Maschinenbau GmbH Outotec (Canada) Ltd. ULTRASONIC TESTING Sermas Industrie Wagstaff, Inc. ACI-Canefco Sistem Teknik Ltd. STI Advanced Dynamics STIRRING/ VORTEXING Almex USA Inc. SCRAP SUBMERGENCE EQUIPMENT Hertwich Engineering SYSTEMS Apogee Technology, Inc. HPI GmbH Apogee Technology, Inc. Furnace Engineering Pty. Ltd. Furnace Engineering Pty. Ltd. Gillespie & Powers, Inc. USED EQUIPMENT / Gillespie & Powers, Inc. Pyrotek Inc. EQUIPMENT AGENTS Hertwich Engineering Zmag America, Ltd. (PRIMARY BUSINESS) Molten Metal Equipment Innovations Phipps Company Pyrotek Inc. STRAPPING/ PACKAGING Zmag America, Ltd. ACI-Canefco VIBRATORY FEEDERS Advanced Dynamics Furnace Engineering Pty. Ltd. SEPARATION SYSTEMS Hertwich Engineering Gillespie & Powers, Inc. Zmag America, Ltd. o.d.t. Engineering Pty Ltd. Mansell & Associates Outotec (Canada) Ltd. Outotec (Canada) Ltd. SHREDDERS REISCH Maschinenbau GmbH Bosch Rexroth Corporation WEIGHING EQUIPMENT Granutech – Saturn Systems TEMPERATURE Hertwich Engineering JMC Recycling Systems Ltd. MEASUREMENT/ CONTROL o.d.t. Engineering Pty Ltd. SSI Shredding Systems, Inc. EQUIPMENT Outotec (Canada) Ltd. Accurate Sensors Technologies SOW CASTING/ HANDLING Consolidated Ceramic Products Inc. EQUIPMENT Hauck Manufacturing Co. Acme Machine Works, Inc. Mechatherm International Ltd. Advanced Dynamics Metal 7 Inc. Bosch Rexroth Corporation Pyrotek Inc. Bradley Lifting Corp.

LIGHT METAL AGE, AUGUST 2013 75 Directory of Secondary Aluminum Equipment Manufacturers & Suppliers Alphabetical Listing of Companies

ABB Analytical Measurement Almex USA Inc. email: [email protected] 585 Boulevard Charest East, Ste 300 6925 Aragon Circle web: www.bsmetallurgy.com Quebec City, QC, G1K 9H4, Canada Buena Park, CA 90620 Contact: Rob Bailey Tel: (418) 877-2944 Tel: (714) 522-7340 email: [email protected] email: [email protected] Butech Bliss web: www.abb.com/analytical web: www.almexusa.com 550 South Ellsworth Ave. Contact: Jasmin Proulx Contact: Kedar Tilak Salem, OH 44460 Tel: (330) 337-0000 ABB Inc. ALTEK-MDY, LLC email: [email protected] 90 Consumers Drive Whiteland Business Center web: www.butechbliss.com Whitby, ON, Canada L1N 7L5 748 Springdale Road, Suite 100 Contact: Al Waigand Tel: (905) 666-2251 Exton, PA 19341 email: david.a.domanski@ Tel: (484) 713-0070 Can-Eng Furnaces International ca.abb.com email: [email protected] 6800 Montrose Road web: www.abb.com web: www.altek-al.com Niagara Falls, ON, Canada L2E 6V5 Contact: David Domanski Contact: James Herbert Tel: (905) 356-1327 email: [email protected] Accurate Sensors Technologies Ltd. AMG Aluminum web: www.can-eng.com Misgav Industrial Park 435 Devon Park Dr., Bldg. 300 Contact: Tim Donofrio Misgav, 20179 Israel Wayne, PA 19087 Tel: (972) 4-9990025 Tel: (800) 523-8457 Castal Engineering email: [email protected] email: [email protected] Hippocrates 18 web: www.accuratesensors.com web: www.amg-al.com 14563 Kiisia, Greece Contact: Haim Damir Contact: Tim Donnelly Tel: (30) 210 8073088 email: [email protected] ACI-Canefco Apogee Technology, Inc. web: www.castal.gr 488 Basaltic Road 1600 Hulton Rd. Contact: F. Samaropoulos Concord, ON, L4K 5A2, Canada Verona, PA 15147 Tel: (905) 417-0036 Tel: (412) 795-8782 A. Cesana Srl email: [email protected] email: [email protected] Via Turati 23 web: www.aci-ca.com web: www.apogeetechinc.com 20016 Pero, Milan, Italy Contact: Helgar Bergmann Contact: Scott Stauffer Tel: (39) 02 3534941 email: [email protected] Acme Machine Works, Inc. B&O Saws, Inc. web: www.acesana.com North 1220 Bradley Rd. 825 Reed St. Contact: Alberto Cesana Spokane, WA 99212 Belding, MI 48809 Tel: (509) 927-9066 Tel: (616) 794-7297 Chinook Sciences LLC email: [email protected] email: [email protected] 20 Commerce Dr., Suite 326 web: www.acmemachineworks.com web: www.bosaws.com Cranford, NJ 07016 Contact: Don McManus Contact: Doug Kohn Tel: (908) 272-5091 email: [email protected] Advanced Dynamics Bloom Engineering web: www.chinooksciences.com 1700 Blvd. Marie Victorin 5460 Horning Rd. Contact: Harry Perry Saint Bruno, QC, J3V 6B9, Canada Pittsburgh, PA 15236-2822 Tel: (450) 653-7220 Tel: (412) 653-3500 Consolidated Ceramic Products email: kevinwilliams@ email: [email protected] Inc. (CCPI) advanceddynamics.com web: www.bloomeng.com 838 Cherry St. web: www.advanceddynamics.com Contact: Jim Checkeye Blanchester, OH 45107 Contact: Kevin Williams Tel: (937) 783-2476 Bosch Rexroth Corporation email: [email protected] Air Liquide Industrial U.S. LP 2315 City Line Rd. web: www.ccpi-inc.com 2700 Post Oak Blvd. Bethlehem, PA 18017 Contact: Kari Dixon Houston, TX 77056 Tel: (610) 694-8300 Tel: (713) 624-8740 email: [email protected] Consolidated Engineering email: [email protected] web: www.boschrexroth-us.com Company web: www.us.airliquide.com Contact: Sales 1971 McCollum Pkwy NW Contact: Marissa Olvera Kennesaw, GA 30102 Bradley Lifting Corp. Tel: (770) 422-5100 Air Products and Chemicals, Inc. 1030 Elm St. email: [email protected] 7201 Hamilton Boulevard York, PA 17403 web: www.cec-intl.com Allentown, PA 18195 Tel: (717) 848-3121 Contact: Paul Crafton Tel: (800) 654-4567, code 534 email: [email protected] email: [email protected] web: www.bradleylifting.com Continuus-Properzi S.P.A. web: www.airproducts.com/ Contact: Dino Petrucci Via Cosimo del Fante 10 nonferrous 20122 Milano, Italy Contact: Marie Kistler B.S. Metallurgy, Inc. Tel: (39) 02 988492-1 1601 Madison Street email: [email protected] Manitowoc, WI 54220 web: www.properzi.it Tel: (920) 686-6000 Contact: Carmelo M. Brocato

76 LIGHT METAL AGE, AUGUST 2013 Directory of Secondary Aluminum Equipment Manufacturers & Suppliers Alphabetical Listing of Companies

DryLube email: [email protected] HPI GmbH 8516 Hwy 6 South web: www.gillespiepowers.com Schloss Strasse 32 Houston, TX 77083 Contact: Rob Nash 5282 Braunau-Ranshofen, Austria Tel: (281) 498-9474 Tel: (43) 7722 68420 email: [email protected] GLAMA Maschinenbau GmbH email: [email protected] web: www.dry-lube.com Hornstrasse 19 web: www.hpi.at Contact: Bob Tilley 45964 Gladbeck, Germany Contact: R. Edtmeier Tel: (49) 2043 9738-0 EFR email: [email protected] Inductotherm Corp. 213 rue de Gerland web: www.glama.de 10 Indel Ave, PO Box 157 “Les jardins d’entreprise” Bât F2 Contact: Werner Nowitzki Rancocas, NJ 08073 69007 Lyon, France Tel: (609) 267-9000 Tel: (33) 4 78 58 27 55 GNA alutech inc. email: [email protected] email: [email protected] 9495 Trans-Canada Hwy. web: www.inductotherm.com web: www.fours-efr.com Saint-Laurent, QC, H4S 1V3, Canada Contact: Joseph T. Belsh Contact: Eric Edel Tel: (514) 956-1776 email: [email protected] Infa S.A. Excellent Foundry Fluxes Company web: www.gna.ca Ruta n° 4 s/n 12-B Pkt A-13 Kalakajee Extn Contact: Ted Phenix Puerto Madryn, Chubut New Delhi 110019, India Argentina, U9120ACV Tel: (91) 11 2999 3327 Granutech-Saturn Systems Tel: (54) 2965 451342 x6502 email: [email protected] 201 East Shady Grove Rd. email: [email protected] web: www.excellentproducts.co.in Grand Prairie, TX 75050 web: www.infa.com.ar Contact: V.P. Sharma Tel: (972) 790-7800 Contact: Luis Azcona email: [email protected] Fives North American Combustion web: www.granutech.com Innovatherm 4455 East 71st Street Contact: Matt Morrison Am Hetgesborn 20 Cleveland, OH 44105 35510 Butzbach, Germany Tel: (216) 271-6000 Hatch Tel: (49) 6033 9696-0 email: [email protected] 1600 West Carson St., Ste. 1 email: [email protected] web: www.ivesgroup.com/ivesna Gateway View Plaza web: www.innovatherm.com Contact: Clive Lucas Pittsburgh, PA 15219 Contact: Detlef Maiwald Tel: (412) 497-2022 Furnace Engineering Pty Ltd. email: [email protected] JMC Recycling Systems Ltd. 50 Howleys Road web: www.hatch.ca 2 Harrimans Lane Notting Hill, Vic., 3168, Australia Contact: Sales Dunkirk, Nottingham, NG7 25D, U.K. Tel: (61) 3 9544 2922 Tel: (44) 115 940 9630 email: [email protected] Hauck Manufacturing Company email: [email protected] web: www.furnace.com.au 100 N. Harris St. web: www.jmcrecycling.com Contact: Peter Newman Cleona, PA 17042 Contact: Phillip Pownall Tel: (717) 272-3051 Gautschi Engineering GmbH email: [email protected] Otto Junker GmbH Konstanzer Strasse 37 web: www.hauckburner.com Jägerhausstrasse 22 8274 Tägerwilen, Switzerland Contact: Rick Carpenter 52152 Simmerath, Germany Tel: (41) 71-666 66 66 Tel: (49) 2473 601-0 email: [email protected] HCT Ltd. email: [email protected] web: www.gautschi.cc Bretton St., Savile Town web: www.otto-junker.de Contact: Stefan Blum Dewsbury, West Yorkshire Contact: Sales WF12 9DB, UK GES, Inc. Tel: (44) 1924 506 506 Linde 5628 Clifford Circle email: [email protected] 575 Mountain Ave. Birmingham, AL 35210 web: www.hotworkct.com Murray Hill, NJ 07748 Tel: (866) 472-1861 Contact: Denis Hunzinger Tel: (908) 771-1215 email: [email protected] email: [email protected] web: www.geselectrodes.com Hencon B.V. web: www.linde.com Contact: Hunter Kearney PO Box 16 Contact: Tony Palermo 7070 AA Ulft, The Netherlands GHI Hornos Industriales, S.L. Tel: (31) 315-683941 LOI Thermprocess GmbH Aperribay, 4 email: [email protected] Am Lichtbogen 29 Galdakao 48960, Bizkaia, Spain web: www.hencon.nl 45141 Essen, Germany Tel: (34) 9444 91600 Contact: Gerrit Hiddink Tel: (49) 201 1891-1 email: [email protected] email: [email protected] web: www.ghihornos.com Hertwich Engineering web: www.loi-italimpianti.de Contact: Jose D. Berasategui Weinbergerstr. 6 Contact: Andrea Kehry Braunau 5280, Austria Gillespie & Powers, Inc. Tel: (43) 7722 806-0 9550 True Drive email: [email protected] St. Louis, MO 63132 web: www.hertwich.com Tel: (314) 423-9460 Contact: Hermann Zeillinger

LIGHT METAL AGE, AUGUST 2013 77 Directory of Secondary Aluminum Equipment Manufacturers & Suppliers Alphabetical Listing of Companies

Major Furnace Australia Pty Ltd. web: www.moessner-kg.de PMC Systems, Inc. 92 Fairbank Rd. Contact: Oliver Vogt PO Box 486 Clayton, Vic., 3193, Australia North Jackson, OH 44451 Tel: (61) 3 8558 1800 Nederman Tel: (330) 538-2268 email: [email protected] 102 Transit Ave email: rick.kitchokoff@ web: www.majoreng.com.au Thomasville, NC 27361 pmcsystems.com Contact: Andrew North Tel: (773) 230-9207 web: www.pmcsystems.com email: david.edgerton@ Contact: Rick Kitchokoff Mansell & Associates nederman.com 551 Spring Valley Rd. web: www.nederman.com Precimeter Control AB Tuscumbia, AL 35674 Contact: David Edgerton Östra Hamnen 7 Tel: (256) 366-9325 Hono (Gothenburg) 475 42, Sweden email: emansell@ North American Construction Tel: (46) 31 764 55 20 mansellandassociates.net Services, Ltd. email: [email protected] web: www.mansellandassociates.net 5000 Commerce Ave web: www.precimeter.com Contact: Ed Mansell Birmingham, AL, 35210 Contact: Jonatan Lindstrand Tel: (205) 956-8191 Mechatherm International Ltd. email: [email protected] Properzi International, Inc. Hampshire House, High St. web: www.namfg.com 909 Ridgebrook Rd, Suite 102 Kingswinford, DY6 8AW, U.K. Contact: Matt Owens Sparks, MD 21152 Tel: (44) 1384 279132 Tel: (443) 212-4320 email: [email protected] Novelis PAE email: [email protected] web: www.mechatherm.co.uk Centr’Alp – BP 24 web: www.properzi.com Contact: James Parkes Voreppe 38341, France Contact: Giuseppe Marcantoni Tel: (33) 4 76 57 87 00 Mersen USA Greenville-MI Corp. email: [email protected] Pyrotek Inc. 712 Industrial Park Dr. web: www.pae.novelis.com 9503 E. Montgomery Ave. Greenville, MI 48838 Contact: Céline Reynas Spokane Valley, WA 99206 Tel: (800) 472-3483 Tel: (509) 926-6212 email: [email protected] o.d.t. Engineering Pty Ltd. email: [email protected] web: www.graphite-eng.com 521 Hammond Rd. web: www.pyrotek.info Contact: Sales Dandenong, Vic., 3175, Australia Contact: Clint Whitsett Tel: (61) 3 9706 4135 Metal 7 email: [email protected] Quality Consultants BV 285 les Pionniers web: www.odt.com.au Kooikershof 6 Sept-Iles, QC, G4R 4X9, Canada Contact: Markus Oswald 5256 KD, Heusden, Netherlands Tel: (418) 968-5822 Tel: (31) 416 662179 email: [email protected] Outotec (Canada) Ltd. email: [email protected] web: www.metal7.com 1551 Corporate Dr. web: www.qualityconsultants.nl Contact: Alexandre Neron Burlington, ON, L7L 6M3, Canada Contact: F. Bijlhouwer Tel: (905) 335-0002 MetlSaw Systems Inc. email: [email protected] Refraco Inc. 2950 Bay Vista Court web: www.outotec.com 1207 Antonio-Lemaire Benicia, CA 94510 Contact: Joe Grasso Chicoutimi, QC, G7K 1J2, Canada Tel: (707) 746-6200 Tel: (418) 545-4200 email: [email protected] PENTA Engineering, P.A. email: [email protected] web: www.metlsaw.com 13835 South Lakes Drive web: www.refraco.com Contact: Doug Jamieson Charlotte, NC 28273 Contact: Luc Flamand Tel: (704) 588-8877 mfs engineering ltd. email: [email protected] REISCH Maschinenbau GmbH P.O. Box 1437 web: www.pentaengr.com Sonnenbergerstrasse 4 CH-8280 Kreuzlingen, Switzerland Contact: David Stephens 6820 Frastanz, Austria Tel: (41) 79 600 7329 Tel: (43) 5522 51710-0 email: [email protected] Permatech Inc. email: [email protected] Contact: Sales 911 East Elm Street web: www.reisch.at Graham, NC 27253 Contact: Arno Reisch Molten Metal Equipment Innovations Tel: (336) 578-7757 15510 Old State Road email: kiersten.itzgerald@ Remelt Technologies, Inc. Middleield, OH 44062 permatech.net PO Box 915353 Tel: (440) 632-9119 web: www.permatech.net Longwood, FL 32791 email: [email protected] Contact: Kiersten FitzGerald Tel: (407) 880-2444 web: www.mmei-inc.com email: [email protected] Contact: Sarah Mikash Phipps Company Contact: Gary Bowden PO Box 1164 August Mössner GmbH + Co. KG Roxboro, NC 27573 The Schaefer Group, Inc. Hohenstaufenstr. 3 Tel: (336) 597-2370 1500 Humphrey Ave. 73569 Eschach, Germany email: [email protected] Dayton, OH 45410 Tel: (49) 7175 99806-0 web: www.phippsmetals.com Tel: (937) 253-3342 email: [email protected] Contact: Ron Phipps

