March 2017 VOLUME 11 ISSUE 1

Industry News from the Smelter to the Foundry pyrotek.com Aluminium and Foundry Auto Sales and Production in EGA Files Patents, Operations Use Pyrotek’s Develops Cell Hydraulic Ladle System to China Continue Growth Trend Preheating Frame Improve Metal Transfer Emirates Global Aluminium Pyrotek offers a new hydraulically (EGA) has filed four patents tilting transfer ladle system, which for in-house innovations in can be an ideal solution for optimal aluminium production intended to increase productivity and control during metal transfer pours operating efficiencies. inside aluminium and foundry The UAE-based aluminium operations. producer started filing patents The hydraulics design by Pyrotek several years ago when it provides a more predictable and began to consider licensing its smooth tilting action to help technology to others, it says. operators avoid turbulence and The recent patent applications improve metal quality and safety. target improvements in the “Anyone who has a series of aluminium smelting process. furnaces that need to be filled could Three of those process use this system,” including in tight developments reduce energy areas, says Jim Bintz, a USA-based consumption and process costs, project manager for Pyrotek. EGA says. Those include a bi- Use of a standard molten metal metallic insert in the cathode transfer ladle typically relies on the Japan automaker Honda reported record monthly production in China for collector bar, a copper electrical skill of a forklift operator, and they November 2016. Honda CRV photo courtesy of Honda Motor Co. contact in the cathode assembly would be limited by the rotational and a split anode riser busbar Automotive sales and production in China increased in 2016, reflecting system. The other patent is for a Continued on page 6 strong demand. The growth was fueled, in part, by a tax break on small-engine potline energizing procedure. vehicles. Separately, EGA has developed For the first 10 months of 2016, sales of automobiles topped 22 million units, a preheating frame for anode 12.3 percentage points higher than the same period the previous year, the assemblies. China Association of Automobile Manufacturers says. Production increased “The new frame enables 13.8 percent to 22 million from January to October, the latest period for which quicker and safer preparation of data is available. cells for preheating and improves The association said auto sales could increase 13 percent in 2016 over 2015, the thermal homogeneity of the Reuters reported in December. process,” Mahmood Abdulmalik, “Yale Zhang, managing director of Shanghai-based consulting firm an EGA engineer, said in a press Automotive Foresight, said demand for passenger cars ... will likely be weaker release. “This is key, given that but still manage to grow 3 percent to 5 percent next year, compared to the the cells are not producing 16 percent growth he predicts for China’s passenger car market for this year,” metal during preheating. The Reuters said. reduced potential for damage In December, China’s Ministry of Finance extended a tax incentive for small- to the cathode is an excellent engine vehicles through 2017. The 7.5 percent purchase tax is higher than advantage, especially in terms of last year’s 5 percent, but it is below the normal 10 percent. While the Chinese maximizing the cell life.” market saw weaker sales in 2015, the tax incentive spurred growth, news reports say. Ford Motor Co., of Michigan, USA, sold a record 1.27 million vehicles in 2016 in China, up 14 percent from 2015. That total includes sales by joint ventures Improve Changan Ford Automobile and Jiangling Motors Corp. and sales of Ford models imported to China, Ford says. “We have built some great sales momentum in China, particularly in the Metal Transfer second half of 2016, on the strength of our expanded vehicle lineup,” Peter Fleet, Vice President of Marketing, Sales and Service, Asia Pacific, said in a press Covered and heated release. “Record numbers of customers are choosing our 3-row Edge crossover, trough systems elegant Taurus sedan, Explorer premium SUV and Lincoln luxury vehicles.” General Motors (GM), of Michigan, USA, and its joint ventures delivered a • Reduced energy costs record 3.9 million vehicles in China in 2016, an increase of 7.1 percent from the • Increased refractory life previous high in 2015. “In 2016, GM’s SUV deliveries surged 45 percent from a year earlier to 673,409 • Uniform and controlled units. Its comprehensive SUV portfolio includes the Buick Envision and Baojun heating 560, which were among the segment leaders with year-on-year growth of 52 percent and 116 percent respectively,” GM said in a press release. China is GM’s largest retail market, accounting for more than one-third of the pyrotek.com Continued on page 3 2 Technical Topics Pyrotek Provides Sheet Ingot Casters with Critical Consumables RFM Skim Dams performance. When the RFM control fill openings between hot-facing Pyrotek’s skim dams made of pins wear, the body remains attached refractory and other backup layers or reinforced fibreglass material to the tip and doesn’t separate the steel