78 LIGHT METAL AGE, AUGUST 2013 Directory of Secondary Aluminum Equipment Manufacturers & Suppliers Alphabetical Listing of Companies email: david.nelson@ email: [email protected] Wahl Refractory Solutions theschaefergroup.com web: www.ssiworld.com 767 State Rt 19 South web: www.theschaefergroup.com Contact: Dave Wilson Fremont, OH 43420 Contact: David Nelson Tel: (419) 334-2650 STAS email: [email protected] Scottish Chemical Industries 1846 Rue Outarde web: www.wahlref.com 5th Floor, Span Centre Chicoutimi, QC, G7K 1H1, Canada Contact: Timothy Albertson South Avenue, Santacruz-W Tel: (418) 696-0074 Mumbai, 400054, India email: [email protected] Williamson Corp. Tel: (91) 22 2605 6666 web: www.stas.com 70 Domino Dr. email: [email protected] Contact: Patrice Duchesne Concord, MA 01747 web: www.scottishchemical.com Tel: (978) 369-9607 Contact: Mr. Rishab Surface Combustion, Inc. email: [email protected] 1700 Indian Wood Circle web: www.williamsonir.com SECO/Warwick Maumee, OH 43537 Contact: Bud Foran 180 Mercer St., PO Box 908 Tel: (419) 891-7150 Meadville, PA 16335-6908 email: [email protected] ZIRCAR Ceramics, Inc. Tel: (814) 332-8437 web: www.surfacecombustion.com PO Box 519 email: [email protected] Contact: Amy Syroka Florida, NY 10921 web: www.secowarwick.com Tel: (845) 651-6600 Contact: Dominick DiRienzo Tellkamp Systems, Inc. email: [email protected] 15523 Carmenita Rd. web: www.zircarceramics.com SELEE Corporation Santa Fe Springs, CA 90670 Contact: David Hamling 700 Shepherd St. Tel: (562) 802-1621 Hendersonville, NC 28792 email: [email protected] Zircar Refractory Composites, Inc. Tel: (828) 697-2411 web: www.tellkamp.com PO Box 489 email: [email protected] Contact: Scott Bogut Florida, NY 10921 web: www.selee.com Tel: (845) 651-2200 Contact: Watt Jackson Thermserve Limited email: [email protected] Halesield 2 web: www.zrci.com Sentech Precimeter Inc. Telford, Shropshire, TF7 4QH, U.K. Contact: Nancy Miehe 2215 S. 48th St., Suite C Tel: (44) 1952 684 488 Tempe, AZ 85282 email: [email protected] Zmag America, Ltd. Tel: (480) 829-1923 web: www.thermserve.com 10260 SW Greenburg Rd., Ste 400 email: [email protected] Contact: Paul Armitage Portland, OR 97223 web: www.precimeter.com Tel: (503) 293-8481 Contact: Jerry Wilkins Thorpe Technologies Inc. email: [email protected] 449 W. Allen Ave., Suite 119 web: www.z-mag.net Sermas Industrie San Dimas, CA 91773 Contact: Eishin Takahashi 343 Chemin du Stade Tel: (562) 903-8230 38210 St. Quentin sur Isére, France email: [email protected] Tel: (33) 476 07 42 42 web: www.thorpetech.com email: [email protected] Contact: John Allen web: www.sermas.com Contact: Brigitte Charles Urja Products Private Ltd. 423 Gidc Estate Sistem Teknik Telephone Exchange Lane TosB-Taysad O.S.B Odhav, Ahmedabad 1 Cadde 14, Sok No. 3 Gujarat 382415, India 41420 Gebze, Kocaeli, Turkey Tel: (91) 79-228 73434 Tel: (90) 262 658 2226 email: [email protected] Screw it! email: [email protected] web: www.urjafabrics.com Recycling initiatives are popping web: www.sistemteknik.com Contact: Anshul Nanavaty Contact: Erdal Sahin up all over the world. Alupro in part- VHE ehf nership with the European Alumin- Solios Thermal Melabraut 27 ium Foil Association (www.alufoil. Heath Brook House, Heath Mill Road IS-220 Hafnarfjordur, Iceland org) and British Glass, launched a Wombourne, Wolverhampton Tel: (11) 354 5757-9700 new campaign, “ You Can Leave Your WV5 8AP, England email: [email protected] Cap On,” to encourage recyclers to Tel: (44) 1902 324000 web: www.vhe.is screw the caps back on their empty email: fabienne.virieux@ Contact: Barry Woodrow bottles before recycling, as the metal ivesgroup.com can be successfully extracted. Fol- web: www.ivesgroup.com Wagstaff, Inc. lowing research by the two organiza- Contact: Fabienne Virieux 3910 North Flora Rd. tions into the U.K. closure market, Spokane, WA 99216 it was discovered that approximately SSI Shredding Systems Tel: (509) 922-1404 5,000 tonnes of aluminum from 9760 SW Freeman Dr. email: [email protected] caps and closures could be recov- Wilsonville, OR 97070 web: www.wagstaff.com ered, and be diverted from landill. Tel: (503) 682-3633 Contact: Kevin Person For info: www.alupro.org.uk.

LIGHT METAL AGE, AUGUST 2013 79 Light Metal World… Magnesium Awards Presented in China International Aluminium Institute compares with an average of 126.7 (IAI) monthly production report by IAI thousands of metric tons in May 2013 The International Magnesium As- Members and Oficial Correspondents and 127 thousands of metric tons in sociation (IMA) awarded innovative was 3,935 thousands of metric tons April 2013. designers and engineers in the 2013 produced in June 2013, compared to IAI data now includes China and Awards of Excellence competition. 3,928 thousands of metric tons produced Estimated Un-Reported igures when Winners in three categories were an- in May 2013 and 3,809 thousands of tabulating world production. Further nounced at the IMA’s 70th Annual metric tons produced in April 2013. clariication regarding IAI statistics canWorld Magnesium Conference held in June’s average daily production wasbe found on its website at: www.world-Xi’an, China in May. 131.2 thousands of metric tons. This aluminium.org/statistics. The Design Class encompassed three categories for 2013: Cast Prod- uct Commercial, Cast Product Auto- motive, and Wrought Product. First Place for the Cast Product Commer- cial category was awarded to Fujiilm Sonosite Inc., Bothell, WA, for their “M2” UltraSound System. Using low simulation software and experience, the die caster provided feedback on the design, which included thin wall castings to minimize product weight, determining the appropriate gating for each casting, and developing a cross hatched, rib-like pattern to aid in metal low across the surface of the large casting. For the Cast Product Automotive category, the First Place award was presented to Georg Fischer GmbH & Company, KG, Altenmarkt, Austria, for their Convertible Roof Top Casting. The product served as the main part of a convertible roof using the alloy AM50 HP. In the Design Category for Wrought Product, the First Place winner was Nippon Kinzo- ku Company, Ltd., Tokyo, Japan. They created the world’s irst practical use and mass production technology of LZ91 alloy. Also taking part in helping produce this design was: NEC Per- sonal Computers, Ltd, Amli Material (*Revised Figure) Technology Company, Ltd., Professor Jian-Yih Wang of National Dong Hwa Annual North American Primary Aluminum Production University, Fuji Light Metal Company, Ltd., and Kasatani Corporation. Rolled The Aluminum Association, in coop- vious month’s rate of 5,038,130 tonnes.thin sheet of LZ91 alloy for stamping eration with the Aluminum Association Compared to a year ago, the annualwas rateused for the housing of the NEC of Canada, reported primary aluminum of production was 3.6 percent aboveUltrabook the computer. production in North America (U.S. June 2012 rate of 4,845,254 tonnes. Dur- First Place in the Process category and Canada) was at an annual rateing the of irst six months of 2013, actual was awarded to Jiangsu RM Wheel 5,019,346 tonnes during June 2013,- productionde totaled 2,497,426 tonnes, up Company, Ltd., Yangzhou, Jiangsu, clining 18,784 tpy (-0.4%) from -the 4.1pre percent over the same period in 2012. China for their Superplastic Mono- block Forged Molding Magnesium Wheel Technology. By applying AZ80 alloy in wheel production they reduced car weight and allowed for energy savings and emission reductions. First Place for the Application category was awarded to Pan Asia Techni- cal Automotive Center, in cooperation with General Motors Corp. in Warren, MI, for their industry-irst application of magnesium sheet in a structural and functional application of a Magnesium This report contains information reported to the Association by the domestic producers, which Intensive Decklid. The Decklid has is aggregated by the Association and expanded to represent the total industry. While the As- sociation believes that its statistical procedures and methods are reliable, it does not warrant been applied commercially on Cadillac the accuracy or completeness of the data. All data contained herein is subject to revision. For automobiles. More information on the further information: Tel: 703-358-2984 or email: [email protected]. awards is available at: www.intlmag.org.

80 LIGHT METAL AGE, AUGUST 2013 aluMiniuM: the GaMe chanGeR!

OctObeR 21-25, 2013 MONTREAL | canada A CONFERENCE ON INNOVATION, A WORLD-CLASS EXHIBITION

The Aluminium Association of Canada (AAC) and its members, Alcoa, Aluminerie Alouette and Rio Tinto Alcan, will host the irst Canadian International Aluminium Conference (CIAC).

The global importance of the aluminium industry around the world will be emphasized while showing the future of aluminium through its properties and forward looking applications.

a PROGRaM FOcused On aluMiniuM’s innOvative aPPlicatiOns -

Market trends • New and potential applications • Primary production’s environmental performance in the world • Aluminium’s contribution to sustainability • Economic issues and opportunities for the global aluminium industry • Looking ahead to 2030 • Future growth

a PROGRaM FOcused On PRiMaRy PROductiOn & the enviROnMent -

The politics of growth • The development of environmentally-friendly smelters in Russia, China and India • GCC Smelters – setting new environmental standards • Trends & Innovations in packaging • Best practices in recycling • Environmental developments in mining and reining • Best practices for future growth, current technological trends • AP60 presentations

a PROGRaM FOcused On ideas, ReseaRch & innOvatiOn - Bringing innovative ideas

Aluminium building and civil engineering structures; A review of research and structural design • The Stage of aluminum construction in the U.S. • The Status of the aluminum industry in Canada • Program Subject Area: New product design and construction, Processes Emerging technologies, Structural Design, Market Sectors, Surface treatment, New product design & development

a WeeK-lOnG seRies OF events all Related tO aluMiniuM! • Monday & Tuesday: Inalco’s 12th Conference • Monday 6 PM: VIP event at the Rio Tinto Alcan Planetarium • Tuesday to Thursday: a 3-days world-class exhibition • Tuesday to Thursday: CIAC Conference • Tuesday PM: the Aluminium Association of Canada (AAC)’s VIP cocktail reception in the exhibit hall • Tuesday & Thursday: the Aluminum Extruders Council (AEC) will present its “Excellence in Extrusion Workshop” • Wednesday & Thursday: AluSolutions’ Conference • Wednesday: technical courses on Aluminium: Design of Aluminium Structures, Design for Aluminium in light weight vehicles structures & Aluminium and transformation • Wednesday PM: Mission Design & Facteur D’s famous Facteur D Soirée • Monday, Wednesday & Friday: Industrial visits

WWW.CIACMONTREAL.COM

HOST AND CO-HOSTS LEAD SPONSORS

OTHER SPONSORS

INSTITUTIONAL PARTNERS ALUMINIUM PARTNERS MEDIA PARTNERS Inalco 2013 Heralds Aluminum’s Momentum in Structural Design

nalco 2013, the 12th International Aluminium Confer- possibilities for engineering and architectural profession- ence, to be held October 21-22 at the Palais des con- als. Kissell co-holds two U.S. patents, including one for grès de Montréal in Montréal, Québec, Canada, will an aluminum bridge deck. His structural designs have feature three keynote speakers, Professor IR. Frans been featured in Civil Engineering and Engineering News- Soetens,I Randy Kissell, and Jean Simard, presenting their Record and at ASCE Structures Congresses. He is chair- unique perspectives on the aluminum industry, its strengths man of the ASME B96 Committee for Welded Aluminum and challenges to an international audience of aluminum Alloy Storage Tanks, secretary of the American Welding industry professionals, including engineers, designers, and Society’s Subcommittee on Aluminum Structures, and scientists. The conference offers a host of technical presen- a member of the ASTM Light Metal Alloys Committee, tations by leading researchers, engineers, and innovators the American Society of Civil Engineers Load Standards in the global aluminum industry from countries including Committee, and the American Petroleum Institute’s Canada, the U.S., Italy, Sweden, the Netherlands, Belgium, Pressure Vessel and Tank Committee. France, Japan, Brazil, Gambia, and Iran. Session categories Kissell’s keynote on October 21, entitled “ The State include: Alloys & Properties, Metal Forming, Metal Joining, of Aluminum Construction in the U.S.,” addresses us- Construction, Manufacturing Research, Automotive Design age rates for aluminum in the building and construction & Fatigue, Sustainability, and Student presentations. New market, current design codes that govern U.S. aluminum product design and development, construction, processes, construction, and relevant seminars for aluminum struc- emerging technologies, structural design, market sectors, tural engineers. He will discuss recent developments that and surface treatment represent highlighted conference include new software used in aluminum structural design topics. The program and its technical content are subject and friction stir welding, and examine key challenges fac- to change at the discretion of the Inalco 2013 Organizing ing the U.S. aluminum structural industry. and Scientiic Committees. Jean Simard is president and Professor IR. Frans Soetens, general manager of the Alu- an aluminum structural design minium Association of Canada, expert, researcher, and industry in Montréal, and is president of consultant, is afiliated with the the upcoming Canadian Interna- Department of the Built Environ- tional Aluminium Conference. ment, Unit Structural Design and (CIAC). Simard is a public affairs Chair of Aluminium Structures at and government relations consul- Eindhoven University of Technolo- tant in the ields of the environ- gy in Eindhoven, the Netherlands. ment and energy, and joined Gaz From 1975-2010, Soetens worked Metro as vice president of sustain- for the Netherlands Organisation able development and govern- Jean Simard. for Applied Scientiic Research Professor IR. Frans ment relations. He holds a degree (TNO). His 35 years of experience Soetens. in civil law from the University of includes research, consulting, and Ottawa, is a member of the Bureau du Quebec, and is on knowledge transfer in the behavior of steel and aluminum the Board of Directors of the Aluminium Research and structures and in aluminum structural design. He has led Development Centre of Quebec (CQRDA) and Mission numerous national and international research projects Design, a non-proit organization in the ield of design. for companies, universities, and research organizations On Tuesday morning, October 22, Simard will address throughout Europe. On Monday morning October 21, the general session, presenting “ The Status of the Alumi- Soetens will present his keynote address to the general ses- num Industry in Canada.” sion, “ Aluminium Building and Civil Engineering Struc- These keynote presentations introduce two days of alu- tures: A Review of Research and Structural Design.” He minum technical sessions at Inalco 2013, with the theme: will discuss critical problems and challenges that designers “ Bringing Innovative Ideas to the World of Tomorrow,” face when seeking optimum structural solutions. Current held in conjunction with the CIAC, October 21-25, the Eurocode 9 design rules and their implementation in sev- lagship of the week-long aluminum industry events in eral Dutch structural applications will be highlighted, in- Montréal, including a three-day international exhibition, cluding an overview of research on aluminum’s structural plant visits, technical courses, and a full-day workshop. behavior and how this research has shaped European standards development. Latest Research, Technology, and Innovations Randy Kissell, P.E., is a senior partner with the TGB Partner- The following technical presentations are scheduled ship, an engineering irm special- for Inalco 2013 in Montréal, with more to be added to izing in aluminum structures in the inal conference program. Hillborough, NC. Kissell is sec- 5 Dimensional CFD Simulation and Optimisation of retary of the Aluminum Associa- Ventilation for Smelter Process Applications: E. Baltuch, tion’s Engineering Advisory Com- and S. Baltuch, Air-Therm Inc., Montréal, QC, Canada mittee, responsible for Speciica- Casting a Very Unconventional Aluminium Alloy in Low tion of Aluminum Structures, used Pressure Permanent Mould (LPPM): N. Giguère and F. throughout the U.S. for alumi- Chiesa, Centre de Métallurgie du Québec, Trois-Rivières, num structural design. He is co- QC, Canada author of Aluminum Structures – A Randy Kissell, P.E. Effects of Lubricating Conditions on Machinability Guide to Their Speciication and De- of AA6061-T6: J. Kouam, V. Songmene, ÉTS, Montréal, sign, which demonstrates how aluminum opens up design QC, Canada; M. Balazinski, École Polytechnique, Mon-

82 LIGHT METAL AGE, AUGUST 2013 tréal, QC, Canada; and P. Hendrick, Université libres de ducting Polymer Polypyrrole on Aluminium Substrates: Bruxelles, Belgium A. Siddaramanna and D.K. Sarkar, University of Quebec Modeling the Formation of Transverse Weld in Billet- at Chicoutimi (UQAC), QC, Canada to-Billet Extrusion using Finite Element Method: Y. Mah- Development of Aluminium High Stiffness Panels: M. moodkhani, M. Wells, University of Waterloo, Waterloo, Takahashi, Sumitomo Light Metal Industries, Ltd., Na- ON, Canada, and N. Parson, Arvida R&D Centre, Rio goya, Japan, and N. Ohtaki, Sumikei-Engineering Co., Tinto Alcan, Jonquière, QC, Canada Ltd., Japan Process Optimisation of a Friction Stir Lap Welded Modelling Surface Grain Structure Evolution in 5456 Aluminium Alloy: M. Jahazi, ÉTS, Montréal, QC, AA6082 Hot Direct Extrusion: W.Z. Misiolek and N.H. Al- Canada, and E. Salari, and A. Khdabandeh, IAU-Uni- harthi, Lehigh University, Bethlehem, PA; A. Güzel and versity, Department of Materials Engineering, IAU-S&R A. Jäger, TU Dortmund, Germany; Luigi De Pari Jr.; and Branch, Tehran, Iran A. Erman Tekkaya, Atilim University, Turkey The Development of AA3065 – an Extrudable Alloy Vibration Characterisation of a Modular Aluminium with Improved Mechanical Properties for Heavy-Duty Pedestrian Bridge: S. Walbridge, S. Narasimhan, and A. Heat Transfer Applications: N. Parson, A. Maltais, and Sychterz, University of Waterloo, Waterloo, ON, Canada R. Guay, Arvida R&D Centre, Rio Tinto Alcan, Jonquière, Aluminium Use in Vehicular Bridge Applications: A QC, Canada State-of-the-Art Review: S. Walbridge, University of Wa- A Streamlined Approach to the Flexural Strength of terloo, Waterloo, ON, Canada, and A. De la Chevrotière, Aluminium Members: R. Kissell, TGB Partnership, Hill- MAADI Group Inc., Montréal, QC, Canada borough, NC Increased Robustness in Three-Dimensional Friction Design for Fastener Tension and Pull-Out from Tapped Stir Welding using Force and Temperature Feedback: J. Aluminium: J.C. LaBelle, Computerized Structural De- De Backer and G. Bolmsjö, University West, Trollhattan, sign, S.C., Milwaukee, WI, and T.A. Dolby, Kawneer Com- Sweden pany, Inc., Norcross, GA Selection of Spectrographic Certiied Reference Mate- Structural Behaviour of Aluminium Bolt-Channel Joint: rial for the Analysis of Aluminium Alloys: J.F. Archam- Calibration of Numerical Models on Testing Results: V. bault, P. Bégin, and R. Hark, Arvida R&D Centre, Rio Macillo, L. Fiorino, and F.M. Mazzolani, University of Tinto Alcan, Jonquière, QC, Canada Naples “ Federico II” , Naples, Italy A New Heating System for Refractory used in the Effect of High-Speed Machining on Surface Integrity Aluminium Industry: S. Tremblay, M. Bouchard, and J. of 7075-T651 Aluminium Alloy: W. Jomaa, V. Songmene, Bouchard, Pyrotek Inc., Chicoutimi, QC, Canada and P. Bocher, ÉTS, Montréal, QC, Canada The Use of Promag NI as Reining Agent in Molten Screwed Joint for Aluminium Extrusions: Experimen- Aluminium Treatment: S. Tremblay and J. Bouchard, Py- tal and Numerical Investigation: L. Fiorino, V. Macillo, rotek Inc., Chicoutimi, QC, Canada and F.M. Mazzolani, University of Naples “Federico II” , Effect of Grain Shapes of the Microstructure on the Naples, Italy Mechanical Properties of the Binary Aluminium Alloy: S. Effect of Feeder Pocket Geometry on the Streaking Hamid and D. Larouche, Laval University, QC, Canada Tendency of 6xxx Extrusions: J.F. Béland, NRC, Sau- Strategic Management of Innovation to Improve Com- genay, QC, Canada; C.W. Jowett, Rio Tinto Alcan, ON, petitive Advantages of Middle East Primary Aluminium Canada; and N.Parson and A. Maltais, Rio Tinto Alcan, Industries: H. Fanisalek, Marzban Petro Energy (MPE), QC, Canada Tehran, Iran A Step for Aluminium Global Market Growth: A. Can- Fracture Study of a Welded Aluminium Cylinder Con- ice, Canice Maritime Alutec, Banjul, Gambia taining Longitudinal Crack and Subjected to Combined Particle Emission and Dispersion during Dry Machin- Residual Stress and Internal Pressure: M.R.M. Aliha and ing of Aluminium Alloys: A. Djebara and A. Bahloul, H. Gharehbaghi, University of Science and Technology, IRSST, Montréal, QC, Canada, and V. Songmene, ÉTS, Narmak, Tehran, Iran, and R. Ghafoori Ahangar, Ecole Montréal, QC, Canada Polytechnique, Montréal, QC, Canada Welding Training with an Interactive 3D Technology: C. Designing Eficient and Cost-Effective Structures Uti- Choquet, 123 Certiication Inc., Montréal, QC, Canada lizing Aluminum Extrusions: C. Werner, Werner Extru- Turning Post-Consumer Scrap into Wrought Alloy: sion Solutions, LLC, Libertyville, IL F. Bijlhouwer, Quality Consultants VOF, Heusden, the Optimisation of Friction Stir Welding Tool Advance Netherlands Speed – Monte-Carlo Simulation of Non-Linear Fi- The Use and Misuse of Aluminium in Packaging: F. Bi- nite Difference Heat Transfer Algorithm for Friction jlhouwer, Quality Consultants VOF, Heusden, the Neth- Stir Welding: K.A. Fraser, L. Kiss, and L. St-Georges, erlands University of Quebec at Chicoutimi, Chicoutimi, QC, New Generation Surface Pretreatment Methods for Canada Adhesive Bonding of AA6061-T6 Alloys: N. Saleema, Design Considerations for Aluminium Products: F. and D. Gallant, NRC, Saguenay, QC, Canada, and D.K. Racine, R. Bihamta, Y. Archambault, P. Buzatu, and A. Sarkar, University of Quebec at Chicoutimi, QC, Canada Chapdelaine, Alcoa Innovation, Montréal, QC, Canada Retrogression Heat Treatment of Aluminium Extru- RTA CastProTM Advanced Compact Filtration (ACF): sions and Rolled Products to Facilitate Forming and Join- Industrial Operation Feedback and Commercial Avail- ing in Structures: J.C. Benedyk, Illinois Institute of Tech- ability: F. Breton, Rio Tinto Alcan, Arvida R&D Center, nology, Chicago, IL Jonquière, QC, Canada, and J. Crépeau, Rio Tinto Alcan High-Temperature Forming Processes for the Manu- Corporate, Montréal, QC, Canada facturing of Complex Components using Aluminium Structural Design for Manufacturing with Aluminium: Alloy Sheets: G. D’Amours, J.F. Béland, and E. Samuel, A. de la Chevrotière, MAADI Group Inc., Montréal, QC, NRC, Saguenay, QC, Canada Canada Deburring and Edge Finishing of Aluminium Alloys: A Review: S.A. Niknam and V. Songmene, ÉTS, Montréal, Additional information on the Inalco 2013 Confer- QC, Canada ence, scheduled events, and registration may be found Structural Studies of Electrochemically Deposited Con- on the conference website: www.inalco2013.com.

LIGHT METAL AGE, AUGUST 2013 83 New Equipment Spotlight… Hot Dross Processing Aluminum Recovery System Kobayashi Aluminum is a secondary aluminum producer in Osaka, Japan. Their monthly production of aluminum alloy ingots is 550 tons with full capacity at 600 tons from one 25 ton reverberatory furnace. For a secondary alloy maker, dross processing is an indispensable pro- cedure since the amount of metal recovered is no small matter. Ko- bayashi Aluminum melts 25 tons of scrap in one charge, which produces about 600 kg of dross. From that 600 kg of dross, 300 kg of aluminum is recovered. In the month of January, one month’s aluminum recovery was 6,600 kg; one year was 79,200 kg, or about 80 tons. The alloy ADC12’s selling price is approximately 300,000 JPY (US$3,052.50) per ton. Therefore, one year’s recovered aluminum translates into 24 million JPY (US$244,196). It is no exaggeration Figure 1. Full system (Model Type 350) showing front and side of ARS. The open area of the that depending on how eficiently machine visible behind the yellow banisters is where dross processing begins. dross processing is carried out, a company’s proit line can dramatical- The entire system is at ground lev- pot were designed to prevent any ly luctuate. Kobayashi needed to- reel, which promises to facilitate safe issuring. Agitation eficiency is - im place their existing dross processors operation, inspection, and cleaning proved by using the patented double and tried Sanshin Sanwa Group’s (Figure 2). Additionally, the system’s vane. (SSG’s) hot dross processing Alumin- compact design keeps forklift us- The inner and outer vanes im- ium Recovery System (ARS) (Figure age to a minimum. “ Compared to prove agitation eficiency by rotating 1). Results were so outstanding that the previous methods, this ARS has at variable speeds. A triangular vane the company ordered a second ARS. served to be a complete processing cross section allows easy separation For Kobayashi’s 600 kg of dross, system for us,” said Kobayashi. through hot dross. Improved vane two SSG processing pots with a ca- agitation eficiency makes manual pacity of 400 kg are wheeled to the speed-changing functions unneces- front of the melting furnace with 300 sary. The vanes are integrated into kg of dross raked into each pot. The the machine, which eliminates mal- mobile pots are moved by forklift be- functions that could be caused by tween the melting furnace and hot the vanes’ vertical movement. The dross processing equipment. Dross transfer torque is ampliied by using processing time is about 5 minutes, a roller chain to rotate the vanes in- and with two pots, a total of 10 min- stead of a gear drive. The design uses utes is aimed for. From 300 kg, 150 only one geared motor to drive the kg of aluminum metal is recovered. vanes (other systems often employ a From here, the processed residual reducer). ARM achieves a dust-proof dross contains a small percentage of design by applying positive air pres- aluminum and is sold to a specialized Figure 2. Interior of Kobayashi Aluminum with sure inside the machine housing. residual dross processing company. melting furnace on the left and ARS on the Transfer Unit: This unit transports Whether or not the dross in the right. the residual hot dross, which was sep- pot is agitated properly signiicantly arated and collected during alumi- alters recovery eficiency. A major Description of ARS num reclamation/dross processing, feature of the SSG system is the tri- to the Super Cooler. This unit is ex- angular-shaped double vane struc- Hot Dross Processing Aluminium Re- clusive to SSG and indispensable for ture used for stirring. These vanes covery Machine (ARM): This machine residual dross reclamation. Thanks are design patent registered with the processes the hot dross that is gen- to its unique inverting mechanism, Japanese Utility Model Registration. erated from the melting furnaces the transfer unit can operate at loor One pot’s processing time is 5 ±2 reclaiming over 90% of the molten level without needing to create a pit. minutes. At the most, a total of 10 aluminum from the hot dross. Once All residual dross left in the pot after minutes could be spent on process- a pot has been illed with the hot aluminum reclamation is completely ing, depending on how much alu- dross from the melting furnace, the discharged by tilting the pot to the minum is left in the residual dross. pot only needs to be set once within necessary degree angle. According to Kobayashi’s president, ARM, and from that point, all pro- Cooled Dross Supplier: This machine Hiroyuki Kobayashi, “ Other compa- cessing and reclamation is automat- controls the temperature of the hot nies cannot keep up with this stirring ed. The integral molded castings that dross while it is being processed in eficiency.” are manufactured on the processing the pot by injecting the cooled dross