equipment shell. It provides (RFM®) can help improve total into the spout or ingot causing excellent insulation and a leak barrier ingot recovery and ingot quality by contaminated or uncontrolled metal to any metal that seeps behind the preventing oxides from entering the flow. refractory or between joints. Because rolling surface, which can often lead it expands as it foams and puts the to oxide patches or cracks on the refractory under slight compression, ingots. it helps to protect against crack RFM is denser than calcium-silicate propagation and catastrophic failures Aluminium slabs photo by Jorgeprz, board, which allows the RFM skim of the refractory liners. courtesy of Dreamstime. dam to sit lower in the melt, stopping Pyrotek RFM control pins. Casting Lubricants Sheet ingot casters strive to keep more oxides from flowing under the Lubricants provide critical slip up with the world’s demanding skim dam and entering the ingot. Distribution Troughs interfaces between molten metal metal quality standards, supplying Because it’s a high-strength Pyrotek’s distribution trough and direct-chill casting moulds. customers who make increasingly composite material, RFM can be refractory materials and backup The unique electrically charged complicated, lightweight and formed with relatively thin cross insulation are durable and help Perlube™ lubricants Pyrotek provides strong products for today’s vehicles, sections, providing larger interior prevent heat loss while channeling can reduce the volume needed for buildings, consumer goods and dimensions as well as the ability to molten metal. metal casting compared to generic more. fit into tight spaces. It can be custom The metal facing refractory oils like rapeseed, canola and castor. Pyrotek offers consumable designed for various ingot shapes materials are non-wetting, resistant They also can help reduce water- products, from combo bags to and mounting styles. to thermal shock and reduce heat treatment costs using specialized distribution troughs, for the sheet The material is non-wetting loss during transport of molten additives. ingot casting process that help to molten aluminium and offers metal. If properly maintained and These lubricants are supplied casters maintain the highest molten excellent crack and erosion coated, such as with ZYP Boron globally through Pyrotek’s network metal cleanliness and quality. resistance. With proper maintenance Nitride Lubricoat®, the trough of distribution centres. and the use of a boron nitride refractory materials can outlive For all of these consumables, TF Combo Bags coating, RFM skim dams last up Cast after cast, thermally formed similar products. Pyrotek consults with sheet ingot to three times longer than similar Finally, Pyrotek’s trough backup casters to determine the optimal (TF) combo bags can give aluminium products. producers consistent molten metal insulation, Wollite 30ST-1 or Pyrocast products for their operations. distribution during ingot casting. 450, can be poured into place to pyrotek.com TF combo bags provide optimal flow control for consistent, even Rusal and Fellow Russian Company Join to Establish temperature distribution around a Facility to Produce Cables and Wires mould, delivering more predictable Russian aluminium producer UC Rusal and Russian cable product company casts. Similar products on the market ELKA-Cable have agreed to establish the new Bogoslovsk Cable Plant, a don’t provide the same control of jointly-owned facility for producing cables and wires. temperature distribution, which can The new facility will be established at a site currently occupied by Rusal’s lead to problems like cracking or Bogoslovsk aluminium smelter. Once the new plant reaches full capacity, aborted casts. TF combo bags also it will be making more than 4000 tonnes of aluminium products per year. collect large oxide patches or small Those products will include oil-submersible cables, flexible cables and pieces of refractory material floating displaceable wires and self-supporting insulated wires. in the aluminium. “This joint venture will enhance our presence in the cable and wire sector, Pyrotek TF combo bags stay rigid which is among the largest and fastest-growing aluminium consumption at molten aluminium temperatures segments,” Alexey Arnautov, a director of new projects at Rusal, said in a press for up to 75 minutes. That rigidity release. also makes them easier to insert into Equipment foundation work began late last year. the mounting system. Top, skim dam in use. Bottom, Compared to some competitors’ Pyrotek RFM dam with combo bag. products, they produce little flame British Car Production Increases in 2016 when they come into contact with RFM Control Pins The UK’s Society of Motor UK Car Production molten aluminium and produce Pyrotek also uses its RFM Manufacturers & Traders, says 2015 and 2016 little nontoxic smoke. This improves UK car production reached technology in control pins for Manufacturer 2015 2016 % Change health and safety conditions for plant regulating molten aluminium into a 17-year high in 2016, with over 1.72 million vehicles. Jaguar Land Rover 489,923 544,401 11.1% employees. moulds. The material strength allows For 15 manufacturers, total for a hollow and lightweight design, Nissan 476,589 507,444 6.5% production rose 8.5 percent MINI 201,207 210,973 4.9% which reduces the drain of heat from over 2015. the melt and the likelihood of costly Growth was primarily Toyota 190,161 180,425 -5.1% cast freezes. RFM pins only need to generated by overseas Honda 119,414 134,146 12.3% be preheated to 300°C (572°F), which demand. About eight out of Vauxhall 85,241 118,182 38.6% can provide both lower energy costs 10 cars made in the UK are and increased safety for operators now exported, the society Others 25,142 27,127 7.9% compared to solid cast pins. says. Demand increased All Makes 1,587,677 1,722,698 8.5% RFM control pins, with the 47.2 percent in 2016 in the Source: Society of Motor Manufacturers and Traders fibreglass reinforcement, can last USA, the UK’s largest export Pyrotek thermally formed (TF) up to 10 times longer than cast destination after the European Union. Notable growth was also seen in Turkey, combo bag. pins, with good thermal shock Japan and Canada. Chinese growth was modest at 3.1 percent. 3

Hydro Acquires Remaining Shares in Bauxite Mine Norsk Hydro ASA, of Norway, has Pyrotek Profile: completed the acquisition of Vale’s remaining stake in the Paragominas bauxite mine in northern Brasil. Sylvain Hydro’s net payment totaled USD$113 million, the company says. Tremblay Hydro now owns 100 percent of the shares. Title Vale says the transaction is Sales Manager, Aluminium Sector– connected to its aluminium asset Canada, Global Combo-bag Specialist sale announced in February 2011. Photo of Paragominas mine courtesy of Educational Background According to Hydro’s website, Norsk Hydro ASA. Master's degree in ceramics Paragominas has deposits to and bachelor's in metallurgical support 41 years of mining activities. It also says the mine produces 9.9 million engineering, Laval University tonnes of bauxite per year. How many years have you worked for Pyrotek? Auto Sales and Production in China Continue Growth I joined the Pyrotek team in 1995 and am going on 21 years. I have Trend always been located in Chicoutimi, Quebec, Canada. The region is Continued from page 1 considered the Rio Tinto “kingdom” with over 2 million tons of primary aluminium produced each year. company’s sales globally. The automaker has 11 joint ventures, two foreign How long have you worked in the aluminium industry? enterprises and more than 58,000 After three years in the steel industry, I joined the Alcan research employees in China, the company says. centre in Arvida, Quebec. Prior to Pyrotek, I spent over 10 years in various France-based PSA Group sold 618,000 positions, mainly associated with the aluminium casting process. in China and Southeast Asia in 2016. What questions do customers often ask? In December, joint venture Dongfeng What Pyrotek can bring to improve molten metal quality or to improve Peugeot broke a monthly record with molten aluminium casting efficiency? 43,800 deliveries to customers, mainly Are there any exciting developments in the industry? due to the success of the Peugeot 4008 Photo courtesy of INFINITI. The introduction of an all-aluminium body panel in a pickup truck is a SUV, PSA Group says. major breakthrough in the automotive industry. All car manufacturers will Elsewhere in Asia, sales of the group’s Peugeot brand grew 72 percent in the do the same in the next few years when rolling capacity increases. Philippines and 40 percent in Singapore last year. The Citroën brand continued to grow in Southeast Asia. Where do you see the aluminium industry in the next five Honda Motor Co. recorded record production in November in China, or 10 years? climbing 26.3 percent to 132,401 units, compared to the same month the In spite of few sluggish years, the aluminium industry promises a bright previous year. Production increased to 1.1 million units during the first 11 future. Aluminium will be used more and more in the automotive industry months of 2016, up 28.9 percent from the same period of 2015, Honda says. to meet gas consumption targets. The aircraft industry will continue to “Production in regions outside of Japan experienced a year-on-year increase grow as well, and aluminium will be their material of choice. for the fourth consecutive month (since August 2016), setting record-high pyrotek.com production for the month of November. This includes record-high production for the month of November in North America, Asia and China,” the Japanese automaker said in a press release. Nemak Lands Funds to Build Lightweight Engine Blocks Retail volumes for Jaguar Land Rover vehicles in China rose 36 percent in Nemak of Canada Corp., of Windsor, Ontario, and Arbec Tool and Machine December 2016, the strongest monthly performance on record. The UK-based Ltd. have received a CAD$3 million (USD$2.3 million) grant from the Canadian company attributes the growth partly to the introduction of the XFL, the first government’s Automotive Supplier Innovation Program. The funds will allow SUV Jaguar developed for Chinese customers. Nemak to install a new automated manufacturing process that will