84 LIGHT METAL AGE, AUGUST 2013 from the ARS’ cooler. The cooled designed for enhanced durability, is can realize a substantial ROI within dross supplier is also exclusive to the used for the round shape of the bot- a few months. Its unique design of- system. An installed vibration-damp- tom of the housing. fers excellent operability and high ing device prevents malfunctions. Screw Conveyor: This conveyor durability. According to over 300 Cold dross that has overlowed dur- transfers ine- and medium-sizeusers domestic and abroad, the sys- ing ultra-cooling in the super cooler dross particles after being sorted by tem has yet to malfunction since its is collected and put into lexible con- the cooler. A single-bearing design installation, which attests its repu- tainer bags. has been employed to transfer and tation for long-lasting, trouble-free Super Cooler (patent pending): This handle the dross without transfer operation. component cools and sorts the re- complications that can often occur sidual hot dross after the aluminum from trapped ash, overloads and/or portion is removed (Figure 3). The wear and tear. The V-shaped hous- Super Cooler is equipped with a ing also aids in assuring smooth op- trommel for ine ash particles thaterations. Overloads are prevented cools all residual dross particles to an through the vane distance adjust- ultra low temperature. This was de- ment control measure. veloped in 2003 and brings the tem- Classiication System: The residual perature of residual dross/ash from dross, which is left over after alumi- 600°C to 40°C/1.5 m³ in 15 minutes. num recovery, is separated by par- The cooled ine grain residual dross ticle size. Upon its discharge from (30 mesh but can be adjusted to it the conveyor, this turn-style sifter operations’ requirements at time automatically classiies the cooled of installation) travels through this particles by grain size into 2-3 types cooler and is inally sent to lexibleand sorts them respectively into lex- container bags for collection. Middle ible container bags. and coarse grain residual dross par- Advanced Electrical Control System: ticles are also sent to their respec- ARS implements the Mitsubishi Figure 4. Hot dross is being processed, re- tive lexible container bags. This Electric sequencer MELSEC Q-Se- sulting in aluminum metal reclamation. processing low has proven to be ofries PLC control system. Over ten of huge merit for recycling operations. ARS’ various mechanisms’ perfor- The streamlined processing of re- The Super Cooler’s original design mance, interlock coniguration, and sidual dross with ARS prevents any enables extreme cooling eficiency. management are being controlled. harmful impact from dross dust dif- Cooling eficiency is 85-95%, using For safety, a designed-for-security in- fusion on the surrounding environ- only a small quantity of circulation terlock mechanism has been adopt- ment and nearby residents’ health. water: approximately 180 L/min. ed. Additionally, the MMI that is be- The residual dross can be further re- The compactness of the unit offers ing employed is Mitsubishi Electric’s used as landill material, pavement space saving with ultra-high capac- GOT 1000 Series, operated using a material, or cooled dross (already ity processing. The system utilizes touch panel screen. integrated to adjust dross tempera- an easy-to-maintain open type water Optional Dust Collector: When dust ture during ARS hot dross process- spray system (spray tube is made of and ash are produced from dross ing). Some users go one step further SUS304). A steam release duct in- processing facilities, environmental and adjust the amount of aluminum cludes a natural exhaust system. pollution from dust diffusion can content within the residual dross be reduced depending on how the to then sell to steel manufacturers, dust is sent to a dust collector. This who use this adjusted residual dross dust collecting system abates much as deoxidizers or insulation agents. of the harmful pollution that can be The latter particularly is a common caused from hot dross processing practice within Japan. Such smooth systems. The system is able to con- reuse of by-products after the metal nect to existing dust collectors as recovery stage is what sets ARS apart well. from other dross processing methods in contributing to environmen- Beneits tal preservation and sustainable use of resources. ARS processes and recovers metal ARS comes in a range of equip- at high-speed, extracting aluminum ment, such as the entire system (ARS) Figure 3. Super Cooler cools all sizes of re- with only a few minutes needed for for large operations down to the ARM sidual dross particles rapidly. each processing cycle. The system LG150, which is especially suitable for promptly recovers large volumes of aluminum die casting manufactur- Cooled Dross Supply Conveyor: This aluminum, which can then be di- ers; the ARM LG150 has an excellent conveyor transfers the classiied drossrectly used for production (Figure reputation due to its compact size yet that was cooled and sorted by the 4). It can reclaim more than 90% of high eficiency and exceptional oper- cooler. This scraper type conveyor was the available aluminum metal from ability. ARS has been installed in over irst employed in Japan 25 years ago. dross, which is a drastic improve- 300 companies within Japan and is It offers high sealing performance ment in aluminum recovery ratio the leading equipment of its type in and is optimal for handling residual compared to conventional meth- that country with an over 85% indus- ash consisting of large and small par- ods, i.e. press, pit, rotary kiln, grind- try market share. ticles of various shapes. The conveyor ing/screen, etc. This remarkable chains, although exposed to the hard- reclamation ratio delivers a quick Editor’s Note: More information on ARS est loads, offer extreme durability. return on investment. According can be found at: www.sanwacorporation. Wear-resistant steel plating, which was to SSG, results now verify that users co.jp/english.html.

LIGHT METAL AGE, AUGUST 2013 85 Equipment Spotlight… Chinese Plants Obtain Signiicant Savings by Recycling Scrap Aluminum

he key drivers in eficiently for this is 1% metal loss to every 1% remelting scrap aluminum contamination; however, the true are having a very energy ef- melt loss due to contamination has icient process and ensuring a ratio of 1.5-to-1 or greater. Higher Tthe yield from the scrap is as high contamination levels are due to oils, as possible. In recent years, the Chi- paints, and plastics, all of which are nese aluminum industry has invested part of the hydrocarbon family. heavily in the production of elec- Pyrolysis is the conversion of these trolytic aluminum, achieving new contaminants into simpler forms of standards in the energy per tonne hydrocarbon— oils, methane, bu- produced. The Chinese industry’s tane, etc.— and can only occur in an integrated approach to producing atmosphere where there is little or both electrolytic aluminum and the no oxygen. In the scrap chamber of Figure 2. A vortex for chip and small scrap inished product on the same site a twin-chamber furnace, heat from recycling. has led to a push to improve the en- the furnace and fuel from contami- ergy eficiency and yield recoveries nation exist. If oxygen is present, the coveries due to the trapped oxides of scrap aluminum produced both contamination will burn. By remov- and contamination. Introduction of in-house and in general recycling. ing the oxygen from the scrap cham- scrap into the Pyrotek LOTUSS in Recent Chinese governmental ber, the contamination will pyrolyze, loose form allows the mechanical policy is also sparking the improve- or decompose. The gasses and vapor- forces in the vortex to strip the ox- ment in the aluminum recycling ized oils from this pyrolyzation in a ide layer from the low-density scrap. industry there, with government- twin-chamber melting furnace are As the scrap is submerged, there is issued minimum targets for energy then fed into the main chamber of no further growth of the oxide layer, eficiency and metal yield.1 In ad- the furnace where they are used as maximizing aluminum recovery. dition, environmental targets must an additional combustible fuel, re- Results from plants in China uti- be met before authorization for any ducing the amount of fuel required lizing these technologies show sig- new plant and equipment can be re- to heat the chamber. niicant improvements in energy - ef ceived.2 Circulation of the furnace is also iciency and metal yield, with natural Several plants in China are lead- key to its energy eficient operation, gas consumption at one site reduced ing the way in the eficient recyclingthe electromagnetic pump system from 1,104 kW hours to 576 kW of either in-house scrap or general (EMP™) produces a directed “ jet” of hours per tonne and a melt-yield im- scrap with the use of twin-chamber hot metal underneath the surface provement from 92.5% to as high as furnace technology integrated with of the melt, so that once the con- 98.6%. Four Chinese plants are cur- Pyrotek’s electromagnetic pumping tamination has been pyrolyzed, the rently utilizing this technology, and and LOTUSS™ vortex systems (Fig- remaining aluminum scrap can be an additional four plants are expect- ure 1). Key to achieving high energy pushed into the liquid bath. Due to ed to install it within the next couple eficiency, high scrap yield and good the directional low from the EMP, of years. Plants using the technology environmental performance are a this increases the mass low around typically see a return on their capi- number of technologies and process- the scrap, whilst taking the hotter tal investment within one year due es that have been combined within metal from the main furnace cham- to the reduced energy consumption the twin-chamber furnace system, in- ber. Thus, the convectional heating and improved metal yield. Environ- cluding pyrolysis of organic contami- rate of the scrap is greatly increased, mental measurements on the plants nation and the high-eficiency cir- leading to an increase in the heat- have also shown that the emission culation and submergence of small absorption rate of the scrap from standards met would satisfy Europe- scrap. around 1°C (~2°F) per second to up an standards, as well as Chinese re- All scrap is contaminated in some to 3°C (~5°F) per second and reduc- quirements. way, and any contaminated alumi- ing the amount of time taken to melt num introduced into a melting fur- the scrap and, ultimately, the energy References nace will lead to melt loss due to required. impurities. The industry standard Using an EMP charge well con- 1. National Development and Re- taining a Pyrotek LO- form Commission (NDRC), People’s TUSS vortex enables Republic of China, http://en.ndrc. the submergence of gov.cn/. smaller scrap, such as 2. “ Commercial Information Cir- machine and scalper cular No. 115/2013 – The Mainland chips, edge trim, and of China: ‘Entry Requirements for sawings (Figure 2). In Aluminium Industry (2012)’ (Con- China, smaller scrap sultation Draft),” Trade and Indus- traditionally has been try Department, Government of either briquetted or Hong Kong, January 29, 2013, www. baled before introduc- tid.gov.hk/mobile/english/aboutus Figure 1. Twin chamber furnace with integrated electromagnetic tion into the furnace, /tradecircular/cic/asia/2013/ pumping and LOTUSS vortex system. which leads to low re- ci1152013.html.

86 LIGHT METAL AGE, AUGUST 2013 Secondary News… Alumetal doubled the capacity of its Nowa Sol secondary aluminum facility Novelis Inc. is initiating a closed-loop in Poland to 66,000 tpy with the launch recycling system at its Oswego, NY, of a second production line. The com- facility to cater to its automotive cus- pany now operates three sites in Poland tomers, such as Jaguar Land Rover. with a total capacity of 170,000 tpy. The Aluminum sheet stamping operations new facility will be ramping up produc- can typically produce 50% scrap, which tion through the end of the year. used to be shipped to scrap dealers. In the new closed-loop system, the scrap Secondary aluminum producer, Fracsa Al- Novelis Sheet Ingot GmbH ordered will be placed in the same container loys, made the irst long distance delivery ofthree 130 tonne sidewell melting fur- liquid aluminum in Mexico. Delivered in 7.5 that delivered the coil and shipped backton crucibles (2.4 m high with a diameter of naces from Mechatherm for its new to Novelis’ facilities. 2.2 m), the liquid metal was shipped 200 km SIG expansion project in Germany. The from the company’s plant in Parque Industrial furnaces will be designed to process de- Plibrico Company, LLC appointed Querétaro to Ryobi, an auto parts manufacturer in the Castro Industrial Park, Irapuato coated UBC scrap with installation to Clayburn Refractories, Ltd., head- Guanajuato River. commence in October 2013. quartered in Abbotsford, BC, Canada, to its network of refractory contractors. Abengoa closed the €620 million sale Fracsa Alloys, a secondary aluminum proof its subsidiary Befesa to Triton. Be- ducer of ingot and liquid metal in Mexico, Alloy Resources Corp. opened an fesa is an international company that is investing $200 million to add six new aluminum and zinc recycling plant manages 2.2 million tonnes of industrial manufacturing facilities, located in Mexico in Muskegon, MI, which processes waste, of which 1.2 million tonnes is re- State, Querétaro, Coahuila, Aguascalien- dross, building materials, auto wheels, cycled. The company recently signed a tes, Guanajuato, and Puebla. According to aluminum cans, extrusions, cookware, contract to manage the dross from the the company, Mexico consumes an aver- and other scrap. The new plant in- Novelis plant in Nachterstedt, Germany. age of 54,000-60,000 tons of aluminum per cludes a 90,000 lb per year capacity month to manufacture automotive parts. reverberatory furnace with state-of- The Japanese Aluminum Can Recy- Fracsa hopes to have an installed capacity the-art charging, degassing, and pour- cling Association reported that, in the to cover up to 80% of that market. They ing systems. iscal year ending in March 2013, total also expect this demand to grow further as aluminum cans consumed in Japan was Honda, Toyota, Mazda, and other auto Summit Showa Aluminum Ltd. be- 19,121 million with 19,018 million cans companies complete new manufacturing came a wholly owned subsidiary of sec- recycled. As a result, the recycling rate installations. Fracsa’s new plants in Mex- ondary aluminum alloy producer Asahi increased 2.2 points from a year earlier ico State and Querétaro are already opera- Seiren Co. and changed its name to SS to 94.7%, maintaining a high rate of tional with the remaining facilities to come Aluminum Ltd. over 90% for four years in a row. on line over the course of ive years.

DRYPLUS Less Sludge – Less Costs Dras c reduc on of sludge volumes from anodizing lines With DRYPLUS you reduce by 50% the volume of aluminium hydroxide sludge! Considered Parameters Standard With Dryplus (waters treatment from an anodizing line with 30.000 A installed capacity) Dry percentage of the sludge [%] 20% 45% Sludge produc on [tons/year] 1300 578 Es mated Cost for sludge disposal [€/ton] 80 80 Cost for disposing of the sludge [€/year] € 104.000 € 46.222

Total Saving [€/year] € 57.778 ($75,891.00) Technical and nancial data are indica ve and only provided for informa onal purposes. Italtecno will be keen to submit a tailor-made proposal. Feel free to ask!

Via Gino Marinuzzi 38 - 41122 Modena (Italy) - Tel. +39 059 280362 - Fax +39 059 280462 [email protected] - www.italtecno.com - www.diecleaningplant.com

LIGHT METAL AGE, AUGUST 2013 87 Extruder News… The Canadian International Trade Tribunal began an expiry review -of alu Constellium completed the sale of its minum extrusions from China to - deter French extrusion plants in Ham and mine whether dumping or subsidization Saint-Florentin, dedicated to the pro- would likely continue without duties. duction of proiles for the building and construction industry, to OpenGate Matalco Inc., a member of the Gi- Capital. This announcement follows ampaolo Group, plans to build a new clearance from antitrust authorities and greenield remelt extrusion billet facility completion of regulatory processes. Grupo Cuprum is supplying ten different aluminum proiles for the front and back suspen - producing an excess of 300 million lbs sion of the VUHL 05, a Mexican sports car of aluminum annually. The expansion Jilin Midas Aluminium Industries, a designed by brothers Iker and Guillermo Ech- will integrate Triple M Metal LP’s subsidiary of Midas Holdings Limited, everría. The 05 also features a bonded alu- new nonferrous plant to both procure won a RMB44.3 million contract from minum monocoque chassis made of a combination of 6061-T6 extrusions and aluminum and handle all of Matalco’s aluminum CNR Changchun Railway Vehicles honeycomb. Aluminum can also be found in scrap requirements. Co., Ltd., China. The contract includes the safety systems (three-stage programmed the supply of aluminum proiles for 44 energy absorption crash box and double-lay- Vapormatt invested in a precision 3D er high wall sides), the block and head of the train sets (or 264 train cars) for Chang- four cylinder turbocharged engine, and the measuring system from Alicona, which chun Metro Lines 1 and 2, with deliv- calipers of the braking system. Delivery of the will help the company with its ISO9001 ery expected to take place from 2013 to irst units to the U.S. and Canada will begin in quality control procedures and enable 2015. spring 2014. it to demonstrate the capability and re- peatability of its wet blasting systems. Mitsubishi Aluminum Co. is investing Dana Holding Corporation was recog- Y1.74 billion to add one 3,000 ton extru- nized as a winner of the 2013 Automo- Crystal Finishing Inc. selected sion press each to two of its plants, Ther- tive News PACE Award for its Spicer® Tellkamp Systems, Inc. to design, malex, Inc. in Alabama and Muang- Diamond Series driveshaft, a one piece manufacture, and install a high perfor- Max (Thailand) Co. in Bangkok, Thai- aluminum driveshaft made of aluminum mance vertical liquid painting system land, boosting capacity to 13,000 tons extruded tube supplied by Sapa Extru- for aluminum extrusions with a maxi- and 7,200 tons, respectively. This will sions North America. mum length of 30 ft. The system will be provide a combined production increase operational by Spring 2014. of 37%. The new presses will produceTubelite Inc. completed the initial setup heat exchanger microchannel aluminum of its new 27,500 sq ft facility in Dallas, Personalities & Plants… tubes for the auto market, which is- exTX, which will provide CNC machining pected to grow in each country. Com- for door and frame fabrication, as well mercial production is expected to begin as carry stock inventory and provide de- in the latter half of 2014. livery service. Hydro Building Systems signed a three Vimetco Extrusion, Romania, or- year, €5 million contract with CEVA dered a STeP5 log heater and a hot log Logistics for handling and distribution saw from Turla. Production start up is activities for its extrusions at three of planned for the beginning of 2014. CEVA’s warehouses in Italy. Dr. Joachim Schön- Steve Schabel The Aluminum Extruders Council ap- beck Futura Industries announced a series plauded the U.S. Department of Jus- of initiatives to leverage its expanding tice for the recent arrest and indictment SMS Group announced that Dr. infrastructure and further meet market of ive individuals and three companies Joachim Schönbeck will manage SMS demand for aluminum extrusions. The for conspiring to smuggle Chinese alu- Meer and will continue to be a member initiatives include the acquisition of a minum extrusions into the U.S. in order of the managing board of the group. 220,000 sq ft manufacturing facility in to defraud the U.S. of approximately the same location as their current two $26.7 million in antidumping and coun- Alexandria Industries promoted Steve plants in Clearield, UT; the purchase of tervailing duties. Schabel to chief sales and marketing a new 9 inch, 3,500 ton, front loading oficer and appointedChris Flemming Presezzi press with energy conservation general manager of its Alexandria Ex- control system; and an extensive invest- trusion South operation. ment in primary operating equipment to support the additional output of the new Tubelite Inc. hired John Priebe as an press. architectural representative serving South Central U.S. Altest Ltd. added a Nitrex compact system at its Bulgarian plant for the ni- Abtex Corporation hired Jason Saner triding of extrusion dies. The NXK-412 as market development manager. system has a capacity of 880 lbs. Technoform Bautec North America, Purso ordered an automatic two-axis Inc. appointed Bill Blazek to its market- basket logistics system, as well as new Exco Extrusion Dies Corp. ordered a 10 ing team in charge of aluminum archi- proile destacker and full basket proile bar vacuum hardening furnace and a pair tectural systems. cleaning station, for its extrusion plant of nitrogen tempering furnaces from SECO/ Warwick Corp. The furnace cell is designed in Finland. The equipment will be sup- for the hardening and tempering of aluminum Purso appointed Markku Rajala pro- plied by Turla with start up planned for extrusion dies for Exco’s new plant in Brazil. duction manager of its machining de- January 2014. The equipment will be installed in early 2014. partment.

88 LIGHT METAL AGE, AUGUST 2013 milkadv.it EXTRUSION + DIECASTING + FOUNDRY + ROLLING + FINISHING + MACHINING + FABRICATING + RECYCLING

11-13 JUNE 2014 VERONA-ITALY

EXPO OF CUSTOMIZED TECHNOLOGY FOR THE ALUMINIUM & INNOVATIVE METALS INDUSTRY

Main sponsor Diamond Sponsor www.metef.com Contracts and Expansions… Ormet Corporation, including all of its assets and a certain amount of its afili - Trimet Aluminium SE, Germany, ates, was sold to Smelter Acquisition, submitted a binding offer to acquire LLC, a portfolio company managed by two production plants in Saint-Jean-de- Wayzata Investment Partners LLC, Maurienne and Castelsarrasin, France with the approval of the U.S. Bank- from Rio Tinto Alcan. The two plants ruptcy Court for the District of Dela- produce aluminum wire rod used to ware. make electric cabling for the energy industry and connecting elements for the ThyssenKrupp Aerospace launched automotive industry. Aerospace Park Mghira in Tunisia Ma’aden-Alcoa ordered a new heat treat- (its irst plant on the African continent), Alcoa completed the expansion at its ment line for aluminum coils for its integrated a new facility that provides cutting of joint venture complex in Saudi Arabia. The block drafts from aircraft grade alumi- Kitts Green facility in the U.K. to serve line consists of a single coil lifting hearth fur- growing aerospace demand for the com- nace from Tenova LOI Thermprocess. The num plates and distributes metal plate pany’s third generation of aluminum- installation is scheduled for late 2013. and sheet, as well as aluminum proiles lithium alloys. This is the second phase to the regional aerospace industry. of aluminum-lithium expansions, with Kobe Aluminum Automotive Prod- a third phase under construction near ucts (China) Co., Ltd., a joint venture The Aluminum Association commend- its Lafayette, IN, plant, scheduled for between Kobe Steel, Ltd., Mitsui & ed the formation of a bipartisan Congres- completion in 2014. Co., Ltd., and Toyota Tsusho Corpo- sional Aluminum Caucus, which will ed- ration, completed the second phase of ucate U.S. policy makers and community Mubadala Development Company, its forging plant, which produces au- leaders on economic and environmental AbuDhabi, and the Investment Cor- tomotive suspensions. The addition of issues relevant to the aluminum industry poration of Dubai announced the cre- a melting furnace and casting line en- and their constituencies. ation of Emirates Global Aluminium, ables the company to double production a jointly held, equal ownership com- capacity to 250,000 pieces per month. Alupress AG acquired the Laurens Coun - pany that will integrate the businesses According to the company, automobile ty, SC, operations of Koerber and an- of Dubai Aluminium (DUBAL) and manufacturing in China, the world’s nounced plans to open a US$19.9 million Emirates Aluminium (EMAL). The largest auto market, is forecast to in- aluminum casting plant on the site, aimed two smelting operations have a com- crease to 28 million cars in 2022, from at servicing automotive clients in the re- bined installed capacity of 1.8 million 19 million in 2012. gion. The Brixen, Italy-based aluminum tpy (with 1 million tpy for DUBAL die caster’s U.S. facility, named Alupress and 800,000 tpy for EMAL). EMALNovelis commissioned its expanded LLC, will begin operations in 2014. recently completed the major civil andaluminum rolling operations in Pinda- mechanical work on its Phase II expan- monhangaba, Brazil, increasing produc- Siemens Industry, Inc. completed the sion with 120 steel structures providedtion capacity by more than 50% to over acquisition of Service Guide, Inc., an by Emirates Steel now in place. The 600,000 tonnes of sheet per year. The Ohio-based company that has provided Phase II potline will increase capacity US$340 million investment included the repair and refurbishing services for alu- by 520,000 tonnes when it is completed installation of a third cold rolling mill, minum and steel mills since 1964. in 2014. a new ingot casting center, and a new pusher furnace for the hot rolling mill. Alcoa and OJSC Rusnano signed an Century Aluminum completed the The company is also currently expand- MOU to produce technologically ad- transaction with Rio Tinto Alcan to ing its recycling operations at the site to vanced oil and gas aluminum drill pipe. acquire all of the assets of the 205,000 increase the use of post-consumer scrap With the help of the Alcoa Technical tpy Sebree aluminum smelter in Hen- and provide accelerated development of Center, the companies plan to pursue derson County, KY. The company also new alloys with greater recycled con- the potential application of the nano- inalized deinitive power agreements tent. The recycling expansion is set to technology-based coating for drill pipe with Kenergy Corp. and Big Rivers come on-stream in 2014. to enhance its wear resistance in harsh Electric Corp., which could provide corrosive drilling environments. power for the company’s Sebree andAstronics Corp. purchased PECO, Hawesville smelters. The agreements Inc., a company in Portland, OR, that AMAG Austria Metall AG concluded are subject to approvals from variousmanufactures highly engineered com- a multi-year contract with EADS for the third parties, including the Kentucky mercial interior components and sys- supply of aluminum plate and sheet to Public Service Commission and other tems for the aerospace industry. The manufacture structural and skin compo- regulatory agencies. transaction was overseen byHoulihan nents for all current Airbus aircraft types. Lokey’s Aerospace-Defense-Govern- Constellium N.V. implemented a €23 ment Group, which acted as a inancial Aluminium Bahrain B.S.C. (Alba) million expansion project at its rolling advisor. completed the upgrade of potline 5 to and recycling facility in Neuf-Brisach, AP37 cell technology with an increase France. This included two projects: the Hydro signed an agreement with Rio in line current to 370 kA. This will- in modernization of a casting complex for Tinto Alcan to acquire 50% ownership crease production by around 1,000 tpy. rolling slab production, increasing ca- in Vigeland Metal Reinery AS and pacity and providing safety and qual- 100% ownership in the AS Vigelands Rexam started production at its new ity improvements, and the complete -re Brug hydropower station, located in beverage can plant in Benevides, Great- placement of a pusher furnace dedicated Vennesla, Norway. The reinery haser Belém, Brazil, which has an installed to the homogenization and preheating of an annual production capacity of 8,500 capacity of 800 million cans per year, slabs before rolling, which lowers ener- tonnes of high purity (over 99.99%) alu- bringing the company’s beverage can gy consumption, increases throughput, minum for use in semiconductors and capacity in South America to more than and optimizes quality. electronic applications. 14 billion cans per year.

90 LIGHT METAL AGE, AUGUST 2013 New Products… New Literature… Quick Change Powder Coating Downstream in Saudi Arabia Nordson introduces a new engineered Ma’aden (The Saudi Arabian Min- powder coating system, called Color- ing Company) issued a guide outlin- Max 2, which provides contamination ing several investment opportunities free color changes in under 10 minutes. within the downstream aluminum The fully integrated system has fea- industries in Saudi Arabia. Down- tures, like a breakaway cyclone, which stream aluminum is witnessing re- provides easy accessibility inside the markable growth in the Gulf region, booth for cleaning, a key aspect in fast including aluminum foil, alloy manu- and contamination free color changes. facturing for specialized applications, The booth is constructed of an Appo- and aluminum for industrial purpos- gee® composite material and a non- es. The distribution of this guide is part of the company’s sustainabil- conductive canopy that minimizes powder attraction and retention, ity strategy, which aims to serve and develop the community, support which means less powder to clean during a color change. For more the industrial sector, and provide investment opportunities that assist information: Bob Allsop, Nordson Corporation. Tel: (440) 985-4459. the effort of creating jobs for Saudi youth in the private sector. For email: [email protected]. www.nordson.com/powder. more information: Aqeel Al-Onazi, Ma’aden. Tel: (+966) 1 874-8045. email: [email protected]. www.maaden.com.sa. Milling Anodes End Deburring Systems Under certain conditions, carbon anodes can experience spike (or mushroom) Abtex published a four page, full color brochure on its line of end formation on the bottom surface, which deburring systems, which contains speciications for its manually op- results in pot instability and reduced cur- erated proile end preparation system, single head semi-automatic rent eficiency. VHE offers an anode mill- system, double head low through systems for long and short parts, ing machine, which mills away spike and and double end tube deburring system, as well as wet dust collectors irregularities on the anode, while it’s still for each of the systems. These machines can be considered stan- hot or after cooling, for improved geom- dard systems, but many times, the company can customize them for etry and extended usable life. The milling speciic customer needs. This brochure is a companion piece to the system can be installed in a ixed location company’s new catalogue/capabilities brochure. For more informa- or on a trailer mounted machine, both of tion: Abtex Corporation. Tel: (315) 536-7403. email: sales@abtex. which can operate in semi-automatic and com. www.abtex.com. manual modes. For more information: Barry Woodrow, VHE. Tel: (+354) 575 9705. email: [email protected]. www.vhe.is. EcoLuminum Sludge Reduction in Anodizing Lines Tubelite launched a new website on EcoLuminum™ , the recycled alumi- The DRYPLUS process, patented by Italt- num option (with content from post- ecno, increases the “dry part” in the sludge consumer and pre-consumer material) produced as a waste in aluminum anodizing for its extruded products, including lines. DRYPLUS has a speciic locculation curtainwall, thermal entrances, sun- agent, which allows for the precipitation of shades, light shelves, and framing aluminum hydroxide with high density crystal and entrances. The website provides formation (i.e., a quantitiy of dry parts). The speciications for each of the products crystal formation is essentially doubled (40- available with these recycled alloys 50%) compared to what is achievable with and offers information on the avail- conventional processes, providing a signii- ability of environmentally friendly an- cant reduction in sludge formation and reduc- odized matte inishes. Using recycled ing costs for the disposal of the sludge. This content contributes toward LEED MR4.1 and 4.2 points. EcoLumi- agent can be added to any existing waste num should be requested at the time of quotation. For more informa- water treatment plant. For more information: Italtecno. Tel: (39) 059 tion: Tubelite, Inc. Tel: (800) 866-2227. email: dependable@tubelite. 280362. email: [email protected]. www.italtecno.com. com. www.ecoluminum.com. Welding Warrior Heat Transfer Calculator ESAB introduces Warrior, a new multi- Heat Flow is a new online steady state heat transfer calculator that process power source and feeder de- allows users to simulate an unlimited number of heat transfer sce- signed for harsh welding environments narios using Morgan Advanced Material’s insulation and refractory in shipbuilding, rail car construction, products, as well as other user-deined materials. The Heat Flow -ap mobile machinery construction, energy plication comes preloaded with nearly 400 products in ten catego- generation contruction, pipe welding, ries, and registered users have the ability to add other materials into general fabrication, and repair and main- a unique personalized database to run calculations. The calculations tenance. Designed for GMAW (MIG), use ASTM C680 formulas (with the latest 2010 revision), the inter- FCAW (lux-cored), SMAW (stick), and national standard for estimating heat loss and surface temperatures. GTAW (TIG) welding, as well as ACAG For more information: Scott Bentley, Morgan Advanced Materials. (arc gouging), this new machine deliv- Tel: (44) 1299 827000. email: [email protected]. http:// ers up to 500 amps at 60% duty cycle. morganheatlow.com. The air tunnel design creates a “dirty” air side and a separate “clean” air side to Master Alloys and Grain Reining ensure long-term reliability of critical electronics. For more information: ESAB Welding & Cutting Equipment. Tel: (843) 669-4411. www. AMG Aluminum published a new lyer intro- esabna.com/warrior. ducing their master alloy and grain reining capabilities. The lyer lists the company’s Measurement of Weight Changes in Al available product forms and chemical speciications for its grain reiners (titanium, boron, Thermogravimetry (TGA) systems measure weight changes in a ma- and carbon-based), hardeners (chromium, terial (subjected to temperature variation in a controlled atmosphere) copper, magnesium, nickel, etc.), tablets and and are one of the most powerful systems in a materials laboratory, compacts (chromium, copper, iron, manga- capable of measuring corrosion, pyrolysis, adsorption/desorption, nese, etc.), strontium modiiers for hypoeutec- loss of solvent, and more. The SETSYS Evolution from SETARAM tic and eutectic aluminum-silicon alloys, spe- has the widest temperature range for TGA measurements (ambient- cialty alloys (beryllium, boron, lithium, etc.), 2,400°C), covered by a single oven. It features sophisticated gas mechanical alloys, and chemicals and luxes control systems with options for corrosive gases and even high hu- (potassium aluminum luoride, potassium midity gases, as well as an option for operation under H2 and other luoborate, etc.). AMG has business units located in North America, lammable gases. For more information: SETARAM Inc. Tel: (908) the U.K., Brazil, Mexico, and China. For more information: AMG Alumi- 262-7060. email: [email protected]. www.setaram.com. num. Tel: (610) 406-1680. email: [email protected]. www.amg-al.com.