be used to “Customer response has been very positive this year, resulting in record retails produce lightweight aluminium engine blocks that will help make cars more across most of our key regions. These results mark significant steps in Jaguar fuel efficient. Land Rover’s strategy to become a truly global business and meet the growing Up to 70 jobs could be created as a result, Canada’s department of Innovation, international demand for its two iconic brands,” Andy Goss, Jaguar Land Rover Science and Economic Development said in a press release. Group Sales Operations Director, said in a press release. “I am confident that in 2017 our British lineup will continue to expand.” Chinese sales of BMW and MINI vehicles increased 11.2 percent to 472,705 vehicles from January to November 2016. Sales in Asia, including China, Elevate increased 9.5 percent to 680,540 vehicles during the first 11 months of last year compared to the same period in 2015, BMW Group says. Production of Nissan vehicles in China increased to 1.2 million units from Ingot Casting January to November 2016, up 10.6 percent from 1.1 million from the same period the previous year. Sales increased 9.3 percent during the first 11 months of the year to 1.2 million units, Japan-based Nissan Motor Co. Ltd. says. China’s Geely Automobile Holdings Ltd. said the group’s total sales volume Deliver more predictable for 2016 reached 765,851 units, up about 50 percent from the same period of casts with optimal flow 2015. The automaker sold a monthly record of 108,230 units in December, a more than 100 percent increase over December 2015. control and temperature China-based Great Wall Motor Co. sold 923,923 vehicles during the first 11 distribution. months of 2016, up 22 percent from 756,964 during the same period in 2015. Pyrotek TF Production increased 23 percent to 952,463, Great Wall says. combo bags INFINITI set a monthly record with 41,590 vehicles sold in November in China, an increase of 3 percent over the same month of 2015. Hyundai Motor Co., of South Korea, says its Chinese sales of its Elantra, pyrotek.com Tucson and other models increased steadily last year. 4

German Die Caster Expands Facility to Meet Demand Pyrotek Relaunches Global Website, Pyrotek.com Pyrotek has relaunched KS HUAYU AluTech GmbH, a KS HUAYU was recently awarded its global website at a new Neckarsulm, Germany-based die a major contract by a German address, pyrotek.com. caster, is expanding its facility original equipment manufacturer The website is designed to meet customer demand. to make aluminium components to be a user-friendly The company is a joint venture for battery boxes. Production resource for customers and between Rheinmetall Automotive for the EUR€65 million (USD$70 prospects. Pages featuring AG and HUAYU Automotive million) order is expected to begin products and services are Systems (part of China’s SAIC mid-2018, the company says. organized by customer Group). “Weighing around 9 kilograms, process, making navigation fast and intuitive. KS HUAYU says it has received these components serve to Users can be connected to a local application engineer by clicking links on an influx of orders for aluminium hold the rechargeable battery each page or by using the “Contact Us” page. die castings and has expanded cells installed in two electrically While Pyrotek has provided advanced technology and engineered solutions its product offerings, prompting powered vehicles of this OEM. to the aluminium industry for 60 years, the new website also presents the wide the need for a new foundry. These are a crossover SUV and range of other industries it serves, from glass to graphite. While it primarily manufactures a high-power sports limousine. The site also includes information about Pyrotek’s mission, events, news and components for vehicle power Both feature all-electric drive and more. trains, it anticipates increased are presently destined for the Over time, Pyrotek will increase the level of content hosted on the website. demand for additional parts like European market,” Rheinmetall said While the site was launched in English, content in additional languages also will suspension-strut mounts and in a press release. be added for the worldwide markets we serve. transverse links. To meet demand, KS HUAYU is “While expanding its business adding 5000 square metres (53,800 in engine block castings, KS square feet) of floor space, which HUAYU will also broaden its focus includes a new 3400-square-metre on products for non-internal- (36,600-square-foot) foundry. combustion engine vehicles. Production is expected to begin Given our casting expertise, in July 2018, KS HUAYU says. we already are a sought-after In addition to the “double- partner in the production of digit million euro” construction structural components as well as project, the company plans to add the highly complex aluminum new die casting machines and parts needed in electric vehicles,” other equipment. The facility’s Lothar Schneider, head of the aluminium smelting capacity also castings business at Rheinmetall will be increased to 100 tonnes per Automotive, said in a press release. day, Rheinmetall says.