LIGHT METAL AGE, AUGUST 2013 91 INTL SECONDARY ALUMI- as aluminum alloy ingots and the like which are used —LMA— on the market commonly are replaced by using the NUM, REMELT, RECYCLING molten aluminum method herein, and the molten CN102328202 (A) — METHOD FOR RECYCLING aluminum directly forms aluminum alloy products AND REUSING ALUMINUM ALLOY ENGINE PATENTS by a casting process. In the method, the integral WASTE CYLINDER BODY AND COLD-TYPE production process of aluminum scrap remelting CYLINDER SLEEVE REMOVAL EQUIP- ingots is directly eliminated, so fuel consumptionnd a MENT FOR WASTE CYLINDER BODY —LMA— environmental pollution in the process of remelting —Honda Automobile Co. Ltd. (China) — The the aluminum scraps are avoided correspondingly, invention discloses a method for recycling and CN202667568 (U) — REMELTING ALUMINIUM and the smelting loss and physical performance loss reusing an aluminum alloy engine waste cylinder INGOT CASTING PRODUCTION CONTROL of the aluminum scraps are avoided. body and cold-type cylinder sleeve removal equip- SYSTEM — Beijing Haotian Zhongsheng Tech- ment for the waste cylinder body. In the method, nology Co., Ltd. (China) — The utility model —LMA— a cylinder sleeve inside a piston cylinder of the discloses a remelting aluminum ingot casting pro- aluminum alloy waste cylinder body is ejected out duction control system, and relates to the ield of JP2009108346 (A) — METHOD AND APPARATUS automatic control. The remelting aluminum ingot FOR REFINING ALUMINUM SCRAP — Asahi casting production control system comprises a pour- Seiren Co. Ltd. (Japan) — PROBLEM TO BE ing machine, a casting machine, a receiving device, SOLVED: To provide a method and an apparatus a cooling conveyer, a stacker, a inished product for reining aluminum scrap by means of which the conveyor, a cooling device and a programmable following process can be performed more eficiently logic controller (PLC) control module, wherein the and inexpensively than heretofore: a process of melt- pouring machine, the casting machine, the receiving ing aluminum scrap, performing vacuum reining device, the cooling conveyer, the stacker, and the to remove unnecessary components contained in inished product conveyor are connected with each the resulting molten material, and then casting the other, and the cooling device is connected with the reined molten material into an ingot of prescribed casting machine. The PLC control module controls size to carry out recycling into aluminum metal high-temperature aluminum liquid to be injected again. SOLUTION: Steps of melting and reining into a casting machine aluminum liquid distributor aluminum scrap are separated, and the reining step through the pouring machine, the high-temperature aluminum liquid inside the casting machine is cooled to form a remelted aluminum ingot through the cooling device, and the remelted aluminum ingot is demolded to be arranged inside the receiving device and conveyed to the cooling conveyor through the receiving device. The remelting aluminum ingot is done secondary cooling to a preset temperature in the cooling conveyor and conveyed in order to the of the aluminum alloy waste cylinder body by using stacker, and the remelted aluminum ingot is controlled the cold-type cylinder sleeve removal equipment; to be stacked into an aluminum pile according to and after the aluminum alloy waste cylinder body a pre-set rule and packed by the inished product subjected to cylinder sleeve removal is melted and conveyor to inish inished product transportation. the temperature of the treated aluminum alloy waste The production capacity of a remelting aluminum cylinder body is maintained, a new aluminum alloy ingot production line is improved, production - ef engine waste cylinder body is cast. The equipment iciency is improved, the number of operators and has the advantages of low investment, small occupied labor intensity are lowered, human resources can be area, low recycling cost, convenience for operation, deployed reasonably, and the remelting aluminum high security, simple logistics, and the like; and as ingot casting production control system is low in the cylinder sleeve is removed at normal tempera- cost, economical, and practical. ture, zero pollution and zero emission are realized. is coupled with a casting step. Only the melting —LMA— of the aluminum scrap is performed in a melting —LMA— furnace, and the resulting molten metal is tapped CN102304619 (A) — METHOD FOR PRODUCING into a ladle. The ladle is covered with a refractory CN201954976 (U) — ALUMINUM ALLOY REFIN- DIRECTLY-MOLTEN ALUMINUM BY USING cover communicating with an exhaust means. The ING FURNACE WASTE GAS RECYCLING ALUMINUM SCRAPS — Jihua Liu (China) — The molten metal is held for a prescribed time while DEVICE — Zhejiang Seiichi Heavy Industries invention discloses a method for directly producing reducing the pressure of atmosphere in the ladle to Co., Ltd. (China) — The utility model discloses an molten aluminum by using aluminum scrap. In the a prescribed pressure to remove volatilizable com- aluminum alloy reining furnace waste gas recycling method, the molten aluminum which can be cast is ponents from the molten metal. Then the pressure device, which comprises an aluminum alloy reining produced by pretreatment means of four-stage sort- is recovered to the atmospheric pressure again, and furnace (1), a rotary aluminum scrap drying machine ing, two-stage crushing, paint and oil removal, and the molten metal is continuously poured into a mold. (2) and a heat exchanger (3), wherein the exhaust the like in combination with automation modes of pipeline (11) of the aluminum alloy reining furnace computer batching, automatic weighing, polishing, —LMA— and proportioning of a molten aluminum machine JP2001294943 (A) — METHOD AND FACILITY FOR RECYCLING USED ALUMINUM CANS — Mitsubishi Materials Corp., Mitsubishi Aluminum, Oote Kinzoki KK (Japan) — PROB- LEM TO BE SOLVED: To provide an economical used aluminum can recycling facility in which the aluminum alloy is eficiently recovered and recycled from recovered cans mainly including the used aluminum cans, and a price of the recycled aluminum alloy is reduced, and to provide a recycling method environmentally excellent. SOLUTION: A machine for smashing recovered and crushed used aluminum (1) is connected with the air inlet nozzle (21) of the cans, equipment separating non-aluminum materi- rotary aluminum scrap drying machine (2), and the als a furnace, delacquered aluminum cans passing exhaust pipe of the rotary aluminum scrap drying through the separating equipment, a furnace melting machine (2) is connected with the air inlet pipe of the aluminum cans discharged from the delacquer- the heat exchanger (3). Aluminum scraps are dried and the like. A secondary smelting process of the ing furnace, and a casting machine obtaining a by using the waste gas of the aluminum alloy rein- conventional aluminum alloy ingot is replaced by slab or recycled ingot from the molten aluminum ing furnace, and the waste heat is reclaimed through a one-time direct smelting process of the molten obtained in the melting furnace are successively the heat exchanger, so that the utilization rate of aluminum; cast aluminum alloy raw materials such arranged in one site. energy is improved. 92 LIGHT METAL AGE, AUGUST 2013 INTL SECONDARY ALUMI- — Zhejiang Jinfei Kaida Wheel Hub Co., Ltd. material storage box, a vibrating screen, permanent (China) — The utility model discloses an alumi- magnets, a charging container, a weighing device, NUM, REMELT, RECYCLING num scrap recycling and smelting furnace which a motor and a speed reducer, and is characterized can effectively solve the problems of high burning in that the material storage box is arranged at the PATENTS, cont. loss and low recycling rate for waste aluminum. upper end of the sorting device. The front end of The aluminum scrap recycling and smelting fur- the material storage box is provided with a mate- nace comprises a smelting furnace body, a stirring rial outlet; the vibrating screen is arranged at the —LMA— pond, and a smelting pond, wherein the smelting front end of the material outlet; the lower end of furnace body is connected with the stirring pond the vibrating screen is provided with two driving CN102011145 (A) — METHOD FOR RECYCLING through an entry channel, the stirring pond is con- ELECTROLYTES AND PRODUCING ALUMI- nected with the smelting pond through an eddy NUM-SILICON ALLOY AS BYPRODUCT BY channel, and the smelting pond and the smelting USING ALUMINUM ELECTROLYSIS WASTE furnace body are connected through a backwater MIXING MATERIAL — Yichuan Longhai Technology Industrial Co., Ltd. (China) — The invention discloses a method for recycling electrolytes and producing an aluminum-silicon alloy as a byproduct by using an aluminum electrolysis waste mixing material, relating to the technical ield of recycling of the aluminum electrolysis waste mixing material, wherein the aluminum electrolysis waste mixing material mainly refers to the mixture of multiple refractory materials without the waste cathode carbon blocks and the side silicon carbide. The application of the method provided by the shafts which are connected with the motor by the invention comprises the following steps: crushing speed reducer; the middle part of the vibrating the aluminum electrolysis cell waste mixing mate- screen is provided with a screen; a recycling box rial into the particles the particle size of which is channel; the middle part of the smelting pond is is arranged at the lower end of the screen; the tail 0 to 6 mm; and then adding the particles into the provided with a hopper-shaped eddy part, and the end of the vibrating screen is provided with a row running aluminum electrolysis cell periodically, eddy channel is connected with the upper part of of permanent magnets; the front end of the vibrating wherein the addition of the particles is performed the smelting pond. The aluminum scrap recycling screen is connected with the charging container; and twice per day, the time interval is 6 to 12 hours, and smelting furnace has the advantages that, as the bottom end of the charging container is provided the addition amount is 10 to 50 kg, the particles the eddy part is hopper-shaped, molten aluminum with the weighing device. As the sorting device is are added from the aluminum discharging end of eddy can be formed and aluminum scraps are not adopted, impurities in the raw material are reduced, the aluminum electrolysis cell or from the opening directly contacted with lames and are smelted under the oxidization of the raw material in the smelting when the anode is replaced, and the addition is the action of the molten aluminum eddy, therefore, process is reduced, and the quality of aluminium realized mainly by manually and also can be real- the burning loss of aluminum alloy is reduced to alloy is greatly improved. ized mechanically. In the invention, the innocent be lower than 5 percent. treatment is adopted, the pollution problem of the —LMA— aluminum electrolysis waste refractory materials is —LMA— solved effectively, and the recycling of the solid CN101921933 (A) — HIGH-PURITY STABILIZED wastes with certain economic beneit is realized. CN201906720 (U) — DEVICE FOR SORTING ALUMINUM ALLOY INGOT AND PRODUC- MASSIVE ALUMINIUM ALLOY RAW MA- TION METHOD THEREOF — Ye Chiu Metal —LMA— TERIAL — Qqinhuangdao Development Zone Recycling China Ltd. (China) — The invention Mei Aluminum Co., Ltd. (China) — The utility discloses high-purity stabilized aluminum alloy ingot CN201876117 (U) — ALUMINUM SCRAP RE- model relates to a device for sorting a massive which comprises the following components in weight CYCLING AND SMELTING FURNACE aluminium alloy raw material, which consists of a percent: 3.1-3.8% of Cu, 7.9-9.3% of Si, 0-0.1% of

We have second hand extrusions presses

Visit: www.extrusionsupplies.com Extrusion Facility Available For Sale Spacer Bar Covers Kevlar Felt for Handling Systems

Contact: Tom Nentwick Mobile: (330) 506-9291 Email: [email protected]

LIGHT METAL AGE, AUGUST 2013 93 INTL SECONDARY ALUMI- —LMA— to the ingot melting furnace and the scrap melting furnace by channels, and an induction heating fur - NUM, REMELT, RECYCLING KR20080076038 (A) — ALUMINUM SCRAP SORT- nace; and alloying equipment including a holding ING METHOD AND AN APPARATUS FOR furnace, and an overlow channel for connecting PATENTS, cont. EFFECTIVELY SEPARATING BOTH FER- an upper portion of the principal melting furnace ROUS AND NONFERROUS COMPONENTS and an upper portion of the holding furnace. The FROM ALUMINUM SCRAPS — Dongyang apparatus further comprises a ceramic ilter installed Mg, 0-2.3% of Zn, 0-0.9% of Fe, 0-0.5% of Mn, Gangchul., Ltd. (Korea) — An aluminum scrap in the overlow channel of the alloying equipment. 0-0.5% of Ni, 0-0.35% of Sn, 0-0.1% of Ti, 0-0.25% sorting method and an apparatus are provided to of other trace elements and the balance of Al. The recycle aluminum scrap and to improve the recovery —LMA— invention further discloses a production method of rate of aluminum from aluminum scrap by effectively the high-purity stabilized aluminum alloy ingot. The sorting out ferrous and nonferrous components from CN102553823 (A) — SORTING DEVICE FOR high-purity stabilized aluminum alloy ingot of the various kinds of aluminum scrap. The aluminum scrap SOLID MATERIALS WITH DIFFERENT invention has low gas and slag content, high clean- sorting apparatus consists of a magnetic separator i s SPECIFIC WEIGHTS — Guangzhou Jieshiduo ness of molten aluminum, uniform components of the composed of a irst crusher for crushing aluminum Aluminum Alloy Co. Ltd. (China) — The inven- product and thin crystal structure; and the production scrap, a irst conveyor for moving the scrap broken tion discloses a sorting deice for solid materials method has low production cost and high eficiency, in the irst crusher, the magnetic separator for sepa - with different speciic weights. The sorting device and effectively solves the pollution problem of the rating magnetic components included in the scrap comprises a trough, a bunker, a loating sand power secondary aluminum industry. carried by the irst conveyor, a second conveyor device, and at least one guide plate, wherein a for moving the scrap that ferrous components are runner is arranged for sand to low in the trough; —LMA— separated, a second crusher for secondly crushing the the bunker is arranged upstream of the runner; the scrap carried by the second conveyor, and a vortex loating sand power device is arranged upstream KR20100011252 (A) — ALUMINUM SCRAP separator classifying the secondly crushed scrap of the runner and is used for enabling sand in the CRUSH SELECTION APPARATUS — Jae Kyung into scrap and nonferrous components by a vortex. upstream of the runner to become lowing sand; and Industry Co., Ltd. (Korea) — An aluminum scrap at least one guide plate is obliquely arranged in the crushing and sorting device is provided to reduce —LMA— runner along the direction of the runner forming an melting time of aluminum scrap which is scrapped obtuse included angle with the low direction of to small size with a plurality of crushers in a melt- KR20080040969 (A) — METHOD FOR MANU- the runner. A plurality of through holes for sand to ing furnace and to minimize energy consumed for FACTURING AN ALUMINUM ALLOY BY pass is arranged in the guide plate, and the lower melting the aluminum scraps. The aluminum scrap USING ALUMINUM SCRAP, COMPRISING A bottom edge of the irst guide plate is higher than crushing and sorting device comprises the follow- LOW GRADE SCRAP SORTING PROCESS, the bottom of the runner. The sorting device can ing: a supply hopper (200) installed on the top of a A MELTING PROCESS, AND AN ALLOYING be used for sorting solid materials with different PROCESS, AND APPARATUS THEREOF — speciic weights, resulting in less environmental Dongyang Gangchul., Ltd. (Korea) — A method and pollution and operating requirements, while being an apparatus for manufacturing an aluminum alloy by high in eficiency and being particularly suitable using aluminum scrap are provided to manufacture for sorting of aluminum scrap. an aluminum alloy eficiently by using low grade scrap together with process scrap, aluminum chips, —LMA— supply conveyor (100), a crusher (300) consecutively and the like. The apparatus for manufacturing an installed on the bottom of the supply conveyor, a aluminum alloy by using aluminum scrap comprises: CN202129145 (U) — MAGNETIC FORCE SORT- irst sorting conveyor (400) composed of a rotat- low grade scrap sorting equipment including a irst ING DEVICE FOR ALUMINUM BLOCKS — ing magnetic roll (401), a magnetic selector (500) crusher, a magnetic separator, a second crusher, and Guangdong Longda Aluminum Co., Ltd. (China) installed on the top of the irst sorting conveyor, a an eddy current separator; melting equipment includ- — The utility model relates to the technical ield of irst transfer conveyor (600) transferring aluminum, ing a principal melting furnace of a twin chamber aluminum scrap recovery devices, and particularly a second sorting conveyor (700), and a second structure divided into an ingot melting furnace and relates to a magnetic force sorting device for aluminum transfer conveyor (800) transferring the aluminum a scrap melting furnace by a partition wall, a chip blocks, which is used during the aluminum scrap to a destination location. melting furnace of which both sides are connected recovery process. The magnetic force sorting device

End Deburring Faster For Less Maximize productivity, quality, safety and consistency with an Abtex end deburring system—abrasive tools and application-specific delivery equipment—all from a single source. Systems from semi-automatic to fully automatic for your toughest deburring challenges.

www.abtex.com • 888-662-2839 PO Box 188 • 89 Main Street • Dresden, NY 14441 Email: [email protected] • Phone: 315-536-7403 • Fax: 315-536-0280

94 LIGHT METAL AGE, AUGUST 2013 INTL SECONDARY ALUMI- —LMA— —LMA— NUM, REMELT, RECYCLING CN201940391skirt portion; (U) providing — ALUMINUM an electrically SCRAP insulated WASH - CN201940284comprising: a sacriicial (U) — anodeVIBRATING having a top TYPE surface RE- U.S. ATNTS, cont. shieldING memberDEVICE directly — Suzhou supported Kadiya on said Alumimum hanger, andCYCLED a bottom surface, ALUMINUM the sacriicial SCRAP anode FLOTATION having PATENTS, cont. whereinCo., Ltd. said (China) work is — supported An aluminum on said scrap hanger washing in a recessAND withWASHING a loor, theDEVICE recess extending— Suzhou from Kadiya axis, which chambers are delimited by the side walls suchdevice a way belongs as to close to thesaid technical annular circumferential ield of washing the Alumimum top surface Co., through Ltd. the (China) sacriicial — The anode utility in model a and inner plates extending between the side walls, machinery and comprises a frame, a washing roller directionrelates ofto thea vibrating bottom surface;type recycled a magnet aluminum having scrap forwherein the aluminum the collar partsblocks, are provided two channel-shaped by the utility driving mechanism and a washing roller. The washing an lotation upper surface and washing and a device, lower surface, belonging the to magnetthe technical model,lengths comprises with upper a edgesmachine pointing frame, awaywherein from a thehopper roller driving mechanism is arranged on the frame, ield of a cleaning device. The vibrating type recycled usedmiddle for axis receiving of the materialsattachment is means arranged and atlanking the uppe r and the washing roller which is provided with a aluminum scrap lotation and washing device comprises endwalls part delimiting of the machinea channel frame, base. a magnetic force t bel feed inlet and a discharge outlet matches with the a pair of oscillating arm mechanisms, a vibrating washing roller driving mechanism. The aluminum plate, a water supply mechanism, and a vibrating used for capturingÐNOCÐ iron blocks is arranged below the discharge opening of the hopper. The magnetic force scrap washing device is characterized in that a water plate actuation mechanism, wherein the oscillating WU"belt 9.624.436" is provided D4" Ï"with EQPXGTUKQP" a driven roller EQCVKPIU"and a driving guiding device is further arranged on the frame in arm mechanisms are arranged in parallel; the vibrating rollerKPENWFKPI" driven by CNMCNKPG" a motor, the GCTVJ" magnetic OGVCN" force belt a matched manner and communicated with the feed plate is connected to the oscillating arm mechanisms HNWQTKFG" EQORNGZGU" Ð" RRI" Kpfwuvtkgu" inlet via a pipeline, and blow-off holes which sur Qjkq."Kpe0."Engxgncpf."Qjkq"*WU+"Ð"A process for coating a metal substrate comprising: a) contacting a metal surface with a phosphate-based composition, wherein said phosphate-based composition comprises iron phosphate and stannous ion in an

amount ranging from about 10 to about 500 parts inserted within the recess so that the lower surface abuts the loor of the recess; and a plug sealing per million followed by; b) contacting said metal the magnet within the recess, the plug abutting the surface with an aqueous composition comprising a roup IIA dissolved metal ion; a dissolved complex grooves of said piston crown portion while retaining upper surface of the magnet; wherein the sacriicial small gap relation with said piston crown portion, anode is attached to the metallic substrate by an metal luoride ion comprising a metal atom selected from roup IIIA, roup IA, roup I, roup wherein the piston crown and the shield member electrically-conductive adhesive. do not contact one another, and said shield member A, and roup metals, and water, wherein the ÐNOCÐ composition is substantially free of roup IIA metal being provided with openings to expose the sliding surfaces of said skirt portion; immersing said work WU"9.624.499"D4"Ï"OGVJQF"QH"HQTOKPI"OGVCN" luoride precipitate followed by; c) contacting said in an inclined state with one side higher than the other metal surface with a rinse composition comprising in said plating bath; and depositing a plating metal HQCOU" D[" EQNF" URTC[" VGEJPKSWG" on said sliding surface on said skirt portion, said Ð"side; GzzqpOqdkn" the water supply Tgugctej" mechanism cpf" Gpikpggtkpi" is connected with sequentiallyan aqueous solutionwraps the of driving a rare earthroller metaland the prior driven to a water source pipeline and corresponds to the high application of a paint to said metal surface. hanger supporting said work and said shield member Eqorcp{."Cppcpfcng."P0L0"*WU+"Ð"A method of roller; both the driving roller and the driven roller at a position between said two anode plates in said formingside aof metallic the vibrating foam layer plate; on a substrate and the compri vibratingsing plate are ixed on the ÐNOCÐ machine frame through bearing plating bath and in a tilted posture parallel with said the actuationfollowing steps:mechanism providing is arranged a substrate at forone coating end of the WU"supports, 9.624.453" a D4"irst Ï" receiving OGVJQF" groove CPF" CRRCTCVWU"used for receiv- anoderound plates the wall while of conducting the washing current roller between are disturbed said of avibrating metallic foam;plate incold a matchingspraying a way mixture and ofis metaconnectedl ingHQT" theRCTVKCNN[" aluminum blocks RNCVKPI" is further YQTM" formed UWT/ below workon the serving wall of as the a cathodewashing androller. said The anode water plates, guiding particleswith theand vibratinga foaming plate. agent Byonto adopting said substrate the technical to theHCEGU" discharge Ð" Pkrrqp"opening Rncvge"of the Eq0."hopper, Nvf0." and Vqejkik" a second whereindevice said is disposed work and on said the shield frame, member water are is sup- guided formscheme, a substrate recycled coated aluminum with an unexpanded scrap to be metallic sorted can receiving*Lcrcp+" Ð"grooveA method used for partiallyreceiving plating the iron a work blocks portedinto theby the feed hanger inlet in by a tilted the waterposture guiding before being device, layer;be foamscattered heat treatingon the vibratingsaid substrate plate, coated impurities with in isfor formed a piston, below said the work magnetic having force sliding belt. portions The mixed on immersedthe blow-off in the holes plating are bath, arranged during on the the depositing wall of the an unexpandedthe recycled metallic aluminum layer atscrap a temperature can be eliminatedabove materialsa skirt portion falling under into a thelidded hopper piston drop crown through portion the ofwashing the plating roller, metal accordingly and after beingdirty aluminumremoved from scraps the usingdecomposition a proportional temperature relation of said foaming during agent vibration of dischargewith annular opening circumferential of the hopper. grooves The therearound, aluminum thecan plating move bath.under rotation of the washing roller after for thea time vibrating suficient plateto form and a heated water substrate supply coa ofted the water blocksand having drop ainto boss the portion irst receivingto receive groovea piston directly pin, , being fed into theÐNOCÐ washing roller via the feed inlet, withsupply an expanded mechanism, metal and foam the recycled layer; and aluminum cooling scrap andsaid the method iron comprising blocks are the stuck steps onto of: the providing surface a of dirt attached to the surfaces of the aluminum scraps saidwith heated different substrate weights coated can with be ansorted. expanded Therefore, metal the theplating magnetic bath illedforce withbelt anand electrolyte eventually and fall having into the WU"9.624.455"D3"Ï"CRRCTCVWU"are washed away, identifyingCPF"OGVJQF"HQT" effect for follow-up foamdevice layer has to the about advantages ambient that temperature the sorting to eficienc form y secondtwo anode receiving plates groove.set in position The magnetic within said force platin sortingg ECVJQFKECNN["manual sorting is enhanced, RTQVGEVKPI" sorting speed OGVCNU" and sort- a cooledis high, substrate the sorting coated quality with is an also expanded high, manpower metal devicebath; directlyfor the supportingaluminum blocks said work has onthe aadvantages hanger CICKPUV"EQTTQUKQP"Ð"Ingp"G0"Oqticp."ing quality are improved, and quality of smelted foaminput layer, can whereinbe saved, said and cooled the labor substrate intensity coated of sorting ofadapted high operating to immerse eficiency said work and in good said sortingplating bath,quality . Oggmgt."Qmnc0"96:66"*WU+"Ð"aluminum is improved. A passive cathodic withworkers an expanded can be metalreduced. foam layer comprises an said piston crown portion positioned above said protection system for a metallic substrate, the system integral part of downhole casings, pipelines, transfer AMCOL Corporation EPICS Metalworking Fluid Systems helping industry meet ecological criteria since 1902

Extruders at over 95 plants Butt Shear and in 14 countries use Foy Log Shear Inc’s proven software. Lubrication EPICS, the state-of-the-art solution for your extrusion needs. Below are just some of the robust features in EPICS. Billet End Order Entry Invoicing and Dummy Custom Screen Design Press Recipes Block Lubrication Packing/Stock Tickets Rack Tracking Work Orders Drawing Viewer Department Scheduling Production Data Collection Reporting Shipping Documentation Stock Maintenance Order Inquiry Precision Bar Coding/Scanning Production History Applied Saw Auto-Response to Customers Pricing and Quotes Lubrication 111 Farmersville Pkwy, St.100 111 Farmersville Pkwy Suite 100 Farmersville, TX 75442 21435 Dequindre, Hazel Park, MI 48030 PH 972-782-7282 Phone: 248-414-5700 • Fax: 248-414-7489 FX 972-782-7130 Visit us on the web at—www.amcolcorp.com [email protected] www.foyinc.com

LIGHTLIGHT METALMETAL AGE, FEBRUARYAUGUST 2013 2013 9595 2013 Conference Calendar 2013

September 9-12: Lw2013 – 5th Inter- September 24-26: AeroTech Congress info: Matt Meenan, Aluminum As- national Aluminum Proile Technol- & Exhibition—Montreal, Canada. For sociation. Tel: (703) 358-2960. Fax: ogy Seminar & Exhibition—Guang - info: Peggy Bartlett, SAE International. (703) 358-2961. email: mmeenan@ zhou, China. For info: Zitao Wang, Tel: (724) 772-4055. Fax: (724) 776-4026. aluminum.org. www.aluminum.org. Aluminum Processing Technology email: [email protected]. www.sae.org. Center. Fax: (86) 20-8724 2261. email: October 8-9: International Confer- [email protected]. www.lw- September 25-27: ESTAL Congress ence on Extrusion and Benchmark aluminum.com. 2013—Krakow, Poland. For info: Mar- (ICEB)—Dortmund, Germany. For tine Kalmar, ESTAL Secretariat. Tel: info: Prof. A. Erman Tekkaya, IUL. Tel: September 9-13: EUROMAT 2013 (41)– 43 305 09 71. email: m.kalmar@ (49) 231-755-6923. email: iceb2013@ European Congress and Exhibition actreu.ch. www.estalcongress2013.org. iul.tu-dortmund.de. www.ice-b.net. on Advanced Materials and Process- es—Sevilla, Spain. For info: Euromat October 1-2: 21st Magnesium Auto- October 16-18: TiExpo 2013 – 8th Technical Secretariat. Tel: (34) 954 22 motive and User Seminar—Aalen, China (Beijing) Intl. Titanium Indus- 40 95. email: euromat2013@barcelo Germany. For info: Gabriele Haag, try Expo—Beijing, China. For info: Or- congresos.com. www.euromat2013. EFM e.V. Tel: (49) 7361-9274-17. ganizing Committee. Tel: (86) 10-6863 fems.eu. Fax: (49) 7361-9274-32. email: post@ 7413. email: hwexpo.lucy@hotmail. efm-aalen.de. www.efm-aalen.de. com. www.ti-expo.com/en/index.asp. September 10-11: SAE 2013 Inter- national Vehicle Lightweighting October 1-3: 22nd Annual Interna- October 17-19: ALEXASIA 2013— Forum—Shanghai, China. For info: tional Anodizing Conference—Se- Mumbai, India. For info: Anand Melissa Jena, SAE International. Tel: attle, WA. For info: Aluminum Anod- Joshi, Aluminium Extruders’ - Coun (724) 772-4008. email: [email protected]. izers Council. Tel: (847) 526-2010. cil (ALEX). Tel: (91) 985-097-6341. www.sae.org/events/lwf. Fax; (847) 526-3993. email: mail@ email: [email protected]. www. anodizing.org. www.aacconf.org. alexasia2013.com. September 12-13: 16th Seminar – “The Newest Trends in Heat - TreatOctober 1-3: METALCON Interna- October 20-24: TMS – Industrial Alu- ment”—Lagow, Poland. For info: Pa- tional—Atlanta, GA. For info: Metal minum Electrolysis—Doha, Qatar. For trycja Dzierzanowska, SECO/Warwick Construction Association. Tel: (847) info: The Minerals, Metals & Materi- Europ S.A. Tel: (48) 68 3819 914. 375-4718. Fax: (847) 375-6488. email: als Society (TMS). Tel: (724) 776-9000. email: p.dzierzanowska@secowarwick. [email protected]. www. email: [email protected]. www.tms.org. com.pl. www.secowarwick.com. metalconstruction.org. October 21-22: 12th International September 12-14: ALUMINIUM In- October 1-3:nd International2 Confer- Aluminium Conference (INALCO dia—Mumbai, India. For info: Jessica ence and Exhibition “Aluminium-21/ 2013)—Montréal, Quebec, Canada. For Kristian, Reed Exhibitions. Tel: (49) Transport”—St. Petersburg, Russia. info: INALCO 2013. Tel: (847) 526- 211 90191-232. Fax: (49) 211 90191- For info: Ellen Belova, Alusil-MVT. Tel: 2010. Fax: (847) 526-3993. email: info@ 193. email: jessica.kristian@reedexpo. (7) 495 785-2005. email: conference@ inalco2013.com. www.inalco2013.com. de. www.aluminium-india.com. alusil.ru. www.alusil.ru. October 21-25: Canadian Inter- September 17-18: 16th Annual Alu- October 1-3: Aluminum Welding national Aluminium Conference minum Welding Conference— Technology Program—Traverse City, (CIAC)— Montréal, QC, Canada. For Chicago, IL. For info: Zoey Oliva, MI. For info: AlcoTec Wire Corpora- info: Suzanne Bienvenu, CIAC. Tel: American Welding Society. Tel: tion. Tel: (800) 228-0750. Fax: (231) (514) 288-4842 #224. email: bienve (305) 443-9353 x264. www.aws.org/ 941-9154. www.alcotec.com/us/en/ [email protected]. www.ciacmon conferences/2013aluminum.html. education/training-alcotec.cfm. treal.com.