Pyrotek's team in Turkey recently received an Excellent Overall Performance supplier award from CMS, the country's largest wheel caster. Manager Murat Ozaydinli, middle left, and Sales Manager Arzu Kizilok received the award on behalf of Pyrotek. As part of CMS's Supplier Day celebration, Pyrotek Sales Engineer Aytac Ergun gave a presentation about the company. Alcoa Increases Revenues in Fourth Quarter Alcoa Corp., a Pennsylvania, USA-based producer of bauxite, alumina and aluminium products, says revenue was up 9 percent to USD$2.5 billion in the fourth quarter of 2016. This reflected higher volumes in the company’s rolled Production of structural parts made of aluminium at KS HUAYU AluTech products business, Alcoa says. GmbH. Photo courtesy of Rheinmetall Automotive AG. “Rising alumina and aluminium prices improved the bottom line, our alumina segment had exceptional profit growth in a stronger market environment and doubled margins, while our bauxite business also increased profits and reported robust margins,” Roy Harvey, CEO of Alcoa, said in a press release. Optimize Furnace The company reported a net loss of USD$125 million for the fourth quarter, a result of costs to streamline its portfolio, however. Separately, Alcoa announced last month that it intends to permanently close the Suralco alumina refinery and bauxite mines in Suriname. Temperature “As we enter 2017, we also continue to streamline and strengthen our portfolio to better focus on our businesses and the growth opportunities Cast iron protection tubes ahead,” Harvey said. manufactured worldwide by Pyrotek Alcoa plans to continue to operate the Afobaka hydroelectric facility, which supplied power to the Suralco operations. • 100% ultrasonic tested • Robust and durable Hyundai Ranked First in Passenger Car Sales in Chile South Korean automaker Hyundai Motor Co. sold more passenger cars than • High-quality coating resists any other manufacturer in Chile in 2016, according to a list by the National oxidation Automotive Association of Chile. This is the first time Hyundai has reached chart-topping status in this market, selling 31,398 units. While passenger cars such as the Accent, with 10,987 units sold, and the pyrotek.com Grand i10, with 5464 units, comprise most of the sales, the new Tucson SUV took the highest-selling SUV title with 3716 units, Hyundai says. 5 Two Wheel Makers Introduce New Aluminium Products for Heavy Duty Vehicle Aftermarket Pyrotek Improves Its Cast Iron Protection Tube Two wheel manufacturers recently for Thermocouples launched new product lines for the heavy Pyrotek has improved the quality of duty vehicle aftermarket. its cast iron thermocouple protection Accuride Corp., of Evansville, Indiana, tubes by altering its manufacturing USA, has introduced a wheel made with its process in an effort to advance the new, proprietary Quantum 99 Alloy that is temperature sensing technology 20 percent stronger than the company’s relied on by aluminium producers previous alloy. The new alloy allowed globally. Pyrotek’s new proprietary method increases the protection tube’s Accuride to reduce the weight of its wheel dimensional consistency, wall thickness and productivity. by 11 percent to 18 kilograms (40 pounds). The cast iron protection tubes all undergo ultrasonic testing to ensure “To help our customers achieve greater they meet Pyrotek’s highest standards for wall thickness and uniformity. fuel economy and lower emissions, Additionally, a layer of enameling can be added to help resist oxidation. Accuride continues lightweighting our Maxion has launched a forged Pyrotek’s wide range of thermocouples and thermocouple protection products while maintaining superior aluminium truck wheel line for the tubes are manufactured at multiple Pyrotek plants around the world. Field levels of safety and performance,” North American market. Photo engineers work with customers to determine the best thermocouples and Accuride President and CEO Rick Dauch courtesy of Maxion Wheels. protection tube materials for each application. announced at Heavy Duty Aftermarket pyrotek.com Week 2017 in Las Vegas, Nevada, USA. “As the latest step in our efforts, we’re excited to introduce our next-generation Quantum 99 