September 17-19: AEC Management October 1-3: 2013 Americas AltairErrata: In the June 2013 issue of Conference—Rosemont, IL. For info: Technology Conference—Garden Light Metal Age, within the article Aluminum Extruders Council. Tel: Grove, CA. For info: Altair Hyper “Fundamentals and Operation of (847) 416-7219. email: [email protected]. Works. email: [email protected]. Stretchers in Aluminum Extrusion,” www.aec.org. www.altair.com/atc the Turla stretcher pictured on page 18 was erroneously described as a 40 September 17-19: 28th International October 3-6: ALUEXPO 2013—Istanbul, ton stretcher. The stretcher pictured Aluminium Conf.— Geneva, Switzer- Turkey. Suphan Ilker, Hannover-Messe was a 400 ton type. A Turla 40 ton land. For info: Usha Tharmalingam, Ankiros Fuarcilik A.S. Tel: (90) 312 439- inger type stretcher is shown below. Metal Bulletin Events. Tel: (44) 20 6792. email: [email protected]. www. 7779 8989. Fax: (44) 20 7779 8294. aluexpo.com. email: registrations@metalbulletin. com. www.metalbulletin.com. October 6-9: Titanium 2013—Las Ve- gas, NV. For info: Jennifer Simpson, September 22-25: Liquid Metal Pro- International Titanium Association. Tel: cessing & Casting Conference 2013— (303) 404-9111. email: ita@titanium. Austin, TX. For info: The Minerals, org. www.titanium.org. Metals, & Materials Society. Tel: (724) 776-9000. Fax: (724) 776-3770. email: October 7-9: Aluminum Association [email protected]. www.tms.org. Fall Meeting—Farmington, PA. For

96 LIGHT METAL AGE, AUGUST 2013 Roberto Oliveros Vasquez Classiieds... Roberto Oliveros minum industry in Vasquez died on May discussions and co- WANTED H-13 SCRAP 3, 2013 at the age of operation with local 76. He was known government authori- for his passion for ties and to similar promoting the alu- associations in other minum industry in countries, such as Mexico through his the Aluminum Asso- efforts as executive ciation. He also or- director of the Insti- ganized the annual tute of Aluminum IMEDAL Congress (IMEDAL). and other events for Wanted ~ Following his grad- the institute. Obsolete extrusion uation from the In- Roberto is remem- tooling for remelt stituto Politechnico bered as a positive, Nacional in 1966 with a degree in friendly, and strong man, who em- BC Salvage! Don’t give Public Accounting, Roberto worked powered and motivated others to as a manager of credit & payment at make their lives better. He would your scrap away Aluminio S.A., an aluminum foundry take someone who started out as a get the best price that was one of the founding mem- messenger and help them to work bers of IMEDAL. When he left his their way up into becoming an im- Call 813-641-1615 position at Aluminio S.A., he worked portant person within a company. email: in a number of other industries be- “ In Mexico, we have a saying, fore returning to the aluminum in- ‘When you love your work, you wear [email protected] dustry. the tee shirt,’” said Mónica Oliveros In 1994, Roberto began work at Cortés, Roberto’s daughter and ad- USA ~ MEXICO ~ IMEDAL as an administrative man- ministrative manager at IMEDAL. CANADA ~ EUROPE~ ager. One year later, he was ap- “ My father always wore the tee shirt SOUTH AMERICA pointed executive director and also for IMEDAL and the aluminum in- served as president for one year dustry. And now, he has passed the BC SALVAGE from 2004-2005. He retired from shirt on to me.” 6022 US Hwy 41N, #148 the institute in July 2012. During Roberto is survived by his wife, Apollo Beach, Florida 33572 his 18 years of service at IMEDAL, Isabel, daughter, Mónica, and two Fax: (813) 641-2420 he represented the Mexican alu- grandsons, Roberto and Walter.

The Gold Coast Nick Adams Retires from Aluminum Association Welcomes Extruders Nick Adams retired networked, something Australia’s beautiful Gold Coast in as vp of Business In- he considers one of Queensland will be the site for the 5th formation & Member his greatest accom- Australasian Paciic Aluminium Ex- Services of the Alumi- plishments. The As- trusion Conference during May 25-28, num Association in sociation dramatically 2014. As the last conference was held May. Nick spent over improved the timeli- in Melbourne in October 2009, the lo- 30 years with the Asso- ness and accuracy of cal industry fully supports this opportu- ciation and witnessed data through automa- nity for sharing technical and practical great changes in both tion. Developing an expertise and innovations. The event the Association and MOU with Mexico on features two days of presentations, as the industry. Many will statistics was also a sig- well as an integrated trade exhibition recall that Nick was niicant achievement. in conjunction with the Aluminium primarily responsible He sees the U.S., Cast House Conference. Optional ex- for compiling statistics Mexico, and Canada tras are the extrusion workshop and a for the Association, though he has as a single market and believes the plant tour. The workshop will again be also worn a few other hats over the Aluminum Association should see it- hosted by Chris Jowett from Rio Tinto years. self as a North American association Alcan and will utilize invited speakers Within the Association, techno- through strong alliances with IMED- to cover various aspects of extrusion logical improvements changed the AL and the Aluminium Association practice. Queensland is the home to no landscape for member engagement, of Canada. less than ten extrusion presses, and ex- as well as how the association has op- Always responsive and personable, trusion plant tours will follow the con- erated. “ You can do more with less,” Nick was devoted to statistical accu- ference, visiting the INEX and Capral Nick said. “ Email and the internet racy. He doesn’t plan to stop working plants. The INEX Loganlea operation opened up a breadth of avenues for after he retires, but says he is going was commissioned in 2011 with mod- us. We could receive and push out to enjoy himself and is looking for- ern handling equipment and induction statistical information much faster, ward to devoting more time to his log heating. Capral Bremer Park has as well as other work the association volunteer work with the Boy Scouts four presses and is a high volume op- does.” of America. He wants to thank every- eration with powder coating and anod- Nick was a proponent for comput- one for their help and support over izing facilities. For more information, erizing the Association and getting it the years. visit: www.aluminiumcasthouse.org.

LIGHT METAL AGE, AUGUST 2013 97 Constellium N.V. appointed Paul Blalock as the company’s new head of Investor Relations U.S. Roy Harvey Hermann-Josef Burkhard Dhamen Gina McCarthy Hulamin Limited appointed Simon Hanny Jennings as an independent non-exec- Alcoa named Roy Harvey chief operat- SMS Group announced that Burkhard utive director of the company. ing oficer for Global Primary Products Dhamen will manage SMS Siemag (GPP), Leigh Ann Fisher as chief inan - and Eckhard Schulte will be cfo of the UC Rusal appointed Aleksandra Buriko cial oficer of GPP, and Libby Archell group. In addition, Heinrich Weiss will and Ekaterina Nikitina as non-executive was appointed vice president of Corpo- assume chairmanship of the supervisory directors of its board of directors. rate Affairs. board after 45 years of development and leadership of the company. Dr. Man- Chuck Johnson, formerly vice presi- Hermann-Josef Hanny, commercial fred Bischoff will retain his position as dent of Environment, Health, and Safe- director of Foundry Alloys and Divisiona member of the supervisory board. ty is now vice president of Policy at theHead Casting Alloys Aleris at Recy- Aluminum Association. In addition, cling GmbH, was named the new chair- Gina McCarthy, known for working Joe Quinn was appointed vice president man of the aluminum recycling division closely with the recycling industry, was of Public Affairs. in the Gesamtverband der Aluminium- conirmed by a 59-40 vote to serve as industrie (GDA). the next head of the U.S. Environmen- Michael Brandt, senior staff manager, tal Protection Agency. quality systems at Alcoa Inc., received Allegheny Technologies Inc. named the ASTM International Award for Patrick J. DeCourcy interim chief - i Hindalco Industries, part of Aditya Bir- Merit for exceptional and sustainednancial oficer. la Group, named Satish Pai as the next leadership and technical contributions chief executive oficer of its aluminum within Committee B07 on Light MetalsThe North American Die Casting As- business in India. and Alloys. sociation hired Jeff Brennan as its new technology manager. Chemical Coaters Association Inter- Scotwood Industries, Page Transpor- national (CCAI) presented Jim Docken tation, and Alloy Technology Innova- Wagner Companies hired Phillip of DuBois Chemicals with its highest tions joined the Aluminum Association Krueger as a modeling engineer, Pete honor, the James F. Wright Lifetime as associate members. Losiniecki as manager of Information Achievement Award. CCAI also named Systems, and Norm Hollander to the Sam Woehler, George Koch Sons LLC, Andreia Reis, head of Business Rela- newly created position of New York ac- as its president and Kevin Coursin, KMI tionship and Development inHydro’s count executive. Systems, as its vice president. Bauxite & Alumina business, was appointed a member of the board of directors of the Brazilian Mining Institute Advertiser Index (Ibram). Abtex ...... 94 Hertwich Engineering ...... 99 Aluminium Bahrain B.S.C. (Alba) ap- Albarrie ...... 23 Houlihan Lokey ...... 51 pointed Ali Al-Baqali as its new chief Almex ...... 5 Italtecno ...... 87 inancial oficer and Amin Sultan as its Amcol ...... 95 Lake Park Tool & Machine ...... 100 new power station director. BC Salvage ...... 97 METEF ...... 89 Belco ...... 43 ...... 31 Bharat Aluminium Company (BAL- Novelis PAE CO), a Vedanta Group company, ap- Briteline ...... 61 Presezzi Extrusion N.A ...... 21 Bruno Presezzi Spa ...... 39 Pyrotek ...... 33 pointed Ramesh Nair as its chief execu- Butech Bliss ...... 45 Reliant Aluminum ...... 59 tive oficer, succeeding Gunjan Gupta. Castool ...... 4 Sanshin Sanwa Group ...... 94 Handtmann A-Punkt Automation CIAC ...... 81 SECO/Warwick ...... 49 GmbH appointed Andreas Leiner as Consolidated Engineering Company .... 11 Sentech Precimeter ...... 71 a co-managing director alongside An- Continuus-Properzi S.p.A...... 65 SMS Siemag...... 63 dreas Podiebrad and Werner Carli as DUBAL ...... 35 Tecalex USA ...... 57 head of its new Service Support Team. emmebi ...... 19 Tellkamp ...... 3 ETS ...... 41 Thermika ...... 47 The Industrial Heating Equipment As- ExtrusionSupplies ...... 37, 93 Thorpe Technologies ...... 7 sociation elected Tim Lee of Maxon, a Foy, Inc...... 95 Vapormatt ...... 55 division of Honeywell, as its president, Gautschi ...... Wagstaff ...... 2 Bob Green of Bloom Engineering as its 75 Gillespie & Powers, Inc...... 13 ...... vice president, and BJ Bernard of Sur- WEFA Cedar, Inc. 17 face Combustion as treasurer. Granco Clark ...... 25, 27, 29 Zmag America ...... 9

98 LIGHT METAL AGE, AUGUST 2013 Melting Furnaces State-of-the-art scrap and dross remelting

Leading technology in the aluminum casthouse

There are many benefi ts in one-stop-shopping of indus- Common features and advantages of trial goods. At Hertwich Engineering we provide customer Hertwich melting furnaces oriented service throughout the project duration and service life of equipment. We design and build plants to ■ Remelting of clean and contaminated scrap with meet both, our own stringent standards and individual paint, plastic and oil customers specifi cations. Based on many years of experi- ■ Integrated scrap preheating and gasifi cation ence, we cover the full range of equipment in a modern of organic compounds aluminum casthouse. ■ Internal combustion and energy reclamation of organics – no after burner required! Major benefi ts ■ Very low heating fuel consumption Hertwich Engineering is well-known for leading edge ■ Extremely low oxidation losses (metal losses) technology. Our valued customers deserve to get the ■ Fully automated charging systems best value for money. Commitment to innovation, solid ■ Turn-Key solutions with reliable, proven and sophis- engineering and own R&D are instrumental for staying ticated process control ahead with continuous improvements and new products.

HERTWICH ENGINEERING GMBH Weinbergerstrasse 6 Phone: +43 7722 806-0 E-mail: [email protected] 5280 Braunau, Austria Fax: +43 7722 806-122 Internet: www.hertwich.com Save money…get better quality.

Containers Three good reasons why you should call us for a new container, a reline, or a repair job: 1. Unmatched experience—we have built or refurbished more than 11,000 containers! 2. We are your U.S. source for the industry standard Marx Smart Container.TM Controlled- temperature extrusion gives you better quality products and longer tooling life. 3. Our expanded facilities let us handle containers up to 70,000 pounds.

Marx Smart ContainerTM Stems Tremendous force is concentrated on the stem throughout the extrusion cycle. Lake Park stems, which are manufactured to original speciﬁcations, are available for bayonet, screw, and all current ﬁxed-dummy-block connections. Upgrades/replacements We supply parts that are equal to or better than the original: billet loaders, butt shears, container housings, crossheads, cylinders, die ejectors, die slides and shuttle tables, main cylinders, platens, tie rods, and more.

Maintenance services We provide everything from preventative and predictive maintenance plans to major repairs and press installation. Visit us in Booth 118 at ET’12

1221 Velma Court • Youngstown, OH 44512 330-788-2437 • Fax: 330-788-4946 Contact Dave Cornelius at [email protected] • Web site: www.lakepark.com Lake Park Tool & Machine, Inc.