alloy and 40-pound aluminium wheel. … Quantum 99 will serve as the foundation of a new series Car Companies to Add Thousands of Jobs in USA of lightweight aluminium wheels.” Three vehicle manufacturers plan to add thousands of jobs in the USA over Testing showed the new wheel has twice the fatigue life of other 18-kilogram the next several years due to investments and other efforts. (40-pound) wheels on the market. It will initially be available at the standard FCA US LLC, the USA subsidiary of Italy-based Fiat Chrysler Automobiles size of 57 x 21 centimetres (22.5 x 8.25 inches). N.V., plans to add 2000 jobs as part of the second phase of its industrialization The new wheel will be available during the third quarter of 2017, and effort that includes investing USD$1 billion in its Michigan and Ohio plants. The additional wheels using Quantum 99 will be added later, Accuride says. company is also expanding its Jeep lineup. Separately, Maxion Wheels, of Novi, Michigan, USA, has launched a forged “The conversion of our industrial footprint completes this stage of our aluminium truck wheel product line for the North American market. transformation as we respond to the shift in consumer tastes to trucks and “Maxion Wheels developed the forged aluminium commercial vehicle four- SUVs, and as we continue to reinforce the USA as a global manufacturing hub wheel product line in response to the market’s growing need for lighter vehicles for those vehicles at the heart of the SUV and truck market,” Sergio Marchionne, as a means of reducing fuel consumption and greenhouse gas emissions,” CEO of FCA N.V., said in a press release. Maxion said in a press release. Michigan, USA-based General Motors (GM) will invest USD$1 billion more in The company will begin offering a standard-sized aftermarket wheel— its USA manufacturing operations. 57 x 21 centimetres (22.5 x 8.25 inches)—in the next few months with other “A combination of 1500 new and retained jobs are tied to the new sizes to follow. The standard size weighs 20.5 kilograms (45 pounds). investments,” GM said in a press release. “Our forged aluminium truck wheels are built for today’s toughest road The company also plans to move production of axles for full-size pickup conditions,” Donald Polk, President of Maxion Wheels, Americas, announced trucks to Michigan from Mexico, which would create 450 jobs in the USA. at Heavy Duty Aftermarket Week. “Maxion Wheels’ commercial vehicle wheel “As the USA manufacturing base increases its competitiveness, we are able product strategies will continue to focus on minimizing corrosion, reducing to further increase our investment, resulting in more jobs for America,” GM weight and offering more styling alternatives.” Chairwoman and CEO Mary Barra said in a press release. Over the last four years, GM has created 25,000 jobs in the USA, some of Pyrotek to Present at Metalcasting Congress which have been shifted from other countries. Insourcing IT jobs, streamlining its engineering operations and other moves will help create more than 5000 Rafael Gallo, a technical consultant for Pyrotek, will jobs in the USA over the next few years, GM says. present two papers at the American Foundry Society’s Meanwhile, Japan-based Toyota plans to add 400 jobs at its Princeton, 121st Metalcasting Congress in Milwaukee, Wisconsin, Indiana, USA, plant. The company is investing USD$600 million to modernize USA. The trade show and conference, to be held the plant, which will meet growing demand for its Highlander midsize SUV. The 25–27 April, will bring together suppliers, foundries Indiana plant produced over 400,000 vehicles in 2016, the highest volume in 20 and casting professionals. Along with technical and years. The plant upgrade is expected to begin in late 2019, Toyota says. management presentations, the event offers attendees expert panels, roundtable discussions, institute courses Rafael Gallo and exhibits. Automakers to Form Joint Alba Hits High with Sales • The first presentation will address the interrelated aspects that define Ventures in India and Production Record molten metal quality and the collection and analysis of data to determine PSA Group, a France-based Aluminium Bahrain B.S.C. (Alba), an the source of inclusions. Titled, “I have Inclusions, Get Me the Cheapest automaker, and India’s CK Birla aluminium smelter based in Bahrain, and Best Flux for Cleaning My Melt–Is This the Best Driven Cost Saving Group have agreed to form two joint says it was able to reach record metal Approach by a Foundry?,” it will be held on Wednesday, 26 April, at ventures to produce and sell vehicles production of 971,400 tonnes in 3:15 p.m. and components in India by 2020. 2016. The production figure was up • Gallo also will present a silver anniversary paper covering the last 25 PSA will hold a majority stake in 1.1 percent compared with 960,600 years of technological advancements in molten metal processing. a joint venture being formed with tonnes in 2015. “Molten Aluminium Cleanliness 25 Years in Review–The Technological Hindustan Motor Finance Corp. Ltd. Tim Murray, Alba CEO, said in a Advancements and the Foundry Practices” will be held on Thursday, to assemble and distribute PSA- press release that the mark was 27 April, at 8 a.m. brand vehicles. reached despite “tough market In the second agreement, PSA will Gallo has held a number of technical and management positions at conditions.” operate a 50-50 joint venture with CK metals and automotive companies throughout his decades-long career. He Alba sold 974,000 tonnes of Birla affiliate AVTEC Ltd. to make and also has served as chairman of the American Foundry Society’s executive aluminium in 2016, up 2.3 percent supply powertrains. aluminium division. Gallo holds a master’s degree in metallurgical from 2015. Both facilities will be based in engineering from The Ohio State University, an MBA from Baldwin-Wallace For the fourth quarter of 2016, India’s Tamil Nadu state. Initial College and a bachelor's in mechanical engineering from the Chihuahua sales increased 1.5 percent to production capacity will be 100,000 Institute of Technology in Mexico. 256,500 tonnes from 252,600 tonnes vehicles per year, PSA says. in the same quarter of 2015. 6

Aluminium and Foundry Operations Use Pyrotek’s Hydraulic Ladle System to Improve Metal Transfer In Brief CALENDAR Continued from page 1 14–16 MARCH capabilities of the truck to control the Nissan Begins Assembling Bauxite & Alumina Conference speed and acceleration of the tilt. That Vehicles in Myanmar Conrad, Miami, USA inevitably leads to sloshing of the metal metalbulletin.com/events/bauxite- and accompanying safety concerns. Japan automaker Nissan Motor Co. alumina-seminar/details.html Ltd. and Tan Chong Motor (Myanmar) During a pour with a standard 21–22 MARCH crucible, the centre of gravity changes Co. Ltd. have begun assembling cars in Myanmar for the first time. A 20th Global Foundry Sourcing throughout the tilting using a forklift Conference truck. Because of this, the operator must Nissan sedan, called the New Sunny, is being assembled at Tan Chong’s Shanghai, China raise the crucible while tilting it to pour castings.foundry.cn the metal into a furnace. facility, Nissan says. 25–27 APRIL “Because the operator has less to AFS 121st Metalcasting Congress worry about with Pyrotek’s hydraulic Federal-Mogul Motorparts Milwaukee, Wisconsin, USA ladle system, this also reduces the Buys Beck/Arnley Brand www.afsing.org chances for overfills and the subsequent Pyrotek's hydraulic ladle system Federal-Mogul Motorparts, a safety and cleanup issues,” says David provides a smoother metal transfer. 25–27 APRIL division of Southfield, Michigan, Ransdell, a USA-based application engineer for Pyrotek. 7th International Conference USA-based Federal-Mogul Holdings One of the advantages of the Pyrotek hydraulic ladle design is the spout, on Electrodes for Primary Corp., has acquired the Beck/Arnley which offers a fixed point for metal flow. Operators are able to place the spout Aluminium Smelters brand and certain associated assets. in the area they want to fill and simply begin the process. Reykjavik, Iceland Based in Smyrna, Tennessee, USA, rodding-conference.is The ladle within the hydraulic system uses a Pyrotek-made precast liner, Beck/Arnley is a provider of parts and which can be kept in stock for replacements or in case of emergencies. 15–17 MAY fluids for foreign nameplate vehicles “It is much easier to tear out a precast shape as there are not loads of anchors Aluminium Middle East 2017 in North America, Federal-Mogul throughout the refractory,” Ransdell says. Dubai, UAE says. Alternatively, most operations will experience downtime of 3–5 days during aluminium-middleeast.com replacement of a cast-in-place refractory system. Replacing a precast shape 23–26 MAY can be done in one day, or even in one shift in some cases, saving significant Ford Introduces SUV With Cast-Ex downtime and resources. Aluminium Body Nitra, Slovakia Pyrotek’s hydraulic ladle system provides further value because of its Ford Motor Co., of Dearborn, 10times.com/cast-ex insulation for molten metal. The use of an engineered refractory lining Michigan, USA, has introduced its 13–16 JUNE configuration allows for optimal shell temperatures and molten metal heat 2018 Expedition SUV, which features Metal + Metallurgy China retention. Pyrotek uses software that can provide analysis of potential heat loss a new high-strength, aluminium- Shanghai, China for a given refractory package. “We have done these analyses in the past and alloy body and redesigned high- mm-china.com the heat-loss savings can be significant,” Ransdell says. strength steel frame, Ford says. 20–24 JUNE Case Study Aluminium Two Thousand 2017 Pyrotek engineered a hydraulic ladle system for a permanent mould die Chinese Consortium Buys Verona, Italy casting customer in Georgia, USA, improving the way aluminium is fed into its Canada’s Valiant TMS aluminium2000.com crucible holding furnaces. 21–24 JUNE Because of the hydraulics, the transfer ladle filling design provided a more Late last year, a Chinese METEF predictable and smoother tilting action for a consistent pour. consortium bought the Valiant Verona, Italy Pyrotek’s hydraulic ladle system allows the operator to control the speed and TMS Group of Cos., an automated metef.com acceleration, ensuring a safe and smooth fill. production systems provider based Prior to using the hydraulic ladle system, the customer relied on pumps and in Ontario, Canada. Valiant TMS troughs. Using that system, the customer experienced freezing metal and has 27 facilities in 15 countries, the broken pump parts, shorter life of consumable parts, high maintenance costs company says. and increased downtime. Overall, the benefits to the customer from using the hydraulic ladle system British Automaker Aston Publisher: Pyrotek Inc. included reduced downtime, consistent metal temperatures and levels, Martin Builds New Facility 705 W. 1st Avenue decreased maintenance costs and an easy filling process. Spokane, WA 99201 USA UK automaker Aston Martin has pyrotek.com pyrotek.com begun building a new facility in Wales following regulatory approval Contributors: David Cole, Sandra and the purchase of land. The plant Hosking, Marily Wenner Increase Metal Quality will employ about 750 people. The This document is for informational project is part of a GBP£200 million purposes only. The information Pyrotek's underheated immersion furnace (USD$253 million) investment in new contained in this document has been is the proven solution for die casters. products and facilities, Plastics News compiled from sources believed to be Europe reports. • Improve casting quality reliable. While every effort has been made to ensure that the information • Increase thermal efficiency Nemak Completes is correct and that the views are • Lower energy and maintenance Acquisition of Die Caster sound, Aluminium Insight cannot be made liable for any loss, no matter costs Nemak, S.A.B. de C.V., of Monterrey, Mexico, has completed its acquisition how it may arise. Pyrotek is the leader in underheated of Cevher Döküm Sanayii A.Ş., a Aluminium Insight is produced by furnace technology, with over 100 Turkey-based supplier of complex Pyrotek Inc. for its customers. furnaces installed in North America. aluminium automotive castings. Copyright 2017. All rights reserved. Cevher Döküm exports most of the Perlube™ is a trademark of Pyrotek. products it makes to Europe and RFM® is a registered trademark of Pyrotek. pyrotek.com generated revenues of USD$70 ZYP Boron Nitride Lubricoat® is a registered million in 2015, Nemak says. trademark of ZYP Coatings Inc.